95 ZRT 800 problems, electrical? help!~

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95 ZRT 800 problems, electrical? help!~

  • OK guys here we go. long winded but please help! ok i have this 95 ZRT 800 that i've been riding. its got 1200 miles on it and ran like a top until i went to michigan. it was in a nasty wet ice/sleet storm with no cover on it and ever since has not run right.  i put 60 miles on it and it ran sweet before the trip.

     

    the carbs have been gone through twice now. it has compression and spark, and the fuel pump works and primes easily still. however it will not run. when i start it, it will start on the second pull in the garage. it seems to struggle to idle and the second i touch the gas it dies. if i let it struggle to idle and touch the brake it dies as well, and the brake light does not light up. i checked all the grounds on the engine and chassis i could find and cleaned them all, they seem to be fine. it has spark, but it almost seems as if its too weak, or the timing is off, or something of that matter.

     

    the only wiring issues i can find with the sled are on the carbs. there are connectors coming from each carb to a connector on the harness, i have no idea what they are for. it has a cable choke and they are round slide carbs. the connector was twisted and two wires are showing bare. the center carb connector is corroded and doesnt look like it makes contact. so i guess my question is.... what do the wires going to the carbs do on these old dinosaurs? would it affect anything with the CDI box? i don't understand how it can have spark but no brake light, and hitting the brake makes the sled die. help!

    04 ZR900 sno-pro. 136'd set on asphalt. 10.85@116 current best.

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  • SOunds like you have an issue in your handlebar switches somewhere. I have also heard of shorted out hand warmers ect...causing this, An easy way to verify the problem is in your switches/handlebars is to unplug the 4 prong plug coming from your stator that contains the 2 yellow wires. Use a jumper wire and connect the 2 NON-yellow wires together. This completes the circuit on your ignition and you can start the sled up. Start it and see if it runs good now. If it does, then the 1st thing you need to do is bypass the TSS & kill switch. There is a 3 prong connector under the handlebars down the steering shaft just a bit @ about the point where your shroud is located that has your key switch on it. Unplug that 3 prong plug and use a jumper wire and connect the 2 outside connectors together. This completes the circuit (you have a closed loop system) and bypasses the TSS and kill switch. Start it up and try it again. If it still spits and sputters bypass the tether switch. Just take the wires off of the back of the tether and splice them together. Even if it ends up being shorted out hand warmers ect... you should bypass all 3 of these handlebar switches anyways because they are prone to failure. You now just use the key to shut it off. If you unplug the 4 prong connector with the 2 yellow wires and jump it like I mentioned before and it still runs like ***, then you have an issue with your stator, cdi, coils or possibly trigger assuming that there are no shorted wires anywhere. Try the bypassing instructions and report back.

    Wanted: Dead Arctic Cat Stators. All Types. PM Me.
  • ok going to try this tonight i'll report back. thanks for the input!

    04 ZR900 sno-pro. 136'd set on asphalt. 10.85@116 current best.

  • tried bypassing the 3 wire connector at the shroud. it has no spark that way. plug it back in and i have spark. i'm going to try at the stator. if it has spark, how can it be a switch?

    04 ZR900 sno-pro. 136'd set on asphalt. 10.85@116 current best.

  • little update. i tried the jumper at the stator. i had spark there, but it still wouldnt run for more than about ten seconds at a time. this is getting frustrating. it has fuel spark and compression. it will only fire about every tenth pull or so. if i let it sit for a long time and try again it will start and struggle to run and once i hit the gas it will die. anyone want a yard ornament?

    04 ZR900 sno-pro. 136'd set on asphalt. 10.85@116 current best.

  • Try this for an experiment, just because you think your getting gas doesn't mean your are for sure. I've had a weird problem like this before. 

    fill a squeeze bottle with gas.  squirt some gas in the carbs while wide open, release throttle, start sled, once the sled starts continue squirting gas into the carbs and see if the motor will continue to run. Report back

  • You need to see if it is a spark or fuel issue. As previously stated, put a little gas in the carbs or right down the cylinder and see if it fires right up. If you're not getting enough fuel it should start right up as long as you don't put too much in and flood it. If it still doesn't start very well and it may be even worse trying to start it, then you have a weak/intermitten spark issue. Did you measure the stator specs yet?

