Regulator/Rectifier - Toro 500 EFI Service Manual

Side by side off road utility vehicle

Table of Contents



NOTE: The fuel pump will cycle 5-10 seconds after

the ignition key is turned on.

4. If the pump is producing fuel pressure that is out of

specification, check all electrical connectors and ver-

ify the pump is getting proper voltage (battery volt-

age).

5. Connect a multimeter to the power supply leads with

the red tester lead to the red wire and the black tester

lead to the black wire; then turn the ignition switch to

the ON position. The meter should read battery volt-

age.



NOTE: Low voltage will produce a low fuel pressure

reading.

6. If normal battery voltage is present and the ground

wire has been checked for continuity to chassis,

replace the fuel pump. If no voltage is present, deter-

mine if the fuel pump fuse, relay, wiring, tilt sensor,

or ECM is causing no voltage.



NOTE: If the gauge is flashing FUEL OFF, the tilt

sensor system has intentionally deactivated the fuel

system.

REMOVING

1. Remove the key from the ignition switch.

! WARNING

Always ensure that power cannot be inadvertently

applied to the ignition/ECM when working on the fuel

system. If the ignition switch is turned on, the electric

fuel pump will start and gas could be rapidly pumped

and spilled resulting in fire and severe injury.

2. Remove the seat, seat back, and seat base; then dis-

connect the negative battery cable.

3. Disconnect the electrical plug from the main harness;

then disconnect the gasline hose from the fuel pump.

4. Mark the fuel pump mounting and gas tank for

installing purposes; then remove the screws securing

the fuel pump to the gas tank and remove the fuel

pump.

CAUTION

Take care not to damage the float or float arm or

replacement of the entire assembly will be necessary.

136

5. Using duct tape or other suitable means, cover the

fuel pump opening.

INSPECTING

AT THIS POINT

If the pump has failed earlier test and must be replaced,

proceed to INSTALLING.

1. Inspect the fuel screen and blow clean with low pres-

sure compressed air.

2. Move the float lever and check for free movement.

The float assembly should return to the lower posi-

XR172

tion without force. If not, replace the fuel level sen-

sor assembly.

3. Test the fuel level sensor by connecting a multimeter

to the fuel level sensor leads; then select OHMS. The

multimeter should show 5 ohms at full fuel position

and 95 ohms at empty fuel position.



NOTE: If readings are erratic, clean the resistor

wiper and resistor with clean alcohol and retest. If

still not correct, replace the fuel level sensor.

INSTALLING

1. Place the fuel pump assembly into the gas tank with

a new gasket aligning the match marks; then secure

with the four screws. Tighten securely.



NOTE: It is important to install the fuel pump with

the correct orientation to ensure adequate float lever

clearance.

2. Connect the gasline hose to the fuel pump pipe and

secure with the hose clamp; then connect the electri-

cal plug to the main harness.

3. Connect the negative battery cable; then turn the

ignition switch to the ON position and verify that no

gas leaks are present, the pump runs for 2-3 seconds,

and the gas gauge reading is normal.

4. Start the engine to verify proper engine operation;

then shut off the engine and install the seat base, seat

back, and seat.