4.40
500 EFI FUEL SYSTEM
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
© Copyright 2011 Polaris Sales Inc.
FUEL PUMP ASSEMBLY
Operation / Testing
NOTE: All EFI units utilize quick connect fuel lines.
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, regulator and fuel gauge sender.
The pump is rated for a minimum output of 25 liters per
hour at 39 psi and has a non-serviceable internal 30-
micron filter.
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, or
• 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.
NOTE: FUEL GAUGE SENDER TEST - To test fuel
gauge sender function, refer to Chapter 10 in this
service manual.
FUEL PUMP TEST
NOTE: If a fuel delivery problem is suspected, make
certain the 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, a reduction of fuel pressure may occur
resulting in a lean starting condition. If required,
testing of the fuel pump and circuitry may be
conducted.
1. Insert the fuel test valve adapter PU-47476. Connect
the pressure hose of the Polaris pressure tester (PN
PU-43506) to the test valve. Route the clear hose into
a portable gasoline container or the equipment fuel
tank.
2. Turn on the key switch to activate the pump and check
the system pressure on the gauge. If system pressure
of 39 psi ± 3 is observed, the ignition switch, ECU,
fuel pump, and pressure regulator are working
properly. Turn the key switch “off” and depress the
valve button on the tester to relieve the system
pressure.
NOTE: If the pressure is too high or too low, replace
the fuel pump assembly.
Check the fuel test valve for any possible fuel
seepage after performing any tests or procedures.
Fuel is extremely flammable and may cause severe
burns, injury, or death. Do not use any device that
produces a flame or electrical devices that may
spark around fuel or fuel vapors.
Fuel Pump Pressure - 39 psi 3
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