Fuel Pump Testing; Fuel Pump Disassembly; Fuel Pump Inspection/Assembly - Polaris Magnum 2x4 Service Manual

FUEL SYSTEM/CARBURETION
Fuel Pump
The fuel pump is located under the headlight cover at the front of the machine on 425 Magnums; at lower left side
of fuel tank (near oil tank) on 500 Sportsman. To test the fuel pump:
1. Remove headlight cover. (425s only)
2. Turn fuel off.
3. Disconnect impulse line from pump.
4. Connect Mity-Vac™ (PN 2870975) to the impulse line fitting on the pump.
5. Apply 5 inches of mercury vacuum to the pump fitting. The diaphragm should hold vacuum indefinitely.
If fuel is present in the impulse line or vacuum chamber of the pump, the diaphragm is ruptured and the pump
diaphragms must be replaced.
A
WARNING
Gasoline is extremely flammable and explosive under certain conditions.
Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where
gasoline is stored.
If you get gasoline in your eyes or if you should swallow gasoline, see your doctor immediately.
If you spill gasoline on your skin or clothing, immediately wash it off with soap and water and change
clothing.
Fuel Pump Disassembly
1. Refer to illustration on page 4.43.
2. Remove the screws from the pump diaphragm cover. Note the location of the two longer screws.
3. Remove the diaphragm cover gasket, diaphragm, and valve body gasket.
4. Remove the outlet check valve cover, diaphragm, and gasket.
Fuel Pump Inspection/Assembly
1. Inspect inlet and outlet check valves for cracks,
warpage or damage. Inspect the diaphragms for
cracks, holes or swelling.
2. To clean the valves or pump body, remove the set
screw and washer. Remove the valve and wash
with soap and water. Carburetor cleaner may be
used to clean the pump body when the check valves
are removed. CAUTION: Some carburetor
cleaners are very caustic and should not be used to
clean the non-metal parts of the fuel pump.
3. Check the sealing surfaces of the pump body and
covers. Carefully remove all traces of old gasket
and check the surfaces for damage. Replace
diaphragms and gaskets as a set.
4. Reassemble the pump in the reverse order of
disassembly. Tighten all screws evenly.
10/96
4.44
425 Fuel Pump Location
500 Fuel Pump Location
Polaris Industries Inc.