Fuel Tank Pressure Test; Cfi Fuel Rail/Injector(S) Removal/Installation - Polaris IQ 2007 Service Manual

Fuel Systems

Fuel Tank Pressure Test

1. Connect a Mity Vac hand pump to the fuel tank vent
fitting.
2. Connect a eight-inch piece of 5/16
clamps across the fuel supply and return fittings at the fuel
pump flange.
3. Pressurize the tank to 5 PSI.
NOTE: Fuel tank deformation will occur when the
tank is pressurized.
WARNING
Do not over-pressurize the fuel tank past 6 PSI.
NOTE: Using a hand pump to pressurize the fuel
tank may take a very long time. The installation of an
in-line Schrader Valve (PN: 2872602) and the use of a
low pressure pump
recommended.
4. Once the tank is pressurized, saturate the area around the
PFA gasket with a mixture of water and mild detergent.
5. If any bubbles form, re-check the PFA nut torque. If bubble
formation continues, the PFA gasket will have to be
replaced, or tank replacement is required.
NOTE: There may be bubbles present from the initial
application of leak detector. Slightly blow on the
bubbles to pop them. Watch for new bubble
formation. New bubble formation may very small so
look closely. Apply
solution if required.
4.30
"
fuel hose and two gear
(bicycle tire pump)
additional water/detergent

CFI Fuel Rail/Injector(s) Removal/Installation

NOTE: Keep the red protective cap on the end of the
injector to prevent damage when installed. Follow
the steps and remove when instructed to do so.
600 / 700 CFI INJECTOR KITS
KITS
INJECTOR
2203325-053
2203325-027
2203325-015
800 CFI INJECTOR KITS
KITS
INJECTOR
2203575-053
is
2203575-027
2203575-015
1. Depressurize the fuel rail. See "Fuel Rail Bleeding /
Pressure Testing" on page 4.29.
2. Remove the panduit straps as shown.
NOTE: The engine must be removed from the engine
compartment to access the lower two fuel injectors.
COLOR
Yellow
Blue
Red
COLOR
Yellow
Blue
Red