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2020 Renegade X 900 Turbo Fuel Pump replacement

3.5K views 10 replies 8 participants last post by  Wiemerib  
#1 ·
Yesterday, after traveling about 75 miles, the sled started hesitating and backfiring when accelerating. If I accelerated very slowly, and smoothly, it barely did it but I couldn't get over 35 MPH or else it would start to hesitate. The fuel level was full when we left the house and was down about 4.5 gallons when the issue started. I filled up at a gas station and the issue went away immediately until about 60 miles down the trail when it started again. This time it was slightly worse and had difficulty getting the sled to travel over 20 MPH. Up hill was even worse... After a bit of research I narrowed it down to the fuel sock, or possibly the fuel pump. I took the tank off and removed the fuel pump and the fuel sock inside was slightly dirty but no where near where I would have expected if it was responsible for the running issues. The local dealership had a fuel pump in stock and I was able to switch it out. It was immediately improved. Looks like the fuel pump solved the issue. The only issue I had, while re-installing the new fuel pump, I didn't get the o-ring seated properly and I had the sled half way back together when I put gas in it and it started pouring out all over the floor... Super frustrating and made a HUGE mess. Was able to yank the machine outside before too much gas leaked on the floor. I then tripple checked it before I re-installed it in the sled. If you are replacing a fuel pump, put some gas in the tank and check to make sure the o-ring is seated properly before you put the machine back together...
 
#7 ·
Hate to say it but, spend the $300 and buy a new pump so you don't have to worry about it leaving you stranded. I also worried about the machine running lean on fuel and if that could cause serious issues with the motor if allowed to occur over and over when the tank gets low.
 
#5 ·
there could something wrong with the return hose
not keeping the surge tank full
maybe the pick up hose is not in the bottom or fell off pump
 
#6 ·
I was wondering if it had to do with the level in the tank being easier for the pump to "pump" when the entire pump was submerged in fuel vs when the tank is only partially full and it has to suck it into the housing via the hose. The fuel pump was still working enough to pump some fuel but my guess is it wouldn't have been too long before it quit for good. Everything looked good on it, no issues with the pick up hose, it was flexible and laid perfectly flat in the bottom of the tank, the filter sock looked ok, it was slightly grey but not bad at all, and I didn't see any obvious issues.

I appreciate the "new o-ring" suggestions. I'll do that for sure next time!!!
 
#9 ·
at wot as it runs out of gas could cause damage
 
#10 ·
Had the same issue with it failing at low fuel levels. Started at 1/4 then moved up. Seeing how the sock is placed in the canister I am assuming it allows more fuel exposure at higher levels. Warranty replaced both pump and sock. Never really knew if the pump failed or sock plugged. Going for sock replacement every couple of years now. Pain in the g ass.