Fuel Pump / Fuel Tank Removal - Polaris 2009 Sportsman XP 850 Service Manual

Fuel Pump / Fuel Tank Removal

IMPORTANT: Syphon as much fuel from the tank as
possible before attempting to remove it from the ATV.
WARNING
Always wear safety goggles when working with
high pressure or flammable fluids. Failure to do
so could result in serious injury or complications.
NOTE: The fuel pump cannot be replaced as an
individual component, the entire fuel pump and fuel
tank must be replaced as an assembly. Refer to the
"Electronic Parts Catalog" for the proper part
number.
1. Remove the seat and both upper side panels (see Chapter 9
"Seat and Side Panels").
2. Disconnect the negative battery cable.
3. Remove the (4) push rivets from each front mud guard and
remove the guards from the vehicle (see Chapter 9 "Mud
Guards").
4. Remove the front rack assembly (see Chapter 9 "Front
Rack").
5. Remove the front cab assembly (see Chapter 9 "Front
Cab").
IMPORTANT: Be sure to cover the fuel tank inlet with
a shop towel prior to front cab and fuel tank removal
(see Chapter 9 "Front Cab").
6. Remove the (4) screws from the bottom of the right-hand
footwell.
7. Remove the (2) fuel tank mounting screws located on the
upper portion of the fuel tank.
ELECTRONIC FUEL INJECTION
8. Remove the vent line from the fitting on top of the fuel tank.
Vent Fitting
9. Disconnect the fuel pump electrical harness.
Fuel Line
Connector
10. While holding a shop towel over the fuel line connector,
disconnect the quick connect fuel line from the fuel pump.
NOTE: A small amount of fuel may come out of the
fuel line or tank. Properly drain fuel into a suitable
container.
11. Carefully pull the fuel tank out the right side of the ATV.
3
Pump
Harness
3.13