Electric Fuel Pump/Fuel Level Sensor - Arctic Cat 500 Service Manual

3. Secure the water pump with the two cap screws and
tighten securely; then connect the coolant hoses and
secure with hose clamps.
4. Install and tighten the coolant drain plug securely;
then fill the cooling system with the proper amount
of recommended coolant and install the radiator cap.
5. Start the engine and check for coolant leaks; then add
coolant if necessary to proper level.
CAUTION
After operating the ATV for the initial 5-10 minutes, stop
the engine, allow the engine to cool down, and check
the coolant level. Add coolant as necessary.
Electric Fuel Pump/Fuel
Level Sensor
 NOTE: Preliminary checks may be performed on
this component using the diagnostic mode on the
LCD gauge (see EFI Diagnostic System in the Electri-
cal System section).
The electric fuel pump and fuel level sensor are not ser-
viceable components. If either component fails, it must
be replaced.
TESTING
! WARNING
Whenever any maintenance or inspection is made on
the fuel system during which there may be fuel leakage,
there should be no welding, smoking, open flames, etc.,
in the area.
 AT THIS POINT
Prior to removing the electric fuel pump, the following
check should be performed to determine that removal
is necessary.
1. Turn the ignition switch ON and listen for a momen-
tary "whirring" sound of the pump building pressure.
If the sound is heard (10 seconds), no electrical
checks are necessary. Turn the ignition switch OFF.
2. Disconnect the gasline hose from the throttle body;
then install a suitable pressure gauge.
! WARNING
Gasoline may be under pressure. Place an absorbent
towel under the connector to absorb any gasoline spray
when disconnecting.
3. Turn the ignition switch to the ON position. The fuel
pressure should build until the pump shuts off. Pres-
sure should read 3.0 kg-cm
4. If the pump is not running, disconnect the fuel
pump/tank sensor connector by reaching under the
rear rack from behind.
5. Connect a multimeter to the power supply leads with
the red tester lead to the red wire and the black tester
lead to the black wire; then turn the ignition switch to
the ON position. The meter should read battery volt-
age. If battery voltage is indicated and the fuel pump
does not run, replace the pump assembly. If no bat-
tery voltage is indicated, check the ECM and the
vehicle tilt sensor.
REMOVING
1. Remove the rear rack and fenders (see Steer-
ing/Frame/Controls); then disconnect the power sup-
ply/fuel hose connector.
2. Remove the spring clamp; then remove the fuel hose.
3. Remove the screws securing the fuel pump to the gas
tank; then make a reference mark on the fuel pump
and tank.
4. Lift out the fuel pump assembly carefully tilting it
forward to clear the voltage regulator; then guide the
pump and float lever through the opening in the gas
tank.
CAUTION
Take care not to damage the float or float arm or
replacement of the entire assembly will be necessary.
5. Using duct tape or other suitable means, cover the
fuel pump opening.
INSPECTING
 AT THIS POINT
If the pump has failed earlier test and must be
replaced, proceed to INSTALLING.
1. Inspect the fuel screen and blow clean with low pres-
sure compressed air.
2. Move the float lever and check for free movement.
The float assembly should return to the lower posi-
tion without force. If not, replace the fuel pump
assembly.
FI092A
(43 psi).
2
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