No reverse, cuts at PTO, 1 blink in check engine

[Troll-Tor]

Newly rebuild RMK 900 engine.

I partly submerged my 900 and bent my crankshaft.. Engine rebuilt with new parts.

Before the engine was rebuild I had to change the stator due to a sudden not starting sled (so Stator is basically new but have been under water ) I dont know what caused the first one to fail but if any one does know, let me know..

Out testing, everything worked perfect. Suddenly Spark plug on PTO side dies. Changes Plug everything fine for a while....

Got exhaust temp on Y pipe so I see wich one stops.

Sled runs fine for 1 hour, then suddenly the problem with the temp on PTO side happen again.

No I can not engage the Reverse, but this works fine after some more riding.

Next day temp problem again.
See 1 red blink on Check Engine This happens every now and then Could be 15 minutes between the blinks or more.
Also I saw the "battery indicator" was without scale.

Just so many things at once...

 

[sloan188]

a low battery reading on the mfd is indicative of a bad capacitor if your RPMs were up when observed. The cap is in front of the tank on the left and there is a test that you can use to check it.

Wrt the dropping PTO plug, you might want to check the coil to pug wire and the sled to coil connections. I had an intermittent problem once with sled dropping to 1 cylinder and it turned out to be a pushed pin in the sled to coil connector.

 

[Troll-Tor]

a low battery reading on the mfd is indicative of a bad capacitor if your RPMs were up when observed. The cap is in front of the tank on the left and there is a test that you can use to check it.

Wrt the dropping PTO plug, you might want to check the coil to pug wire and the sled to coil connections. I had an intermittent problem once with sled dropping to 1 cylinder and it turned out to be a pushed pin in the sled to coil connector.

I switched the coils.. No change. The way I did this was by switching the white and blue connections and switch the spark plug cables from PTO to MAG

I'll check on all the connectors tonight..
The battery low was while running on idle speed.

 

[Troll-Tor]

The problem is not there when engine is cold

 

[Troll-Tor]

There are some connection issues with the TPS wires.. I pull Them and the blink occures.
Also the EGT solenoid is clicking a lot.. Anyone know if this is normal? Loud clicking

Now when the engine idle, the problem came back.
It keeps misfireing on the PTO side (Not so Shure this is only the PTO side any more). Very rough idle, like if i am pumping the throttle gently. Can not engine reversere. The battery indicator is normal

 

[sloan188]

When my TPS harness went the sled was running very badly and wouldn't go into reverse sometimes...maybe that is your problem.

Have you tried disconnecting the TSS/kill switch?

 

[Troll-Tor]

Don't know if this is relevant, but the breaklight indicator and breaklight is not working. I noticed That while on parkbreak, suddenly the speedo parkbreak indicator was on and next time i started the engine It did not work..still don't..
I am building a TPS tester today.

 

[sloan188]

Don't know if this is relevant, but the breaklight indicator and breaklight is not working. I noticed That while on parkbreak, suddenly the speedo parkbreak indicator was on and next time i started the engine It did not work..still don't..
I am building a TPS tester today.

Wrt your brake light, provided the MFD and headlights are working your issue is either with the switch in the brake lever or corroded compression pins in the sled side VR connector in front of the tank on the left side. You can check your switch by unplugging the brake connector on the handlebars and shorting the sled side connector with a short piece of wire. When you short it, the indicator and light should come on...if it doesn't it is almost definitely the corroded pins I alluded to earlier. You will need to take the orange pins out of the connector where there is not corresponding pin on the VR connector. To release the pins, look inside to see barbs holding them in, compress the barbs and pull the wires/pins out. Clean well with sandpaper or something similar; open the barbs so they will continue to retain the pins in the connector and reinsert.

