My new 2002 ZL600 EFI doesn't start with key - Snowmobile Forum: Your #1 Snowmobile Forum

1ninjanina · 01-13-2013, 09:10 PM

I just bought a 2002 ZL600 EFI ESR, and the guy took a little off the price because he didn't have a battery installed. Upon purchasing, charging, and installing a battery, I discovered why he didn't have a battery in it. I turned the key, and it didn't do a thing. No click or anything. It starts second pull with the pull cord, so I know it runs. I didn't receive a manual with it either.

I plan to take it to my dealer to have them check it out and tell me what other maintenance issues may need to be addressed, but I was wondering if anyone has any links or just directions on how to check the ignition switch, and other wiring to the starter. I do have some background in automotive, so I should be able to understand any instruction someone gives me.

Josh Kidner · 01-13-2013, 09:19 PM

One thing ive always done (and prob. Isnt the best idea in the world) is run jumper cables from the battery to the starter for just half a second to make sure the starter actually works. Make sure all of the wire connections are clean and not corroded. If you still cant get it going try to "hotwire" it by bypassing the switch, but first you need to know which wires are which. Wish i could tell ya. Good luck!

smokingcrater · 01-13-2013, 10:12 PM

Are you 100% sure it has a starter? Not many zr's came with them, so he could have been halfway through a retrofit to put one in.

**RJ Gleason** · 01-14-2013, 04:43 AM

ZL with ESR means it came with Electric Start and Reverse.

Check the relay, that is often the first part of the system to fail.
If you jumper the large terminals on it, the starter motor should spin if you have a good battery.

**kccats** · 01-14-2013, 06:04 PM

It may been shot/broken!

Dsperfslage · 01-14-2013, 07:24 PM

Could be the solenoid. Here is what msny service manual says to try.

Solenoid (Electric Start Models) TESTING NOTE: The electric start solenoid may be tested using either one of the following methods.
Method #1
1.Disconnect the electric start harness from the main wiring harness.
2.Place the ohmmeter leads across the solenoid coil terminals (brown wire and red/white wire).
3.The ohmmeter must read between 3 and 5 ohms.
Method #2
1.Connect the battery to the solenoid coil terminals (brown wire and red/white wire).
2.A loud, audible “click” should be heard as the solenoid internal contacts make connection.
3.Disconnect the battery from the solenoid.
4.A loud, audible “click” should be heard as the 5-36 solenoid internal contacts release

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1ninjanina · 01-18-2013, 12:01 PM

We jumped the starter to the battery and it started the sled, so the problem isn't the starter. I noticed there's a black thing hanging on a wire that says 'fuse' on it. I opened it up and it doesn't have a fuse in it. Does anyone know what size it takes and what kind? It looks like a small two pronged automotive style. One AC forum thread I saw said the ignition fuse was 30A, but i don't know if that's the fuse they were talking about. I was able to find an owners manual for my sled but its not any good for diagnosing a non functioning ignition. I must say AC fell short of Polaris in this area. My Polaris ATV manual has a diagnostic chart. I can test the solenoid and switch but I'm not sure exactly how without a diagram, and if the problem is only a missing fuse, then I don't want to go to the trouble. Thanks.

rgoers · 01-18-2013, 12:27 PM

An owner's manual is different from a shop manual. I had a shop manual (on CD) for my '00 Cats. It had extensive troubleshooting info along with full wiring diagrams.

1ninjanina · 01-18-2013, 02:41 PM

OK thanks, I'll look into it. But I'd still like to know about the fuse in the meantime. I can get a pic of it by Sunday or Monday if need be.

rgoers · 01-18-2013, 10:40 PM

Hey... I just noticed your location. I grew up in Webster. After getting married, I lived in Macedon for 7 years, and Farmington for 15 years. That was all before Xerox laid me off... and I ended up in Utah as a result.

