Fuel Tank Pressure Test; Throttle Body Removal - Polaris 2007 Two Stroke Service Manual

FUEL DELIVERY
9. Using the PFA spanner wrench (PS-48459-1) and nut
socket (PS-48459), carefully remove the PFA nut.
10. Carefully extract the PFA out of the tank making sure the
float and fuel hoses do not become kinked or bent.
11. Remove the old gasket and destroy.
WARNING
Never re-use a used PFA gasket.
12. Clean the tank's gasket mating surface with Isopropyl
Alcohol. Allow the surface to dry completely.
13. Install a new gasket ensuring the inside portion of the
gasket hooks onto the bead on the inside diameter of the
neck.
14. Remove any containments from the gasket with Isopropyl
Alcohol.
15. Carefully place the PFA back into the tank. Push the float
assembly against the hoses to fit it into the hole.
16. Hand tighten the PFA nut keeping the arrow between the
PFA alignment marks.
17. Using the PFA spanner wrench and nut socket (PS48459-
1 and -2), tighten the PFA to specification.
PFA Nut Torque = 21 Ft.Lbs. (28 Nm)
18. Fuel tank installation is the reverse of removal. Always test
the PFA gasket seal before tank installation by performing
a pressure check.
4.22
= T

Fuel Tank Pressure Test

1. Connect a Mity Vac hand pump to the fuel tank vent
fitting. Seal the fuel supply and return fittings.
2. Pressurize the tank to 5 PSI.
WARNING
Do not over-pressurize the fuel tank past 6 PSI.
NOTE: Using a hand pump to pressurize the fuel
tank may take a very long time. The installation of an
in-line Schrader Valve (PN: 2872602) and the use of
a low pressure pump (bicycle tire pump) is
recommended.
3. Once the tank is pressurized, spray the area around the PFA
gasket with a mixture of water and mild detergent.
4. If any bubbles form, re-check the PFA nut torque. If bubble
formation continues, the PFA gasket will have to be
replaced, or tank replacement is required.

Throttle Body Removal

1. Remove the air box.
2. Remove the throttle body air box adapter.
3. Pinch off the coolant lines with the hose pincher tool PN
PU-45149.
4. Remove the coolant lines from the throttle body.
5. Loosen the intake boot clamps and pull the throttle body
upward, enough to gain access to the throttle cable and TPS
connector.
6. Loosen the throttle cable lock nut and remove the cable
from the throttle body.
7. Disconnect the TPS from the throttle body.
8. Remove throttle body.