Question: - Egimotors
Contents
1. 20 dicembre Bollettino Tecnico Numero 20 12 2010 Numeri di serie Modeli A MOTOSLITTE 800 CFI TUTI I MODELLI 800 CFI CORSO TECNICO MOTSLITTA 800CFI E DISPONIBILE UN CORSO TECNICO IN LINGUA INGLESE DEDICATO ALLE MOTOSLITTE CON MOTORE 800 CFI DUE TEMPI QUESTA SPECIALE PUBBLICAZIONE E DEDICATA A CHI VOLESSE APPRENDERE FINO IN FONDO IL FUNZIONAMENTO DELLA PROPRIA MOTOSLITTA ED AI CONCESSIONARI PER COMPLETARE LA LORO FORMAZIONE TECNICA Egimotors srl Questa comunicazione riservata ai Concessionari Qualsiasi uso in parte o completo espressamente vietato Pagina 1 di 1 ore CLEANFIRE FUEL INJECTION Performance Diagnostics Guide Gp POLARIS Polaris Industries Inc Webcast Series Updated 12 7 2010 Performance Diagnostics Guide CI CLEANFIRE FUEL een INDUSTRIES CLEANFIRE Performance Diagnostic Guide ollect Customer and Service Information The Service Advisor should collect accurate and relevant information from the customer to assist the service technician with an accurate diagnosis and successful repair Collect the following Customer and Machine Information Vehicle Identification Number verify VIN on the machine Miles and or hours as applicable on the machine Description of concern fault in customers words Snow depth conditions when fault occurred Ambient Temperature when fault occurred Operating Altitude when fault oc2. JASO FD ISO EGD 2 stroke oil classifications Reduces deposit buildup on exhaust valves Pour Point VES GOLD PLUS exhibits a pour point of less than negative 60 degrees Celsius This insures superior and uniform oil delivery on cold start up a well as superior pour ability at very low temps Lubricity Index VES GOLD PLUS exhibits superior lubricating properties as opposed to the majority of aftermarket oils e Smoke VES GOLD PLUS is formulated to be extremely low smoke outperforming JASO criteria for low smoke two stroke oils by 5096 Cold Engine Starting Pull effort reduction VES GOLD PLUS is formulated with super synthetic base stocks that maintain good flow and exhibit no resistance to movement at temperatures well below 40 F G POLARIS INDUSTRIES Page 36 CLEANFIRE Performance Diagnostic Guide m spension and Chassis e nspect ski track alignment e nspect suspension wheels bearings and bushings for excess wear or binding e Verify if factory studded track is being used e Verify factory recommended final gear ratio elnspect jackshaft and driveshaft bearings for excess wear or binding e Verify brake caliper pads are not dragging Gp PGLARIS Page 37 INDUSTRIES INC CLEANFIRE Performance Diagnostic Guide Machine setup and calibration Verify required scheduled maintenance has been performed Inspect for modifications that can reduce performance Gather accurate and complete informat
3. Tamera es Ce CX BhwsTemenue E HN M VO Rjectorlgnition Supply Voltage 1 amp 7Volts m to 484 LW Yo FO Po Yo NM NE NY NN en pont DI Throttle Position X4 RM 4508 2E 3E ja G POLARIS INDUSTRIES INC Page 24 CLEANFIRE Performance Diagnostic Guide naust System continued e Inspect exhaust resonator for loose internal components e Service variable exhaust system components and verify operation of exhaust valves e Always replace exhaust valve base gasket whenever removed Gp POLARIS INDUSTRIES INC Page 25 CLEANFIRE Performance Diagnostic Guide e Correct TPS voltage provides easy startup and maintains engine idle RPM e Verify Throttle Position Sensor TPS voltage is within specifications e Perform Throttle Position Sensor adjustment procedure outlined in service manual or Digital Wrench Use Digital Wrench to set display TPS voltage since it displays the actual ECU values Verify warm engine idle RPM is within specifications 1700 200 RPM Verify throttle plates are ani opened with throttle lever GE POLARIS INDUSTRIES INC Page 26 CLEANFIRE Performance Diagnostic Guide gine Management System TPS continued New machine with no previous TPS adjustment e Verify TPS voltage with Digital Wrench e Verify TPS voltage is within specifications e f TPS voltage is within specification no further action
