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16' axys rpm problems

madmax

Well-known member
Lifetime Membership
Just wanna see if anyone has any insight. Have a 16 stock axys 800 that started not pulling rpms a few weeks ago. Will rev very good to 7500 and just stay there. Its like its rev limited to 7500. No check engine lights, no codes. Clutching is all new and in very good shape. Here are the other things I've tried.
Pulled the EV and cleaned
EV cable good shape
EV recalibrated at dealer
Replaced all 3 relays. They were in very bad shape.
Adjusted TPS by myself and the dealer
Tried the EV actuator out of a good running sled
Tried exhaust temp probe out of good running sled.
Tried EV PWM converter out of good running sled.
Tried ECU out of good running sled.
Ground wires on bumper bolt cleaned and good connection.

Nothing fixes or changes the 7500 rev limit. While I was trying the EV actuator out of the other sled, i noticed sled revs great with the EV actuator wiring unplugged and EV held wide open. Weird! So i can plug everything back in, all 100% stock and rev on track stand and rev limited to 7500rpm. Unplug wiring to EV actuator and hold EV open and it revs as high as you wanna go, 8400+ easily.
The only thing I can think of is a main harness problem/short/broken wire somewhere. Anyone else have any ideas?
 
man that's strange...if the EV cable isn't broken you might be on to something with the wiring harness.... I was thinking the engine mounts until you got it to tack by unplugging the EV and manually opening them... it hast to be in the EV system somewhere. if the cable is broken every thing reads good on digital wrench but wont open the valves. did you manually check the cable? dint know if you read this but it might help
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Sled won't rev past 7500rpm----> A solution Murph <!-- ADDED BY BRIAN FOR DATE --> - 01-27-2018
 
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All the motor mounts are new. Then the EV were out for cleaning, the cable easily moves the valves open and closed. One other weird thing, with the EV actuator plugged in and the EV held wide open manually, still only revs to 7500. Unplug EV actuator wires and hold EV wide open, revs to the moon.
 
My buddy went down this road. Found the bolt that goes in to ev blade was broken. And the second time it was the wiring harnesses.
 
Had a friend with a broken bolt on the EV. I’ve had them out twice to inspect. Nothing broken, EV and cable are in working order. I think I’m going to try the wiring harness out of my other sled. Already pulled the harness out of this sled, it’s actually pretty easy to pull the harness.
 
Someone on another post said that on a 17 or 18, he had a throttle body that was letting the throttle plates go past 90* thus being past wide open and starting to close. Just another thought!
gtwitch in wyoming
 
All the motor mounts are new. Then the EV were out for cleaning, the cable easily moves the valves open and closed. One other weird thing, with the EV actuator plugged in and the EV held wide open manually, still only revs to 7500. Unplug EV actuator wires and hold EV wide open, revs to the moon.
Wiring harness not commanding position change.s on motor or something like that sounds like exactly it. watch the EV motor when you start the sled, it normally cycles the EV's from mid to closed position. Very obvious if its not happening. it just sits still. Also when you put them into reverse it keeps in the mid or open position I believe.
 
Wiring harness not commanding position change.s on motor or something like that sounds like exactly it. watch the EV motor when you start the sled, it normally cycles the EV's from mid to closed position. Very obvious if its not happening. it just sits still. Also when you put them into reverse it keeps in the mid or open position I believe.

its doing those things when you start and in reverse.
Thanks for the ideas to check
 
Did you try even just trackstanding it see if it is comanding the EV through the full range? like maybe it goes low to mid but never cycles out to high/. If it revs out with the valves held open, its just isolating why the valves aren't opening it seems.
 
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