4.28
9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual
© Copyright Polaris Industries Inc.
11. Remove new fuel pump assembly
t
, gasket
y
and
PFA nut
u
from packaging. Use care not to bend
float arm
i
during un-packaging. Do not lift or carry
fuel pump assembly by the float arm.
12. Use cleaning wipes provided to clean fuel tank
surface and threads
o
. Remove all debris, grease
and oil. Allow surfaces to dry completely.
13. Install new PFA gasket onto fuel pump assembly
using care not to damage gasket or bend float arm.
14. Install fuel pump into fuel tank, hold float arm to the
pump body and tilt assembly to ensure float arm
does not get caught or bent during installation.
15. Gently push down on fuel pump flange ensuring
flange is centered.
16. Roughly align orientation mark on fuel pump
between the orientation marks on fuel tank to ensure
float arm does not get bent or snagged.
WARNING
Failure to align the orientation marks may lead to
interferences with the fuel level float armand cause
incorrect function.
17. While maintaining downward pressure, thread new
PFA nut onto fuel tank and hand tighten. Use care
when starting PFA nut, ensuring threads are properly
aligned. Verify orientation marks are still aligned
between fuel pump and fuel tank.
18. Torque PFA nut to specification using the Fuel Pump
Service Tool (PU-50326) and a calibrated torque
wrench.
TORQUE
Fuel Pump PFA Nut:
70 ft-lbs (95 Nm)
19. Verify alignment of fuel pump and tank orientation
marks.
20. Connect the fuel supply line to the pump (see
Chapter 2 – Fuel Lines, page 2.20 for specific
installation procedures).
NOTE
Be sure to engage the retainers on each fuel line until
each snaps into place. Pull on fuel lines lightly to
confirm connection.
21. Install the fuel tank vent line onto the tank fitting.
22. Connect the fuel pump electrical harness.
23. Test the fuel pump by turning on the key and
listening for the pump to activate. Cycle the key
several times to prime the system.
24. Install the passenger seat / storage box.
FUEL SYSTEM
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