4. belt with 800 CFI machines e The 3211080 drive belt is narrower and has a 2 degree greater angle the which will adversely change the belt to sheave clearance Inspect clutch belt alignment center to center belt to sheave clearance and driven clutch float e Verify installed weights springs and helix are correct for application e Inspect and clean clutch crank taper Ne e Torque all clutch fasteners to specifications Ek A GE POLARIS INDUSTRIES INC Page 14 CLEANFIRE Performance Diagnostic Guide tch and Drive Belt Inspection and Service continued Engine Mounts and Torque Stop e Inspect engine mounts and torque stop clearance spec 0 010 0 030 0 25mm 0 75mm e 2010 Front PTO side engine mount hardware can be installed on 2008 2009 800 CFI Models Parts required to retrofit 2010 mount 1 1015891 plate nut front 1 7518753 bolt 1 5411685 rubber mount top 1 5411686 rubber mount bottom 4 7616637 rivet Front PTO side engine mount GE INDUSTRIES INC Page 15 CLEANFIRE Performance Diagnostic Guide ch and Drive Belt Inspection and Service continued Inspect the following clutch components Drive clutch sheaves for grooves or cracking Weight pockets for wear Drive and driven clutch rollers washer should be flush with roller Bushings in moveable sheave cover helix and weights Weights for grooves or ramp damage and verify they move
5. is required Data Item Value Units RPM 0 RPM Cylinder 1 MAG Knock Signal 0 0 Volts Cylinder 2 PTO Knock Signal 0 0 Volts Cylinder 1 MAG Ignition Timing 30 0 Deg BTDC Cylinder 2 PTO Ignition Timing 30 0 Deg BTDC MAG Cyl Crankcase Injection Time 4893 us MAG Cyl Port Injection Time m PTO Cyl Crankcase Injection Time 4893 us PTO Cyl Port Injection Time 0 us Injector Supply Voltage 11 360 Volts TPS Voltage 0 942 Volts TA LA 14 16 I I A IA IA 1 ESPEEBBSSSSE 009 200 CFIIO Switchback RMK Gp POLARIS INDUSTRIES INC Page 27 CLEANFIRE Performance Diagnostic Guide engine Management System TPS continued e TPS has not been previously adjusted e Verify TPS voltage with Digital Wrench e TPS voltage is outside of specification e Adjust air screw to bring TPS voltage into specification Throttle Body Air Screw Note Consult service manual INDUSTRIES INC Page 28 CLEANFIRE Performance Diagnostic Guide gine Management System TPS continued e TPS out of specifications and has been previously adjusted Perform TPS voltage adjustment procedure located in Digital Wrench Special Tests Menu or service manual Perform TPS Base Setting Procedure Always perform TPS adjustment with Temperature Barometric Air Pressure TBAP sensor connected Visually verify throttle plate synchronization Check throttle lever free play Check throttle lever and cable for bi
6. curred Gp PGLARIS Page 2 INDUSTRIES Inc CLEANFIRE Performance Diagnostic Guide ect Customer and Service Information continued Load carried on machine or being towed when fault occurs Frequency of fault occurrence intermittent or constant Warning lights or indicators illuminated check engine temperature detonation Engine RPM when fault occurred Machine speed when fault occurred Engine temperature at which fault occurs Throttle opening at which fault occurs Type of fuel being used fuel selector position Determine type of oil currently being used G POLARIS Page 3 INDUSTRIES INC CLEANFIRE Performance Diagnostic Guide LARIS CLEANFIRE FUEL INJECTION Performance Diagnostics Guide CLEANFIRE Performance Diagnostic Guide e CLEANFIRE FUEL INJECTION Performance Diagnostics Guide CLEANFIRE Performance Diagnostic Guide CA CLEANFIRE FUEL INJECTION Performance Diagnostics Guide CLEANFIRE Performance Diagnostic Guide Qe LARIS CLEANFIRE FUEL INJECTION Performance Diagnostics Guide M chine Maintenance History e Obtain maintenance history from customer e Consult periodic maintenance table in manual e Lack of required maintenance may be cause of performance issue 2010 2011 Pro Ride Rush Switchback RMK Service Manual CLEANFIRE Performance Diagnostic Guide Periodic Maintenance Table Drive Driven Clu
