900 fusion wont start

[triple650]

got my sled all back together and put my new silencer on, wont start no fuel no spark. and everything is connected cant figure out whats wrong with it. i had it running about 2 months ago and it started right away. i didnt touch any electrical and me and my dad dont know to much about the wiring maze on this sled. Its as if your trying to start the sled with the key turned off. so if you have any info that could help. thanks in advance.

 

[guidoxpress]

what exactly did you do to it recently...you added an aftermarket muffler...thats all?

get detailed what you did..i KNOW with enough input..we WILL get you the correct answer your looking for...

 

[94fordguy]

what exactly did you do to it recently...you added an aftermarket muffler...thats all?

get detailed what you did..i KNOW with enough input..we WILL get you the correct answer your looking for...

Ya, we really need to know what your definition of "All back together" means... what all did you have apart?

 

[triple650]

ok so all i did was change the exhaust gaskets, put a new exhaust deflector and i had removed the a-arms and painted them. only thing that was removed would have been the air box, exhaust with manifold, chain case cover , chain, sprokets, and the dash that i had to unplug the ignition switch for the key to get the dash removed. besides that i didnt touch any electrical my dad phoned the polaris dealer and said theres a wire by the computer that on some sleds they had was broken, but that we need to remove the seat and gas tank, ever here of this?

 

[frozen north]

Got it- double check that the kill switch if you got one is still pluged in good- and the ignition switch- double check real good- take the time- do not rush- if those are good- double check the CDI plug is in good- also check the wiring going to the teather if you got one- if it's off- no start-

Let us know

 

[ghostwhite]

If the key connector is unplugged it will allow it to start. The key in the off position is effectively grounding out the circut and shuts off the sled. So an open kill circut allows the sled to keep running.

 

[triple650]

the kill switch is good, no teather cord, whith the key we checked for conductivity in the switch should there be any current when they key is on or off, cause when it was on, some of them had a current and some didnt. not shure how electronics work. also my sled sat on its side for a day, is that bad?

 

[guidoxpress]

Well...

there could be all kinds of "possiblities" of wiring by the ECU..

But it would be highly unlikely that some random wire there just broke all of the sudden w/o you removing the tank...i do not know which wire your dealer is talking about..but there is alot of routing issues on most of them, and the wiring rubs through from chaffing or are zip tied too tight..

i would start basic..

--unplug your kill switch and then try and start it..or at least check for spark..
--make sure the plug wires ar on good
--make sure the wiring from the COILS are good as well..you could have pulled one out with the console..
--un plug the key switch and check for spark...dont run it incase it starts..you will have no way to shut it off...safely..
--check ALL the wiring by your console for visible damage or for an unplugged wiring harness that does not look obvious that it was not to be plugged in..(ie. fuel prime ect)
--unplug your grip heaters and thumb warmer as well...you might have shorted them out grounding out..and check for spark



i am willing to bet that you either pulled on a wiring harness fairly hard when you removed the console, oaccident of coarse..hopefully..or you might have damaged the wiring around your steering column when you removed it..

i wont say who (ok me) accidentally mixed up the wiring for the thumb warmer and plugged it in the kill switch harness...(no spark then)...maybe you mixed some up

have you had all your recalls done on your sled...some have had fuel pump issues, which i think grounded the fuel pump and it wouldnt run? not 100% sure on that though..

have the dealer run your VIN just incase for any updates..

i will keep thinking..and you get the work done

 

[triple650]

thank you thank you, ok what i did is i go outside, unplug all the wires from my handle bars turn the key on, the plugs are out of the cylinders i pull it over theres spark. im like "YES" put the plugs back in pull once pull twice starts right up, drive it in my yard a bit get it warmed up. so i one by one plug the kill switch into one of the three wires, so i got it working now all i gotta do is figure which one is wich for the thumb or hand warmer.

i cannot thank you enough, here i was all depressed that i had done all that work to something i love the most and it wont start lol. so again thank you.

 

[LUBA]

If the key connector is unplugged it will allow it to start. The key in the off position is effectively grounding out the circut and shuts off the sled. So an open kill circut allows the sled to keep running.

Hmmm, I wonder if that is what's wrong with my sled? Mine will start no problem just won't shut off.

 

[ghostwhite]

i wont say who (ok me) accidentally mixed up the wiring for the thumb warmer and plugged it in the kill switch harness...(no spark then)...maybe you mixed some up

Haha don't feel bad Sean, I accidentally wired my tether into the p.e.r.c. switch the first time around. Had it all soldered, heatshrinked, and covered before I tested it.

Started it up, pulled the tether, nothing just keeps running, try kill switch and it dies. Start again, pull the tether, nothing, pull the tether button out and release and brrrr, switches to reverse.

