800 wont idle but no engine codes
I had my 2011 sportsman 800 rebuilt for the second time 2 weeks ago and finally got it back. I went on Wednesday for a trail ride of about 90 miles. I went to St. Helen MI and rode from there to Roscommon and back, then to Rose City and back. I had enough time I thought what the heck I will ride to Houghton Lake and back and call it a day.
Well on the way back from Rose City the machine seemed to hickup a little at a couple stop signs but I thought well maybe I am just being paranoid because of all the problems I have had with this machine. Anyway I filled back up with gas in St. Helen at the trailer and took off towards Houghton Lake. At the first stop sign when I stopped it came back to idle and really started chugging and eventually stalled itself out. I restarted it and again it idled for a second then stalled itself out. No check engine light or anything. The next time I tried to restart it, it almost didnt want to go so I headed back to the trailer. Well as long as you are on the gas it is fine it just wont stay running unless you keep it over 2500 rpms.
I loaded it back up and headed home to Birch Run. By the time I got back the motor was cold so I tried to start it again on the trailer. It would roll over but literally would not start until I kept tapping the throttle then it would start. As soon as you let off the throttle it would stall immediately. Still no engine codes or check engine light. I took it back to the dealer immediately since it is still under the extended warranty.
Now I know a lot of guys would probably say its a sensor and I would agree but how come no codes or check engine lights? Back before the first top end rebuild it tried dying twice randomly in a row that day but came back on. No engine codes and no check engine light. The first time for the rebuild was a dead right cylinder that was believed to be due to cylinder wash out from too much fuel. Never did find a cause of it. The mechanic at that dealer said he found that the ECU was never grounded to the chasis.
The second rebuild was due to a bad rebuild the first time and that dealer didnt want to do anything about it just for me to keep adding oil to it. When I told the new dealer mechanic about all that had happened. He is feared that the ECU may not be functioning right. When I first got the machine it would barely idle and would stall unless it was warmed up, the cutting out randomly 2 times, the ground not being connected on the ECU, the cylinder washing out, now it wont idle again after 75 miles on new rebuild and just the general lack of any check engine lights or engine codes.
Do you think he may be on the right track? The only other thing I have done is after the 2nd rebuild I got it home and put my new QSC muffler on it. I was told by Adam and the paperwork that came with it that I didnt need a fuel controller. Like I said it never popped ever and when I got it home and it wouldnt start I pulled the plug on the right cylinder and it was tan so I really dont think that the muffler had anything to do with it. I was a little concerned that if it was too lean I may have burned to exhaust valves but I really dont think any of that happened.
I know he will check it out good and figure out what is wrong but what do you guys think?
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