1993 Indy 500 EFI problems

Discussion:

(too old to reply)

p***@uslink.net

2009-01-19 03:03:31 UTC

I have lots of problems with my sled. The fuel pump kicks in when it
wants to,when it does the thing will start and then when your going
down the trail it will just stop, you try to restart and the fuel pump
wont run. The battery is new and gets the correct voltage up to the
ecu,replaced the acs,stator. Could the fuel pump be my problem and if
so how can I test it. Thanks

David Courtney

2009-01-19 16:28:00 UTC

Permalink

The fuel pump isn't supposed to run before you re-start it, IF the
engine has been running within the last few minutes. The pump only runs
before starting when the engine has been off long enough for the fuel
pressure to bleed down.
You should really purchase a shop manual for your sled from a Polaris
dealer... there is TONS of information on troubleshooting the EFI models
(plus it explains exactly how the system is supposed to work so you don't
worry about the non-issues and miss the important stuff).

Post by p***@uslink.net
I have lots of problems with my sled. The fuel pump kicks in when it
wants to,when it does the thing will start and then when your going
down the trail it will just stop, you try to restart and the fuel pump
wont run. The battery is new and gets the correct voltage up to the
ecu,replaced the acs,stator. Could the fuel pump be my problem and if
so how can I test it. Thanks

p***@uslink.net

2009-01-20 04:56:36 UTC

Permalink

- Show quoted text -

Thank You for your reply, I went through all of my wiring and silcon
greased all connections and now it runs great,must of been moisture is
what I am thinking

p***@uslink.net

2009-01-22 13:33:53 UTC

Permalink

Post by p***@uslink.net

- Show quoted text -

Thank You for your reply, I went through all of my wiring and silcon
greased all connections and now it runs great,must of been moisture is
what I am thinking- Hide quoted text -
- Show quoted text -

Well I thought it was running great, But know I am not getting power
to the brain box, Could this be the stator? What would cause the
stator to go bad? I am still looking for a shop manual my local dealer
has to order one, but if anyone could help so I can ride again. Thank
You

David Courtney

2009-01-22 15:40:16 UTC

Permalink

You MUST have at least 12.2 volts at the battery or the system won't
power up. Batteries are by far the biggest problem with these sleds. There
is also a circuit breaker in the main power line from the battery that you
should check.
Next, I would try unplugging the voltage regulator that's mounted behind
the right foot rest... if that regulator shorts out internally, there will
be no rpm signal to tell the computer to turn on. (Don't rev the engine up
with the regulator unplugged or you'll burn out all your lights... turn the
handwarmers & thumbwarmer on for extra load, too.)
There are also two black relays on the brain box... one for the computer
and one for the fuel pump. Swap them and see if the computer powers up (the
fuel pump may not work then... but at least you'll know the relay is bad).
If that doesn't help, you need to look at the "Alternator Controlled
Switch" mounted on the battery box (it looks like a regular voltage
regulator with more wires). The ACS (alternator controlled switch) senses
the engine rotation by reading the pulses from the alternator... if the ACS
goes bad or the wires are damaged, then the brain box won't power up. You
need a voltmeter to check the ACS:
At the brain box, you should have 12.2 volts or more on the RED wire
with a GREEN STRIPE.
Then check the ORANGE wire with a BLACK STRIPE while the engine is being
cranked over... 12.2 volts or more.

Post by p***@uslink.net

Post by David Courtney
The fuel pump isn't supposed to run before you re-start it, IF the
engine has been running within the last few minutes. The pump only runs
before starting when the engine has been off long enough for the fuel
pressure to bleed down.
You should really purchase a shop manual for your sled from a Polaris
dealer... there is TONS of information on troubleshooting the EFI models
(plus it explains exactly how the system is supposed to work so you don't
worry about the non-issues and miss the important stuff).

- Show quoted text -

Thank You for your reply, I went through all of my wiring and silcon
greased all connections and now it runs great,must of been moisture is
what I am thinking- Hide quoted text -
- Show quoted text -

Matt Mead

2009-01-25 21:19:13 UTC

Permalink

David is an expert on these old systems, so trust him.

My experience with a couple of older Polaris EFI machines is....

Batteries. When it is acting funny, the battery is low or shot.

Relays. On my wife's RXL, I've had bad connections at the relays in
the engine compartment down by the right footwell. If I unplug and
replug, or just wiggle them around, I regain power to the fuel pump.

Good luck.

