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4 Strokes Z1 Turbo / Z1 / T660

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Old 01-03-2016, 11:32 AM   #1
F5?
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2004 T660 Dies while riding/non turbo

At the end of last season I picked up a 2004 660 touring for some family fun. Other than the sled obviously having been hauled on an open trailer and not as well taken care of as I would have liked. I went ahead and purchased it (decent deal).

I have a good back ground in snowmobiles and did some routine maintenance on it. Such as changing the fluids and checking bearings.

So, last night was the first time we took it out. Rides well for how big it is and its age. However it wants to kill when riding (fine at idol). It seems to me its like the kill switch is shutting the entire sled down. Lights flicker or go completely out, loses power and then a half second or a full second later the sled roars back to life and keeps going. May do it again 5 min later, may happen back to back.

I checked it over this morning and it seems like the kill switch is operating correctly, the key switch seems to be in good shape and functioning properly. I had installed a brand new battery in it. I checked those connections and everything good there. Don't see any chaffed, rubbed or broken wires. All connections look good and I do not see any corrosion.

Could the safety switch on the throttle cause it to completely lose power?

Any help is much appreciated. Thanks
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Old 01-03-2016, 06:38 PM   #2
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sounds like A ground or a bad relay
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Old 01-03-2016, 06:40 PM   #3
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Update on some more tests with this problem.

Adjusted the throttle cable per some instruction from some buddies that are very familiar with cat products. That did not work.

I did notice on the test ride that when this thing acts up, if you continue to hold the throttle in the same position as when the problem starts to occur the sled will ultimately kill. Restarts right back up?'

Thought it may be the throttle position sensor. Unplugged that, sled rode and ran fine but had the same problem.
___________

A relay could be the problem. Anyone have an Idea of what each relay controls?

I see no visible grounds, I suspect it is under the engine as that is where the battery cable runs

Last edited by F5?; 01-03-2016 at 06:44 PM.
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Old 01-03-2016, 06:50 PM   #4
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you just going to have to tear into it and locate the ground stud to the chassis and start there
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Old 01-03-2016, 08:20 PM   #5
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my 02 660 did same thing first ride,tightened all grounds and cleaned cable ends. same thing second ride. , changed fuel filter, and didnt do it today? coincidence?
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Old 01-03-2016, 08:47 PM   #6
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 Quote: Originally Posted by kenvb View Post
my 02 660 did same thing first ride,tightened all grounds and cleaned cable ends. same thing second ride. , changed fuel filter, and didnt do it today? coincidence?
Maybe not, especially not knowing if filter was ever changed or not.
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Old 01-03-2016, 11:51 PM   #7
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Sled should not die completely because of the runaway protection for the throttle lever
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Old 01-06-2016, 09:39 AM   #8
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Sounds like the TPS to me...

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Old 01-07-2016, 10:43 AM   #9
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mine hasnt done it since?
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