7. e 33 CLEANFIRE Performance Diagnostic Guide A e Vv l e S L q o VS engine Mechanical continued e Verify precision measurement tools are calibrated e Verify torque wrench accuracy and calibration e To avoid component distortion torque all engine fasteners to specifications e Cylinder inspection and honing procedure e Measure the bore 1 2 from the top of the cylinder in line with the piston pin and 90 to the pin to determine if the bore is out of round Material transfer Deep grooves Flaking FIGURE A FIGURE B FIGURE C GE POLARIS Page 34 INDUSTRIES INC CLEANFIRE Performance Diagnostic Guide sine Mechanical continued Cylinder inspection and measurement procedures eRefer to service manual for engine specifications Measure 800 piston 24 5 mm up from bottom of skirt e Measure installed ring gap from top and bottom of cylinder variation e between gaps indicates taper e Measure cylinder to piston clearance note measurement location on pistons cylinder measuring techniques and measurement tools Follow engine break in fuel oil premix requirements 40 1 Polaris Blue Semi Synthetic Piston Ring T pra 1 2 1 1 2 1 3cm 2 1 3cm Feeler Gauge 24 5 mm G POLARIS INDUSTRIES INC Page 35 CLEANFIRE Performance Diagnostic Guide e VES GOLD PLUS far exceeds the detergency low smoke lubricity and port blocking requirements of the
8. enance has been performed e Common maintenance items such as the drive belt exhaust valves fuel filter spark plugs and type of fuel used can reduce performance level Verify type of fuel in tank and the fuel selector position e Verify all applicable service or safety bulletins have been performed unit inquiry CH POLARIS Page 12 INDUSTRIES INC CLEANFIRE Performance Diagnostic Guide zital Wrench Diagnostics Utilize Digital Wrench to perform the following procedures Save a service report include VIN before starting any diagnostic procedures e Verify most recent up to date version of Digital Wrench is installed e Check for diagnostic trouble codes with Digital Wrench and utilize guided diagnostics procedure e Verify most recent flash file set is installed and injector color matches map file set e Compare engine management sensor values to known good data from saved service report s Note if sensor values are not correct verify connector terminal wiring integrity All wire terminals should be fully seated and not distorted G POLARIS INDUSTRIES INC Page 13 CLEANFIRE Performance Diagnostic Guide tch and Drive Belt Inspection and Service The PVT system transmits engine power to the track Clutch components that are damaged excessively worn or misadjusted can reduce performance e Inspect belt for excessive wear glazing or cord pop out e Polaris recommends using the 3211115
9. freely on pins Spring for distortion or breakage and measure free length Drive clutch spring should be replaced periodically Note Thrust washers not in alignment with roller indicates excessive roller bushing wear GE POLARIS Page 16 INDUSTRIES INC CLEANFIRE Performance Diagnostic Guide e Polaris recommends using the highest octane rating fuel available 91 93 e Fuel should not be stored in metal containers e Fuel used from storage containers should be poured through a screened funnel e Period use of Polaris Carbon Clean Plus PN 2871326 is recommended e Polaris Carbon Clean Plus is an excellent fuel stabilizer and removes unwanted carbon deposits from engine components and exhaust valves e Do not use fuel de icer with ethanol blended fuel Polaris Carbon Clean REGULAR MID GRADE PREMIUM PREMIUM Plus PN 2871326 Page 17 S POLARIS INDUSTRIES INC CLEANFIRE Performance Diagnostic Guide al System continued e Determine fuel ethanol content with volume test Oxygenated fuel contains alcohol or ether compounds Machines are calibrated for 91 Octane Oxygenated E 25 si 90 a 3 Fuel Sample i 9 10 9 m d mal EL wane LT i Alcohol TE Water li Zmlixture ethanol content test G POLARIS INDUSTRIES INC Page 18 CLEANFIRE Performance Diagnostic Guide System continued e dentify location of fuel selector wi
10. ion from the customer Utilize Polaris information resources including STOP Unit Inquiry Team Tips Service Manuals and training materials Complete all available diagnostic procedures as outlined in service manuals or Digital Wrench Consult a service manual for specifications repair and diagnostic procedure After using all available resources and you require additional diagnostic assistance use ASK Polaris to contact technical service G POLARIS Page 38 INDUSTRIES INC
