3 gallons or less in your tank!!

[justinator]

these new sleds now have a pressure regulated vent and as far as lawn equipment goes, they plug all the time from the corn evaporating. any fuel starvation problem should always be tried with a loose cap once to be sure. is the fuel pressure regulator in the tank or on the rail?

the regulator is mounted on the fuel rail

 

[Motorhead]

I think your problem with fuel starvation while under 3 gallons left in tank, is not a normal, or better said, not a problem that many are experiencing. Hope someone can shed some light on what may be a repair for this whereas many of us have the Winders that are getting some age and miles on them and this could become a more widespread problem in our near futures!

My 17 with a tune, will run the tank empty without any fuel starving issues for now. Always running it past that Low fuel level light and having to put over 9 gallons in it. Ran it dry last season once. Had 147 miles on that tankful and once we arrived at our truck / trailer, I had shut it off and parked it out back of the trailer getting ready to load them. It was on a slight downhill grade and when I was ready to start it to load, it would not start. Could tell by listening to the pump that it would not pick up fuel. So we added a gallon and it still would not pick up fuel until we turned the sled half way around for a more level stance. At that point you could hear the pump prime and pick up. It then started.

At the next weeks fill up for our next ride, I put 8.8 in it.

On another occasion it took 9.8 at the pumps. I had purposely drained all the gas from my tank for season beginning maintenance because of new tune. It still started and was able to load it in my trailer. That was my best without running out!

So not sure what would be the cause but it sounds like a component in the tank sucks air when under that 3 gallon fuel level in your tank. Pump, lines or pickups is my guess.

 

[jonlafon1]

I’m going to drain it when I get home. Take a peak at what’s going on in the tank. I got something f up.

 

[jonlafon1]

Today right @ 85 miles on tank sled started doing its “thing”. I counted 13 times when fuel pressure dropped until filling tank at 95 miles. My sled took 7.4 gallons and the ski lifts started again! Pissed me off though. If I would just cruise on flat level ground with consistent speeds no issues. When slowing down taking a corner or stopping I could just get back into throttle and feel the fuel starvation. Hesitation. Slight. If I crunched the throttle done backfire like popping. Just took it real easy and steady on throttle until fill up.

 

[snowcaine]

Today right @ 85 miles on tank sled started doing its “thing”. I counted 13 times when fuel pressure dropped until filling tank at 95 miles. My sled took 7.4 gallons and the ski lifts started again! Pissed me off though. If I would just cruise on flat level ground with consistent speeds no issues. When slowing down taking a corner or stopping I could just get back into throttle and feel the fuel starvation. Hesitation. Slight. If I crunched the throttle done backfire like popping. Just took it real easy and steady on throttle until fill up.

Did you pull the fuel pickup lines/tubes out of the tank to inspect them? How well does the tube seal to the pump? It should be very tight...you shouldn’t be able to just pull it off. How about the sock filter? Is it fully snapped into the bottom of the pump? Does the filter then fold up the side of the pump? You may want to take a picture of how the pump sits in the banana-shaped surge tank along with the S-shaped fuel line running from the pump to the sending unit. I would want to see if the sock filter is bound up or if the S-shaped fuel tube is kinking when sitting in place.

Of course, Mr. Knapp and Sideshowbob’s comments are probably your best line of inquiry here first!

 

[jonlafon1]

Did you pull the fuel pickup lines/tubes out of the tank to inspect them? How well does the tube seal to the pump? It should be very tight...you shouldn’t be able to just pull it off. How about the sock filter? Is it fully snapped into the bottom of the pump? Does the filter then fold up the side of the pump? You may want to take a picture of how the pump sits in the banana-shaped surge tank along with the S-shaped fuel line running from the pump to the sending unit. I would want to see if the sock filter is bound up or if the S-shaped fuel tube is kinking when sitting in place.

Of course, Mr. Knapp and Sideshowbob’s comments are probably your best line of inquiry here first!

I’m up north in the UP. I have no heated garage or anything. When I get home I will dig in more.
thanks.

 

[Another Phase]

I would pull the fuel gauge sending unit out first, before you pull the pump. This will allow you to look into the tank and see where the two pickups are sitting before you disturb things by removing the pump assembly. I would siphon the fuel out so you can clearly see how the pickups are oriented and if they're laying on the bottom of the tank as they should be.
You may have to use a small mirror and light, but everything should be quite visible with the fuel removed.

 

[jonlafon1]

I would pull the fuel gauge sending unit out first, before you pull the pump. This will allow you to look into the tank and see where the two pickups are sitting before you disturb things by removing the pump assembly. I would siphon the fuel out so you can clearly see how the pickups are oriented and if they're laying on the bottom of the tank as they should be.
You may have to use a small mirror and light, but everything should be quite visible with the fuel removed.

Great call! Thanks.

 

[NYTurbo]

I had a friend had same issue last year, ended up having to replace the entire fuel pick up assembly.

 

[jonlafon1]

I had a friend had same issue last year, ended up having to replace the entire fuel pick up assembly.

That’s my plan. I’m sitting at 9300 miles.

 

[jonlafon1]

Try running the return line back into the fuel pump tube.

As you have suggested and KNAPP. This is what I will try first. If it still happens then it will be new fuel pump. I removed pump and checked things out tonight. NOT seeing anything that’s off or catches my eye. One thing I did notice and guys have talked about is I still had the older RED return part on the front of the tank. Some guys were drilling this out. I did use the updated part for my reroute back.

 

[deweysgt]

to what diameter should one drill out the Red return elbow?

 

[jonlafon1]

to what diameter should one drill out the Red return elbow?

Just replace it with the updated elbow.

 

[justinator]

As you have suggested and KNAPP. This is what I will try first. If it still happens then it will be new fuel pump. I removed pump and checked things out tonight. NOT seeing anything that’s off or catches my eye. One thing I did notice and guys have talked about is I still had the older RED return part on the front of the tank. Some guys were drilling this out. I did use the updated part for my reroute back.

nice work, looks factory

 

[deweysgt]

My issue ended up being the fuel pump. I have a '17 SW with almost 6000 miles. It had the red elbow on the return line so the first thing I tried was drilling it out. Upon lake testing I found the same issue, no good. Next I inspected inside the fuel tank and completely vacuumed out all of the gas to eliminate any chance of "bad" gas. All looked good. Next was to change out the fuel pump. I have extended warranty but my dealer said that the pumps are on back order. I could have purchased one from Cat for around $350 but instead I found a almost brand new fuel pump assy on eBay for $120. I ran the new (used) pump assy this weekend, over 400 miles running the tank down till the light came on several times and had no issues. In fact the sled is running better than it has all season. At 3/4 to wo throttle it has not been running correctly, like it was starving for fuel. hmmm

I do believe what is happening is the pump is starving for fuel and eventually the pump goes bad. Precision EFI has a great set up, fuel pump replacement with return line pumping the fuel back into the fuel cup but it is very $$. Jonlafon did the same thing for a fraction of the cost. I will be using a automotive fuel rated elbow that is threaded with 1/8 npt on one side and serrated nipple on the other, drilled and tapped into the top of the assembly. Problem solved, next problem