Kitty took a dip
Aug 31, 2010 | 08:13 AM
#21
Pro Rider
Joined: Jul 2008
Posts: 258
Likes: 0
From: Minot ND.
Glad ro hear you Kitty survived no worse for wear! 
I've got an idea bout your stalling. Check the rubber boot between the EFI throttle body and the motor. There's a recall from AC concerning the "disintegration" of the boot itself due to bad clamps.
IF YOU HAVE 2 clamps....there's a good chance you boot is cracked thru or gone "spider-webbed" (my wifey's 550 did). If this is the case your sucking air, causing the miss/stalling....... and in the worst-case-senerio your sucking in dirt/debris/water into your motor. - DOUGH!!
AC's fix is a new boot and ONE LARGE BAND CLAMP.
It's listed for ONLY the 700 MUDPRO.....but it seems to expand to pretty much ALL EFI machines as it's the same set-up.
Hope this helps.
Here's the service bulletin:
I've got an idea bout your stalling. Check the rubber boot between the EFI throttle body and the motor. There's a recall from AC concerning the "disintegration" of the boot itself due to bad clamps.
IF YOU HAVE 2 clamps....there's a good chance you boot is cracked thru or gone "spider-webbed" (my wifey's 550 did). If this is the case your sucking air, causing the miss/stalling....... and in the worst-case-senerio your sucking in dirt/debris/water into your motor. - DOUGH!!
AC's fix is a new boot and ONE LARGE BAND CLAMP.
It's listed for ONLY the 700 MUDPRO.....but it seems to expand to pretty much ALL EFI machines as it's the same set-up.
Hope this helps.
Here's the service bulletin:
Aug 31, 2010 | 08:43 AM
#23
Extreme Pro Rider
God forbid he lets the polishing secret out!
God forbid he lets the polishing secret out!
Joined: Jul 2006
Posts: 11,805
Likes: 0
Aug 31, 2010 | 10:41 AM
#24
Weekend Warrior
Joined: Aug 2010
Posts: 12
Likes: 0
I've got an idea bout your stalling. Check the rubber boot between the EFI throttle body and the motor. There's a recall from AC concerning the "disintegration" of the boot itself due to bad clamps.
IF YOU HAVE 2 clamps....there's a good chance you boot is cracked thru or gone "spider-webbed" (my wifey's 550 did). If this is the case your sucking air, causing the miss/stalling....... and in the worst-case-senerio your sucking in dirt/debris/water into your motor. - DOUGH!!
AC's fix is a new boot and ONE LARGE BAND CLAMP.
It's listed for ONLY the 700 MUDPRO.....but it seems to expand to pretty much ALL EFI machines as it's the same set-up.
Hope this helps.
IF YOU HAVE 2 clamps....there's a good chance you boot is cracked thru or gone "spider-webbed" (my wifey's 550 did). If this is the case your sucking air, causing the miss/stalling....... and in the worst-case-senerio your sucking in dirt/debris/water into your motor. - DOUGH!!
AC's fix is a new boot and ONE LARGE BAND CLAMP.
It's listed for ONLY the 700 MUDPRO.....but it seems to expand to pretty much ALL EFI machines as it's the same set-up.
Hope this helps.
Thanks for the info on the boot/clamp! I'm going to contact the local AC dealer and find out how much this part comes with. I believe that aside from the gearing and factory snorkel kit, my machine is essentially the same so I will check it out. Even if mine is ok, this sounds like a good, proactive thing to do. Thanks again!!
