Hi guys, looking for some help to try and get to the root cause of this ... sled starts after a few pulls when cold, sounds lethargic at idle, dies after a while. Runs boggy at all rpms, does not rev over 7000 rpm. Somestimes bogs down and dies altogether, esp if given more than v slight increase in throttle. Problem gets worse as it warms up. V hard to start when warm. Last time couldn't start it from warm, changed plugs though they weren't wet, but that helped as it started up on first pull. Always need slight throttle when starting from warm. Plugs black, tops of pistons looks black too when looking thru holes after pulling plugs. ECU showing 6 blinks which I believe is APV servo motor? Manual only lists ECU codes up to 5 blinks. Occasionally some backfiring when trying to start sled, esp from cold.
Have pulled and cleaned APVs, one was pretty hard to get out so thought might have been sticking, both v dirty with carbon and oil. Do not use any special kind of APV oil, just regular sled oil. Some screws were missing (again) from covers and on the one that was stuck, all the screws holding the valve unit in place had come undone ... also the one that was stuck, the wire had come unhooked from the servo motor!! Which may be why it was stuck, it was not in use ....
After all that, restarted sled, sounded initially better but same symptoms when warm after riding and ECU still showing 6 blinks on startup. We had tested sled with track raised up to make sure servo was working and could see it moving when got up to around 7000 - 8000 rpm. As said, cannot get over 7000 rpm when on trail. Also checked that cable lengths were the same and within spec. Was hard to get accurate measurement there though, does it matter if one cable is v slightly longer than the other? The amount of slack was supposed to bbe 34mm I think it was and one was 34 and the other was 33.6 after adjustment, had been 31.5.
Have been reading many threads here and elsewhere and it seems like there are so many things this could depend on, such as faulty APV servo motor (though we can see it is moving, could it be out of alignment? - We hooked the cables up in the same place and without rotating the motor, after APV cleaning), volt regulator, faulty temp sensor, faulty coolant sensor, stator, the ECU itself, TPS, TSS, smart valves, sled in "limp mode" for some reason .....
We checked the volt / ohm reading for the temp and coolant sensors but values were way off those listed in the manual? Volts were OK but ohms were a fraction of what they should be. Stator seemed OK. BTW lights shine v dimly when sled at idle, brighten up when rpms raised. Brake light does not work, though neither filament in the bulb is broken ... (rear light OK). So maybe volt regulator on the way out? But would that also cause rest of symptoms? Or do lights just shine dimly because of low idle?
Sorry for v long post, any ideas appreciated!
Have pulled and cleaned APVs, one was pretty hard to get out so thought might have been sticking, both v dirty with carbon and oil. Do not use any special kind of APV oil, just regular sled oil. Some screws were missing (again) from covers and on the one that was stuck, all the screws holding the valve unit in place had come undone ... also the one that was stuck, the wire had come unhooked from the servo motor!! Which may be why it was stuck, it was not in use ....
After all that, restarted sled, sounded initially better but same symptoms when warm after riding and ECU still showing 6 blinks on startup. We had tested sled with track raised up to make sure servo was working and could see it moving when got up to around 7000 - 8000 rpm. As said, cannot get over 7000 rpm when on trail. Also checked that cable lengths were the same and within spec. Was hard to get accurate measurement there though, does it matter if one cable is v slightly longer than the other? The amount of slack was supposed to bbe 34mm I think it was and one was 34 and the other was 33.6 after adjustment, had been 31.5.
Have been reading many threads here and elsewhere and it seems like there are so many things this could depend on, such as faulty APV servo motor (though we can see it is moving, could it be out of alignment? - We hooked the cables up in the same place and without rotating the motor, after APV cleaning), volt regulator, faulty temp sensor, faulty coolant sensor, stator, the ECU itself, TPS, TSS, smart valves, sled in "limp mode" for some reason .....
We checked the volt / ohm reading for the temp and coolant sensors but values were way off those listed in the manual? Volts were OK but ohms were a fraction of what they should be. Stator seemed OK. BTW lights shine v dimly when sled at idle, brighten up when rpms raised. Brake light does not work, though neither filament in the bulb is broken ... (rear light OK). So maybe volt regulator on the way out? But would that also cause rest of symptoms? Or do lights just shine dimly because of low idle?
Sorry for v long post, any ideas appreciated!
2002 Mountain Cat 600 EFI runs rich / boggy /no idle
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