4.41
500 EFI FUEL SYSTEM
4
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
© Copyright 2011 Polaris Sales Inc.
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 pump assembly.
NOTE: If the voltage is 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.
NOTE: If the pump still does not operate, replace the
fuel pump assembly.
Fuel Tank Replacement
NOTE: All EFI units utilize quick connect fuel lines.
1. Disconnect the negative battery cable.
2. Remove the seat side panels and front cab/fender
assembly. Refer to Chapter 5 for details.
3. Remove the clamps on the PVT intake duct and
remove the PVT duct.
4. With all the body panels removed from the front of the
ATV and the fuel tank exposed, disconnect the pump
wiring harness.
5. Relieve the fuel pressure.
6. Loosen the fuel tank hose and pull the fuel line from
the tank.
Always wear safety goggles when working with
high pressure or flammable fluids. Failure to do so
could result in serious injury or complications.
Wear safety goggles while performing this
procedure, failure to do so could result in serious
injuries.
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