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

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  • čas přidán 4. 08. 2024
  • This video showing the fuel pump replacement, fuel line routing, and a detailed explanation on how the fuel system works on a Polaris ATV.
    The ATV shown in this video is a 2008 Polaris Trail Boss 330. I bought this ATV and it had been sitting for several years so I replaced the carburetor and ATV would run, but cut out and bog down. This told me that the engine was running out of fuel. So I decided to replace the fuel pump, it was cheap and a pretty straight forward replacement. When I was looking at the fuel lines I thought that I maybe connected some of them to the wrong positions when I replaced the carburetor so I made this video to show the proper fuel line routing. I also saw that the fuel pickup tubes that go inside the tank had a fair ammount of junk on them so I cleaned them. I also replaced all the fuel lines.
    Once I got everything put back together, this ATV is no longer bogging down or cutting out when I ride it.
    Parts Used:
    Fuel Line - www.amazon.com/LDR-Small-Engi...
    Fuel Line Cutter - www.amazon.com/Performance-To...
    Fuel Pump - ZW5jcnlwdGVkUXVhbGlmaWVyPUEzNDVFNTFRRTdTRkREJmVuY3J5cHRlZElkPUEwNzU5ODY3Mzg2WlhFRDRZSldHMyZlbmNyeXB0ZWRBZElkPUEwMzQwOTg1M00zU0JTR0pSMzhLWiZ3aWRnZXROYW1lPXNwX2F0ZiZhY3Rpb249Y2xpY2tSZWRpcmVjdCZkb05vdExvZ0NsaWNrPXRydWU
    Link to Parts Drawing - www.babbittsonline.com/oempar...
    The steps shown in this video may also be applicable to the following models. Please note that the fuel pump may be under the front access cover on some of the 90's model ATV's
    Trail Blazer 250 1990 - 2006
    Sportsman 325: 1999-2000
    Sportsman 500: 1996-2004
    Sportsman 500 HO: 2010
    Sportsman 400: 2001-2004
    Sportsman 600: 2003-2005
    Sportsman 700: 2002-2007
    Sportsman MV7: 2005-2007
    Sportsman 6X6: 2000-2004
    Magnum 325: 2000-2002
    Magnum 330: 2003-2006
    Magnum 500: 1999-2003
    Magnum 2X4: 1995-1998
    Magnum 4X4: 1995-1998
    Magnum 6X6: 1996-1997
    Outlaw 450: 2009-2010
    Outlaw 500: 2006-2007
    Outlaw 525: 2009-2011
    Trailblazer 330: 2010
    Trail Boss 330: 2010
    Scrambler 500: 2010
    Predator 500: 2003-2007
    XPEDITION 325:2000-2002
    XPEDITION 425:2000-2002
    0:00 Intro
    0:45 Fuel Pump Line Routing
    3:18 Fuel Petcock Line Routing
    6:45 Fuel Tank Pickup Tubes
    8:28 Fuel Line Replacement
    9:34 Outro
    *This video is intended to provide educational tips to its viewers, no information in this video overrides vehicle manufacturer's recommendations. Always consult with a professional prior to performing any repairs. Any injury, damage, or loss that may result from improper use of these tools, equipment, or from the information contained in this video is the sole responsibility of the user and not the Video Publisher*

Komentáře • 79

  • @jesseroncone5749
    @jesseroncone5749 Před rokem +9

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

  • @dayltolliver7219
    @dayltolliver7219 Před 2 lety +3

    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
      @FixItFarm  Před 2 lety

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

  • @realtorjohnq
    @realtorjohnq Před 10 měsíci +2

    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
      @FixItFarm  Před 4 měsíci +1

      I appreciate this comment!

  • @dustinjung3699
    @dustinjung3699 Před 2 měsíci +1

    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

  • @oneluckyquacker
    @oneluckyquacker Před 2 lety +2

    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
      @FixItFarm  Před 2 lety +2

      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
      @oneluckyquacker Před 2 lety

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

  • @RollinRizlas
    @RollinRizlas Před rokem +1

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

  • @caseyvaughn3535
    @caseyvaughn3535 Před 10 měsíci +1

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

  • @johnc6798
    @johnc6798 Před rokem +1

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

  • @stallskiandclutch7329
    @stallskiandclutch7329 Před 2 lety +1

    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
      @FixItFarm  Před 2 lety

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

  • @artmeadath2016
    @artmeadath2016 Před 3 lety +1

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

    • @FixItFarm
      @FixItFarm  Před 3 lety

      Thank you I’m glad that it helped!