11. nding by turning handlebars through full range of motion CH POLARIS Page 29 INDUSTRIES INC ngine Management System TPS continued CLEANFIRE Performance Diagnostic Guide TPS has been previously adjusted and throttle plates are out of synchronization TPS voltage adjustment procedure located in Digital Wrench Special Tests Menu or service manual Perform TPS Base Setting Procedure before attempting synchronization Perform Full Setting Procedure if TPS voltage is outside of specifications and the throttle plates are out of synchronization Always perform TPS adjustment with Temperature Barometric Air Pressure TBAP sensor connected Visually verify throttle plate synchronization Check throttle lever free play Check throttle lever and cable for binding by turning handlebars through full range of motion G POLARIS Page 30 INDUSTRIES INC CLEANFIRE Performance Diagnostic Guide ine Management System A broken modified or improperly mounted air box may cause detonation backfiring and high idle hang The engine management system cannot compensate for air box flow changes Verify air box boot integrity elnspect air box inlets for modifications or leaks 2007 2008 sealed two piece 2009 2010 sealed air box air box with air horn plate GS POLARIS INDUSTRIES INC Page 31 CLEANFIRE Performance Diagnostic Guide gine Cooling System A correctly functioning cooling system maintains op
12. res fuel resistor plug on machine e f unsure of fuel Octane Rating or Oxygenated Compound content UNPLUG the selector wire or install the 1096 ethanol 24 ohm fuel resistor fuel Octane R M 2 Fuel Resistor wires OOO Non oxygenated 91 or less 240 Un plugged Oxygenated Up to 10 87 89 91 240 Un plugged Non oxygenated 91 1600 Plugged in Factory Setting 7 4 4 H P i Y E Tf A a w Pn A gt n GE POLARIS INDUSTRIES INC Page 19 CLEANFIRE Performance Diagnostic Guide Handle the fuel injectors with extreme care during service procedures Inspect condition of green injector isolators and o rings prior to installation Thoroughly inspect the injector tip for damage Always replace a fuel injector that is damaged e Verify fuel filter is not restricted filter should be replaced initially at 1000 miles and every 2000 miles thereafter Arestricted filter can reduce fuel flow to the injectors which may result in serious engine damage e Verify fuel pressure holds 58 60 psi at all RPM s Note fuel pressure should drop slowly when pump is not running PU 43506 A GE POLARIS INDUSTRIES INC Page 20 CLEANFIRE Performance Diagnostic Guide e Verify spark plug cap retention with audible click e Verify spark plugs are correct for application e Do not use spark plugs with a threaded top terminal e Route and secure plug wires to reduce movement eRun engine to f
13. tch peT Engine ek Brake System Fuel System HERI S POLARIS INDUSTRIES INC Page 8 CLEANFIRE Performance Diagnostic Guide hine Maintenance H istory Periodic Maintenance Table a d Frequency Intervals continue Item 150 mi 500 mi 1000 mi 2000 mi Pre 240 km 800 km 1600 km 3200 km Season Dies ME EE d d CL Electrical System Runa Swath PeRewsedon 3 Tote Safety Swich Prefidemspecioo WwenSwkh Pefemsedon 1 Headighis Brake wht Tags PreRidemspecioo MawWunbwames Pefemsedon Perc Reverse System E _ Chassis Suspension Wmememn LU 1 3 L SupemonMom nBos PefeWsedon 1 steering Fasteners Linkage Handlebars Diveshat JackshatBeaings J foo Sees TT Dive Chan Tension TT Chamncase cessi Y 1 R n Track Alignment Track Tension od o dodo pon jog Rebuildable IFP Shocks High penormance shocks should have oil changed and recharged at the end of every riding season Rail Slide Condition OO 2010 2011 Pro Ride Bogie WheelCondtion FastenerBols 1 f 1 f Hood Seat Chassis Engine Compartment C e Rush Switchback RMK L Lubricate Inspect or Adjust R Replace C Clean Service Manual S POLARIS INDUSTRIES INC Page 9 CLEANFIRE Performance Diagnostic Guide Perform walk around inspection of machine with c
