I have a 2004.5 Polaris Sportsman 700 EFI with a bad fuel pump.
It has been an on-going problem but has never been serious enough to take back to the dealer.
It seemed to want to die when the machine was warm and running for a at least an hour.
Last week it decided to completely shut down.
So I took it to the dealer where I was told he had just finished another one.
I purchased mine in March of 2004 and will look at the build date as soon as I can.

I would like to know how many others are out there with the same problem?
BUILD DATE?

I have made contact with Polaris on the issue and need to follow up with good information.
700 miles and the fuel pump goes out... POOR QUALITY... and they know it!

Jon

 

Mine crapped out at 200 miles and 50 hrs, on very cold winter night right in my driveway.

 

Does any of you know how much a new fuel pump costs, just curious in case mine ever fails.

 

I pick mine up tonight...
Seems it is all part of the fuel tank...
One piece!
I think the part was around 400??
All together it's going to cost me over $500 to get her back!
Just to top it off my new 800 blew the water pump out....
and melted the plastic!
Warranty!

 

Well I picked up the beast yesterday...
Polaris Part Number 2520461 Fuel Tank w/ Fuel Pump $429.99
5431053 Vent, Tank $5.19
Labor Charge 1.35 hrs $74.25

$537.72 in damages!
The machine had 745 miles and 137 hours on it!
When the ATV would hit peak temp the fuel pump would quit working!

I kept the old parts and will be disecting them for my own knowledge...
If I can find another fuel pump... I will let everyone know!
Somebody has to make it... Right?

Later!

 

I hope I never have to change one of those. What a rip off that you have to buy the tank as well. I seen a pump only on ebay of $50 so you can take them apart.

 

Does anyone know what the correct fuel pressure is on these machines?

I am sure there is a cheaper automotive pump that can be made to work.

I can buy fuel pumps for a lot of EFI cars for about $80.

All it has to have is close to the correct pressure. The Fuel pressure regulator can handle some varaition in pressure.

 

Yeah,
I've had the exact problem. Mine is a 2006 sportsman 700 EFI. After the machine gets warm (20-30 minutes), it shuts down. The longer you let it sit with machine off, the longer it will run but then shuts down again. There is a replacement automotive pump which can be purchased around $100. The address is:
http://forums.atvconnection.co...key=y&keyword1=airtex

I replaced my original pump with this one and it didn't fix my problem. I explaned the situation to the mechanic and he said that it could be the fuel regulator which would not have been connected to the replacement pump. Looks like I'm going to have to brake down and spend the $500 for the tank/pump to fix my problem. There is a recall with certain sportsman models which can be found at the polaris website (type recall in search option) so I need to take it in and so my recal can be serviced. I'll let the mechanic check the fuel pressure while it is there. He said the machine should maintain 40psi when you turn the key on without starting. He checked the pressure before I replaced it witht he replaced automotive pump and it was not holding the 40psi.
It seems to me that there are a lot of fuel pump problems with the polaris EFI modules and polaris should stand by their machines by having a recall replacement with a better pump. And yeah, it is a joke that polaris will not replace just the pump but you have to purchase the entire tank to get the pump. It's all about $

 

I have a 2006 sportsman 500 EFI with 8 hours on the machine and the fuel pump went out. Polaris response was oh call the dealer. The dealer response was $1200.00 please. I agree VERY POOR Quality.

 

my 2006 was built 12/15/2005. thanks