06 Polaris Sportsman 500 EFI

[TroyC]

I know this is the go-to place when I can't fix something or need help, so here goes!

History:
2006 Sportsman 500 EFI (gas) fuel issues. They only made this tank/fuel pump for 2 years or so, it's the 5 bolt model, currently cost more than the wheeler is worth. Dealer put a new tank unit in it 2006 as the fuel sender quit working- bad design, new one never worked either. I can live with that.

Problem: Two years ago the original fuel pump went out so I replaced the pump with an aftermarket one. Pump hangs inside the tank. Replaced the pump and strainer, worked OK until last week. Won't start now, just took it apart and pump is froze. Yeah, I know, cheap parts, unreliable fix.

Here is what I need to know. The system is designed for 39psi to the injector. If I made a straight passageway from the bottom of the tank and eliminated the pump and pressure valve, would an external adjustable frame mounted pump work? Would it have enough suction to raise the fuel a foot or so and stay primed? I hate to start cutting lines and such but replacing this pump every year or two is no fun.

Pics of pump unit are in my gallery. I'm trying to figure how to get pic in post.

[beenthere]

Just get your gallery up and click the pic, then scroll to the line next to the bottom that has the BBC code. Copy that line to your post. You add the two others. 

This will result.

[TroyC]

Alright! Thanks a bunch. I'll give it a try.

[TroyC]

Ha! It worked! Looks like I may be stuck replacing the original pump again. A quick look did not reveal an external pump that wold deliver 39 psi.

[moosehunter]

A high pressure fuel pump needs to be in the fuel to keep it cool.
Most manufacturers recommend not letting the fuel level get below a 1/4 tank, the pump needs to be submerged for proper cooling.
mh

[TroyC]

Thanks, makes sense. I replaced pump with a higher quality one, hopefully it will last longer. I was really surprised, I only use non-ethanol fuel in my small engines, and this pump only lasted about 2 years. It was rusted much more than I anticipated.