Running horrible need help????

[Boozer]

I've been trying to figure this out since the end of last season. Can't get it out of mid-range, bogs and sputtters. Some times it will get to full rpm but only if you go from nothing to full throttle, it you back off the throttle a little and ask for it again it bogs out and looses power. This year already I have replaced the stator, new tps, new tps harness. Cleaned the exhaust valves at the end of year last year might pull them and clean them again in case I missed something. New plugs and tps is set to specs. My next step will be to try to go through the wiring as good as I can, this problem is really kicking my but!
The computer doesn't bring up any codes.
Could this be an injector problem? And how can you test them?
The local dealer doesn't have a clue and doesn't seem interested in helping. If anything stands out or any good ideas I would appreciate the help. You guys on here seem to know way more than my local dealer.
Thanks!

 

[Z-Man]

have you replaced the bellows and gaskets in the exhaust valves or did you just clean them? Could have a hole in one of the bellows.

 

[garlic bear]

bog

had an intermitent bog in mine found the wire for the air sensor in the air box shorted out had no codes just ran ****ty

 

[guidoxpress]

could be a broken wire in the TPS harness that caused the bog.

hole in the exhuast bellows like Zman stated will do this as well.

do you have a boondockers control box on it by chance?

 

[Boozer]

I have the sled tore apart again. Bellows were fine but I am going to put a new set in anyway, scrubbed the guelletines back to shiny, and going to put a new set of springs in. I have the gas tank off and went through every connection I could find and cleaned all the pins and put them back together. Is there anything else I could check while the gas tank is off?
Im going to take the throttle bodies off and check the reeds. Is it worth putting different reeds in since I have it apart or is that no big deal.

Guido I do not have a boondocker controll box on the sled, but looks like maybe there was one before because there are some electrical connecitons that are not plugged into anything???

Garlic Bear how did you find out the air sensor was bad?

To give a little more info on the machine, I bought it as a 700 the dealer warrantied it for a year, blew the motor on the second ride. The dealer had 900 motor on the shelf he put in the sled. Ran great for about 400mi then blew the crank in it. Dealer put the newer bigger crank in it and at about 100mi developed a midrange bog and have been messing with it every since. The dealer is out of business and left the country so I'm shot there. Looking at the ecu last night it says (ecu for yellow injectors 4 - 700). Would that mean the ecu is for the 700 and could be messing something up? The dealer told me the ecu's are the same and that would not be the issue.

Sorry for the lengthy post but I am lost and just want to ge the thing running again!
Thanks

 

[guidoxpress]

Guido I do not have a boondocker controll box on the sled, but looks like maybe there was one before because there are some electrical connecitons that are not plugged into anything???


To give a little more info on the machine, I bought it as a 700 the dealer warrantied it for a year, blew the motor on the second ride. The dealer had 900 motor on the shelf he put in the sled. Ran great for about 400mi then blew the crank in it. Dealer put the newer bigger crank in it and at about 100mi developed a midrange bog and have been messing with it every since. The dealer is out of business and left the country so I'm shot there. Looking at the ecu last night it says (ecu for yellow injectors 4 - 700). Would that mean the ecu is for the 700 and could be messing something up? The dealer told me the ecu's are the same and that would not be the issue.

Sorry for the lengthy post but I am lost and just want to ge the thing running again!
Thanks

ok...good post there..

1. there are LOTS of wiring harness on the 700/900s that go to nothing on the sled...can be for dealer truobleshooting, fuel prime, accessory plug ect...so no worries there..

the Boondockers control boxs didnt tie into anything on the sled except the injectors and accessoru plug...and if not grounded properly, it would cause a bad mid range bog...so you dont have to sweat that, if you dont have one.

2. if your dealer DID NOT relash your 700 ECU to the 900 flash...IT ***MUST*** be done..if you have an SLP pipe, you need the 06 900 SLP flash, if stock pipe, you need the 06 900 stock flash...

i would do the flash legwork right away...even if you sent it off and it was flashed, you now know its good to go...but no way to tell.

if your local dealer is no longer around...i would send your ECU to Carls Cycle in Idaho, Tri-City Polaris or Triple S Polaris in Utah or whatever good reputable POLARIS dealer is near you...

