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Old 10-03-2012, 07:45 AM   #1 (permalink)
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2003 REV 600 H.O.(What to look out for?)

Hi guy's ,I recieved my father's sled this spring ,he passed away last year.I know it will need a going over ,he rode it a couple of times in the past 3 years.The fuel will defently have to be drained & carbs gone through but is there anything for these first year REV's I should be looking for? Thanks.
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Old 10-03-2012, 08:29 AM   #2 (permalink)
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very sorry bout your father. mine passed
when i was 15yrs old, very rough!!

remove carbs and clean as well as draining
all fuel. dont skip the pilot jets!!!
does the sled have the beavertail? that
would be the first thing id change if it
were me, when backing up the flap acts
like a plow and track just spins.
whats the mileage? just askin.
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Old 10-03-2012, 08:59 AM   #3 (permalink)
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Make sure the nun isnt bent

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Old 10-03-2012, 09:31 AM   #4 (permalink)
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did your dad buy it new, or used? how was it ridden?
need more info bud. i also believe there was
a ring flaking problem with the 600s more than the 800s.
not to sure. but if you have any questions on carb removal
just ask, ive had mine off several times and will walk you
thru the process.
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Old 10-03-2012, 10:07 AM   #5 (permalink)
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There was a recall for rings on the 600s, other than that, they were very good.
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Old 10-04-2012, 06:14 AM   #6 (permalink)
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Also, I think the ring issue wasn't until 2004?
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Old 10-04-2012, 08:52 AM   #7 (permalink)
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Well... thanks for caring guys . I know the sled was purchased new from my dad's good friend ,what I know is that the ring issue was fixed back in 2004 ,the sled has approx. 2200 miles , a complete new tunnel to except the 136" track & rail extention .The sled was mostly used for transportaion back & forth to the last owners cabin across from my dad's lodge.
OH.. & I have rebuilt some ROTAX's in my day ,& they are still running to this day
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Old 10-15-2012, 08:17 AM   #8 (permalink)
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Well... decided to drain the tank on the 2003 Rev ,& pull the carbs also so I could remove the drain plugs on them. Some fine sediment was noticable in a small clear bowl that I had dumped the fuel in. Other than that the inside looked clean.Flat style carbs & heated ... different to me? ,never worked on those style before .In draining the tank lot more sediment & water ,so in getting rid of the old fuel, got rid of the other nasty stuff in there also
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Old 10-19-2012, 07:32 AM   #9 (permalink)
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I do have question ?,since I don't have the shop manual for it yet. Does the bolt that holds on the secondary clutch take a (loctight blue 242 )? Also the tourqe specs for that bolt?
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Old 10-30-2012, 07:00 AM   #10 (permalink)
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The snow did fall last week 10 to 12in. of white frozen H2O & no sled to ride! I tryed Sunday to get the REV going after the white stuff fell.Fueled it up with 91 oct ,scrubbed the sheves with some scotchbrite pad,put a new belt on ,& tryed to fire the thing up &....nothing not even a cough!
No fuel ,plugs were dry ,& has good spark . the fuel should of passed through the carbs by now after killing the battery & my arms. I'm wondering if the fuel pump is shot? There is no rebiuld kit for this pump that I've found outThe pump looks like a pain to get at ! I'm finding these REV's are not the easiest to work on! Is there anything I should be looking out for as to taking the pump out,so far it looks like I'll have to take the air box ,& carbs out again.Anything else in your guy's line of experiance on these REV's?
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Old 10-30-2012, 07:37 AM   #11 (permalink)
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i have the shop manual for my 04 rev, and
the fuel pump is a pain in the a$$ to get at!!
i havent heard of many pump failures? so make
sure the lines arent rotted to pump.

i havent used any locktight on my clutch
bolt. just torqued to doo specs.
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Old 10-31-2012, 07:24 AM   #12 (permalink)
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Oh joy... looks like I'll have to loosen off the tank , seat & part of that framing to the tunnel & pull it back a bit to get the air box out again. It has the tunnel extention with the cooler at the back running the coolant down the running boards,then the rubber hoses go between the tank & the air box! The new revalution in frustration!
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Old 10-31-2012, 08:29 AM   #13 (permalink)
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wow, im sure glad my 04 isnt like that. obv
it has the beaver tail??
all i have to remove is my secondary
clutch and airbox comes right out.
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Old 11-01-2012, 07:46 AM   #14 (permalink)
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I had a similar issue last year after putting my 2004 back together. I wasn't getting fuel to the carbs and it turned out to be a kinked fuel line.
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Old 11-01-2012, 08:34 AM   #15 (permalink)
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also i bypassed the carb heater hoses to
aid in removal of carbs. ive never used
that option anyhow. lol

but very easy to kink fuel lines
when installing carbs.
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Old 11-01-2012, 06:12 PM   #16 (permalink)
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Hope this weekend I can put this sled in a heated shop (brother) since I do not have one built yet.Shee's cold & windy where I live, & I'ed be a frozen robot by the time I get her apart & back together! Man... in rebuilding my Ultra & working on the Rev... time is just not on my side .
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Old 11-05-2012, 06:32 AM   #17 (permalink)
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Well...got to work on the 2003 Rev 600 HO this weekend. Pulled everything that had to come off to access the fuel pump,tore apart the fuel pump & seemed pretty clean,& the diaframe gasket ,spring & snap discs look all ok .Rubber gasket diaframe with spring has no pin hole ,or anything of the sort ? Put back together & hooked the pulse line ,fuel from tank & outlet to carbs ,but not hooked up to carbs for testing ,pulled it over about a dozen times still nothing. If I take the pulse line off the pump & suck & blow on that inlet manualy the fuel starts to flow through the clear line to the carbs.

The pulse line from the crank case seems not to have enough pressure?,but I can feel ever so slightly with my finger vac.& pressure with my finger . New pump is $112.00 plus tax.No rebuild kit avilable .I'm figuring there is another problem?Compression ,or maybe a crank seal ? At this point I'm open for advise form you guy's , thanks.
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Old 11-05-2012, 06:55 AM   #18 (permalink)
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Are the lines clamped?
Use a worm drive clamp to ensure a tight fit.
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Old 11-09-2012, 05:34 AM   #19 (permalink)
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I did have the pulse line clamped ,but not with a worm style, may try that?

When I did pull the sled over trying to get it to pump,noticed a slite cherping sound coming from inlet with carbs off. Is this the reeds making this sound?If I hold my hand over one of the carb boots it has suction & a back pressure ,pushing my hand away ever so slitely? Is there a chance the reeds may be damaged ,bent ,or cracked to let this pressue to escape ?The reeds are designed to let air in,but not let air out...right?
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Old 11-09-2012, 09:12 AM   #20 (permalink)
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That would be correct.
There should be minimal push back even at a slow roll over.
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'90 Wildcat Project in progress.

Vintage (sorta)
1980 Indy Trail 440 (for sale)
1980 AC Pantera (donor engine to the 90 wildcat)


http://www.dcdrifters.net/


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