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IMPORTANT

The Owner's Manual for this vehicle contains warnings, instructions and other information you must read and fully understand before safely riding or performing maintenance on this vehicle. Always follow the warnings and instructions in Owner's Manual.

Click the link above for the Table Of Contents, or download a full PDF of the Owner Manual in the Owner Support area of Polaris.com.

Fuel Tank Removal / Installation

WARNING

Allow engine and exhaust to cool completely before disconnecting fuel line or removing tank. Protect fuel tank finish when removing, storing, and installing tank.

  1. Depressurize fuel system. See Fuel System Depressurization.

  2. Remove the console by unscrewing fastener at back of console 1.

  3. With fastener removed, lift the rear of console enough to clear fuel cap and push forward to release front mount from keyway.

  4. Lift console up and out, away from the fuel tank, to complete removal.

    STOP!
    Do not use anything other than fingers to remove the quick connection. The use of tools can damage the connection.

  5. Remove fuel quick connect 2 by wrapping a clean rag around the connector and squeezing both of the release buttons (one on each side of the fitting) and gently slide fitting straight off fuel tank.

  6. Unplug electrical connector from fuel pump 3.

  7. Unplug electrical connector from fuel cap, and remove electrical harness 4.

  8. Remove the left-hand v-cover by removing its fasteners.

    STOP!
    Do not use anything other than fingers to remove the quick connection. The use of tools can damage the connection.

  9. Disconnect fuel line at fuel rail 5 by wrapping a clean rag around the connector and squeezing both of the release buttons (one on each side of the fitting) and gently slide fitting straight off fuel rail. Cover fuel fitting to keep debris out.

  10. Remove the seat. See Seat Removal.

  11. At rear of tank, disconnect the fuel vent line 6.

  12. On models equipped with an EVAP system, disconnect the EVAP vent line located above the EVAP canister on the right hand side of the fuel tank 7.

  13. Remove fuel tank fasteners 8.

  14. Lift rear of tank upward and pull rearward to remove. Place the fuel tank in a secure location with a drain pan to catch any fuel than may leak or drip from disconnected hoses or fittings.

Installation

Installation is the reverse of the removal procedure. Verify no fuel leaks or kinks are present around the fuel line connectors or fuel pump seal area.
TORQUE

Fuel Tank Fastener:

18 ft-lbs (24 N·m)

IMPORTANT
Verify fuel supply line is properly seated and locked in place by listening for audible "click" when pressing into place. Pull gently on quick connector once seated to ensure a proper connection has been made. IF THE FUEL LINE FAILS TO CLICK, OR FAILS THE PULL PORTION OF THE TEST ABOVE, REPLACE THE FUEL LINE.