How to Renew the Fuel Line on a 2014 Big Boss 800 6x6 Utility ATV
Shop parts for a 2014 Polaris Sportsman Big Boss 800 6X6 ATV.
Confirming What You Are Working With
Before a wrench touches the 2014 Sportsman Big Boss 800 6x6, settle one question: this machine is fuel injected. There is no petcock beneath the tank, no gravity feed to a carburetor, and no float bowl drain screw to crack open. Fuel travels under pressure from a pump mounted inside the tank to the throttle body, which means the very first task is relieving that pressure rather than closing a valve. Owners coming off older carbureted utility quads often reach for a fuel valve that was never installed here.
The rest of the chassis matters too. Six wheels means a long frame, three axles, and an on-demand all-wheel-drive front end, all of which add routing clips and clearance points the hose has to navigate on its way from the tank to the engine. A shorter two-wheel-drive quad gives you a simpler, straighter run.
How Fuel Hose Deteriorates
New fuel line is soft because of the plasticizers blended into the rubber. Those compounds migrate out over the years, leaving material that is harder, more brittle, and much less willing to move. On a working Big Boss the hose gets heat cycled constantly by the 800 twin and flexed by a frame that twists whenever a loaded dump box crosses uneven ground. Hardened rubber under repeated movement is exactly how surface cracks begin.
Climate plays a role as well. Dry air pulls moisture from the hose wall and hardens it noticeably faster than humid conditions do. Ethanol-blended pump gas attacks from the other side, absorbing water and slowly degrading the inner liner while the outer surface continues to stiffen. That combination is why a hose can pass a casual visual inspection while quietly flaking material downstream toward the injectors.
Warning Signs a Line Is Failing
Catch it before it leaves you sitting. The common indicators are:
- Fuel collecting on the skid plate or dripping onto the shop floor after the machine has sat for a while
- A persistent gasoline smell around the tank, sharpest in the minutes right after shutdown
- Cracks, crazing, or a chalky surface texture on the hose, or a stiff section that no longer flexes by hand
- The engine bogging, hesitating under load, or behaving as though the tank is nearly empty when it is not
- A ring of caked dirt around a fitting where fuel has been weeping and drying
Remember that pressurized fuel escaping a small crack tends to mist and evaporate. Strong odor with no visible puddle is still a genuine leak on an injected machine, even though it would almost always drip on a carbureted one.
Tools, Parts, and a Real Word About Gasoline
Gasoline vapor is heavier than air and pools low, near the outlets, cords, and heaters most garages keep at floor level. Open the building up or move the Big Boss outdoors, and keep every flame and spark source well clear. Wear gloves too, because gasoline strips skin oils immediately and carries dissolved residue through the skin.
Have this ready:
- Replacement hose rated for fuel-injection pressure, matched to the original inside diameter
- New clamps of the correct type, and a quick-disconnect release tool if a locking coupler is used at the pump flange
- Line-clamping pliers to pinch off low-pressure sections, filling in for the absent petcock
- An approved fuel container plus a shallow catch pan
- Nitrile gloves, rags, a flat-blade screwdriver, and sockets for the seat, cargo box, and body panels
Taking the Old Hose Off
Pull the fuel pump fuse or relay first, crank the engine until it dies, shut the key off, and disconnect the battery negative cable. With pressure gone, remove the seat and any plastics blocking access to the tank outlet and the hose run heading aft.
Slide the pan under the first fitting and cover it with a rag, since residual fuel remains in the line regardless of pressure. Move any worm-gear or spring clamp well down the hose before you touch the joint. For a quick-connect coupler, squeeze the tabs evenly and draw it straight off; sideways prying breaks collars that have grown brittle. When old hose has varnished itself to a barb, break the bond with a gentle twist, or slice it lengthwise and peel it away instead of yanking on the fitting.
Trace and record the routing before the line is completely free. Every clip and pass-through on this long six-wheel chassis needs to be reproduced, particularly where the run threads past front drive components.
Installing and Verifying the New Line
Cut the new hose to the original length. Too long and it rubs the frame or drifts toward the exhaust; too short and the fittings carry tension they were never meant to hold. Press each end fully onto its barb dry, with no grease, oil, or silicone anywhere near the sealing surface — lubricant is what lets pressurized fuel work its way out from under a clamp. Soften a stiff end in hot water if it fights you.
Place new clamps just behind the bead on each fitting and tighten them evenly without biting deeply into the rubber. A self-locking quick-connect requires no clamp: push until it clicks, then tug to make sure it latched. Seat the hose back into all of its original retainers so it stays away from moving driveline parts and hot surfaces.
Reinstall the fuse, Reconnect the battery, and cycle the key on and off several times without cranking. Each cycle primes the pump and pressurizes the line, giving you a dry-surface leak check at both joints. Wipe them down, then start the engine and inspect again at idle before reassembling the bodywork.
Finally, note where the filter lives on this model. It is inside the tank as part of the pump module, not inline on the hose you just replaced, and there is no serviceable bowl drain like a carbureted machine offers. A fresh line will not fix a plugged in-tank filter, so if fuel delivery still feels weak, that assembly is the logical next step.
Related Shopping Categories
Shop Fuel Lines for a 2014 Polaris Sportsman Big Boss 800 6X6 ATV.
Shop Fuel Line Clamps for a 2014 Polaris Sportsman Big Boss 800 6X6 ATV.
Shop Petcocks for a 2014 Polaris Sportsman Big Boss 800 6X6 ATV.
Shop Fuel Filters for a 2014 Polaris Sportsman Big Boss 800 6X6 ATV.
Shop Fuel Stabilizer for a 2014 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.