[Chukars]

Hi folks,

I am new to the forum and hoping someone could help me diagnose an issue with my ATV. I have a 2009 Rancher 420fe. It is fuel injected and is in good shape with low hours/miles. Two day's ago, I ran out of fuel while tinkering around the house. I reached down and hesitantly switched the fuel selector to reserve. I started it back up (without priming it). I drove forward a few feet and it died again. I figured it was just starved of fuel after running out so I tried starting it again. After giving the starter a workout, I decided to give her an oil change new air filter change and a new plug since I had been putting off that maintenance for awhile and had the parts in the shop. While I was tinkering, I pulled apart the fuel pump assembly and checked the fuel filter and housing for silt/filth. All looked great-greased up the o-rings a bit, added some die-electric grease to the pump's connector and put the small project on hold till morning. Come morning, I put the fuel pump back together and primed it by cycling the key between off and on about ten times. I pressed the start button and it fired up like always. About 20 seconds later, it died. I tried priming it again, gave the starter a work-out and not much worked. I found that it would occasionally start if I gave it some throttle while pressing the start button but quickly died. Other relevant factors: When I turn the key to the on position, I hear the pump runs for a few seconds, and then a buzzing sound for a few seconds. I ordered a replacement fuel filter. It should be here on Monday.

Frequently, I use Sta-Bil and occasionally will throw a bottle of liquid seafoam in the gas tank. Can someone point me in the right direction?....I am a novice diagnostician and a confident parts mechanic....

 

[Chukars]

....before you scold me for not searching, please know that I searched, read and researched a lot. There may be a post or thread about my exact problem, I just did not see it. I found similar issues, but nothing that gave me that OH! moment. Thanks in advance for the help, I truly appreciate your efforts....

 

[b52bombardier1]

I had to replace my neighbor's 420 fuel pump because of bad fuel that had gummed up the pump. Will your bike start with just a little starting ether / fluid sprayed into the air intake hole? If yes, it is probably a fuel pump problem.

I don't recommend the use of starting fluid to operate a bike and get it started all the time because it can break down the oil film on your cylinder wall. But it is a very good diagnostic tool.

Rick

 

[ktriebol]

I'm not totally familiar with the 2009 Rancher, but am kind of surprised that it has a fuel shut-off/reserve valve, since it is a fuel injected machine. You don't mention that you filled the tank back up with fuel. Are you sure you just aren't out of gas? And turn the fuel selector back on RUN.

 

[Larryw]

Question?? Is there fuel coming out of the main tank line, filling up the fuel pump tank?? And you should of changed the filter on that fuel pump as long as you had it out.. The inner part of the fuel filter gets gray and starts slowing down the flow and when the fuel pump gets hot it can start cutting out...

 

[Chukars]

Question?? Is there fuel coming out of the main tank line, filling up the fuel pump tank?? And you should of changed the filter on that fuel pump as long as you had it out.. The inner part of the fuel filter gets gray and starts slowing down the flow and when the fuel pump gets hot it can start cutting out...

Fuel is coming from the tank to the pump, I checked by opening the selector valve briefly when the assembly was disconnected. You are right, I should of changed the filter, but nobody had one in stock and all the shops are an hour drive, so UPS is bringing me one!....it should be here Monday. The filter was a bit gray, but turned white when it dried out overnight. I thought pump also but it seems like most pump issues happen when hot, mine won't even start.....

 

[Chukars]

I had to replace my neighbor's 420 fuel pump because of bad fuel that had gummed up the pump. Will your bike start with just a little starting ether / fluid sprayed into the air intake hole? If yes, it is probably a fuel pump problem.

I don't recommend the use of starting fluid to operate a bike and get it started all the time because it can break down the oil film on your cylinder wall. But it is a very good diagnostic tool.

Rick

I haven't tried starting fluid yet. I figured starting fluid would not isolate the pump vs plugged filter, vs plugged intake (in the tank) vs bad relay or anything else because it would bypass the fuel system. What do you think?

