First off want to thank OPT for all his assistance and all of you who may have posted to the questions I have ask during the time getting this 2007 Polaris quad back in shape. I changed filters reset the valves and finally narrowed the problem down.

Finally came to the conclusion that the pump in this quad was not performing when giving it a second pressure test. It would get to the 39psi but as soon as the pump stopped the pressure would start to fall and would drop to 35.5 then just sit there and the pump would not restart. The quad would start and run perfect but as the rpm's increased to about 3500-4000 rpm it would just almost quit.

So after talking to the Polaris dealer and learning that I would have to buy a whole tank assembly ( their quote was around $650.00 plus tax) and could not just buy a pump I started doing the research and ended up choosing the Carter P72118 fuel pump as it matched the stock pump pretty close. Now I did find the stock pump and it was from a company located in China but there was none for retail purchasing so that was a dead end. It took some work and head scratching to get this pump into the stock plastic fuel assembly but it worked and to see how it went check out the video link below


As of this time I have been running this quad everyday for around a week (it's a working quad) with no issues and it runs perfect. The only worry I have is with the new filter sitting on the bottom of the tank for which it was not designed to do. Now the pump ended up almost exactly the same length as the stock pump so there is not a lot of pressure on the new filter so should last.

I made a video of the pump assembly to start with just for my own use so I could reference it when putting the pump back together but got thinking there has to be a bunch of people out there having these same issues with the older quads and a video could help. So I put one together and posted on YouTube. Hope it can help someone. Here is the link below.
http://api.viglink.com/api/click?for...%3DHR1mJUvKhrE


this link now works even though it is a different name. stendori

 

I don't know why it posted the video twice but at least it posted it.

 

Good video that can help others.I know some have used Carter along with Airtex E8198 pumps. We did one pump at the shop(supplied by the owner) when we had some free time to see what was involved. Yes like you say it's a little tough,but beats having to pay oem prices.I retired shortly after that and that was all my experience on these pumps.Replaced a bunch of Bosh pumps on recall for the Victory line we carried for a while. Polaris does offer pump replacements on some atv models now but not all of them and are way too high.Only problem is that I don't know if anyone has found any replacement regulators if they go out. Good video that should go to the sticky section. By the way,any markings on the oem pump as to manufacturer?

 

Nice video. Agree with OPT. This needs to be in the sticky. Only a matter of time when more people start having fuel pump issues with their aging EFI 500's. Too bad there isn't a quick fix like some of the other models.

 

The OEM pump is a BOSH part number 0 580 453 476 made in China. I searched quite a bit and did find that pump in a couple places but no where could I find an outlet that sold it. I got pretty frustrated to say the least.

 

Bosch kinda says it all for me as that's the pump we had to change out in all the Victories on a couple different recalls. Just like any other manufacturer Polaris probably had a good deal from them.Some ways doesn't matter as most of the stuff is from China anyway.Bosch used to be a good respectable German brand name.Found a bunch of different pumps,don't even think AC Delco,Delphi are even made in America anymore. Gonna need a fuel pump for the old Chevy soon as the regulator is starting to bleed down over night and getting harder to start,but once started runs fine.
http://www.jcwhitney.com/fuel-pumps-...2062j1s17.jcwx Plus found one guy's list of replacement pumps for the Bosch. Sounds like you can take your choice if the list is correct.
I found these cross references to BOSCH 0580453476

AIRTEX E2068;E8335
AC DELCO EP2019H;EP432;EP482;EP487
FORD F23Z-9H307A;F32Z-9A407A;F4PZ-9H307A;f52z-9350aa;
F57Z-9H307D;F57Z-9H307J;F58Z-9A407C;F5AZ-9350A;
F5RZ-9350A;F65Z-9A407AALF65Z-9A407BA;F68Z-9A407B;
F75Z-9A407GA;F75Z-9A407HA;F7CZ-9350AA;F7UZ-9A407AB;
F7UZ-9A407EA;E7UZ-9H407EB;E7UZ-9H407FB;F85Z-9H307AA;
F87Z-9H307AA;F87Z-9H307BALF87Z-9H307CA;F8XZ-9H307EB;
JEEP 5003861AA;50038689AA
MITSUBISHI MR391856
TOYOTA 23221-03040;23221-21020
BOSCH 0580453481;0580454001
DELPHI FE0150

Application QCURA CL 2001
FORD PROBE 1993-1994
WAZDA MIATA 1990
MX-6 1991-1997
626 1994-1997
HONDA CICIC 1992-1996
ISUZU TROOPER 1998-2000
JEEP CHEROKEE 1996-1999
LADA EORMA 1994
MISSAN MAXIM 2000
KIA SEPHIA 1995-1997
SPORIAGE 1995-1997

 

Thanks for the cross references above. Have saved them off for future reference if needed. Will run this Carter and see what the outcome will be. Little concerted about the filter rubbing on the bottom of the tank but time will tell if that is a weak point of this conversion.

Noticed yesterday had a little bog right around 5200 rpm's. So will keep fooling with this thing and see if there are any other issues. Thanks for all your help OPT appreciate it!

 

bump for the now working link.