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Acts Like It's Hitting Rev Limiter at WOT? HELP

This is a discussion on Acts Like It's Hitting Rev Limiter at WOT? HELP within the RZR XP 900 forums, part of the General RZR category; Quote: Originally Posted by Fimea Quote: Originally Posted by AlbaNate Quote: Originally Posted by poflo Getting pretty common for the Castle Nut to back off ...


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  #16  
Old August 28th, 2012, 04:57 AM
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Re: Acts Like It's Hitting Rev Limiter at WOT? HELP

Quote: Originally Posted by Fimea View Post
Quote: Originally Posted by AlbaNate View Post
Quote: Originally Posted by poflo View Post
Getting pretty common for the Castle Nut to back off in the primary.......I have seen 4 already,including mine
Just had an XP4 do it on the dyno.

Nate
Alba Racing
I'm confused, are you guys referring to the spider jam nut, or the castle lock nut on the shift weights?
Spider jam nut
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  #17  
Old August 28th, 2012, 10:09 AM
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Re: Acts Like It's Hitting Rev Limiter at WOT? HELP

Quote: Originally Posted by HIGHOCTANE View Post
Quote: Originally Posted by Fimea View Post
Quote: Originally Posted by AlbaNate View Post

Just had an XP4 do it on the dyno.

Nate
Alba Racing
I'm confused, are you guys referring to the spider jam nut, or the castle lock nut on the shift weights?
Spider jam nut
Do you have to buy that tool from Polaris (PU-50578), or is there something else that will work? Since it gets torqued to 250lbs, it needs to be strong. When it backs off, does it come far enough off to allow the spider to come apart? I ask, because the manual says it's imperative to mark all the pieces before disassembly since its a balanced unit, and if it's not reinstalled correctly - the assembly MUST be replaced.

It's to bad Polaris doesn't take the 5 seconds to put a punch mark in the pieces so you can assemble it it the correct sequence.

The manual (pg 6.11) says "Using a permanant marker, mark the cover, spider, movable and stationary sheaves for reference, as the cast in X's may not have been in alignment before disassembly." I guess that's Polaris' way of saying our people are too careless to assemble it correctly, before it goes off to balancing? If it's so critical, why don't they do it right from the factory? You'd expect those X's to be there for a reason...

I guess anyone that ever changes their belt should take the time to mark the pieces so if somebody forgets, it's already done?

Last edited by Fimea; August 28th, 2012 at 10:12 AM. Reason: Typo
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  #18  
Old August 28th, 2012, 10:31 AM
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Re: Acts Like It's Hitting Rev Limiter at WOT? HELP

I had to order the tool. We have tried tightneing without it twice now and it just keeps coming off...

Nate
Alba Racing
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  #19  
Old August 28th, 2012, 02:09 PM
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Re: Acts Like It's Hitting Rev Limiter at WOT? HELP

Quote: Originally Posted by AlbaNate View Post
I had to order the tool. We have tried tightneing without it twice now and it just keeps coming off...

Nate
Alba Racing
SENT PM on the fix
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  #20  
Old August 29th, 2012, 01:10 PM
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Re: Acts Like It's Hitting Rev Limiter at WOT? HELP

Quote: Originally Posted by poflo View Post
Quote: Originally Posted by AlbaNate View Post
I had to order the tool. We have tried tightneing without it twice now and it just keeps coming off...

Nate
Alba Racing
SENT PM on the fix
Is it a good enough fix that it's worth sharing?
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  #21  
Old September 4th, 2012, 04:51 PM
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Re: Acts Like It's Hitting Rev Limiter at WOT? HELP

I guess not?
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  #22  
Old September 4th, 2012, 05:54 PM
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Re: Acts Like It's Hitting Rev Limiter at WOT? HELP

I'm curious about this also. Mine is doing the same thing
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  #23  
Old September 4th, 2012, 06:29 PM
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Re: Acts Like It's Hitting Rev Limiter at WOT? HELP

Well I took mine in for 19 hour service and told them all the things recommended on the forum. They found no water or no loose parts in the clutch. I drove it a few more times before taking it in to the dealer. I think it was water in the clutch cover that evaporated as I drove it.

