I have a 2005 Sportsman 800 with approximately 100 miles on it. When riding through some rough terrain this weekend I noticed it stopped revving out to redline. Essentially the machine wont rev above 4900 rpm in H and 5300 rpm in L. I checked the diagnostics mode in the speedo and no errors showed up. I also removed the 16 pin connector at the speedo, to verify it wasnt the reverse override, there was no change. Additionally I checked the air filter (stock) and it is in great shape and confirmed the intake boots are well sealed.
Any thougths/suggestions.

Thanks!!

 

Thats odd. Stock mine would rev to about 5800 in high but that was in a mud hole. I don'e ever look at it in low. I would have checked because it sounds like something is wrong. Have you checked your belt?

 

Havent checked the belt yet, that will be next up on the list. It is odd it feels like a power loss or flattening of power when I get about 12 mph or so.

 

Check your fule filter and fule pump to make sure your getting the correct pressure. Also check your air filter and intake becasue it might be air starvation or too much air For grins check you plug wires and plugs to make sure you don't have bad wires and or a broken plug. Look for the simple causes becasue they typically are the cause of many problems. Heck even check for a loose connections in you pod newr your speedo and ECM.

 

There used to be nut on the primary clutch that would sometimes come loose and prevent full shift out, which I think would also limit rpm. I'm sure someone with a lot more clutch knowledge than me will speak up and let you know if this could be the problem.

 

What will it rev to in neutral?

 

thats funny you said should rev it all the way up in neutral too dangous. it sounds like a clutch problem if the engine isnt bogging.

 

I have it at the dealer [img]i/expressions/face-icon-small-sad.gif[/img]

Will advise when they let me know.

Thanks for all the input.