i posted this in my 06 900 build thread, but wanted to post again on here incase someone had the same issue later and was wondering...and for those that are BASIC members and cant read my build thread
prepare yourself for a long read, lol.
well after i finished building this monster, i took it to wok to run up some heat cycles and finsih up a few things and have been fighting ever since..
long story short...for future reference for you guys...
the sled would idle fine..then found out the handwarmes and control housing switch didnt work..ok no big deal..
then i noticed the oil pressure gauge for the external oil pump for the turbo didnt work..meaning no oil pressure to the $1000 turbo...NOT good..thank god i installed an inline oil pressure gauge..
sled was only putting out 10.5 vdc, all my other sleds were putting out 13.5vdc....and when i start the sled, it would spike up to 4psi on the oil gauge and then back to 0psi (and show 12 vdc on the voltmeter), shut off sled and it would spike to 4 psi again on the gauge (and show 12+ vdc on the voltmeter)..then back to 0psi
when i would hook up a 12 vdc battery to the electrical test port on the wiring harness, the oil pump would pump 4psi on the gauge and remain stable until power was removed..
i had a stator rebuilt by RM Stator in Canada and its basically brandnew now with 1yr warranty...so figure it was ad (since it was originally fried before the rebuild)..so i switched the stator out...which isnt bad normally, but when the turbo is there and done..its HUUUUGGGEEE PINA!!!!
new stator in, no change...switched VR out...no change...found some bad connections and cut wires IN he wiring harness...switched harness...no change, switched chassis relay..no change...installed new grounds...no change...unplugged everything from handlebars...no change..changed ECU..no change
i have at least 40 hours of ohm-ing wires, cleaning wires, testing, switching parts...
then figured i switched out everything except 1 thing...but didnt think it was affecting my low voltage issue...and BAM its perfect now..everything is great..
what was it you ask...
well, i added 12vdc from a battery and charged the capacitor (for 10 seconds per the manual), the voltage is suppose to SLOWLY discharge the power when the sled shuts off and power is no longer applied..no specifics per the manual on amount, just slowly...but around 1vdc per 8-10 seconds...well my capacitor would discharge 12 volts in prolly 15 seconds...
switched out capacitor and WALLA...consistent oil pressure, no voltage spikes and no gauge flickering...
the capacitor holds 1-13vdc to supply power to the fuel pump on initial startup, then maintains the 13+ vdc to supply voltage to the fuel pump, and all electrical components at a CONSTANT power since t he stator and VR do not supply a constant voltage across the boards, rather fluctuating between 9-15 vdc.
So...f you have charging issues, and the gauges, lights flicker..if the chassis relay is good, it IS the capacitor...(i should say, i never looked at the analog charging meter on the gauges, wish i would have, but like i said i didnt think it was related so never bothered to look before.
2. my head light flickered cause the hood harness had a pshed in pin.
3. my handwarmers didnt work cause there was a brown grounding wire in the wire loom that went no where.
4. the conrol housing didnt work case there was another ground wire that went no where, which i assume went to the handwarmer ground that was missing.
i have to finish the chassis wiring harness now (tie in the A/F gauge, EGT gauge in to the accessory port for power), do my ski alignment, and put in a straight 46ER helix in the secondary and i am good to go, i will have it dne this coming week and have it on the snow FINALLY on next sat..
just in time to get a few SIIIIICK rides on the this beast to tune it and feel the power of a 900 turbo, then park it for my 1 yr in korea...
but will continue to rip it up when i move to Anchroage Alaska after korea
ride on...thanks for reading my CRAZY A$$ life, lol.
