Hello, I want to share my findings on fuel pump issues on my 2017 Sportsman 570. I purchased it 6 months ago and it has 4500 miles.
1st ride ran great but I noticed it hesitating a couple times toward the end of a 4 hour ride. I chalked it up to some water I had been running thru.
2nd ride, started out fine then stumbling about 30 min into the ride. It got progressively worse until I was barely able to limp back to camp.
Home, I read the discussion board, tested all electrical sensors and inspected as much wiring as I could. Didn't find anything of significance so I decided it was probably the fuel pump.
Ordered a new pump assembly from Quantum.
3rd ride, ran great for 4 hours then quit and would not restart. Towed back to camp.
Home, ordered a fuel pump pressure test kit. Tested pump and showed 8 psi. Removed the pump and discovered the pressure line was off (see pic)
Installed hose clamps and pressure test shows 58psi. Since my fuel line came off completely it was easier to diagnose than leakage around the hose fittings under pressure. Since it was a hot day and a long ride the fuel line became very pliable. I wonder if partial leakage around the fuel fittings after the tank is warm is a very difficult to diagnose issue for many?
This got me curious about the old fuel pump I had replaced. This was a factory pump with the Quantum kit in it. I tested it and the pressure was low 20psi to low 40 psi. While testing I observed leakage around the pressure hose fittings even though they had clamps. On inspection of the pressure hose I discovered it was deteriorated, rock hard and would spin in place even though clamped. Further inspection revealed it was NOT submersable fuel hose. Additionally while comparing the new pump assembly with the old pump/kit I discovered the orientation of the fuel strainer on the old pump (on the right) is 180 degrees off from the new pump (on the left see pic) and what is shown in the Polaris service manual.
The incorrect strainer on on the old pump appears to be the same as the replacement shown on the Quantum website. I will call Quantum Monday to see if a replacement with the correct orientation is available as I cannot find it on the website. If anyone knows the part number or where I can procure please let me know! I think it is important as when inserted into the tank with the wrong strainer the strainer folds up and could be contributing to fuel starvation, especially when below 1/2 tank of fuel. I re-tested the old pump with a temporary replacement fuel line and no strainer, 58psi.
My takeaways:
Only use submersible fuel line.
Always install Injector hose clamps on both ends of the pump pressure line.
Make sure the fuel strainer has the correct orientation.