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Discussion Starter #1
I posted about this problem before and thanx for everyone for the tips so far but nothing worked yet.
My 98' ZL500 (carb) wont shut down. The kill, key or tether has no effect. The only way to shut the sled down is to pull the spark plug wires. I try grounding and jumping the kill switches. I went over the entire wiring on the sled. Including pulling the Stator. I cleaned and checked for tightness of everything. I unplugged all the accessories like lights and warmers.
I checked the voltage output for the ignition wire (black/red) from the stator to CDI and it ouput is about 60 volts AC and up to 90 when RPM's increase. When I ground this wire the sled shuts down. This wire is purple after leaving the CDI and has NO voltage. When I ground this wire it has no effect.
Ok here is the kicker: When I jump the ignition wire to the purple wire all the switches work fine. My dealer said I will cook something so I cant leave it this way.
You would think the CDI is bad but I had a spare and it does the same thing.
MY dealer said he never heard or saw this before. He even called other Cat dealers and they said the same. He gave up and now I am at a loss on what to do....
I put a house switch on the handle bars to groung the ignition wire but this is crazy I need to get this damn Cat fixed.
PLEASE I REALLY NEED HELP WITH THIS ONE.
 

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According to the performance manual your stator readings are low.
The coil outputs should be 164 volts at 2000 to 219 at 4000.
 

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Discussion Starter #3
Wow, a bad Stator. I was thinking the Stator would be good because the sled runs fine. Sounds like my readings are cut in half. I'm going to check them again off another meter.
Thanx for that tip, cus I pretty much ruled out a bad Stator.
 

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Discussion Starter #4
I checked the the output for the ignition coil again and it's about 52 volts at 1600 RPM's and about 80 volts at 4000 RPM's. I did this using the BLACK wire with red stripe and ground. According to your manual this is way too low. Before I hunt down a Stator could you please check if those readings you gave me before are for the ignition coil output and not the lighting coil output.
Also is there a way to check the resistance of the ignition coil.
Thanx for your help. So far I think you may have solved my problem..
 

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i am guessing here but a friend of mine a while back had a old yamaha rd250 2 stroke motorcycle and that too would not shut off heres the strange part it turned out to be the timing was way advanced and the motor ran on the heat of the unburned fuel, he had to shut it off by running it out of gas shutting off the petcock and the dealer gave up on it but he knew someones brother that was a dirt rider and a good wrench who retarded the spark only a very tiny bit made all the difference crazy hu but it worked :wacko:
 
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