Polaris Fuel Pumps

ATV Rancher · Jul 22, 2015

We've had numerous Polaris ATVs; 850s, a 550, and a 900 Ranger, with the first 850 being new in '09. Every one of them had the fuel pump go bad, usually at 4000 and some odd miles. The last one to go bad was two days ago. A 2015 850, app. 5 months old with 3400 miles on it. Took it to the dealer yesterday, and they were good enough to pull the pump off a new unit to put on it, because the pumps are backordered (WTF?) until middle of August. Anybody else having issues? It seems like when they begin to fail it's after a couple hours of steady riding, then it's downhill after that. Have always been able to get back to civilization by letting them periodically cool down when they start cutting out.

youngpolarisguy · Jul 23, 2015

I did one on my 850 last year, just under 5000km. quad ran fine just did seem to have the power it used and i decided to check fuel pressure and it only had like 28psi, new pump in runs great. I think the problem with mine was the sock was so plugged that it just couldn't suck enough fuel.

whoDEANie · Jul 24, 2015

If you had one or two burn out, I'd suggest that it was probably just par for the course since they do burn out from time to time. However, if you're burning them out on every machine, I'm thinking there's something within your control that's causing it.

- If you frequently run them out of fuel (or even close to empty), that might explain it right there - you'll overwork your pump when this happens. I believe you can roast a pump pretty quickly that way under the right conditions.
- You may be fouling you fuel filters with dirty fuel. I'm uncertain if these machines have a serviceable fuel filter - there's a good chance you have to replace the filter and pump as a unit. If you do have a serviceable filter, clean/replace it often. You may also want to consider filtering you gas before pouring it into the quad.

RMPERK · Jul 24, 2015

I have had a couple go at appx 4000 km and just seems like poor life. Never run out of fuel and hardly any hills etc as the kids use it up and down the road

QMAO · Jul 25, 2015

Just a bit of info for anyone needing to replace thier fuel pump/filter that is a unit in the tank,, do some searching on the net.
The OEM complete unit for many machines is about $600.00. Any time I have had problems and had to replace a fuel pump, I have ben able to find a replacement pump and filter for less than $100.00

Sledderglen · Jul 25, 2015

QMAO said:
Just a bit of info for anyone needing to replace thier fuel pump/filter that is a unit in the tank,, do some searching on the net.
The OEM complete unit for many machines is about $600.00. Any time I have had problems and had to replace a fuel pump, I have ben able to find a replacement pump and filter for less than $100.00

From where. Napa matching up numbers or visual???

QMAO · Jul 25, 2015

If you do some research either a Walboro or Airtex part number will be available. I have found that many Ebay adds will show which vehicles (make,year,model) the part number will fit into.
Most auto parts supplier should be able to get.

Give me an example of a machine you might need a pump for and I will research and post my results with links.

ATV Rancher · Jul 25, 2015

whoDEANie said:
If you had one or two burn out, I'd suggest that it was probably just par for the course since they do burn out from time to time. However, if you're burning them out on every machine, I'm thinking there's something within your control that's causing it.

- If you frequently run them out of fuel (or even close to empty), that might explain it right there - you'll overwork your pump when this happens. I believe you can roast a pump pretty quickly that way under the right conditions.
- You may be fouling you fuel filters with dirty fuel. I'm uncertain if these machines have a serviceable fuel filter - there's a good chance you have to replace the filter and pump as a unit. If you do have a serviceable filter, clean/replace it often. You may also want to consider filtering you gas before pouring it into the quad.

Wish the problem could be contributed to something logical, like you mention. I can only recall one machine ever being run out of gas, and it had an inaccurate fuel gauge. They're filled out of a bulk tank with a spin on filter after the pump. The fact that Polaris has the pump back ordered leads me to suspect an ongoing quality issue that they need to address.

ATV Rancher · Jul 25, 2015

QMAO said:
Just a bit of info for anyone needing to replace thier fuel pump/filter that is a unit in the tank,, do some searching on the net.
The OEM complete unit for many machines is about $600.00. Any time I have had problems and had to replace a fuel pump, I have ben able to find a replacement pump and filter for less than $100.00

Good alternative. My boys replaced a couple King Quad pumps with ebay replacements.....been a while. They worked alright, except for the fuel gauge sending unit, gauge always showed Empty from then on, and took a while for delivery. The original King Quad pumps did last ~~10,000 miles, but the machines had other issues, and not nearly as user friendly, or pleasant and fun to ride as the Sportsman, IMO.

doorfx · Jul 25, 2015

ATV Rancher said:
Wish the problem could be contributed to something logical, like you mention. I can only recall one machine ever being run out of gas, and it had an inaccurate fuel gauge. They're filled out of a bulk tank with a spin on filter after the pump. The fact that Polaris has the pump back ordered leads me to suspect an ongoing quality issue that they need to address.

