Fuel Pump / Tank Assembly Replacement - Polaris MS4000 Service And Owner's Manual

3. Connect the hose from the Fuel Pressure Gauge Kit (PU-
43506-A) to the test valve on the Fuel Pressure Gauge
Adaptor. Route the clear hose into a portable gasoline
container or the vehicle's fuel tank.
4. Turn on the key switch to activate the pump and check the
system pressure on the gauge. If system pressure of 39 psi
± 3 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 Pump Pressure: 39 psi. ± 3
NOTE: If the pressure is too high or too low, replace
the fuel pump / tank assembly.
5. If the pump did not activate (Step 4), disconnect the plug
from the fuel pump. Connect a DC voltmeter across
terminals "A" and "C" in the plug on the vehicle harness
side. Turn on the key switch and observe voltage to ensure
a minimum of 7 volts is present.
NOTE: If the voltage was below 7 VDC, test battery,
ignition switch, relay(s), wiring harness and ECU.
6. If the reading is between 7 and 14 volts, turn key switch
off and connect an ohmmeter between the terminals "A"
and "C"' in the plug on the pump harness to check for
continuity within the fuel pump.
NOTE: If there was no continuity between the pump
terminals, replace the fuel pump / tank assembly.
7. If voltage at the plug was within the specified range, and
there was continuity across the pump terminals, reconnect
the plug to the pump, making sure you have clean
connections. Turn on the key switch and listen for the pump
to activate.
NOTE: If the pump starts, verify you have the
correct amount of fuel pressure.
NOTE: If the pump still does not operate, replace the
fuel pump / tank assembly.

Fuel Pump / Tank Assembly Replacement

NOTE: All EFI units utilize quick connect fuel lines.
PV-48656
high pressure or flammable fluids. Failure to do so
NOTE: The fuel pump cannot be replaced as an
individual part, the entire fuel pump and fuel tank is
replaced as an assembly. Refer to your parts book
for the proper part number.
1.
PU-43506-A
2.
3.
4.
5.
NOTE: A small amount of fuel may come out of the
fuel line or tank. Plug the fuel line and tank inlet or
use a shop towel during removal.
NOTE: Properly drain fuel into a suitable container.
6.
ELECTRONIC FUEL INJECTION
WARNING
Always wear safety goggles when working with
could result in serious injury or complications.
Disconnect the negative battery cable.
Remove the seat.
Disconnect the fuel line from the fuel pump.
Harness
Disconnect the fuel pump electrical harness.
Remove the fuel tank vent hose
Remove the RH rear fender and fuel cap.
4
Fuel Line
Vent Hose
4.13