Fuel Pump Replacement - Polaris RZR PRO R Service Manual

FUEL PUMP REPLACEMENT

REMOVAL
1. Remove the driver and passenger seats.
2. Remove upper and lower rear close off panels.
3. Disconnect the battery cables from the battery,
located under the driver's seat.
4. Remove the lower floor panels. See Console and
Lower Floor Removal page 11.25.
5. Disconnect the fuel pump electrical harness.
6. While holding a shop towel over the fuel line
connector, disconnect the fuel supply line
NOTICE
A small amount of fuel may come out of the fuel lines or
pump fitting. Properly drain fuel into a suitable
container.
7. Place the Fuel Pump Service Tool 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.
NOTICE
Apply downward force on the fuel pump flange while
removing the fuel pump PFA nut.
Fuel Pump Service Tool:
PU-50326
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.
9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual
© Copyright Polaris Industries Inc.
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.
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
INSTALLATION
w
.
1. Use cleaning wipes provided to clean fuel tank
surface and threads. Remove all debris, grease and
oil. Allow surfaces to dry completely.
2. Install new PFA gasket onto fuel pump assembly
using care not to damage gasket or bend float arm.
3. Install fuel pump into fuel tank, hold float arm to the
pump body and tilt assembly to ensure float arm does
not get caught or bent during installation.
Fuel pump pickup tube should face FORWARD when
Fuel pump pickup tube should face REARWARD when
Incorrect fuel pump orientation will result in an
4. Gently push down on fuel pump flange ensuring
flange is centered.
5. Roughly align orientation mark on fuel pump between
the orientation marks on fuel tank to ensure float arm
does not get bent or snagged.
Failure to align the orientation marks may lead to
interferences with the fuel level float arm and cause
6. While maintaining downward pressure, thread new
PFA nut onto fuel tank and hand tighten. Use care
when starting PFA nut, ensuring threads are properly
aligned. Verify orientation marks are still aligned
between fuel pump and fuel tank.
7. Torque PFA nut to specification using the Fuel Pump
Service Tool (PU-50326) and a calibrated torque
wrench.
EFI / FUEL SYSTEM
NOTICE
debris.
IMPORTANT
installing on 2-seat vehicles.
installing on 4-seat vehicles.
inaccurate fuel level reading.
WARNING
incorrect function.
TORQUE
Fuel Pump PFA Nut:
70 ft-lbs (95 Nm)
5
5.23