06 800 Rev Summit - No Spark, no power

[n16ht5]

Picked up an 06 Summit 800 Rev from a friend. He was having problems with it shutting off on him randomly, which progressively got worse until he could not even start it.

I got it and checked the stator, impedance looks good, not grounded out on any pole and no resistance between the three.

replaced the regulator/rectifier.

replaced primary relay under dash

hooked everything up and it started sputtering (sat for 2 years) like it was trying to start. I had to stop progress and come back in a few hours...

then nothing. not even a cough.. just wet plugs, can't see a spark (hard to see when pull starting, no one to help)

replaced plugs.. nothing. still can't see spark. adjust gap to 0.18 (was at 0.30)

nothing

starting fluid.

nothing.

replaced plugs with new plugs

nothing, just wet plugs.

I am at a loss as to why it won't run, please help. I don't know how to test the ECM. My next guess would be to try a new coil then a new ECM.. Hate throwing money at it.

Thanks,

Chris

 

[Anylizer]

don't see coils fail very often. 80% of the time it is stators... even if they pass testing.. next is the MPEM... same deal, can be bad even if it passes testing. Best shot with MPEM is to swap it with a "known Good" one and see what happens!

.02

 

[sledsrock]

Have you pulled the ECM connector and inspected the pins/sockets for corrosion?

 

[n16ht5]

don't see coils fail very often. 80% of the time it is stators... even if they pass testing.. next is the MPEM... same deal, can be bad even if it passes testing. Best shot with MPEM is to swap it with a "known Good" one and see what happens!

.02

MPEM.>??? please explain. I called dealer and suggested to look at the "trigger" from the flywheel. will check out that.. I dont think its the stator as once they fail they never work again in all the cases that I have seen.

Hmm... thanks for help guys, anyone in WA with some parts I could try>

 

[summit800]

theres a relay thats on the frame rail up under the plastic of the gas tank, tap on it a few times and try to start it ( rails r the ones that go from the midway tank up to the bars)

 

[wwracer]

Have you pulled the ECM connector and inspected the pins/sockets for corrosion?

DITTO.. check those connections, and consider relocating the ECM to the top of the oil tank....

 

[jhubs]

Check the tether. Make sure it is making good contact with the post. I ve had trouble with my summits starting and running right if it the key wasn't seated right. Also check or disconnect the kill switch. I had a problem with one of my kill switches acting up. Just some ideas

 

[n16ht5]

So I put a new relay + short relay harness in, new coil, new rectifier. still the same.. every once in a while it sputters a few times and runs for a second or two, then nothing for a long time, with no apparent spark but getting gas. The connections all seem good. I want to try the pickup coils next and the stator, but how do you get the flywheel pulled>!!?? Thanks for the tips

 

[Cheney]

Do the easy/free stuff first. Bypass the kill switch, borrow a good ecm. As to your question, you need a flywheel puller. Borrow one from an auto parts store.

 

[turboshorty]

06 no start problem

Check the connector at ecm for bad pins. ECM is under hood right below the headlight on the shock tower cross brace. This has been an issue with them from when they first came out. It gets water from snow melting into the ecm connector and corrodes. Then you have to replace the ecm and whole wiring harness sometimes. Move the ecm back over the oil reservoir to get it out of the way of snow coming in the hood vents. If it not corroded put diode electric grease on the pins and connector.

 

[n16ht5]

thanks for the tips. I pulled the flywheel, but I can't figure out how to get the stator or pickup coils out.. the wiring goes back behind the motor and comes out again on top. I don't even see how the plugs can fit through that hole

is there a spec sheet online to where I could test them where they are? the bottom pickup coil read 175ohm, top read 172ohm. My lead on my tester quit on me so I couldn't check anything else.

I noticed a buildup of grease from the crank inside the flywheel and on the bottom pickup coil. I wonder if that could have caused any problems?

I looked at the ECM connector but I didn't see corrosion.

Thanks


heres pics, I cleaned up some of the grease before these. Is there a method to getting the wiring pulled and swapped??!

new stator// how the heck does that plug go through the hole???

 

[sledsrock]

Rubber Grommet

Pull the rubber grommet out of the case where the wires go through.....that will give the space for the connector.

 

[BBP]

With all that grease, I would suspect bad crank seals.

 

[rocks rev]

Was out rideing my 04 one day and it would die when I would put it in reverse so I figured the stator was going, we headed back to truck and on one stop I forgot and shut it off and it would not start back up. We had to tow it out about 10mi. I pulled starter and it was covered in grease. Ended up just catching it before it went BOOM.

 

[n16ht5]

With all that grease, I would suspect bad crank seals.

Me too

 

[n16ht5]

it lives again.. it was the stator. thanks for guidance.