1ninjanina · 01-18-2013, 11:10 PM

Rgoers, even weirder, my older sister lives in Salt Lake, and my younger brother moved there to live with them and go to school.

rgoers · 01-19-2013, 09:53 AM

Okay - now that *IS* weird. Pretty funny... I'll tell you, the economy here is completely different from what I left behind in NY. No problem finding jobs here, even high-tech jobs. In NY, there were few choices in that area, beyond Xerox and Kodak (neither of which are doing very well anymore). :-(

After being here about 3 1/2 years, we just moved into a new house... my taxes here are 1/6 of what they were in NY for a house twice the price of what I had in NY. Completely different world!!!

Hey, if you ever decide to go visit your "Sis" and would like a riding partner, let me know. There are plenty of places to rent sleds out here, and I think you'd enjoy the different type of riding conditions Utah offers.

1ninjanina · 01-21-2013, 05:29 PM

Well, I called the dealer, and they said the no-start was likely the missing fuse. I went to them and bought the 7.5A fuse, plugged it in, and the sled started right up! I will never pull start that thing again! I consider myself a strong female, but it's still more effort than I wanted to put into it. On a 35 degree day it took two good pulls to start it. Last week I tried to start it on a 25 degree day, and it took a few partial pulls before I could even get a full pull, then it took 2-3 full pulls.

We haven't gotten much snow, and I don't know how much is in the forecast, so my friend is going to see how much local lake effect places might have gotten nearby. He said maybe we'll go for a drive and see. He's only been out twice on his brand new Polaris, and I haven't been out at all since I got mine a month ago.

It's all set and ready to go now. I should probably grease it, since I don't know when it was last greased.

I bought a snowmobile helmet with a dual shield and a sun visor built in. I don't have snowmobile gear yet, but I'll get it if it looks like we're going to be able to ride regularly. I own Carhartt insulated work clothes, so it's not like I don't have anything warm.

rgoers · 01-21-2013, 10:55 PM

Quote:

Originally Posted by 1ninjanina

Well, I called the dealer, and they said the no-start was likely the missing fuse. I went to them and bought the 7.5A fuse, plugged it in, and the sled started right up! I will never pull start that thing again! I consider myself a strong female, but it's still more effort than I wanted to put into it. On a 35 degree day it took two good pulls to start it. Last week I tried to start it on a 25 degree day, and it took a few partial pulls before I could even get a full pull, then it took 2-3 full pulls.

We haven't gotten much snow, and I don't know how much is in the forecast, so my friend is going to see how much local lake effect places might have gotten nearby. He said maybe we'll go for a drive and see. He's only been out twice on his brand new Polaris, and I haven't been out at all since I got mine a month ago.

It's all set and ready to go now. I should probably grease it, since I don't know when it was last greased.

I bought a snowmobile helmet with a dual shield and a sun visor built in. I don't have snowmobile gear yet, but I'll get it if it looks like we're going to be able to ride regularly. I own Carhartt insulated work clothes, so it's not like I don't have anything warm.

Glad you got it sorted out! E-start is nice, and reverse is even better!

I understand that the Cortland area is getting hit with some serious snowfall right now.

I've ridden in my Carhartt overalls before , but warm is one thing, and waterproof is another. If you do any serious riding, you are going to want to get something waterproof!

**RJ Gleason** · 01-22-2013, 08:27 AM

Today;
North of Syracuse is getting pounded with snow, Yesterday there was 3+ft recorded up near Polaski and another 2+ft predicted for today.

An here I only have about 4" on the ground.

rgoers · 01-22-2013, 01:29 PM

Quote:

Originally Posted by RJ Gleason

Today;
North of Syracuse is getting pounded with snow, Yesterday there was 3+ft recorded up near Polaski and another 2+ft predicted for today.

An here I only have about 4" on the ground.

You're probably better off...

I went up there once when they got 4 feet of fresh on the ground overnight, and spent the whole day digging sleds out... Our 136" was NO MATCH for fresh snow that deep. Even the guy we met that day with a long track was getting stuck. The groomers weren't even running in that stuff.

Must have been 2006 or 2007... seems it was the year before I left NY state. The interstate was closed, with semi's stuck in snow up to the top of their hoods on the on/off ramps...