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Discussion Starter #1
Want to know if any one else is having this problem with there zr800 efi.  Engine will cut out at times while driving or when starting to open throttle. Its not a "bog." The engine will stumble or hesitate if you hold the throttle steady it will continue to hesitate. If you let off and then back on again the engine will start to accelerate properly. Please advise if you have this trouble or not. Checked all connections in handle bars and at engine. This sled has been doing this from new. Now have 500 miles on it. Its still doing it and has not got any worse.  Thanks to all who respond.
 Taz800
 
 
 

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I would take it to your dealer and have them fix-it afterall its a new sled and still has a warranty. save yourself the aggrevation.
 

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What you have is a common problem. It is the saftey switch that is designed to kill the sled if the throtle cable or carbs freeze up. some times it can be ajusted to work right. Most of the time I just disconect them. I have a new ZL 800 SS efi and it will cut out when it is cold and you play with the throtle. As soon as I get the time I will make up a wiring pig tail and the switch in the handle bars is history.
 

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i just talked to my dealer 1 hour ago and he said it is a normal problem with the 02's, he said let it warm up for 1 minute and then ride for a few miles before cracking it. mine does the same thing!!!
 

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This is not normal, and any dealer who says it is shouldn`t be allowed to play with anything sharper than a beachball! It does sound like the safety switch in the throttle. This was a huge problem in `98-`99. The new two piece switch was supposed to solve this. It can be disconnected to see if it is the problem, but it is a safety switch so don`t ride with it disconnected. Your dealer should be able to help you. If not, find another one.
 

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Discussion Starter #6
Yes my dealer told me that I am not the only person complaining about this problem. He told me that they have one sled that is very bad. They have called artic cat factory on this problem. It appears to be only with the 800 efi engine.
My dealer does not know what to do right now until the service guys at factory get back to them. So until then I keep riding and hoping it does not quit for good.
 
 
 

Taz800
 

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Mine does the same thing, but only when it's cold. Goes away when engine is warm. Have 98' 600 efi with same problem, disconnected saftey switch and cured problem. This has been an ongoing problem for efi equipped cat's. Wish they would put a little more r&d into designing a throttle block that won't do this!!!
 

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I have asked in this forum and others about a "dead spot" in some of the EFIs I have had.  96 Pantera 580 EFI and 01 ZL500.  It seems as though when I am not giving it throttle is wants to drop to almost zero rpms and die out.  I tend to ride or rev the throttle in order to prevent getting into this dead spot.  It's almost like a hesitation in the acceleration too.
Is this the same thing you are talking about?  Is this from the safety switch?
My 00 ZL600 doesn't have this problem.
 

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It might be the smart valves.  Look at the earlier post involving "02 efi fuel pump problems" or another post a page back that I discussed my problems with "01 ZR600 EFI starving for gas."
 

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Discussion Starter #10
Boatmaan. After reading the post on these so called smart valves. I am wondering when having a intermitain problem if you would be able to tell by taking the valve apart. If you look at it and its not stuck closed then it will look ok for now??
 Taz800
 
 
 

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Ok i have 2 2002 zl800's and the same thing happened to me last weekend on bolth sleds. went for a ride the day before and it was raining & 40 deg, the next morning when i started them up it was -5 deg. they would bolth idle then would bog when i grabbed some throttle, feathering the throttle i was able to get it going (i assumed i had some ice in the gas from the rain) took a little 1 mile ride when i came back the other sled was fine after it warmed up. but the one i rode took another mile or so before it too "fixed" it's self. my thoughts were some kind of warm-up saftey to protect against cold seizure. but really felt like it was starving for fuel
 

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Okay guys what I have been told is that there is a lean spot in the EFI maping. It is not a bad thing once you get used to it. Cat has made these  800 efi's work and we should be thanking them for doing thair jobs (not fat running anymore)if everyone complains about it then they will just re map the efi in the future and then they can be dogs like they have been in the past.
 
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