I am having intermittent issues with my new to me sled. It is an 800 EFI Mt Cat. Took it through the yard last week, started misfiring, then only firing on clutch side. Changed plugs, cleaned plug caps, wouldn't start, or even fire. Played with all the connections on the handlebars (I know Cat has had issues with kill switches) after about what felt like 300 pulls, it fired, then ran fine. Took it out yesterday, rode around the yard a bit, let of the throttle and it died, wouldn't start. played with the connections and eventually fired back up, ran fine. I have 2 thoughts, one, I installed a cord for my heated helmet, or I washed the sled when I picked it up and thinking there is some moisture somewhere. Thoughts???
'03 Cat 800 EFI??
- Thread starter maj16
- Start date
6mile
Member
Throttle safty switch is probbaly the issue. Look for the three wire connector that comes from the throttle side of the bars. Disconnect it and start the sled this will disable the push button engine stop and the throttle safty switch. you will know you got the right connector when the push button does not stop the engine. You will have to use the key switch to shut down the engine. If that cures the problem then you most likely will have to replace the bushings on the pin that holds the throttle lever to the block. This is a pretty common issue on this era of sleds. The bushing kit is under 10 dollars at the dealer.
What the dealer cant tell you. Follow the wires down from the kill switch . Do like 6mile says unplug the one that disables the kill switch. Once that is found bend it slightly and plug back together leaving the middle pole outside the connection. It will bypass the safety switch( known big problem) and kill switch on the bar will still work
6mile
Member
Tito, I was not going to go there, but seeing that you did, I ended up doing this as well on the trail. After replacing the bushings a couple of times I gave up because they did not last more than a season.
disclamer: If you chose to disable the TSS, it is your choice. I will bare no responsability should your sled decide to ghost ride off in to the sunset and smash in to the only tree with in 100 acers at 60+ mph. On that note get a teather switch and use it properly.
disclamer: If you chose to disable the TSS, it is your choice. I will bare no responsability should your sled decide to ghost ride off in to the sunset and smash in to the only tree with in 100 acers at 60+ mph. On that note get a teather switch and use it properly.