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King Cat EFI no spark on hill

Arcticatdan

Active member
Lifetime Membership
A couple of weeks ago my KK stoped on the hill for no reason. No spark checked everything swaped coil,ECU, disconnected everything on the handle bars also the key. Still no spark after fooling with it for a long time and getting ready to figure a way out towing. It was suggested to disconnect the tail light, then it fired right up. Worked fine the rest of the weekend. When I got it home I went through the wiring from the tail light to the main harness and double checked everything, could not find anything worng. Put it back together and all was good. Still do not feel good about it. Has anyone else had this happen?
 
You might have just moved the right wire.

Several of us have had the wiring harness under the engine or the oil tank wear through on the underside. I couldn't see it at all, til I removed the old one and replaced with a new one.

Owen
 
Had this exact thing happen. We stopped for lunch. about 30 minutes one of the 900 efi sleds would not start. Sure enough no spark. WTF After towing it off the mountain and getting it in the garage it fired on the 2nd pull. Couldnt find anything. About a month later it did it again. Get it home in the garage and this time it would not start, still no spark. Found a broken wire under the servo motor where all the wires go through the square hole in the aluminum plate. It was in a 4 wire plug, seams like there were 2 of one color and 2 of another color. Anyway one of those wires was rubbing on the punch out hole edge and it finally cut through. I am guessing that the day it wouldn't start after lunch it was grounding out. Sorry for the long story but I hope this helps!
 
My sled is currently dead in the backcountry from this very same situation. I'm pretty sure the sled is grounding out somewhere and thats why there is no spark.... well, let me clarify that. There is spark, but it's so weak you can barely see it with the sun out (it was very bright out yesterday).

Same situation.... I just finished climbing a small draw and was meandering through the woods looking for the rest of our crew. I stopped, turned the key off (my kill switch is broke) like normal, and waited. About a minute later a friend pulled up, we listened for our friends, and then we decided to start up and move farther down the hill. Only problem is I didn't start. I know my EFI very well, so when it doesn't start on the first pull I know something isn't right. 5 pulls later I knew something bad was going down.

Long story short, pulled the plugs (nice chocolate brown), pulled the key switch apart, pulled the kill switch housing apart, tested spark (very very very faint), loaded fuel in the cylinders to check if fuel pump was the issue, traced all cables near the handlebars, tapped on the ECU (praying it would "wake up").... nothing.

Now after getting home and talking to a couple people it became obvious.... probobly a wiring issue. Something is grounding out. I'm going to check my motor ground and look at some other cables if I can ride back there today. Any other suggestions other than above?

Thanks fellas.
 
I could find no rubbed wires or any exposed wires. The cat wouldn't start today and is STILL 20 miles back in the backcountry.

I do, however, have a melted hood wiring harness. I smucked a tree the 2nd season I had this sled and melted the rubber housing around the hood wiring harness (right at the pipe in the front belly pan where it connects to the hood harness). I've ridden for two more years without any problems and all my gauges working. Think this might be causing it?

I check my tail light harness and it's good. I couldn't find any other exposed wires. Anymore help would be awesome because it's in a spot that has to be either choppered out or I have to get it early summer/late spring after the snow melts. Very crappy deal.
 
Magneto

Had these same symptoms on my 04 mountain cat. Took the magneto apart and one of the magnets on the flywheel had broken and completely nuked the stator. Replaced both and it fired first pull.
 
Had these same symptoms on my 04 mountain cat. Took the magneto apart and one of the magnets on the flywheel had broken and completely nuked the stator. Replaced both and it fired first pull.

I've never messed with or replaced a stator. Is that a repair that can be performed on the mountain?

Thanks diggerdown. I'm going to take a meter with me. Am I just checking for current when the sled is being pulled over?
 
stator

You should check to see if it's bad first and that can be done easily on the mountain. Go to you tube and type in a search for 'snowmobile stator' and there is a guy on there named BlaineDP that has good videos for testing and replacing the stator.
 
You should check to see if it's bad first and that can be done easily on the mountain. Go to you tube and type in a search for 'snowmobile stator' and there is a guy on there named BlaineDP that has good videos for testing and replacing the stator.

Excellent info. Now I know how to check my stator and further troubleshoot the problem. I guess if the stator is good, all un-needed electronics are unplugged, and she doesn't start.... it's the computer. Going in on Saturday with my meters and check everything out again.
 
Thanks to high times private message input I got the engine started. I ended up disconnecting the 4 wire plug near the rack and she fired on the first pull. This plug apparently disconnects a lot of auxiliary stuff, so now I have to go on the hunt for the wiring issue.

However I am now missing my top end... probably above 6k RPM. I'm thinking that disconnecting this plug put the computer into limp mode and thats why I'm not getting full RPMs. Sound possible?

Thanks for all the great help guys!
 
Probably disconnected the servo motor for the power valves when you unplugged the four wire deal. I wouldn't chase the top end issue until you have everything pulled back in properly.
 
Probably disconnected the servo motor for the power valves when you unplugged the four wire deal. I wouldn't chase the top end issue until you have everything pulled back in properly.

Agreed. I just want to get it out. I should be able to snag it on Friday!
 
HOW FUNNY!!!

Everyone o here just described what I had been going through for the last three weeks. I did everything I could think of. Changed coil, wires, injectors, fuel pump, you name it. Luckily my cousin has same sled so he would let me use his parts. Kill buttons, hand warmer controls, ect.. Ok here is the kicker would onl do it once in a while. was so pissed was ready to use sled to cook hotdogs. I removed my gas tank on Saturday because I had some debree in it from the rubber seal on the gas gage getting britle and falling in tank. So after I rmoved my tank I also decided to redo and trace all my wiring and put diode grease on all the connections. As I was doing this I noticed they had zip tied from the factory the wiring bundle to the sled right behind the gas tank below the steering post. Well I had traced my wires several times before but was never able to get to those and they looked fine from what I could see. They branch and go toward the tail light under the tank. Right were they were zip tied I cut the zip off and sure enough under the wires had rubbed through on 4 of the wires. I fixed them and my sled has never ran better. Its a 2005 king Kat and only has 1200 miles on it. You would sure think they could atleast wrap those wires up good enough we didn't have to worry about it. My sled is spotless and almost stock. So for that to happen I call poor quality. So I would suggest to EVERYONE to take the time and remove the tank and trace all your wires one at a time and I will bet that you will find a short rubbing somewere. I hope this helps some of you guys if you have any questions would be glad to help ya in any way I can. GOOD RIDING to ALL!!!!!! Greg
 
ECU NEEDED FOR EFI KING CAT

My power valves quit working and we found a short in the wire under the oil tank. Everything works but those so it sends me into limp mode. Were asuming that the ECU is fryed. Trying to find an ECU part #3006-936. Any ideas out there???
 
My power valves quit working and we found a short in the wire under the oil tank. Everything works but those so it sends me into limp mode. Were asuming that the ECU is fryed. Trying to find an ECU part #3006-936. Any ideas out there???

Country Cat New ECU

$1,370.72. I would make doubly sure that your ECU is fried. Do you know anyone local with the same ECU Square?
 
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