[meierjn]

Was going over the brother-in-law's sled a couple of nights ago and wanted to check the fuel filters out. We finally had to resort to the manual... It looks like there are 2 fuel pickups in the tank and there are screens/filters on the pickups. Am I missing anything here? Can the filters be cleaned or replaced?

He started experiencing a bogging problem late in the season this year. The sled will start to bog at higher speeds then after he slows down feathering the throttle will bring it back to life. The bogging is not consistent and the stator was replaced early in the season this year. Thanks for the help…

 

[billww]

most times if gas filters are getting pluged the motor will run bad all the time. Check the plug gaps and run some gas cleaner in it . Take run on it and hit the kill switch ,pull the plugs and see how they look should be a light tan?

 

[94ZR580]

You should be able to clean the pick ups and replace them if necessary. Have you bypassed the TSS (Throttle Safety Switch)? When the TSS starts to go bad it cuts the ignition intermittently while riding. The 97 may still require the bypass loop to ride the sled with the TSS unplugged. The typical fix is often to replace the plastic washers / bushings on the throttle pivot pin.

 

[meierjn]

Haven't replaced the TSS yet. May be worth a try though. Thanks for the suggestion.

 

[94ZR580]

Haven't replaced the TSS yet. May be worth a try though. Thanks for the suggestion.[/b]

The TSS is always the first thing to look at when you have intermittent ignition interuption, or weird bogging while riding. This is an infamous and very common problem with these systems. The bypass loop came in the tool kit, for the older sleds that require the loop for thier ignition wiring, and it doesn't cost anything to test the system.

 

[jeffmsu]

sorry to say this but I would bet anything you need a new stator. I have replaced them on 3 different 97 ZR 580's.

good luck

 

[meierjn]

sorry to say this but I would bet anything you need a new stator. I have replaced them on 3 different 97 ZR 580's.

good luck[/b]

Hope not, it is a new stator.

 

[billww]

Have you tryed gas treaments and checked plug wires for arking and plug gaps ? most gas carb cleaners will open up gas lines. If the stator is getting bad the motor would have bogging problems at all speeds. before you start to rebuild that sled try some stp.

 

[Spaceman]

No bypass on the 97 just unplug the wire on the handlebar base. tree wire plug if I remember right. one wire is purple. It does sound like a stator.

 

[meierjn]

No bypass on the 97 just unplug the wire on the handlebar base. tree wire plug if I remember right. one wire is purple. It does sound like a stator.[/b]

It is a 1997 ZR 580 EFI with no battery. Three wire plug and unplug the purple one you say?

 

[94ZR580]

It is a 1997 ZR 580 EFI with no battery. Three wire plug and unplug the purple one you say?[/b]

Just disconnect the plug. The sled should run with the plug disconnected, but the kill switch will be disabled. Cutting the one wire will reinstate the kill switch, but it will eliminate the safety switch. Only cut the wire if you do not want to fix the safety switch, but you do not have to cut the wire to test the system to see if it is the problem.

Make sure oyu do these tests one at a time, so that you know what fixed the problem. Disconnect the TSS and ride the sled. If that does fix the problem, then fish the fuel pick ups out of the tank and clean, or replace the ends and ride the sled again, etc. Let us know how you make out.

 

[Spaceman]

Just disconnect the plug. The sled should run with the plug disconnected, but the kill switch will be disabled. Cutting the one wire will reinstate the kill switch, but it will eliminate the safety switch. Only cut the wire if you do not want to fix the safety switch, but you do not have to cut the wire to test the system to see if it is the problem.

Make sure oyu do these tests one at a time, so that you know what fixed the problem. Disconnect the TSS and ride the sled. If that does fix the problem, then fish the fuel pick ups out of the tank and clean, or replace the ends and ride the sled again, etc. Let us know how you make out.[/b]

Far better post than mine. Good job.