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Old 08-10-2008, 09:40 PM   #1 (permalink)
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1991 Polaris RXL SKS

I have a RXL with some issues. When it fires it sputters out almost instantly. The plugs are new, when I turn the key the fuel pump runs, the plugs get wet and there is plenty of spark. But the sled just doesn't run. I don't think the computer is storing any codes, the light isn't flashing. Does anybody have any ideas?
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Old 08-11-2008, 07:37 AM   #2 (permalink)
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When you take the plugs out and clean them does it do the same thing every time?
The symptoms are pointing to a spark problem, not a fuel problem.
Weak spark will start the engine with dry plugs, but then they get wet and stop firing.
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Old 08-11-2008, 10:50 AM   #3 (permalink)
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Originally Posted by RJ Gleason View Post
When you take the plugs out and clean them does it do the same thing every time?
The symptoms are pointing to a spark problem, not a fuel problem.
Weak spark will start the engine with dry plugs, but then they get wet and stop firing.

I tried so many different things yesterday I can't recall what happened after I cleaned them off. I'll try it again tonight and let you know. I did test the spark and it seemed bright and strong....but I'll see what happens tonight.
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Old 08-11-2008, 07:10 PM   #4 (permalink)
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The spark may appear to be good with the plugs out, but not when under compression.
Use an inline tester to check the spark.
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Old 08-12-2008, 10:41 AM   #5 (permalink)
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The spark may appear to be good with the plugs out, but not when under compression.
Use an inline tester to check the spark.
I figured it out, I pulled the airbox out, and the throttle body off then found that the fuel supply was not connected to the bottom of the fuel pump. The hose had broken. That doesn't explain why the plugs were wet, I assume the hose was partially cracked then broke off all the way. But after I replaced all that the sled fired right up. Man that pump is in the most akward position, I debated pulling the motor but I eventually got the new hose installed. I'd hate to have that hose brake out on the trail. How does a person change the fuel pump on a RXL, do you have to pull the motor out?
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Old 08-17-2008, 06:43 AM   #6 (permalink)
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Old 09-30-2008, 11:13 AM   #7 (permalink)
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Question headlights dim and code on efi long dash followed by two short dashes

Hey I just bought a 91 rxl 650 efi and the headlights are dim and the auxillary lights are not showing up at all, we just put in a new battery. any thoughts if this would be related to the stater or the voltage regulator? also is the voltage regulator the same thing as the lighting regulator, just different words??

There is also a code of a long dash and two short dashes in the efi. Not sure what that means.

Any help would be appreciated. Thank you!
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Old 10-01-2008, 06:30 PM   #8 (permalink)
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Hey I just bought a 91 rxl 650 efi and the headlights are dim and the auxillary lights are not showing up at all, we just put in a new battery. any thoughts if this would be related to the stater or the voltage regulator? also is the voltage regulator the same thing as the lighting regulator, just different words??

There is also a code of a long dash and two short dashes in the efi. Not sure what that means.

Any help would be appreciated. Thank you!
The flashing led 1 long and two short is code 12 -crankcase temp sensor
it is screwed into the crankcase below the mag side throttle body . There should be a yellow wire going to it which has likely come unplugged.

The Efi system uses a combination voltage regulator and rectifier unit to change the a/c from the magneto to d/c and then charge the battery. It is screwed to the side of the battery box. Do not confuse this unit with the lighting regulator.

The headlight circuit is completely isolated from the efi and the battery and powered by a/c voltage generated in the magneto. The voltage regulator is located on the back of the console below the ignition switch. This is the most likely cause of your dim lights.
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Old 10-01-2008, 10:34 PM   #9 (permalink)
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Old 01-19-2010, 04:32 PM   #10 (permalink)
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i have a 91 rxl 650 efi. i bought it 4 years ago and ive yet to drive it. i only got it started once i looked over everything and put in lots of work trying to figure it out. now i need a cdi box for it witch i can get for 80 bucks but theres still some problems. theres this brown wire that comes out by the battery box and looks like it goes on the battery?? but i dont know! also i havent seen it flash a code since i bought it and it has a new battery and everything. is there some way i can just hotwire this thing to go all the time. im pissed at this thing i just want to drive it allready.
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Old 02-01-2010, 10:41 AM   #11 (permalink)
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can u get a picture of this or exact detail of where this wire is coming from??? a picture is ideal.
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Old 02-02-2010, 07:08 AM   #12 (permalink)
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turns out it was ust a brown ground wire. i ripped the whole sled apart. i bought the Polaris CLYMER Book and read that a few times. ive been looking at the wiring and theres alot of f*cked wires that i never seen and were all wrapped up and hidden. i bought a CDI off of ebay and that should be coming soon. im going to look a little further into it all and clean it up a bit more.once i got the motor out i found the fuel filter was crushed with a big hole in it, i pulled the bleeder bolts out of the bottom end and old oily s**t came out. looked like oil and coolent with old gas. very milky. im replacing the spark plug wires, some electrical along with fuel lines and filters and the list goes on. should have it back together in a few days though.

Last edited by RJ Gleason; 02-02-2010 at 02:15 PM.
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Old 02-02-2010, 02:25 PM   #13 (permalink)
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Originally Posted by RXL650INDY View Post
turns out it was ust a brown ground wire. i ripped the whole sled apart. i bought the Polaris CLYMER Book and read that a few times. ive been looking at the wiring and theres alot of f*cked wires that i never seen and were all wrapped up and hidden. i bought a CDI off of ebay and that should be coming soon. im going to look a little further into it all and clean it up a bit more.once i got the motor out i found the fuel filter was crushed with a big hole in it, i pulled the bleeder bolts out of the bottom end and old oily s**t came out. looked like oil and coolent with old gas. very milky. im replacing the spark plug wires, some electrical along with fuel lines and filters and the list goes on. should have it back together in a few days though.

If it was coolant in there you're bound to have more issues....
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Old 02-09-2010, 07:07 PM   #14 (permalink)
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I figured it out, I pulled the airbox out, and the throttle body off then found that the fuel supply was not connected to the bottom of the fuel pump. The hose had broken. That doesn't explain why the plugs were wet, I assume the hose was partially cracked then broke off all the way. But after I replaced all that the sled fired right up. Man that pump is in the most akward position, I debated pulling the motor but I eventually got the new hose installed. I'd hate to have that hose brake out on the trail. How does a person change the fuel pump on a RXL, do you have to pull the motor out?
i had to pull out the pump to find out a few issues but only had to pull box carbs and fuel line not a whole lot but still its a pain in the a to remove
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