Seems some are having problems with the belt tripping the limp-mode switch after putting on some miles on the 650.
This is a electrical problem not directly a belt problem. What is happening is some Cat 650s have triggered the sensor switch which engages the limp-mode while just criusing along with no-load on the engine.
AC has a fix & hopefully this will cure the problem.
Part # 0486-161, this is a Reset-Plug not a bypass plug.

 

Is this going to be a recall or just a fix for machines that have actually experienced it?

 

As far as I know it is not a recall. I have no idea how many 650s have suffered from this electrical limp-mode problem, must of been enough complaints for AC to come up with this solution.
I did 2 things, first I tried to order the jumpier wires part # 0486-144, in case I had to do a re-set of the limp mode while out riding I could.
The part # -144 is now updated to the Part# 0486-161.
If you are having this Electrical limp-mode problem now with your 650, then the warranty should cover this part.
I already had 1 limp-home mode happen, I do not want another one, I'll spend the $9.83 for the reset-plug.
Mine was mechanical due to a loose belt.
From what I gather, most of the 650s that are having this problem are the ones with mileage in the 450+ range & include both the LE & MRP Models.

This is a CAT issue not a Kawasaki Prairie problem.
I never had any problems with my limp-mode on my Prairie 650s & have heard nothing from all of the 650/700 Prairie owners out there that are having this happen.

** This Reset Plug is for a electrical problem with the limp-mode.**

Alpha-sports does carry this limp mode reset plug if you want to order it yourself instead of going thru your dealer..

 

Will leaving the reset plug in all the time cause any other problems, seems like it would try to reset every time you turn
on the key & confuse the ECM, possibly cause some damage or some other driveability concern???

 

The Reset plug can not be left in. Once you have a limp-mode lite flashing, then you install the reset plug & follow the instructions (4-Steps) to rest the limp-mode lite to off, then you must remove the reset plug.
Cat is working on the problem right now to fix this for good. So right now this reset -plug is just a Bandaid fix.

 

Easy as pie, 10 min. fix," don't leave home without it". Hope it doesn't happen again. Road tested O.K. I will not have to ride Timberwolf on Saturday's trailride after all. The Arctic Cat 650
service manual @ $22 is a good buy. Information gathered on this forum is very good indeed!
Jerico1

 

Fix for AC limp mode? I hope AC fixes it good. I have friends looking at Cats.

There is a run of early 03 Prairies that did this. It is caused by varying electrical conditions that are relatively normal to ATV's. Some people have fixed it by cleaning every connector and applying tune up grease (electrical paste stuff) to every plug. Also make absolutely sure the battery connectors are perfect.

Kawasaki made a change to the CDI and the prob is gone on late 03 Prairies and 04. It sounds like a similar prob is happeneing to the AC.

I am not sure if the plug for the CDI is the same as a Prairie. If you were desperate, you might try a Prairie CDI from an 04.

Also FYI:

02 650 CDI - has no limp mode. The plug is different. You would have to hard solder the CDI to your harness, might not be a good idea. But this problem would be a thing of the past. The only thing that slows an 02 650 is if the belt switch is flipped or the trans is in reverse. The CDI does not have a mode that needs to be reset. Once the belt switch is flipped back, full power is back.

KFX Vforce 700 CDI - no limp mode. The plug is different. You would have to hard solder the CDI to your harness, might not be a good idea. The 700 CDI has the advance your AC 650 needs for full power at low RPM and high RPM.

Dyna aftermarket CDI - no limp or reverese limiter. More advance than the Vforce CDI. Might actually fit your AC650 wiring harness. I'm not sure, but if I were to guess I would say the CDI for the 03,04 Prairie would fit.

 

I just picked up my new 650 today, and it came with the reset plug.

 

That is interesting that Cat is including the reset plug now with the purchase of the 650.
My dealer said on Saturday that Cat knows what the problem is, I ask him what, he said he didn't know.
The Service Repair Manual for the Cat 650 already has the reset plug # 0486-161 listed in the reset instructions & this reset plug can also be used at the magic 100 hour reset L/M. 4 steps & only 10 minutes for the reset.
Thanks Nyroc for the excellent information.

 

well guys ive had my le for a month now no sighn of limp mode i hear alot about this limp mode at 100 miles and now 100 hours i bought the reset conn from my dealer havent had to use it i just put a hl ign module in what a difference now it does powerwheelies with 28in tires and as far as belt slip the epi clutch kit will take care of that