Its all good now

 

[guidoxpress]

thank you thank you, ok what i did is i go outside, unplug all the wires from my handle bars turn the key on, the plugs are out of the cylinders i pull it over theres spark. im like "YES" put the plugs back in pull once pull twice starts right up, drive it in my yard a bit get it warmed up. so i one by one plug the kill switch into one of the three wires, so i got it working now all i gotta do is figure which one is wich for the thumb or hand warmer.

i cannot thank you enough, here i was all depressed that i had done all that work to something i love the most and it wont start lol. so again thank you.

AWESOME..i am glad we could get that figured out for you..i told you, this is teh BEST 900 forum you will find..

the wiring will be easy to match up..its all color coded...worse case...plug one in..hit the switch (1 at a time) and see what heats up ;0

BUT!!!!!!!!

i am more concerned with your "warm-up" procedures...you let the crank heat soak and let the temps warm up BEFORE you MOVE the sled right???

i want you to explain your warm up cycles...trust me...its more imp then anything u will ever do on that sled...

your welcome btw,

 

[triple650]

ya i let the sled warm up to operating temperature wich is 126 about before i move it. i ment warm up as get everything moving cause i was worried that having it sit on its side for a day might have done something. even in the winter if i try and move it before 100 degrees it fouls a plug thats what happended when i braught it home the guy who had it before me said to start driving at 70 degrees! so right after i get home i start it on the traler and i go to back it off at 80 degrees it fouls a plug i couldnt beleive it i had just baught it, so i went on the internet and read that you have to let it warm up properly. so i always let it get to 120 atleast. even after i always drive nice and slow in my yard before riding.

 

[guidoxpress]

good deal..but i would let it warm up, shut it off, let sit for 5 mins or so...repeat, then the 3rd start...let it warm up, and then lift the rear and spin the track a few times...and then on your way..

with that kind of heat soaking to the crank/clutch..it will last you as long as possible (but get your primary balanced if you dont know if it has been done before)

look into the motor mounts offered on here as well (compfusion) and the FBF throttle/cable) they are EXCELLENT and will help you last a LONG time


with the plugh issue...if you have the champion, try the NGK (research the threads) and if you have NGK, try the champion...some run better on one brand only..and then stick with that one..

 

[triple650]

well i start it lift up the back end slam the back end down so i knocks out all the ice, and when i go out of the garage i back out so it shoots out the back and doesnt get all jammed, plus it helps when you clean out the slushy snow before you put it away. As for the mounts and stuff well i dont realy have money for that this year, and im not shure if i can get my clutch balanced around here. I am only 16 and im still learning but i do love this sled and i would like to keep it for a long time. so thanks alot. lol

 

[triple650]

well hello, alright my sled runs good got to drive it a bit, but when i start it it will run for about 25 seconds and then sputter and stall. I pull it once again starts and runs fine, its wierd got any ideas?

Another thing i have no idea who could balance my clutch around here let me tell ya not to many bright minds in these neck of the woods, i gotta phone the guy who rebuilt my 650 engine he might no someone.

Thanks alot!

 

[triple650]

any one?

 

[94fordguy]

well hello, alright my sled runs good got to drive it a bit, but when i start it it will run for about 25 seconds and then sputter and stall. I pull it once again starts and runs fine, its wierd got any ideas?

Another thing i have no idea who could balance my clutch around here let me tell ya not to many bright minds in these neck of the woods, i gotta phone the guy who rebuilt my 650 engine he might no someone.

Thanks alot!

Hmmm

I have experienced a similar problem on my 900... I think the cause is something in the fuel system that allows the pressure to bleed off when the sled sits for long periods of time, but I can't remember what it's called, not sure if there was a recall or update for it or not... kinda grasping for straws on this one.

As far as clutch balancing, get ahold of Indy Dan or SLP, either one will be able to get it balanced for you. SLP is pretty inexpensive if I remember correctly.

 

[triple650]

alright well i started it, the other day and didnt stall at first so it seems fine its got old gas in it so maybe thats why. another thing i dont want to highjack jsledder's thread, but what is the best compression for these sleds? i got 125 psi on both cold, and 5040 miles, the one time i had no coolent left and it got to 240!!!! but i dont know how acurate that is because there was no coolant hardly, ran fine for the rest of the winter and still does.

but i noticed some scoring when i had the manifold off, so if i where to rebuild it and my cylinders where scored what do i do with it?

also do you guys think i should rebuild it?? any help or tips would help alot,

thanks.

 

[f15ejedi]

Old fuel can cause it to stall like that. I would pull the tank, drain it and also check the wiring to the pump which is on the tank. Could also be the stator but that would be a stretch. The stators on the 900's are known to fail. But like I said that would be a stretch.