Mercedes Mullins
If you need to drain your RZR fuel tank, it's likely because of water or dirt contamination. A common method to drain the tank is to use a siphon, but some prefer to remove the tank and rinse it thoroughly with gasoline. To remove the tank, you'll need to take out the seats, seat bar, clutch cover, heat shield, fuel tank straps, and fuel pump assembly. It's also important to unplug the harness to the fuel pump. The process usually takes around 20 minutes, but it can be longer if it's your first time.
| Characteristics | Values |
|---|---|
| Fuel tank removal | Remove seats, seat bar, clutch cover, heat shield, fuel tank straps, and fuel pump assembly |
| Fuel tank cleaning | Rinse with gasoline, soap, and water |
| Fuel filter | Located in the tank and not serviceable |
| Fuel tank guard | Factory UTV full UHMW package recommended |
| Fuel tank removal difficulty | Not too difficult, can be done in 20 minutes |
| Fuel tank mounting | Torque the tank mounting strap bolts |
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What You'll Learn
Removing the fuel tank
First, make sure you have the necessary tools and safety equipment. You will need a reciprocating saw, safety gloves, and eye protection. It is also recommended to have a service manual for reference.
Begin by removing the seats and any easily accessible lines and straps connected to the fuel tank. This includes the fuel tank straps, fuel pump assembly, and the harness to the fuel pump. If necessary, loosen the passenger bottom harness bolt to swing the mount out of the way.
If you are having trouble accessing the locking nuts due to a crushed rock slider, use the reciprocating saw to cut through the slider. Be careful not to damage any other components and only cut away enough to access the locking nuts.
With the locking nuts accessible, remove them and carefully lift the fuel tank out. Be cautious as the tank may still contain fuel. Once the tank is removed, you can rinse it out with gasoline or soap and water, ensuring it is thoroughly cleaned.
It is important to note that some RZR models may have slight variations in the fuel tank removal process, so it is always a good idea to refer to the specific service manual for your model. Additionally, always exercise caution when working with fuel and flammable liquids.
By following these steps, you should be able to successfully remove and clean the fuel tank of your Polaris RZR.
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Cleaning the fuel tank
To clean the fuel tank of your RZR, you will first need to drain the tank and remove it. This process involves taking out the seats, seat bar, clutch cover, heat shield, fuel tank straps, and fuel pump assembly. It is also important to unplug the harness to the fuel pump.
Once the tank is removed, you can begin the cleaning process. If there is a significant amount of debris or sand in the tank, it is recommended to wash it out with gasoline first, followed by soap and water. Rinse the tank thoroughly and let it dry completely before reinstalling it. This process can take several days.
In some cases, a more intensive cleaning method may be required. One approach is to use a pressure washer, which can help dislodge stubborn debris and reach into tight spaces. Another method is to fill the tank with nuts and thinner, then drive around with it to break up any varnish.
If the fuel tank is severely corroded or damaged, it may be more cost-effective to simply replace it with a new one. Universal fuel tanks are readily available online and can be purchased for a reasonable price. Additionally, local radiator shops may offer fuel tank cleaning services for a fee.
It is important to note that fuel tank cleaning and removal can be complex, and it is always recommended to refer to the manufacturer's instructions or seek professional assistance if needed.
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Using a siphon to drain water from the tank
To drain water from your RZR fuel tank using a siphon, you'll need to get a siphon hose and access the fuel tank.
First, locate the fuel filler inlet and check for any bends in the hose. If there are bends, it will be difficult to push the siphon hose down to the bottom of the tank, where the water is. Water is denser than gasoline, so it settles at the lowest point in the tank. If you can't reach the bottom of the tank with the siphon, you won't be able to remove all the water.
If you are able to access the bottom of the tank with the siphon, insert it and begin drawing out the fluid. You'll need to inspect the fluid to see if it's just water or if it's a mixture of water and gasoline. One way to do this is to fill a glass jar with the fluid and let it sit for an hour. If there are no layers, the fuel is fine to use. If there are layers, drain the tank and fill it with fresh fuel.
Another way to inspect the fluid is to use a fuel-water separating filter. An E-TEC 115-HP engine has one of these under the engine cowling, and the filter has a sensor that will alert you to water in the fuel.
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Removing the gas cap
First, locate the gas cap on your RZR. It is usually found on the top of the fuel tank, which is typically located at the rear or side of the vehicle. The gas cap is the covering that seals the fuel filler neck, where you would normally insert the fuel nozzle when refuelling.
Next, you will need to unscrew or unlock the gas cap. Most gas caps on the RZR are threaded, meaning you will need to twist them counterclockwise to remove them. Some models may have a locking mechanism, so ensure you know how to unlock it before attempting to remove the cap. This may involve pressing a button or lifting a lever to release the cap.
Once the gas cap is removed, set it aside in a safe place to avoid misplacing it. If you are concerned about losing the gas cap, consider attaching a small chain to it, which you can then secure to a fixed point on the RZR, such as an eye hook mounted behind the seat. This will ensure the cap remains with the vehicle even when it is open.
When removing the gas cap, be cautious of any residual fuel that may be present, especially if you have recently filled up. Have a clean cloth or paper towel handy to wipe away any spilled fuel, and ensure the area is well-ventilated to avoid inhaling fumes.
Finally, if you are planning to drain the fuel tank, it is recommended to download the service manual for your specific RZR model, as different generations and models may have slight variations in their fuel systems. The manual will provide detailed instructions on safely draining the fuel tank and accessing the necessary components.
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Taking out the seats
To drain the fuel tank of your RZR, you will first need to take out the seats. This is a straightforward process, but it is important to follow the correct steps to ensure that you do not damage your vehicle.
Begin by removing the seat bar. This will give you access to the clutch cover, which you should also take out. Next, you will need to remove the heat shield and the fuel tank straps. Be sure to unplug the harness to the fuel pump if you have one. If you have harnesses, loosen the passenger bottom harness bolt and swing the mount out of the way if necessary.
With the seats and easily accessible lines and straps removed, you will now have access to the fuel tank. It is recommended that you do not take out the fuel pump assembly and instead perform the draining process through the filler. However, if you choose to remove the fuel pump assembly, be cautious of the little brass fittings that the screws go into as these can be difficult to deal with.
By following these steps, you will be able to efficiently and effectively remove the seats and access the fuel tank of your RZR for draining.
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Frequently asked questions
The RZR fuel tank does not have a drain. To empty the tank, remove it and rinse it thoroughly with gasoline.
Take out the seats and remove all the easily accessible lines and straps. You can also remove the seat bar, clutch cover, heat shield, fuel tank straps, and fuel pump assembly.
Wash the tank out with gasoline, then soap and water. Rinse it thoroughly and let it dry for about three days.
If your RZR starts sputtering or loses power, there may be water in the fuel tank. You can use a siphon to remove the water.
