Fuel Tank Removal - Polaris Sportsman XP 1000 S 2020 Service Manual

FUEL TANK REMOVAL

NOTICE
Syphon as much fuel from the tank as possible before
attempting to remove it from the vehicle.
WARNING
Always wear safety goggles when working with high
pressure or flammable fluids. Failure to do so could
result in serious injury or complications.
IMPORTANT
Be sure to cover the fuel tank inlet with a shop towel
prior to front cab and fuel tank removal.
1. Remove the front rack / storage box, front cover, and
front cab.
2. Remove the seat, both front mud guards and side
panels, and the RH footwell.
3. Disconnect the negative (-) battery cable.
4. Remove the airbox assembly. See Intake
Replacement page 3.21.
5. If equipped, peel back the rubber cap over the fuel
pump assembly to gain access to the fuel pump
electrical connector and fuel line.
6. Ensure that static has been discharged by touching a
ground source such as the engine or frame.
7. Pull up the rubber fuel pump cover to gain access to
the fuel pump line and electrical connector.
8. Disconnect the fuel pump electrical harness.
9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual
© Copyright Polaris Inc.
9. While holding a shop towel over the fuel line
connector, disconnect the quick connect fuel line from
the fuel pump. See Fuel Line Quick Connect Removal
page 5.2.
IMPORTANT
It is possible for pressurized fuel to be present when
disconnecting the fuel line. Place a shop towel under
the connector and properly drain fuel into a suitable
container.
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 fuel pressure to
drop.
10. Remove the fuel tank mounting fasteners located on
the upper portion of the fuel tank.
11. If replacing the fuel pump, carefully pull the fuel tank
out far enough to service the fuel pump (see Fuel
Pump Replacement page 5.13). If removing fuel tank
assembly, proceed to the next step.
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12. Disconnect the vent line
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the fuel tank .
13. Carefully pull fuel tank out the right side of the
vehicle.
FUEL SYSTEM
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from the fitting on top of
5.9
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