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Old 03-05-2012, 05:25 PM   #1
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ZRT 800 won't idle

My zrt 800 wont idle. its a 1995. it has a new stator, the reed valves are all new, the carb boots are all new, the plugs are all new. I cleaned the carbs multiple times and adjusted the choke, air/fuel screws, and idle screw to the proper adjustment. even with doing this and spending countless hours on it, it still will not run. it does run on choke and will run for a few seconds with out choke before stalling out. i have literally checked everything i could think of and done everything that people have said to do in other posts. any ideas of what could be wrong with this thing?
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Old 03-05-2012, 06:46 PM   #2
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when you cleaned the carbs did you replace the pilot jets? or did you remove them and clean them?
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Old 03-05-2012, 06:49 PM   #3
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I dont know what others have had you try but here is a few ideas. It sounds like a fuel prob. Check the line inside the tank. Check the pulse line going from the motor to the fuel pump. Check the pumps them self. Check motor comp and make sure all are close to the same. Make sure the slides in the carbs are adjusted the same.

What do the plugs look like? Wet, or dry?
Have you disabled the tss. Have you bypassed the wiring harness with a jumper wire at the stator?
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Old 03-05-2012, 06:54 PM   #4
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the plugs were wet so it was getting gas and they were not fouled or anything like that. and i did everything that you have mentioned. and i cleaned the jets. i also bypassed the tss, still no change. it really doesnt make sense to me as to why it wouldnt idle if everything is in good shape and adjusted properly
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Old 03-05-2012, 07:25 PM   #5
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what color spark? blue? or yellow? what is your compression? Does the sled run above idle? you say it runs with the choke on so I still lean toward a fuel issue. I would put in new pilot jets and fully clean and snyc the carbs also check the choke adjustment . If you have weak spark clip the plug wires about 1/2 inch and try again it should be bright and blue. if your compression is low that may be part of your problem
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Old 03-05-2012, 08:16 PM   #6
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the compression reads between 120 and 135. what should the compression be? the spark is bright blue and the sled idles with the choke on and it will run at higher rpms when i rev it but only with the choke. it will run with out the choke if i keep reeving but eventually it does die. i completely took apart the carbs apart, replaced the jets, cleaned them, adjusted them, and still nothing. also the float arms were not put in correctly by the previous owner so i fixed that.
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Old 03-06-2012, 12:34 AM   #7
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 Quote: Originally Posted by njrextreme View Post
I dont know what others have had you try but here is a few ideas. It sounds like a fuel prob. Check the line inside the tank. Check the pulse line going from the motor to the fuel pump. Check the pumps them self. Check motor comp and make sure all are close to the same. Make sure the slides in the carbs are adjusted the same.

What do the plugs look like? Wet, or dry?
Have you disabled the tss. Have you bypassed the wiring harness with a jumper wire at the stator?
I'm working on the ZRT 800 with my son Nat311346.....

How is the tss disabled or bypassed? The tss seems to be the only thing left to do.

The carbs have been removed and stripped and cleaned, vacuum line is fine, carb bowls have plenty of gas in them and the float is adjusted correctly. There are no air bubbles in the fuel lines. Air/fuel is at one turn and the idle setting sync is set to 1/8 inch, the choke is set to 1/8 also. It starts with 2 pulls with choke when cold, smokes a lot, and with choke set off it will run at 2500-3000 rpm (I have been unable to properly set the idle) then dies out in 30 sec or so. Using the throttle does nothing as its stalling. Put the choke back on and it starts with one pull. All 3 exhausts are running hot. It has a new stator. Compression on all three cylinders is 120-125.

We are at a loss as to what to do next.
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Old 03-06-2012, 10:33 AM   #8
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To completly bypass the whole wiring harness you splice the two non yellows together at the stator or wire in a switch. Mine were two brown wires. That will bypass the key,kill,tether,and tss system. A member here told me to try it and it is running great now. But I only have my key to kill it now.

Last edited by njrextreme; 03-06-2012 at 11:24 AM.
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Old 03-06-2012, 11:41 AM   #9
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Have you tried starting with the track off the ground and revving it up to clear it out. You may have alot of excess gas in the engine. Have you messed with the oil inj. at all. You say you have alot of smoke when you start it. If it needs choke to run, it sounds like pilot jets clogged as stated above. Hard to tell without being there to go over it.
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Old 03-07-2012, 10:08 PM   #10
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The bypass at the stator, odd as it sounds, worked once but not any more. I metered the system and all the it open and close when they are supposed to. More playing and I think its the choke system. I have got it idling, first only on one cylinder (only one pipe was hot) then after playing with the chokes the other 2 are running now. Still very ruff and smoking a lot. Question about the choke plunger...is it supposed to have a rubber or plastic bottom. These are copper with a plastic middle but a smooth bottom.

Not much fun...working on our MG Midget is so much easier.

Last edited by inptct; 03-08-2012 at 12:26 PM.
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