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  1. #1

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    Triple outlet fuel pump

    I have a 1992 sl650. I put a triple outlet fuel pump on it last summer, rebuilt carbs, and cleaned fuel tank. After couple hours of riding it burnt a hole in #1 piston(think this is pto, it's the one towards rear of ski). I think I had too short of fuel going to this cylinder and it leaned it out. Looked at return line to tank and didn't see a restrictor anywhere. Wanting to know if one is needed with new fuel pump? Got new piston and rings, getting ready for summer, trying to avoid this problem again. Any help would be appreciated.


  2. #2
    Click avatar for tech links/info, donation request K447's Avatar
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    Pistons are numbered from the front.

    1 = MAG
    2 = CEN
    3 = PTO

    What adjustment screw settings did you use for the carburetors?

    Do you know what jet sizes are in the carburetors?

    I vaguely recall there were some revisions to the carb specs for the 1992 model year (which was the very first production year for Polaris watercraft). One of the Fuji experts around here is sure to know.

    Is this machine entirely factory stock, no updates or changes?

  3. #3

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    Pistons were numbered

    3
    2
    3,
    who knows what all has been done?

    When I got it, didn't run and was in pieces! What screws and jets should be used?

    I do know the pistons are .5 over. Carbs were rebuilt with what came out of them.
    Does it need a restrictor in the fuel line. I didn't see anything in the return line? The engine flush line for pto line clogged with sand, cleaned all the today. Is it possible it got hot?

  4. #4
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    Post pictures of the damage. We can help. Im not sure about the restrictor in the 92

  5. #5

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    Can't figure out how to load pics. Working on that! Lol. Got a melted hole size of your pinky in center of piston. No carbon build up on it at all

  6. #6

  7. #7
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    That went really lean. Was the fuel line to that cylinder kinked?

  8. #8
    Click avatar for tech links/info, donation request K447's Avatar
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    Quote Originally Posted by checkmate305 View Post
    Pistons were numbered

    3
    2
    3,
    who knows what all has been done?

    When I got it, didn't run and was in pieces! What screws and jets should be used?

    I do know the pistons are .5 over. Carbs were rebuilt with what came out of them.
    Does it need a restrictor in the fuel line. I didn't see anything in the return line?

    The engine flush line for pto line clogged with sand, cleaned all the today. Is it possible it got hot?
    Was the engine itself in pieces?

    If there was sand in a cooling line then I would be concerned about more sand in the engine water jackets.

    The 1992 and 1993 (as I recall) Fuji engines have water cooling into the crankcase. These water jackets seem to be prone to sand accumulation. After 1993 the lower crankcase does not have a water jacket and the water cooling flow is significantly different.

    I seem to remember something about revising the water flow routing on the early Fuji engines, but this could just be my imagination.

  9. #9
    john zigler's Avatar
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    Do a leak down test, to determine condition of crank seals.

    Also go through carbs again, and MAKE sure rear carb is minty clean.

  10. #10

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    The carb rack, air filter was off, reeds were out and missing. Finally got it back together and in water. Was hard to get running, but finally took off. New fuel pump was just hanging-was just seeing if it was even gonna run and it did. So bolted everything in place. It ran about 15 to 20 mins(give or take), then ran and sounded bad. Pulled plugs to check and found problem. The fuel line to this piston was short(all I had at time) and I think it pinched off flow. As far as sand, the hose on bottom of case was clogged not the passage way. It ran ok until I bolted on fuel pump.

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