[Dboy352]

Hello all, I’m new here and have issues lol. I have a 2010 Polaris Ranger 800 crew. Recently rebuilt the motor, original motor had a piston end up sideways inside the cylinder. Got another motor and made 1 out of 2. Replaced the exhaust manifold, spark plugs, all gaskets, impeller, tps, air intake sensor, crank sensor and I think that’s it. Before the old motor blew it had codes 27 and 41 present which is why I changed 2 of the sensors (but they weren’t oem replacements just Amazon ones with good ratings) before I go on and on about everything I’ll get to my point. The exhaust manifold is now glowing red hot after running for just a couple minutes. The glow seems to die down when giving it throttle though. This led me to thinking maybe the exhaust is clogged. Cut the muffler open and cleaned it out and braised it back together, pipes are clean as far as I can tell and still glows. Taking the muffler off it still glows red but takes longer to glow and doesn’t seem to glow as bright. Codes 27 and 41 are still showing, and being the glow seemed to die down some with throttle I was thinking the motor is running lean.
So I’m stuck at do I spend the $100 plus on a new air intake sensor and hope it works, new injectors (fuel pressure was within range at the rail) or an entirely new exhaust?

Any ideas or has anyone experienced anything like this? Thank you all in advance for any guidance. The pictures below are idle (first picture) and under load (second picture)

 

[larrygugliotta]

Appears to be Running very lean, pull the plugs to take a look at their condition. Fuel delivery issue or air intake leak ? Since motor was apart any possibility a timing issue?

 

[Dboy352]

Appears to be Running very lean, pull the plugs to take a look at their condition. Fuel delivery issue or air intake leak ? Since motor was apart any possibility a timing issue?

View attachment 30507

Honestly not sure, seems to run great sounds great and idles fine, both fuel injectors fire at the same time which I felt was odd but read it was normal for this motor. I will pull the plugs in the morning and see and also spray some break clean around and see if it changes the idle at all for an intake leak.

 

[Dboy352]

Appears to be Running very lean, pull the plugs to take a look at their condition. Fuel delivery issue or air intake leak ? Since motor was apart any possibility a timing issue?

View attachment 30507

So I pulled the plugs, one looked normal the other looked rich and was a little wet and smelled like gas. After I started it and sprayed some brake clean around I pulled them again. The one that was rich looked about the same but was no longer wet looking. This was the first time I started it in over a week as well. Also while it was running I sprayed brake clean around and didn’t notice a change in engine sound or rpm so I assume there is no intake leak. The pictures attached are from looking at the top of the motor, left spark plug, right spark plug after running, then right spark plug before running. No idea why it attached them in that order but the wet looking plug was before running lol.
I replaced the fuel injectors just to see if it helped. I will attach whatever I can after I test just waiting for my wife to get home to crank it while I look.

 

[Dboy352]

Here is a video of it running with me spraying brake clean. It held idle right around 1200 rpm the entire time.

March 17, 2023

youtube.com

 

[Dboy352]

Here is a link with the new fuel injectors. I’m not sure what it should look like but to my eye looks like the one on the far side which would be the left side of the motor looking from the top is not spraying enough.

March 17, 2023

youtube.com

 

[Dboy352]

And here is a video of it running with the new injectors. There is still a glow but not nearly as bad as it used to be. It is also idling higher in the mid 1300’s. When I gave it gas it also did not want to drop to idle at first and stayed somewhere around 2200 then dropped back down. I assume the old injectors weren’t spraying as much as the new injectors which to me would explain the higher idle now and the glow not being as bad. I set the tps with a multimeter so it should be where it needs to be but still shouldn’t idle this high I don’t think.
Again I’m not a mechanic I’m very new to this so any advice is much appreciated.

 

[larrygugliotta]

the one on the far side which would be the left side of the motor looking from the top is not spraying enough.

Spray pattern is not equal one is either too much of the other too little. Which cylinder and injector combo has the rich looking plug? can you swap injectors to see if the rich cylinder follows the injector? might tell you which new injector may be at fault. Not sure if both injectors share a common circuit from the ECU or if each injector has it's own firing pulse.