4.32
ELECTRONIC FUEL INJECTION
9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual
© Copyright 2012 Polaris Sales Inc.
Fuel Pump Replacement
NOTE: The photos used in this procedure depict the
RZR XP model. Even though the fuel tank is located
differently, the replacement procedure is the same
for the RZR XP 4 model.
1. Move the vehicle to a well ventilated area. Shift the
transmission into Park and turn the ignition key off.
2. Remove the passenger seat to access the fuel pump.
3. Be sure the top of the fuel tank is clean. If it requires
cleaning, hand wash the top of the tank to ensure no
debris will enter the fuel system when the fuel pump
is removed.
4. Ensure that static has been discharged by touching a
ground source such as the engine or frame.
5. While holding a shop towel over the fuel line
connectors, disconnect the fuel supply line (A) from
the pump and the fuel return line (B) from the tank (see
“Fuel Lines - Quick Connect Fittings” for specific
removal procedures).
NOTE: A small amount of fuel may come out of the
fuel lines or pump fitting. Properly drain fuel into a
suitable container.
6. Remove the fuel tank vent line (C) from the tank fitting.
7. Disconnect the fuel pump electrical harness (D).
8. Place the Fuel Pump Service Tool (PU-50326) over
the fuel pump PFA nut. Using a 1/2” drive ratchet or
breaker bar, loosen and remove the PFA nut. Discard
the PFA nut.
NOTE: Apply downward force on the fuel pump
flange while removing the fuel pump PFA nut.
Always wear safety goggles when working with
high pressure or flammable fluids. Failure to do
so could result in serious injury or complications.
Failure to clean area around fuel pump may lead
to debris entering the fuel tank during service.
Excessive debris in fuel tank may cause
premature wear of fuel pump and/or clogging
of internal fuel filters.
It is possible for pressurized fuel to be present
when disconnecting the fuel line.
It is recommended to allow the vehicle to sit for
a period of one hour after shutting off the engine
before servicing the fuel pump. This allows the
exhaust to cool and fuel pressure to drop.
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