Fuel Pump Service; Fuel Pump Operation Overview; Fuel Sender Test; Fuel Pump Test - Polaris GENERAL 2016 Service Manual

FUEL PUMP SERVICE

FUEL PUMP OPERATION OVERVIEW

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, fuel filter, regulator and fuel level
sender. The pump is rated for a minimum output of 9.25
gal (35 L)/hr at 58 ± 2 psi (400 ± 14 kPa) and has two
non-serviceable fuel filters.
When the key switch is turned to "ON", the ECU
activates the fuel pump, which pressurizes the system for
start-up.
The ECU 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.
• 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
illuminate, but turn off after 4 cranking revolutions if the
system functions properly. Once the engine is running,
the fuel pump remains on to maintain fuel pressure.

FUEL SENDER TEST

1. Remove the fuel pump assembly from the fuel tank.
Refer to Fuel Pump Replacement procedure.
2. Using an Ohm meter, measure the resistance of the
fuel sender as shown below.
# POSITION
q EMPTY position
FULL position
w
Measure between
e
the two pins
9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual
© Copyright Polaris Industries Inc.
3. Allow the sender float to sit in the EMPTY position
4. Slowly move the sender float to the FULL position
5. If the readings are out of specification, or if the
6. If none of the conditions exist, the fuel sender

FUEL PUMP TEST

If a fuel delivery problem is suspected, make certain the
fuel pump filters are not plugged, that the pump is being
activated through the ECU, all electrical connections are
properly secured, the fuses are good, and a minimum of
10.0 volts is being supplied. If during starting the battery
voltage drops below 10.0 volts, the ECU will fail to
operate the system.
produces a flame or electrical devices that may spark
1. Remove the passenger seat from the vehicle.
2. Cover the fuel line connection at the fuel tank with a
3. Install the Fuel Pressure Gauge Adapter (PA-48838)
4. Connect the hose from the Fuel Pressure Gauge Kit
READING
450 Ω ± 5%
100 Ω ± 3%
—
and compare to specification.
and compare to specification.
reading is erratic or LCD display "sticks", check the
following before replacing the fuel pump assembly:
• Loose float
• Float contact with tank
• Bent float rod
assembly is faulty. Replace the fuel pump assembly.
Refer to Fuel Pump Replacement procedure.
WARNING
Fuel is extremely flammable and may cause severe
burns, injury, or death. Do not use any device that
around fuel or fuel vapors.
shop towel and disconnect the line from the fuel
pump outlet
in-line between the fuel pump outlet and fuel line.
(PU-43506-A) to the test valve on the Fuel Pressure
Gauge Adapter (PA-48838). Route clear hose into a
portable gasoline container or the vehicle's fuel tank.
FUEL SYSTEM
4
4.33