Snowmobile Polaris Two Stroke (2007 year). Instruction - part 25

4.17

FUEL DELIVERY

CLEANFIRE INJECTION (CFI)

Injector Replacement

The Cleanfire system utilizes 3 different color injectors. If you
are replacing an injector you must replace it with the same color
injector you remove.

The color is indicated in three ways, 1) it will be on the short wire
harness that is attached to the injector, 2) the injector will have
a colored dot on the shaft of the injector 3)it is indicated on the
label of the ECU.

If the color injector is not available you may replace all injectors
with a different color and you must program the ECU to run the
new installed color.

If it is verified that an injector needs to be replaced, you must
first find out what injector color is on the unit. You can do this
by checking the decal that is located on the top portion of the
ECU or by the color band that is next to the injector on the
harness.

Bleed the fuel rail. See “Fuel Rail Bleeding” on page 4.20.

Remove the seat and fuel tank. See “IQ Fuel Tank
Removal” on page 10.6.

If removal of the engine is needed. See “600/700 CFI
Engine Removal” on page 5.29.

Replace the injectors.

Install engine. See “600/700 CFI Engine Installation” on
page 5.35.

Re-flash ECU with Digital Wrench.

Test run.

600/700 CFI Injector Replacement

If an injector is suspect to failure please use the following
procedure to replace injector(s) on the

CFI

engine.

Using Digital Wrench, identify which injector needs to be
replaced.

NOTE: If the injector is on the upper fuel rail, only
the air box needs to be removed to gain access to
the failed injector.

NOTE: If the injector is on the lower fuel rail, engine
removal is necessary for injector access. See “600 /
700 HO CFI ENGINE” on page 5.29.

600/700 CFI Fuel Rail/Injector(s) Removal/

Installation

NOTE: When installing replacement injector(s) 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” on
page 4.20.

Remove the panduit straps (1-4) as shown.

Remove the fuel rail by taking out the two hex bolts (5,6)
holding it to the engine.

INJECTOR

COLOR

1202853-053

Yellow

1202853-027

Blue

1202853-015

Red

INJECTOR

KITS

COLOR

2203325-053

Yellow

2203325-027

Blue

2203325-015

Red

4.18

FUEL DELIVERY

If replacing a lower injector, remove the lower two bolts
from the lower part of the fuel rail.

Remove the failed injector(s).

NOTE: Make sure that the green rubber washer (9)
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 (10).

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. Insert the fuel rail, with injectors back onto the engine.

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

fasteners and torque to specification.

13. 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.

14. Install the engine if it was removed. See “600 / 700 HO CFI

ENGINE” on page 5.29.

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

re-flash the ECU to accept the new colors.

16. Clear all codes with Digital Wrench.

3” (76.2mm)

= T

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

4.19

FUEL DELIVERY

Cleanfire System Overview

The Cleanfire fuel system uses a fuel pump (A) that is located
inside the fuel tank, a fuel rail (C) with in-line fuel filter (B), and
injectors (D). The fuel pump will create a pressure in the system
and deliver the fuel mixture to the injectors. The injectors get a
signal from the engine controller unit (ECU) and sprays into the
engine.

The only maintenance that is needed with this system is that the
fuel filter (B) needs to be changed every 1,000 miles (1600km).

Fittings should be inspected for cracks or leaks. Do not use pliers
or other tools that may damage fuel lines when installing or
removing fuel rail.

Fuel travels from the fuel pump through the fuel filter and to the
injectors. Any fuel that is not delivered through the injectors will
travel back to the fuel tank through the return line.

Fuel Pump (700)

This fuel pump on this system is non-serviceable and can not be
replaced. If fuel pump fails, the whole fuel tank assembly must
be replaced.

FUEL PUMP: Located inside tank. It provides system with fuel
at 58psi (4bar) pressure. If the fuel pressure is suspect to be
defective apply 12 VDC to the fuel pump prime (Red (#1) and
the Brown (#3) wires) and check for audible fuel pump
operation as well as fuel rail pressure. The fuel pump should
sound when pumping and the pressure should show 58psi (4 bar)
pressure.

Fuel Level Indicator

If the fuel gauge is suspect to failure you can check the
continuity from the fuel sender to the gauge. The given
resistance below is from the Violet/White (#2) wire to the
Brown (#4) wire located at the front of the fuel pump.

700 CFI

PIN

COLOR

ITEM

Red

power to the pump

Violet/White

fuel level signal

Brown

ground

Brown

fuel level ground

TANK LEVEL

RESISTANCE (

Ω)

FULL

2 - 4

Ω

EMPTY

85 - 95

Ω

4.20

FUEL DELIVERY

2007 Fuel Supply / Return Fittings

NOTE: Align pump flange so that the arrow is
between the two alignment lines.

Fuel Rail Bleeding

The 2007 600 CFI units will have one of two different styles of
Schrader valves.

A shallow core valve (1) and will use the adapter that comes with
the fuel pressure gauge (PN PV-43506-A).

A deep core valve (2) will need the adapter PN PS-48167.

The fuel pressure gauge (PN PV-43506-A) is used to check or
bleed the pressure in the fuel rail lines. You will need to bleed
off the fuel pressure if any service is needed to the fuel system
or if engine is to be removed.

Select the appropriate adapter for your valve type.

• Adapter (3) is used on the shallow core valve.

• Adapter (4) is used on the deep core valve.

Attach the correct gauge to the valve on the fuel pressure
tool.

Once the gauge is onto the Schrader valve, the pressure
gauge will indicate the pressure in the fuel rail.

To bleed the pressure from the fuel rail, you can turn the
bleeder valve on the gauge and bleed the system safely.

At this point the fuel rail is ready for service.

= T

PFA Nut Torque

21 Ft.Lb. (28 Nm)

ARROW

ALIGNMENT LINES

SUPPLY FITTING

RETURN FITTING

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