Polaris General 2020

5
9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual
© Copyright Polaris Inc.
5.1
FUEL SYSTEM
CHAPTER 5
FUEL SYSTEM
GENERAL INFORMATION - FUEL SYSTEM .. . . .. . . .. . ... . . .. . . .. . . .. . . .. . . .. . . .. . ... . . .. . . .. . . .. . . .. . 5.2
SERVICE NOTES - FUEL SYSTEM . . . .. . . ... . ... . .. . . .. . . .. . . .. . . .. . . ... . .. . . .. . . .. . . .. . . .. . . .. . . .. . . . 5.2
SPECIAL TOOLS - FUEL SYSTEM. ... . ... . .. . . .. . . .. . . .. . . ... . ... . .. . . .. . . .. . . .. . . .. . . ... . .. . . .. . . .. . . 5.3
SERVICE SPECIFICATIONS - FUEL SYSTEM . .. . . ... . ... . ... . ... . .. . . .. . . .. . . ... . ... . ... . .. . . .. . . .. . . 5.3
ASSEMBLY VIEWS - FUEL SYSTEM .. . ... . .. . . .. . . .. . . ... . ... . ... . .. . . .. . . .. . . .. . . ... . ... . .. . . .. . . .. . . 5.4
FUEL SYSTEM ASSEMBLY VIEW . .. . . .. . . .. . . .. . . .. . . .. . . .. . ... . . .. . . .. . . .. . . .. . . .. . ... . ... . . .. . . .. . . 5.4
EVAP FUEL SYSTEM ASSEMBLY VIEW.. . .. . . .. . . .. . . ... . ... . ... . .. . . .. . . .. . . .. . . .. . . ... . .. . . .. . . .. . . 5.5
FUEL PUMP ASSEMBLY VIEW . ... . ... . ... . ... . . .. . ... . ... . .. . . ... . ... . ... . ... . ... . .. . . .. . . ... . ... . ... 5.6
EVAP SYSTEM . . ... . ... . .. . . .. . . .. . . .. . . ... . ... . ... . .. . . .. . . .. . . .. . . ... . ... . .. . . .. . . .. . . .. . . .. . . ... . .. . . . 5.7
EVAP SYSTEM OVERVIEW . ... . . .. . . .. . . .. . ... . ... . ... . ... . . .. . . .. . ... . ... . ... . ... . ... . . .. . ... . ... . .. 5.7
EVAP CONDITIONS AND SYMPTOMS . ... . ... . ... . ... . ... . .. . . .. . . .. . . ... . ... . ... . .. . . .. . . .. . . .. . . ... 5.8
CARBON CANISTER FILTER REPLACEMENT . .. . . .. . ... . ... . ... . ... . . .. . . .. . . .. . ... . ... . ... . ... . . .. . 5.9
CARBON CANISTER REPLACEMENT . . . .. . ... . ... . .. . . ... . ... . ... . ... . ... . ... . .. . . ... . ... . ... . ... . .. 5.9
PURGE VALVE REPLACEMENT. . . .. . ... . ... . ... . ... . ... . . .. . ... . ... . ... . ... . ... . ... . ... . ... . ... . .. . .5.10
PURGE VALVE OHM TEST . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . ... . . .. . .5.10
FUEL LINES .. . .. . . .. . . .. . . .. . . .. . . ... . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. 5.11
FUEL LINE ROUTING . . ... . ... . ... . ... . ... . . .. . . .. . ... . ... . ... . ... . ... . . .. . ... . ... . .. . . .. . . ... . ... . .. 5.11
FUEL LINE ROUTING - GENERAL 4 . . ... . . .. . . .. . . .. . . .. . . .. . ... . ... . . .. . . .. . . .. . . .. . ... . ... . ... . . .. .5.13
FUEL LINE ROUTING (EVAP MODELS) . . ... . ... . .. . . .. . . .. . . .. . . ... . ... . .. . . .. . . .. . . .. . . .. . . ... . .. . .5.15
FUEL LINE ROUTING - GENERAL 4 (EVAP MODELS) . . ... . ... . ... . ... . . .. . ... . ... . .. . . ... . ... . ... . ..5.19
FUEL LINE QUICK CONNECT REMOVAL . . . .. . . .. . ... . ... . . .. . . .. . . .. . . .. . ... . ... . ... . . .. . . .. . . .. . ..5.23
FUEL LINE REPLACEMENT. .. . . .. . . .. . . .. . . .. . . .. . ... . . .. . . .. . . .. . . .. . . .. . ... . ... . . .. . . .. . . .. . . .. . ..5.24
VENT LINE TERMINATION FITTING.. . ... . .. . . .. . . .. . . ... . ... . ... . .. . . .. . . .. . . .. . . .. . . ... . .. . . .. . . .. .5.25
FUEL INJECTOR . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . ... . . .. . . .. . . .. . . .. . . .. . ... . ... . . .. . . .. .5.26
FUEL INJECTOR OPERATION OVERVIEW. ... . ... . ... . ... . .. . . .. . . .. . . ... . ... . ... . .. . . .. . . .. . . .. . . ..5.26
FUEL INJECTOR O-RINGS. .. . ... . ... . ... . . .. . . .. . . .. . ... . ... . ... . ... . . .. . . .. . . .. . ... . ... . ... . ... . . ..5.26
FUEL INJECTOR TEST. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . ... . ... . . .. . . .. . . .. . . .. . ... . ... . .5.27
FUEL INJECTOR REPLACEMENT . . ... . . .. . ... . ... . .. . . .. . . ... . ... . ... . ... . ... . .. . . .. . . ... . ... . ... . .5.27
FUEL INJECTOR TROUBLESHOOTING . . ... . ... . .. . . .. . . .. . . .. . . ... . ... . .. . . .. . . .. . . .. . . .. . . ... . .. . .5.28
FUEL TANK SERVICE. . ... . ... . .. . . .. . . .. . . .. . . .. . . ... . .. . . .. . . .. . . .. . . .. . . .. . . ... . .. . . .. . . .. . . .. . . .. . . .5.29
FUEL TANK REMOVAL . . . .. . . .. . . .. . . .. . . ... . ... . .. . . .. . . .. . . .. . . .. . . ... . .. . . .. . . .. . . .. . . .. . . .. . . .. . .5.29
FUEL TANK INSTALLATION ... . ... . .. . . .. . . .. . . .. . . ... . ... . .. . . .. . . .. . . .. . . .. . . ... . .. . . .. . . .. . . .. . . ..5.30
FUEL PUMP SERVICE. .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . ..5.31
FUEL PUMP OPERATION OVERVIEW . .. . . .. . . .. . . .. . ... . ... . ... . . .. . . .. . . .. . . .. . ... . ... . ... . . .. . . ..5.31
FUEL PUMP TEST . .. . . .. . . .. . ... . ... . ... . . .. . . .. . . .. . ... . ... . ... . ... . . .. . . .. . . .. . ... . ... . ... . ... . . ..5.32
FUEL PUMP REPLACEMENT . . ... . ... . ... . . .. . . .. . ... . ... . ... . ... . ... . . .. . ... . ... . .. . . ... . ... . ... . ..5.33