900 Switchback will not stay running

[Nubsy1]

Hi All,

Having a problem with my '06 Switchback.

Out riding on Saturday and all was fine until the sled simply shut off while idling. Had been trail riding at a normal pace and stopped to allow another sled to turn around. As soon as I went to apply throttle the motor shut off as though I had turned the key off. No loud noises, backfires, or anything unusual. Tried to restart and the sled would fire and run for only a few seconds before shutting off again. Will not stay running. MFD acts possessed, needle sweeps up and down erratically, all indicator lights are flashing on and off.

Here are the things that have been checked out so far:

1. Have good fuel pressure to the rails
2. New Plugs
3. All visible wiring has been checked for loose connections or indications of rubbing through the insulation
4. Reed petals are intact
5. Switches (key, throttle safety, etc.) all check out as good by disconnecting - no change to symptoms.
6. No water in fuel

After reading a few things on here I am leaning toward a stator or relay. Will the Digital Wrench at a dealer get me pointed in the right direction?
Any other ideas or suggestions?

Thank you in advance. Before buying this (3 year leftover) I looked at this sight and used the great knowledge to build it right before riding. Resulted in 2500 trouble free miles up to this point, all with the stock 080 belt!

 

[Cerialsledder]

Have you tried unplugging your kill switch on the throttle block.

 

[sartysrnr]

Pull the flywheel,check the inner liner ..bet its loose and chaffed your wires or the stator is toast!Keep a spare at all times!You can ohm test it should tell you what you need to know.

 

[sloan188]

as said earlier, flywheel inner sheath coming off and taking out the stator is common. BTW, you can ohm the stator to see if its bad but just because all the readings are good doesn't mean that it is good.

I've also experienced similar issues when the TPS pigtail went....to check this simply pull lightly on each of the 3 wires going to the tps and hopefully one doesn't come off in your hands.

 

[Nubsy1]

Thanks for the replies.

I did have the TPS sensor out and did not change anything. Wires were all tight in the connector.

Kill switch was disconnected - no difference.

I will try the stator next. Already ordered a new relay just in case as it is cheap and not the worst thing to carry along.

 

[05900]

Stator is good bet and since your there check the harness for injury and all connector/pin relationships..good way to kill a six pack as well..

 

[Nubsy1]

UPDATE

Took it to local dealer to get it checked with Digital Wrench. Showed three codes for the Crank Position Sensor, and one for the TPS. Cleared codes and unit started and ran. Crank codes did not come back, but TPS code is still there. Understandable since I had removed the TPS while checking things over and did not get it re-calibrated yet.

Looks like I am going to have to pull the flywheel and check for rubbed wires, etc. Anywhere else I need to look?

Going to be hard to trust it on a longer trip without knowing what caused the problem...

 

[konarider]

So I'm having similar problems I'm going to try all of these things. But I don't no what tps is or where it size can anyone tell me this?

 

[Nubsy1]

FINAL UPDATE

Wanted to give what I hope is a final update. Turns out the voltage regulator wiring became so pinched between the regulator and the fuel tank that they were broken and only made contact intermittently. Changed out the regulator and sled has been running fine since. Hand/thumb warmers work much better now also!

New regulator is considerably narrower, allowing the wires some room to move and not get pinched off.

Thanks again for all of the help!

 

[TrailRebel]

http://www.snowest.com/forum/showthread.php?t=287525


In ^^^this^^^ thread, you can see what I and many others have done to prevent this common and annoying problem.