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09 sportsman 800 nightmare of issues

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Old Oct 7, 2020 | 08:08 PM
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Default 09 sportsman 800 nightmare of issues

Ok to make a long story short . I got screwed on this 4 wheeler . Now I am into this for 3200.00 and it’s still not running . New parts , new top end rebuild , new fuel pump , new injectors and wires , new water pump , new oil and water pump seals , new radiator , new stator , flywheel , new crank position sensor . And more .
just got the motor pit back in , go to start it up nothing . Heavy smell of gas , UNPLUGED the fuel pump it starts up and idles at around 13-1400 rpm. Plug the fuel pump back in . Motor dies , Inhave no clue how this could even happen but it does . Now while I am there racking my brain my son comes ups and said dad do you have enough oil in it and I responded yes he said how do you know . So I pulled the dip stick out and guess what it looks like milk . So now I have coolant in my oil of my fresh rebuild and a motor that will run with fuel pump unplugged. I don’t get these new bikes . Ok so I know motor has to come back out torn back a part . Don’t know if it’s head , base gasket , water pump seal or oil seal letting water get into the engine . Any help guys would be great I am at my wits end with this .
 
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Old Oct 8, 2020 | 02:41 AM
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cracked head maybe? these bikes run hot and if the radiator gets even partly plugged they will over heat(at least my 2 800's did). i wonder if the computer is mapped correctly causing too much gas to be pumped in? just a thought.
 
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Old Oct 8, 2020 | 12:49 PM
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The cylinder heads is brand new , this was a complete fresh rebuild . It was only running for about 10 mins total on and off for maybe 2 mins at a time . Engine never got over heated but Onhave coolant in the oil
 
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Old Oct 8, 2020 | 12:50 PM
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I think I will take the ECU up to the shop and have it flashed to factory setting and try that when I get done redoing it
 
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Old Oct 8, 2020 | 07:30 PM
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Well I started to takes thing apart to redo the work and I came a crossed this whole taking off the water pump . Should I just replace this or the mechanical seal and the oil seal .


 
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Old Oct 11, 2020 | 04:15 AM
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well if you flash the ecu, at least you can rule that out. if the other seals look fine then why replace them, but your call. good luck. and thanks for posting discovery.
 
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