A buddy of mine is having trouble starting his sled. It's a 1992 Indy 500 EFI sp.

The problem is that when he hooks up the battery, the fuel pump kicks on and doesn't stop. Neither the ignition switch nor the kill switch have to be on or off. The pump runs regardless.

He has poured gas into the spark plug holes and it would run until that gas runs out. Fuel doesn't seem to be pumping into the cylinders. The fuel line is not shut off.

He thinks it maybe one of the relay switches. Any ideas on how to diagnose this problem? Where should he look?

sounds like the pump isnt getting any fuel and its trying to build up pressure, look for an obstruction somewhere

I will let him know to look into that however would this override the kill switch and ignition?

Anyone with more suggestions?

I don't think the pump should run with the key off! Sounds like a bug in the electrical. Which could be related to the other problems.

Originally posted by GoNe_aWoL@Dec 6 2004, 09:53 AM
I don't think the pump should run with the key off!* Sounds like a bug in the electrical.* Which could be related to the other problems.
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I have a 93 500 EFI witch I have now converted to carbs (long story) The EFI system never turns off it goes into like sleep mode and uses no power until you pull start it. There is no way to shut the system off key or kill switch other then to disconnect the battery, The fuel pump in the EFI use a relay up on the air box there are 2, side by side the one towards the clutch is the fuel pump relay could be that, also I have found with the EFI 92 and 93 that if the battery isn’t fully charged you can have fuel pump problems, Make sure there is fuel getting to the pump and getting to the Throttle bodies (rail). One way to check the fuel system is working is pull the return line off the tank and pull it over see if there is gas going back to the tank, There is also a fuel pressure regulator if that is not working you may not be building enough pressure in the system so the pump wont turn off. Just some ideas from dealing with a total of 4 EFI sleds. Good Luck

Mike

I'm not familiar with Polaris early FI system, but it sounds like either a shorted relay is causing it to run constant, or your regulator is stuck open and it never builds pressure. Both should be easy to test.....

Originally posted by macfan@Dec 7 2004, 10:58 AM
I have a 93 500 EFI witch I have now converted to carbs (long story) The EFI system never turns off it goes into like sleep mode and uses no power until you pull start it.
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ie-yie-yie! *nods@macfan* That wouldn't take a long story for me, lol that would be the first mod I performed :D

So how 'bout it Grimm? Is the pump seeing fuel? If so, I'm betting Damage nailed it with the regulator/relays. I'd check the fuel lines going to the tank even if there is fuel at the pump though. Catch them before they cause a problem.

I'll let y'all know when I hear something, k guys.

My buddy conceded defeat and brought it in to the shop. Time was an issue.

As it turns out, a new fuel pump was in order. Thanks all.