Service Manual

3.5
ELECTRONIC FUEL INJECTION
3
FUEL LINE
Quick Connect Removal / Installation
All EFI models use quick connect fuel lines. Refer to the
following steps for fuel line removal / installation:
1. Thoroughly clean the connector and place a shop towel
around the fuel line to catch any dripping fuel.
2. Squeeze the connector tabs together and lift up on the white
retainer. NOTE: Use an O-ring pick or similar tool to
disengage the inner white tab if the fuel tank is installed.
3. Pull out on the fuel line and remove it from the pump outlet.
4. To install the line, verify the connector and fuel pump outlet
are clean and free of debris.
5. Place the connector end over the fuel pump outlet and push
the white retainer and tabs back into place.
NOTE: Confirm attachment by pulling on the fuel line.
6. Repeat this process when removing the fuel line from the
fuel rail.
EFI SERVICE NOTES
For more convenient and accurate testing of EFI components, it
is recommended dealers utilize the Digital Wrench™
Diagnostic Software (dealer only), or limited testing may be
done manually using the procedures provided.
80% of all EFI problems are caused by wiring harness
connections. Follow a common sense approach when
diagnosing a potential EFI issue:
1. Disconnect the harness at the suspected sensor connector.
2. Inspect the connector ends for damage or contamination. If
damaged, repair; if contaminated, clean. Reconnect and
check function.
3. If problem persists, perform a sensor bench test according
to the specific sensor requirements (if applicable).
4. If the sensor bench tests pass, disconnect the connector at
the ECU and perform a continuity check between the sensor
connector and the appropriate pin at the ECU connector (all
connections for that sensor). Wiring resistance should be
less than one (1) ohm.
5. If the resistance is high (or open), a wiring harness
inspection is required (including a thorough inspection of
the ECU connector for contamination or damage).
6. If the sensor passes and the wiring passes inspection, and
reconnecting the ECU does not resolve the issue, then at
that point a known-good ECU (from another Polaris 850)
may be used to test for problem resolution.
• Never attempt to service any fuel system component
while engine is running or ignition switch "on".
• USE CARE when removing or installing the ECU
connector, as well as all other harness connections on
the unit. Properly connect and disconnect the ECU
harness to minimize damage to the connector pins and
locking mechanism.
• Although every precaution has been taken to prevent
water intrusion failure, avoid direct water or spray
contact with system components.
• Do not disconnect or reconnect the wiring harness
connector to the ECU or any individual components
with the ignition "on." This can send a damaging
voltage spike through the ECU.
• Do not allow battery cables to touch opposite terminals.
• Never start the engine when the cables are loose or
poorly connected to the battery terminals.
• Never disconnect battery while engine is running.
• Always unplug ECU from the wire harness before
performing any welding on the unit.
CAUTION
Verify fuel system has been depressurized
before performing this procedure.
Lift white retainer
before removing
Fuel Pump
Outlet
Fuel Rail