Rave Check Valves
Events - (Engine will reach maximum rpm only for a moment) The sled would pull well for 2-3 seconds, then rpms start drifting low forcing you to turn out.
1)Ensure that all rave check valves are phased in the proper direction.
2)Check valve leak test - Install test pump and pressure to 5psi. Valve should stand pressure. Install pump opposite side, pump, air should flow freely.
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800R Engine Detonation Level Detected - Too high - Code P-1326
Ski-Doo has made available to their dealer network a new software update for their 2009 Ski-Doo models fitted with the 800R engine package. Some units would go into a permanent limp-home mode (engine detonation level detected too high) that required a dealer to reset the mode.
If this should occur,(Code P-1326) an authorized Ski-Doo dealer can upload the new calibration into your machine. This calibration will still protect the engine from detonation and if needed it will limit the engine to limp home.
This new calibration allows the user to reset the limp-home by simply shutting the unit off and restart-it, instead of having to take it into the dealer to be reset with BUDS.
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Crankshaft Information
800R known for bad crankshaft wobble that contributes to excessive clutch wear and short belt life.
Get the clutch off the engine.
Get a dial indicator on the end of the crankshaft stub to check for crank end excessive runout. Crank taper may be out of spec and this will certainly cause excessive premature wear of new clutch components.
Put dial indicator 1/8 inch in from end of crank stub.
Maximum deflection PTO side is 0.06mm (.0024) engine type = ALL
I have had a customer who warantee a crank on an 08 and it took 4 crankshafts from BRP before a spec crank showed up - crank came in, checked runout,(.003+) sent it back Nuther crank come in, again (.003+) sent it back, nuther crank come in (.0025) sent it back. 4th crank come in and (.002) The 4th crank came with less than out of spec runout.
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Intermittent Electrical Fluctuations on XP's
We've had a few reports on fluctuations in electrical power on a few REV-XPTM model units. Dealers have reported finding the RD/BL wire contacting the frame in the area of the voltage regulator. The regulator and associated wiring can be found directly behind the chain-case and can be easily accessed by removing the after muffler.
Simply repair any damage to the wiring. DC voltage is supplied through the regulator originating from the stator and the entire system is dependant a constant supply. Regulator output can be tested at any available RD/BL wire found in the chaincase area. We recommend the B.U.D.S. diagnostic port.
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A- Contaminated Carburetors No. 2008-12
B- Kinked DPM Vent Hose
C-Corroded DPM solenoids 2009 model
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D- 800R rave valves. 2010 update
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Thermostat Installed Reverse in housing on 800R
A few 2009 models had overheat issues when the sled is run for the first time, found that the thermostat was installed backwards.
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TRA-7 Sliding sheave bushing clearance
The latest bushing material update SCP-500 is durable and wear resistant, best bushing to date. There are a few instances of "sticking" to where tight tolerances of the bushing to the fixed sheave when new. The sled may reveal high or erratic rpms upon full throttle application then rpms drift back to normal. The bushing clearance may be too tight. Hone bushing to clearance of .0025~.003" for smoothest clutch stroke action.
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FUEL CHOICE
Note E-10 fuel should not be equated with E-85 which contains 85% ethonol.
If E-85 is used it will cause engine starting difficulties and engine power fluctuations and even engine damage.
E-10 fuel = 10% ethonol, the BRP engine is designed to run with, use the highest octane available.
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Pulley alignment
REV XP chassis types please note the following specifications.
"Z" Distance 21.0mm .827 in.
"X" Offset 37.1 +- 0.5mm 1.461 +- .020 in
"X-Y" Difference 1.62mm 0.064 in.
Please note: Although these are the target specifications, pulley alignment is not adjustable. These dimensions are for reference only.
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After-Muffler Outlet Damage from Impacts
Don't overlook a basic inspection point when diagnosing the engine having low rpms when full throttle or engine does not have full power. Inspect exhaust after muffler outlet and confirm there is no damage to the roundness of outlet.
If outlet is obstructed by dent, then straighten and look inside to inspect for internal damage to the inner wall to further see if deeper obstruction.
Additional snow deflector BRP#502006935
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Binding of TRA lever pins
During break in period on TRA clutches it is possible for the mating surfaces of the clutch lever pins and bushings to collect build up debris from wearing system parts. Debris has a sticky gum feel to it and prevent the lever from moving freely on the axle.
Excessive debris can reveal fluctuating rpms from erratic shift character.
Also possible for build-up to occur later on as parts wear with more use.
Clean foreign debris build-up and always verify TRA lever retainer bolts are torqued to proper specs.
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Alignment changes after Break-in
Alignment changes after Break-in, Alignment changes after Break-in, Alignment changes after Break-in - The Y-X dimension will change after break in.
For proper alignment procedure refer to skidoo bulletin 2009-12.
The primary clutch fixed sheave crankshaft taper may not be pressed far enough into the clutch and can give a further-away relationship to the engine, which will change the X dimension and alignment. (like my personal 08 xp has this problem and solved with doodoctor floating secondary, my alignment was so bad it was 1.2mm out even after full shim kit behind the secondary shaft jackshaft bearing) If that measurement is in question then borrow or get another tra-7 primary clutch and put it on the engine to verify this measurement to eliminate the possibility of such an out of place event as I have experienced.
The engine back stop can move out over a 1/4 inch. The clutch alignment can be good at rest however under full load the torque would twist the engine out of parallel.
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New Clutch Alignment Bar
We are introducing a new Engine Alignment bar and Procedure for all REV-XP™, REV-XR™ and REV XU™
models on Service Bulletin 2009-12. This procedure is not found in the 2009 Shop Manual. The part number for the bar is P/N 529036157 and can be ordered through normal parts channels.
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Throttle Cable Adjustment
If you have changed your handlebar riser, confirm that the throttle cable is adjusted properly. I have had customers who run the 09xp clutch kit and could not get correct rpms at all even after emptying the flyweight pins. After much grief looking all over the sled at engine management and such, ended up taking the airbox off and running the throttle full open - notice that the throttle slides only going to about 3/4 open.
Have had 2 customers end up with this result so hope it is one of the details you check after you do a mod.
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Summit Rear Suspension
The Summit® suspension was design for maximum climbing ability, cornering and comfort. In order to achieve these criteria's the suspension was developed with a long rear suspension front arm that limits the skis lift effect and gives better stability while climbing. To maximize the suspension performance it is important to adjust it correctly according to the driver weight and the load carried.
Make sure to adjust the rear suspension spring pre-load according to the load carried (Driver with riding gear, jerry can, tunnel bag, ect.). Refer to Service bulletin 2009-7.
Compared to the REV® chassis the REV-XP™ rear mountain suspension was developed with a lower ride-height like many motocross or racing ATV's, it is important to understand that this lower ride-height is normal if the suspension is adjusted according to our specification.
The correct suspension adjustment on Summit® is measured between the spring and the rubber bumper on the rail. It should be 6" to 7" with rider and gear on the vehicle.
It is important to know that many suspension adjustments may affect the ride height.
First the ride height can only be measured on a flat surface like a garage floor. It should never be adjusted on the trail.
It is important to know that many suspension adjustments may affect the ride height. For example.
-Increased ski shock preload.
-Rear spring pre-load set too soft.
-To short of a limiter strap adjustment.
