Fuel Pump / Tank Assembly Replacement - Polaris Sportsman 800 EFI 4x4 2012 Service Manual

4. Turn on the key switch to activate the pump and
check the system pressure on the gauge. If system
pressure of 39 psi ± 3 is observed, the ignition
switch, ECU, fuel pump, and pressure regulator are
working properly. Turn the key switch off and
depress the valve button on the tester to relieve the
system pressure.
NOTE: If the pressure is too high or too low,
replace the fuel pump assembly.
5. If the pump did not activate (Step 2), disconnect the
plug from the fuel pump. Connect a DC voltmeter
across terminals "A" and "C" in the plug, turn on the
key switch and observe if a minimum of 7 volts is
present. If voltage is between 7 and 14, turn key
switch off and connect an ohmmeter between the
terminals "A" and "C"' on the pump to check for
continuity.
NOTE: If there was no continuity between the
pump terminals, replace the fuel pump assembly.
If the voltage was below 7 Vdc, test the battery,
ignition switch, wiring harness and ECU.
6. If voltage at the plug was good, and there was
continuity across the pump terminals, reconnect the
plug to the pump, making sure you have good, clean
connections. Turn on the key switch and listen for the
pump to activate.
NOTE: If the pump starts, repeat steps 1 and 2 to
verify correct pressure.
If the pump still does not operate, check for
correct ECU operation by plugging in a known-
good ECU of the same model.
If the pump still does not operate, replace the
pump assembly.

Fuel Pump / Tank Assembly Replacement

NOTE: All EFIs utilize quick connect fuel lines.
Always wear safety equipment when working with high
pressure or flammable fluids. Failure to do so could
1. Disconnect the negative battery cable.
2. Remove the side panels and front cab assembly.
3. Remove the clamps on the PVT intake duct and
4. Remove the gas tank cover vent hose. Be sure to
5. With all the body panels removed from the front of
6. Relieve the fuel pressure at the fuel test valve.
7. Loosen the fuel tank hose and pull the fuel line from
9924864 - 2012-2014 SPORTSMAN 800 / 6X6
© Copyright 2013 Polaris Sales Inc.
FUEL SYSTEM - GENERAL
WARNING
result in serious injury or complications.
Refer to Chapter 5.
remove the PVT duct.
properly route the vent hose upon reassembly.
the ATV and the gas tank exposed, disconnect the
pump wiring harness.
WARNING
Wear safety equipment while performing this
procedure, failure to do so could result in serious
injuries.
the tank. NOTE: A small amount of fuel may come
out of the fuel line or tank. Plug the fuel line and tank
inlet or use a shop towel during removal.
NOTE: A small amount of fuel may come out of
the fuel line or tank. Plug the fuel line and tank
inlet or use a shop towel during removal.
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