Rajan Wilcox
The fuel filter in the Polaris RZR 800 is located in the fuel tank, at the bottom of the fuel pump. It is not a serviceable fuel filter, but it can be serviced, although the screws holding the pump in the tank are tricky to remove. There is a second fuel filter, which is a black plastic container right above the fuel pump.
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What You'll Learn
The fuel filter is attached to the bottom of the fuel pump
The fuel filter on a Polaris RZR 800 is attached to the bottom of the fuel pump, which is located inside the fuel tank. This means that the fuel filter is not directly accessible and can only be reached by removing the fuel pump from the tank. While it is possible to service the fuel filter, it is important to note that the screws holding the pump in the tank can be tricky to remove. Therefore, when replacing the fuel filter, it is common to replace the entire fuel pump assembly, rather than just the filter itself.
The fuel filter plays a crucial role in the fuel delivery system of the RZR 800. It is designed to remove impurities, such as dirt and rust, from the fuel before it enters the engine. By filtering the fuel, the fuel filter helps to ensure the smooth operation of the engine and prevents clogging in the fuel injectors.
As the fuel filter is located within the fuel tank, it is important to take certain precautions when working on this component. Before attempting any maintenance or repair work on the fuel filter, it is essential to relieve the fuel system pressure and disconnect the negative battery cable. It is also crucial to work in a well-ventilated area and avoid any open flames or sparks, as the fuel system contains flammable liquids and vapors.
Due to the location of the fuel filter, it may be more challenging to access and service compared to fuel filters found in other vehicles. However, with proper tools and knowledge, it is possible to replace or clean the fuel filter when necessary. Regular maintenance of the fuel filter can help improve the performance and longevity of the RZR 800's engine, ensuring reliable operation during off-road adventures.
It is worth noting that some older models of the Polaris RZR 800 may have a slightly different fuel filter design. While the fuel filter is still located within the fuel tank, it may be a canister-style filter that is more accessible for maintenance. It is always recommended to refer to the specific service manual for the exact year and model of your RZR 800 to ensure accurate information regarding the fuel filter location and maintenance procedures.
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It's inside the fuel tank
The fuel filter on the Polaris RZR 800 is located inside the fuel tank. It is attached to the bottom of the fuel pump and can be serviced, although the screws holding the pump in place can be tricky to remove. This fuel filter is quite large and will likely only plug up if the tank is filled with a lot of dirty gas.
There is also a second fuel filter on the RZR 800, which is located in a black plastic container right above the fuel pump. This secondary fuel filter cannot be purchased separately, and the whole assembly must be replaced if it is plugged.
Some older models of the Polaris RZR 800 may also have a serviceable filter under the front cargo box, although newer models do not. Additionally, some users have reported installing a paper media fuel filter on the vent line, although this is not a standard feature.
Overall, while the fuel filter on the Polaris RZR 800 is located inside the fuel tank, there are multiple fuel filters and fuel injectors that work together to ensure the proper functioning of the engine.
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It's a sock-style filter
The fuel filter on the RZR 800 is located at the end of the fuel pump. It is attached to the bottom of the fuel pump, which is located inside the tank. The fuel filter cannot be purchased separately, and you will have to buy the whole assembly.
Some RZR 800 owners have mentioned using a sock-style filter, also known as an air filter sock, as a pre-filter for their stock air filter. This is placed over the air filter to provide added filtration. Outerwears, Inc. manufactures these fabric socks, which can be custom-made to your specifications. Other RZR 800 owners have used ladies' knee-high pantyhose from Walmart as a sock-style filter, spraying a spot of air filter oil on them and stretching them over the filter.
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The whole assembly must be replaced
The Polaris RZR 800 fuel filter is located on the fuel pump inside the gas tank. It is attached to the bottom of the fuel pump and can be serviced, although the screws holding the pump in place can be tricky to remove.
The fuel filter cannot be purchased separately, so if it becomes plugged, you will need to buy the whole assembly. This can be frustrating, as the plastic assembly is glued together and cannot be reassembled once taken apart. The part number for the whole tank assembly is "2521011" and can be purchased from Babbits Cycle Web Site for $215.79.
It is worth noting that there are two filters on the 2008 model. One is clear and 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.
Some users have reported finding replacement fuel pumps from other vehicles, such as a 1993 Jeep Wrangler, that are identical to the Polaris pump but available at a lower cost. Additionally, you can purchase a replacement fuel pump from Amazon (Alba Racing) for $25, which comes with a new filter bag.
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It's a paper-style filter
The fuel filter on a RZR 800 is located on the end of the fuel pump. It is a paper-style filter, and the plastic assembly is glued together. While it is possible to take the assembly apart, it is challenging to put it back together.
The fuel filter is quite large and is unlikely to plug unless the RZR is filled with a lot of dirty gas. There are two filters on the 2008 model. One is clear and located at 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.
The fuel pump is a common problem on the 800 models, and it is not possible to buy just the fuel filter; you have to buy the whole assembly. However, you can take the whole assembly apart.
It is important to note that the paper-style fuel filter should not be cleaned with compressed air and reused. It is designed to be disposable, and attempting to clean it with compressed air can result in media failure, which can cause issues with the engine.
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Frequently asked questions
The fuel filter is attached to the bottom of the fuel pump, which is located in the tank.
No, you have to buy the complete assembly.
Yes, it is the black plastic container right above the fuel pump.
