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Old 04-06-2013, 06:49 PM
cmruffin's Avatar
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FIXED: 2008 polaris sportsman 500 HO EFI fuel pump

2008 Polaris Sportsman 500 HO EFI

It looks like I've got a bad fuel pump - voltage looks good at the connector but it won't pump gas. I pulled the pump from the tank but I'm having trouble locating a replacement part, does anyone know how to buy/replace the actual pump in the assembly?

The assembly has the following part numbers stamped on the top::

Polaris 2520794
Bosch f01rb0s139
788202

How do I locate a replacement? Are there any best known techniques for replacing the pump in the assembly?
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2008 polaris sportsman 500 HO EFI fuel pump-20130406_163159.jpg   2008 polaris sportsman 500 HO EFI fuel pump-20130406_163219.jpg  

Last edited by cmruffin; 04-07-2013 at 05:41 PM.
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Old 04-06-2013, 08:01 PM
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The only way Polaris sells it, is with the tank and all for about $500. There is a carter fuel pump folks here have had luck with, that sells for about $100. I have no personal experience with it, and am sure someone (AKStew) will be along shortly with a part number, etc.

Sean
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Old 04-07-2013, 12:04 AM
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Welcome to the board!
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Old 04-07-2013, 12:56 AM
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2008 polaris sportsman 500 HO EFI fuel pump

Carter fuel pump #P72118.

Rockauto.com is a good place to get it.
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2011 Sportsman 500 HO Touring: Polaris 3500 lb. Winch, Kimpex Adventure XL Trunk, 7" Passenger Foot Risers, UNI Foam Filter
2006 Sportsman 500 X2 EFI: Superwinch Terra 25 w/Synthetic Rope, Kolpin 4 gal Gas Pack, 3" Passenger Foot Risers, 3-Headlight Mod, K&N Filter

SOLD 2010 Sportsman 300: Polaris 2500 lb. Winch, Kolpin Rear Seat (for the dog), UNI Foam Filter
SOLD 2006 Sportsman 700 Twin EFI: 27" Mud-Lite XTR, Superwinch Terra 35 w/Synthetic Rope, Polaris HD Front Springs, OEM Front Bumper Guard, WES Rear Seat, Kimpex Fender Guards w/Footpegs, 3-Headlight Mod, K&N Filter, Symtec Heated Grips
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Old 04-07-2013, 05:38 PM
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After I got the actual pump out of the assembly it had the following markings:

Bosch F01R 00R 007

I couldn't find the Carter P72118 pump locally but it cross-referenced to an airtex E8198 at the o'reillys website so I decided to give it a try. Unfortunately that pump didn't work out in my model. The molded plastic assembly the pump fits into is designed around the inlet for the filter screen/sock, and it didn't allow the filter screen/sock to be attached once it was encased in the assembly.

I did however locate an airtex E8335 which cross-referenced down at o'reillys to a Bosch 69544 which I bought since it had a lifetime warranty. It turned out to be a drop-in replacement.

I'm back up and running! Thanks for your help on this it got me pointed in the right direction.
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Old 04-07-2013, 11:16 PM
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2008 polaris sportsman 500 HO EFI fuel pump

Sorry about the part number snafu and glad you were able to fix it despite my "help."

Stew
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2011 Sportsman 500 HO Touring: Polaris 3500 lb. Winch, Kimpex Adventure XL Trunk, 7" Passenger Foot Risers, UNI Foam Filter
2006 Sportsman 500 X2 EFI: Superwinch Terra 25 w/Synthetic Rope, Kolpin 4 gal Gas Pack, 3" Passenger Foot Risers, 3-Headlight Mod, K&N Filter

SOLD 2010 Sportsman 300: Polaris 2500 lb. Winch, Kolpin Rear Seat (for the dog), UNI Foam Filter
SOLD 2006 Sportsman 700 Twin EFI: 27" Mud-Lite XTR, Superwinch Terra 35 w/Synthetic Rope, Polaris HD Front Springs, OEM Front Bumper Guard, WES Rear Seat, Kimpex Fender Guards w/Footpegs, 3-Headlight Mod, K&N Filter, Symtec Heated Grips
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Old 06-22-2013, 11:54 AM
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I just learned something else. In that fuel pump assembly, between the pump and regulator there is something encased in black housing. I think it is a filter. I had changed two pumps and it was still bogging, like 5 mph when hot. I tracked the restriction down to that component. I can't find info on it or replacement so I just drilled a hole in it. It is on my 08 500 x2, but my 07 doesn't have it. Thanks for info guys.
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