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Ongoing wire solving


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#1 cadenblazek

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Posted 21 July 2020 - 04:31 PM

Hey all,

2004 rev, previous owner cut up a bunch of wires. I will attach pictures of the wires I am trying to figure out as well as zoomed out pictures to identify their locations. To those who commented on my last post, you were a great help. Thank you! bb9ea96e68ab880b1f7246eeac5217ab.jpg
https://uploads.tapa...1e9b85c16.plist
723aa6d6b40e4b288aa535c3ddd29d9f.jpg
3f4081e42b90e59f08194e931fa92b6e.jpg
6c12bfcd50d9a7791ed65229784b912a.jpg


Sent from my iPhone using Tapatalkhttps://uploads.tapa...31b915aa4.plist

Edited by cadenblazek, 23 July 2020 - 08:55 PM.


#2 smurfy71

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Posted 21 July 2020 - 08:58 PM

Hey all,

2004 rev, previous owner cut up a bunch of wires. I will attach pictures of the wires I am trying to figure out as well as zoomed out pictures to identify their locations. To those who commented on my last post, you were a great help. Thank you! bb9ea96e68ab880b1f7246eeac5217ab.jpg
https://uploads.tapa...1e9b85c16.plist
723aa6d6b40e4b288aa535c3ddd29d9f.jpg
3f4081e42b90e59f08194e931fa92b6e.jpg
6c12bfcd50d9a7791ed65229784b912a.jpg


Sent from my iPhone using Tapatalk


The last pic, the 3 wire connector on each side is for a temp gauge and fuel gauge. Sleds are pre-wires for them but not all have them. Great power source for add ons at the dash.


Sent from the Island of Misfit Toys

2004 600HO SDI
2005 MXZ 500ss
94 MX 470

I have both the 2004 and 2005 service manuals in pdf, ask for a link if you need them.  No longer have the 2005, someone I gave the link to deleted it from my cloud drive, thanks.
Nun replacement (service bulletin)


#3 Daag44

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Posted 21 July 2020 - 09:03 PM

Second picture with 4 wires (white/green?, red/brown, red/blue, black), looks like it goes to the Configuration Harness. Click the link for a picture of this harness. The one on the left is for Manual Start, and the other on the right with a fuse is for Electric Start.

 

Does the white wire have a green stripe?


Air/Fuel Ratio for two and four strokes
Air/Fuel Ratio for 1200 with boost
Air/Fuel Ratio is measured through emissions
Wideband and EGT
Wideband readings of Air/Fuel Ratio on a two stroke
600 SDI MY2004 Lean/Hot spot running 6900-7000 rpm @ 40-45% Throttle Opening
800R Cranking Compression
800R Oil Injection / Premix combo
800R Turbo?
900 ACE Turbo - muffler turning red hot
1200 4-TEC Mapping
1200 4-TEC MY 2009 to 2011 Fuel Line issues that could cause a fire
Batteries
Belt Blowers: Overview of UPMICHIGANDER's experience
BUDS 3.3.0 won't connect to SDI
BUDS not connecting to HO or SDI - Try a CanDoo
CVT efficiency - BlueMax
Deep snow intake for XP chassis
Diagnoses
E-TEC 600HO Clutching
E-TEC Oil Pump
E-TEC Dial-A-Jet
E-TEC Engine Management
E-TEC Stator fault codes P1562 or P1563
E-TEC Capacitor Charge Hold Test and Residual Voltage Test
Fuel Issues: Could new Ester type oxygenated additives be deteriorating the Fuel Sender Grommet?
Fuel pump and regulator replacement for ACE, E-TEC and SDI
Gasoline quality and storage
Bad Gas for a Two Stroke - Is it a Myth ?
G4 Clutch Alignment, Engine Movement, Sheave Runout and Clutching
GNR CVT Alignment for the G4
Grip N Rip Clutch Alignment testing
G4 850 Throttle Jerkiness solved with clutching
G4 850 Snappy throttle/clutch engagement
G4 850 pDrive tech - A question of Engineering
G4 850 Tuned Pipe @ 12.6 lbs and Muffler @ 15.4 lbs vs 800R and 800RE muffler weight
Pictures - How to resize and upload to DooTalk
Pipe Pressure testing on a dyno
Pipe Pressure testing from LRD (#1) and (#2)
Pipe Pressure testing results from BRP
Oil versus Fuel consumption
Power at the Crankshaft vs Track - BlueMax
Power Curves: 600 HOE (E-TEC)
Power Curves: 600 vs 800 vs 850 vs 1000 vs 1200
Power Curves: 1000 vs 800 vs 600
Power curves: 800RE 2010.5 to 2016 vs 2016.5 850
Quebec/NY State border crossing
REV Gen1 Gauge Display stuck on "SCALE"
REV Gen1 Volt and Temp Gauge install
REV Gen1 electrical connectors for sensors and MPEM (Multi Purpose Engine Module)
Seafoam for E-TEC injectors
Shortblock or Rebuild?
Ski-Doo Snowmobile Tech Training
Stator testing for E-TEC using a T harness/Bridge
Stator testing for 1200 4-TEC
Stator replacement for a 1200 4-TEC
Suspension Adjustment
Triples - Coolant Pump Assembly
Y-Pipe bolts loosening fix


