Fuel Pump Replacement - Polaris A12MH46AX Service Manual

3. Move the seal out of the sealing channel and pull up
on the front of the access cover. Remove the access
cover.
4. Locate fuel pump / sending unit connector.
5. Disconnect the fuel pump / sending unit connection
and measure the resistance between the Purple and
Brown wires (see chapter 10 for further details). If out
of specification, replace the fuel pump.
Fuel Sender Resistance Specifications:

Full: 90 +/- 5%

Empty: 6 +/- 5%
ECU

9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
© Copyright 2011 Polaris Sales Inc.
500 EFI FUEL SYSTEM

Fuel Pump Replacement

WARNING
Always wear safety goggles when working with
high pressure or flammable fluids. Failure to do
so could result in serious injury or complications.
1. Disconnect battery.
2. Remove seat, side covers and front cab to gain
access to the fuel pump. See chapter 9.
3. Ensure that static has been discharged from you by
touching a ground source such as the engine or
frame.
4. Disconnect the fuel pump electrical harness.
5. While holding a shop towel over the fuel line
connector, disconnect the quick connect fuel line from
the fuel pump.
CAUTION
It is possible for pressurized fuel to be present
when disconnecting the fuel line.
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
exhaust to cool and fuel pressure to drop.
NOTE: A small amount of fuel may come out of the
fuel line or tank. Properly drain fuel into a suitable
container.
6. Be sure the top of the fuel tank is clean. If it requires
cleaning, hand wash the top of the tank to ensure no
debris will enter the fuel system when the fuel pump
is removed.
CAUTION
Failure to clean area around fuel pump may lead
to debris entering the fuel tank during service.
Excessive debris in fuel tank may cause
premature wear of fuel pump and/or clogging
of internal fuel filters.
4
4.43