Author Topic: UL/6mile 99' ZR500 help  (Read 4158 times)

Offline 2qik

  • Hero Member
  • *****
  • Posts: 2516
  • Karma: +4/-1
    • View Profile
UL/6mile 99' ZR500 help
« on: December 25, 2009, 10:51:06 PM »
Last ride of the 08/09 season with warm temps melting the trails down my 99' ZR500 began to cut out as if it had fouled a plug.  Unfortunately when I changed plugs it didn't come back.  It backfires hard, will run a short distance then goes down. It will sputter for a few seconds then backfires and dies.  I managed to get it to a pitstop and wait out a trailer.  Over the summer I dug in a little and found the airbox to carb seal was shot and the airbox was loose.  Replaced the seal and the plugs.  Fired up just fine yesterday in the snow, but 5 blocks later it cut out and was backfiring when attempting to restart.

Manual says throttle ignition monitor switch, plugs, high tenson wires/coil, carb to cylinder leak, carb dirty, carb loose, oil injection pump, are the things to check with a backfire.  Sled has 6400 miles.

Weigh in with your thoughts.  :(

- 2qik
Just a typical snowmobiler...

Offline Up Late

  • Donating Member
  • Hero Member
  • *
  • Posts: 14285
  • Karma: +63/-60
    • View Profile
Re: UL/6mile 99' ZR500 help
« Reply #1 on: December 26, 2009, 12:03:24 AM »
Sounds like your throttle safety switch is bad or not adjusted correctly. Try tightening your throttle cable a little and see if that fixes it. It only tolerates about 1/16" of slack or so when you hit the throttle. You can unplug it and bypass it with a jumper too. That will tell you if it's a bad switch.

Also:

Did you clean you carbs?

Airbox to carb seal shouldn't affect it.

Check your compression in both cylinders to see where they are at.
« Last Edit: December 26, 2009, 12:05:57 AM by Up Late »
Current Sleds in Stock: None. SOLD OUT!

Offline 6Mile

  • Waconia, MN
  • Hero Member
  • *****
  • Posts: 4319
  • Karma: +21/-45
    • View Profile
Re: UL/6mile 99' ZR500 help
« Reply #2 on: December 28, 2009, 10:21:39 AM »
Like UL said.  Pull apart the Throttle safety switch wires.  You do not need to jumper anything though, as this is a normally open ignition system.  That means it will run when the wires are disconnected.   It is a three wire connector that will be near the base of the handle bars.  You will know you got the correct one when you start it and the stop button on the handle bars does not shut down the engine any longer.   Just be sure that the throttle closes properly before you start the machine.  Would not want to read about you sled going for a ghost ride and crashing due to advice you got on some website.

If this cures you problem it is a really easy fix.  you can get new new throttle lever bushings from your local dealer to replace the worn ones you have.
Work harder, millions on welfare depend on you...

Sleds:
2013 Polaris Switchback Assault 144 800
2007 Polaris Switchback 600 Wife's sled
1997 Arctic Cat Puma DLX 340 has more time on it last  season than the above sleds.

MNUSA

Offline Up Late

  • Donating Member
  • Hero Member
  • *
  • Posts: 14285
  • Karma: +63/-60
    • View Profile
Re: UL/6mile 99' ZR500 help
« Reply #3 on: December 28, 2009, 12:56:31 PM »
If you can determine that it isn't the throttle safety switch then it is your stator.
Current Sleds in Stock: None. SOLD OUT!

Offline AdrenalineJunkie

  • Trump Train is rollin coal.
  • Hero Member
  • *****
  • Posts: 1483
  • Karma: +17/-198
    • View Profile
Re: UL/6mile 99' ZR500 help
« Reply #4 on: December 28, 2009, 01:23:48 PM »
Try removing the base gaskets?  :floor:
"Sometimes we choose to make our own cross to carry, sometimes we are given it"

Offline 6Mile

  • Waconia, MN
  • Hero Member
  • *****
  • Posts: 4319
  • Karma: +21/-45
    • View Profile
Re: UL/6mile 99' ZR500 help
« Reply #5 on: December 28, 2009, 02:59:41 PM »
How is the snow up there?
Work harder, millions on welfare depend on you...

Sleds:
2013 Polaris Switchback Assault 144 800
2007 Polaris Switchback 600 Wife's sled
1997 Arctic Cat Puma DLX 340 has more time on it last  season than the above sleds.

MNUSA

Offline David

  • Donating Members
  • Hero Member
  • *
  • Posts: 2096
  • Karma: +5/-6
    • View Profile
Re: UL/6mile 99' ZR500 help
« Reply #6 on: December 29, 2009, 07:54:21 AM »
6mile,

Your talking about part #8 below, (top and bottom) correct? 




[attachment no longer available]
You're not the dalai lama of sled appraisals bro   :biggrin: :beer2:
You never see a snowmobile parked in front of a Psychiatrist office.

Offline 6Mile

  • Waconia, MN
  • Hero Member
  • *****
  • Posts: 4319
  • Karma: +21/-45
    • View Profile
Re: UL/6mile 99' ZR500 help
« Reply #7 on: December 29, 2009, 09:53:47 AM »
Yes that is the one.  I did not have enough time to post the pic.  Thanks David.
Work harder, millions on welfare depend on you...

