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Issues with DPS. Coupler failed. Advice welcome.

7.7K views 4 replies 3 participants last post by  styk  
#1 · (Edited)
This is my first post to this forum. I have a 2013 Commander 800 DPS. I am starting to have wear and tear issues and have found this forum to be helpful in the past so I thought I would join and ask for some advice. A few weeks back, I noticed my DPS steering was beginning to be sluggish. As if it was not responding at certain positions while turning like it was sticking somewhere. I road it for a few more hours and then my steering went out completely! Lucky it was at a slow speed and I was not hurt or killed. I see an impending lawsuit with this issue for sure. Eventually I have discovered that the coupling joint between the rack and pinion and the DPS unit had failed. The splines wore out and had slipped. So, I removed the rack and pinion and the DPS motor to get the coupling off. However, after I removed the rack and pinion but before removed the dps motor, I started the bike and noticed that the steering still had binding points in it. This did not make sense to me since there was no pressure from the rack and pinion on the motor. Regardless, I have to replace the coupler and I have ordered it but my question is, why would I still get this sluggish reaction from the DPS unit? When I removed it the motor would turn freely using my hand so there is no bearing issue. Could it need to be reset? Will it reset just by me disconnecting it from the electrical system when I removed it? Would like to hear suggestions. Thamks.
 
#3 ·
Thanks, however I don't believe the issue is with the rack and pinion since when you turn the steering wheel with the rack and pinion removed the steering still has dragging points in it. The drag seems to be being introduced by the DPS unit. The coupler definitely has to be replaced because it is completely stripped and I lost all steering. I could just spin the steering in circles with no control. Very scary. However, this coupler failure has caused something to go wrong with the DPS as its still sluggish even when jacked up on stand with tires and rack and pinion removed.
 
#4 ·
The servo motors work on magnets and the magnets break and fall loosely in the DPS units and they work randomly when the magnets line up by chance. My dealer has replaced a lot of DPS units already because of this.
I'm referring to the ATV DPS, but its likely the same on the UTV.
 
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