Fuel pump failing?

[Murph]

Fixed---Fuel pump failing?

Just got back from 4 days riding in Alpine, WY.

Sled ran great put on just over 200 miles.

Sled now has 500 miles.

Got back home to Tahoe and went for a ride.

Sled had a problem. Would occasionally cut out, and then run and then cut out. Activated DET sensor a couple of times ( first time ever for me out of three Pros). Running ethanol resistor. 10-62 clutching at 6500 feet.


First thought ignition. Checked plugs, coil leads, caps, etc. Seemed fine.

Seemed to be getting progressively worse as the day wore on. Stab the throttle from stand still and the sled would bog, then go. TSS switch is over ridden with tape, has been since 35 miles.

Thought fuel. Heard a whining noise from fuel tank and thought maybe the tank vent was clogged. Opened cap when sled was running to see if the noise would go away when the cap and possible vacuum was removed. No rush of air when cap was removed BUT pump was making a distinctive whining sound-- sounded almost like a hamster wheel.

Thinking this is my culprit-- it would explain DET light if the engine was starving for fuel. It explains the bog. The whining sound is intermittent, as is the cut out. Thinking now the pump is not receiving 16 volts, or the signal, or the pump itself is failing. The whining sound makes me think it is the pump itself.

Anyone experienced with a Polaris fuel pump failure on a Pro or anything else that uses the same pump? Will the pump whine if it is receiving less than 16 volts?

Will swap out entire tank / pump assembly from my 2011 to see if it rectifies the situation. Isolate it to see if it the pump itself or the signal and/ or voltage to the pump.

Any input appreciated.....

 

[AKSNOWRIDER]

check the fuel filter, and run a pressure and volume test on the pump..a plugged filter will make the pump whine, and if run too long like that will hurt the pump....

 

[Murph]

Thanks for that. What's the procedure for pump pressure and volume tests. I see the pressure test in the service manual-- is the Polaris tester a special part or will any pressure gauge work that can be attached to the schraeder valve? Is the volume test applying voltage to pump and measuring output-- while applying priming voltage maybe? Or is it something else?

I have a new filter sitting on the shelf, I'll pull the old one and try and blow through it, then put the new one on and see if that cures it. If that's not it, I'll swap tank and pump assemblies and go from there.

Really bummed my Polaris dealer in town just went out of business, a lot more hassle going to the next closest dealer.

Thanks again for the reply. This is why I signed up for SW and try and ignore the brand cheerleading/ bashing.

 

[AKSNOWRIDER]

volume test is simply free flow into a pan to verify it is pumping good..kind of a yeah it looks ok or no it looks low...figure if it puts a solid stream out the size of the hose its good.as long as it meets the pressure spec...........any pressure guage will work with a shraeder vavle connection and napa might be the best place to get a cheapy..

 

[Woodsrider]

Just had this problem with a rush in the Iron dog. The sock on the pick up was clogged. Parts fish shows it can be replaced. Believe part# is 2521161.

 

[Murph]

Thanks AK, understood on the volume test " visual inspection". Are you supplying power via the prime circuit and testing flow where the line connects to throttle body?

Woodsrider, how did you determine it was pick up sock in the tank? Visual inspection with pump assembly removed?

 

[AKSNOWRIDER]

yes use the prime circuit, but just undo the line at the filter if its easier...

 

[Murph]

Are the pumps the same as the IQ pumps?

Do they have a failure history (I searched and couldn't find any incidences).

I'm thinking fuel filter, or pick up sock-- seems strange with only 500 miles on sled but not unheard of to have contaminants in fuel.

 

[AKSNOWRIDER]

As far as I know of murph they are the same pumps..but not 100% on that, yeah is pretty weird, I havent personally seen a dragon or pro pump fail yet so not normal as far as I know..but plugged screens filters could kill a pump pretty fast...

 

[volcano buster]

I just had an issue with my '10 600 that sounds similar. When it would bog, usually sidehilling at WOT, I would let off and get back on the throttle and it would clear up. It started doing it more often and then when I came up behind the other guy, it just simply died like I hit the kill switch. Pulled plugs, everything looked good and it had spark, just acted like not having any fuel.

Once home, the sled still would not start so I primed the pump and it sounded ok. Pulled the tank and pump out and still everything looked fine and ran 12V to the pump while in a bucket of gas and it ran fine. Reinstalled pump into tank and hooked back up to motor and the sled fires up now.

I'm not sure what the issues on mine is, but I had an opportunity to run gas back and forth between the tank, bucket and fuel jug and filtered out more water than I thought I would. Not sure if that was the issue or not.

http://www.awdirect.com/mr-funnel-fuel-filter-funnel-25-gallon-min-flow/website_exclusive/ pretty cool filter!

 

[Woodsrider]

Murph

One of the other Trail class guys was with Polaris factory told me that generally when the pump whines it is the sock getting plugged. Did not have the line tool so had to run for about 600 miles shutting down about every half hour let the pump rest then go again. Finally found a line tool and pulled the pump and squeezed the sock and got some black gunk out of it. Did not have a new sock as I was Kaltag but sled ran 100% better. Mostly likely I hurt the pump. If I run next year will replace it.

 

[Murph]

Would a strap wrench or something similar work on the fuel pump mounting nut in the gas tank? The Polaris SPX PS-48459 removal tool is listed at almost $400.

Looking for an alternative

 

[Murph]

2204376 pick up was substituted by 2521161

ASM -pick up-w/filter

Wonder what the reason was for the new part?

 

[Rick!]

Would a strap wrench or something similar work on the fuel pump mounting nut in the gas tank? The Polaris SPX PS-48459 removal tool is listed at almost $400.

Looking for an alternative

these will work:

 

[Boston Racing]

We lost one in a 2012 this weekend with 200 miles. It started making a grinding noise and the sled would die.

 

[ReTodd]

these will work:

Thats what worked for me!

 

[RMKRAZIE]

just bring it to your dealer for warranty if the tool to do it your self costs 400 and the deductible costs 50 money ahead and it will get fixed, or if you have a good dealer they might even wave the deductible.

 

[Woodsrider]

Just looked at the fish for 2011 Pro RMK and it does not use the same pick as Rush. Looks like it has a filter in the line but part is not listed. Pick assembly part number is 2877636 and a little pricey.

 

[diamonddave]

A light tap on the plastic ring with a large, dull screwdriver and hammer will usually break it free without incident.

 

[volcano buster]

I used something similar to this on mine. Worked great. This one is $4.99 at Sears.