96 zr580 efi idle problem - ArcticChat.com - Arctic Cat Forum

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Old 01-11-2016, 10:18 PM   #1
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96 zr580 efi idle problem

I have a 96 zr 580 efi that will not idle I can tilt the throttle lever at a slight angle which I'm assuming is then partially hitting the TSS switch and then I can get it to idle but it is not consistent. I've tried another TSS switch I have replaced the plastic washers for the lever. Check all the grounds and cleaned and grease all connectors. The battery is brand new as of a week ago. Other then this problem the sled runs and revs great. I've heard you can't by pass the TSS. Any input would be great! Thanks in advanced
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Old 01-12-2016, 10:15 AM   #2
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You can by pass the TSS. There is a plug just follows the wires from the throttle it will be a three wire plug. If you unplug it and the problem goes away the TSS is your problem. But if you run it like that you do not have a Kill switch. You can jumper the plug across the two control wires the third is a ground and it will restore your kill switch. I ran one of my ZR's for years like that. Arctic Cat used to have a jumper plug that did just that. But they are hard to find.
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Old 01-12-2016, 02:17 PM   #3
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In the 96, bypassing the TSS is not as simple as just unplugging a cable. You have to actually install a jumper plug. These were originally included in the toolkit, but often dissappear over the years. The New style of TSS acts by grounding the coil to kill the sled, so when unplugged, there is no path to ground, so the TSS is disabled. On your sled, however, a continuous circuit has to be made for the sled to run. This circuit includes the Throttle Switch, kill switch, ignition switch, and Magnetic switches on the carbs (if your model has them) If any one of these is bad it will cause the circuit to break, and the sled will kill. to test these, you just bypass each with a jumper one at a time. Your problem sounds like it could just be your throttle cable tension is mis-adjusted.

Last edited by Wyelde; 01-12-2016 at 03:34 PM.
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Old 01-12-2016, 07:21 PM   #4
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Ok thanks for the replies guys. I've tried jumpering the terminals a couple different ways. The one way that the sled will actually run it idles at 3k and never comes down. I'm going to try and check the throttle adjustment tonight.
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Old 01-12-2016, 07:57 PM   #5
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 Quote: Originally Posted by Zr58044241 View Post
Ok thanks for the replies guys. I've tried jumpering the terminals a couple different ways. The one way that the sled will actually run it idles at 3k and never comes down. I'm going to try and check the throttle adjustment tonight.
If it's running at 3k I'd bet the 1.5bil in Powerball you need new intake flanges.
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Old 01-12-2016, 08:12 PM   #6
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The thing I do not get is why is it that I hold the throttle lever just in the right spot and the thing idles perfect
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Old 01-13-2016, 09:38 AM   #7
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Throttle control is probably shot as the guys have said. Just do the jumper mod to bypass it near the plug as suggested.
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My new favorite bumper sticker seen outside The Bent Wrench, Fountain, MN: "Your loud can doesn't make up for your small d*ck

Think about that the next time a trail is shut down because of loud sleds.

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