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Old 07-26-2011, 02:28 PM
guyrand57's Avatar
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Fuel pump in 2005 atv 700cc

I recently discovered my fuel pump was going out in my 2005 Polaris 4 wheeler. I was told by the repair shop that it would cost over $600 to buy the new fuel tank/fuel pump. I was told that the two were sold as one unit, and they could not replace just the pump. After crying to the service department about how long it would take me to save that kind of money, he told me he did some searching, and he thought a fuel pump from a Hunday Sonata would do the trick, and he could order just that part, and take the old one off my tank and swap it out. The new pump would run about $150, and he thought it would work. My comment to him was that if it doesn't work, I'm out the cost of the replacement pump, and then probably have to fork out the whold $600 to buy the parts that Polaris recommends. has anyone come across anything like this? I'm looking for a little education, I haven't had time to tear the tank off and take a look for myself. Any help is greatly appreciated.
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Old 07-26-2011, 04:28 PM
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airtec _E8198 or Carter E-7000 from your local parts house will work around $120 I think I used the Carter on the last one I did, still runnin fine
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Old 07-26-2011, 08:57 PM
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Old 07-27-2011, 10:07 AM
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Are those Polaris part numbers?
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Old 07-27-2011, 10:47 AM
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No that is a brand and model number I believe that your local auto parts store should be able to look up and cross reference. They probably fit the Sonata like your repair guy said.
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04 Sportsman 700 efi black and silver, Big Gun Evo exhaust and tuner,3 light mod,reverse override,bar and thumb warmers,Moose pregressors,Black Rock wheels,Polaris(warn) winch and plow, 2 inch receiver, Filtermag.
08 Sportsman 500 efi Browning camo, Big gun Evo exhaust and tuner,3 light mod,reverse override,bar and thumb warmers,Moose pregressors,Polaris(warn) winch, Cycle Country plow, 2 inch receiver, Black rock wheels,Filtermag
00 Magnum 325 not very HO green, rolled, wrecked and rebuilt,heated grips and thumb warmer, Filtermag.
88 Yamaha Warrior 350 my first
88 Honda Foreman 350 takes care of the yard work
91 Suzuki DR 350 solves the urge to ride wheelies and catch big air
05 Kawasaki KLR 650 scratches the paved road itch
92&93 Indy 500 EFI SKSs takes care of the need to get away from home in the winter
04 Yerf Dog spiderbox buggy was supposed to be for the kids but I find I cant quit tinkering with it
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Old 07-27-2011, 11:48 AM
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Can anyone comment on being able to just change the fuel pump out? Service desk at the dealer told me that I had to buy both the tank, and the pump. Does anyone know if I can pull the bad pump off my tank and swap it out for the new one? And is the pump on the bottom of the tank, or inside? As you can tell, I haven't torn it all apart yet.
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Old 07-27-2011, 12:00 PM
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I have not done it my self but have read of others doing it. I believe Russ C has done it. You have to cut the old pump out of the factory wiring and splice the new pump in. Polaris did not make them to be replaced. Why? I don't know. From my reading it didn't sound hard. The worse part was getting everything apart and the pump assembly out of the tank. Once out you just cut the wires to the old pump and splice the new one in.
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04 Sportsman 700 efi black and silver, Big Gun Evo exhaust and tuner,3 light mod,reverse override,bar and thumb warmers,Moose pregressors,Black Rock wheels,Polaris(warn) winch and plow, 2 inch receiver, Filtermag.
08 Sportsman 500 efi Browning camo, Big gun Evo exhaust and tuner,3 light mod,reverse override,bar and thumb warmers,Moose pregressors,Polaris(warn) winch, Cycle Country plow, 2 inch receiver, Black rock wheels,Filtermag
00 Magnum 325 not very HO green, rolled, wrecked and rebuilt,heated grips and thumb warmer, Filtermag.
88 Yamaha Warrior 350 my first
88 Honda Foreman 350 takes care of the yard work
91 Suzuki DR 350 solves the urge to ride wheelies and catch big air
05 Kawasaki KLR 650 scratches the paved road itch
92&93 Indy 500 EFI SKSs takes care of the need to get away from home in the winter
04 Yerf Dog spiderbox buggy was supposed to be for the kids but I find I cant quit tinkering with it
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Old 07-27-2011, 12:12 PM
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the fuel pump can be removed by removing the screws around the pump flange,you are going to have to remove the front rack and front fender,clutch cover breather tube .you have to remove the fuel lines,they are quick disconnect,and unplug the pump/fuel guage electrical connector.remove the two rear bolts holding the gas tank down,unplug the tank breather tube.i would also blow the fuel filter out or change the filter.the fuel pump is mounted to the top front of the fuel tank.
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Old 07-27-2011, 05:24 PM
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just like mstermechanic907 said < Ive done two or three of them over the years, I think the plug ins will even work but its been awhile so you might have to splice the old one onto new pump, cant remember , its hell to get old
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Old 11-16-2011, 08:23 AM
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I just replaced my fuel pump on a 2007 sportsman 500 efi. No fuel priming sound when key was turned, no fuel to the fuel rail and no fuses to be checked. As said earlier in this thread, the airtex E8198($85 auto zone) will work perfectly. I went with the Bestest
BE2044($80 O'Reillys) and it is running just fine. No splicing of wires was required from old pump to new one, just pull the neg and pos terminals from the old and hook them back up to the new one. Before dropping the new pump back in tank after swapping the neg and pos terminals, turn the key to make sure the new pump works. A couple of zip ties to secure the pump to the pick up tube and your good to go. I do reccommend getting a new fuel strainer($8) that goes on the bottom of the pump and also change out your fuel filter($35 at dealer) It was crazy to find out that the dealer couldn't just sell the pump, which would probably be $300 anyways, without the tank. Hope this info will save everyone time and money.
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