H.O. Boy

I had the exact problem with my 670 H.O im not sure about the running wierd bit but when it went my handle grips got so hot that i couldent touch my bars and i lost all lights and gauges (besides the speedo)  it was my voltage regulator    swapped it out and it was fine   i got one off e-bay for 3 bucks plus a whole 2 dollars shipping

Well im not so sure on the ceramic coating but my buddies 01 mxz 800 had the same problem  and to weld it you either need a really weak welder or some good experiance it is very tricky business but it can be done     if it is just the end of the flange that needs some rebuilding then just go very easy and build many layers (considering the inside shape must stay the same)   a MIG works very well for it    if you've snapped it right off you might want to consider finding another Y pipe  cutting off the ends and trying to weld your new end on but for the 50 bucks your problly going to spend id say buy the new one and save some headaches

Oh  and btw what are you asking for your banshee???

H.O. Boy, Have you checked the choke cable to see if there is any slack.  When you say it runs good when it's really cold or after you put in new plugs I get the feeling she's running rich.  What would cause this?  Chokes not coming off when the lever is released or float level in the carbs set wrong.  When you say cuts in and out is it a shut down like electrical or stalling type bog from carburation.  Also if you have DPM you may be having trouble with one of the sensors.  They can be checked by a Ski Doo tech.  For now I would follow that choke cable from the dash right to the carbs and get a feel for whats happening when you play with the lever.   Hope this helps,  Kendo

good call but ive already been through the choke cable  i noticed on one of my last runs i could make it run a little tiny bit better at half choke   so i checked my cable and it was very tight much to tight so i loosened it with very little difference  i suppose it is possible i adjusted it too far or not far enough but theres about 1\4 inch slack in it now just so it does nothing at no choke and i think just enough at full     but at this point  i am leaning towards your idea of the DPM sensor because it is one of the only things i cant check myself  lol     so now that it is warm as could be here does anyone know the best way to keep a liquid cold while test running in the summer ??? will a garden hose on the exchanges do it ???   anyways that aside since i am officially out of snow too   does anyone know how this sled is as a mid summer water crosser with minimal setup ???

I have the updated recoil on on mine and the back is vented, wouldn't that let moisture in as well? If so, moisture hasn't affected mine.

i asked the same question at the dealer and they say that the hole doesnt let in any amount of moisture that would do any damage but my buddies recoil was really really loose and he wasent really keeping the sled dry lol im not sure how common of a problem this is but we are sure it was his another thing was just before it really fried he was having problems(intermittent spark ran like s***) and his d.e.s.s key light was always on i dont know if that will give you any insight but i wish you luck it was an uphill battle for us

The clutching is a possibility i know that they are not  lined up because after putter over 200km on it i discovered a motor mount compleatly spun 180 degrees hitting my steering arm after that i checked through and found the torque bolt (i cant remember the name lol) compleatly backed off i straightend the engine best i could with measurements off my buddies mxz 800  whoever had this sled before me had NO idea what they were doing ,as far as the plugs go it runs just a little lean on the mag side i was adding a little oil to every tank of gas when i was running but now i am parked becasue i have no ice or snow left      also     on my coolant res there are two nipples to put a hose onto one at the top and one at the botton the top is an overflow  whats the bottom one for???   oh well  lol  its going to be a "edit for bad language" to do this after it gets really warm so i would love to get it figured   no more Treasure bay runs this year !