 

[Boozer]

Thanks Guido I just found a nick in one of the wires that go to a sensor on top of the head in between the sparkplugs. I'm going to fix that put the sled back together and pray. If that fixes I will make sure that the computer is flashed correctly.

Thanks for the help

 

[guidoxpress]

the thing is bud..

if your running the 06 700 flash on the ECU, i wouldnt even ride the sled just incase...you could be running lean compared to the 900 flash?

granted you said you put some mileage on the sled already, but still not worth chancing IMO.

i would get the ECU checked/flashed ASAP if it was me.

good luck bud.

 

[garlic bear]

wires

the machine had a an after market air box and the air sensor wires were rubbed through and would intermitently short to the frame causing the sled to run poorly and bog and over fuel repaired the wires ran great. As guido said make sure the ecu is flashed right they will need to now the color of your injectors if the 900 came with injectors hope you get it figured out

 

[pwdrking]

I had similar problems on my 06 900 and come to find out my fuel pump was only making around 30 psi and this caused mid bog on mine

 

[ryan900]

Make sure you have the right fuel pump cause the 06 900 have 110 psi fuel pressure and the 05 have around 40-53 psi.

 

[Danbot]

TTT any updates?
I agree about getting the ecm checked to be sure it is for the 866 and the correct injectors as a starting point.
Wiring gremlins can be horrible to diagnose, so start with the easy stuff most of which has been suggested already.

Did you set the TPS or did the dealer?

Have you verified correct fuel pressure?

Definitely check the reeds, I had a damaged reed petal once and it ran similar to how you describe your problem.

Have you unplugged the throttle safety switches to see if the problem is there?

Another thing that comes to my mind is your VES solenoid, have you plugged your VES hoses to test for the solenoid being stuck or sticking open?
You can also watch the tips of the valves poking through the plastic caps while running on a stand to verify they are opening correctly?
Just rattling thoughts off.....

 

[Z-Man]

Wow, just checked and the entire main harness is only $129. Think if mine gets electrical gremlins I will just replace the whole wire harness.

 

[Danbot]

Wow, just checked and the entire main harness is only $129. Think if mine gets electrical gremlins I will just replace the whole wire harness.

Engine harness swap just fixed a weird problem on mine, I had a spare though.

 

[Z-Man]

Engine harness swap just fixed a weird problem on mine, I had a spare though.

Looks like there are two more harnesses for the ignition and injection and they are more expensive at around 200 each.

 

[guidoxpress]

thats why i have like 4 harness, lol...

the 05 and 06 use the same harnesses EXCEPT for the injection side, but thats only from the ECU to injectors mainly and no need to place that one since its so short you could troubleshoot it fast

 

[Z-Man]

Think I am going to pull all the connectors and put dielectric grease in them to try to keep them from going bad while I have the engine out.

 

[Boozer]

Ok put the sled back together last night. Took it for a spin out back and it runs 90% better but the mid range bogg is still there but it gets through it easily where before it wouldn't even get out of it. I'm having the computer reflashed this afternoon and will have the fuel pressure checked also. I was looking at fuel pumps this morning and the 05 and 06 are different pn# but they discontinued the pump from 06 and the 05 pump is the only one you can get now???? Anyone know why that is?

Disco Dan I set the tps myself so I know that is good. I have not verified fuel psi but am going to do that this afternoon. The polaris mechanic looked at the reeds a couple weeks ago and said they were ok but I will have to look at them myself....you know how that goes. I haven't checked the throttle safety switch or even know what that is, my guess is it is the little button on the throttle block on the handlebar?????? And I will fire the sled up on the stand and watch to see if the valves are operating right. Should they open at the same time, at a certain rpm, or is there anything in certain I need to watch for? Thanks again for all the ideas and help ill keep you posted.

 

[guidoxpress]

The pumps on those 05 and 06 are the same..just switch the fuel pressure regulator..but check the psi first..I have an 05 pump I can sell if u need one..pm me if u do..

 

[Boozer]

Got the ecu reflashed this afternoon and I am running 110 psi for fuel so everything there should be good. Still fighting the bog but the sled is running way better than before. Getting close, im going to keep digging until I find this. Thanks for the ideas