[Freedomflyer]

Having some issues with one of my Ranchers. We've been out 4 times in the last 5 weeks and 2 out of the 4 times I've had some sputtering with one of my Ranchers. They are both 2013 macghines, both fuel injected. When it happened the first time I thought maybe it had something to do with the heat (94 degrees) and that there might have been some vapor locking going on. And it happened right at the end of the ride about a mile or so from the truck. The tank is vented, and it acted as if is was starting to run out of gas, but a quick stop and check on the fuel tank, it showed 3/4 full after roughly 35 miles of riding. Made it back to the truck loaded up and went home. I try to run ethanol free fuel if I can find it but that is getting tougher and tougher to find around here, but do run premium with an additive that is suppose to combat the ethanol. Over the course of the week I pulled the plug, it didn't look terrible but put a new one in anyway, added more fuel treatment and when for a ride last Sunday, ran like a top, not one miss or sputter. Fast forward to today, headed out at 8a.m. this morning, unloaded, road all morning into early afternoon with out any problem then as it warmed up and we were about 10 miles from the truck it started acting up again. I looked at the fuel gauge and it was at the 3/4 mark. Question: This is seeming like a fuel supply issue, at first I thought fuel pump or injector, but with it running fine one day on the entire ride and running good all morning into the afternoon today, I'm wondering if it could be a fuel filter issue? that maybe the bottom part of the filter is plugged and with a full tank of fuel it's getting ample supply. I have read the fuel filter and pumps are inside the tank so this isn't a real simple fix. Any thoughts as to what might be causing this? The other one is running flawlessly in the same exact conditions, same fuel, and same fuel treatment. Thanks to anyone with some suggestions. FF.

 

[retro]

I'm no shadetree but maybe I can help..? A couple things... if you pull the fuel line off from the throttle body and drop the end of it in a big can or jar, then turn the key on, you should see a minimum fuel flow volume of 12 ounces per each 10 seconds that the fuel pump runs. Less fuel volume than this indicates either a clogged filter or failing pump. Next up you can test the fuel pressure (or have someone with a gauge test it for you),,, it should read between 48 & 53 PSI on an idling motor. Again, if the fuel pressure tests low then that indicates a clogged filter or a failing pump.

Also check that the fuel supply line coming from the top of the fuel tank and going to the throttle body is not kinked or damaged or improperly routed.

To service either the pump or the filter requires that the pump assembly be removed from the fuel tank and disassembled for separation from the strainer case.

If the sputtering symptoms ONLY exist while traversing steep angled terrain (driving up, down or across steep grades, such that the bike leans over very hard in any direction), quit it... Your Rancher has a Bank-angle sensor on it that shuts everything down in event of a rollover crash. Sometimes those BAS' can prematurely activate as grades become steep or there is a sharp impact (to the suspension) while on a grade.

I'd suspect a fuel supply issue first...

Edit:
All these tests are outlined in the service manual in section 7.

 

[Freedomflyer]

Retro,
Hope I didn't offend by listing Shade in the Title I know there are a lot of guys out there that might have a suggestion or answer for my quandary so apologize to all of you as well, I appreciate your response and when I have time will try to give some of those suggestions a try. I really don't know of anyone personally that works on these things so to find someone to check the fuel pump pressure would be a little tough. The other tests I could probably handle. It was doing it on the last 4 miles out from the trail head on a pretty flat road as well as on the trail so I don't think it is the bank-angle sensor as you suggested. We were riding some pretty steep stuff yesterday morning and it didn't miss a beat. As I got to thinking about this I made mention that the fuel level may have something to do with it, that with a full tank it didn't act up at all and seemed to do it after about a 1/4 tank was gone, but after the first time it happened and I got it home and it was cooled down, I ran it around and it didn't act up at all. Total full throttle response every time I accelerated. So my thought has been that there is something restricting the fuel supply as well whether a fuel filter, pump, or kinked line, I'll try to investigate. It's frustrating because this thing has been bullet proof from the day we bought it and to have it start out working well on one ride have issues then not have one problem at all the next ride is just strange. I ride pretty much the same way all the time, gentle and easy mixed with some hard acceleration and higher speeds whenever possible. Thanks again, I'll try the things you've suggested and see what I come up with. FF

 

[shadetree]

my thoughts ?, I think your fuel pump may be going out ?. it's hard to say ?, I don't work on many newer models. I do know In the past, the early 420 ranchers were very bad about defective fuel pumps !.

 

[Melatv]

Hi: If the bike is running good and when it only starts sputtering only after a long ride getting hot -- may indicate a temp sensor problem also. The bike does not shut down right??

Is this happening on both bikes??

