Fuel / Intake

Many problems that occur with the Full-Size Polaris Ranger stem from underlying issues with the machine’s fueling systems and intake components. But before you do anything drastic when your Ranger engine turns over but never fully starts, there are some tricks and common problem areas you should check first. If your machine struggles to start, putters, sputters, or backfires while you drive, or even shuts down when riding, you could have a fuel-related problem.

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If you are experiencing issues, the first thing you do is check the wiring harness under the seat just below the black support bracket that holds the seat up. Over the years we at Everything Polaris Ranger have seen many Full-Size Rangers with wiring that had the rubber insulation worn away, exposing bare wires and causing the machine to short. Throttle position sensors are also prone to short, but If you’ve looked your machine over and it’s not a wiring issue, your machine’s ECU unit could be calibrated incorrectly and mishandling the fuel.

Next to check if you’re machine seems like it is having fuel problems are its fuel pump and fuel lines. Check the fuel pump pressure once while the Ranger is running; it could be losing prime. The fuel pump may seem fine when cold but could lose pressure when hot. To properly test your fuel pump performance, you have to run it with a gauge to monitor fuel PSI during normal operation. Look over the vent hose on the tank as well and make sure that it is cleaned out periodically. Clogged vent lines on the fuel tank and other simple and easy-to-fix fuel system issues often get overlooked.

Vapor Lock issues can also make it hard to start your machine when it is warm, a problem that can be fixed by insulating the fuel lines with heat wrap. In some cases, you may want to get the new pump and ECU flash. Putting wooden clothespins on the fuel rail can also help.

Shop: 2023 Full-Size Ranger

Shop: 2022 Full-Size Ranger

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