Good Morning
I am new to your forum but sure glad I found you. I need some help. I have a 2004 Polaris 700EFI Sportsman 4X4. The fuel pump went out, makes it hard to ride! I pulled the unit out of the gas tank. It is a combination fuel pump and gauge. I priced a new one and found Polaris in all their wisdom decided not to sell just the fuel pump but the pump and tank at about $500. The man I talked to said I could go to Kragen and get just the pump.
Finally my question. Is there a shop manual or wiring diagram for this bike? There is a plug with 3 wires and I am guessing one is for the gauge and will not allow the pump to run when empty. I would like to be able bypass the gauge for a test and don't know the wiring
Thanks
Pam

 

try your question in the polaris section. and yes. there are 3 wires. im not shure of what the colors you havr are. but a 2008 500 efi are the brown is ground, vioelt/white is the fuel level sensor wire, red/dark green is the fuel pump + wire.

 

Thanks for your reply. I took the unit to my auto mechanic and he just laughed and said Polaris was really cheating people it is just a regular fuel pump. He found the necessary pressure and stuck a new pump on the unit for me. Maybe that is why they discontinued it. Too many people could replace it without buying their expensive one.
Thanks for the help
Pam

 

yup iv heard that also. and sounds good..

 

That is good to know.

 

I have the same problem with my machine, its an '04 sportsman 700 twin. The pump has had it and I called the dealers here, They told me $670 for the tank and pump which is crazy. What kinda pump did you get for you're quad or what's it for so hopefully I can fix mine reasonably cheap too. Thanks

 

I also have pump issues. I have an 06 500 x2 efi with a faulty pump. The old pump is out and on the workbench, when I put 12v power to it it clicks once but does not turn. So I ordered (3/26) the airtex E8198 pump and the airtex FS111 strainer from Advaced auto online. About $90 delivered. I'll let you know how it goes. The next problem I have is there a fuse or breaker for the red w/ green strip fuel pump wire? I have no power to it regardless of the key is on or off.

Thanks

 

Only with the key turned on will the red w/ green strip fuel pump wire register 12v on the meter when the brown fuel pump wire is used as the ground. Grounding to the frame (or neg batt teminal) will not show the voltage).

I am sure most everyone here knows that, but i just found out for myself. Still trying to figure out where the fusable link, fuse, or circuit breaker(s) are on my 06 500 EFI X2. Any feedback?

 

Read though this link of common aftermarket parts and see if it helps. My dealer wanted $320 for a Fan and I picked one up for $65 do to this link. LOL

Make a list of common numbers we need

 

Completed the fuel pump replacement on a 06 X2 500 EFI. Runs like new.

A few comments:
- Replace the silver furnance duct tape on the bottom of the tank.
- Blow out or vaccum the gas tank before ressembly.
- Save the original fuel pump / tank gasket. One in the kit is too large.
- Make sure you get clearance on the left (driver side) rear tank bolt so you do not puncture the crankcase vent.
- Rememer to put the hard plastic washers under the tank (prevents tank to frame rub).
- Kit had hose and clamps.
-Parts used: Advance auto online (under $90 delivered)

Fuel pump:
Airtex E8198 (on the pump A205 10208-1 Made in the USA)
SKU # 3141594

Fuel strainer:
Airtex FS111
SKU # 3140822


2Besure..........