Found out this week that I need a fuel pump for my sportsman 500. Dealer told me I would have to by complete fuel tank more than $500 for the part. I rolled up my sleeves and started researching an alternative solution. Found that a Bosch Fuel pump # 69-424 would interchange and I had to purchase a new strainer sock Car Quest #FS111. The specs for factory fuel pressure is 39 lbs. +/- 3lbs. the bosch is rated at 43 lbs. PSI. We installed the pump tonight and all is well runs great. Hope this helps.
Found out this week that I need a fuel pump for my sportsman 500. Dealer told me I would have to by complete fuel tank more than $500 for the part. I rolled up my sleeves and started researching an alternative solution. Found that a Bosch Fuel pump # 69-424 would interchange and I had to purchase a new strainer sock Car Quest #FS111. The specs for factory fuel pressure is 39 lbs. +/- 3lbs. the bosch is rated at 43 lbs. PSI. We installed the pump tonight and all is well runs great. Hope this helps.
did you look at the top of the page at the sticky about fuel pump replacement. still good info you researched though.
This may not apply to every efi but regarding the 04 700 efi, I have worked on 3 that had excessive pressure which made them run rich. The last one I did was running 60 psi. Mounted above the fuel pump in the tank is the regulator and it has a filter in it that clogs and causes the regulator to not work right. There is a clip that holds it on and it is easy to clean, just make sure the orings go back on right when reinstalling.
A fuel pressure gauge is a must when working on efi, they can save a lot of time.
The fender removal to get at the fuel tank is the hardest part.
you can buy the fuel pump at the parts house for around $100.00, I have 2 numbers, a Carter # E-7000 and an Airtex # E-8198, take the front plastic off, unplug the pump, unlatch from top of fuel tank, pull and replace pump.I have done this on 2 macines , not a hard job.
I have same question, I have a 2006 500 EFI with a bad fuel pump. As result of helpful info from this forum, I'm going to my local autozone to ge an airtex E8198 fuel pump, $86.99. I'm planning on installing this within the next couple of weeks.
I know what you are talking about. I have a 05 sportsman 700 that is having a fuel issue. I talked to the dealership about repairing it he said it was my regulator. he said I had to replace tank, pump and regulator all at the same time. It's cost is over $500.
I have same question, I have a 2006 500 EFI with a bad fuel pump. As result of helpful info from this forum, I'm going to my local autozone to ge an airtex E8198 fuel pump, $86.99. I'm planning on installing this within the next couple of weeks.
welcome to the forum guys. as far as i know the pump should work fine in the 500 efi as well as the 7 and 800. according to polaris pn#s they used the same fuel tank assembly from the 05' to 06 700 and 800's as well as the 06' 500 efi. hope that helps out. alot of people have used these aftermarket pumps and none(that i have read anyways)have had any issues.
Polaris Sportsman 500 EFI fuel pump
replacement fuel pumps in STICKY
