Fuel Tank Service; Fuel Pump Service - Polaris 600 RUSH 2010 Manual

Fuel Tank Service

1. Remove the tank cap and siphon the fuel in the tank
into a suitable container.
2. Remove the seat assembly
3. Remove the door panels and hood.
4. Remove the console.
5. Remove the two screws attaching the fuel tank
bracket to the steering post assembly (if applicable).
6. Disconnect the fuel supply and return hoses from the
fuel pump. Disconnect the fuel pump power/level
sender wire harness connector.
7. Remove the fuel tank assembly from the snowmobile.
8. Inspect the tank for signs of damage/excessive wear.
Inspect the foam pads that the tank rests on. Replace
pads if torn, missing, or damaged.
9. Installation is the reverse of removal.

Fuel Pump Service

1. Siphon the fuel out of the fuel tank into a suitable
container.
2. Remove the door panels, hood, and console.
3. Disconnect the ground (-) battery cable from the
battery if applicable.
4. Bleed the pressure from the fuel rail. See "Fuel Rail
Bleeding / Pressure Testing" on page 4.18.
5. Disconnect the fuel supply and return hoses from the
pump flange. See "Disconnect Fittings" on page 4.19.
6. Disconnect the wiring harness.
7. Using the PFA spanner wrench and nut socket (PS-
48459), carefully remove the PFA nut.
8. Carefully extract the PFA out of the tank making sure
the float and fuel hoses do not become kinked or bent.
Cleanfire Fuel Injection
9. Remove the old gasket and discard.
CAUTION
ALWAYS REPLACE PFA GASKET WITH NEW
GASKET AFTER REMOVING FUEL PUMP.
10. Clean the tank's gasket mating surface with isopropyl
alcohol. Allow the surface to dry completely.
11. Install a new gasket ensuring the inside portion of the
gasket hooks onto the bead on the inside diameter of
the neck.
12. Remove containments from the gasket with isopropyl
alcohol.
13. Carefully place the PFA back into the tank. Push the
float assembly against the hoses to fit it into the hole.
14. Hand tighten the PFA nut keeping the arrow between
the PFA alignment marks.
SUPPLY FITTING
ARROW
ALIGNMENT LINES
NOTE: The pump flange assemblies on 2013 models
do not feature alignment marks. Align the supply
fitting with the arrow on the fuel tank during pump
installation.
SUPPLY FITTING
ARROW
RETURN FITTING
4.31
4