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Old 02-05-2009, 10:15 AM   #1 (permalink)
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Exclamation 97 ZRT 600-No Spark

I just bought this zrt, so I know very little history on it(except the previous owner didn't take very good care of it, thankfully he only had it for about 2 yrs). Anyway he told me it always started hard when cold, but then ran fine. So I put new plugs in, and new gas, and after a lot of pulling got it started. It idled fine, but seemed to bog when the clutch started to engage...but if u let off the throttle, it would go back to idling fine. So anyway, I'm fairly new to snowmobile repairs, but I decided to start by cleaning the carbs. That went fine thanks to the step-by-step posted on this site! I also drained the gas tank completely, and cleaned the spider/fuel pump?? as there appeared to be some water in the carbs. Refilled the tank, etc.
However, when I tried to start it, I now have no Spark!! I'm at a loss for what to do, as there seemed to be no ignition issue before the carb cleaning. Everything on the sled is installed except the hood and the speedo cable...and I couldn't think of any reason that would have any affect on it starting. So any help or advice would be great.
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Old 02-05-2009, 10:41 AM   #2 (permalink)
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Did you make sure to reconnect any wiring attached to the carbs? As I remember, there are throttle sensors that will not allow spark unless the throttle is in the correct position. If the carb switches aren't connected properly, this could be your problem. you should be able to get a manual online for troubleshooting. If not, let me know by PM at dmckay2003@comcast.net and I will get one to you. I have a PDF that covers everything from 90 - 98 Arctic Cat and should help you figure it out.
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Old 02-05-2009, 11:01 AM   #3 (permalink)
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Yes, the sensors are reconnected. I found a PDF manual for $5.99 on payloadz.com...it appears to be the same one you have for 90-98 arctic cat. Thanks for the info!
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Old 02-05-2009, 01:04 PM   #4 (permalink)
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The caps with the throttle cables seemed to attach correctly, except there is a little play in the throttle lever that wasn't there before. Could this mean that the throttle cables need adjusted for the sensors to read correctly?
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Old 02-05-2009, 01:36 PM   #5 (permalink)
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There should be appx 1/4" of travel on the throttle lever before it starts to pull the cable.
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Old 02-05-2009, 02:36 PM   #6 (permalink)
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Ok, thanks. That's about what I have, so that should be right. Any other ideas?
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Old 02-05-2009, 04:49 PM   #7 (permalink)
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You say it bogged when the clutch started to engage? Did you verify the track was freed up? Maybe the brake was stuck? Just wondering. As far as the spark goes, it's odd that removing the carbs and cleaning them would cause that unless somewhere or somehow you disconnected a wire or possibly blew a fuse or even put something back together wrong. Is there a fuse box on that sled? I have a EFI 580 and it has fuses. I would try bypassing all of the switches and seeing if it sparks, if so you have a bad switch. The manual should tell you how. Does it have a tether switch, those seem to be problematic on a sled that hasn't been ridden for awhile. I found out something very interesting on our 2000 summit. You can start the sled, rev it up and have it idle but if the tether isn't on correctly the sled won't move, it will cut off revs at 4000rpm and not move like the track is stuck. The only way you know it's the problem is there is a light on the dashboard with a pic of a key on it and it flashes. Get the tether on right and it stops. Apparently, there is a lock triggered by the tether switch. It took some time to figure that one out. We had just bought the sled and didn't know about that feature. Make sure your Tether line is on or bypass the tether if it has one. ACat has a plug that you can bypass to test for switch problem. It should be in the handlebar cover and should have 4 prongs. Connect the brown and black wire and cover the exposed pin and that bypasses your switches. THIS IS FOR TROUBLESHOOTING ONLY! NEVER bypass a safety measure on purpose, fix it.

Last edited by CATDRIVER; 02-05-2009 at 04:53 PM. Reason: found a mistake
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Old 02-05-2009, 05:47 PM   #8 (permalink)
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the track is free and the brake wasnt on...i did get it to move a little bfore it bogged, and it was turning fine with no pressure on the track(back end off the ground). as to the spark, there is no tether or fuse box...i saw the four plug wen i had the cover off to remove the tank...i will try that this evening.
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Old 02-05-2009, 07:05 PM   #9 (permalink)
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the free four-plug has brown, yellow, and red in it but no black...i tried crossing the 2 wires going directly into the key switch...it made no difference.
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Old 02-05-2009, 07:39 PM   #10 (permalink)
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ok i think i misread your last post catdriver...so ignore my wiring post! anyway, i have no four-prong plugs anywhere near the handlebars...i have a three-wire right along the handlebars(all black)...and a six-plug with four free plugs...but no black wires.
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Old 02-06-2009, 06:37 AM   #11 (permalink)
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Down where the wires come out of the engine there are 2 plugs. One goes to the CDI and is a 3 wire deal. The other is 4 wires and has yellow brown and black wires in it. You would unplug that and use the jumper across the brown to black to see if any of the switches are the problem.
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Old 02-06-2009, 07:28 AM   #12 (permalink)
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update: I got it running last night. I was reading the AC manual from my previous sled(96 z440) and it said if no spark, compress throttle and pull...so I tried that it worked. So it says to adjust or replace carb safety switches...but it doesn't say how. Aren't they just electronic plug-ins? or is there some kind of adjustment?
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Old 02-06-2009, 07:37 AM   #13 (permalink)
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There are throttle pin bushings that wear out ($1 item) and they can cause that problem as well. If you have to hold the throttle, that is usually the problem.
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w/ Comet 108 Pro-4 clutch & 01 ZR skid

'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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Old 02-06-2009, 08:08 AM   #14 (permalink)
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ok...any recomendations on getting these online?(I don't have any dealers nearby)
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Old 02-06-2009, 02:06 PM   #15 (permalink)
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w/ Comet 108 Pro-4 clutch & 01 ZR skid

'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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http://www.masonicdryden472.org/

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Old 02-06-2009, 06:39 PM   #16 (permalink)
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Thx RJ. I was able to rig the throttle safety enough to get the sled running today(new bushings are on order) and it seems to be starting easier and no more bogging! Its idling high and seems to be burning a little rich, but hopefully some minor adjustments will take care of that. Thanks for all your help!
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