Help Ranger Dale!!! 08 RZR

grant22 · 2008-10-19 17:00:10

Obviously, anyone who can help, please do....not just Ranger Dale:)

Did a 100 mile ride today in AZ. Fair weather, some dust, new clean air filter. 32 hrs on the meter, so it's not the first rodeo for this RZR!

2/3's into the ride, the RZR stalls whenever I hit the breaks hard to slow down for something, or whenever I am on the brakes downhill. Then the exhaust pops once or twice.

When I go to start the RZR after these occurences, it won't! I have to start it while hitting the gas to get it to start and stay running.

Got home, swapped air filter for a clean one........problem not fixed
Polaris FMF pipe is blue in one large spot and the tip is jacked up (some spot welds gave up either from excessive heat or from vibrations).

Ran the trouble codes and "25" is the only one.........25 is not listed in my manual.

I have ran this RZR for 32 hours with an upgraded filter and pipe but NO fueler or clutch kit. Pipe has always been a little blue, but more so now. Do you think this is a lean condition? Is this the first time I'm having a problem because it was a 100 mile ride (compared to typical 40 mile rides)?

Please help

RANGERDALEXP · 2008-10-19 18:03:16

I am not sure why you are getting an invalid gear on the transmission code 25 but that is the first thing to check then I would Check your TPS setting on the throttle body, If the TPS sensor is sending incorrect voltage to the ECM it would cause a lean condition and shut the engine down, You really need to look into a injector control module do to the fact that you will have a lean condition with the pipe, running to lean will melt the engine down :!:, and the Polaris ECU only monitors the incoming air and has no idea what is coming out do to the fact there is no O2 sensor like what a car has, so if it is way to lean it has nothing to look at You need to check your Plugs and see how it is burning the fuel:?: :idea: , I will think on this a little more. :?:

grant22 · 2008-10-19 19:19:11

Have you heard of foam/oil filters causing this problem? I did some more research (turns out the 25 and my symptoms are un-related.......still not getting a "lean" code) and some people are getting similar/same symptoms due to their foam air filter oil seeping into the throttle body.

I'll look into this more tomorrow.

RANGERDALEXP · 2008-10-19 22:10:23

The sensor in the intake could cause a major problem and it is called a T-MAP sensor, if it gets contaminated with oil from the air intake it will give false readings to the computer, It monitors air intake temp and barometric pressure for altitude and tells how much fuel to provide the engine, It could cause problems if it gets oil in it, You need to remember that your ECM only monitors the intake for the fuel calculation as well the TBS sensor so what happens after it is not monitored and would not see a lean condition, if the intake says it is all good on its end, it passes the buck at that point with nothing watching the after math, The only way the engine knows there is a lean condition after the combustion system is the o2 sensor looking for what is coming out of the exhaust and it would not no a lean condition at this point without a o2 sensor, these ECU do not do that, they are not that smart, When you make intake and exhaust changes you need to do it the old way buy seeing what the plugs are doing or the new way use a gas analyzer to see how thing are burning, On any dirt bike if you put a exhaust on them you need to add more fuel for it by changing to a bigger jet size, that is what the fuel modules do, Your code 25 is a transmission input:invalid gear code and that needs to be looked at also, My guess at this point would be a faulty T-map sensor due to oil contamination from the air cleaner, But that is a guess not being there to look at it my self. :?: .

RANGERDALEXP · 2008-10-19 22:28:17

Remember The Polaris T-MAP sensors are not serviceable according to the service manual and at this point you are the first on the UTV sites I have heard of this problem, But have had this issue with cars that have had K&Ns installed I think you are on the right track on the oiled air filters :idea: .

grant22 · 2008-10-20 13:49:11

Hi Ranger Dale. I'm on my way to buy some Electrical component cleaner. Meanwhile, check this out:

Spark Plugs (look norm to me)

I found this while in there after I removed the bed (this may be normal though)

Here's the bluing on the silencer

I can't get the pics to work, so you should be able to copy and paste each one to your address bar.

RANGERDALEXP · 2008-10-20 14:39:22

The barbs are normal and the plugs beleave it or not are a little rich, Unburned gas could cause blueing in the silencer, Starting to look more like the T-bap/T-map sensor at this point. :?:

grant22 · 2008-10-20 15:09:44

I'm about to clean that now. Assuming my problem goes away, what do you suggest I do to keep this from happening again?

Should I put my stock pipe assembly back on until I buy a fueler?