 

[Troll-Tor]

So TPS adjusted.. No change in Idle problem or temp problem. The exhaust temp is now even worse..
I am uploading a video on YouTube. Called RMK 900 PROBLEM
Compression is 8,6 PTO and 8,4MAG in kg

 

[Troll-Tor]

http://youtu.be/uwhzn1NWHRI

 

[Troll-Tor]

Pulled off the Kill switch and the sled is starting .. No need for jumper

WTF??



Next thing... After fixing the Brake light switch.. (i know this should have nothing to do with it) The MAG Side is now igniting.. Not the PTO Again WTF??

Measured the Stator. Everything seems ok But The Brown Wire Grounds. Should it? BTW that was the only wire that grounded..

 

[Troll-Tor]

Sled started misfire on PTO again..
Pulling TPS contact. Video link below

https://www.youtube.com/watch?v=7ogHqiC3rpI

still much lower temp on PTO side after pulling.. over 100 degrees @ idle

Thinking Fuel Problem...

 

[Super Dave3]

If this is a 06 900 I would bet money that the TPS harness has a broken wire inside the connector. Polaris sells a replacement harness repair kit. On 06,s I saw almost a 100% failure of that harness.

 

[Troll-Tor]

If this is a 06 900 I would bet money that the TPS harness has a broken wire inside the connector. Polaris sells a replacement harness repair kit. On 06,s I saw almost a 100% failure of that harness.

Ok, so I should be able to measure that broken wire with a multimeter then?
I Can remove the connector, change the 3 wires from top and hook them up to the harness to check this?

 

[Super Dave3]

Yeah you can ohm test the three wires from the connector to say about 6 inches up the wire. The break will most likely be inside the connector.

 

[sloan188]

http://youtu.be/uwhzn1NWHRI

That is one sick sounding 900!

 

[sloan188]

Pulled off the Kill switch and the sled is starting .. No need for jumper

WTF??



Next thing... After fixing the Brake light switch.. (i know this should have nothing to do with it) The MAG Side is now igniting.. Not the PTO Again WTF??

Measured the Stator. Everything seems ok But The Brown Wire Grounds. Should it? BTW that was the only wire that grounded..

disconnecting disables both the kill switch and the TSS....

Where was your brakelight problem?

Brown is wires in general are ground...Some require connectors in place for continuity to ground...

 

[sloan188]

Sled started misfire on PTO again..
Pulling TPS contact. Video link below

https://www.youtube.com/watch?v=7ogHqiC3rpI

still much lower temp on PTO side after pulling.. over 100 degrees @ idle

Thinking Fuel Problem...

I have never tried to run the sled without the TPS connector plugged in...surprised it runs so well...in fact it sounded better with the connector off than when it was on...

To check the TPS pigtail, pull gently but firmly on each of the 3 wires that go to the TPS connector. I think my red wire failed inside the connector...Pay close attention to any give when you pull on the wire as there should be none once taught...

 

[Troll-Tor]

Yeah you can ohm test the three wires from the connector to say about 6 inches up the wire. The break will most likely be inside the connector.

Okay..
Disconnected the ECU contact and "beep-tested" the 3 wires with the multimeter from contact to contact.... All wires were fine according to this test...

And yes, It is a 06'

Another thing I've noticed is that if i pull off the spark plug cap on the not healthy side while engine running, wait a couple of secounds and put it back on.. it actually fires for a second or two... So I am even more suspicious of that there could be a fuel problem... All injectors were ohmed 3 was 13,8 and 1 was 13,5.. I doubth the 0,3 makes any diffrence

The last time I fired it up after measuring the TPS wires, it gave me 7 blinks on check engine... I'll check tomorrow if a contact is loose..

 

[Troll-Tor]

disconnecting disables both the kill switch and the TSS....

Where was your brakelight problem?

Brown is wires in general are ground...Some require connectors in place for continuity to ground...

Brake light problem was inside the switch.. Took me TOO much time to assemble the little b**tard once it fell apart in my hands

How do i buypass TSS/Kill switch on this ?