Fuel Tank Removal; Fuel Pump Replacement - Polaris Sportsman 850 Service Manual

FUEL TANK REMOVAL

NOTE
Syphon as much fuel from the tank as possible before
attempting to remove it from the ATV.
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. Remove the seat and upper side panels from the
vehicle.
2. Remove the (4) push rivets from each front mud
guard and remove the mud guards from the vehicle.
3. Remove the front rack.
4. Disconnect the negative battery cable.
NOTE
Be sure to cover the fuel tank inlet with a shop towel
prior to front cab and fuel tank removal.
5. Remove the front cab assembly.
6. Remove the (4) screws from the bottom of the right-
hand footwell.
7. Remove the air box assembly.
8. Remove the (2) fuel tank mounting screws
on the upper portion of the fuel tank.
9. Ensure that static has been discharged by touching a
ground source such as the engine or frame.
10. Disconnect the fuel pump electrical harness.
11. While holding a shop towel over the fuel line
connector, disconnect the quick connect fuel line
from the fuel pump.
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
A small amount of fuel may come out of the fuel line or
tank. Properly drain fuel into a suitable container.
12. If replacing the fuel pump, carefully pull the fuel tank
out far enough to service the fuel pump (see "Fuel
Pump Replacement"
Replacement, page 4.9 If removing fuel tank
assembly, proceed to the next step.
13. Remove vent line
tank.
q
located
14. Carefully pull fuel tank out the right side of the ATV.

FUEL PUMP REPLACEMENT

1. Slide fuel tank out to allow enough access to service
the fuel pump, see Fuel Tank Removal, page 4.9.
Take care not to damage the Idle Air Control (IAC) valve
FUEL SYSTEM
CAUTION
and fuel pressure to drop.
NOTE
procedure). Fuel
w
from fitting on top of the fuel
NOTE
upon fuel tank removal.
4
Pump
4.9