Polaris 2012 Sportsman Forest 500 International, Service Manual

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4.42
500 EFI FUEL SYSTEM
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
© Copyright 2011 Polaris Sales Inc.
NOTE: A small amount of fuel may come out of the
fuel line or tank. Plug the fuel line and tank inlet or
use a shop towel during removal.
7. Remove the air box cover and remove the two fuel
tank mounting bolts at the rear of the gas tank.
8. Carefully pull the fuel tank out of the frame. Keep the
fuel tank horizontal during removal, this will keep the
fuel in the tank from spilling out the top inlet.
Fuel Tank Installation
1. Reinstall the tank assembly.
2. Reconnect the sender wiring harness and route the
harness properly. Install the fuel line(s) and verify
they are secure.
3. Reinstall the two fuel tank mounting bolts at back of
tank.
4. Reinstall the PVT intake duct, fuel tank vent line, front
cab assembly, and side panels.
NOTE: Properly route the gas tank vent lines, use
tape to secure the vent line in place. (See Pic 1).
5. Reconnect the negative battery cable. Test the fuel
pump sender for proper operation. Check for leaks
and repair as necessary.
Fuel Sending Unit Test
If the fuel gauge reading on the instrument cluster is not
working, or if the display reading differs in large
comparison to the fuel in the tank, perform a resistance
test on the fuel sender.
1. Open the front rack storage area.
2. Remove the (4) T-25 screws securing the access
cover to the front cab as shown below.
CAUTION
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.