Rebuilding a sled

[Blueside]

I'm pretty new here, I've been lurking around a bit up mostly in the swap meet until now.

So I don't know why, but this summer I decided to pull every nut and bolt and replace anything looking broken and basically clean everything. Pretty well just an excuse to be with my sled in the summer months.

Anyway winter is coming and its time to put it all back together.

Engine is in and all neccessary parts for the engine to run but no avail?
What's the most common things over looked when putting everything back together?

I was getting fustrated and came in but the plugs are not wet, will check for spark tomorrow.

 

[Rixster]

Is there fuel in the carbs? It takes a while to get there just from pulling the motor over. I use my air compressor to pressurize the fuel tank and blow fuel into the carbs. Check all the elec. connections again, and then check them one more time.

 

[JHG]

I would guess something's not grounded. What kind of sled?

 

[Blueside]

So its an electrical problem, I have no spark.
Didn't have time to frig with it today, but I'll get on it this weekend.

On a side note, if I have 159" rails can I cut them down or move them forward to fit a 156" track?

Big Hoe, Its a 02 Polaris Edge 800.

 

[Rixster]

HMM maybe, Clip the front of the rails like an inch or so and then move them forward.

 

[polarisfornow]

i would check everything that is connected to the key and the kill switch. start there and work your way down to the stator.

 

[TBWdracula2003]

is it possible that you could have missed a ground? or broke a wire inside the insulation some how?

 

[Blueside]

Thanks guys, I'll update on sunday with some pics!
Hope to meet some of you on the mountain.

 

[Blueside]

So it's running now, well it ran for about 5 seconds, I have spark now, disconnected the kill switch and voila. I think its just a fuel issue now. Any thoughts on where to start?

My camera is also not working properly I'll try and get some half decent pictures soon.

 

[Rprecision]

So it's running now, well it ran for about 5 seconds, I have spark now, disconnected the kill switch and voila. I think its just a fuel issue now. Any thoughts on where to start?

My camera is also not working properly I'll try and get some half decent pictures soon.

If its been all apart it may take a little work to get fuel back into the pump, lines etc.

I would manually fill the carbs with a squeze bolttle of fuel and try again. Once its running the higher pulse usally fills things up pretty fast. Unless there's another problem

 

[Blueside]

How do you do that jsut disconnect the fuel line and squeeze it in?

 

[Hardass]

If you disconeccted the kill switch and it started then you have a problem in the throttle block.

 

[Blueside]

Well I installed a billet throttle block, and there is no space for the kill switch and I have a teather so do I really need the kill switch?

 

[sledhooligan]

T-block

You don't have to have the kill switch hooked up.Your sled works on an open circut. If the system is closed (black wire to brown or ground) your sled will die or not run. After you know if your sled is getting fuel. Unplug the small black/white wire near your stator housing by the plug that has the yellow and brown wires in it. If your sled runs with this unpluged you have a closed circut in your kill switch wiring (if it runs with this unpluged you'll have to plug it back in or pull the plug wires to kill the sled) Make sure your tether switch is built for a normal open circut sled. If you still don't have spark your proplem is in your CDI, stator, or coil or related wiring. If you can't find these wires go to your dealer and see if they'll give you a copy of the wiring diagram. Another thing to check is when you gutted your handle bars there was two small switches that was in your t block.These are wired into your kill circut. If one of those is not pushed in the sled will not run. They can be removed by cutting the wires were they tie into the brown and black.