#4 cadenblazek

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Posted 23 July 2020 - 06:10 PM

Second picture with 4 wires (white/green?, red/brown, red/blue, black), looks like it goes to the Configuration Harness. Click the link for a picture of this harness. The one on the left is for Manual Start, and the other on the right with a fuse is for Electric Start.

Does the white wire have a green stripe?


It has what looks to be either purple or a faded black stripe


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#5 Daag44

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Posted 23 July 2020 - 06:44 PM

It has what looks to be either purple or a faded black stripe


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It would be so much easier if I had a Gen1 REV handy. It would take me 2 min to open the RH panel and find it. I don't keep any, they just come on for repairs and they go. But not all is lost. The faded black stripe was enough to send me in the right direction for the BUDS plug with a White/Grey wire.
 
The wires for the BUDS are White/Grey for the beeper/alarm, Red/Blue and Red/Brown for power to ECM and Accessories, and the Black for ground.


Edited by Daag44, 23 July 2020 - 07:32 PM.

Air/Fuel Ratio for two and four strokes
Air/Fuel Ratio for 1200 with boost
Air/Fuel Ratio is measured through emissions
Wideband and EGT
Wideband readings of Air/Fuel Ratio on a two stroke
600 SDI MY2004 Lean/Hot spot running 6900-7000 rpm @ 40-45% Throttle Opening
800R Cranking Compression
800R Oil Injection / Premix combo
800R Turbo?
900 ACE Turbo - muffler turning red hot
1200 4-TEC Mapping
1200 4-TEC MY 2009 to 2011 Fuel Line issues that could cause a fire
Batteries
Belt Blowers: Overview of UPMICHIGANDER's experience
BUDS 3.3.0 won't connect to SDI
BUDS not connecting to HO or SDI - Try a CanDoo
CVT efficiency - BlueMax
Deep snow intake for XP chassis
Diagnoses
E-TEC 600HO Clutching
E-TEC Oil Pump
E-TEC Dial-A-Jet
E-TEC Engine Management
E-TEC Stator fault codes P1562 or P1563
E-TEC Capacitor Charge Hold Test and Residual Voltage Test
Fuel Issues: Could new Ester type oxygenated additives be deteriorating the Fuel Sender Grommet?
Fuel pump and regulator replacement for ACE, E-TEC and SDI
Gasoline quality and storage
Bad Gas for a Two Stroke - Is it a Myth ?
G4 Clutch Alignment, Engine Movement, Sheave Runout and Clutching
GNR CVT Alignment for the G4
Grip N Rip Clutch Alignment testing
G4 850 Throttle Jerkiness solved with clutching
G4 850 Snappy throttle/clutch engagement
G4 850 pDrive tech - A question of Engineering
G4 850 Tuned Pipe @ 12.6 lbs and Muffler @ 15.4 lbs vs 800R and 800RE muffler weight
Pictures - How to resize and upload to DooTalk
Pipe Pressure testing on a dyno
Pipe Pressure testing from LRD (#1) and (#2)
Pipe Pressure testing results from BRP
Oil versus Fuel consumption
Power at the Crankshaft vs Track - BlueMax
Power Curves: 600 HOE (E-TEC)
Power Curves: 600 vs 800 vs 850 vs 1000 vs 1200
Power Curves: 1000 vs 800 vs 600
Power curves: 800RE 2010.5 to 2016 vs 2016.5 850
Quebec/NY State border crossing
REV Gen1 Gauge Display stuck on "SCALE"
REV Gen1 Volt and Temp Gauge install
REV Gen1 electrical connectors for sensors and MPEM (Multi Purpose Engine Module)
Seafoam for E-TEC injectors
Shortblock or Rebuild?
Ski-Doo Snowmobile Tech Training
Stator testing for E-TEC using a T harness/Bridge
Stator testing for 1200 4-TEC
Stator replacement for a 1200 4-TEC
Suspension Adjustment
Triples - Coolant Pump Assembly
Y-Pipe bolts loosening fix


