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Old 12-14-2010, 11:08 AM   #21 (permalink)
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It should shake right out of there. The pickup is just a weighted screen with a hose nipple end on it. The pickup is attached to fuel line that attaches to the pipe nipple on the outside of the tank. See my pics above - that's what it attaches to.

I'll try and take some pics of the throttle linkage for ya. Otherwise, just google OEM Polaris snowmobile parts and you can find a parts schematic online.
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Old 12-14-2010, 03:18 PM   #22 (permalink)
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unscrew the white plastic nipple in front of the tank. your pick up line will or should be on that. if not fish it out the tank. as for the spring, is it a lot of play or just a lil? you should have a lil play .
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96 XCR 440 clutched (sold)
92 indy 500 bored,clutched. piped(sold)
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Old 12-14-2010, 05:27 PM   #23 (permalink)
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There is so much play that the cable is loose and the throttle handle won't return to it's position no matter what and the end of the cable comes through the opening of the handlebar. I'm pretty sure it needs a return spring hooked up there somehow to keep it under tension. When I get to the sled on Thursday I'll take a picture of the area. It's in the storage unit right now.

When I get the old rotted fuel line and filter out of the tank I'll match it up and get things reattached.
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Old 12-17-2010, 09:03 AM   #24 (permalink)
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The line is off and I could barely see the filter in the bottom, so I drained all the remaining gas and crud out of it then turned it upside down and shook the thing a ton trying to get a hold of the filter and if there was any line left on it. No luck so far.
Is there a problem leaving the old filter in the bottom and just running a new line and filter? I don't see any old line in the bottom, but that could be attached to the filter or completely gone. Need better lighting and longer needle nose pliers.
What type of filter is it?
I have 1/4 fuel line already, but now to figure out how much I need to cut.

The float was nasty, so that is all cleaned up and ready to go which now slides up and down with ease.
No pics of the throttle spring... forgot about taking pics.
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Old 12-17-2010, 09:31 AM   #25 (permalink)
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Quote:
Originally Posted by my69mach View Post
The line is off and I could barely see the filter in the bottom, so I drained all the remaining gas and crud out of it then turned it upside down and shook the thing a ton trying to get a hold of the filter and if there was any line left on it. No luck so far.
Is there a problem leaving the old filter in the bottom and just running a new line and filter? I don't see any old line in the bottom, but that could be attached to the filter or completely gone. Need better lighting and longer needle nose pliers.
What type of filter is it?
I have 1/4 fuel line already, but now to figure out how much I need to cut.

The float was nasty, so that is all cleaned up and ready to go which now slides up and down with ease.
No pics of the throttle spring... forgot about taking pics.
Just me, but I would make sure to get that pickup screen and old fuel line out of the tank before proceeding. That pickup should easily come out, unless there's some fuel line still attached to it. It's an OE part, from what I can tell. Can you hold the tank upside down and then see it through the filler opening? It should be right there. Keep after it.

I think you'll need 3/16 fuel line. That's what I used and looked like the right size. If you go smaller in size, you could have trouble getting enough fuel.

My float was a mess, too. Cleaned it and put it back in. Works fine now.

I attached some pics, but they did not come out very well. The last one shows the linkage.
Attached Thumbnails
92 Indy 500 EFI help-throttle-body.jpg   92 Indy 500 EFI help-throttle-body-linkage.jpg  
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Old 12-17-2010, 10:04 AM   #26 (permalink)
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I tried everything I could to get that filter out. It was rotted off the nipple that screws into the tank and I know now from what I remember seeing inside the tank that the filter has no hose on it because I could see the flange that the hose slides onto.
I included a few questions in the photo which should explain what I was getting at the other day. Your pics were very helpful.
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92 Indy 500 EFI help-throttle-body-copy.jpg  

Last edited by my69mach; 12-17-2010 at 10:29 AM.
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Old 12-17-2010, 10:23 AM   #27 (permalink)
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I looked at the pic. The wire around the hose is just there to keep the hose in place. THere should be a screw going through the loop to keep the wire/hose in place. I'll try and get a closer pic today.

The spring I don't know. Is there no tension on that for you? It should twist, but then spring back into place. I'll try to get some more pics for you.
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Old 12-17-2010, 10:41 AM   #28 (permalink)
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no screw for the hose piece.
I'll have to dig further to see why the throttle lever cable won't stay tight.
Can't find any diagrams on line for a return spring, but I'll keep checking.

Thank you for the help.
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Old 12-17-2010, 01:15 PM   #29 (permalink)
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go here and look up your sled. Arctic Cat, Polaris, Suzuki, Kawasaki, Honda, Yamaha, Sea-doo, Can-Am dealer Muskegon, Michigan
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97 ultra spx slp can geared clutch and 144 studs.(mine)
96 XLT studded with reverse(12y/o son)
98 xcf 440 (wifes sled)
96 puma 340 elec start(kids sled)
96 cougar 550 2up bone stock (sold)
96 XCR 440 clutched (sold)
92 indy 500 bored,clutched. piped(sold)
85 indy 400 (11 y/o son's sled)(sold)
87 yamaha excel 340 (parting out)(sold)


2011/2012 miles :00000000
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Old 12-17-2010, 01:17 PM   #30 (permalink)
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Ok. Went to the farm over lunch and took some pics for ya. Hope that helps.

The throttle turns clockwise. The spring sets right on the end there with an "ear" on each end to keep tension on it. Fairly simple. Is your spring there or missing?

