4
9929422 R02 - 2017-2019 ACE 900 Service Manual
© Copyright Polaris Industries Inc.
4.23
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 filters, regulator and fuel
gauge sender. The pump is rated for a minimum output
of 25 liters per hour 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 go on, but
will turn off after 4 cranking revolutions if system function
is OK. Once the engine is running, the fuel pump remains
on.
FUEL SENDER TEST
1. Remove the fuel pump assembly from the fuel tank.
Refer to Fuel Pump Replacement page procedure.
2. Using an Ohm meter, measure the resistance of the
fuel sender as shown below.
ITE-
M
POSITION READING
q
EMPTY position
450 Ω ± 5%
w
FULL position
100 Ω ± 3%
e
Measure between the two
pins
—
3. Allow the sender float to sit in the EMPTY position
and compare to specification.
4. Slowly move the sender float to the FULL position
and compare to specification.
5. If the readings are out of specification, or if the
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
6. If none of the conditions exist, the fuel sender
assembly is faulty. Replace the fuel pump assembly.
Refer to Fuel Pump Replacement page procedure.
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
7.0 volts is being supplied. If during starting the battery
voltage drops below 7.0 volts, the ECU will fail to operate
the system.
WARNING
Gasoline is extremely flammable and explosive under
certain conditions.
Always stop the engine and refuel outdoors or in a well
ventilated area.
Do not smoke or allow open flames or sparks in or near
the area where refueling is performed or where
gasoline is stored.
Do not overfill the tank. Do not fill the tank neck.
If you get gasoline in your eyes or if you swallow
gasoline, seek medical attention immediately. Do not
induce vomiting.
If you spill gasoline on your skin or clothing,
immediately wash it off with soap and water and
change clothing.
Never start the engine or let it run in an enclosed area.
Engine exhaust fumes are poisonous and can result
loss of consciousness or death in a short time.
Never drain the fuel when the engine is hot. Severe
burns may result.
Always wear safety goggles when working with high
pressure or flammable fluids. Failure to do so could
result in serious injury or complications.
1. Access the top of the fuel pump. Refer to “Fuel
Pump Replacement” page for more detail.
FUEL SYSTEM
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