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There have been a few reports of 2004 Ski-Doo models fitted with the 600 H.O. SDI engine package experiencing fuel starvation under hard acceleration....

There have been a few reports of 2004 Ski-Doo models fitted with the 600 H.O. SDI engine package experiencing fuel starvation under hard acceleration. Some of these instances have been caused by the fuel pickup at the rear of the tank being installed backwards or too high in the tank. In some cases, the machine would momentarily act like it was running out of gas, even with 1/4 to 1/3 of the fuel remaining.

If your 2004 SDI 600 acts like this, an inspection of the fuel pickups should be performed. The rear fuel pickup is at the end of a length of fuel hose positioned at the rear of the tank. The pickup should lie flat on the bottom of the tank, so the angle at which the pickup is installed into the fuel line is critical. Adjust as needed.

Also, the length of the fuel line to the back of the tank shouldn’t be so long that it lets the pickup ride up on the rear wall of the tank. This fuel pickup line is only available as an assembly due to the critical nature of indexing the pickups to the fuel pump. Replace this fuel line assembly if needed to keep the pickup laying flat on the bottom of the tank.

If the rear fuel pickup is installed backwards, no fuel can be drawn through it. This can be identified by inspecting the fittings on top of the fuel pickup. The exposed fitting (opposite the fitting where the fuel line is attached) should be smooth with no “barb” or “nipple” exposed. If the exposed fitting does in fact have a barb or nipple at the end to attach a fuel line to, it is installed backwards.

Proper indexing of the pickup assemblies to the fuel pump is critical, so be sure to accurately align the arrows of the fuel pump with the arrow on the fuel tank. Refer to the appropriate shop manual to ensure proper positioning of the fuel pickups.

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