Aug 31, 2010 | 10:43 AM
#25
Weekend Warrior
Joined: Aug 2010
Posts: 12
Likes: 0
Sep 1, 2010 | 03:27 AM
#26
Thread Starter
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Weekend Warrior
Joined: Apr 2010
Posts: 16
Likes: 0
Hello Everyone, finally have a few minutes to provide an update after a glorious week of vacation last week! Here's the lowdown on the repairs:
Removed clutch cover, cleaned with diesel, Removed both clutches, cleaned with diesel. Replaced clutch bearing. Intake/exhaust hoses removed and cleaned. Airbox cleaned. Air filter cleaned and re-oiled. Both diffs drained (no water got in them) and new gear oil put in. 8 oil changes (9 if you include the 5th one which was pure diesel... let machine turn over for 1 minute, obviously no spark plug action lol) and a new oil filter. Also found that at some point my drain bolt went AWOL so got that taken care of. No wonder the clutches/cover were dirty.
I'll note that after the first 2 oil changes, it was firing up and idling with no issues at all. Took it for a 30 mile test run, mostly trails but a few hundred feet of foot deep water as well. No issues. Took it out Sunday for a group ride... 70 miles. Had a few issues. Stalled several times when I came to a stop, backfired a few times, and several times very briefly (1 second) lost power but kicked right back in. I'm going to replace the fuel filter and spark plug (should have done that anyways) and throw some seafoam in the gas tank as well and do another test run. On the whole though, it performed very well considering... I even got the chance to play tow truck and pull 3 machines out of the mud on the group ride. Love the low end and pulling power of this machine!
Oh, and as far as electrical goes, everything appears to be 100%. Gauge pod working fine, fuse box was dry, all lights are dry (no condensation) and working... rad fan is working fine as well. HUGE thanks to cdn pete for his assistance in the tear down, fixing and clean up. And of course, thanks again to all of you for your input. The Cat Came Back!
Removed clutch cover, cleaned with diesel, Removed both clutches, cleaned with diesel. Replaced clutch bearing. Intake/exhaust hoses removed and cleaned. Airbox cleaned. Air filter cleaned and re-oiled. Both diffs drained (no water got in them) and new gear oil put in. 8 oil changes (9 if you include the 5th one which was pure diesel... let machine turn over for 1 minute, obviously no spark plug action lol) and a new oil filter. Also found that at some point my drain bolt went AWOL so got that taken care of. No wonder the clutches/cover were dirty.
I'll note that after the first 2 oil changes, it was firing up and idling with no issues at all. Took it for a 30 mile test run, mostly trails but a few hundred feet of foot deep water as well. No issues. Took it out Sunday for a group ride... 70 miles. Had a few issues. Stalled several times when I came to a stop, backfired a few times, and several times very briefly (1 second) lost power but kicked right back in. I'm going to replace the fuel filter and spark plug (should have done that anyways) and throw some seafoam in the gas tank as well and do another test run. On the whole though, it performed very well considering... I even got the chance to play tow truck and pull 3 machines out of the mud on the group ride. Love the low end and pulling power of this machine!
Oh, and as far as electrical goes, everything appears to be 100%. Gauge pod working fine, fuse box was dry, all lights are dry (no condensation) and working... rad fan is working fine as well. HUGE thanks to cdn pete for his assistance in the tear down, fixing and clean up. And of course, thanks again to all of you for your input. The Cat Came Back!
Sep 1, 2010 | 12:40 PM
#27
Weekend Warrior
Joined: Aug 2010
Posts: 12
Likes: 0
Hi Duke....got to stop meeting like this...No problem about repair ..love working on cats.You get to know your machine intimately . If you had a perfect machine you would be a "stranger" ...lol or only an operater to it....good idea about seafoam,you may have got h20 in gas tank.Maybe isopropyl?
I'm not sure the wife would think it's a good thing if I knew my machine "intimately" LOL! She just needs to be made to understand that it's a toy, and toys of this nature are going to break, whether by regular use or her husband's bad judgment is the question.
I was talking to a friend at his place the other night and he said do the seafoam. It will draw out the water and apparently will help with the injectors as well. Can't hurt, and it's only like $10. Also going to run over to Chabot's today and see if they have a fuel filter and maybe spark plug in stock. Not sure the local CA has the one required.
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