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

FUEL SYSTEM - GENERAL

Fuel Pump Replacement

WARNING
Always wear safety goggles when working with high
pressure or flammable fluids. Failure to do so could
result in serious injury or complications.
1. Disconnect battery.
2. Remove seat, side covers and front cab to gain
access to the fuel pump. See chapter 9.
3. Ensure that static has been discharged from you by
touching a ground source such as the engine or
frame.
4. Disconnect the fuel pump electrical harness.
5. While holding a shop towel over the fuel line
connector, disconnect the quick connect fuel line
from the fuel pump.
CAUTION
It is possible for pressurized fuel to be present when
disconnecting the fuel line.
It is recommended to allow the vehicle to sit for a period
of one hour after shutting off the engine before
servicing the fuel pump. This allows the exhaust to cool
and fuel pressure to drop.
NOTE: A small amount of fuel may come out of
the fuel line or tank. Properly drain fuel into a
suitable container.
6. Be sure the top of the fuel tank is clean. If it requires
cleaning, hand wash the top of the tank to ensure no
debris will enter the fuel system when the fuel pump
is removed.
WARNING
Failure to clean area around fuel pump may lead to
debris entering the fuel tank during service. Excessive
debris in fuel tank may cause premature wear of fuel
pump and/or clogging if internal fuel filters.
4.18
7. Place the Fuel Pump Service Tool (PU-50326) over
the fuel pump PFA nut. Using a 1/2" drive ratchet or
breaker bar, loosen and remove the PFA nut.
Discard the PFA nut and use a new PFA nut upon
reinstallation of the fuel pump.
NOTE: Apply downward force on the fuel pump
flange while removing the fuel pump PFA nut.
8. Carefully lift the fuel pump out of the fuel tank. As the
fuel pump assembly is being removed, be aware of
float arm and pump pre-filter. Hold the float arm to
the pump body as you lift and tilt the pump to ensure
that the float arm is not bent when removed from the
tank.
9. Transfer old fuel pump to a suitable container
capable of safely holding fuel. The fuel pump will
retain some fuel.
10. Inspect the inside of the fuel tank for debris (may
require flashlight and mirror). If debris like mud or
sand is present, fuel tank should be flushed and
cleaned out prior to installation of new fuel pump
assembly.
NOTE: It is recommended to remove the fuel
tank from the vehicle and rinse it with a small
amount of clean fuel. Do not use water or any
other chemicals to remove debris.
11. Remove new fuel pump assembly, gasket and PFA
nut from packaging. Use care not to bend float arm
during un-packaging. Do not lift or carry fuel pump
assembly by the float arm.
9924864 - 2012-2014 SPORTSMAN 800 / 6X6
© Copyright 2013 Polaris Sales Inc.