Polaris ATV Fuel Pump Replacement & Fuel Line Routing Trail Boss, Trail Blazer, Sportsman, Scrambler

[@jesseroncone5749]

Hands down the most helpful and detailed video I've ever seen in my certified KZbin mechanic career. Thank you🙏

[@FixItFarm]

Thank you!!

[@antonvera9259]

Completely agree

[@jbuchan8114]

I agree best video on fuel routing I have seen thank you. Not confused any longer.

[@Justinbaker-t4q]

This was extremely helpful. I work on vehicles, not atvs. This is a first for me. Very well made. Very detailed, thanks

[@dayltolliver7219]

Just want to say that this is the beat explanation of the fuel pump and hose diagram that I've seen yet. Great Job. Dale

[@FixItFarm]

Thank you I am very happy that this has helped so many people!

[@rmderon]

Thank you, even with the service manual I could not make sense of the fuel line path on my Magnum 330. Your video was very clear and I was finally able to get gas flowing to the carburator and its now running better than ever. Without your video I think I would have had to take it into the shop and with the work involved I think it would have cost me a bundle. Thanks very much!

[@oneluckyquacker]

I have looked and looked for fuel line routing and finally stumbled upon this video.. I bought a 2002 Sportsman 400 that someone disconnected the fuel pump from and put a 2 line petcock on it (leaking). I have new parts ordered and thanks to this video I know how to connect everything!

[@FixItFarm]

I am glad this was able to help you. I spent several hours fighting this as well so once I figured it out I decided to make this video. Thanks!

[@oneluckyquacker]

@@FixItFarm also, thank you for shopping at O'Reilly Auto Parts!

[@realtorjohnq]

THANK YOU for making this video. I took my Polaris Trail Boss 330 apart to clean the carb and to replace the petcock and forgot to take a picture to remember where all the lines went.

[@FixItFarm]

I appreciate this comment!

[@xs650abear6]

2010 Sportsman 500 HO. Just installed the 3rd fuel pump in 12 yrs. 510 hours. Always the same, it's running great then just quits. New pump and its fine for another 6 years. First 2 pumps were Polaris factory pumps. This time I installed a Quantum pump, lifetime warranty and a lot cheaper than factory.

[@FixItFarm]

If at all possible, try to find some ethanol free gasoline. The fuel with ethanol is very hard on elastomers (from my experience)

[@xs650abear6]

@@FixItFarm Its difficult to find Ethanol free fuel in my area but for all my small engines including the 500HO I do use Sta-Bil 360 marine ethanol treatment and an ounce of Marvel Mystery oil. Maybe the Sta-Bil 360 isn't doing what it's supposed to be doing.

[@FixItFarm]

I understand. With normal fuel prices, running 100 octane aviation gas is a reasonable alternative. You can typically buy this at a small local airport.

[@caseyvaughn3535]

Great video been moving lines around. Never messed with a quad with a fuel pump. Such helpful video much MUCH appreciated

[@dustinjung3699]

Very helpful definitely recommend for anyone with a older Polaris very well described and very good visualization tactics used, great video very helpful and insightful on the workings and routing of the lines if you're still confused after the video replay and pay attention!! Lol

[@RollinRizlas]

Really appreciate your video and taking the time to explain everything in a simple manner!

[@stallskiandclutch7329]

Thanks for the outstanding explanation. I have a 05 Linhai 300 4x4 ,a clone more or less of your rig. You saved me a lot of time and headache. Much appreciated.

[@FixItFarm]

Thank you! I try to provide as much detail as possible. I am glad this helped!

[@elmele4810]

Thhanks man i needed this video this bikes been giving me a headache and now i know exactly where to put everything and how everything works

[@FixItFarm]

I’m glad that this helped you!

[@TepcoCycleRepair]

That dual line fuel insert that goes into the tank is no longer available. So if you're watching this, be gentle with that part, they are no where to be found right now, Jan 2022.

[@FixItFarm]

Good to know. Hopefully I don’t need one again!

[@johnc6798]

This video has been a life saver. THANK YOU!!

[@bgta894]

Thank you for that video working on a magnum and the same layout. Bought bike and fuel lines all off was easy with your help and 3d board

[@FixItFarm]

Glad this helped you and good luck!

[@jefff721]

Thanks for the video you saved me I had taken all the fuel lines off and lost diagram I made for my 01

[@FixItFarm]

Glad it helped you!

[@rubywarrior1604]

Great knowledge n research by this man, helped me out a lot.

[@tuberez]

Thanks! Mice chewed spark plug wire and hoses u really helped! Now my wife likes me again.

[@artmeadath2016]

Excellent vid....just what I was searching for.......thank you!!!!!

[@FixItFarm]

Thank you I’m glad that it helped!

[@louismays7810]

Ty 4 video i replaced fuel lines on my friends sportsman but they had them wrong so ill go back n fix it

[@FixItFarm]

Awesome!

