2006 REV 800 cutting out top end!!

[live2ride]

I have 1300 miles on my '06, the last couple of rides, I have had a issue on top end. It is missing and cutting out, I don't get full RPM's then I run it WOT and it clears out then runs great. Pulled the plugs they are wet and black so obviously rich. Put new plugs in, went 1/3 mile and started all over. All the electrical is working (lights, hand/thumb warmers, speedo/tach), not flashing codes. It had stable in it, and this is the 3rd ride of the year. Lost some exhaust bolts last spring, replaced them and a spark plug wire. I doubt that has anything to do with it. Hubby also cleaned the exhaust valves. This is happening on hard pack and in the pow. Any suggestions????

 

[EndlessWinter]

Choke stuck on?

 

[milehighassassin]

IF your plugs are plugging up that fast, I would say that is your problem.
Any mods?

I maybe your oil injection is up to high?


Keep an eye on those exhaust bolts, this is a known repeating problem.

 

[live2ride]

I have a can is it!! Since both sides are doing it, not sure on the choke deal. What would make the oil injection go up now??? We tighten them every time now and I carry a few extra!!

 

[milehighassassin]

When you say top end... at what RPM exactly does it act up?

Maybe the exhaust valves didn't get put in correctly, or have something keeping them from opening up correctly? Might be worth it to go through them again.

I mentioned the oil injection because of your fouled plugs. Not sure why it would change.

 

[Benchwarmer]

I had pretty much the same issue first ride out this year pulled carbs and cleaned them had just a little water in float bowls next ride it was mint!

Good luck

 

[Farmer]

I kinda had the same thoughts as alot of the rest of you guys, I figured stuck chokes, stuck powervalve, DPM hose issues, ect. So far everything looks good.

The sled is bone stock except for a HPS can that has been on it since it was new. I checked the following

Power valves
Chokes
DPM hoses
Cylinder compression
Y-pipe bolts
Carburator slides
Checked air box for blockages

Everything looks good.

Next I'm going to pull the float bowls and check the carbs better. i'm also gonna start pulling electrical plugs apart and check for a bad or loose connection.

Any ideas or advice is gladly accepted. Thanks!

 

[hymark860]

Mine would do the same thing when I got moisture in the MPEM connections. You might look at the ECM connections for corrosion and moisture and repack with dielectric grease.

 

[beans]

I have been experiencing the same thing on my 05 800. However it only seems to happen in deep snow when the engine is really working hard. RPMs drop down below 7k- on a couple instances it started sputtering so bad it nearly cut out.

There is a Dynoport can on it that has been there since day 1. I was told to try the stock can again. I have a tough time believing that this an exaust issue. Especially since this sled has ran well with the can until this week.

My first thoughts were a possible electrical connection. I will try dielectric grease to see if that helps.

Any other tips or ideas would help.

 

[live2ride]

Last year I had moisture in one of the connections, and it would completely throw me over the bars, with the bog....it is different, just does not hit good rpm 7600 max for a while then once cleaned out hits 8100 and runs good. What about carb heaters, it has been cold.

 

[blksumit]

live2ride,
If it were my sled, I wouldn't let Sean touch it! More seriously, try the dielectric grease in the MPEM connections, are your air intakes clear? I've only had it happen(knock on wood) on really deep fluff days. Got dielectric in the plug caps? The carb heater idea might be right-on. I didn't think of using mine until a few weeks later, wish I had tried though. They got eliminated this summer. Good luck

Dave

 

[SPOOLED]

I have 1300 miles on my '06, the last couple of rides, I have had a issue on top end. It is missing and cutting out, I don't get full RPM's then I run it WOT and it clears out then runs great. Pulled the plugs they are wet and black so obviously rich. Put new plugs in, went 1/3 mile and started all over. All the electrical is working (lights, hand/thumb warmers, speedo/tach), not flashing codes. It had stable in it, and this is the 3rd ride of the year. Lost some exhaust bolts last spring, replaced them and a spark plug wire. I doubt that has anything to do with it. Hubby also cleaned the exhaust valves. This is happening on hard pack and in the pow. Any suggestions????

i had this exact same problem the hose that goes to the air box wasn't fitting quite right, make sure the hose is on properly, with the grommet and there are no cracks or kinks, it took me awhile to figure this out i went over everything all electrical connections coil ecm turned out to be a simple stupid hose.

 

[live2ride]

live2ride,
If it were my sled, I wouldn't let Shawn touch it! More seriously, try the dielectric grease in the MPEM connections, are your air intakes clear? I've only had it happen(knock on wood) on really deep fluff days. Got dielectric in the plug caps? The carb heater idea might be right-on. I didn't think of using mine until a few weeks later, wish I had tried though. They got eliminated this summer. Good luck

Dave

It was different last year with the moisture in the MPEM....this is happening all the time not just in the pow like last year. I sure hope it was the carb heater we will see.....Sean has checked everything else...urgh!!

 

[tfunk]

06 summit

My 06 Summit was cutting out at about 6500RPM. My problem was a hose was disconnected from the DPM module. It was obvious and just hanging from the module but you can't see it until you remove the airbox through the left side access panel.

 

[summitdude]

My 06 Summit was cutting out at about 6500RPM. My problem was a hose was disconnected from the DPM module. It was obvious and just hanging from the module but you can't see it until you remove the airbox through the left side access panel.

Agreed....this same thing happened to my bud! a T connector on the carb(connected to DPM line) was broken! had to take off airbox to get to it! had us scratching heads till we found the problem! this caused the altitude compensation not to function..and defaulted to rich setting(too much fuel)!

wiggle all the dpm lines too see if anything is loose..or broken!

if your carb heaters were on...then anytime you stopped the engine..and let it sit for a while..the hot carbs would boil the gas out of the carbs..and would be hard to start!

 

[skidooer1]

Agreed....this same thing happened to my bud! a T connector on the carb(connected to DPM line) was broken! had to take off airbox to get to it! had us scratching heads till we found the problem! this caused the altitude compensation not to function..and defaulted to rich setting(too much fuel)!

wiggle all the dpm lines too see if anything is loose..or broken!

if your carb heaters were on...then anytime you stopped the engine..and let it sit for a while..the hot carbs would boil the gas out of the carbs..and would be hard to start!

add another person to that list...ran great in iowa. not so well in wyoming. matt

 

[milehighassassin]

Water in your fuel? I know a guy that had a couple rides and then ended up with water in his fuel bowls. Might check that as well.