2009 Sportsman 500 H.O. Fuel Pump - Polaris ATV Forum
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post #1 of 44 (permalink) Old 02-13-2017, 05:40 AM Thread Starter
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2009 Sportsman 500 H.O. Fuel Pump

Hi All: Getting back as Im still having a fuel issue with this bike and not sure if its pump, carb. or what. I bought an "aftermarket" pump and carb. and the bike will not start after sitting for awhile. And im not sure why but if I blow into the tank either by mouth or air nozzle itll fire up. as it warms up i start to see fuel coming out of the rubber hose at bottom of bowl. As I rev it up more fuel comes out. It eventually will stall out and more than likely have to pressurize tank again to get it to start. Any thoughts or troubleshooting techniques would be greatly appreaciated.
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post #2 of 44 (permalink) Old 02-13-2017, 06:27 AM
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have you hooked up the hoses right?
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post #3 of 44 (permalink) Old 02-13-2017, 06:29 AM
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I have seen it before on this forum. Aftermarket carb may not be set right or have the right jets for your machine. The ad will say it "fits" your machine, but you need to go through it and make sure it's set up right.

I have also seen that a fuel pump will lose it's prime after sitting a while. Usually they will fire up if you crank them a bit and get the fuel moving again.

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2001 Magnum 325 with a blown engine; rebuilt 2004. Broke timeing chain 2016 rebuilt again and still running. Warn winch and Moose 60" plow

Wife's machine:
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My Trail Machine:
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post #4 of 44 (permalink) Old 02-13-2017, 06:31 AM Thread Starter
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Pretty sure, cant find a pic of lines and hoses. But pretty sure everything is. But here's a question, if I did hook up wrong to begin with, and tried running it, would it or could it ruin the pump?
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post #5 of 44 (permalink) Old 02-14-2017, 04:12 AM Thread Starter
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How do you know if pump is working correctly, as far as pulse line and line going to carb of how much fuel is being delivered.
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post #6 of 44 (permalink) Old 02-14-2017, 04:57 AM Thread Starter
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ANd another question, I was told a clogged vent line could cause this condition. What line(s) are these and their locations?
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post #7 of 44 (permalink) Old 02-14-2017, 06:04 AM
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Pull the line that goes to the carb off at the pump. You can take it off at the carb, but easier at the pump. Put another length of hose on the pump and run it into a container. With the engine off, turn on the fuel. You should see a trickle of fuel or none at all. Now with the spark plug off so it won't start, crank the engine. You should see a steady pulse of fuel. It will be enough difference that you can tell it right away.

Reference the vent lines....do you mean the ones off the top of the carb? There should be at least on line off the top of the carb that runs into a hole in the frame or somewhere else that it can get crap in it. I have seen them with a filter on the end just hanging out too.

This pic is my MOSE. It is 2001 and only a 330 engine. But the principle is the same. The clear lines at the back of the carb are the vent lines.
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1st Machine
2001 Magnum 325 with a blown engine; rebuilt 2004. Broke timeing chain 2016 rebuilt again and still running. Warn winch and Moose 60" plow

Wife's machine:
2007 Sportsman 500 EFI, Polaris Winch, 26" Bear Claw HTRs on Moose 427x Wheels. 12x7 front, 12x8 rear, QSC Clutch Kit
My Trail Machine:
2004 Sportsman 600 Twin, 25" RipSaw Tires on stock steel wheels, Moose rear box
Completed Project machine:
2001 Magnum 325 MOSE with a blown engine. Transplanted a 2005 Magnum 330 engine. Committed suicide on the trail Oct 2016. Spun Rod Bearing after oild cooler line failure. Rebuilding Engine.

Last edited by stave7119; 02-14-2017 at 06:09 AM.
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post #8 of 44 (permalink) Old 02-14-2017, 07:36 AM Thread Starter
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Thanks, and being I cant find a manual for this year anywhere, can anyone tell me the hookups on carb. Right now I have the fuel line with the fuel filter inline going to the right side of carb, as you are sitting on machine and pulse line going to left side. Does this seem correct?
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post #9 of 44 (permalink) Old 02-14-2017, 08:54 AM
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Here is a site that costs $5 for a service manual download of that model. Polaris ATV Service Manuals PDF Download

2011 Sportsman 500 HO
Warn Winch
Heat Demon Handwarmers
Nothing else special

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post #10 of 44 (permalink) Old 02-14-2017, 09:05 AM
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Quote:
Originally Posted by polarisman1999 View Post
Thanks, and being I cant find a manual for this year anywhere, can anyone tell me the hookups on carb. Right now I have the fuel line with the fuel filter inline going to the right side of carb, as you are sitting on machine and pulse line going to left side. Does this seem correct?
Yes, pulse line goes to airbox and line with fuel filter goes to right side of carb. The pulse line should have zero fuel in it. Pull and check it at pump. If it has fuel, pump is done for.

Did you check the line going to the carb as stave7119 suggested? That'll tell you if pump is working correctly. Luck.

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