#6 Daag44

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Posted 23 July 2020 - 07:30 PM

Fourth/last picture


The large black connector on the right of the picture connects to the Handlebar Harness.
- Any wire that feeds to the handlebars goes through this connector.
- The Handlebar Harness goes from this connector to the two handlebar connectors located on the center of the handlebar.
- This length of harness goes through constant twisting from turning the handlebars.

The two grey connectors in the center of the picture are obviously the headlights.
- The only common problem I see with those is one or more terminals work loose from the socket.
- A simple visual check while lightly/reasonably tugging on the wires is priceless.

The black connector on the left of the picture is the Right Hand portion of the Handlebar Harness that attaches to the center of the handlebar.
- This is the connector that feeds everything on the right hand side of the handlebar.
- This is also a handy connector to unplug to eliminate any possible problem from the Kill Switch.
- The Kill Switch from a Gen1 REV is one of the most common failure points, hence the old style that resurged in newer sled.
- So don't be too quick to put the Gen1 style back on your sled.
 
The Grip and Thumb warmers are the most common for electrical issues.
- The Grip warmers are at least twice as likely a problem than the Thumb, but the Thumb is still high on the list.
 
Control Block
- This is the main controls on the left hand side of the handlebar.
- The Hi/Low beam and Start/RER buttons are two possible problems.
 
In competition for the most common electrical problems:
- In no particular order
 
1. Grounds; 
2. Kill Switch;
3. Start/RER switch;
4. Hi/Low beam switch;
5. Grip/Thumb warmers;
6. Rear/Brake light harness that follows along the seat.
7. Headlight and grip/thumb terminals popping out of their connectors;

 
 
I will probably need to amend the list as this is off the top of my head from what comes to mind at this instant. The reason I mention everything in this reply is to give you some hints into re-wiring or restructuring the handlebar harness.
 
- I have a new thread going for Throttle fatigue.
- I need to look into the throttle of the G4 to see if it fits, because it is designed to flip forward as a finger trigger.
- The Kill Switch and Throttle Block are currently the two things I really want to change.
- The two possible switch/connection problems on the Control Block are easy enough to clean, and reliable enough for my liking.

