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Note to self: Do NOT drive Trail any distance on one cylinder!

7.1K views 25 replies 15 participants last post by  DeanTeck  
#1 ·
The wife and I went out for a ride the other night. I got about five miles or so away from the house and my Trail started running on one cylinder. We were all by ourselves, so I decided to limp it on home that way. It was slow but steady. As we approached our driveway we could smell melting plastic. When I shut if off and got out we found the exhaust looking like this:



My theory is the raw fuel from the cylinder that wasn't firing built up in the exhaust and started burning from the heat of the catalytic converter. I didn't want to do it, but I sprayed the exhaust with the garden hose to cool it off and stop the body from melting. The plastic was already oozing away when we stopped.

It turned out that they never screwed the spark plug wires down into the coils when they built it, and one of the wires fell out as we were riding. I'm kind of surprised that it hadn't happened before this. Fortunately it didn't do any other damage.

I thought I'd pass this along so that my fellow Trail owners can take a look at their plug wires and make sure they are firmly attached to the coils. In my case the wires were just slid into the fitting on the coil, and the rubber boot was all that was holding the wires in. For those unfamiliar, there is a sheet metal screw type thing in the bottom of the plug wire fitting on the coils, and the wire has to be threaded down onto that to hold it in place.

The next time you have the access cover off your machine you might want to give your plug wires a tug to make sure they are firmly attached to the coils.
 
#4 ·
DRock I don't know what kept it from burning to the ground.Brett you are one lucky dude.......Issues like this makes me wanna run without the inspection cover.
 
#3 ·
Sorry it happened to you and thanks for sharing. Its a common issue on this machine as is it popping off the plug itself.
 
#6 ·
Sorry it happened, and you are very lucky, go play the lottery!

It is a very cool picture though!
 
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#8 ·
That's a mess alright, but a tell tale photo! We have good reason to buy an aftermarket exhaust now as they have no catalyst to run out of control. Thats like a reactor meltdown in SxS form. Good luck with the repairs and glad it wasn't worse for both of you!!!
 
#10 ·
Punch out the cat.
 
#14 ·
O man thats no good...glad thats all that happened...did it get the taillight harness or backside of the light? I thought the rzrs were the only ones that you were supposed roast marshmellos on lol
 
#15 ·
holysh.t !? :- () how did you realize- running only 1 cylinder!?? vibration, sound??

-i like the trail- but this modern things are so f.ckin fragile its horrible- we all had cars running not perfect- never had to be afraid to burn them down !?? ;- ()
 
#16 · (Edited)
JGreen - nothing but cosmetic damage. I was pleasantly surprised by that one! Actually, once I trimmed away the melted plastic you can barely tell that anything happened. But if I would have had to drive it one mile further.....

izom - it wasn't hard to tell, it only has half as much power on one cylinder as it does with two... LOL! Seriously, it was really running rough. It was pretty obvious.

The good news is we rode all day yesterday and it ran perfect all day long.

I'm looking at the D & D QT muffler as a way to get rid of the cat and gain some performance too. Anyone know anything about those?
 
#20 ·
JGreen - nothing but cosmetic damage. I was pleasantly surprised by that one! Actually, once I trimmed away the melted plastic you can barely tell that anything happened. But if I would have had to drive it one mile further.....izom - it wasn't hard to tell, it only has half as much power on one cylinder as it does with two... LOL! Seriously, it was really running rough. It was pretty obvious.The good news is we rode all day yesterday and it ran perfect all day long.
I'm looking at the D & D QT muffler as a way to get rid of the cat and gain some performance too. Anyone know anything about those?
had the d&d qt on our first trail...cooled things down with a great sound...just a lil' louder than i cared for so went another route (see signature below)...just get rid of the oem or gut it out sooner than later...
 
#18 ·
I'm still thinking just how hot that had to be.....
 
#19 ·
There was a guy on the Facebook group who's exhaust was cherry red on the inside if you looked in the tip, also from running on one cylinder, but holy crap I've never seen something like that! When did you realize it was melting? Start to stink? Extremely lucky nothing worse happened. Stuff like this is why I'm happy I got the extended warranty. It'll be on the credit card for another 6 months haha but peace of mind.
 
#21 ·
DeanTech - So the EZRYde is quieter than the D & D QT? Is there a significant difference, or is it barely noticeable? A local dealer can get me a D & D, that's why I ask how much difference there is. How about performance? It's not a big priority to me (the stock setup has all the power I need), but I'm curious as to what your opinion is as to performance between the two. Thanks for the info!
 
#22 ·
DeanTeck - So the EZRYde is quieter than the D & D QT? Is there a significant difference, or is it barely noticeable? A local dealer can get me a D & D, that's why I ask how much difference there is. How about performance? It's not a big priority to me (the stock setup has all the power I need), but I'm curious as to what your opinion is as to performance between the two. Thanks for the info!
like both the d&d and the ezryde...don't have any sound meter proof of the db levels of each but i felt the ezryde to be a quieter exhaust...one thing i didn't care for was the yellowing of the chrome pipe on the d&d...both units worked as far as a cooler running exhaust than the oem heat retainer...with the oem we had melting on the cargo box to the right of the spark plug access panel over the heat shield/header area and later on the passenger side firewall that the dealer found replacing the firewall for the new owner with the 2016 version firewall...the rig ran great with both but i'm not a heavy foot top end guy so i couldn't really attest to one over the other...
 
#23 ·
I'm glad to hear that and glad to hear that there is not one less AC on the trail sry I can't help you with the exhaust either but I like mine loud and couldn't be happier with my yosh on my fullsize
 
#24 ·
If you replace the bed, you can get the updated part number 7506-696. The bed is about $75, the rear fascia (4406-264) that holds the taillight is $25, and if you need a taillight (0509-074) is around $45.
 
#25 · (Edited)
Thanks again DeanTech for that info. My hot rodding days are behind me too. I rarely run mine at even half-throttle, let alone wide open! As long as the exhaust volume is acceptable from idle to half throttle I'd be covered at least 95% of the time.

I live in an area where I'm fortunate enough to have private landowners around me that allow us to ride on their land. We take some fabulous rides right from my front yard. That's why I want an aftermarket muffler that's quiet - I don't want to be the asshole that pisses the landowners off and not let us ride on them any more! I probably shouldn't the use foul language on here, but this is a real sore spot with me! I see D & D is offering a 10% discount to Wildcat Forum members through the end of June (I found that on another thread here), but with me living in NY the sales tax pretty much cancels the discount out.

Decisions... decisions....
 
#26 ·
Thanks again DeanTech for that info. My hot rodding days are behind me too. I rarely run mine at even half-throttle, let alone wide open! As long as the exhaust volume is acceptable from idle to half throttle I'd be covered at least 95% of the time.
I live in an area where I'm fortunate enough to have private landowners around me that allow us to ride on their land. We take some fabulous rides right from my front yard. That's why I want an aftermarket muffler that's quiet - I don't want to be the asshole that pisses the landowners off and not let us ride on them any more! I probably shouldn't the use foul language on here, but this is a real sore spot with me! I see D & D is offering a 10% discount to Wildcat Forum members through the end of June (I found that on another thread here), but with me living in NY the sales tax pretty much cancels the discount out.
Decisions... decisions....
don't know what happened w/ezryde but they were suppose to become a vendor on this forum...maybe hollywood could chime in as he had posted it...however, if you call them they were offering a 20% forum discount to forum members...last year they had a special and we only paid $209 and that included shipping...