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Turbo Troubleshooting Help!

I just returned from a couple days in Revy that were both cut short due to issues with my sled. Prior to this trip, I had just over 500 trouble free miles on this sled with respect to the motor/turbo. I did have an issue with my overstructure (both front and rear) which was replaced under warranty. Following this warranty work, I did have two rides without issue before heading to Revy.

Day one, hit the 30+km's of trail into Area 51, sled ran fine though I was never much past 1/2 throttle as the trail was pretty whooped out. Did a few climbs above the old cabin and sled seemed fine, just a bit boggy in top end, figure its something to due with the amount of snow covering thee hood/intakes. After a lunch break, hit same hill and sled does a big bog when when I hit it wide open, RPM's drop down to 6000 instantly. Check primary spring, plugs, all the easy on hill stuff, but it does it all the time now whenever I give it some throttle. Turbo is spooling, idles fine, runs great until it needs to be stepped on. Have it set at about 8 lbs at the cabin. Don't feel like having my sled stranded this far from truck so call it a day and head back to town.

Day two, checked all hoses and plugs that I could reasonably get at with hood and panels off, looked for kinks in boost line from intercooler to control box, all looks good. Decided to give it another try into Sale. Again, mostly 50-60% throttle to start so no issue, running good, as snow gets much deeper and start giving it more throttle, issue comes back. I did some testing and reviewed the MAX data on control box. Box is set at about 7 lbs and I seem to be able to build to about 6.4 before bog hits but now I notice that the AUX injectors showing zero fuel on the stats screen. I turned boost up to see if I could get them to show a reading and pin it till bog hits again but box continues to show zero for the AUX and about 70-74 for the stock injectors. Figure there's not much I can do on the hill and call it a trip.


My first thought was that the injectors are pooched but I would think the control box would still be trying to send fuel to them, even if they where plugged and still show a reading on the box. Tonight, I will look over all lines, tubes, cables, connnections, etc. but I have kind of already done this with no success. Also going to check fuel pressure to see if the fuel pump is OK. Where else should I be looking/testing that could have this type of result? seems to be a fuel delivery issue. My only other thought is that the control box is faulty. Any suggestions appreciated.

Sleds a 2014 Pro RMK with a Boondocker 2860 Intercooled kit.
 
Sounds like the secondaries are not working I would start there had this issue earlier this year with mine.
 
Check fuel filter. I had similar and replaced plug fuel filter solved problem. How many miles doesn't matter, mine was plug at 200 miles. I can't prove it but I think there was something in the tank from new that plug it.
 
so just some i'm straight here, would a plugged fuel filter still allow enough fuel through for the stock injectors at low load/rpm then not allow anything to get to the secondary injectors? I would just think that the secondaries would receive something but maybe i'm wrong. regardless, its worth a shot. Thanks!
 
Can u do a buzz check with ur bd box to ensure they are getting the signal? Sounds to me like maybe the bd box is faulty if the injectors aren't...
 
Can u do a buzz check with ur bd box to ensure they are getting the signal? Sounds to me like maybe the bd box is faulty if the injectors aren't...

Will be trying this today, just need to get the push button from the dealer as I cannot seem to get my box to run the test function with just the box. Also, going to check fuel pressure. Filter seemed fine as I could very easily blow fuel through it but might still change it if nothing else shows a problem.
 
Tested control box and flooded injectors so we know they are firing. Even swapped out the entire control box for another and same issue, no fuel to secondaries unless doing the test. Can build boost on the stand and box is reading the boost signal. Swapped out boost actuator and checked fuel pressure and all good. Tested fuel filter by gently blowing into it and fuel easily flowed out of return line but am going to replace just to rule out 100%. If the filter does not solve the problem, I really don't know where else to go with this.
 
Check fuel filter. I had similar and replaced plug fuel filter solved problem. How many miles doesn't matter, mine was plug at 200 miles. I can't prove it but I think there was something in the tank from new that plug it.

Turns out filter was plugged and full of debris even though I could blow fuel through it. Pumped out tank as well and lots of debris in there too. Hard to tell if it's from my jerry cans or from manufacture but I will be straining my fuel from now on. Thanks for all the suggestions and help.....at least I know my turbo system better now :face-icon-small-coo.
 
it is pretty amazing how much manufacturing schmootz can be found in a gas tank. had pretty much the same problem a couple of years back, change filter, drain tank... even better to give it a couple of good swishes with some clean gas and drain again.
 
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