Air/Fuel Ratio for two and four strokes
Air/Fuel Ratio for 1200 with boost
Air/Fuel Ratio is measured through emissions
Wideband and EGT
Wideband readings of Air/Fuel Ratio on a two stroke
600 SDI MY2004 Lean/Hot spot running 6900-7000 rpm @ 40-45% Throttle Opening
800R Cranking Compression
800R Oil Injection / Premix combo
800R Turbo?
900 ACE Turbo - muffler turning red hot
1200 4-TEC Mapping
1200 4-TEC MY 2009 to 2011 Fuel Line issues that could cause a fire
Batteries
Belt Blowers: Overview of UPMICHIGANDER's experience
BUDS 3.3.0 won't connect to SDI
BUDS not connecting to HO or SDI - Try a CanDoo
CVT efficiency - BlueMax
Deep snow intake for XP chassis
Diagnoses
E-TEC 600HO Clutching
E-TEC Oil Pump
E-TEC Dial-A-Jet
E-TEC Engine Management
E-TEC Stator fault codes P1562 or P1563
E-TEC Capacitor Charge Hold Test and Residual Voltage Test
Fuel Issues: Could new Ester type oxygenated additives be deteriorating the Fuel Sender Grommet?
Fuel pump and regulator replacement for ACE, E-TEC and SDI
Gasoline quality and storage
Bad Gas for a Two Stroke - Is it a Myth ?
G4 Clutch Alignment, Engine Movement, Sheave Runout and Clutching
GNR CVT Alignment for the G4
Grip N Rip Clutch Alignment testing
G4 850 Throttle Jerkiness solved with clutching
G4 850 Snappy throttle/clutch engagement
G4 850 pDrive tech - A question of Engineering
G4 850 Tuned Pipe @ 12.6 lbs and Muffler @ 15.4 lbs vs 800R and 800RE muffler weight
Pictures - How to resize and upload to DooTalk
Pipe Pressure testing on a dyno
Pipe Pressure testing from LRD (#1) and (#2)
Pipe Pressure testing results from BRP
Oil versus Fuel consumption
Power at the Crankshaft vs Track - BlueMax
Power Curves: 600 HOE (E-TEC)
Power Curves: 600 vs 800 vs 850 vs 1000 vs 1200
Power Curves: 1000 vs 800 vs 600
Power curves: 800RE 2010.5 to 2016 vs 2016.5 850
Quebec/NY State border crossing
REV Gen1 Gauge Display stuck on "SCALE"
REV Gen1 Volt and Temp Gauge install
REV Gen1 electrical connectors for sensors and MPEM (Multi Purpose Engine Module)
Seafoam for E-TEC injectors
Shortblock or Rebuild?
Ski-Doo Snowmobile Tech Training
Stator testing for E-TEC using a T harness/Bridge
Stator testing for 1200 4-TEC
Stator replacement for a 1200 4-TEC
Suspension Adjustment
Triples - Coolant Pump Assembly
Y-Pipe bolts loosening fix


#7 Daag44

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  • Sled:2007 1000 SDI

Posted 23 July 2020 - 08:11 PM

Third picture
 
The Black and Red plug is for Accessories.
- Note that I also use Accessories as a general term for anything that not related to keep the engine running, so lights, gauges, warmers and any 12V plug including the Visor.
- In this case I am referring to either the Visor or a common 12Vdc plug.


Air/Fuel Ratio for two and four strokes
Air/Fuel Ratio for 1200 with boost
Air/Fuel Ratio is measured through emissions
Wideband and EGT
Wideband readings of Air/Fuel Ratio on a two stroke
600 SDI MY2004 Lean/Hot spot running 6900-7000 rpm @ 40-45% Throttle Opening
800R Cranking Compression
800R Oil Injection / Premix combo
800R Turbo?
900 ACE Turbo - muffler turning red hot
1200 4-TEC Mapping
1200 4-TEC MY 2009 to 2011 Fuel Line issues that could cause a fire
Batteries
Belt Blowers: Overview of UPMICHIGANDER's experience
BUDS 3.3.0 won't connect to SDI
BUDS not connecting to HO or SDI - Try a CanDoo
CVT efficiency - BlueMax
Deep snow intake for XP chassis
Diagnoses
E-TEC 600HO Clutching
E-TEC Oil Pump
E-TEC Dial-A-Jet
E-TEC Engine Management
E-TEC Stator fault codes P1562 or P1563
E-TEC Capacitor Charge Hold Test and Residual Voltage Test
Fuel Issues: Could new Ester type oxygenated additives be deteriorating the Fuel Sender Grommet?
Fuel pump and regulator replacement for ACE, E-TEC and SDI
Gasoline quality and storage
Bad Gas for a Two Stroke - Is it a Myth ?
G4 Clutch Alignment, Engine Movement, Sheave Runout and Clutching
GNR CVT Alignment for the G4
Grip N Rip Clutch Alignment testing
G4 850 Throttle Jerkiness solved with clutching
G4 850 Snappy throttle/clutch engagement
G4 850 pDrive tech - A question of Engineering
G4 850 Tuned Pipe @ 12.6 lbs and Muffler @ 15.4 lbs vs 800R and 800RE muffler weight
Pictures - How to resize and upload to DooTalk
Pipe Pressure testing on a dyno
Pipe Pressure testing from LRD (#1) and (#2)
Pipe Pressure testing results from BRP
Oil versus Fuel consumption
Power at the Crankshaft vs Track - BlueMax
Power Curves: 600 HOE (E-TEC)
Power Curves: 600 vs 800 vs 850 vs 1000 vs 1200
Power Curves: 1000 vs 800 vs 600
Power curves: 800RE 2010.5 to 2016 vs 2016.5 850
Quebec/NY State border crossing
REV Gen1 Gauge Display stuck on "SCALE"
REV Gen1 Volt and Temp Gauge install
REV Gen1 electrical connectors for sensors and MPEM (Multi Purpose Engine Module)
Seafoam for E-TEC injectors
Shortblock or Rebuild?
Ski-Doo Snowmobile Tech Training
Stator testing for E-TEC using a T harness/Bridge
Stator testing for 1200 4-TEC
Stator replacement for a 1200 4-TEC
Suspension Adjustment
Triples - Coolant Pump Assembly
Y-Pipe bolts loosening fix