The dealer found nothing wrong when they test drive it also. So who knows at this point. Taking it to the UP of Michigan for 4 days next week. We will see if it acts up then.
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  #24  
Old September 4th, 2012, 06:50 PM
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Re: Acts Like It's Hitting Rev Limiter at WOT? HELP

Just a little update… I called to see where the dealer was with the figuring out why it was hitting the rev limiter at 55. They told me there was nothing obvious they could see. They have a call in to Polaris on this issue and would let me know what direction they would go. I ask them about the “nut” backing off and they said it was tight. Now here we go…….. There are only two parts to this equation from the best I can tell. It is either the primary or the secondary clutch. For the price I paid, I think they should just replace either both or do a process of elimination to determine which one it failing. I am going to give them till the end of the week and then go pick it up and order a clutch kit for it and do it myself. This is sad to do but at this rate, it is un-telling when I will get it back. I will keep you all posted if any turn of events happen.
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  #25  
Old September 5th, 2012, 08:03 AM
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Re: Acts Like It's Hitting Rev Limiter at WOT? HELP

There's a possibility one of your rollers is sticking, or has a flat spot on it, not allowing your shift weights to move all the way out. Your shift weight might even have a rough spot on its back side, Be missing a piece of metal, or be missing one of its bushings. To raise engine RPMs, you need to lighten the shift weights, or keep them from fully extending. (as far as clutching is concerned).

If you pull your cover, then belt (note direction), then using a pry tool, gently spread the primary sheaves together, until you can put your finger in between the roller and shift weight, so you can manually spin the rollers.

Be careful to either use something to hold the sheave together, or make sure your pry tool is secure, so you don't get your finger caught in there. This tool will help:
UTV - Tools - Sheave Clamp Tool - Starting Line Products

Have you blown a belt, and not get all the debris out of the sheave? With the cover off, and the belt removed, start the engine and cycle the RPMs a few times so you can visually inspect that the sheaves are opening and closing properly. I recommend facial protection, because it has the possibility to fling debris out of the sheave with violent force due to the high RPM required to get the sheaves to open.

Here's a link for the spider nut socket:
UTV - Tools - Drive Clutch Spider Nut Tool - Starting Line Products

Good luck!

PS, don't lubricate any of the clutch pieces in a way that some of the lubricant could come into contact with the belt or sheave's belt contact area! Centrifugal force can/will fling stuff everywhere!!!
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  #26  
Old September 5th, 2012, 08:20 AM
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Re: Acts Like It's Hitting Rev Limiter at WOT? HELP

You can also remove the 6 primary cover bolts and then the movable sheave will slide freely...so you can check the rollers and weight ect with no need to pry on anything. Mark the cover relationship so you put it back on just as it came off.
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  #27  
Old September 5th, 2012, 08:54 AM
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Re: Acts Like It's Hitting Rev Limiter at WOT? HELP

Quote: Originally Posted by AlbaNate View Post
I had to order the tool. We have tried tightneing without it twice now and it just keeps coming off...

Nate
Alba Racing
Quote: Originally Posted by poflo View Post
Quote: Originally Posted by AlbaNate View Post
I had to order the tool. We have tried tightneing without it twice now and it just keeps coming off...

Nate
Alba Racing
SENT PM on the fix
I'd be interested to know Don, please send me a PM...

Thank you...
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  #28  
Old September 5th, 2012, 09:04 AM
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Re: Acts Like It's Hitting Rev Limiter at WOT? HELP

It sounds like a lean condition. Mine did the same The same thing. Power commander and auto tune fixed it right up. These machines are way lean from the factory for emissions.
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  #29  
Old September 7th, 2012, 12:27 PM
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Re: Acts Like It's Hitting Rev Limiter at WOT? HELP

Ok, I went and picked my 900 up today. I asked them what they found and the service manager said “ it had a bolt lose in the clutch.” So I ask what bolt it was and he said, it was not the spider nut but a nut that holds one of the rollers in. I ask him if test drove it and he said “yes”. Then he proceeded to tell me it only missed one time around 65mph after they tightened the bolt up (is this normal). He told me to “ride the fire out of it to check it out”. I could not test run the machine at the dealer and had to work tonight but I will take it for a test run in the morning. If it is still not right, I may order a clutch kit for it and put it in myself. I was just wondering if it would void the warranty further down the road. I got the extended warranty (five years) but it does me no good if they can’t fix it…..
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  #30  
Old September 7th, 2012, 12:37 PM
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Re: Acts Like It's Hitting Rev Limiter at WOT? HELP

Please keep us informed, I'm going to take mine apart tomorrow and I will let you know if I find anything also. Mine accelerates great but when I reach about 55mph the tach goes to 8450rpms and starts skipping it just started this two weeks ago. I noticed it after cleaning it up and driving it down the road to dry it off. Mine is definitely in the clutch. I have had it apart before when I installed the adjustable weights, I'm thinking one of the bolts that hold the arms on is loose also.
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