Fuel Pump Test - Polaris General 2020 Service Manual

FUEL SYSTEM

FUEL PUMP TEST

If a fuel delivery problem is suspected, make certain the
fuel pump filters are not plugged, that the pump is being
activated through the ECU, all electrical connections are
properly secured, the fuses are good, and a minimum of
10.0 volts is being supplied. If during starting the battery
voltage drops below 10.0 volts, the ECU will fail to
operate the system.
Fuel is extremely flammable and may cause severe
burns, injury, or death. Do not use any device that
produces a flame or electrical devices that may spark
around fuel or fuel vapors.
1. Remove the passenger seat from the vehicle.
2. Cover the fuel line connection at the fuel tank with a
shop towel and disconnect the line from the fuel
pump outlet
3. Install the Fuel Pressure Gauge Adapter (PA-48838)
in-line between the fuel pump outlet and fuel line.
4. Connect the hose from the Fuel Pressure Gauge Kit
(PU-43506-A) to the test valve on the Fuel Pressure
Gauge Adapter (PA-48838). Route clear hose into a
portable gasoline container or the vehicle's fuel tank.
5. Turn on key switch to activate the pump and check
the system pressure on the gauge. If system pressure
within specification 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.
Fuel Pressure:
58 ± 2 psi (400 ± 14 kPa)
NOTICE
If the fuel pressure is out of specification, replace the
fuel pump assembly.
5.32
WARNING
6. If the pump did not activate (Step 5), disconnect the
harness connector from the fuel pump. Connect a DC
voltmeter across terminals "3" and "4" in the plug on
the vehicle fuel pump harness. Turn on the key switch
and observe voltage to ensure a minimum of 10 volts
is present.
NOTICE
If the voltage was below 10 VDC, test the battery,
ignition switch, relay(s), wiring harness and ECU.
7. If the reading is between 7 and 14 volts, turn key
switch off and connect an ohmmeter between
terminals "3" and "4"' at the white fuel pump
connector to check for continuity within the fuel pump.
NOTICE
If there was no continuity between the pump terminals,
replace the fuel pump assembly.
8. If voltage at the plug was within the specified range,
and there was continuity across the pump terminals,
reconnect the plug to the fuel pump, making sure you
have a clean connection. Turn on the key switch and
listen for the pump to activate.
NOTICE
If the pump starts, repeat steps 3, 4 and 5 to verify
correct pressure.
9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual
© Copyright Polaris Inc.