94 Polaris Rxl 650 Service Manual
My RXL was running great but just up and quit on me while riding last week. This has happened one time before and it turned out to be the fuel enrichment switch for the EFI. One of the two wires on it fell off, thus creating an open void in the EFI system. I replaced that switch and it has perfect ever since. When the sled quit, I pulled off the trail for about 5 minutes and then it started right back up on the 1st pull, so I rode about another 1/4 mile before it died again, this time permanently.
The fuel pump does not run anymore when you lift the kill switch and turn the key. The battery shows 12.7 volts and I do not see any code flashing on the EFI (view window is right next to the plug, correct?).
I pulled the EFI plug and ran a wire from the pink wire slot to ground and her a relay click. I'm wondering if the fuel pump is bad. I don't any fuses anywhere and there are two relays right behind the right bulkhead below the ignition, etc.
Does anybody have some ideas for me? Where is the fuel pump located? Thanks, Janny in Michigan. Hey MeBurdick, I tore the ole RXL apart tonight looking for the fuel pump. I think I found it located at the bottom right rear corner of the engine. It's tucked in there tighter than tight and I can't get a look at the entire unit, but it sure as heck looks like the fuel pump.
Looks to me like the motor may have to at least partially come out to gain access to the pump (awe heck!!!). I ain't going though all that crap as I'm too old and unmotivated to get that deep into this sled. Ya know anybody looking for a bunch of good used 1996 Polaris parts? The engine is stroong and the rest of the sled is pretty much unblemished-track is great, seat is great, hood is real good. Everything is in real ghood shape but the darn thing just won't run. I got it finally.
There is a ground bolted to the top right side of the block right next to where the pull rope passes. I just happen to brush by fingers against the wire insulation while the key & kill switch were on and the fuel pump relay clicked. This ground is bolted into the top of the block and then there is a clamp bolted into the side to keep this wire from interfering with the pull rope. I removed the bolts and peeled the insulation back to find one of two wires broken off at the connector! Easy fix and I'm a happy camper once again. Lucky find on that broken wire, glad to hear that's all your problem was and you were able to find the thing! What you thought was the fuel pump underneath the engine on the right hand side would be correct.
Not sure where the in-tank fuel pump thing came from, but they're definitely underneath the engine and a real PITA to get to, so be glad it wasn't a bad pump. If you were closer and I would have seen this sooner, I likely would have taken you up on the for sale offer. I had a '91 and have been looking for another RXL ever since. Haha, no way my mother would allow four sleds in the yard again. We had five, got rid of two and she's not going back. Plus, being at college I wouldn't be able to use it much anyways.
I got my '91 at 13 years old, it was quite a bit of sled but I learned fast and had prior seat time anyways and I absolutely loved that sled. It had 8,890 miles on it when it dropped the Mag cylinder due to I let it overheat, but it was the original components.
Polaris Rxl 650
Pistons still had the Polaris stars cast into them on the inside of the skirts. She would bury the speedometer and keep on trucking, whether that's actual speed or not I don't know but it was fast regardless. I learned a ton with that sled and it has a special place in my heart.
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