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Snowmobile Polaris IQ (2007-2008 year). Manual - part 28

4.30

Fuel Systems

Fuel Tank Pressure Test

Connect a Mity Vac hand pump to the fuel tank vent
fitting.

Connect a eight-inch piece of 5/16

″

fuel hose and two gear

clamps across the fuel supply and return fittings at the fuel
pump flange.

Pressurize the tank to 5 PSI.

NOTE: Fuel tank deformation will occur when the
tank is pressurized.

NOTE: Using a hand pump to pressurize the fuel
tank may take a very long time. The installation of an
in-line Schrader Valve (PN: 2872602) and the use of a
low pressure pump (bicycle tire pump) is
recommended.

Once the tank is pressurized, saturate the area around the
PFA gasket with a mixture of water and mild detergent.

If any bubbles form, re-check the PFA nut torque. If bubble
formation continues, the PFA gasket will have to be
replaced, or tank replacement is required.

NOTE: There may be bubbles present from the initial
application of leak detector. Slightly blow on the
bubbles to pop them. Watch for new bubble
formation. New bubble formation may very small so
look closely. Apply additional water/detergent
solution if required.

CFI Fuel Rail/Injector(s) Removal/Installation

NOTE: Keep the red protective cap on the end of the
injector to prevent damage when installed. Follow
the steps and remove when instructed to do so.

Depressurize the fuel rail. See “Fuel Rail Bleeding /
Pressure Testing” on page 4.29.

Remove the panduit straps as shown.

NOTE: The engine must be removed from the engine
compartment to access the lower two fuel injectors.

WARNING

Do not over-pressurize the fuel tank past 6 PSI.

600 / 700 CFI INJECTOR KITS

INJECTOR

KITS

COLOR

2203325-053

Yellow

2203325-027

Blue

2203325-015

Red

800 CFI INJECTOR KITS

INJECTOR

KITS

COLOR

2203575-053

Yellow

2203575-027

Blue

2203575-015

Red

4.31

Fuel Systems

Remove the hex screws securing the fuel rail it to the
cylinders.

If replacing a lower injector, remove the two bottom screws
bolts from the lower fuel rail.

Remove the failed injector(s).

NOTE: Make sure that the green rubber washer
comes out with the failed injector(s).

Measure from the end of the injector (as shown below)
3" (76.2mm) and cut the injector off.

Strip the harness end injector wire covering .25" - .375"
(6.35 - 9.525mm).

Crimp the ends of the new injector firmly on to the wire
harness.

Tape exposed wire and splices (11).

10. Apply 2-stroke oil to the fuel injector o-rings, seal and

mating surfaces (fuel rail & case sides).

11. Remove the fuel injector cap.

12. Insert the fuel rail, with injectors into the engine.

13. Apply a light amount of 262 Loctite® to the fuel rail

fasteners and torque to specification.

14. Replace the harness to the original routing and apply

panduit straps back to the original locations, making sure
they are not applied over any mesh part of the fuel rail.

NOTE: Refer to Step 2 for proper routing and strap
location.

15. Install the engine if it was removed.

16. If different color injectors were installed you will need to

re-flash the ECU to accept the new colors.

WASHER

3” (76.2mm)

= T

Fuel Rail Hex Screw Torque: 9 ft-lb (12N-m)

4.32

Fuel Systems

2007 700 CFI Fuel System

2007 700 CFI Fuel Pump Service

The fuel pump flange assembly (PFA) can be removed and
replaced without replacing the entire fuel tank assembly.

Note that the 2007 700 CFI fuel pump does not feature a fuel
level sender.

Remove the fuel from the fuel tank. Store the fuel is an

appropriate fuel-holding container.

Remove the following components:

• Seat Assembly

• Console (Loosen fasteners, then lift console away from

tank and set to the side.)

• Air box.

If electric start is installed, disconnect the negative (-)
cable, the positive (+) cable from the battery.

Relieve the fuel pressure.See “Fuel Rail Bleeding / Pressure
Testing” on page 4.29.

Unplug the fuel pump electrical connector.

Remove the fuel hoses from the fuel pump. See
“Disconnect Fittings” on page 4.29.

Remove the fasteners securing the fuel tank to the tunnel.

PIN

COLOR

ITEM

Red

Pump Power

N/A

Black

Pump Ground

Brown

Chassis Ground

4.33

Fuel Systems

Remove the fuel tank from the chassis.

Place the fuel tank is a well-ventilated area.

10. Remove and discard the six fuel pump flange screws.

11. Carefully extract the fuel pump assembly out of the tank.

12. Discard the fuel pump flange gasket. If the pump has failed,

discard the fuel pump. If the fuel tank is to be replaced,
obtain the new fuel tank.

13. Saturate a clean rag with isopropyl alcohol and clean the

surface of the fuel pump flange area, and the fuel pump
flange. Dry all surfaces with a clean rag. Allow adequate
drying time for the alcohol.

14. Install a new, clean gasket by carefully sliding it over the

fuel lines, and pump components. Position the gasket with
the barbs/locating pins facing the flange. Align the pins/
barbs with the holes, then push and pull the barbs/pins
through the holes in the flange.

15. Carefully slide the pump assembly into the fuel tank until

the gasket rests on the tank.

16. Using new screws, supplied with the new gasket, thread in

one of the top two screws to locate the gasket and flange in
the fuel tank. A few turns of the screw is sufficient.

17. Thread the remaining five screws in by hand.

18. Using a nut driver or socket and following the specified

torque sequence, sequentially turn each screw a few
revolutions at a time until the gasket is just seated between
the flange and the fuel tank.

19. Using a torque wrench and the specified torque sequence,

tighten all screws to 10 in.lbs. (1.13 Nm). Tighten each
screw in one continuous, quick motion.

20. After completing the initial torque sequence, tighten each

screw to 23 in.lbs. (2.6 Nm) in one continuous, quick
motion.

21. After installing the fuel pump assembly, the fuel tank must

be tested for leaks by pressurizing the tank.See “Fuel Tank
Pressure Test” on page 4.30.

CAUTION

NEVER RE-USE THE FUEL PUMP FLANGE GASKET.

ALWAYS INSTALL FUEL PUMP USING A NEW

FALNGE GASKET.

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