'97 Zl 440 starting problems - Snowmobile Forum: Your #1 Snowmobile Forum

kylerding · 02-03-2013, 11:44 PM

I am having problems getting my Zl to start. When I try to start it, it will run for about 5 seconds and then die out, I have tried giving a little throttle, all choke positions, and just letting it sit, but it will not stay running. When I do get it running, it might back fire once, but once warmed up, it runs like a champ, but it is the inital start that is giving me trouble. It is really bad when it is cold. There is new gas in it, but I put in some older injection oil a while ago, but I didn't think that that would be my problem, but it seems like that is when it all started. I might have to lean the idle screw out too maybe. What are your guys' thoughts?

**RJ Gleason** · 02-04-2013, 04:34 AM

Have you gone through the carbs and ensured that all the passages are clear?

Hard starting usually points to these conditions;
1. low compression
2. weak spark
3. not enough fuel

kylerding · 02-04-2013, 08:27 AM

The carbs are good and clean, I went through them first of the winter. It has good spark, I just put in new plugs a couple weeks ago. It seems like it has good compression, but I don't have a tester, so I guess I don't know about that one. Not enough fuel would be possible, I will get a different filter, I think that one is a couple years old. It really seems like it is running rich, like alot of carbon on the plugs, should I lean it out more? What are the signs of it running rich?

edge800ves · 02-04-2013, 04:26 PM

I had alot of carbon on one of my plugs on my 1990 indy 500 sks, it was hard starting at that time too. did a compression test and it was way low on that side took it apart and there was a very bad piston (small hole burning through) turns out my crank seal was shot, I'd buy a compression tester. better to fix it b4 it blows if thats your case too.

kylerding · 02-04-2013, 06:41 PM

I will will borrow a compression tester from someone and try it out. I called the dealer and he told me how far to have the air screw out, so I got it running. I just have to mess with it some more to get the idle up.

**kccats** · 02-04-2013, 07:22 PM

Be sure to test at Wide open throtle! And check the reeds too!

babzog · 02-04-2013, 08:36 PM

Quote:

Originally Posted by edge800ves

I had alot of carbon on one of my plugs on my 1990 indy 500 sks, it was hard starting at that time too. did a compression test and it was way low on that side took it apart and there was a very bad piston (small hole burning through) turns out my crank seal was shot, I'd buy a compression tester. better to fix it b4 it blows if thats your case too.

How did you link a burnt piston to a faulty crank seal?

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Rczr600rider · 02-04-2013, 08:46 PM

Your fuel charge passes through the crank case on its way to the cylinder. If the seal is leaking it allows air to be added to the mixture, leaning out the charge. It's a recipe for a burn down.

**kccats** · 02-05-2013, 07:26 AM

And if you don't figure out why you had a melt down, it will be back!

edge800ves · 02-05-2013, 11:41 AM

Quote:

How did you link a burnt piston to a faulty crank seal?

^^^^^
Seeing it was my pto side piston, it was naturally the 1st thing I checked, my carbs were clean and my boots were solid so symptoms pointed to my crank bearing. Theres always a reason like kccats said if you dont diagnose the cause your gonna burn up again.

kylerding · 02-07-2013, 04:24 PM

What is the idle rpms supposed to be?

**RJ Gleason** · 02-07-2013, 04:53 PM

1500 to 1800.

kylerding · 02-07-2013, 05:30 PM

Okay, I will try some more. It starts and idles at 1400 then when it gets warm, it comes up to 3000.

**kccats** · 02-07-2013, 06:29 PM

Sounds like a seal, or the carb boot?

kylerding · 02-07-2013, 09:59 PM

What seal? All the boots are in good shape.

**RJ Gleason** · 02-08-2013, 04:55 AM

Crank seal!

**kccats** · 02-08-2013, 05:50 AM

Behind the clutch.

kylerding · 02-08-2013, 09:01 AM

So just the PTO side. I think I can handle that. This is the right seal right http://www.mfgsupply.com/501444.html And then I will just pull the clutch off and pull the old seal out, then tap the new one in. Right?

**kccats** · 02-08-2013, 06:58 PM

No not really! The flywheel has to come off, engine out and the cases split! The 97 should have a ridge around the outer edge?

kylerding · 02-08-2013, 08:12 PM

I don't think I am that mechanically advanced, what happens if I leave it?