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Old 09-20-2011, 02:51 PM   #1
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Unhappy No Spark

My son has a 2002 zrt 600. Last fall he took the motor out , and cleaned, and painted inside A-Frames. He put it all back together except he was missing a bolt that attached the 3 ground wires. He took it out for a ride, and it started spitting ,and coughing after a while.We got it home grounded the wires, it would run on idle then die.We unplugged the main harness, still getting a occassional spark.We tested the ohms on the stator, and the trigger, and both tested to specs.We decided to change out the stator with a new one, but still have no spark.The manual says to check peak voltage at the coils with the red wire to the poss. spade, and the black wire to the neg. spade, and now you pull the motor over at 2000 rpms with a voltage of 105-116V.I get no reading accross either coil, but I get a -high reading coming of the cdi if I unplug the 2 wires coming off the coils, and plug it to the multimeter. Does anyone no what this means? Manual doesn't tell you what is wrong just to check it. Thanks for any input. Dale
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Old 09-20-2011, 09:11 PM   #2
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My concern would be with running it too long with no grounds attached. That stator uses a fairly robust coil for the ignition, because it also needs to power the power valves. Stator voltage increases with RPM and I would expect excess voltage to be shunted or bled off through the ground. If there's no where for it to go, I imagine it could damage electrical components in the CDI. Do you know anyone that you can try swapping with? Maybe try swapping the external coil packs as well.
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Old 09-21-2011, 06:47 AM   #3
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 Quote: Originally Posted by kev View Post
My concern would be with running it too long with no grounds attached. That stator uses a fairly robust coil for the ignition, because it also needs to power the power valves. Stator voltage increases with RPM and I would expect excess voltage to be shunted or bled off through the ground. If there's no where for it to go, I imagine it could damage electrical components in the CDI. Do you know anyone that you can try swapping with? Maybe try swapping the external coil packs as well.
X2. Kev knows what he is talking about.
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Old 09-21-2011, 11:00 AM   #4
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I did have an older zrt in the yard to to swap one of the coils out, I couldn't get the other one off.I plugged the wires dirrectly to that coil from the cdi,and I got no spark.Unforunately this cdi was only made for this sled year, not very many around.Bummer,well thanks for the input guys,I can see $$$$$ signs coming.
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Old 09-21-2011, 01:13 PM   #5
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The coils rarely go bad...or at the very least are one of the last electrical items to go bad in the system.
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Old 09-21-2011, 09:22 PM   #6
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 Quote: Originally Posted by Juliene@Dale View Post
I did have an older zrt in the yard to to swap one of the coils out, I couldn't get the other one off.I plugged the wires dirrectly to that coil from the cdi,and I got no spark.Unforunately this cdi was only made for this sled year, not very many around.Bummer,well thanks for the input guys,I can see $$$$$ signs coming.
Ya, that CDI is pretty specific. I would think 01's should work too.
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Old 09-22-2011, 01:59 PM   #7
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Ya, both 01's,and 02's have the same #'s on the box CB7208,but the next four don't match, and the part #'s don't either, so I don't know what differences their are,and neither does one of the dealers I talked to.Do you guys know anybody that might know this the answer?I've seen a few of new,and used 01's, only new in 02's.Thanks Dale
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Old 09-22-2011, 09:19 PM   #8
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Not sure what changed between 01 and 02 for ZRT 600's. In other cases they change the timing curve. Maybe that's the case here too.
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Old 09-24-2011, 11:38 AM   #9
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Ya, I talked to someone in th midwest,place called country cat.They had a 2001 cdi they were selling, and he said cat did change some timing,ignition specs for that 2002 year. Nice!!! I'll keep everyone in touch when we find one thats reasonably to put in,and makes this cat purrrrr again. Thanks again for all the info. you guys. Dale
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Old 09-24-2011, 07:33 PM   #10
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I've bought from country cat before. Good people to deal with. Were you thinking of trying the 01 CDI? I hope that fixes it. With ignition it can be hard to trouble shoot without swapping components and it gets expensive real quick.
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