Service Manual

4.22
ELECTRONIC FUEL INJECTION
1. Remove the cap from the fuel test valve.
2. Connect the pressure hose of the Polaris pressure tester
(PU-43506-A) to the test valve on the fuel rail. Route the
clear hose into a portable gasoline container or the
equipment fuel tank.
3. Turn on the key switch to activate the pump and check the
system pressure on the gauge. If system pressure of 39 psi
± 3 is observed, the ignition switch, ECU, fuel pump, and
pressure regulator are working properly. Turn the key
switch off and depress the valve button on the tester to
relieve the system pressure.
NOTE: If the fuel pressure is out of specification,
replace the fuel pump assembly. See the “Electronic
Parts Catalog” for fuel pump availability. It may be
possible that the fuel tank assembly must be
replaced.
4. If the pump did not activate (Step 3), disconnect the harness
connector from the fuel pump. Connect a DC voltmeter
across terminals “A” and “C” in the plug on the vehicle
harness side. Turn on the key switch and observe voltage
to ensure a minimum of 7 volts is present.
NOTE: If the voltage was below 7 VDC, test the
battery, ignition switch, relay(s), wiring harness and
ECU.
5. If the reading is between 7 and 14 volts, turn key switch off
and connect an ohmmeter between the terminals “A” and
“C”' in the plug on the pump harness side to check for
continuity within the fuel pump.
NOTE: If there was no continuity between the pump
terminals, replace the fuel pump assembly. See the
“Electronic Parts Catalog” for fuel pump availability.
It may be possible that the fuel tank assembly must
be replaced.
6. If voltage at the plug was within the specified range, and
there was continuity across the pump terminals, reconnect
the plug to the pump, making sure you have clean
connections. Turn on the key switch and listen for the pump
to activate.
NOTE: If the pump starts, repeat steps 1, 2 and 3 to
verify correct pressure.
7. If the pump still does not operate, check for correct ECU
operation by plugging in a known-good ECU of the same
model.
NOTE: If the pump still does not operate, replace the
fuel pump assembly. See the “Electronic Parts
Catalog” for fuel pump availability. It may be
possible that the fuel tank assembly must be
replaced.
Normal Fuel Pressure: 39 psi. ± 3
Test Valve
Fuel Pressure Gauge Kit
PU-43506-A
Disconnect and Test Here
Pin “A”
Red
Pin “C”
Brown