gasteck, i hate to keep pushing this but i would really pull it apart yourself at least the gas tank and hand it over if you do not feel you can do it. it would save you a ton of labor cost and i beleave its pretty basic to tank the tank off or get a book and save that 50.00/hr. price.

 

gastech; i have a 06 500 efi and when i got it i didnt think the fuel gauge worked right. the sending unit and pump-pickup screen are all one unit. the sock-screen is farely large and unless you put very dirty gas in the tank i dont think it would be pluged on this new of machine. i dont think you can get the pump sender float out of the tank with out bending the float rod. the unit is larger than the hole it goes in to. i was going to pull mine and thought better not to after i saw the setup. you can get it about half way out of the tank test and check. if the pump isnt making any noise i would go back and check the wireing again. the wireing harness runs from the head light pod as i rember. you need to back probe the tank side of the connector with a 2 paper clips or pins and make sure you HAVE POWER AND A GROUND in to the pump. the sending unit wire also runs in this connector and i dont rember what color it was but when i checked mine i didnt have any trouble figuring out one from the others. i think you have to pull the front plastic to get to the conector but you need to do that any way if you end up changing the tank. i have seen the out side of 800 tank and it looks the same as my 500 efi so i think they could be differnt part #'s but will be the same to work on. i know this wasnt the answer you were looking for but hope it helps in the end.

 

I know everybody is saying how come this fool doesn't just take this thing apart himself and do it. Welllllllll, the reason is I live in one of the hotest parts of Arizona and my garage is a metal garage with no insulation. I just went by the bank on the way home from work and the outside temp. was 111 Deg. F, it's probably at least 20 Deg. hotter in the garage. I work in the desert most of the day and when I get home it is just to much to go back out in it. (By the way when I go to work at 5 a.m. it's normally between 88 and 92).

I know you are all saying Whah! Whah! Whah! but at least now you know the reason why.

The ridge runner thing may be a good referral. The reason the have the gas tanks for sale is they take the fuel pumps out to use on their applications. By the way if you need any plastic for the 700's or 800's or any other parts for that matter check these people out they are great.

Thanks for the excellent help, I'll post on here to let everyone know how I made out.

 

First of all thanks to everyone for the help! The referral to Ridge Runner was great! They were able to sell me only the fuel pump only so I didn't have to buy the pump and tank together from Polaris, this saved me close to $300. It took a total of 2 hours labor. You guys saved me a bundle of money, Thanks, Thanks, Thanks!!! This proves how valuable and useful these forums are. Now I gotta get ready to go to the Rocky Mountain ATV Jamboree in 2 Weeks (let the fun begin).

If you ever need any parts for a Sportsman, give them a call first.

Gastech

 

glad to help anyway i can. i know this forums info is priceless to me. the experince that we all have and to share it w/ other riders is the best in the business.

 

So far I have not had one in my shop that needed a fuel pump. Sooner or later I will.

I intend to find another aftermarket automotive pump that will work.

All that is needed is that it fit in the tank and have the correct pressure.

Most multi port EFI systems work off almost the same fuel pressure so finding one with more or less the correct pressure should not be a problem.

One with a bit too much pressure will still work because the fuel pressure regulater will make up for that.

I need to know from the guy that just bought the pump exactly how big it is.

How long and how big around.

 

found one on e-bay fuel pup w/tank complete auction ends in 2 days. Take Care,Ride safe! Perry

http://cgi.ebay.com/ebaymotors/Polar...QQcmdZViewItem

 

Here's the dimensions of the pump, this isn't going to be easy. The main body of the pump is 2.75 in. long and 1.5 in. in diameter. The pick up portion of the pump that extends down from the main body is .5 in. long and is 7/8 in diameter. The plastic portion that extends up from the main body of the pump with the discharge and the wire terminals is approx. 2 1/8 from the main body to the top of the fuel discharge hose connection. I hope this helps, I got the measurements as close as I could with what I had to measure.

Gastech