99 Cat ZL 500 WON'T SHUT OFF

rkw

New member
Neither the ignition switch or the kill switch will turn off the machine.
I have to unplug the coil primary wire to kill her. Any ideas?
 

marty700

Member
First of all, try using the choke to kill the engine if the switches won't work. If that doesn't work (you should check your choke), try shorting the spark by resting a screwdriver across the top of one spark plug boot and touching the top of the engine. Make sure its a well insulated screwdriver or you'll get "bit" with quite a shock. If the screwdriver is well insulated, though, you should have no problem.

As for the problem, the common ground wire has probably either separated from the plug or broken. One way or another, you're not getting a ground. Check all of the black wires going into and out of the main electrical plugs. If nothing is evident, check the plugs themselves. I had this exact problem a few weeks ago. One of the black ground wires was not making contact inside the plug that connected the main wire bus from under the airbox to the engine. I simply pressed the wire further into the plug until it made good contact and then used a little epoxy to hold it securely in place in the plug. At some point in the off-season, I'll replace the plug.
 

booondocker

New member
Yep, ground wire. All the plugs corrode in time and need to be cleaned up. Start at the battery...make sure the engine ground wire (sometimes two wires lead to the ground, and in hast or neglect you only hooked up one???) then move along from there.

Then check the ground wire to the motor block, they can get loose and corrode too.

When the kill switch, ingition switch and tether switch all won't work...I bet ground for sure. If only one, then it is likely the switch itself that has gone bad.
 

snowboss

New member
Also check the 4 prong plug that comes out of the Mag. If that is unpluged or not making a good conection you will have all the problems that you have discribed
 
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