 

[Freedomflyer]

Thanks Shade,
Melatv,
No, it doesn't shut down and will sit and idle all day, no starting issues at all, and no, the other machine runs perfectly in the same identical conditions running same fuel and additive. My thoughts are that it is the fuel pump and or fuel filter. They are both in the tank so not easy to get to. Will make some calls Monday to get prices on both. Been trying to research and youtube any pump replacement for this machine not having a lot of luck. Where can I find a service manual again? I think I asked this once before tried to down load it and didn't have any luck. Thanks for the input guys I appreciate it. FF

 

[Melatv]

Hi: The fuel pump is in the Sub fuel tank.

 

[Larryw]

Change the fuel filter in the fuel pump tank.. Located in front of the motor on the right side.. Its a can looking thing with 3 hoses coming out of it (1 supply from tank, 1 return and 1 pressure supply to throttle body.. Push lock type fittings. (Kind of a pain in the but to get them off.. There is like 8 little bolts that hold the top on.. The fuel filter kit is like 35 bucks from honda dealer.. The fuel filter starts plugging up and makes the fuel pump run hotter and it starts kicking out the fuel pump when the temps get hot.. (imo * fuel pumps) Try this first. My buddy has to change his filter every year or it does the same thing..

 

[retro]

Retro,
Hope I didn't offend by listing Shade in the Title I know there are a lot of guys out there that might have a suggestion or answer for my quandary so apologize to all of you as well, I appreciate your response and when I have time will try to give some of those suggestions a try.

No offense & no need to ever apologize! I knew shadetree was working on a big project (isn't he always?), so I jumped in, in case he didn't see your post. I agree with everyone else here that you probably need to replace the fuel filter... Have fun!!

 

[shadetree]

Retro,
Hope I didn't offend by listing Shade in the Title I know there are a lot of guys out there that might have a suggestion or answer for my quandary so apologize to all of you as well, I appreciate your response and when I have time will try to give some of those suggestions a try.

No offense & no need to ever apologize! I knew shadetree was working on a big project (isn't he always?), so I jumped in, in case he didn't see your post. I agree with everyone else here that you probably need to replace the fuel filter... Have fun!!

fuel filter is cheaper than the fuel pump !..lol.

 

[Freedomflyer]

Thanks guys I'll try to dig in this week and see what I find I'll keep you all posted.

 

[Jeepwm69]

I agree with above. Fuel filter. I've seen some that looked like someone just poured mud in the gas tank.

 

[Melatv]

Hi: If the bike will run and idle all day and not shut down at all -- just starts to miss & sputter after a long ride for hours when it gets hot out. Wouldn't a dirty filter cause the the problem right off the start.

 

[Jeepwm69]

I've had a couple that would run fine for a bit then start spitting and sputtering. I think the dirt dispersed a bit in the filter, but the longer the pump sucked, the tighter the dirt was packed around the intake on the fuel pump.

I've also had those symptoms due to a partially clogged petcock. Fuel was getting through, but after awhile the flow couldn't keep up with the fuel use. The fuel pump reservoir will let a bike run for a while, and fuel was flowing into the reservoir, but not as fast as it was being drawn out.

 

[Larryw]

No the fuel filter starts to plug up and restricts the flow and makes the pump run hotter.. And on hot days with more heat behind the radiator and under all them shrouds it starts cutting out..

 

[Freedomflyer]

Ordered a new fuel pump today should be here Wednesday. Doesn't look like it is going to be too big of a deal to put in, for some reason i thought it was going to be inside the tank but it's not!!:grin

 

[retro]

Ordered a new fuel pump today should be here Wednesday. Doesn't look like it is going to be too big of a deal to put in, for some reason i thought it was going to be inside the tank but it's not!!:grin

In 2014 the fuel pump was moved to the fuel tank. 2013 & previous FI Ranchers had the fuel pump on a sub-tank/canister looking thang... The fuel filter is in there too.

 

[Freedomflyer]

Yup, Thank goodness!:grin

 

[Melatv]

Ordered a new fuel pump today should be here Wednesday. Doesn't look like it is going to be too big of a deal to put in, for some reason i thought it was going to be inside the tank but it's not!!:grin

In 2014 the fuel pump was moved to the fuel tank. 2013 & previous FI Ranchers had the fuel pump on a sub-tank/canister looking thang... The fuel filter is in there too.

In the tank is a much better place -- easier to remove

 

[Freedomflyer]

Okay.......so this was suppose to be easy.....remove the 3 lines in the top of the pump assembly, unplug the power plug attach said lines to the new pump assembly, plug in the power plug and bolt into place. Wrong! Can't get the one line (injection line I think) loose, some weird little retaining clamp on in it that I'm afraid if I mess with it too much will ruin it. I've tried everything I can think of and afraid I'm going to break something or render it useless to hook back up. Will probably end up hauling it in, what a pain in the a$$. I've looked on youtube to see if anyone has posted a video of how to get this thing off, nothing that I can find I'll keep looking unless someone here knows exactly how to explain getting that little sucker off of there.