[@louismays7810]

@@FixItFarm i fixed it 2day got it running unfortunately carb leaks at float bowl if hes lucky might be a drain screw

[@nekcutter]

Excellent video, thank you for posting it.

[@justken4851]

Very informative video. 👍 Wish you would have shown how to remove the fuel pump from the bike.

[@FixItFarm]

Thanks. There are just two bolts that hold the pump onto the frame. Then you just need to remove the hoses by disconnecting the clamps off and then pulling on each hose. This will allow you to get the hoses off.

[@justken4851]

@@FixItFarm thank you for the information it was helpful.

[@sploofy4878]

@@FixItFarm if I dont have a fuel pump, can I gravity feed gasoline only using one hose

[@FixItFarm]

You can try this, but I don’t think the tank is high enough above the carburetor to supply enough head

[@Bhartrampf]

@@sploofy4878 I had a fuel pump problem, the shop I took it to to replace the starter made it gravity fed. It only worked for awhile, then filled the crankcase full of fuel as the furl shut off failed. I recommend getting a fuel pump. also it would cut out on inclines. I am just replaced my fuel pump and fuel shut off using this video.

[@BisonWorkshop]

you may have just saved me from cussing . lol my neighbor ask me to fix there bike after they did a BAAAAAAAAD job. they have fuel lines going to vents and to the transmission.. i wonder why it won't run ? so now i have to start from scratch and fix it right. thank you for uploading this video lmao

[@brettashment2959]

Thank you for your time !!

[@FixItFarm]

I’m glad this helped you!

[@gen-xboomer]

Youre a hero! Thank you!

[@fritzlannowack2701]

How is the fuel pump held on because I found a nut that I’m guessing fell but I can’t get the 2 bolts on the fuel pump to thread in.

[@thebrothers4311]

Your actual petcock middle barb went to the fuel pump. However, your diagram drawing said to the carb. Im confused, fuel pump or carb?

[@kyler5720]

Gfdh

[@thebrothers4311]

@@kyler5720 what??

[@chrisshell1094]

I’m not the only one who caught that part of the video . He went from showing you that the middle line coming out went to the fuel pump to the next words out of his mouth saying that it went to the carb lol

[@MichaelDionisi]

Where did you find the the duel fuel outlet at ? . Can’t seem to find it anywhere.

[@mikejiskra7976]

Very good video, Thanks Mike J.

[@FixItFarm]

I am glad that this helped you Mike!

[@carlosaillerie3057]

thanks for the video it helps me a lot,what needle carb setting you are using,middle or high?

[@cadeplayz3921]

Great video! I’m having the same problems with my 2005 Polaris Magnum 330. Same fuel setup. Hope this works!

[@FixItFarm]

I hope so too. Thanks for checking out the video!

[@HCHR-z9w]

Awesome video!! Thank you.

[@FixItFarm]

Thanks I’m glad this helped!

[@t34bmentor]

Thanks great video. One question: If the selector of the petcock is in the middle position, does it stop the gas going to the fuel pump?

[@pigzaj2]

On the petcock, down is on, middle is off and up is reserve.

[@johnrfranklin9072]

Lots of help Thanks!

[@FixItFarm]

Thank you for watching!

[@michaelmcnamara6293]

Do you have the link to the fuel pump you purchased?

[@1seanofmilford]

The fuel line that is underneath the speedometer cover on a 800 sportsman there are 2 lines that are not connected. Where do they hook to cannot find where on the internet sites

[@FixItFarm]

I would look at the OEM parts drawing for that model. Babbitts.com has Polaris parts drawings on their website, just select for your make and model. Hope this helps you get it fixed!

[@averagejoebear]

Thank you!

[@FixItFarm]

Hopefully this helped you

[@rickeyjohnson4491]

Did that fix your problem

[@FixItFarm]

This did help with the problem. There was also an issue with the ignition that I showed in my Shop Vlog#5 video

[@chrisshell1094]

Only one person in the comments other than myself wonders about the middle line coming out of the fuel selector. Does it go to the fuel pump or does it go the carb because you said said it went to the pump and showed that with your finger and then the next thing you said was it went to the carb

[@The_Native_wolfAK]

Any idea why my trailboss isn’t powering on?

[@FixItFarm]

Check all wiring, grounds, battery etc. Does it have spark?

[@The_Native_wolfAK]

@@FixItFarm no it doesn’t

[@FixItFarm]

@@The_Native_wolfAK I would check the key and kill switch. Start there and then work into the wiring harness

[@sploofy4878]

@@FixItFarm wouldnt it be a bad spark plug

[@adamstalsberg9947]

Where did u buy that carb

[@FixItFarm]

I picked the carburetor up off of ebay. Same with the fuel pump. They were both very reasonable on price. I didn’t notice any change in performance so I would say it’s comparable to what was on there stock!

[@adrianlecuyer]

I just removed the one on my Magnum 425 seems rather useless to have one 🤷