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Discussion Starter #1
Looks like i have the opposite problem of the post for the 2015 that is up. Have spark but the plug is dry after I tried starting it.

It was stored with a full tank of gas with a fuel stabilizer product in it and then neglected for a few years. Very low hours and worked fine prior to storing it. After replacing the battery, filling tires, topping off fluids, and greasing the suspension I couldn't get it to start. There is a spark but the spark plug is dry. After turning the key off there is the clicking sound mentioned in the other thread. Not sure if that is the fuel pump turning off or what that is. My best guess is a fuel pump or fuel injector problem. What should I do next?

Hoping to get this going for Saturday.
 

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Discussion Starter #3
Thanks for the suggestion. Trying to come up with a few things to check tonight when I get home later today. Came across this vid showing how to check the pressure at the fuel rail:

Would this be worth doing? $20 from HF isn't bad but I see auto parts stores lend them out too.
 

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Discussion Starter #4
Ok now that I am home to mess with it I realize I cannot hear the fuel pump power on. Pulled each of the lines coming off the top of the tank and cranked it to see if anything would squirt out and got nothing.

I was able to locate a 2012 RZR 570 service manual which I assume should be fairly close to my machine. It says to check pins 3 and 4 on the wiring harness for the fuel pump and to look for 7v. I am getting 4.9v. Checked continuity on the pump and got .001 so it looks like the pump should be good.

Manual says "If the voltage was below 7 VDC, test the battery, ignition switch, relay(s), wiring harness and ECU." Battery is a little low after cranking on it a bunch but still 12.4v. I am going to have to do some more reading to try and figure out how to do this. Unfortunately the gas cap gasket has deteriorated and fallen apart and a chunk of it has fallen into the gas tank so I also have that to figure out. It is looking less and less likely that I make my trip this weekend unless I take it in to the dealer to work on and hope they can fix it in time.
 

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Might want to try swapping the fuel pump relay with one of the other relays The Headlight Relay May be the same


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Discussion Starter #6
Might want to try swapping the fuel pump relay with one of the other relays The Headlight Relay May be the same


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Thanks for the suggestion. I read that in another thread but couldn't pull it out. Went and tried again with pliers after your comment and crushed the one I planned on swapping in. I guess I will be buying two new ones tomorrow and hope that gets me riding.
 

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If you hear the fuel pump come on for a couple od seconds with key, then it would not be relay. Low fuel pressre from the pump would keep the injector from opening. Always go back to basics as we overthink, dry plug, FUEL, wet plug ELECTRICAL. Interesting following this post as the final anwswer, thanks for keeping us posted.
 

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The pump only has power for a few seconds to prime untill the motor is running for safety reason. If your testing for power to the pump you need to be aware of this. The fuel pump being stuck is more likely than a defective relay.
 

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Discussion Starter #9
If you hear the fuel pump come on for a couple od seconds with key, then it would not be relay. Low fuel pressre from the pump would keep the injector from opening. Always go back to basics as we overthink, dry plug, FUEL, wet plug ELECTRICAL. Interesting following this post as the final anwswer, thanks for keeping us posted.
The pump only has power for a few seconds to prime untill the motor is running for safety reason. If your testing for power to the pump you need to be aware of this. The fuel pump being stuck is more likely than a defective relay.
I am not hearing the fuel pump come on and I have already checked to see if it is pumping fuel and it is not. The service manual had me check the electrical of the fuel pump. Says there should be at least 7v on the harness. I have 4.9v. Also says that if the fuel pump is good there should be continuity across those pins and there is. "If the voltage was below 7 VDC, test the battery, ignition switch, relay(s), wiring harness and ECU." Just trying to follow the service manual, suggestions here, and whatever I find searching. If you see where I went wrong I'd be happy to check something else. I've already tried your suggestion of banging on the fuel pump while cranking.

There were instructions for testing the ignition switch in the service manual but I was done for the night. Didn't really see what to check on the ECU or wiring harness but I'll try and do some more reading today.

