Fuel Pump / Tank Assembly Replacement - Polaris 2007 SPORTSMAN X2 800 Service Manual

FUEL INJECTION
3. If the pump did not activate (Step 2), disconnect the plug
from the fuel pump. Connect a DC voltmeter across
terminals "A" and "C" in the plug, turn on the key switch
and observe if a minimum of 7 volts is present. If voltage
is between 7 and 14, turn key switch off and connect an
ohmmeter between the terminals "A" and "C"' on the pump
to check for continuity.
NOTE: If there was no continuity between the pump
terminals, replace the fuel tank assembly.
NOTE: If the voltage was below 7Vdc, test the
battery, ignition switch, wiring harness and ECU.
4. If voltage at the plug was good, and there was continuity
across the pump terminals, reconnect the plug to the pump,
making sure you have good, clean connections. Turn on the
key switch and listen for the pump to activate.
NOTE: If the pump starts, repeat steps 1 and 2 to
verify correct pressure.
NOTE: If the pump still does not operate, check for
correct ECU operation by plugging in a known-good
ECU of the same model.
NOTE: If the pump still does not operate, replace the
pump/tank assembly.

Fuel Pump / Tank Assembly Replacement

NOTE: All EFI unit utilize quick connect fuel lines.
WARNING
Always wear safety equipment when working with
high pressure or flammable fluids. Failure to do so
could result in serious injury or complications.
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. Disconnect the negative battery cable.
2. Remove the side panels and front cab assembly. Refer to
"COVER PANEL REMOVAL" in Chapter 5 for details.
4.10
3. Remove the clamps on the PVT intake duct and remove the
PVT duct.
4. Remove the gas tank cover vent hose. Be sure to properly
route the vent hose upon reassembly.
5. With all the body panels removed from the front of the ATV
and the gas tank exposed, disconnect the pump wiring
harness.
WARNING
Wear safety equipment while performing this
procedure, failure to do so could result in serious
injuries.