Fuel Rail/Injector Removal And Installation - Polaris 600 RUSH 2010 Manual

Fuel Rail/Injector Removal and Installation

FUEL INJECTOR ASM.
FUEL RETURN
FUEL SUPPLY
B
A
A
A: 9 ft-lbs (12 Nm)
B: 3.3 ft-lbs (4.5 Nm) Apply Loctite® 243.
Removal/Installation Process
NOTE: Do not touch fuel injector inlet/outlet. Leave
protective caps in place while handling.
1. Open the door panels and remove the hood
assembly.
2. Relieve fuel system pressure.
3. Disconnect the fuel supply and return hoses from the
fuel pump.
4. Remove the ECU, ECU bracket, and oil tank from the
clutch cover assembly.
5. Remove the air box intake tube and top to gain access
to the fuel rail.
6. Disconnect the fuel injector assembly wiring harness
connector.
7. Remove the two screws that mount the fuel rail to the
cylinder.
2011-ISOLATOR O-RING
2012-2013-GREEN BUSHING
FUEL RAIL ASSEMBLY
= T
Cleanfire Fuel Injection
8. Carefully pull the rail away from the engine and
injectors. Remove the injectors from the cylinder.
NOTE: Always use new o-rings/isolators after fuel
injectors have been removed.
9. Using a pick, remove the two fuel injector isolators or
bushings from the injector ports in the cylinder.
Discard the isolators/bushings.
10. Remove the fuel injector o-rings from fuel injectors.
Discard the fuel injector o-rings.
11. To reinstall the fuel rail assembly, lightly coat two new
fuel injector isolators with two-stroke engine oil. Install
the new isolators or bushings into the cylinder injector
ports.
12. Install four new oil-coated fuel injector o-rings.
13. Install both fuel injectors into the cylinder. Carefully
install the fuel rail assembly.
14. Tighten fuel rail screws evenly. Once both screws are
seated, torque to specification.
15. Reconnect the fuel injector harness wiring connector.
16. Reinstall the air box components.
17. Install the oil tank, ECU bracket, and ECU.
18. Reconnect the fuel supply and return fuel hoses on
the fuel pump.
4
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