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Offline Ussnewco

Engine won't start after riding a while
« on: December 26, 2016, 12:39:18 PM »
Hi, everybody, back in September I bought 2 500HO's (orange and camo) and I've run into this problem a couple of times after riding for a while it wouldn't start back up. It turns over fine and no indication of it overheating , it sounds like it's not getting gas. I check it when we stop for gas on the way home and it starts right up, that's about an hour and a half from my ride site.the  only other problem I've had is once it started abdominal was idling high about 3700 rmp but that was on the first trip and hasn't happened since but the not starting has happened twice.  Anyone else have this problem or have ideas how to fix it?
Thank in advance
Tom Newcomb

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Offline Wheels

Re: Engine won't start after riding a while
« Reply #1 on: December 26, 2016, 07:49:51 PM »
Ok, we have found a solution (bandage fix) for this problem.
On a few (150 or so ) units there is some problem with the main-cable leaking/and diodes allowing reverse flow.
You can apply a jumper wire to the fuel pump relay to stop this problem. Basically a fused wire running directly from battery to the bottom power side of the fuel pump relay.
Sorry I don't have a photo of the harness we have made up, give me a couple days as I'm on the road.
In the mean time, if you in counter this problem, reset the ecu by unplugging the main cable from starter relay under the seat.
Count to ten reconnect and the bad boy should start, you may need some throttle finesse, If the injector has already filled the cylinder with fuel.

If it has Pistons or Tits you will encounter problems.

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Offline Wheels

Re: Engine won't start after riding a while
« Reply #2 on: December 26, 2016, 08:04:56 PM »
As for the high idle or ramping idle, we are still trying to over come this problem,
Customers and I have encountered the idle will climb to 3000+ to 4000+ rpm with no user input.
We have narrowed it down to a bad TPS angle in correspondence to the Fuel map.
A simple adjustment of the idle screw will not completely fix this problem as it changes the fuel map also,
What we have found that works is
1) Remap of ECU
2) Modification to the TPS housing to readjust the tps angle. -5' of angle.

Problem with Number 1 is the remapper tool is not in the hands of dealers, or even most countries.
Problem with number 2 is the method involves removal of the TPS, elongating the two bolt holes and re-positioning the TPS. IN the hands of the wrong person this will cost you a lot of money and time.
If it has Pistons or Tits you will encounter problems.

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Offline Ussnewco

Re: Engine won't start after riding a while
« Reply #3 on: December 26, 2016, 08:55:22 PM »
Wheels! thanks for info, that's really helpful especially how to fix it it on the fly if it happens again before I have the chance to apply the fix. your help is greatly appreciated.