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Tech Information => General Help => Topic started by: Ken11487 on November 26, 2012, 07:16:15 PM

Title: Intruder fuel pump rebuild and restart prob.
Post by: Ken11487 on November 26, 2012, 07:16:15 PM

Bought a fuel pump kit at local snowmobile dealer, took fuel pump apart to clean as part of restoration, most of the kit did not fit. The old parts looked ok so I used them where I had to. No leaks so far.
I put a gallon and a half of pre mix in the tank per instructions for first time restart and seem to have a air lock type problem getting fuel to flow. After a lot of pulling and running for a minute on the primer I have only one fuel hose half full.
Should I pre fill the carb bowls?
Do I need more fuel in the tank?
Something wrong in the pump?
I can get the proper pump kit on line but the dealer thought this kit would fit.
is there a trick to restarting after a big restoration.???
Thanks Ken

Title: Re: Intruder fuel pump rebuild and restart prob.
Post by: Invader440 on November 26, 2012, 08:01:06 PM

First guess would be you missed punching out the missing hole in the one gasket.

Title: Re: Intruder fuel pump rebuild and restart prob.
Post by: Ken11487 on November 26, 2012, 08:37:14 PM

It WAS last winter but I think that gasket was reused an therefore had the hole in it.
Is there a method to bench test a fuel pump.?   I suppose a long hose and a guy pulling on the start rope may be a start.

Title: Re: Intruder fuel pump rebuild and restart prob.
Post by: Invader440 on November 26, 2012, 11:57:08 PM

I've always used the correct kit and had no problems as long as I remember to punch the missing hole in the gasket.

Title: Re: Intruder fuel pump rebuild and restart prob.
Post by: gixxer6 on November 27, 2012, 06:40:11 AM

I've had similar symptoms and I assumed it was my fuel pump.  Turned out to be a bad crank seal.  Have the crank seals been changed? 

Title: Re: Intruder fuel pump rebuild and restart prob.
Post by: jimvw57 on November 27, 2012, 07:40:22 AM

Take a look at the tank side hose. It should be full of fuel, no air bubbles. Then check the carb side, they also shouldn't have any air bubbles. A fuel hose that has a bad fit will suck air and the pump will not work correctly. same with a pump that has a gasket upside down or is missing that all important hole for the anti-siphon valve.
Don't overlook the fuel pickup tube in the gas tank.It needs to have a weight on the free end of the hose or it could suck air there too.  Adding more fuel probably wouldn't hurt.

Title: Re: Intruder fuel pump rebuild and restart prob.
Post by: 79 invaders on November 27, 2012, 09:23:25 AM

also your float needle could bee stuck on the one carb also not allowing fuel into the carb,or plugged inlet?

Title: Re: Intruder fuel pump rebuild and restart prob.
Post by: Ken11487 on November 27, 2012, 07:44:41 PM

Thanks for all the good ideas.
The crank seals are new, that's what led to the restoration.
It does seem to move some fuel just way not enough.
The carbs are cleaned. All hoses are new.
Think it must be something like a misplaced gasket or a stuck anti siphon valve.
I will try more gas that's easy to start with.
Better do it now then when there's a foot of snow on the ground.