Alright, its a 95 EXT580, carbed. Today, we ran about 150 miles. We ran to a place called the oasis (bar and grill type place) at lunch, went back out, sled ran fine for the first 50 miles or so of the trip. We get back on the trail after firing up (started no problems)

We got about 2 miles down the trail (We were running pretty hard). I pulled up to a stop sign, and noticed a slight bog, just figured it was loading up a bit. Well, part way down the trail, it started bogging, and I figured it was fouling a plug, so I get to the next intersection and the sled stalled. I figured that it had fouled a plug, so I jump off, buzz the plugs out, they look a little on the darker brown side, but not fouled. Anyways, I threw a new set in it just to be on the safe side. It fired right back up.

Well, we got going a little farther, and it started doing it again, so we stopped for about 15 minutes on the side of the trail. I pulled on it, and it fired right back up and ran like a raped ape for 20 miles or so, no problems what so ever. We get to the next intersection, and it was bogging again at about 1/4-3/4 throttle, but would clean out nicely at WOT, the same thing happened a few more times, 1/4-3/4 throttle bog, we'd stop, and it would run fine after that for a while.

Stopped at a buddies house for an hour or so, and went back out, the sled fired right back up and ran with no problems for 30 miles or so. Low and behold, it started acting up again, so I just busted off the trail and limped it home, running fine sometimes, and not fine other times. I got home and pulled the plugs, and they looked perfect.

It's very annoying when stuff like this happens when you are in the middle of a ride and your sled starts running crappy with all your buds.

I have no idea what's going on here, and I would appreciated any suggestions on where I should start looking, thanks a lot!

Hack Saw, I am running into the same problem with a 96 580 EXT EFI. Once it warms up it is dieing on me. I have been looking into some forums and found possible issues with the Kill Switch, have not given it a try yet. But if I do find a resolution I will let you know. Hopefully someone else has some good information for us though.

This may be a silly question but... are you running into any water on the trails?? Anything wet - mud, water, ect.?

Reason I ask is first ride of last year and our ride today there was a lot of water on the trails, if I hit a puddle wrong and get water in through the hood I get a nasy bog. So bad last year in fact we had to tow it to a local trail stop, but usually ideled ok. After it sat for about 30mins it ran like a banshee.

Today I got some water from a BIG water hole we ran into and it would bog anytime I ran over the rpms we were doing most of our riding at (about 6500 rpm, 35+ mph) Once it sat for awhile where we stopped it ran fine.

I beleive this is because the belt and/or the clutches are getting wet and the belt will start to slip and cause the motor to bog. (Possibly due to poor cowl design ) I dont know if this has anything to do with your problem or if I'm even correct in my reasoning. Anyone know?? I could use some reasurrance on my theory.

Ehh it might be the problem. I would thin kfouled plugs like i put in the other forum. But like u said i could be wrong also im jsut tryna put osme stuff out there to try and maybe help these guys out.

Mike81,

Sounds like you have a bad plug wire, when water gets on bad wires they short out and can cause all sorts of annoying things. When you get water on the belt and clutch it wil rev up and make a god awful chattering noise, not bog down. You can spray water all over the plug wires while it is runing, sometimes hard to hear the difference at idle though. If you look every bit of the wires and caps you should be able to see any problems, really examine them. If you don't find anything I would start looking at all the connectors on the harnesses, take them apart, clean, dielectric grease, make sure they all clip together all the way.


Hacksaw,

You problem sounds similat but I would start with the kill switch system. There are sensors on the side of the carbs that will shut off the ign if the slides stick open, major souce of issues IMO. If they are still active I would disconnect them and get the jumper to bypass them. If it still does it check all connectors. Not sure how to bypass the kill switch side of things on your specific sled, but you might even want to start with that. Just be carefull, since it is only doing it sometimes you will have to drive it a lot to make sure it is the problem, plenty of time for a throttle to stick or something and you won't be able to shut it off. I would personally start eliminating the possibility of a bad connection, then the carb sensors, then bypass the kill switches completely.

It could be the infamous Cat throttle safety switch. There is a three prong connector near the base of the handle bars and use the jumper that came in the tool kit to bypass the safety switch. If it works fine after that then you ned to replace the plastic washers on the throttle pivot pin. You will notice that the throttle pivot pin moves sideways when you first push on the throttle. If you hold the pin, to prevent it from moving, and push the throttle, with the engine idling, it will cut out before it reaches engagement RPM. Another source of the problem could be a poor connection in the spark plug cap. It could be a loose connection to the top of the plug, or it could be the cap to the plug wire connection. Screw the caps tighter onto the wires and see if that helps.

My thoughts are it has to be something electrical due to it only doing it when it was warmed up, or only under certain conditions.

After I get over this flu bug and can get it in the garage (HAH if i can get it in there with the jeep) i'm going to check all that stuff out. Thanks a bunch guys.