1996 600ZRT no spark - Snowmobile Forum: Your #1 Snowmobile Forum

billstevens · 10-30-2009, 01:54 PM

I got a 1996 600 ZRT cat i have absolutely no spark when i try to turn it over. Its a manual start. I have checked the spark plugs and have nothing coming to them. I checked the resistance of the coil and it is ok. Any ideas? Also what is the output voltage suppose to be for the stator?

**RJ Gleason** · 10-30-2009, 03:50 PM

All the switches in the run position?
Check that the TSS is not malfunctioning.

Blaine1 · 10-30-2009, 07:32 PM

Quote:

Originally Posted by billstevens

I got a 1996 600 ZRT cat i have absolutely no spark when i try to turn it over. Its a manual start. I have checked the spark plugs and have nothing coming to them. I checked the resistance of the coil and it is ok. Any ideas? Also what is the output voltage suppose to be for the stator?

There are several possible reasons for a no spark condition. Check all of the connections, check all of the wiring from the stator to make sure nothing is frayed and grounding or shorting. Make sure the ground is clean and tight. You can bypass all of the switches (Kill, key and the always wonderful TSS switch) and then the most important check is the stator and pulse coil ohm (resistance) check. Here are videos I put together to show how to test the stator in the sled, if it is out of a sled and how to test the pule coil. Hopefully it is just the TSS (throttle Switch which consists of the nylon washers on the pivot point of your throttle on your handlebars) and you can bypass it.

Stator testing out of a sled
YouTube - Stator Testing a 2 Stroke Stator

Stator testing in a sled:
YouTube - Stator Testing in a sled

Stator removal:
YouTube - Installing a Stator Pt.1 Removing it

Stator reinstall:
YouTube - Installing a Stator Pt.2 Putting Everything Back Together

YouTube - Pulser Coil Testing

**kccats** · 10-31-2009, 10:37 AM

Start by eliminating problems! Unplug the 4 way connector comeing out of the motor, test! Then jump the brown and black wire on the motor side of the connector, test! This will tell you if it is the many kill switches or the ecu or stator!

polaris40042 · 11-01-2009, 05:18 PM

Try the emergency stop on your dash by the key. Make sure that the spring button under the rubber boot is down far enough. My 96 ZRT 600 did the same thing i had to put a piece of foil in to make it spark.

Blaine1 · 11-02-2009, 07:09 AM

Quote:

Originally Posted by polaris40042

Try the emergency stop on your dash by the key. Make sure that the spring button under the rubber boot is down far enough. My 96 ZRT 600 did the same thing i had to put a piece of foil in to make it spark.

KCCATS suggestion will bypass all switches letting billstevens know if it is a switch issue or it is on the other side of the ignition...i.e. bad stator, bad ground, broken/loose wire somewhere, bad coils, bad cdi, loose jumper wire on the coils ect.... Adding foil to a kill switch is not a good way to fix things. Bypassing the TSS and kill switch permanantly should be done anyways and just use the key switch to turn it off with.