4.2
9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual
© Copyright Polaris Industries Inc.
GENERAL INFORMATION - FUEL SYSTEM
SERVICE NOTES - FUEL SYSTEM
WARNING
* Gasoline is extremely flammable and explosive under
certain conditions.
* EFI components are under high pressure.
* Verify system pressure has been relieved before
disassembly.
* Never drain the fuel system when the engine is hot.
Severe burns may result.
* Do not overfill the tank. The tank is at full capacity
when the fuel reaches the bottom of the filler neck.
Leave room for expansion of fuel.
* Never start the engine or let it run in an enclosed area.
Gasoline powered engine exhaust fumes are poisonous
and can cause loss of consciousness and death in a
short time.
* Do not smoke or allow open flames or sparks in or
near the area where refueling is performed or where
gasoline is stored.
* If you get gasoline in your eyes or if you should
swallow gasoline, seek medical attention immediately.
* If you spill gasoline on your skin or clothing,
immediately wash with soap and water and change
clothing.
* Always stop the engine and refuel outdoors or in a
well ventilated area.
• For more convenient and accurate testing of EFI
components, it is recommended dealers utilize the
Digital Wrench® Diagnostic Software (dealer only).
Some testing may be done manually using the
procedures provided in this chapter.
• 80% of all EFI problems are caused by wiring
harness connections.
• For the purpose of troubleshooting difficult running
issues, a known-good ECU from another POLARIS of
the same model and year may be used without
damaging system or engine components.
• Never attempt to service any fuel system component
while engine is running or ignition switch is "on."
• Cleanliness is essential and must be maintained at all
times when servicing or working on the EFI system.
Dirt, even in small quantities, can cause significant
problems.
• Do not use compressed air if the system is open.
Cover any parts removed and wrap any open joints
with plastic if they will remain open for any length of
time. New parts should be removed from their
protective packaging just prior to installation.
• Clean any connector before opening to prevent dirt
from entering the system.
• Although every precaution has been taken to prevent
water intrusion failure, avoid direct water or spray
contact with system components.
• Do not disconnect or reconnect the wiring harness
connector to the control unit or any individual
components with the ignition "on." This can send a
damaging voltage spike through the ECU.
• Do not allow the battery cables to touch opposing
terminals. When connecting battery cables attach the
positive (red) cable to positive (+) battery terminal first,
followed by negative (black) cable to negative (-)
battery terminal.
• Never start the engine when the cables are loose or
poorly connected to the battery terminals.
• Never disconnect battery while engine is running.
• Never use a battery boost-pack to start the engine.
• Do not charge battery with key switch "on."
• Always disconnect negative (-) battery cable lead
before charging battery.
• Always unplug ECU from the wire harness before
performing any welding on the unit.
FUEL SYSTEM
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