Fuel Injector Troubleshooting - Polaris General 2020 Service Manual

FUEL SYSTEM
9. Carefully pull up on the fuel rail and injectors and
remove them from the intake plenum as an assembly.
Take care not to damage the fuel injector ends during
removal.
10. Pull out on the fuel injector retaining clip and pull the
injector out of the fuel rail. Repeat on the other
injector if removal is necessary.
11. Upon installation of the new fuel injectors, lightly
lubricate the injector O-rings to aid installation.
12. Install the new injector(s) into the fuel rail and reinstall
the retaining clip.
NOTICE
Be sure the retaining clip is positioned on the injector
and fuel rail as shown above.
13. Thoroughly clean the area around the fuel injector
ports on the intake plenum.
14. Lightly lubricate the injector O-rings and reinstall the
fuel rail / injector assembly into the intake plenum.
15. Install the fuel rail mounting fasteners and torque to
specification.
TORQUE
Fuel Rail Mounting Fasteners:
8 lb-ft (11 Nm)
16. Reinstall the fuel line to the fuel rail.
17. Connect the harness leads to the fuel injectors.
NOTICE
Be sure to connect the PTO harness lead to the PTO
injector and the MAG harness lead to the MAG injector
to ensure proper engine operation.
18. Reconnect the negative battery cable and reinstall
the driver's seat.
19. Turn key on to allow the fuel system to prime and
inspect the fuel rail and injectors for fuel leaks.
5.28
20. Lower the cargo box and secure in position.

FUEL INJECTOR TROUBLESHOOTING

Injector problems typically fall into three general
categories- electrical, dirty / clogged, or leakage. An
electrical problem usually causes one or both of the
injectors to stop functioning. Several methods may be
used to check if the injectors are operating.
• With the engine running at idle, feel for operational
vibration, indicating that they are opening and closing.
• When temperatures prohibit touching, listen for a
buzzing or clicking sound with a screwdriver or
mechanic's stethoscope.
• Disconnect the electrical connector from an injector
and listen for a change in idle performance (only
running on one cylinder) or a change in injector noise
or vibration.
IMPORTANT
Do not apply voltage directly to the fuel injector(s).
Excessive voltage will burn out the injector(s). Do not
ground the injector(s) with the ignition on. lnjector(s) will
open/turn on if relay is energized.
If an injector is not operating, it can indicate either a bad
injector, or a wiring/electrical connection problem. Check
as follows:
Injector leakage is very unlikely, but in rare instances it
can be internal (past the tip of the valve needle), or
external (weeping around the injector body). The loss of
system pressure from the leakage can cause hot restart
problems and longer cranking times.
Injector problems due to dirt or clogging are unlikely due
to the design of the injectors, the high fuel pressure, the
use of filters and the detergent additives in the gasoline.
Symptoms that could be caused by dirty/clogged
injectors include rough idle, hesitation/stumble during
acceleration, or triggering of fault codes related to fuel
delivery. Injector clogging is usually caused by a buildup
of deposits on the director plate, restricting the flow of
fuel, resulting in a poor spray pattern. Some contributing
factors to injector clogging include; dirty air filters, higher
than normal operating temperatures, short operating
intervals and dirty, incorrect, or poor quality fuel.
Cleaning of clogged injectors is not recommended; they
should be replaced. Additives and higher grades of fuel
can be used as a preventative measure if clogging has
been a problem.
9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual
© Copyright Polaris Inc.