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  1. #1

    She's alive! .... and i feel like an idiot.

    So my ski mentioned here I finished rebuilding the carbs, replacing all the fuel line, the selector valve and put it all back together with the carbs set at factory settings and it fires up with a tap of the button!

    OK confession time. I did experience the classic "no spark" troubleshooting. Before I went into the carbs and all it had good spark but afterwords it dead as a door nail! So I pulled the E box and checked everything out again, ohmed everything and even tried a different CDI still with no luck! So after spending a couple hours I got out the Clymers book and started going through the ignition troubleshooting section when I saw a pic of the handlebar kill switch with the lanyard attached and a little arrow pointing at it. SOB! Well at least it got one last "go over" of the E box.

    Here's a few pics:

    Carbs with triple pump:
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    After cleaning out the fuel tank I used some Hi-tack gasket sealant to re attach the rubber pads under the fuel tank:
    Click image for larger version. 

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    Time to go get things wet!:yay2: and start building a fishing rack


  2. #2
    BlueFishCrisis's Avatar
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    Always tough to tell with photos, but are you installing a return line to the fuel tank?

  3. #3
    Quote Originally Posted by BlueFishCrisis View Post
    Always tough to tell with photos, but are you installing a return line to the fuel tank?
    Um... I didn't know I needed to.

    LOL just kiddin':

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  4. #4
    BlueFishCrisis's Avatar
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    Quote Originally Posted by smokinbanger View Post
    Um... I didn't know I needed to.

    LOL just kiddin':

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    Ha ha - considering what you have done is a little unconventional, yet creative, not surprising that it looked like you didn't have return line installed....!

  5. #5
    Quote Originally Posted by BlueFishCrisis View Post
    a little unconventional, yet creative
    Oh yeah? What is it you are referring to as being unconventional, yet creative?

    P.S. I admit to being a noob

  6. #6
    BlueFishCrisis's Avatar
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    All of the carb racks that I have touched, and most that I have seen, have the fuel return on the PTO end of the rack. I don't really see any reason why it needs to be there, but that's how most I have seen have been configured. Your PTO end does not have any fittings facing aft. This is also the location of the original fuel input, prior to installing the three outlet pump.....

  7. #7
    The return is on the Mag end of both of the carb racks I have. In reality it seems like a logical location, closer to the tank, less fuel line. Also the PTO carb is the only one I fed from the MAG end, just made it cleaner and with the pump mounted so close there's less a chance of kinks. I used type A1 and it's a lot thicker that B1, makes it a little more difficult to deal with but it works.

  8. #8
    burtonrider10022's Avatar
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    What brand, and maybe a link , for those fuel lines you used? They look to be nice heavy-duty lines.

  9. #9
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    I think in 95 Polaris moved the return line to the mag end of the carb rack

  10. #10
    BlueFishCrisis's Avatar
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    Huh. Learn something new everyday......

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