05 900 Bogs to 6000rpm

[jtpolaris]

I've been having this problem with this sled for the last few years. It seems to come and go, but the sled seems to work better at high altitudes. It only bogged a couple times in Cooke the last trip last spring. But it doesn't seem to have the power it had when it was new. But when I rode it here it would in ND it would go to WOT and then it drops to 6000 rpm and holds there and you pump the throttle and sometimes it comes out of it and most times it wouldn't.
Now whats been done, injectors replaced by polaris two years ago they thought this was the problem, I replaced TPS as it was bad(we thought this was the problem, but it was just one problem) and set and checked again, I rebuilt the motor last fall and installed 06 pistons and had the crank done by Indy Specialty, I just checked Stator and TPS wiring, and other sensors.


Any other ideas. I"ve checked alot of things and am running out of ideas.

Thanks for any ideas.

 

[Z-Man]

Did you check; exhaust valves, Fuel Pump, Fuel Filter?

 

[Z-Man]

One more idea to try, take hood off and take it out and see what the clutches are doing. Upshifting to fast could cause this. I had an old Ski-doo that did exactly this and the spring in the secondary clutch was no good. It would launch hard and then bog the motor and burn the belt.

 

[jtpolaris]

I did check the valves, replaced the bellows, tried blocking off the exhaust valve solenoids to check that they were working. Replaced fuel filter last fall when I did the motor. I did not check the fuel pump pressure, it was replaced though when they did the injectors.

Thanks

 

[jtpolaris]

I put a new secondary spring in last fall.

 

[Z-Man]

only other thing I can think of is maybe a vacuum leak somewhere, but not sure how this would affect a fuel injected sled and I would think you would have cured one when you rebuilt the engine. If the exhaust valve was sticking maybe.

 

[jtpolaris]

I also replaced the Carb boots as they were cracking as they all do. Also replaced the exhaust temp sensor and modified the hood so it don't rub any longer.

 

[BIGGDAWG]

have you checked the rollers in the primary clutch? i have had 2 that the rollers had worn a flat spot or got rough and stuck causing a bog.

 

[jtpolaris]

I will check that tomorrow night.
Thanks

 

[jtpolaris]

The stator did check good, but could that still be the issue? I seen this on another post.

 

[river]

Is the antifreeze staying full in the bottle? I melted a head O ring and it was burning antifreeze and causing it to run something like that something to check. how do the plugs look?

 

[jtpolaris]

It hasn't went down any and it did the same thing before I rebuilt the motor. The plugs have looked a little on the rich side.

 

[guidoxpress]

do you have a boondockers control box installed on there by chance....

 

[jtpolaris]

Yes I do actually. But it was doing it before I put that on.

 

[guidoxpress]

Yes I do actually. But it was doing it before I put that on.

ok...few things i would check right now and post your results..

1. on the boondockers box, do you have the ground wire going to the factory wiring ground? (stock ground is Brown) IF you do have it there...remove it and run the control box wire to the recoil housing for a better ground...the stock ground is NOT good enough ane will cause a bog...so ground to recoil housing.

2. have you tried plugging your exhaust valves (individually NOT together) and see if the bog is gone...you might have a bad exhaust valve solenoid, or even the hoses coming from the exhuast valves could be clogged....plugging the valves will eliminate that for section.

3. have you replaced the TPS harness...if not, i would do that for sure...regardless. factory TPS wired tend to break in the insluation at the plastic harness where it clips to the TPS itself and will cause an intermittent bog as they make contact again...

hope this helps....

 

[jtpolaris]

1. I think I do have it grounded to the stock brown wire. I will check that and change it this weekend.
2. I have tried blocking the valves and it still had the bog.
3. I haven't replaced the harness, but I did check the wiring connections from the tps plug to the plug by the tank. While checking this I was moving the wires to see if I could get any intermittent signal. I think I will look at replacing that harness anyways.

Thanks for the ideas to try.

 

[Z-Man]

I think I would do the exhaust valve mod with the seal after checking the wire if it does not cure it. If for some reason even one of your valves is not opening are falling off it would bog badly. Sounds like you have checked almost every possible thing that could be. It's would be nice if you had a second sled you could swap parts with to swap the exhaust valves and see what happens.