    Here are your specs:

    White to Green (Large Coil) 450 ohms White to Black (Coils in Series) 470 ohms Green to Black (Small Coil) 20-30 ohms

     

    and here is how to test it:

     http://www.youtube.com/watch?v=Uzz2NZiw3fk

     



    [edited by: Blaine at 6:04 AM (GMT -6) on Sat, Jan 09 2010]
    Wanted: Dead Arctic Cat Stators. All Types. PM Me.
  • i just had it running for a solid two minutes. any time i touch the gas it will die, and if i pull the brake lever it brings the idle down about 300 solid rpm. it seems like its a spark issue. the only bad wire on the whole sled is the connector for the center carb, which is corroded and broken. i read somewhere that it's a trigger wire for the CDI box? that can't be good.

     

    adding fuel used to be necessary to get the thing to start, like the fuel pump had to be primed or something. now adding gas does nothing. it runs the best when its half choked and quarter throttle, but it never seems to come alive. it must have a bad stator or something. i'll get an ohm meter and see if it's within spec

    04 ZR900 sno-pro. 136'd set on asphalt. 10.85@116 current best.

  • LittleboyBlueRoom

    i just had it running for a solid two minutes. any time i touch the gas it will die, and if i pull the brake lever it brings the idle down about 300 solid rpm. it seems like its a spark issue. the only bad wire on the whole sled is the connector for the center carb, which is corroded and broken. i read somewhere that it's a trigger wire for the CDI box? that can't be good.

     

    adding fuel used to be necessary to get the thing to start, like the fuel pump had to be primed or something. now adding gas does nothing. it runs the best when its half choked and quarter throttle, but it never seems to come alive. it must have a bad stator or something. i'll get an ohm meter and see if it's within spec

     

    Sounds like electrical. The trigger wire for the cdi goes to the stator housing above your flywheel. Any wires going to your carbs have to do with your TSS switch. If you have the TSS bypassed you don't have to worry about that wire. Check your stator and also check you coils by pulling out the plugs and pulling the sled over and checking to see if one plug has bright blue spark and the other 2 are yellow.

    Wanted: Dead Arctic Cat Stators. All Types. PM Me.
  • all the spark is blue and bright. the newest thing i noticed now is i can go out and start the sled in the garage, no choke, no throttle, and it will struggle to idle at about 400 rpm and it'll do that endlessly. any time i try to bring up the rpm it will die. seems like a weak stator or something maybe? can that happen?

    04 ZR900 sno-pro. 136'd set on asphalt. 10.85@116 current best.

  • Have you measured your stator ohms yet?

    Wanted: Dead Arctic Cat Stators. All Types. PM Me.
  • i just got an ohm meter. i'll report this evening with what i find. thanks for the advice so far!


    [edited by: LittleboyBlueRoom at 4:10 PM (GMT -6) on Mon, Jan 11 2010]

    04 ZR900 sno-pro. 136'd set on asphalt. 10.85@116 current best.

  • my stator wires are not green,black, and white.  it has two yellows, one black, and one white i believe. this is the four wire connector coming from the stator housing.

    04 ZR900 sno-pro. 136'd set on asphalt. 10.85@116 current best.

  • nevermind i was looking at the other connector coming from the stator.

    all the ohm readings check out for the stator. its got good spark from waht i can tell.

     

    i havent looked at the trigger for the stator, would it be possible that the sled won't run over 500 ish rpms because the pickup for the stator is corroded? it starts first pull and idles at like 500 rpm but any time i touch the gas it dies or bogs. fuel system is clean and seems to be fine. fuel pump is priming fuel. running out of things that could be wrong! oh and compression is 150 across the board.

    04 ZR900 sno-pro. 136'd set on asphalt. 10.85@116 current best.

  • one more update i have tried to get the trigger wire off the block where it mounts but the screws are rusty i can't get one of them off. tested it at the two wire connector it's showing 180 ohms is that the correct number?

    04 ZR900 sno-pro. 136'd set on asphalt. 10.85@116 current best.