Sleds:
2013 Polaris Switchback Assault 144 800
2007 Polaris Switchback 600 Wife's sled
1997 Arctic Cat Puma DLX 340 has more time on it last  season than the above sleds.

MNUSA

Offline 2qik

  • Hero Member
  • *****
  • Posts: 2516
  • Karma: +4/-1
    • View Profile
Re: UL/6mile 99' ZR500 help
« Reply #8 on: December 30, 2009, 03:21:10 PM »
How is the snow up there?

Rode yesterday and it was nice.  Groomers are out.  The state trails are a mixed bag, especially those groomed by DNR staff.  The club maintained trails are excellent.  Easy to tell who has a passion for the sport.

- 2qik
Just a typical snowmobiler...

Offline 6Mile

  • Waconia, MN
  • Hero Member
  • *****
  • Posts: 4319
  • Karma: +21/-45
    • View Profile
Re: UL/6mile 99' ZR500 help
« Reply #9 on: December 30, 2009, 05:08:18 PM »
So you got the sled to run?
Work harder, millions on welfare depend on you...

Sleds:
2013 Polaris Switchback Assault 144 800
2007 Polaris Switchback 600 Wife's sled
1997 Arctic Cat Puma DLX 340 has more time on it last  season than the above sleds.

MNUSA

Offline 2qik

  • Hero Member
  • *****
  • Posts: 2516
  • Karma: +4/-1
    • View Profile
Re: UL/6mile 99' ZR500 help
« Reply #10 on: January 11, 2010, 12:16:01 PM »
So you got the sled to run?

6mile,

ZR is still down, been riding my wife's ZL440 as a backup, taking some sh!t as the sled has a big purple windshield bag.  Time to get the ZR back...

Intermitant spark, leaning toward stator like UL said.  Problem is stators are freaking expensive!  Anyone know where to get a cheap stator for a zr500?

- 2qik
Just a typical snowmobiler...

Offline MNNavy

  • Annual Subscribers
  • Hero Member
  • *
  • Posts: 2216
  • Karma: +8/-5
    • View Profile
Re: UL/6mile 99' ZR500 help
« Reply #11 on: January 11, 2010, 12:21:21 PM »
So you got the sled to run?

6mile,

ZR is still down, been riding my wife's ZL440 as a backup, taking some sh!t as the sled has a big purple windshield bag.  Time to get the ZR back...

Intermitant spark, leaning toward stator like UL said.  Problem is stators are freaking expensive!  Anyone know where to get a cheap stator for a zr500?

- 2qik
Hey!  What's wrong with purple windshield bags?  I have one on my '98 ZL 500.  Color matches the sled a lot better than green does, and I refuse to put an orange one on there.
The American Republic will endure until the day Congress discovers that it can bribe the public with their own money.  --  Alexis de Tocqueville

Offline 2qik

  • Hero Member
  • *****
  • Posts: 2516
  • Karma: +4/-1
    • View Profile
Re: UL/6mile 99' ZR500 help
« Reply #12 on: January 11, 2010, 12:36:36 PM »
So you got the sled to run?

6mile,

ZR is still down, been riding my wife's ZL440 as a backup, taking some sh!t as the sled has a big purple windshield bag.  Time to get the ZR back...

Intermitant spark, leaning toward stator like UL said.  Problem is stators are freaking expensive!  Anyone know where to get a cheap stator for a zr500?

- 2qik
Hey!  What's wrong with purple windshield bags?  I have one on my '98 ZL 500.  Color matches the sled a lot better than green does, and I refuse to put an orange one on there.

I concur, purple matches the sled and looks better than green or orange would, yet it still emphasizes that it's my wifes sled.

Back on topic, know where to get a cheep stator Navy?
Just a typical snowmobiler...

Offline Frostbit

  • Hero Member
  • *****
  • Posts: 2429
  • Karma: +18/-17
    • View Profile
Re: UL/6mile 99' ZR500 help
« Reply #13 on: January 11, 2010, 01:35:35 PM »

The '98-2000 ZR 5's and 6's were notorious for stator failures. I've seen 'em on ebay, but you never know what you're getting. There are a couple outfits rebuilding them; they replace the defective coil and re-do it.

Do a search for "RM Stator", and Ricky Stator", I know there is another, and I'll go look. One is in Canada.  Someone else may chime in here, but this is a start. I would suggest a rebuild, then you have yours back and it comes with a warranty.

I think its a couple hundred bucks.
Frostbit

Nome, Alaska

Offline SNO4ME

  • Hero Member
  • *****
  • Posts: 3355
  • Karma: +22/-18
  • Now that's Vintage
    • View Profile
Re: UL/6mile 99' ZR500 help
« Reply #14 on: January 11, 2010, 01:42:05 PM »
So you got the sled to run?

6mile,

ZR is still down, been riding my wife's ZL440 as a backup, taking some sh!t as the sled has a big purple windshield bag.  Time to get the ZR back...

Intermitant spark, leaning toward stator like UL said.  Problem is stators are freaking expensive!  Anyone know where to get a cheap stator for a zr500?

- 2qik

Look in your back yard. :floor:

Emerson Stahl, 3510 Hahn Rd, Proctor.   624.2183

I've never been there but I know some locals who have.  They say you think your're driving into someones yard with a garage.  You just have to go by the address on the driveway. :shrug:
LLAP