14. timum engine temperature eThermostat begins to open at 115 F 125 F 5 F 46 C 52 C eDo not operate machine without a thermostat eCoolant bypasses the heat exchangers with thermostat closed to speed warm up eEngine operation above 175 F 80 C the fuel and ignition timing adjusts to protect engine eHot lamp illuminates to alert the operator when overheat condition occurs eOperation with hot lamp flashing and engine misfiring can damage engine eEducate customer on use of ice scratches if equipped Engine Temperature Limit Modes HOT LAMP s MODEL THRESHOLD MODE Hot Lamp llluminates Hot Lamp ON idle 230 F 110 C WOT 185 F 85 C 600 800 PRO Ride Hot Lamp Flashes Hot Lamp RPM Misfire at FLASH Idle 239 F 115 C WOT 208 F 98 C Gp PGLARIS INDUSTRIES INC Page 32 CLEANFIRE Performance Diagnostic Guide ePerform engine compression test for extreme performance loss diagnosis Compression pressure will generally be 115 125psi on a broken in engine 800 CFI at sea level Always hold throttle wide open and pull recoil rope rapidly five times elnspect condition of piston skirts note sacrificial graphite coating ePistons are anodized underneath the graphite composite coating ePistons are packaged with a molybdenum based lubricant on the wrist pin bores and rings do not remove lubricant 800 CFI Pistons BE 4 dE x A Gp POLARIS INDUSTRIES INC Pag
15. ull operating temperature to avoid plug fouling Note Use only solid terminal spark plugs 2010 2011 Pro Ride Rush Switchback RMK INDUSTRIES INC Page 21 CLEANFIRE Performance Diagnostic Guide Severely worn spark plug cap Note Excessive wear on the spark plug terminal damaged terminal and carbon rubber from a loose plug cap Replace spark plug deposits Replace spark plug and and plug cap if this occurs plug cap if this occurs GE POLARIS Page 22 INDUSTRIES INC CLEANFIRE Performance Diagnostic Guide e Verify integrity of exhaust temperature sensor wiring and terminals e Apply anti seize to exhaust temperature sensor threads e Install single copper washer and torque exhaust temperature sensor to specifications 32 ft lbs 44Nm consult service manual e When servicing exhaust do not remove temperature sensor from pipe disconnect at connectors GE POLARIS INDUSTRIES INC Page 23 CLEANFIRE Performance Diagnostic Guide e Verify function of exhaust temperature sensor with Digital Wrench run engine at 3000 RPM 2Minutes e Perform exhaust temperature sensor resistance test 2 3MQ at 392 F 760 at 1652 F Note Do not test with temp sensor at room temperature Data Grid C POLARIS v Barometric Pressure 142ps HB Base Ignition Timing Cylinder 1 21 Deg BTDC EB Base Ignition Timing Cylinder 2 Deg BTDC a X Benen Voltage see To Ci Engine
16. ustomer Note any of the following e Mechanical or cosmetic damage e Performance accessories installed or recently removed e Modifications to chassis suspension G POLARIS INDUSTRIES INC Page 10 CLEANFIRE Performance Diagnostic Guide iachine Modifications Modifications including but not limited to the following may cause severe engine damage and void the limited warranty e Intake Systems Aftermarket Modified Airbox Reeds e Turbocharger e Nitrous Oxide Injection System e Engine Modifications Cylinder porting or altering compression ask customer e Exhaust Components Aftermarket Modified e Clutching modification except factory recommended for elevation recalibration e Track Final Gearing changes e Engine Controller Fuel Controller Modules e Not using Polaris VES Gold Plus Engine Oil e Fuels other than commercial 87 93 octane oxygenated non oxygenated unleaded Note Installing aftermarket parts that reduce the effectiveness of the emission system is a potential violation of the Clean Air Act Tampering with emission controls is prohibited by federal law Gp PGLARIS INDUSTRIES INC Page 11 CLEANFIRE Performance Diagnostic Guide 2rvice Inspection and Testing Technician e Perform a walk around inspection and note any damage or modification on machine e Verify customer concern with a test ride if local conditions allow e Consult service manual and verify all required scheduled maint
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