Should I not use the oil type filters anymore? If I do keep using them, should I squirt some preventative Mass Air meter cleaner or Electronics cleaner in the throat each Air filter change?

Thx

RANGERDALEXP · 2008-10-20 15:53:41

Make sure you check you PM for the link i sent you :!: , It should help a lot and I would wait till you get the module before you make any mods even though you are showing a tiny bit rich on the plugs :?: , this could be false readings from the intake sensor :?: , I have pondered the K&N thing and they do flow more air and the filtration is not as good and in dusty environments could cause engine damage, That is why i do not use one at this time, If you do use the filter from K&N try to cut the amount of oil down till there is just enough to make the filter pink. and good luck

RANGERDALEXP · 2008-10-20 16:14:08

One last thing, I was looking at the ATV CONNECTIONS site and found that there is a connector issue for the T-BAP sensor with the wires breaking in the connector on the 800 engines :idea: .

grant22 · 2008-10-20 16:14:20

Yes, I got yur PM and it was very imformative. I'm still in the middle of the job. I'm currently repl. the spark plugs, cleaning all intake components (found lotsa dirt in there and that is just insane that a major manufacturer would allow this kind of BS!) and putting stock exhaust and stock airfilter back in.

Hopefully this solves it all!

While spraying TB cleaner up into the TB past the butterfly, it drained out with tons of dirt. There should be a recall on the intake system of these RZR's. I change my "Pure Polaris Tru-Flow" air filter after every ride. My Hose clamps were tight. And there's still dirt up in the TB....and of course in the motor?

That's just WRONG!

RANGERDALEXP · 2008-10-20 16:22:12

In 2009 they changed the way the intake system is set up and there is a class action lawsuit involving this problem, On this site we have talked a lot on this an do a search, That guy got a new engine because of it and i posted a phone number for the attorney for him. :x . here is the thread http://www.sidexsideforum.com/viewtopic.php?t=1085
http://www.sidexsideforum.com/viewtopic.php?t=1136

grant22 · 2008-10-20 17:21:18

Yes, I know of "madinidaho" and his jacked up motor. I will be calling the attorney regarding this (although I don't want to spend a bunch in attorney's fees). I also have known for a while that this intake thing has been a problem, I just thought mine was unaffected.

I live in an area where I can ride my RZR or KTM out the garage and spend a half day in the desert and be there within 5 minutes........what I'm saying is I use my stuff, alot! I want them to last....that's why I take really good care of my toys and that's why I've all my toys sell to my friends (they know how well I take care of my stuff, so they buy them up B4 I even get them onto Craigslist).

Good news! (though)

My RZR's intake is all cleaned out, new spark plugs, stock exhaust and A/F back on, and it stared right up w/o any problems. 1 Mile test ride, hit the brakes hard, etc.......it works ok and is now nice and quiet too! THANKS RANGER DALE!!!

RANGERDALEXP · 2008-10-20 19:15:59

When you started to talk about all the dirt that reminded me of the other problem and I really hate the fact that they would release something with out all the proper testing, You are right and that is not right for what they did, But I would like you to do a compression test to see how bad it is and check it with the manual settings I sent you when you have time and can you do a oil change to check for dirt contamination as well, That will tell all :?: . let me know what happens :?: .

#1 2008-10-19 17:00:10

Re: Help Ranger Dale!!! 08 RZR

#2 2008-10-19 18:03:16

Re: Help Ranger Dale!!! 08 RZR

#3 2008-10-19 19:19:11

Re: Help Ranger Dale!!! 08 RZR

#4 2008-10-19 22:10:23

Re: Help Ranger Dale!!! 08 RZR

#5 2008-10-19 22:28:17

Re: Help Ranger Dale!!! 08 RZR

#6 2008-10-20 13:49:11

Re: Help Ranger Dale!!! 08 RZR

#7 2008-10-20 14:39:22

Re: Help Ranger Dale!!! 08 RZR

#8 2008-10-20 15:09:44

Re: Help Ranger Dale!!! 08 RZR

#9 2008-10-20 15:53:41

Re: Help Ranger Dale!!! 08 RZR

#10 2008-10-20 16:14:08

Re: Help Ranger Dale!!! 08 RZR

#11 2008-10-20 16:14:20

Re: Help Ranger Dale!!! 08 RZR

#12 2008-10-20 16:22:12

Re: Help Ranger Dale!!! 08 RZR

#13 2008-10-20 17:21:18

Re: Help Ranger Dale!!! 08 RZR

#14 2008-10-20 19:15:59

Re: Help Ranger Dale!!! 08 RZR

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