Fuel Hose Service on a 2011 Polaris Sportsman Big Boss 800 6x6

Shop parts for a 2011 Polaris Sportsman Big Boss 800 6X6 ATV.

Losing power with a loaded bed halfway across a property is the kind of failure that turns a work machine into a recovery project. On a 2011 Sportsman Big Boss 800 6x6, a deteriorating fuel hose is one of the more common causes, and it gives warning first if you know what to look for.

Reading the Warning Signs

Any of these should send you looking at the hose:

  • Bogging when the bed is loaded, hesitation on hard throttle, or an engine acting starved with fuel in the tank
  • A gasoline smell around the chassis that will not clear, sharpest right after shutdown
  • A wet film or puddle on the skid plate or floor after the machine has been parked
  • Hairline cracking, surface checking, or a chalky white haze on the hose once wiped clean
  • Stiff sections that fail to compress when pinched between your fingers
  • Dust packed into a dark ring at a fitting, which is dried fuel residue gathering grit

Since this machine is fuel injected, leak evidence behaves differently than on a carbureted machine. Fuel escaping a pressurized crack often mists and evaporates before it forms a drop, so the odor typically arrives well before the puddle. A dry skid plate does not clear the line.

Why the Hose Degrades

Fuel line is flexible when new because of plasticizers in the rubber, and heat cycling from the 800 twin drives them out of the wall over the years. A hardened hose cannot absorb movement, so it cracks instead, and the damage starts at bends and beneath clamps where stress collects. On a long chassis that works over rough ground with an engine vibrating continuously, those cracks keep opening.

Dry climates shorten the timeline by pulling moisture out of the hose wall. Ethanol blended pump gas attacks the inner liner instead, absorbing water during idle stretches and breaking down the inside surface, which leaves gum in the passage and loose material heading toward the injectors. A hose can present a decent exterior while doing that, so on a machine this age, replacement based on the calendar is a reasonable call.

Confirming What Feeds the Engine

Delivery on the Big Boss 800 comes from an electric pump inside the fuel tank, pushing pressurized fuel to the throttle body. That eliminates the petcock a carbureted machine would have, so line clamping pliers do the shutoff work. It also means the hose holds pressure after shutdown instead of going quiet under gravity feed, so bleeding the circuit is a required step. There is no float bowl drain to empty the low point either, so the fuel you need to catch is standing in the hose. Check whether the tank outlet uses a self locking quick connect coupler or a plain barb with a clamp, since that decides whether you need a release tool.

Working Around a Long Six Wheel Chassis

This machine is longer than a standard utility quad, carrying a cargo bed and a second rear axle. That means a longer hose run, more frame crossmembers to navigate, and more clips holding the line in place. Bed structure also occupies space that would be open on a shorter machine, so plan on removing the seat and the plastics covering the tank and the hose path, and give yourself room to reach the full length.

All six wheels can be driven, which puts front differential hardware at one end and driveline components running rearward. The factory clips are there to hold the hose away from all of that and from hot exhaust surfaces, so photograph the routing thoroughly before disturbing it. On a chassis with this many guides, memory is not reliable enough.

Tools, Supplies, and a Word on Gasoline

Set out nitrile gloves, a sealed fuel rated container, injection rated hose in the original inside diameter with enough length for this frame, new clamps in the matching style, a quick connect release tool if needed, line clamping pliers, a razor knife, sockets and trim tools, and a generous supply of rags.

Then take the fumes seriously rather than assuming a large shop dilutes them. Gasoline vapor is heavier than air, so it sinks and lingers at floor level where you will be kneeling with an open line. Air moving across the ground is what lowers the concentration, so work outdoors when you can or open the door completely instead of relying on a window overhead. Shut off and move heaters, chargers, grinders, and any pilot light, and keep an extinguisher close enough to grab without standing.

Removal, Fitting, and Final Verification

Bleed the pressure by pulling the fuel pump fuse, cranking the engine until it quits, turning the key off, and disconnecting the negative battery cable. Slide the catch pan under the joint and drape a rag over it before opening, since a bled hose still holds fuel. Push clamps well back along the hose before disturbing the fitting. Quick connects release when the tabs are compressed squarely and the coupler is pulled straight off, with no sideways leverage, because collars grow brittle with age. Break a varnish bond at a barb with a gentle twist, or cut the hose lengthwise and peel it away rather than stressing the fitting.

Cut the new hose to the original length. On a long machine the urge to leave slack is strong, but surplus hose eventually chafes on a frame tube or catches a rotating component. Seat both ends fully onto their barbs dry, keeping grease, oil, and silicone spray off the fittings entirely, since any of them creates a path for pressurized fuel past the clamp. Hot water for a few seconds softens a stubborn end. Position new clamps just behind the raised bead and tighten evenly to snug. Where a self locking coupler is used, push until it clicks and pull firmly to confirm the latch, adding no clamp.

Route the hose back through every original clip, refit the pump fuse, Reconnect the battery, and cycle the key on and off five or six times without cranking so the pump pressurizes the line while the area is clean. Wipe both joints, start the engine, and inspect again at idle with a fresh rag, watching for a bead at either connection. Let it run several minutes and check a final time before reassembling the plastics, because a joint that seals cold can seep once everything expands.

One closing note: the fuel filter here is integrated with the in tank pump assembly rather than sitting inline on the visible hose the way a carbureted machine typically has it. New hose does nothing for a restricted filter, so if delivery still feels soft after a clean install, that assembly is the next stop.

Related Shopping Categories

Shop Fuel Lines for a 2011 Polaris Sportsman Big Boss 800 6X6 ATV.

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Shop Petcocks for a 2011 Polaris Sportsman Big Boss 800 6X6 ATV.

Shop Fuel Filters for a 2011 Polaris Sportsman Big Boss 800 6X6 ATV.

Shop Fuel Stabilizer for a 2011 Polaris Sportsman Big Boss 800 6X6 ATV.

Disclaimer: This guide is provided for general informational purposes only and is not intended to replace your ATV's official owner's manual. Always refer to your manufacturer's documentation for model-specific instructions, torque specifications, safety procedures, and maintenance requirements. If you are unsure or inexperienced, consider seeking assistance from a qualified mechanic or technician.