  • @rubywarrior1604
    @rubywarrior1604 Před 5 měsíci +1

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

  • @jeffadams6319
    @jeffadams6319 Před 4 měsíci +1

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

  • @user-mr3pm3lo6d
    @user-mr3pm3lo6d Před rokem

    Excellent video, thank you for posting it.

  • @elmele4810
    @elmele4810 Před rokem +1

    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
      @FixItFarm  Před rokem

      I’m glad that this helped you!

  • @bgta894
    @bgta894 Před 2 lety +1

    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
      @FixItFarm  Před 2 lety

      Glad this helped you and good luck!

  • @TepcoCycleRepair
    @TepcoCycleRepair Před 2 lety +5

    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
      @FixItFarm  Před 2 lety

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

  • @mikejiskra7976
    @mikejiskra7976 Před 3 lety +1

    Very good video, Thanks Mike J.

    • @FixItFarm
      @FixItFarm  Před 3 lety

      I am glad that this helped you
      Mike!

  • @gen-xboomer9489
    @gen-xboomer9489 Před měsícem

    Youre a hero! Thank you!

  • @brettashment2959
    @brettashment2959 Před 3 lety +2

    Thank you for your time !!

  • @MrLacoyota
    @MrLacoyota Před 2 lety +1

    Awesome video!! Thank you.

    • @FixItFarm
      @FixItFarm  Před 2 lety

      Thanks I’m glad this helped!

  • @xs650abear6
    @xs650abear6 Před 2 lety +1

    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
      @FixItFarm  Před 2 lety

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

    • @xs650abear6
      @xs650abear6 Před 2 lety +1

      @@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
      @FixItFarm  Před 2 lety +1

      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.

  • @cadeplayz3921
    @cadeplayz3921 Před 2 lety +1

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

    • @FixItFarm
      @FixItFarm  Před 2 lety

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

  • @johnrfranklin9072
    @johnrfranklin9072 Před rokem +1

    Lots of help Thanks!

  • @louismays7810
    @louismays7810 Před 2 lety +1

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

    • @FixItFarm
      @FixItFarm  Před 2 lety

      Awesome!

    • @louismays7810
      @louismays7810 Před 2 lety

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

  • @carlosaillerie3057
    @carlosaillerie3057 Před rokem

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

  • @averagejoebear
    @averagejoebear Před 3 lety +1

    Thank you!

  • @fritzlannowack2701
    @fritzlannowack2701 Před rokem

    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.

  • @t34bmentor
    @t34bmentor Před 2 lety

    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
      @pigzaj2 Před rokem +1

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

  • @justken4851
    @justken4851 Před 3 lety +4

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

    • @FixItFarm
      @FixItFarm  Před 3 lety +1

      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
      @justken4851 Před 3 lety +1

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

    • @sploofy4878
      @sploofy4878 Před 2 lety +1

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

    • @FixItFarm
      @FixItFarm  Před 2 lety

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

    • @Bhartrampf
      @Bhartrampf Před 2 lety +1

      @@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.

  • @michaelmcnamara6293
    @michaelmcnamara6293 Před rokem

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

  • @1seanofmilford
    @1seanofmilford Před 2 lety +1

    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
      @FixItFarm  Před 2 lety

      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!

  • @thebrothers4311
    @thebrothers4311 Před 2 lety +2

    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
      @kyler5720 Před 2 lety

      Gfdh

    • @thebrothers4311
      @thebrothers4311 Před 2 lety

      @@kyler5720 what??

    • @chrisshell1094
      @chrisshell1094 Před rokem +1

      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

  • @chrisshell1094
    @chrisshell1094 Před rokem

    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

  • @adamstalsberg9947
    @adamstalsberg9947 Před 3 lety +1

    Where did u buy that carb

    • @FixItFarm
      @FixItFarm  Před 3 lety

      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!

  • @BisonWorkshop
    @BisonWorkshop Před 3 měsíci

    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

  • @The_Native_wolfAK
    @The_Native_wolfAK Před 3 lety +1

    Any idea why my trailboss isn’t powering on?

    • @FixItFarm
      @FixItFarm  Před 3 lety

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

    • @The_Native_wolfAK
      @The_Native_wolfAK Před 3 lety +1

      @@FixItFarm no it doesn’t

    • @FixItFarm
      @FixItFarm  Před 3 lety

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

    • @sploofy4878
      @sploofy4878 Před 2 lety

      @@FixItFarm wouldnt it be a bad spark plug

  • @rickeyjohnson4491
    @rickeyjohnson4491 Před 3 lety +1

    Did that fix your problem

    • @FixItFarm
      @FixItFarm  Před 3 lety

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

  • @adrianlecuyer
    @adrianlecuyer Před 10 měsíci

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