Sorry for the long post, but just trying to include as many details as I can...

2005 700xp EFI

Decided to run it a little this morning to see if the oil leak stops, and the machine started real hard, idled somewhat erratically, and seemed very underpowered. (I have only put about 30 mins on this machine since rebuilding it). I pulled it back in the shop and pulled the mag side spark plug wire off, couldnt get it to start. Put it back on and took the plug wire off the clutch side, started right up and sounded like it has the whole time. Pulled the the spark plugs. The mag side cylinder looked just fine and normal, looked down in the clutch side cylinder and the piston still looks brand new, and assembly oil still sitting in the little dish on top of the piston. Makes perfect sense..figured it probably didnt have any spark and after I switched the plugs, I'd be good to go.

But the spark looked good on both cylinders, put the plugs back in and ran it some more. Clutch side spark plug came out wet and smelled like gas. Wondered if it was an injector issue (was getting error code 51 and 52 yesterday), switched the injectors around to the opposite cylinders (and switched the connections of course), ran it a little more, pulled the plugs out again and the "bad" cylinder plug was bright white. Switched everything back to how it originally was and quit messing it with it for a while..

I'm also back to getting the 51 and 52 error codes again.

Any ideas? Whats my next step?

Should I test the coil? How do I do that?

Test the injectors? How do I do that?

Do a compression test?

 

Don't trust codes to be 100% accurate. I'd do a fuel pump pressure test before you do anything else. Should hold 39 psi +/- 3 psi. Also if it's been a while since you replaced the filter,you might look into that also.The manual has more tests along with electrical trouble shooting and checks.2005 Polaris Sportsman 700 EFI Service Manual PDF Download

 

Thanks for the reply OPT. I tested the fuel pressure and it held a steady 40 psi as I drove around.

I also replaced the fuel filter this afternoon before tested everything.

 

If you've gone through ALL the trouble shooting tests and checks in the manual for the efi and electrical system with no improvement,the most common problems on any efi machine was the sensor wiring and connectors. You can take a chance on either the tps or t-bap harness repair kit solving the problem. https://otbpowersports.com/product/t...epair-harness/ https://otbpowersports.com/product/t...epair-harness/ or let Digital Wrench help narrow down the problem for usually the cost of the two repair kits.

 

I started the machine and let it idle. Disconnected the wire harness for the clutch side injector, nothing changed. Plugged it back in and unplugged the mag side injector - died immediately.

Can you tell me what/where I need to check to pinpoint exactly where the problem is coming from? (This is the first EFI machine I've ever worked on and I'll be the first to admit that a lot of electrical stuff confuses me).

Should I check the voltage at the plug first? Any idea what it should read?

Thank you again for your help!

 

AGAIN look at the wiring diagram in the manual as it has important checks. Ohm the left and right injector wiring in their connectors.Both should show between 13.8-15.2 ohms. If this checks out,check that you have voltage on the opposing connector red/black wires that leads back into the harness. If one side doen't have power,check the splice connectors 1 and 2 as shown. Problem could be there.

 

Thank you again. I looked in the manual but I couldn't find the "checks" you are talking about.

It walks you through each individual step and what/where to check and what it should read?

 

Look at the wiring diagram as it shows the injectors and the ohm valves beside them.Plus it shows how the wiring is routed to the splice joint connectors.A lot of people over look info noted in the wiring diagram and just look through the text.

 

Will do! I'll report back when I do some more checking.

 

Sorry to be a pain, but I really can't find any electrical information on the injectors in my manual. In the fuel injection section, the only troubleshooting things I see are on pages 4.21 (blink codes) and 4.22 (general troubleshooting), and the only wiring diagram I see with the fuel injectors in it is the main schematic on page 11.1 and then again on 11.4, but they don't show any ohm or voltage readings. And it just says "refer to chapter 4 for diagnosing efi system".

Am I missing something??