#8 cadenblazek

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Posted 23 July 2020 - 08:50 PM

It would be so much easier if I had a Gen1 REV handy. It would take me 2 min to open the RH panel and find it. I don't keep any, they just come on for repairs and they go. But not all is lost. The faded black stripe was enough to send me in the right direction for the BUDS plug with a White/Grey wire.

The wires for the BUDS are White/Grey for the beeper/alarm, Red/Blue and Red/Brown for power to ECM and Accessories, and the Black for ground.


Do you think the BUDS system was cut off? The sled still runs properly and won’t rev high with the key unplugged. I appreciate the quick reply, thank you


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#9 cadenblazek

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Posted 23 July 2020 - 08:53 PM

Fourth/last picture


The large black connector on the right of the picture connects to the Handlebar Harness.
- Any wire that feeds to the handlebars goes through this connector.
- The Handlebar Harness goes from this connector to the two handlebar connectors located on the center of the handlebar.
- This length of harness goes through constant twisting from turning the handlebars.

The two grey connectors in the center of the picture are obviously the headlights.
- The only common problem I see with those is one or more terminals work loose from the socket.
- A simple visual check while lightly/reasonably tugging on the wires is priceless.

The black connector on the left of the picture is the Right Hand portion of the Handlebar Harness that attaches to the center of the handlebar.
- This is the connector that feeds everything on the right hand side of the handlebar.
- This is also a handy connector to unplug to eliminate any possible problem from the Kill Switch.
- The Kill Switch from a Gen1 REV is one of the most common failure points, hence the old style that resurged in newer sled.
- So don't be too quick to put the Gen1 style back on your sled.

The Grip and Thumb warmers are the most common for electrical issues.
- The Grip warmers are at least twice as likely a problem than the Thumb, but the Thumb is still high on the list.

Control Block
- This is the main controls on the left hand side of the handlebar.
- The Hi/Low beam and Start/RER buttons are two possible problems.

In competition for the most common electrical problems:
- In no particular order

1. Grounds;
2. Kill Switch;
3. Start/RER switch;
4. Hi/Low beam switch;
5. Grip/Thumb warmers;
6. Rear/Brake light harness that follows along the seat.
7. Headlight and grip/thumb terminals popping out of their connectors;



I will probably need to amend the list as this is off the top of my head from what comes to mind at this instant. The reason I mention everything in this reply is to give you some hints into re-wiring or restructuring the handlebar harness.

- I have a new thread going for Throttle fatigue.
- I need to look into the throttle of the G4 to see if it fits, because it is designed to flip forward as a finger trigger.
- The Kill Switch and Throttle Block are currently the two things I really want to change.
- The two possible switch/connection problems on the Control Block are easy enough to clean, and reliable enough for my liking.


