‘12 pro rmk 800 wont idle, tried everything

[Josshc]

Writing my first forum post in hopes someone could share some info on a fix for this very annoying issue im having.

A little history - bought the sled in January, used to have a boondocker turbo, was removed, sled was sitting for a couple years. Owner started it and loaded on trailer, no problems.

I drained the fuel, oil, chaincase and cleaned exhaust valves. Replaced all fluids fresh

Started it, had engine light and bogged, stalled at various rpms, but not idle. Code was TPS abnormal rate of change.

Tested it and concluded needed new tps.

-Replaced TPS and set myself multiple times with multiple multimeters.
-replaced fuel filter,
-removed injectors(blue) tested with battery and cleaned.
-cleaned throttle bodies
-Checked reeds, cleaned and ordered new pedals due to minor chips.
-New plugs.

Sled pulled hard but wont idle. Idles very low ~800-1200 and then dies. Wont start unless giving blip of throttle.

Finally take to dealer.
Dealer
-Tests and resets tps
-Tests voltage system
-Tests injectors
-Tests ignition coils
-Tests tmap sensor
-Checked fuel pressure
-Air gap on flywheel
-Compression at 120 both sides

All checked out okay

-Replaced reed pedals
-New plugs

Dealer bore scope the cylinders and found scoring on pistons, recommended new top end.


-I just rebuilt the top end with new pistons, gaskets and cleaned up the cylinder.
-Cleaned exhaust valves again, hoses and tested solenoid.
-Took out and cleaned egr sensor
-Removed, cleaned and dialectic greased about every electrical plug
-Cleaned plug caps, cut back wires and re threaded coil end and plug ends



Im really at a loss here on what this could be. Im only seeing 110 on compression but ive only just competed rebuild and have barely done one heat cycle in garage. Rings not seated
The sled would idle for a while when cold before, but doesnt seem to want to at all anymore, for the 10 mins ive run it. Also last day i had it out, before the dealer, for a couple hours it wouldnt go above 5500rpm. Cleared up after and ran at 7300rpm at dealer.

Ive read every form post i can find on google relating to this issue before posting here.

Any help is appreciated……

 

[RHODESIE]

i'd be curious to know if the injector colour matches the mapping in the ecu. replacements are yellow only. then it may need a reflash to match them.

 

[Josshc]

i'd be curious to know if the injector colour matches the mapping in the ecu. replacements are yellow only. then it may need a reflash to match them.

Blue injectors, dealer reflashed ecu to blue tune and even tried a different ecu aswell

 

[Josshc]

Solved..

happy to say its finally fixed, sled runs great and idles great.

Figured id try another used TPS and throttle body combo. Bingo.

I guess the TPS i had replaced it was bad or there was something going on with my throttle bodies… went through the dealer and digi wrench and they didnt catch it.. trust your instincts.

 

[SledEd77]

Solved..

happy to say its finally fixed, sled runs great and idles great.

Figured id try another used TPS and throttle body combo. Bingo.

I guess the TPS i had replaced it was bad or there was something going on with my throttle bodies… went through the dealer and digi wrench and they didnt catch it.. trust your instincts.

That sounds exactly what mine is doing. I haven't changed the TPS but that is the next thing I will do, I hope that is my problem. Wasted my whole winter messing around with this sled. Put way to much money into to turn around and sell it, I'll never get back the amount of money that I have already put into it and I am still not done. If it's not the TPS then I guess it will be the fuel injectors to charge. When I was assembling everything back on the New Engine I noticed that the "O" rings that were sent to me were missing two to change all "O" rings on the injectors, I had already removed the one and it broke apart when I removed it. So I tried to buy a "O" ring for it, and of course I couldn't find one. Polaris doesn't sell just the "O" ring you have to buy the whole injector for $200 plus dollars all because of a 30 cent rubber "O" ring. My buddy has a kit for his dirt bikes so we were able to find one that fit, whether or not it's the right one I don't know. When I brought it to the dealership and got them to put it on the digital wrench I would assume it would have showed up as an error. But I don't even know for sure what they did exactly that time other than charge me $360 to tell me that I needed to change the brand new stator I just installed,then after purchasing a brand new OEM stator and installed it it still was not running right so I tried to adjust the TIPS and the idleing screw because they were both of spec's couldn't get to run. Brought her back over to the dealer for them to spend 5 and 1/2 hours to get it started with a broken throttle cable. When I arrive to pick it up and pay my bill they told me that my throttle cable was finished and needed to be replaced and they were able to get it running but they never went for a test ride with it. So when I got home I drove it off the trailer and then I got 500 ft and it started bogging on me again. So I went and purchased a used throttle cable. Put that one on and was able to have it running by an idled high. They told me to adjust the adjustment for the throttle cable + I got another one out of it and it stopped on me and I haven't been able to get it running since. This is where I am at and winter is now over and still isn't running