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Ski-Doo: REV Sleds 2004.5-200, all models in the REV chassis
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  #1  
Old 12-11-2017, 06:52 AM
jeep4x4 jeep4x4 is offline
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Default 2005 summit 800 no spark

Started sled at end of last season to pull it of of the trailer. The engine started fine then when I switched the engine to reverse it started to fun funny like it was running out of gas. It wouldn’t really rev up without cutting out. Then it died and would not restart. Pulled the plugs they were pretty dirty. So I installed new plugs and I have no spark on either plug. Any ideas were to start to look.
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  #2  
Old 12-11-2017, 11:10 PM
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Check the voltage regulator

Campaign no.: 2008–0016
October 3, 2008 Subject:REV-XP Wiring Harness Issues
No. 2008-20

PROBLEM
On some of the abovementioned vehicles, electrical
irregularities of an unknown source may be experienced.

SOLUTION
This bulletin gives troubleshooting steps in order
to quickly locate and repair electrical irregularities.
The following repair procedures must be completed
as per this bulletin:
– Voltage Regulator Wires Chafing
– Maintenance on Countershaft Support
– Taillight wires chafing
– Cluster gauge issue.

Voltage Regulator Wires
Chafing
Vehicle Preparation
1. Remove RH side panel from vehicle.
2. Remove muffler springs
3. Removemuffler from vehicle.
4. Remove acoustic panel from vehicle.

Voltage Regulator Wires Repair
1. Inspect voltage regulator wires for chafing or
cutmarks and repair if necessary.
2. Reroute voltage regulator harness toward the
top.
3. Attach voltage regulator harness on oil injection
line using a locking tie
4. Clean rivet area using pulley flange cleaner
5. Apply silicone to cover rivet.

NOTE: Make sure to properly cover the rivet to
eliminate any sharp edges or protrusions that
could damage the voltage regulator wires.

Taillight Wires Chafing

NOTICE Taillight lens is held in place by two
plastic pins inserted in rubber grommets. If
lens is forced too far sideways when removing,
the lensmounting pins may break and lens will
have to be replaced. Do not pull lens out too far
to avoid damaging wiring.

1. Remove taillight lens by carefully pulling on
lens at both ends.
2. Rotate bulb holder counterclockwise to remove
it from lens.
3. Carefully pull taillight harness toward the rear
of vehicle.
NOTE: If the lens does not pull out far enough to
work on, the locking tie for the taillight harness under
the fuel tank may have to be removed and the
harness laid down in the tunnel channel. Refer to
the following steps:
– Remove fuel tank side trim panels.
– Remove fuel tank side retaining nuts.
– Remove fuel tank side shoulder bushings.
– Slightly lift up rear part of fuel tank.
– Cut taillight harness locking tie.
– Stretch taillight harness in the tunnel channel.
– Reinstall fuel tank shoulder bushings.
– Secure fuel tank side retaining nuts to 33 N•m
(24 lbf•ft).
– Reinstall fuel tank side trim panels.
4. Pull protector tube toward the bulb holder to
protectwires.
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  #3  
Old 12-12-2017, 03:00 PM
sledsrock sledsrock is offline
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Default

Quote:
Originally Posted by Skidoox View Post
Check the voltage regulator

Campaign no.: 2008–0016
October 3, 2008 Subject:REV-XP Wiring Harness Issues
No. 2008-20

PROBLEM
On some of the abovementioned vehicles, electrical
irregularities of an unknown source may be experienced.

SOLUTION
This bulletin gives troubleshooting steps in order
to quickly locate and repair electrical irregularities.
The following repair procedures must be completed
as per this bulletin:
– Voltage Regulator Wires Chafing
– Maintenance on Countershaft Support
– Taillight wires chafing
– Cluster gauge issue.

Voltage Regulator Wires
Chafing
Vehicle Preparation
1. Remove RH side panel from vehicle.
2. Remove muffler springs
3. Removemuffler from vehicle.
4. Remove acoustic panel from vehicle.

Voltage Regulator Wires Repair
1. Inspect voltage regulator wires for chafing or
cutmarks and repair if necessary.
2. Reroute voltage regulator harness toward the
top.
3. Attach voltage regulator harness on oil injection
line using a locking tie
4. Clean rivet area using pulley flange cleaner
5. Apply silicone to cover rivet.

NOTE: Make sure to properly cover the rivet to
eliminate any sharp edges or protrusions that
could damage the voltage regulator wires.

Taillight Wires Chafing

NOTICE Taillight lens is held in place by two
plastic pins inserted in rubber grommets. If
lens is forced too far sideways when removing,
the lensmounting pins may break and lens will
have to be replaced. Do not pull lens out too far
to avoid damaging wiring.

1. Remove taillight lens by carefully pulling on
lens at both ends.
2. Rotate bulb holder counterclockwise to remove
it from lens.
3. Carefully pull taillight harness toward the rear
of vehicle.
NOTE: If the lens does not pull out far enough to
work on, the locking tie for the taillight harness under
the fuel tank may have to be removed and the
harness laid down in the tunnel channel. Refer to
the following steps:
– Remove fuel tank side trim panels.
– Remove fuel tank side retaining nuts.
– Remove fuel tank side shoulder bushings.
– Slightly lift up rear part of fuel tank.
– Cut taillight harness locking tie.
– Stretch taillight harness in the tunnel channel.
– Reinstall fuel tank shoulder bushings.
– Secure fuel tank side retaining nuts to 33 N•m
(24 lbf•ft).
– Reinstall fuel tank side trim panels.
4. Pull protector tube toward the bulb holder to
protectwires.
That’s for the XP not the Rev. Totally different.
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  #4  
Old 12-13-2017, 12:56 AM
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Theirs a small black relay above the sec. clutch, replace it and see what happens. FYI NAPA ones are way cheaper than the dealer.When I rode Revs I had one go out after I had loaded it on the trailer, wouldn't start when I got home, so after that I carried a few spares. Run into a guy on the mountain one day with a dead sled and it was his relay, he was really greatful I knew this info and had a spare.
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  #5  
Old 12-16-2017, 05:07 PM
sledsrock sledsrock is offline
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I would look elsewhere. My 07 will start and run great with the relay removed. Now, all the accessories will be inoperative but that’s to be expected. Wiring print shows this as well. Rope it over, headlights trying to power up? Might look into VR or Coil.
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Old 12-16-2017, 08:17 PM
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My 07 had tether woes. Fire it up and run off trailer. Shut it off and no start. Drag it back in trailer. It ended up being the post and not the tether.
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Old 12-16-2017, 09:05 PM
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I had one that had a bad tether post also. There is a procedure to test it.


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  #8  
Old 12-17-2017, 01:27 AM
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Quote:
Originally Posted by sledsrock View Post
I would look elsewhere. My 07 will start and run great with the relay removed. Now, all the accessories will be inoperative but that’s to be expected. Wiring print shows this as well. Rope it over, headlights trying to power up? Might look into VR or Coil.
My 04 would not start, I changed he relay and it fired right up, takes 30 sec. to check so why not?
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Old 12-17-2017, 09:53 AM
sledsrock sledsrock is offline
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Quote:
Originally Posted by rocks rev View Post
My 04 would not start, I changed he relay and it fired right up, takes 30 sec. to check so why not?
I suppose the MPEM sleds could be different, without a wiring print I don’t know that. I’m sure the OP will try another relay, you’re right it’s easy enough to try.
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