I appreciate the response. I have already purchased a thumb throttle and kill switch off of a 2014? Summit. Already have them attached to the bars just have to wire them in. Also purchases to grip heaters and headlight. Need to install a tail light and I am considering provendesign’s tail light. Mostly just confused about the 4 wire loom that’s cut up, I believe everyone here has helped me figure out most of the other wiring. Thank you


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#10 Daag44

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  • Location:South Shore, Quebec
  • Interests:1973 Olympic
  • Sled:2007 1000 SDI

Posted 24 July 2020 - 10:25 AM

Do you think the BUDS system was cut off? The sled still runs properly and won’t rev high with the key unplugged. I appreciate the quick reply, thank you


Sent from my iPhone using Tapatalk

I'm thinking only the connector for the BUDS port was cut off, but it won't affect how it's running. The thing is, if the engine doesn't engagement then you might need to get it connected to BUDS to program the key. The only reason I am saying <might need to> is that I don't know if the problem is the key itself, wrong key, or a problem with the DESS post.


Air/Fuel Ratio for two and four strokes
Air/Fuel Ratio for 1200 with boost
Air/Fuel Ratio is measured through emissions
Wideband and EGT
Wideband readings of Air/Fuel Ratio on a two stroke
600 SDI MY2004 Lean/Hot spot running 6900-7000 rpm @ 40-45% Throttle Opening
800R Cranking Compression
800R Oil Injection / Premix combo
800R Turbo?
900 ACE Turbo - muffler turning red hot
1200 4-TEC Mapping
1200 4-TEC MY 2009 to 2011 Fuel Line issues that could cause a fire
Batteries
Belt Blowers: Overview of UPMICHIGANDER's experience
BUDS 3.3.0 won't connect to SDI
BUDS not connecting to HO or SDI - Try a CanDoo
CVT efficiency - BlueMax
Deep snow intake for XP chassis
Diagnoses
E-TEC 600HO Clutching
E-TEC Oil Pump
E-TEC Dial-A-Jet
E-TEC Engine Management
E-TEC Stator fault codes P1562 or P1563
E-TEC Capacitor Charge Hold Test and Residual Voltage Test
Fuel Issues: Could new Ester type oxygenated additives be deteriorating the Fuel Sender Grommet?
Fuel pump and regulator replacement for ACE, E-TEC and SDI
Gasoline quality and storage
Bad Gas for a Two Stroke - Is it a Myth ?
G4 Clutch Alignment, Engine Movement, Sheave Runout and Clutching
GNR CVT Alignment for the G4
Grip N Rip Clutch Alignment testing
G4 850 Throttle Jerkiness solved with clutching
G4 850 Snappy throttle/clutch engagement
G4 850 pDrive tech - A question of Engineering
G4 850 Tuned Pipe @ 12.6 lbs and Muffler @ 15.4 lbs vs 800R and 800RE muffler weight
Pictures - How to resize and upload to DooTalk
Pipe Pressure testing on a dyno
Pipe Pressure testing from LRD (#1) and (#2)
Pipe Pressure testing results from BRP
Oil versus Fuel consumption
Power at the Crankshaft vs Track - BlueMax
Power Curves: 600 HOE (E-TEC)
Power Curves: 600 vs 800 vs 850 vs 1000 vs 1200
Power Curves: 1000 vs 800 vs 600
Power curves: 800RE 2010.5 to 2016 vs 2016.5 850
Quebec/NY State border crossing
REV Gen1 Gauge Display stuck on "SCALE"
REV Gen1 Volt and Temp Gauge install
REV Gen1 electrical connectors for sensors and MPEM (Multi Purpose Engine Module)
Seafoam for E-TEC injectors
Shortblock or Rebuild?
Ski-Doo Snowmobile Tech Training
Stator testing for E-TEC using a T harness/Bridge
Stator testing for 1200 4-TEC
Stator replacement for a 1200 4-TEC
Suspension Adjustment
Triples - Coolant Pump Assembly
Y-Pipe bolts loosening fix





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