So a little history... Took this into my dealer about 6 months ago for lacking power, it would only pull about 6400 rpms. They did some clutch work and told me it had sucked some dirt and needed a valve job, at this time no blue smoke they changed the oil and said to go ahead and use it because it still runs fine and your not gonna hurt anything else. Then about 200 miles later it started smoking horribly and before i got back home it spun a rod bearing.

So now i have pulled the motor and completly rebuilt it.. New pistons new rods all new bearings new crank, had the cylinders and head checked and adjusted the valves. Put it all back together and it runs great starts right up idles normal, no smoke but it still wont pull rpms, almost sounds a little doggy like the ignition timing is off but i have been told this is not adjustable? I found a spec for it in the service manual at 6 degrees btdc but nothing else on how or if its adjustable or setable by any means.


Im at a loss as to why it wont go past 62 or 6300 unless the dealer screwed up my clutches wich he is sure they are fine. Any and all ideas and input would be greatly appreciated as i have just spent about 1500 dollars on this thing and really cant afford to randomly throw parts at it.

 

Retired before I had any major problems on the 850,but did you have the computer reflashed either before or after repairs? Also don't know if this will help but have you had the clutch off and checked if it hit the limiter(think about 7200-7700 rpm? can't remember) OPT

 

No Have not had the computer reflashed. and i also have not had the clutch off, the dealer had just went through the clutches not to long ago maybe 200 miles but thats the direction im heading, going to pull the clutch cover and mark them to make sure getting full range of movement.

 

take the belt off and see what rpms it turns, that would tell if its clutching ormotor, Ive seen my 09-850 hit 8000 once in low, , never hit the rev limiter

 

Took the belt off and it will hit the rev limiter right away. with the belt on going down the road in low range it will shift all the way out with a little hesitation at about 6200 then after a few seconds it will take off. In high range it goes to somewhere between 62 and 64 and its only shifting about 3/4 of the way i held it wide open for about 1/2 mile and it never would climb past that point... Not much of a clutching guy so im still not sure what to do??

 

Check your clutch weights, the wrong ones may have been installed at the factory. Have dealer check your wet clutch, it may be worn or slipping, or wrong lubricant installed. Check fuel injector size, and timing, they may both be off, or injectors are stopped up.
Check spark plugs, wrong type may be installed, gap wrong, or faulty. Check spark strength, blue spark= Hot, Orange=weak, white=acceptable. If orange, check ignition system, it may be grounding on frame.

How is your fuel quality?. Do you run brand name, or whatever is cheaper?. Times are hard, fuel station may be adding water to fuel to stretch stock.

Check air filter and air box for cracks and leaks.

My guesses.

 

so after a little testing found the fuel pressure to be about 28 psi and the book spec is 43+-3 so its quite a ways out of spec. Hopefully this is the problem.. We took it all apart and found a matching pump at the auto parts store, problem is the spec on the pump is 80psi, im hoping that since there is a pressure regulator is the system that this pump will work.

 

It was the fuel pump. HOLY SH?T this thing hasnt ran this good in ALONG TIME!!!

 

Like the old saying: If it has wheels OR t*ts you'll have trouble with it! Sometimes the fix is 360 degrees from where you think the problem is located! Glad you found the problem! OPT