2009 M8 turbo problem

[Snowjunky]

My EBC keeps flashing and my sled dies. Last year it happened at 3/8 throttle. New stator new regulator sent all boondocker electronics to Boondocker. They said I had a bad EBC. So I bought a new one. It is the TPS model. Put it in and hooked the Pink wire to the green/white as directed and the symtoms went from 3/8 throttle to full throttle. Its like clockwork at 7500 rpm. Light goes out on ebc randomly. I have checked the wiring double checked grounds(all acc going to bolt on case). Tonight i jumped the brown yellow wires on the boondocker box and it died just like at 7600 but didnt clean out, Probably because it was just on the stand. Took 5 or 6 pulls to get it running. The sled runs perfect up to that point. Too much fuel? I have the starting numbers boondocker said to use. Same symptoms as last year different EBC different RPM. It seems it is flooding the motor? Bad injector? Why would the light on box go out?

2009 M8
PG Turbo
Fuel upgrade
intercooler
TPS EBC
New stator
New regulator
Boondocker Tested all my wiring harnesses and boxes

 

[Snowjunky]

Sled has 40 psi fuel pressure new 1000 reeds. Any ideas?

 

[kraftymike]

You might try swapping ECU's with a bud. It sounds like that is the only factory electrical item you have left to replace. If not that, I would think it pretty much has to be an issue with your BD components or a connection. Will it act up on a stand? If so, you could disconnect all of the BD electronics to determine if they are at fault.

Electrical gremlins are the worst. Best luck to you.

 

[vigorcs90]

I have a very similar problem. M1200T cuts out at higher levels. Lean pops. Hard to start after it has lost all fuel pressure. EBC blinks, shows only the upper half some of the times. New Stator, fuel board, CCU. Swapped out the ECU. Sent in the EBC to Boondockers, said it was ok. After 5 hours of testing we --------Found the problem-------- It was the EBC, the EBC had an internal short to the exterior of its case. The EBC is mounted to the handle bars and was dead shorting the power from the fuel board. There was just enough power getting to the pump to run up to boost levels. When we isolated it from the handle bars the EBC and fuel pump are getting the proper voltage now.

 

[mynewuseddoo]

Backus Racing got rid of all of their EBC's and sent them back to Boondocker. EBC shorting out.

 

[Snowjunky]

Since it only cuts out at high rpm I would need to remove All turbo componets. I will try isolating the box. That sounds real close to my problem. Last night at 3:00am hoping to ride today I took a long set of pliers and poked wires one by one. Im starting over today. I will try and see if I can do a manual EBC. I only have 90 days for the EBC warranty.

 

[bparks]

give boondocker a call and ask for a presure sending unit it will let you unhook the ebc and hook the box to it so you will still get fuel and run the sled with out ebc i have one on my sled for this reason i had this problem two years ago before they fixed my ebc it would cut out at 6000 to 7000 and sled would die but cliff worked with me on my ebc and now no problems good luck

 

[WyoBoy1000]

Typical BD stuff, good chance if its not a new kit there was the fuel update, and a electrical update because at full throttle it runs out of power, and whatever other updates there are. there are also some kind of settings that if not set right it doesn't divert power to the right place. Its a BD kit and I would be all over them to make it work, I'm sure they can figure it out you just have to make them.

Or save the trouble and hassle and spend 2g's , convert it to a twisted kit and ride the thing without worries.

 

[Snowjunky]

Sam at BD said they loaded the new software in my BD box and the EBC is the new TPS updated one. I have the fuel booster and the wiring harness power taps. One with a few red black connectors and the 3 pos trailer type at the regulator. My experience says electrical gremlins usually end up being a ground issue.
For the record Sam at Boondocker has been one hell of a help. I have been chasing wiring instructions thinking I had something wired wrong. Pete cut me a hell of a deal on the updated EBC since mine took a dump. I cant say enough good things about them...........Unless they held back info about the EBVC grounding out.

Hey Vigor, so just let the EBC hang and that will tell me if thats the issue?
Also anyone know what is causing it? Can I take it apart and fix it??

 

[Snowjunky]

Well it runs on the stand. I went out looking for a bad ground or if the box was grounding out. Nope.....Well I have a hard time admitting defeat so.......Must be something simple and overlooked ,Right! So I started at square one.
I cut all of the little black connectors off the pink black wires going to the fuel pump harness and EBC. Hmm lights dont go out. hmmm checked thru connectors and had continuity.....hmmm shook connector and no continuity. Now to find out if it still cuts out. Will have to wait a week to get to the snow.

 

[Snowjunky]

So more testing on the connectors leads me to believe this is and was never a Boondocker issue at all. Whether the EBC needed replacing or not it would not have worked. I think the wires were shorting out right at the old splice point. Where Boondocker had us splice the fuel pump feed for all the power. The old solder joint was really stiff right where it came out of the harness and had broken many of the wires. This voltage drop would surely be able to smoke the EBC. It seemed like a connector issue until I tested all the way up to the original crimp pins. THIS WOULDNT HAVE SHOWN UP AT THE FACTORY WHEN THEY TESTED IT.

 

[vigorcs90]

The short in the EBC is bad enough that it will not work at all if it is connected to the handlebars. Remove it from the handlebars and it appears to work fine. I opened the case and it is full of liquid silicone, very stickey. It is going back to Boondockers. I spend alot of time this fall and most of last snowmobile season trying to figure out the problem. If we dont get any snow before Christmas I will run it on a dyno after Christmas.