I have a 99 zr600 carb. and it won't shut off. my cat dealer told me it was a c.d.i. so i boughtone (400.00 !!!!) and it still won't shut off. they lent me a jumper to cross it right at the motor. still nothing. so i figure being a zr forum someone may have had this problem. thanks

Check all of your grounds first and mabey the four plug connector near the engine recoil. The ignition needs to be grounded to turn off and both of these things can cause it to run and not turn off.

No dealer in their right mind should be selling a $400 cdi as a first step. Check the obvious things first -- connections and grounds, etc...

I had the same problem on my 99ZR 500. Was told it had to be the CDI box, bought a new one from dealer($480.00 CAD.). Installed the CDI and the problem was still there. Turned out it was the "STATOR", after troubshooting everything else on the sled. There is no way to test a stator,unless you have another sled to try yours on. Turns out the ground inside the stator was burnt(i think it was a green wire). My sled was doing the exact same as yours and all the dealerships said it had to be CDI and no way it was the stator. Even asked many experienced people who work on sleds and they said "CDI or STATOR, but there money was on the CDI". Hope this will save you lots of troubshooting. It was very frustrating, after spending that amount of money on a CDI that could not be returned and didn`t fix the problem. Hope this helps solve your problem.

Jim
:beer2:

I had the same problem on my 96 ZRT600, turned out to be the four plug connector, grease it up so water won't won't work its way in there. Will it shut off using the key nad not the kill switch?? I also had a problem on my 800, the wires coming out of the stator were worn thru from rubbing each other, check that also.

While it is running, disconnect the stator wires if the engine continues running, the problem is most likely the stator. But first eliminate the basics like key and kill switches, or wiring. With a bad CDI the engine will not run or will run erratic when hot.

there is a way to check the stator. get the OHM reading and check it with an OHM meter. I have run into the same problem with a customers sled and it was the stator. i will look up the readings and post them if i can find them.