The relay is crushed now anyway and I have ordered some from Amazon since they have a guaranteed delivery of tomorrow. I read that the relays can be purchased from NAPA and other parts stores but I couldn't find them searching on any of their websites. Had to get the Amazon order in last night if I wanted Wed. delivery so I just went with it figuring losing 1 day was better than losing 2. I've got a quad that needs a carb cleaning and some packing to do that can keep my busy tonight.
 

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Well my first move would be to make sure the fuel pump does work. I would jump the fuel pump relay pins 30-87 and the pump should run. Then I would verify the engine starts.
 

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Discussion Starter #11
Relays weren't the problem. After rechecking the service manual I realized I was probing the wrong wires on the fuel pump harness. I am getting proper voltage so it looks like the fuel pump is the problem after all. Did some more banging on it and cant get it to kick on.

Is it worth buying from the dealer tomorrow? I am seeing a huge range on these. It looks like I can replace the fuel pump motor for as little as $20 or the whole assembly for ~$180 with aftermarket parts. OEM looks to only sell the full assembly for $350+.
 

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I would take the pump assembly out and try to get it working. The pump is just stuck and needs help getting turning again. Perhaps even just jumping the pump directly to a good car battery andvrapping on the pump with a screwdriver handle.

The pump isnt worn out it just needs some help getting back to do its job, kinda like physical therapy. Good luck
 

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Discussion Starter #13
If it were just "stuck" shouldn't I still hear it power on when it is getting voltage? It is dead silent when it gets 12v on ignition and I could feel no signs of life either. I was in the process of hard wiring it to the rzr battery to make sure it worked when I realized that I had checked the wrong pins. If hard wiring it doesn't do the trick how good or bad of an idea would it be to reverse the polarity on it to try to unstick it?

I've only got about an hour after work that I can fool around before the dealership closes. Going to call them later today to find out if they have a pump in stock and how much it will cost.
 

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I agree with Hondaracer, I've had this happen on vehicles after a long sit. Did you pull the pump? If not, that's what I would do. It won't take much to get it going.

And no, you won't hear anything but silence.

See if you can get one from the dealer just in case, and return it if unused next week. I went aftermarket on my 800, with a perfect match that fits a 93 jeep 4cyl.
 

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Discussion Starter #15 (Edited)
Was able to take off work early so now I have the pump removed. Had to use a hammer and push block to undo the retaining ring so I've jostled the assembly pretty good just getting it out.

There were some clear crystals on the top silver part which I brushed off and hit with brake cleaner to flush out. There are three plastic circles on the bottom that are deteriorating which I am not sure if I should be concerned about. Tapped around the pump a bit and I've left it upside down to dry out. Is this pretty much all that I need to do or should I be doing something else to it to get it to work? All of the wired connections look good. Not sure if I should attempt further tear down or just drop it back in with fresh gas at this point.

I also got the pieces of my gas cap gasket out of the tank and cleaned out the bottom as best as I could.
 

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Discussion Starter #16
First reinstall and I got nothing. Called around and the closest pump was 260mi away. $414-$484 quotes and 5+ days. Had nothing else to do but keep trying. More bigger hammer got the job done. Running fine. Thank you for all of the help.

FYI, if anyone else pulls this up in the future and you get your fuel pump going but still can't get it to start cycle your key on and off a few times and then give it a few cranks. Repeat until it starts. There is air in the line the needs to be forced out.
 

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Great job Andrew, thanks for the update and happy trails. I would think of buying a spare now that you have time to shop around just in case of keep the hammer handy haha
 

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Hard to say what was stuck in the pump. Could have been a spot of rust on the shaft or under a brush preventing contact with the comutator. If you research a replacement pump let us know the part number. The fact the rzr only had very little use I dont ghink I would rush to change out the pump. Pumps in cars can last the lifetime of the car.
 

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I helped a friend get his riding mower going today. The shutoff solenoid on the carb was seized with rust and thisck gum or varnish. After cleaning the parts and freezing them up it fired instantly. I wouldn't replaced the solenoid because it was stuck. It's working great now.
 

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Great job Andrew, thanks for the update and happy trails. I would think of buying a spare now that you have time to shop around just in case of keep the hammer handy haha
 
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