2006 SPORTSMAN 800 EFI AWESOME MACHINE HAS CRAZY POWER BUT ON OUR LAST MUD RUN INTO THE BACKWOODS IT QUIT
20 MILES BACK IN BUSH,VERY WARM DAY ALONG LEVEL TRAIL JUST CRAWLING ALONG I DONE A ECU DIAGNOSTIC CHECK AND NO CODES WRE STORED IN THE ECU,REMOVE GAS CAP & COULD SEE FUEL,SEEMED LIKE IT WANTED TO START BUT SOUNDED LIKE IT WAS OUT OF FUEL,WE COULD HEAR FUEL PUMP PRIMING UP,JUST BEFORE TOWING BACK IT TREID PUTTING IN FUEL AND IN STARTED! IT RAN FINE FOR ABOUT AN HOUR AND THE SAME THING HAPPENED AGAIN SO WE OUT MORE FUEL IN AND IT REFIRED RIGHT AWAY.
ONCE BACK IN MY SHOP WE REMOVED FUEL TANK & PUMP DIDN'T SEE ANYTHING WRONG WITH PICK-UP TUBE OR INTERNAL LINES OF PUMP.THE PUMP SITS ABOUT AT THE LEVEL WHERE IT ALWAY QUIT,ONCE WE FILLED THE TANK WHICK WOULD PUT THE LEVEL OVER THE TOP OF SENDING UNIT IT WOULD START AN RUN FINE. FUEL PRESSURE WAS AT SPEC. 40PSI.
POLARIS DEALER SAYS ????????OUT OF WARRANTY. TRY A PUMP ASSEMBLY, PUMP & FUEL TANK HAVE TO BE PURCHASED TOGETHER AS AN ASSEMBLY, (BIG BUCKS) AND MITE NOT BE THE PROBLEM.
THIS PROBLEM HAPPENED ALL WEEKEND AS LONG AS WE KEPT TANK FULL IT RAN FINE.
ANY IDEAS PLEASE !!.
THANKS: RUNNINGREDD, RUNNING OUT OF FUEL!

 

that does sound kinda weird for sure. i thought when the pump went bad they stopped all together. i have a post telling how you can buy a car fuel pump to put in place w/out buying a whole new tank and pump assem. what was your gas gauge reading at the time it quit?

 

Does it start with the gas cap removed? If so, maybe your vent tube is blocked. If not, Ya got me..........

 

I've read about others with this exact problem, it's the fuel pump. The pump heats up and stops when the fuel level in the tank is low, filling the tank cools the pump and it runs again until the problem repeats.

From info I've gathered but not confirmed the pump is made by Airtex #E8198, the 89 to 92 Hyundai Sonata uses this same pump. About a 100 bucks at the local auto parts, fits as stock.

 

that is the correct info if i remeber right w/out going to look it up. so you think w/ the pump not imersed in the gas it heats up and breaks down?could be i guess. if i remember right the were no codes shown when the pump dies. but could be wrong.

 

powerslide is correct, Ive had the pumps get so hot that they actually boil the fuel in the tank, usually cause from lack of matenance on the fuel filter and running contaminated fuel, by experience replace the pump and the filter. Proper matinance on the filter is crutial on the efi units

 

was wondering where fuel filter is located on 800sp..also why does it say to have dealer change it?

 

i havent look at mine as of yet but it should be inline by the frame b4 it goes to the throttle body. just follow the gas line and you'll see it.

 

The filter is in front of the engine and in back of the top of the radiator, silver can type....

 

ok, so it must be differnt form where my old 500 was. good to know thanks.