In this paper, evolution of microstructures, electrical properties and defects of the double Schottky barrier during the sintering process were investigated by quenching ZnO varistor ceramics at different sintering stages. It was found that morphology of the samples changed little when the temperature was below 800 °C. Remarkable enhancement of the Schottky barrier height and electrical properties took place in the temperature range between 600 °C and 800 °C. The Bi-rich intergranular layer changed from β phase to α phase. The interfacial relaxation at depletion/intergranular layers became detectable in the samples. Meanwhile, a distinct relaxation loss peak from electron trapping of interface states was observed instead of two dispersed ones. It indicated that the differences among the Schottky barriers in ZnO varistor ceramics became smaller with the process of sintering, which was also supported by the admittance spectra. In addition, oxygen vacancy was found more sensitive to the sintering process than zinc interstitial. The results could provide guidance for fine manipulating the Schottky barrier and its underlying defect structures by optimizing sintering process.