A Polaris quality issue....I can't believe it. Rzrgade is going to be some pissed when he learns about this.

QMAO · Jul 26, 2015

Ok...I owned 4 King Quads before I went to my RZR. I did replace fuel pumps on my quads when they would not run correctly and it fixed the problem. I strongly believe they failed because of dirty fuel being put into the tank or water and mud getting into the tank throught the vent lines.
I would suspect poor fuel from the bulk tank.
I started using one of these Home and many of my problems stopped.

zeke · Jul 28, 2015

I bought a used razor a 3 yrs ago and the pump went too. Went to cycle works and almost crapped my pants when I heard how much. Found one on ebay for around $100. Still working fine.

ATV Rancher · Aug 17, 2015

Don't enjoy beating a dead horse, well.....maybe a little, but another one went out. This time on a 2013 850 just shy of 5000 miles. This is the third fuel pump for that machine, with the previous one being just replaced in April. The bulk tank the gas comes out of is used by a number of vehicles, as well, and has a Wix spin on filter. Have to round up, move, and ship a bunch of yearlings (steers and spayed heifers on grass) soon so couldn't wait on one from ebay. Anyway, hope someone from Polaris sees this, and maybe finally does something to get this fecal material figured out.

youngpolarisguy · Aug 18, 2015

I don't think its just a Polaris thing my family rides sportsman's and I am the only one who had to replace one and the sock on my pump was black. All high mileage machines My friend has a brute and has lots of fuel pump problems to. You have to think these things never just roll up to the pump and fill up, they are all mostly filled from tidy tanks and jerry cans.

ATV Rancher · Aug 19, 2015

youngpolarisguy said:
I don't think its just a Polaris thing my family rides sportsman's and I am the only one who had to replace one and the sock on my pump was black. All high mileage machines My friend has a brute and has lots of fuel pump problems to. You have to think these things never just roll up to the pump and fill up, they are all mostly filled from tidy tanks and jerry cans.

I wish your family continued good luck! These are usually ridden or trailered back to HQ and refilled from the filtered bulk tank, since they have a fairly good range. Any extra gas is carried in clean 2.5 gallon oil containers that aren't even vented. That pump had only been in there since April. My son changed it and says it was clean, as was the others he's changed. The dealer never mentioned any of the ones changed there being dirty. It seems like some of the early 850s had fewer issues than the newer ones....maybe. Going to try the Ebay route next and keep one on hand.

youngpolarisguy · Aug 19, 2015

I can't see why Napa or a good parts store can't match up a pump. Then all u have to do is change the pump part out and would only cost like 80 bucks. We tried that with buddy's brute but they use a short pump motor and we couldn't find one but if I remember correct my 850 had a full size pump

Sent from my SM-G920W8 using Tapatalk

imdoo'n · Aug 20, 2015

With just a bit of roaming on a few dedicated polaris forums you may just be able to find an aftermarket equivalent.

ATV Rancher · Sep 5, 2015

900 Ranger, on second fuel pump, up and died today. No restart after cooling down. Let me guess, will it be another fuel pump?

QMAO · Sep 7, 2015

Airtex E8335 Electric Fuel Pump, Fuel Pumps & Accessories - Amazon Canada
I am sure this pump will work.

ATV Rancher · Sep 9, 2015

QMAO said:
Airtex E8335 Electric Fuel Pump, Fuel Pumps & Accessories - Amazon Canada
I am sure this pump will work.

One was already ordered from Ebay, but the one you linked to would have been a better deal.

Polaris Fuel Pumps

Active VIP Member

Active VIP Member

Active VIP Member

Active VIP Member

Active VIP Member

Super Moderator

Active VIP Member

Active VIP Member

Active VIP Member

Active VIP Member

Active VIP Member

Active member

Active VIP Member

Active VIP Member

Active VIP Member

Active VIP Member

Active VIP Member

Active VIP Member

Active VIP Member

Active VIP Member

Similar threads