Matt
Doo owner
Manta owner

On Thu, 22 Jan 2009 09:40:16 -0600, "David Courtney"

Post by David Courtney
You MUST have at least 12.2 volts at the battery or the system won't
power up. Batteries are by far the biggest problem with these sleds. There
is also a circuit breaker in the main power line from the battery that you
should check.
Next, I would try unplugging the voltage regulator that's mounted behind
the right foot rest... if that regulator shorts out internally, there will
be no rpm signal to tell the computer to turn on. (Don't rev the engine up
with the regulator unplugged or you'll burn out all your lights... turn the
handwarmers & thumbwarmer on for extra load, too.)
There are also two black relays on the brain box... one for the computer
and one for the fuel pump. Swap them and see if the computer powers up (the
fuel pump may not work then... but at least you'll know the relay is bad).
If that doesn't help, you need to look at the "Alternator Controlled
Switch" mounted on the battery box (it looks like a regular voltage
regulator with more wires). The ACS (alternator controlled switch) senses
the engine rotation by reading the pulses from the alternator... if the ACS
goes bad or the wires are damaged, then the brain box won't power up. You
At the brain box, you should have 12.2 volts or more on the RED wire
with a GREEN STRIPE.
Then check the ORANGE wire with a BLACK STRIPE while the engine is being
cranked over... 12.2 volts or more.

Post by p***@uslink.net

- Show quoted text -

Thank You for your reply, I went through all of my wiring and silcon
greased all connections and now it runs great,must of been moisture is
what I am thinking- Hide quoted text -
- Show quoted text -

p***@uslink.net

2009-01-26 20:57:53 UTC

Permalink

Post by Matt Mead
David is an expert on these old systems, so trust him.
My experience with a couple of older Polaris EFI machines is....
Batteries. When it is acting funny, the battery is low or shot.
Relays. On my wife's RXL, I've had bad connections at the relays in
the engine compartment down by the right footwell. If I unplug and
replug, or just wiggle them around, I regain power to the fuel pump.
Good luck.
Matt
Doo owner
Manta owner
On Thu, 22 Jan 2009 09:40:16 -0600, "David Courtney"

You MUST have at least 12.2 volts at the battery or the system won't
power up. Batteries are by far the biggest problem with these sleds. There
is also a circuit breaker in the main power line from the battery that you
should check.
Next, I would try unplugging the voltage regulator that's mounted behind
the right foot rest... if that regulator shorts out internally, there will
be no rpm signal to tell the computer to turn on. (Don't rev the engine up
with the regulator unplugged or you'll burn out all your lights... turn the
handwarmers & thumbwarmer on for extra load, too.)
There are also two black relays on the brain box... one for the computer
and one for the fuel pump. Swap them and see if the computer powers up (the
fuel pump may not work then... but at least you'll know the relay is bad).
If that doesn't help, you need to look at the "Alternator Controlled
Switch" mounted on the battery box (it looks like a regular voltage
regulator with more wires). The ACS (alternator controlled switch) senses
the engine rotation by reading the pulses from the alternator... if the ACS
goes bad or the wires are damaged, then the brain box won't power up. You
At the brain box, you should have 12.2 volts or more on the RED wire
with a GREEN STRIPE.
Then check the ORANGE wire with a BLACK STRIPE while the engine is being
cranked over... 12.2 volts or more.

Post by p***@uslink.net

- Show quoted text -

Thank You for your reply, I went through all of my wiring and silcon
greased all connections and now it runs great,must of been moisture is
what I am thinking- Hide quoted text -
- Show quoted text -

- Show quoted text -

Thank You for your reply and yes David has been really helpful,I know
I have a lose wire somewhere but i'm still in the process of finding it

David Courtney

2009-01-28 22:06:04 UTC

Permalink

lol... I'm not an "expert" on anything; I just had to read the service
manual a lot of times because so many people have questions about the old
Polaris EFI sled.
A bunch of my friends had them, but they never had problems, so I didn't
work on them very often.

Post by David Courtney
You MUST have at least 12.2 volts at the battery or the system won't
power up. Batteries are by far the biggest problem with these sleds.
There
is also a circuit breaker in the main power line from the battery that you
should check.
Next, I would try unplugging the voltage regulator that's mounted behind
the right foot rest... if that regulator shorts out internally, there will
be no rpm signal to tell the computer to turn on. (Don't rev the engine up
with the regulator unplugged or you'll burn out all your lights... turn the
handwarmers & thumbwarmer on for extra load, too.)
There are also two black relays on the brain box... one for the computer
and one for the fuel pump. Swap them and see if the computer powers up (the
fuel pump may not work then... but at least you'll know the relay is bad).
If that doesn't help, you need to look at the "Alternator Controlled
Switch" mounted on the battery box (it looks like a regular voltage
regulator with more wires). The ACS (alternator controlled switch) senses
the engine rotation by reading the pulses from the alternator... if the ACS
goes bad or the wires are damaged, then the brain box won't power up. You
At the brain box, you should have 12.2 volts or more on the RED wire
with a GREEN STRIPE.
Then check the ORANGE wire with a BLACK STRIPE while the engine is being
cranked over... 12.2 volts or more.

Post by p***@uslink.net

- Show quoted text -

Thank You for your reply, I went through all of my wiring and silcon
greased all connections and now it runs great,must of been moisture is
what I am thinking- Hide quoted text -
- Show quoted text -