Polaris Sportsman 500 Fuel Pump Problems and Solutions

Loose fuel lines, excessive wear in the fuel pump, and overheating are the most common Polaris Sportsman 500 fuel pump problems. Thus, loud noises from the fuel pump are also a common problem in these vehicles. And many users face power loss in the fuel pump as well.

Now every Polaris Sportsman 500 user should know these problems and the reasons behind them. Read on this post and learn how to identify these problems and solve them on your own. 

Problems Of Polaris Sportsman 500 Fuel Pump, Symptoms, and Solutions

Follow the tables to see the overview of all the possible problems, symptoms, and solutions of the Polaris Sportsman 500 fuel pump.




Loose fuel lineBackfire or sputteringTightening the fuel line
Fuel pump wearDecrease in acceleration and top speedFuel pump replacement
OverheatingIncreased heat in the engine bay and burning smellsReplacing fuel pump
Loud noisesWhining noise while acceleratingCooling down the engine
Power lossLosing acceleration or engine dyingChecking the electronics and connections

Problems and Solutions of Polaris Sportsman 500 Fuel Pump

Polaris Sportsman 500 efi fuel pump replacement

You need to take a Polaris Sportsman 500 fuel pump test to figure out the roots of various problems. Before you find the problems and their solutions, take a closer look at the fuel pump diagram to better understand its components.

The base here is the fuel pump assembly. It has multiple diaphragms and gaskets on both sides with screw and washer assembly. You will also find a pressure regulator that maintains the right fuel pressure. And there are the fuel inlet and outlet side by side.

Fuel Pump Diagram
Image: Fuel Pump Diagram

1. Loose Fuel Lines

The fuel tube is connected to the fuel pump with a line. This line can sometimes be loose, which will cause the fuel pump to lose pressure while delivering fuel. 

As a result, the engine assembly won’t get enough fuel and heat up quickly. You may see signs like backfires or sputtering while accelerating. And after some time, the engine will die if you try to accelerate more.


Remove the line connecting the fuel tube to the pump. Spin it on the pump tightly enough so that there is no movement of the line. Then, use metal clamps to keep the line tightly fitted on the pump. It will help the fuel pump generate enough pressure to deliver fuel correctly.

2. Fuel Pump Wear

When fuel pumps are new, they tend to deliver fuel to the fuel injectors at about 60 psi pressure. But as pumps get worn out over time, the pressure drops to 30 psi. 

Due to the pressure drop, the engine will lose acceleration and top speed. So, you might see the RPM gauge drop or the vehicle struggling to increase speed.


To confirm the fuel pump is faulty, you should use a pressure gauge in the fuel tank’s outlet and crank up the engine. If the reading on the gauge is less than 30 psi, you need to replace the fuel pump immediately. It might cost anywhere between $100 and $200 to replace the fuel pump.

3. Overheating

Overheating is one of the common fuel pump problems of the Polaris Sportsman 500. Though these UTVs tend to get a bit hotter than regular cars, excessive heating is a sign of a bad fuel pump. 

When the fuel pump doesn’t deliver enough fuel to the engine, engine components will overheat, and you may feel the heat from the driver’s seat. There might also be burning smells from the engine. And the engine will backfire or make weird noises.


Installing a heat shield under the dashboard may protect the driver from getting scorched by the heat. But the engine might still suffer from overheating. So, replacing the bad fuel pump is the last resort.

4. Loud Noise

Loud whining noises are one of the common problems in Polaris vehicle’s fuel pump. As these models are quite old, they may create deafening noise while the engine is on. If the fuel pump mounting isn’t correct, it can also cause the same problem. 

And the noise is usually dependent on the temperature. If the fuel pump gets hotter, the noise will be much louder. 


As the main reason behind this problem is faulty mounting, you should check whether the fuel pump is tightly mounted. Also, look out for wear in the fuel line and the mount. And if the fuel pump is too hot, you might need to turn off the vehicle and let it sit sometime to cool down.

5. Power Loss

The problems in Polaris Sportsman 500 fuel pump can be caused by low voltage in the pump plug. There can be several reasons behind this problem. 

If the battery is faulty or the integrated fuel pump circuit fails, the vehicle might face this issue. A flawed charging system or improper installation of accessories might also cause the problem.


You need to check the voltage using a DC voltmeter. The minimum voltage in the plug should be 7 volts. If that is okay, you should check for faulty connections. And finally, check the ECU operation to ensure there is no fault in the system.

Check this video to learn how to test fuel pumps.


Check the answers to these frequently asked questions.

Q: What does zero pressure on the fuel gauge mean?

If you get a zero reading on the fuel pressure gauge while checking the fuel line, it means the fuel pump is dead, and you need to replace it.

Q: Does Polaris Sportsman 500 sputter for bad fuel pumps only?

No, sputtering can be caused by a variety of problems like gas leaks or poorly tuned carburetors. Spark issues can also cause this.

Q: Can I fix a bad fuel pump on Polaris Sportsman 500?

Fixing is a temporary solution, and you must replace the pump down the lane.


A correctly working fuel pump is crucial to keep a vehicle up and running. But as the vehicle ages, multiple problems regarding the fuel pump start to appear. Among Polaris Sportsman 500 fuel pump problems, loose fuel lines, loud noises, power loss, and overheating is very common.

We showed how to promptly identify and effectively solve these problems without going to a mechanic. Make sure you follow these solutions to keep your off-roader in good condition.


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