I have 2 sleds 600 & 800 EFI purchased new in 03. This year both have a undiagnosable symptom ,they wont start unless I disconnect the fuel pump from the wire harness and prime it with a battery. They both run flawlessly when running. I have replaced both fuel pumps, started great for a few hours and then back to the battery hassle. Just cant shut them off all day unless I carry a battery and wire with. The 800 has new smart valves and the 600 smart valves I disassembled and cleaned. They both have been to the dealer and thy can find nothing out of spec ( stator, fuel pressure, etc.) My 800 is still at the dealer and they even tried swapping out the stator just to rule that out and installed a new ECU wire harness, The 600 they did "jiggle some wires" and was starting great so we picked it up and after a day & half of riding it is the same hassle again. Dealer has called on the 800 again and said he tried a new fuel pump and it started right up, so that must be it. I am not convinced as I have already done this, they both started right up after new pump install. The fuel relay is in the ECU. It seems to me it is a relay issue when pulling the cord? I dont think the dealer knows which way to go.
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