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Discussion Starter #1
So as part of fall maintenance I replaced the fuel sock on my 2013 switchback.
1) Removed panels and airbox feed.
2) Disconnected fuel fuel pump / sender unit
3) Disconnected fuel lines
4) Unscrewed the cap and carefully removed the assembly.
5) removed the zip ties and the hose clamp. Removed old sock.
6) Heated new sock hose, fitted hose over pump pickup fitting. Crimped new clamp.
7) Carefully replaced the assembly into the fuel tank oriented at the same angle as before.

Buttoned everything back up.
With 5 gallons of new gas in the tank, rode it for about 4 miles... all is good.
Put back in to garage and verified all the other bolts and things were still tight. Topped off the gas tank.

A few hours later started sled and it was running a bit rough. By the time the sled made it to the back yard it was running very rough. Drove it back into garage. It ran increasingly rough.

Next day. Sled would barely start and if I give it any throttle it dies.

Siphoned 6 of the 11 gallons of gas out of tank.

Opened it back up... pulled the fuel filter line off the pump. Ran a hose from the barb on the fitting to a gas can. Pulled the starter and the sled started right up... quite happy.
While the fuel pump proceeded to transfer about a quart of gas from the tank to the gas can.

Was a bit surprised at this point that the sled would actually run without a fuel pump.... it ran out of gas in about 45 seconds and stalled.

Put the fuel filter line back on the fitting, and the sled started right up after a couple of pulls to prime the line. Continued to run for a couple of minutes.

Drained the rest of the tank and did visual inspection of sock on bottom of tank... it was cross ways across the tank such that the fuel sender float rises across the width of the sled. No obvious problems. Adjusted it slightly, added 6 gallons of gas back into tank. Ran it for 5 minutes without issue.

I'll take it out on the lake again during daylight tomorrow night and see if it is "fixed"... but would really like to know what was the root cause. Plugged vent line? Sock folded over or positioned incorrectly? Failing fuel pump?

Any ideas folks?

Mike
 

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Discussion Starter #2
Okay... this is on 2013 Switchback with the later model fuel pump (with straight barbs coming out of tank rather than right angle)...

Does anybody know where to attach fuel pressure gauge? Older manual said in the return line, but I don't see it.

Still has problem.

Thanks,
Mike
 

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Is this what your pump/regulator/stainer assembly look like?

 

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Discussion Starter #5
So further tests. I disconnected the pump output and placed a fuel line over the hose barb and routed it to a fuel can. Jumped the pump with 12V batter. The pump ran smoothly with no unusual noises and filled up a 6 can gas can. I would still like to do a fuel pressure test, but I have not yet found the shraeder tap in the fuel rail for the gauge.
 

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No shraeder in the aluminum block/rail ? Hmmmm, is there an online repair manual link ?
 

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Discussion Starter #7
The service manual I have only runs through 2012. It says valve is in the return line. But I don't see it, and they did make some changes to fuel delivery in the 2013 year.
 

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Discussion Starter #8
Okay, found a 13 manual... the 13 does not have schraeder valve... there is a special adapter used by dealers to insert schraeder valve into the line for testing purpose.

Bummer.

Mike
 

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So further tests. I disconnected the pump output and placed a fuel line over the hose barb and routed it to a fuel can. Jumped the pump with 12V batter. The pump ran smoothly with no unusual noises and filled up a 6 can gas can. I would still like to do a fuel pressure test, but I have not yet found the shraeder tap in the fuel rail for the gauge.
You could do it if you looped the hose to the return barb on top of fuel pump assembly. Put inline gauge in middle of the hose 'loop'.Will hose clamps clamp it tight enough with the fuel pump fittings?

the regulator,I believe, is at the very end of return line in the tank........so this will give you atleast fuel pressure without engine running.
 

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Discussion Starter #11
Okay, just to wrap this up... mechanic error (not mechanical) :)... Failed to bleed the fuel system. Used the handy socket the provide exactly for this purpose, to run the fuel pump without the sled running for about 5 minutes. A couple of burbles, then all was well.

Mike
 

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Okay, just to wrap this up... mechanic error (not mechanical)
... Failed to bleed the fuel system. Used the handy socket the provide exactly for this purpose, to run the fuel pump without the sled running for about 5 minutes. A couple of burbles, then all was well.

Mike
I just changed the sock and filter in my 2014 600 and I didn't bleed the sysytem. It started right up and has ran perfect for over a 100 miles.
 

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Discussion Starter #13
Glad to hear you did not have any problems.

I had replaced the fuel filter last season without bleeding the system, and I also had no problems. I cannot say exactly why it worked then, but the fuel sock replacement appeared to require it... But after a large number of experiments, what solved the problem for me this weekend was running the fuel pump without the engine running.

Mike
 
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