Sylvie Willis
The Polaris 900 XP is a powerful machine, but some owners have reported issues with its fuel system. Some users have questioned the absence of a fuel filter, while others have experienced power loss and engine failure. While some Polaris models do have fuel filters, they are not always easily accessible for maintenance or replacement, and in some cases, the entire assembly must be replaced. This has been a cause for concern among Polaris owners, who have taken to forums to discuss potential solutions and workarounds, including the possibility of installing an in-line filter.
| Characteristics | Values |
|---|---|
| Fuel filter location | Bottom of the fuel pump in the tank |
| Replaceable | No, the whole assembly must be replaced |
| Fuel filter type | Sock on the fuel pump inlet |
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What You'll Learn
The fuel filter is attached to the bottom of the fuel pump
Polaris 900 XP owners have reported that their vehicles do not have a fuel filter that can be changed. However, some older models of the Polaris ATV with EFI machines do have a serviceable filter. For example, the 2008 model has two filters. One is located on the bottom of the fuel sending unit inside the tank, and the other is a non-serviceable fines filter located between the fuel pump and the fuel pressure regulator. This second filter is made of paper and is held within a plastic assembly that cannot be put back together once taken apart.
The fuel filter on the Polaris RZR 900 is located inside the fuel tank on the fuel pump. The fuel pump is known to cause issues, and it is recommended that if you are replacing the filter, you should put a new pump on it. You should also check the bottom of the tank for any water or dirt and clean it out.
Some Polaris ATV owners have reported that they have not had fuel filters on their vehicles and have not had any issues.
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The fuel pump is located inside the tank
To access the fuel pump, you must first locate the battery. On the four-seat model or the crew model, lift up the rear seat. There may be a panel that you need to remove. Loosen the positive terminal and disconnect it from the battery. Tuck the terminal down to ensure it does not make contact. Next, locate the gas tank on the driver's side. Remove the panel covering the gas tank and set it aside.
Use an air blower to remove mud, dirt, and debris from the top of the tank and fuel pump to prevent contamination when you remove the fuel pump. Remove the gas cap to relieve any pressure in the tank. Disconnect the wiring harness by picking up the tab on the connector and wiggling it off. Remove the retaining ring from the fuel pump by spinning it off. Loosen and remove the screws securing the middle panel with the ECU and the fuse block. Shift this panel to the side to access the fuel pump.
The fuel pump can be replaced with a fuel pump from a 93 Jeep Wrangler, which is identical but much cheaper.
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The filter cannot be bought separately
The Polaris RZR 900 XP does feature a fuel filter, however, it is not serviceable. This means that the filter cannot be bought or replaced separately. The filter is attached to the bottom of the fuel pump, which is located inside the fuel tank. While it is possible to service the fuel pump, the screws holding it in place inside the tank can be tricky to remove.
Some older EFI models do have a serviceable filter, which is located under the front cargo box. However, newer models do not have these serviceable filters. Instead, the filter is part of the fuel pump assembly, and the entire assembly must be replaced if the filter becomes plugged.
One option for replacing the assembly is to purchase the Polaris Factory RZR's Fuel Pump, with the part number "2521011" and the description "ASM-FUEL PUMP 1". This assembly has been listed online for $215.79. However, it is worth noting that some users have reported finding alternative fuel pumps that are compatible with the Polaris RZR 900 XP but are available at a lower cost.
Another option is to attempt to take the assembly apart and replace the filter itself. However, this approach should be approached with caution as the assembly is glued together, and it may be difficult to get it to stay together once it has been taken apart. Therefore, it is recommended to only attempt this if you are confident in your ability to successfully reassemble the assembly.
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The whole assembly must be replaced
The Polaris RZR 900 does have a fuel filter, but it is not a serviceable one. This means that if the filter gets plugged, you will have to buy and replace the whole assembly. This is because the plastic assembly is glued together and cannot be put back together once taken apart.
Some users have reported that they have been able to take the assembly apart and replace the filter, but this is not recommended as it is difficult to get the assembly to stay together. Therefore, it is generally advised to purchase a new assembly and replace the entire fuel filter system.
The fuel filter is located inside the fuel tank, between the fuel pump and the fuel pressure regulator. The filter is a paper-style filter, and it is known to plug up over time. This can cause issues with the vehicle's performance, such as sudden power loss and dying while running in high range.
If you are experiencing issues with your fuel filter, it is recommended to consult an authorized Polaris dealer or refer to the Owner's Manual for maintenance tips and procedures. Additionally, you can refer to the online parts catalog to find diagrams and replacement part numbers for the Polaris RZR 900 fuel filter assembly.
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The filter can be replaced, but the screws are tricky to remove
The Polaris RZR 900 does have a fuel filter, but it is not serviceable. This means that it cannot be routinely maintained or cleaned and must be replaced entirely when it gets plugged up. The filter is attached to the bottom of the fuel pump, which is located inside the fuel tank.
While the filter can be replaced, the screws holding the pump in the tank are notoriously tricky to remove. This is because they are located inside the tank, requiring specific tools and techniques to access and remove. Attempting to remove these screws without the proper knowledge or equipment could result in damage to the fuel pump assembly or other components.
Some users have reported that they were able to take the assembly apart and replace the filter, but the plastic assembly is glued together, making it challenging to reassemble. In some cases, the entire fuel pump assembly may need to be replaced, which can be costly.
To avoid the hassle and expense of replacing the entire assembly, it is recommended to take preventative measures to keep the fuel filter from getting plugged up in the first place. This can be done by regularly filtering the fuel before putting it into the tank and taking care to keep dirt and other contaminants out of the fueling process.
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Frequently asked questions
The Polaris 900 XP does not have a serviceable fuel filter. However, there is a sock that is integral to the pump assembly, which can be replaced, although it is not a routine maintenance procedure.
Installing an in-line fuel filter between the tank/fuel pump and the fuel injector(s) will not help. It is recommended to filter your fuel before putting it into the ATV fuel tank and to keep dirt out of the fueling process and the ATV tank.
The fuel filter is located on the bottom of the fuel pump in the tank.
Yes, you need to buy the whole assembly if your fuel filter is plugged.
