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Engine problems

R
May 1, 2008
7
0
1
34
prince george
I own a 900 rmk 166 2005 and i went for a ride today and it is craping out on the top end any one have an idea what it could be i no nothing about these sleds yet. I found an emissions hose coming from the top of a round what ever it is and the goes to my exaust ports. but i seen that it was not hooked up from the bottom of my engine. Does anyone no where it goes or if i can get lost with it. or is it important and if it is where does it go.
 
Last edited:
T
Dec 2, 2007
206
31
28
Kent, WA USA
That hose is I believe part of the control system for the exhast valves so yes it needs to be hooked up and coud very well cause your "crapping out" if your exhaust valves aren't opening right. Problem is I don't have a 900 so I really can't tell you for sure, sorry.
 

mountainhorse

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Dec 12, 2005
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Trailtoy is mostly correct.

Actually the hose FROM the control soleniod is vented to atmosphere... that end is hooked up to nothing and is left dangling in the engine bay behind the engine... it makes a mess.

There is a hose from each exhaust valve to a "Y" fitting, a hose from the "Y" fitting to the exhaust Valve control solenoid and a hose from the solenoid that is left vented to the atmosphere.

Crappy perf?

When were the exhaust valves last cleaned?
Have the exhaust bellows been updated to the new ones?
Check the exhaust valves themselves for cracks or broken shafts.

Have you dissassembled the exhaust valves and CAREFULLY checked the exhaust valve bellows for cracks or splits?

What condition are the throttle body boots that connect the throttle bodies to the reed blocks?


What is the compression in the engine?

Does it idle well? Backfire?

When was the fuel filter changed last?

What quality of gas are you using and can you verifiy that there is no water in your tank? How old is the gas in the sled?

Have you checked your sparkplugs/replaced them and are the caps secure on them?

All of the normal functional check in general.

Have all of the updates been done?

What airbox is on the sled?

What engine mods have been done (pipe, can etc)?



Do you have any MFD blink codes??

MFD Blink Codes
The check engine LED will display a blink code whenever the
ECU determines there is a problem with one or more of the
sensors.

When a blink code is displayed, the CHECK ENGINE light will
illuminate for 1/2 second “on” and 1/2 second “off” with a 1
second “off” interval between close.
DTC Troubleshooting
Always use the Digital Wrench diagnostic software program to
troubleshoot DTCs, MFD blink codes, and overall performance
problems.

VARIABLE EXHAUST SYSTEM (VES)
Overview

The Polaris VES system uses exhaust valves (1 per cylinder) to
control the exhaust port height. The valves are actuated by
controlling cylinder pressure with a solenoid, bellows, and a
series of hoses.
At idle speed and up to a pre-determined level, the solenoid is
powered by the ECU or CDI. This action opens the solenoid’s
internal valve and allows the cylinder pressure to vent into the
atmosphere. During this time the valves are down.
To raise the valves, the ECU or CDI will cut power to the
solenoid which will close the vent path to atmosphere. The
cylinder pressure will then act upon each valve bellows which
will raise each valve.
On CFI engines the timing at which the solenoid is turned off is
determined by engine RPM, TPS position, and pipe
temperature.

NOTE: Solenoid Powered = Vent Path Open
Solenoid Off = Vent Path Closed


900 LIBERTY VES DISASSEMBLY
1. Carefully remove theVES cover bolts (A) cover (B) and spring (C), do not distort the springwhen removing it from the cover.
Spring is under pressure, hold cover tightly against the assembly when removing the cover.
2. Remove the bellows nut (E), bellows (E) and bellows washer (F).
3. Remove the base bolts (K) and remove the base assembly (G) and guillotine (J) from the cylinder.
4. Remove the gasket (H) from the VES base (G) and clean the guillotine (J) with carbon clean or oven cleaner.
900 LIBERTY VES ASSEMBLY1. Place a new gasket (H) on the valve base (G).
2. Place the guillotine (J) in the valve base.
3. Insert the base bolts (K) and torque to 12 ft. lbs. (16 Nm).
4. Place the bellows washer (F) and the bellows (E) on the valve base.
5. Apply Loctite 242 to the bellows nut (D) and torque to 12 ft. lbs. (16 Nm).
6. Install spring (C) and valve cap (B) on to the base and torque the cover bolts (A) to 9 ft.lbs. (12 Nm).

Exhaust Valve Cleaning
The exhaust valve guillotines must be cleaned to ensure
maximum engine performance and throttle response.
1. Remove the vent hose from the EV base fitting.
2. Remove the two fasteners that secure the valve assembly
to the cylinder, but not the two screws that secure the cover
to the EV base.
3. Carefully extract the guillotine out of the cylinder. Discard
the gasket.
4. Using a clean rag or shop towel, remove the oil residue from
the cylinder, guillotine, and EV base.
5. Inspect the guillotine for signs of damage. Replace
guillotine if damage is found, and inspect the cylinder and
piston for damage.
6. Clean the guillotine with brake cleaner and a piece of fine
steel wool. Clean only to remove hardened carbon deposits.
7. Once clean, rinse blade with mild detergent and water. Dry
completely.
8. Install a new gasket, then reinstall the EV assembly. Apply
Loctite 242 to the fastener threads, then torque to
specification.
9. Reconnect the vent hose.
.
 
Last edited:
P
Mar 25, 2003
168
8
18
Ellensburg, WA
also look for oil around the base gasket. Some of these models had case taps that weren't deep enough for the head bolts (mine included). Usually resulting in a lean condition. If it runs that way too long, you wont like the results.
 

mountainhorse

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Plumber... You hit that one on the head!!

As easy as it is.. I'd do it anyway.

Team Tip S-05-09-02 Reminder: 2005 900 Cleanfire Engine Cylinder Bolt Washer AdditionThe possibility exists where the bores drilled for the cylinder bolts in the upper crankcase may not have been
drilled deep enough or metal shavings may be at the bottom of the bore(s). When this occurs, the cylinder bolt
clamp force is reduced even while the desired cylinder bolt torque has been reached.
The primary symptom is a white-carbon build-up on one spark plug metal casing wall.
If this symptom occurs, Polaris recommends the following action:

1. Drain the engine coolant.
2. Remove the cylinder head. Discard the o-rings.
3. Loosen and remove the cylinder bolts. Install a washer, PN 7556234, on each bolt. Re-install the cylinder
bolts and torque to 34 lb.ft. (46 Nm) following the torque sequence in the service manual.
4. Re-install the cylinder using new o-rings and fasteners. Follow the recommended torque specifications and
torque sequences in the service manual.
5. Re-fill the cooling system. Bleed the air out of the system and test.
Polaris recommends the washers, PN 7556234, be added to the cylinder bolts WHENEVER the engine is
removed or re-built for any reason.
 
R
Dec 17, 2006
547
46
28
and like mountainhorse said that hose makes a mess,and can cause your belt to slip from all the gunk ,vent it to the outside .
 
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