[Meech86]

Hello everyone,

Now that I have gotten my fuel pump working and delivering fuel to the carbs, I am faced with new issues. The sled seemed to work well at my buddy's place but we only ran it in his backyard and didn't experience any bogging. I brought the sled up to the cottage and have been experiencing issues ever since. Elevation difference from my buddy's house and my cottage is roughly 300 feet, I'm not certain if this would affect anything in a major way.

When I first started it, it idled fine and seemed fine, i hopped on and gave it some throttle and it immediately started to bog hard, it would rev up and fall on it's face, on and off for a good period. It eventually cleared up and I was able to ride around. I decided to take it out onto the lake and could only reach a top speed of 40MPH at around 5500-6500 RPM if I can remember correctly. I pulled the plugs and they were a little wet but nothing crazy and had the appearance of coffee color.

I decided to jack the machine up and test it to see if it would run better without a load, sure enough there's hardly a bog and I can get it up to 70MPH no problem. I can probably get it to go faster but I was in the shed and there was quite a bit of smoke and noise..

A few things to note from what I can see on the machine.

• Exhaust gaskets at the manifold are leaking
• Carbs may be out of synch, I'm also uncertain if the choke is stuck open, closed or partially closed. I can only seem to hear one of them moving so I'll have to look into it
• 2 of the rollers on the primary clutch are rusted and I believe are stuck in place
• The belt seems to be fairly new and in really good shape
• The track needs to be changed

I will be running a compression test this week, synch the carbs and get a new set of exhaust gaskets. Is it possible that most of this issue is caused by the primary clutch?

 

[polaris754]

replace the plugs first

 

[whitexc]

Yes, the clutch will absolutely have an affect on rpms if not working as designed due to lack of maintenance.

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[Meech86]

replace the plugs first

The plugs are new from last year and it didn't run last year

Yes, the clutch will absolutely have an affect on rpms if not working as designed due to lack of maintenance.

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That's what I figured, I will pull the weights off, inspect and go through the rollers to clean them all up.

 

[polaris754]

but one could have fouled

 

[Meech86]

but one could have fouled

It's very possible, They all seemed to have great spark when I checked yesterday but I'll probably throw a new set in once I get the clutch organized, carbs synched and the new exhaust gaskets. I'll also run through the oil lines to make sure none are clogged

I also performed a compression test yesterday but on a cold engine and throttle closed ( I didn't know the engine needed to be warm and throttle open)... however I still received a reading of 105-110psi across all three cylinders.

 

[Meech86]

Are the buttons supposed to glide along the sides of the clutch or are they not meant to rub at all?

 

[whitexc]

They make contact and are the wear point.

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[Meech86]

They make contact and are the wear point.

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Excellent, thank you very much!

 

[polaris754]

cold or hot compression test should have throttle wfo

 

[Meech86]

cold or hot compression test should have throttle wfo

Thank you for the tip! I had a pretty bad exhaust leak on the center and mag side flanges

 

[Meech86]

Sorry to be asking another question, I received my exhaust gaskets for the section where the manifold meets the head and they are tapered on one side and flat on the other.

I imagine the flat side points towards the head and the tapered side points downstream?

This is the gasket in question. They only have the picture with the tapered side

https://fortnine.ca/en/winderosa-exhaust-gaskets

Thanks again

 

[whitexc]

Flat side to the head, correct.

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[Meech86]

Flat side to the head, correct.

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Thank you

 

[Meech86]

update
I have cleaned the heads/manifold and bolted everything back up as well as synchronized the carbs. Took it out for a rip today and she works as she should. This thing has more power than I thought!

I currently have the airbox off and it seems to run rich anyways (smells heavily of gas) I'll have to check the plugs, but it smells really strong.

Couple things I can do is turn the air screw out a little, it's currently turned out 1 full turn. I can also drop the clip down a notch on the needle, it's currently sitting on the second clip from the top.

If not, then I'll have to do some re-jetting. I was thinking of just throwing some cone air filters on the carbs (I call them air pods) since it's already running rich without the airbox in place. What are people's thoughts on this?

Cheers

Mitch

 

[Meech86]

Back with another update on this sled. I pulled the plugs and they were basically clean and wet. It was running really rich. I stated above that I would drop the clip on the needle jet however that would be incorrect. I brought it all the way to the top to lean out the mixture and turned the air screw out another quarter turn out.

I have added the bottom portion of the air box back on for testing purposes and the sled seems to work much better and smoother. I'll be adding the top portion of the air box tomorrow and take it for a good rip and check the plugs again.

My assumption is that it needs to be re-jetted anyways since I am running at the top notch of the needle jet.

I have decided to give this sled to my buddy I had split it with since I purchased a 09 Venture RS GT. Now I'm just getting it dialed in for him since he doesn't know much about working on engines.

 

[Meech86]

This sled puzzles me... I put the top portion of the air box back on and started her up this morning for a little test. I let it warm up for about 2 minutes and then just gave her to see if she would go. Well it bogged on me again, so i removed the top portion of the air box a tried again.. bogging some more. This sled is so inconsistent that its driving me crazy, does this thing have a cut off if it's it's not up to temp or something in that sort? It ran great the other day and was riding fine and today it's a different story.. It's a 97 680.

Edit: I took it out again at lunch and worked flawlessly for about 2 km's down the road.I turned around and 1/4 of the way back it died on me, turned it back on and then it was bogging most of the way back and at some points would pick-up power again... I'm really stumped here, there's only 87 octane in the tank at the moment but I do not believe it would give this kind of reaction if it indeed requires 91 octane.

 

[whitexc]

Spark issue as in something is getting hot and cutting out? Coil, stator, CDI?

Next time it dies pull the ugs quick and check for spark.

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[Meech86]

Spark issue as in something is getting hot and cutting out? Coil, stator, CDI?

Next time it dies pull the ugs quick and check for spark.

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The thing is that it starts up right away after. And when it cuts out if I let go of the throttle it'll idle no problem. Might have to go through the carbs once again.. 😮‍💨

 

[Meech86]

I may have found the issue! I was removing the air box and noticed the carb boots are crack and dry rotted. This is probably the reason behind my inconsistencies.