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Old 11-08-2004, 09:44 PM   #1
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Sled: 2002 zl600 efi ss
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OK guys...

This is my first post. I'm a new member...just recvd a new 2002 ZL600 EFI(first ever new sled) ...shipped from Wisconson. Put it together...tried to fire it up...nothin.

CHeck spark...seems OK...not super strong. Searched the forums for clues.
- primed fuel pump with 9V battery...no start.
- disconnected yellow wire...no start
- disconnect wire from throttle...no start
- checked vacuum hose on bottom of ecu...no start
- i did prime the cylinders...it popped...no start
- I checked the wire feed the fule pump...seems to be getting juice to the pump ok
- It's hard to say if the plugs are wet...as I've pulled them quite a few times...and most of the time they are bone dry. But the last time i pulled them, they were a bit wet...that's when i was playing with the fuel pump and 9V battery...

I'm atta loss....and extremely frustrated. I hope i can get this fixed.

To make it worse...i tore into the old lady tonight because of the frustration. I'll be on the couch for a while...

it seems the injectors are not gettin the signal to pulse...anyone have a clue?

TIA

JC
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Old 11-09-2004, 04:41 AM   #2
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Not meant to insult you, but did you make sure it's not the kill switch? Only say that because last year watched my co-worker try to get Dept. sled started..electric start...kept turning key,nothing, pulled and pulled...nothing, finally he came to get me...yup, he forgot about the kill switch. Sometimes it's just a simple thing.
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Old 11-09-2004, 06:45 AM   #3
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Dry starting a efi is not fun. If you read the set up book that came with it, it says to unhook the water temp sensor wire and pull it over. It takes quite a few pulls to start. It sounds like your not getting fuel. Keep at it. Pour some more into the cylinders.
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Old 11-09-2004, 06:35 PM   #4
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Sled: 2002 zl600 efi ss
ATV: 2002 bombardier quest 2004 zuki 250
already ahead of you on the kill switch.

I'm gettin spark..

this is what I did tonight. Drained gas (incase it was bad) dried out tank . put 2 gals fresh gas in. I then rigged up a 12v feed to the fuel pump and disconnected fuel line after regulator. ran pump for 2 minutes to clean out fuel rail. hooked all back up.

no starty


rigged up fuel pump to have constant 12v source while pulling over.

no starty


I think it's either:

plugged injectors
or bad ECU


ideas?
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Old 11-09-2004, 07:04 PM   #5
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Injector relay? Fuse(s)? and so on.
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Old 11-10-2004, 01:12 AM   #6
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I had the same problem with harley's sled. This is going to sound kinda strange,but, I took the injectors to the local dealer and had them test thier opperation. He was gone for a while and came back and said he got them to work. Went back home put it all back together and it fired up on the second pull! Releived and very confused, I tried everything to make it quit again with no luck. We kinda came to the conclusion that the plungers must have been stuck closed from varnish from the old fuel (it sat for 2 seasons with stabilized fuel), and the testing procedure broke them loose. Also look for a flashing led under the ecu, it will tell you any faults you have, after pulling over a few times.
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Old 11-10-2004, 04:18 AM   #7
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Sled: 2002 zl600 efi ss
ATV: 2002 bombardier quest 2004 zuki 250
I was also thinking along the lines of fuses...but being that my storage compartment was full of water...my manuals are basically useless. Does anyone have the wiring diagram for this sled (02 ZL600 EFI SS)

As far as the injectors....that sounds right. Beleive or not, this dealer claims to have not started this machine b4 shipping. But I recieved it with approx 2 gals of fuel. Soooo...that means another dealer had this sled and programmed it out to my dealer.

Who knows how freakin old the gas was. I'd bet the injectors are the issue. Is there a free 'em up without taking to the dealer?

This whole situation is such a gaggle.

I'm considering lodging a formal complaint against the dealer i bought from with AC.

- he didnt start the sled b4 shipping
- the storage compartment was full of water...all manuals are no good
- machine was not prepped (greased)
- parts were missing from skis

I called them yesterday...the best they could say was..."welll I've shipped over 100 machines and this has never happened...go see your local dealer"

does anyone have 'good' phone number for AC?
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Old 11-10-2004, 05:43 AM   #8
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It does indeed sound like plugged injectors...pull them and take them to a dealer to test.....I do hope you get him running....I had the exact same sled and he was one of the best I ever owned......
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Old 11-10-2004, 05:06 PM   #9
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Jfccac,... Sorry to hear about your troubles. There is some great advice allready posted here on your topic. My opinion is no different than some of the above... injectors. My younger brother (he's 36 years old) has the exact same sled, 2002 600 efi ss Molten Orange, and it is honestly the best sled ever. He has over 3300 miles of aggressive riding on it and it has never missed a beat, never caused him a minutes grief and is a great performer to boot. Once you get this issue sorted out you will love the Smart Ride Suspension and handeling of the ZR chassis.

Give Cat a call. They will help you out i'm sure. Your local dealer will give you a number for your "area rep". Good luck.

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Old 11-10-2004, 08:59 PM   #10
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Sled: 2002 zl600 efi ss
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I sure appreciate everyone's support and advice. i've contacted my local dealer and they seem supportive.


I'll wait to see how it turns out and let everyone know.

JC
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