Oh, and I did use 1/4 fuel line. My mistake. Sorry.
Attached Thumbnails
92 Indy 500 EFI help-throttle-cable.jpg   92 Indy 500 EFI help-throttle-spring.jpg   92 Indy 500 EFI help-throttle-spring-2.jpg   92 Indy 500 EFI help-wire-retainer.jpg  
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Old 12-17-2010, 01:29 PM   #31 (permalink)
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i have a 92 EFI motor in my garage all but the fuel pump when i changed out with a 90 carb motor. so i have parts if you can't find any.
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97 ultra spx slp can geared clutch and 144 studs.(mine)
96 XLT studded with reverse(12y/o son)
98 xcf 440 (wifes sled)
96 puma 340 elec start(kids sled)
96 cougar 550 2up bone stock (sold)
96 XCR 440 clutched (sold)
92 indy 500 bored,clutched. piped(sold)
85 indy 400 (11 y/o son's sled)(sold)
87 yamaha excel 340 (parting out)(sold)


2011/2012 miles :00000000
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Old 12-18-2010, 07:23 PM   #32 (permalink)
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Parts?

what have you left, diving back in to my 92 and will keep in mind the next time I need another.
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Old 12-18-2010, 08:08 PM   #33 (permalink)
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Originally Posted by Polaristaz View Post
what have you left, diving back in to my 92 and will keep in mind the next time I need another.
i have the whole motor and efi parts but the fuel pump. it had just over 10,000 miles on it and started to make a tick so i pulled it and was going to rebuild it till i found my motor i have now. i took all the efi stuff out and put a carb one in. really i think all it needs is rings but i was going to do the whole motor cuz of the miles.
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97 ultra spx slp can geared clutch and 144 studs.(mine)
96 XLT studded with reverse(12y/o son)
98 xcf 440 (wifes sled)
96 puma 340 elec start(kids sled)
96 cougar 550 2up bone stock (sold)
96 XCR 440 clutched (sold)
92 indy 500 bored,clutched. piped(sold)
85 indy 400 (11 y/o son's sled)(sold)
87 yamaha excel 340 (parting out)(sold)


2011/2012 miles :00000000
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Old 12-19-2010, 12:06 PM   #34 (permalink)
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I got the screen out of the tank finally and bought some fuel line, but it's too big to fit through the hole and I think it was 5/16". Will run and get another piece which is no big deal. Did you use any clamp on the hose because it appears you can't fit a clamp on there and get it inside the tank. I need to blow out any of the old crap that's still in there and I should be pretty much set for the first stage. I will check the other side to see what springs are still in place for the throttle.
Thank you for all your help so far.
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Old 12-19-2010, 12:23 PM   #35 (permalink)
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3/16 or 1/4 inch line. and no i don't use a clamp inside of the tank. they will rust anyways. did you get a new pick up filter for inside there also? don't use the old one. all it is is a weighted filter with a spring around it.
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97 ultra spx slp can geared clutch and 144 studs.(mine)
96 XLT studded with reverse(12y/o son)
98 xcf 440 (wifes sled)
96 puma 340 elec start(kids sled)
96 cougar 550 2up bone stock (sold)
96 XCR 440 clutched (sold)
92 indy 500 bored,clutched. piped(sold)
85 indy 400 (11 y/o son's sled)(sold)
87 yamaha excel 340 (parting out)(sold)


2011/2012 miles :00000000
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Old 12-19-2010, 02:58 PM   #36 (permalink)
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I used the old filter in the tank. Just cleaned it real good and it looked good as new. It's just a weight with a screen on it.

I was wrong earlier about the fuel line. I used 1/4" fuel line and that seemed to be a match to stock.
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Old 12-20-2010, 02:20 PM   #37 (permalink)
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I have everything now including a new filter and some new 1/4" fuel line. Heading over to the sled after dinner to see what I can figure out. Fresh gas, clean tank, new battery and hopefully some luck.
What is the correct length for the fuel line inside the tank?

Why do the Polaris dealers charge $35+ for a piece of fuel line?
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Old 12-20-2010, 06:13 PM   #38 (permalink)
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push it in till it is at the deep end of the tank.about a foot or so.
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97 ultra spx slp can geared clutch and 144 studs.(mine)
96 XLT studded with reverse(12y/o son)
98 xcf 440 (wifes sled)
96 puma 340 elec start(kids sled)
96 cougar 550 2up bone stock (sold)
96 XCR 440 clutched (sold)
92 indy 500 bored,clutched. piped(sold)
85 indy 400 (11 y/o son's sled)(sold)
87 yamaha excel 340 (parting out)(sold)


2011/2012 miles :00000000
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Old 12-20-2010, 06:50 PM   #39 (permalink)
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push it in till it is at the deep end of the tank.about a foot or so.
That's about how much I put in there, too. Long enough so the pickup laid flat on the bottom of the tank.
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Old 12-20-2010, 08:14 PM   #40 (permalink)
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Quote:
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I have everything now including a new filter and some new 1/4" fuel line. Heading over to the sled after dinner to see what I can figure out. Fresh gas, clean tank, new battery and hopefully some luck.
What is the correct length for the fuel line inside the tank?

Why do the Polaris dealers charge $35+ for a piece of fuel line?
I called about that $35 charge and was told the price on the web is for the roll of it but they could sell it by the foot if needed. I had already ordered some from Dennis Kirk so I told them no thanks.
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