I'm not totally familiar with the 2009 Rancher, but am kind of surprised that it has a fuel shut-off/reserve valve, since it is a fuel injected machine. You don't mention that you filled the tank back up with fuel. Are you sure you just aren't out of gas? And turn the fuel selector back on RUN.

I put good fuel in the tank after it ran out (why would I run out of fuel if I had perfectly good fuel in the garage within 100 yards?...now that is a fine question! ha!). I tried starting it while the selector was in the on position and while it was in the reserve position-neither worked. I like the selector function; its weird that mine has one?

 

[Chukars]

Hi folks,

I am new to the forum and hoping someone could help me diagnose an issue with my ATV. I have a 2009 Rancher 420fe. It is fuel injected and is in good shape with low hours/miles. Two day's ago, I ran out of fuel while tinkering around the house. I reached down and hesitantly switched the fuel selector to reserve. I started it back up (without priming it). I drove forward a few feet and it died again. I figured it was just starved of fuel after running out so I tried starting it again. After giving the starter a workout, I decided to give her an oil change new air filter change and a new plug since I had been putting off that maintenance for awhile and had the parts in the shop. While I was tinkering, I pulled apart the fuel pump assembly and checked the fuel filter and housing for silt/filth. All looked great-greased up the o-rings a bit, added some die-electric grease to the pump's connector and put the small project on hold till morning. Come morning, I put the fuel pump back together and primed it by cycling the key between off and on about ten times. I pressed the start button and it fired up like always. About 20 seconds later, it died. I tried priming it again, gave the starter a work-out and not much worked. I found that it would occasionally start if I gave it some throttle while pressing the start button but quickly died. Other relevant factors: When I turn the key to the on position, I hear the pump runs for a few seconds, and then a buzzing sound for a few seconds. I ordered a replacement fuel filter. It should be here on Monday.

Frequently, I use Sta-Bil and occasionally will throw a bottle of liquid seafoam in the gas tank. Can someone point me in the right direction?....I am a novice diagnostician and a confident parts mechanic....

my brainstorm: I can't help but wonder if running out of fuel was a major contributor to my issue....maybe I am too focused on that. What do you guys think? I guess I could just start throwing parts at it?...start with a pump?....but I'd like to test the culprit part and as of now, it seems as though the pump is at least operating (I know this because I can hear it when I turn the key). But on the other hand, I've read that this fuel injection system does not work well if the pressure is not just right, so maybe the pump is operating, just not strong enough due to a clogged filter or a weak pump?

 

[Chukars]

Is there another filter that I'm not aware of? If not, should I consider installing an inline filter between the tank and the pump housing (for the future after I get this kink worked out)?

 

[Chukars]

I had to replace my neighbor's 420 fuel pump because of bad fuel that had gummed up the pump. Will your bike start with just a little starting ether / fluid sprayed into the air intake hole? If yes, it is probably a fuel pump problem.

I don't recommend the use of starting fluid to operate a bike and get it started all the time because it can break down the oil film on your cylinder wall. But it is a very good diagnostic tool.

Rick

Rick, I got it started with starter fluid just now. It died after about 20 seconds of idling....confirmed fuel issue

 

[Chukars]

folks,

After doing a bit more reading on this forum, I learned that when I turn the key on, I should hear three things: the pump, a buzz, and a click. I hear all three, the click is at the end and comes from just rear of the under-the-seat battery. This all makes me hope that it's a filter...keep your fingers crossed for me!....I am hoping that running it that low on fuel caused debris in the tank to clog the filter. I'll let you guys know tomorrow if I can get the filter replaced before I go to work for the evening.

 

[07rancher420te]

Did you get your issue resolved??

 

[Maddog225]

Always change the pump and filter together I learned that the hard way I replaced my filter as soon as I got it all back together and turned the key the pump went out and take the high pressure hose off the injector and fill that line up with gas to make sure there is no air in that line and hurry up and plug it back up to the injector