Fusion 900 Fuel Leak

[sloan188]

Anyone have any thoughts about a fuel leak under the engine on a 900 fusion?
Think I got lucky today that the sled didn't catch fire! Went for a 350 km flatlander ride in lanaudiere Quebec. Should have known something was up from the beginning. The sled usually starts 3rd pull when cold and 1st pull when warm...it took about 6 pulls to start when loading/unloading (suspect the fuel pressure was too low). Then we went for a short trip to montagne noire and couldn't get down the back side so we returned to the car parked at st donat and filled up. I used about twice as much fuel as I normally use for the mileage...rationalized this by the thought that tank wasn't full to start (but I knew it was because I checked it). Next couple of fill ups were exactly the same, I used almost double the fuel I normally do. Checked plugs and looked in the engine compartment (engine off) for signs of a leak but nothing. 350km later when we returned to the car, I got the flashlight out and checked the engine compartment again (this time engine running). Looking in from the PTO side in the hole between the clutches I could see fuel p$&%&%^ing out. I also found a bolt and a washer...they might have something to do with it....maybe vibrated loose and fell out?
Anyway, I'm going to check the manual and see if I can find anything???? Hope I can identify the problem and fix it without having to take the engine out or to the stealer....

 

[triple650]

well there are no fuel lines that pass under the engine. check the fuel line that goes to the crank case there is a T in it, shouldnt be to hard to find since there is only two fuel lines. fallow the line to see if there is a leak anywere might be hard as it is really packed in there. as for the bolt and washer what size? maybe show some pics, would realy help.

 

[duece1]

Check the braided black rubber fuel lines for areas where they may have rubbed and wore through. Yes it is a PITA being there is no room behind the engine to see any of the fuel rail. I am attaching a pic showing the back of the motor and fuel rail. The pic is a 755 motor but should be very close to the same unless yours is an 05.

If the bolt you found is an allen head bolt and washer it may be one of the bolts holding the fuel rail in place. See the pic.

 

[sloan188]

Thanks for the input. I'm out of town and won't be able to look at it until the weekend. You are absolutely right; there seems to be nothing except fuel line/rail where the leak can be and the bolt (which is not allen key) doesn't appear to be related.
It's going to be a PITA but I'll have to check the lines...

Appreciate the engine photo...it's much better than the manual.

 

[sloan188]

So just took out my first 900 engine...it wasn't so bad! took about 3 hours and would have taken less time if I'd realized that the PTO SLP torque arm connected the engine to the frame....

The problem turned out to be the fuel rail....one of the welds was broken and leaking under pressure.

I'm not sure if I'll try to get it welded or buy a new one....

BTW, you absolutely have to pull the engine to get at the fuel rail. I had a dealer tell me that they simply cut the fuel line and pull it through but there is no possible way that you could do this. The engine has to come out.

Here's a pic of the fractured fuel rail weld....

 

[sloan188]

Anyone take the injectors out of the fuel rail before? Is there a trick or do you just pull?

 

[sloan188]

Hi all. I need to replace the fuel rail so I need to remove the injectors from the fuel rail (I have already removed them from the engine). Do they just pull out of the fuel rail?

Anyone ever done this?

 

[duece1]

If I were at home I would go out and look at a spare rail I have, but I think they just pop out of the rail. O-ring connection similar to how the injector is sealed to the engine. I did manage to change my rail out without removing the engine but had to pull all the mount bolts and pull the motor up and forward. It really sucked. Definately easier to pull the motor.

 

[sloan188]

Thanks. They do just pull out. I thought they might but I didn't want to wreck anything so I thought that I would ask. I got the new rail and put almost everything back together. 2moro night I hope to finish up.

Anyone have any tricks to a clean oil bleed while the engine is in the chassis?

 

[Redd]

So just took out my first 900 engine...it wasn't so bad! took about 3 hours and would have taken less time if I'd realized that the PTO SLP torque arm connected the engine to the frame....

The problem turned out to be the fuel rail....one of the welds was broken and leaking under pressure.

I'm not sure if I'll try to get it welded or buy a new one....

BTW, you absolutely have to pull the engine to get at the fuel rail. I had a dealer tell me that they simply cut the fuel line and pull it through but there is no possible way that you could do this. The engine has to come out.

Here's a pic of the fractured fuel rail weld....

you're not alone I'm pulling mine and on/off work time I'm about the same, now just need to remove the seat and tank so I can disconnect elec. and rad. hose. I also had a slight problem with the torque arm that I installed! talk about havin' a moment!