Having a Polaris RZR is a great way to enjoy your weekend on the trail with good company. It bites when you’ve got friends waiting for you to blow off steam, and your RZR either won’t start or is bogged down due to a bad fuel filter.
To change a Polaris RZR fuel filter, first, you must take the passenger seat out. Inspect the area right underneath the seat; the fuel pump is located there. Take out the fuel pump properly to find the fuel filter attached to the bottom of the fuel pump assembly.
In this article, I will go through the steps to replace the fuel filter on a Polaris RZR. I will discuss the proper method to get this job done along with some tips and tricks. So let’s get right into it and get you back on the trail.
1. Prepare the Vehicle for the Task
If you have diagnosed your Polaris and discovered the fuel filter problem, you must prep your RZR to replace it. To do this, you should clean the passenger seat and the area around it. This will ensure that no dirt or debris gets into the fuel tank when you dismount the fuel pump.
2. Remove the Passenger Seat
Once you’re done with the above step, remove the passenger seat. The fuel pump will be located under the rear passenger seat in a four-seater.
You can do this by locating the lever underneath the seat. Depending on the model, this could be found on the front or the back of the seat. Simply pull the lever, and the seat should just pop out (source).
With the passenger seat removed, inspect the area underneath it and clean it out if it’s dirty. Next, you will locate the fuel pump, which should be pretty easy to spot. Just look right under the seat, and it should be there.
3. Remove the Fuel Line and Electrical Connector
Make sure you use a contact cleaner to clean the top of the fuel pump to ensure no dirt or debris makes its way into the fuel tank.
Next, you’ll need to remove the fuel line and electrical connector. These connections have clips holding them in place, so you might have to use a screwdriver. Ensure you do not use excessive force and accidentally break something.
4. Unscrew the Plastic Nut and Remove the Fuel Pump
Before removing the pump, carefully inspect the top and look for an arrow on the fuel pump. This arrow should always align in the middle of the two lines indicated on the fuel tank. When putting in a new pump or putting back the old one, make sure it’s in the correct position.
You will notice a plastic nut keeping the fuel pump in its place. You’ll have to remove this nut, there is a special tool available to do this, but you can probably get away with using an adjustable oil filter piler. Keep in mind that the pump is spring-loaded, so keep your hand on it, pushing it down as you unscrew the nut.
After you have removed the plastic nut, slowly pull the pump out. The pump with the filter attached makes an L shape, so picture a pump going into the tank and extending horizontally. With that said, when you remove the unit, pull it out slowly upward with an angle so that the pump is horizontal in your hand when it’s out.
There should be some fuel dripping from the fuel filter at this point, so make sure you have a pan or something to put it in.
You will notice an O-ring, also called a gasket, right underneath the top of the pump. This is an essential component, so do not forget to put it back on. Polaris recommends replacing the plastic nut and the O-ring whenever you remove the fuel pump.
This video goes into more detail:
5. Replace the Fuel Filter
Polaris does not sell the fuel filters separately; you’d have to buy the whole fuel pump assembly to get a new fuel filter if you desire an OEM part. Although, if you are open to after-market products, you can find a good fuel filter for your model with reasonable ease.
A small clip keeps the fuel filter attached to the pump assembly. You need to remove this clip to detach the filter from the unit. Next, replace the fuel filter with a new one. To get the clip back in place, cover it with some grease, put it on top of a socket, and snap it back into place.
This video goes into more detail:
6. Reinstall the Fuel Pump
With the new fuel filter attached, clean the fuel pump and the top of the fuel tank thoroughly before reinstalling. At this point, check the bottom of the fuel tank and look for signs of sand or debris. If you spot any, remove the tank and clean it out.
Replace the o-ring on the fuel pump to ensure optimum performance. You will also need to replace the plastic nut with a new one, as recommended by Polaris.
Rock the pump back into its place and make sure that the arrow aligns with the two lines on the tank. Push the pump down and screw the plastic nut on. Be careful not to let the pump move from its position as you tighten the nut.
This video goes into more detail:
7. Reconnect the Fuel Line and Electrical Connector
Reconnect the fuel line carefully and ensure that it’s in its place. The electrical connector has a clip that should be snapped back on – you’ll see two tabs you can pinch as you push the line in. Make sure all the connections are properly made before moving to the next step.
8. Do a Test Run and Replace the Seat
Once everything is in place, grab the passenger seat and put it back in its position. It should just snap back into its place with any issues.
Next, put the key in the ignition and do a test run. If your Polaris runs normally, you diagnosed it perfectly and resolved the issue. If not, you’d have to dig more or take your vehicle to a professional.
If your Polaris RZR battery is dead, there might be several reasons. Read my other article to learn more about why the fuel battery is dead and how to fix it.
Conclusion
Polaris is somewhat of a happy pill for most adventure lovers, and having it fail on you due to a choked fuel filter can ruin all the fun. This guide includes everything you need to do to get your RZR back on track.