HI! I just found these boards. I am new to the site, but not to snowmobiling! I love to ride! Well, i bought a 1994 zr 580 years ago. We never really had any snow to ride it though till last year. Well, the second ride i went on, i blew it up! Piston shattered for some reason! I have no idea why it did this! It always ran great! Never even had a stutter! It just all of a sudden went. I did not get a manual with it, so i don't know if the stock jets are in it or not. At the end of last winter, i rebuilt it. It runs and idles great! BUT! Now when i really get on the gas, it cuts out every now and then. Like someone is hitting the kill switch really quick. I made sure noting is in the gas lines. I changed the fuel filter. I changed the fuel pump. I cleaned out the carbs. It still does it. So i am thinking it is something electrical? I replaced the coil. Still does it! Is there some way the kill switch can be doing this? Some kind of short or something? I don't know what to do. I really don't want to get rid of this snowmobile and get a new one because i have put so much money into it. Colored plastic skis. Cobra windshield, vents, pipes. I put so much into it, that i don't want to get rid of it. Anyone have any suggestions on what i could try next? Any help would be greatly appreciated! Thanks!

You may want to check the wiring harness. There could be a bare wire somewhere that's grounding out every once in a while.

Good Luck!

D

Thanks. I will check that out tomorrow. I didn't have time today because i worked all day. I will let ya know what i find!

Why don't you try bypassing that throttle safety switch or whatever it's called. There should be a plug in the tool kit to bypass it. The seem to give quite a bit of trouble. If that's the problem, you can bypass it permanently but also wire it up so that your kill switch still works.

I'd say it is the infamous Arctic Cat throttle safety switch. The switch in the throttle block is know to act up eventually and the parts to fix it should be less than a buck. The plastic washers at the pin that is the pivot for the throttle lever need to be replaced. It only takes a minute or two to replace these and all should be well. I experienced this problem for the first time last year on my 94 ZR 580.