We really like driving the Polaris UTVs. Unfortunately, we have noticed that Polaris built the RZR, RZR-S, and Ranger XP with an unreliable fuel pump. In fact, the fuel pump is one of the top problems we see in our service and performance shop. Symptoms you often experience when the pump fails are poor performance at the upper RPMs, a loss of top speed, and poor acceleration. This definitely makes your Polaris a lot less fun to drive, but more importantly, a fuel pump problem can cause devastating engine damage by not delivering enough fuel. When your engine is not getting the required fuel, it will run poorly.
This creates heat that can cause detonation in the combustion chamber. The worst case scenario (and we’ve seen it many times) is that the intense heat will melt a hole in your piston. This is what is happening. After a little use, the pump will wear out and then drop from the factory PSI setting of 39 psi within 30 seconds. When your top revs are slow, you just don’t get fuel. To test this, install a fuel gauge at the outlet of your tank. You can buy them at NAPA or PEP Boys. You need to rev your engine when testing because many times the pressure will be good at idle, but not at higher RPMs.
To replace your pump with the OEM fuel pump, you will have to spend over $ 600. The high price is because it is only available with the complete fuel tank assembly. Fortunately, you can purchase a replacement fuel pump that will work in most Polaris SXS vehicles. Replacement pumps come with colored instructions and include everything you need for installation. They can usually be installed in about 30 minutes with simple hand tools. The pump plugs in directly without the need for wiring.
If you are underperforming with your Polaris Ranger or RZR, this may be your problem. Check your fuel PSI and get a replacement fuel pump if necessary. You bought your Polaris to have a good time. Now you can use your UTV again and enjoy its peak performance once again. As a side note, this same problematic fuel pump is used in many of the fuel-injected Polaris quads. If you own a Polaris ATV and have similar symptoms, just follow the same procedure to test the PSI. Replacement pumps are also available for the Polaris Sportsman.