5.14
9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual
© Copyright Polaris Inc.
5. Carefully lift the fuel pump out of the fuel tank. As you
remove the fuel pump assembly, be aware of float
arm and pump pre-filter. Hold the float arm to the
pump body as you lift and tilt the pump to ensure the
float arm does not bend.
6. Transfer old fuel pump to a suitable container capable
of safely holding fuel. The fuel pump will retain some
fuel.
7. Drain fuel from tank and wipe with a clean rag before
inspecting the inside of the fuel tank for debris (may
require flashlight and mirror). If debris like mud or
sand is present, fuel tank should be flushed and
cleaned out prior to installation of new fuel pump
assembly.
NOTICE
It is recommended to remove the fuel tank from the
vehicle and rinse it with a small amount of clean fuel.
Do not use water or any other chemicals to remove
debris.
8. Remove new fuel pump assembly, gasket and PFA
nut from packaging. Use care not to bend float arm
during unpacking. Do not lift or carry fuel pump
assembly by the float arm.
9. Use cleaning wipes provided to clean fuel tank
surface and threads. Remove all debris, grease and
oil. Allow surfaces to dry completely.
10.Install new PFA gasket
r
onto fuel pump assembly
using care not to damage gasket or bend float arm.
11. Install fuel pump
t
into fuel tank
e
, hold float arm to
the pump body and tilt assembly to ensure float arm
does not get caught or bent during installation.
12.Gently push down on fuel pump flange ensuring
flange is centered.
13.Align orientation mark on fuel pump
u
with
orientation mark on fuel tank
i
to ensure float arm
does not bend or snag.
IMPORTANT
Failure to align the orientation marks may lead to
interferences with the fuel level float arm and cause
incorrect function.
FUEL SYSTEM
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