Fuel Pump Assembly; Operation / Testing; Fuel Pump Test - Polaris 2007 Sportsman 500 EF Service Manual

FUEL PUMP ASSEMBLY

Operation / Testing

NOTE: All EFI units utilize quick connect fuel lines.
An electric fuel pump assembly is used to transfer fuel to the EFI
system from inside the fuel tank. This assembly includes the fuel
pump, regulator and fuel gauge sender. The pump is rated for a
minimum output of 25 liters per hour at 39 psi and has a non-
serviceable internal 30-micron filter. In addition, the pump has
a replaceable 10-micron filter attached to the pump outlet,
which is located under the strut mount.
Fuel pump not
replaceable, picture
for reference only.
Regulator
Fuel Pump
Internal 30 Micron
Strainer (Bottom)
When the key switch is turned to "ON", the ECM activates the
fuel pump, which pressurizes the system for start-up.
The ECM switches off the pump preventing the continued
delivery of fuel in these instances:
• If the key switch is not promptly turned to the "start"
position.
• If the engine fails to start, or
• If the engine is stopped with the key switch "on" (as in
the case of an accident)
In these situations, the "check engine" light will go on, but will
turn off after 4 cranking revolutions if system function is OK.
Once the engine is running, the fuel pump remains on.
NOTE: FUEL GAUGE SENDER TEST - To test fuel
gauge sender function, refer to Chapter 10 in this
service manual.

FUEL PUMP TEST

NOTE: The fuel pump/tank assembly is a non-
serviceable assembly and must be replaced if
determined to be faulty. If a fuel delivery problem is
suspected, make certain the filters are not plugged,
that the pump is being activated through the ECM,
all electrical connections are properly secured, the
fuses are good, and a minimum of 7.0 volts is being
supplied. If during starting, the battery voltage drops
below 7.0 volts, a reduction of fuel pressure may
occur resulting in a lean starting condition. If
required, testing of the fuel pump and circuitry may
be conducted.
Check the fuel test valve for any possible fuel
seepage after performing any tests or procedures.
Fuel is extremely flammable and may cause severe
burns, injury, or death. Do not use any device that
produces a flame or electrical devices that may
1. Insert the fuel test valve adapter PU-47476. Connect the
pressure hose of the Polaris pressure tester (PN PU-43506)
to the test valve. Route the clear hose into a portable
gasoline container or the equipment fuel tank.
Fuel Gauge
Sender
2. 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, ECM, 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.
NOTE: If the pressure is too high or too low, replace
the fuel pump assembly.
FUEL INJECTION
CAUTION
spark around fuel or fuel vapors.
Fuel Pump Pressure - 39 psi ± 3
4
4.13