Fuel Pump/Fuel Level Sensor - Arctic Cat Wildcar Trail Service Manual

 NOTE: The two longer cap screws go in the dowel
pin locations.
7. Install the coolant hoses; then add the appropriate
mixture of coolant until the appropriate level is
reached (see Fuel/Cooling/Lubricant).
8. If removed, install the muffler, exhaust pipe, and
right-side inner splash panel.
9. If drained, add the appropriate engine oil until the cor-
rect level has been reached.
Fuel Pump/Fuel Level
Sensor
 NOTE: Preliminary checks may be performed on
this component using the diagnostic mode on the
LCD gauge (see EFI Diagnostic System in the Electri-
cal System section).
The fuel pump and fuel level sensor are not serviceable
components. If either component fails, it must be replaced.
TESTING
! WARNING
Whenever any maintenance or inspection is made on
the fuel system during which there may be fuel leakage,
there should be no welding, smoking, open flames, etc.,
in the area.
AT THIS POINT
Prior to removing the fuel pump, the following test
should be performed to determine that removal is
necessary.
1. Turn the ignition switch ON and listen for a momen-
tary "whirring" sound of the pump building pressure.
If the sound is heard (10 seconds), no electrical checks
are necessary. Turn the ignition switch OFF.
2. Disconnect the gasline hose from the fuel rail; then
install a suitable pressure gauge.
! WARNING
Gasoline may be under pressure. Place an absorbent
towel under the connector to absorb any gasoline spray
when disconnecting.
3. Turn the ignition switch to the ON position. The fuel
pressure should build until the pump shuts off. Pres-
sure should read 3.0 kg-cm
4. Check for any flashing DTC (Diagnostic Trouble
Code) on the digital gauge. A disconnected or faulty
tilt sensor will cause the fuel pump not to run and a
code to flash.
5. If the pump is not running, check the 10 amp FUEL
fuse in the PDM under the passenger seat. Replace as
necessary and check for fuel pump operation.
6. If fuse is OK, check the FUEL relay by swapping with
another relay. If the pump runs, replace the FUEL
relay.
7. If the pump still is inoperative, proceed to REMOV-
ING.
REMOVING
1. Remove the passenger seat.
 NOTE: The power supply/wiring to the fuel pump
could be checked by using a multimeter set to DC
volts; then check for battery voltage by turning the
ignition to ON and checking between the black and
red wires.
2. Disconnect the fuel pump/fuel level sender connector;
then wrap a shop towel around the gasline connector
and disconnect the gasline from the fuel pump.
3. Mark the components for assembling purposes and
remove the screws securing the fuel pump to the gas
tank.
4. Carefully remove the fuel pump/fuel level sender
assembly from the gas tank; then tape over the open-
ing.
INSPECTING
AT THIS POINT
If the pump has failed earlier test and must be
replaced, proceed to INSTALLING.
1. Move the float lever and check for free movement.
The float assembly should return to the lower position
without force. If not, replace the fuel level sensor
assembly.
2. Test the fuel level sensor by connecting a multimeter
to the fuel level sensor leads (A); then select OHMS.
The multimeter should show 0-5 ohms at full fuel
FI092A
position and 95-105 ohms at empty.
(43 psi).
2
WT552A
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