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600 sdi mystery


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#1 800_XRS

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Posted 18 April 2020 - 06:50 PM

Had a buddy come over with his 2006 mxz 600sdi. Sled has 9400miles. Good compression still. It died on his on his last trip in March. They replaced all 3 relays with new Panasonic relays. So a decent brand. This did not solve the issue. Today we pulled voltage regulator and cleaned up the ground since it was caked full of gunk. We also pulled the capacitor and cleaned the corrosion off of it also. Rechecked all grounds and connections. We have spark now and the sled will fire up and run for about 30 seconds and dies. Hooked the sleds up to buds and had a long list of codes. Here's what we do not get.

Codes thrown

P1678 relay 3 open

P0616 starter relay open or ground issue

These were both active for 255 counts

This sled is pull start only with the small 12v battery and capacitor. This sled has no proof of it having estart ever. No one understands why relay 3 has a fault code when there is no relay 3 in the fuse block and no wiring for it. It goes 1,2,4 for relays. When I went into the mpem coding the ecm was programmed for estart. The last code change in the ecm was in 2005 which makes me believe this sled never had a swapped mpem.

Back to the sled not staying running.
The battery is good. We swapped it with a brand new battery also to prove it. Both tested good. This did not solve the issue. Next step is a voltage regulator to replace or mpem. One of the codes solutions was a damaged ecm.
What do you guys think it could be? Did we missing something obvious here?

I've included a couple photos of we have from buds. Thanks
Woodsy
70421e6d17c96281138efd56869f8f43.jpg0439875a0192ea4e5fc6af5a5e604263.jpg758aae25b1133e597f7c0eb4aea9b9cd.jpgace784b2d8365d759c16578669c8ed4d.jpg

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#2 OnTheRidge1

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Posted 19 April 2020 - 07:00 AM

I wouldn’t be too concerned with the estart codes, it’s probably throwing those codes because the programming is there for it to work but the hardware isn’t, not a big deal. Gives you the ability to add estart without reprogramming, etc.. You said it will run now for 30 seconds then die, do you know for sure it’s losing spark or is it possibly losing fuel from a bad electric fuel pump? If you have inline spark testers and or a fuel pressure gauge that would definitely eliminate one or the other.

#3 Gordo427

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Posted 23 April 2020 - 07:58 PM

Also what’s your battery voltage before and after running. Good point to see if spark goes away and fuel pressure, are grounds good and been cleaned 30 amp fuse been checked 


Edited by Gordo427, 23 April 2020 - 07:58 PM.


#4 800_XRS

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Posted 18 June 2020 - 08:40 PM

Battery voltage stays roughly the same. Drops .01 per start.

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#5 RVJ

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Posted 18 June 2020 - 10:17 PM

You may have ruled this out all ready;

 

I had a 2006 GTX 600sdi that would just up and quit. I couldn't start it, but if I fooled around with it it seemed to eventually start for some unknown reason.  Had it in to the dealer a couple of times, they checked fuses and replaced relays, but of course it would always run perfectly at the dealer. Kept having the same problem so I researched the issue on line. I looked on line through a few threads and someone mentioned a 20 amp fuse that is right on the battery housing.  I think this fuse often gets overlooked since it isn't in the fuse box. Changed that it and never had a problem again. I spent over $600 at the dealer and then eventually fixed it myself with a cheap fuse!


Edited by RVJ, 18 June 2020 - 10:19 PM.


#6 MrGutz

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Posted 19 June 2020 - 10:18 AM

Fuel Pump.

Once it starts, start flipping the on\off switch on the handle bars, this will keep resetting the FP and it may stay running.

GutZ


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#7 800_XRS

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Posted 19 June 2020 - 10:22 AM

Since this is a buddies sled and he is about an hr away I haven't been up to work on it in a while. But he did make some progress. He put a new voltage regulator and stator in and it ran perfectly. Bad part was the flywheel magents flew off and took the stator out. So a new stator and flywheel is on order. I'll be running back up to see him and clear his codes in hopes this solves the issues. Thanks for the help

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#8 MrGutz

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Posted 19 June 2020 - 12:22 PM

So you have BUDS.... and you live where?

LOL

GutZ


It's not what you do, It's how you do it.... It's not what you've got, It's how you use it.





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