Snowmobile Arctic Cat (2002 year). Manual - part 41

 

  Index      Snowmobiles / ATV     Snowmobile Arctic Cat - service manual 2002 year

 

Search            

 

 

 

 

 

 

 

 

 

Content   ..  39  40  41  42   ..

 

 

Snowmobile Arctic Cat (2002 year). Manual - part 41

 

 

2-147

2

Problem: Engine Stops Suddenly

Condition

Remedy

1. Gas tank empty
2. Spark absent
3. LED trouble code
4. CDI relay faulty
5. Fuel filter(s) obstructed
6. Fuel pressure low
7. Fuel pump faulty
8. Fuel pump relay faulty
9. Gas tank vent hose obstructed

10. ECU faulty
11. Fuel hose obstructed — broken — pinched

12. CDI unit faulty
13. Ignition coil faulty
14. Engine seized
15. Throttle/ignition monitor switch — throttle 

cable tension faulty — adjusted incorrectly

1. Fill tank
2. See No Spark at Spark Plugs sub-section
3. Service — replace problem component
4. Replace CDI relay
5. Replace filter(s)
6. Replace regulator — hose
7. Service — replace fuel pump
8. Replace relay
9. Service vent hose

10. Replace ECU
11. Remove obstruction — repair — replace fuel 

hose

12. Replace ECU
13. Replace ignition coil
14. Overhaul engine
15. Replace throttle control — adjust throttle cable

Problem: Engine Fails to Stop (Continues to Run, Even with All Switches Off)

Condition

Remedy

1. CDI unit shorted to ground
2. Engine wiring harness connections wet

1. Replace ECU
2. Clean — dry connections

2-149

2

c

@

 6000 

R

P

M

d

@

 4000 

R

P

M

e

@

 3250 

R

P

M

f

@

 3500

 R

P

M

g

@

 5000

 R

P

M

h

@

 1800

 R

P

M

i

@ 200

0 RP

M

     

        

j

@ 3000 R

P

M  

   

*E

n

g

ine W

a

rm

  

k

@ 250

0 R

P

M     

   

           

         

  

2002 Arctic Cat 

En

gi

ne

 S

pe

cifi

ca

tions

IT

EM

120 cc

370 cc

44

0 cc

 

50

0 cc 

55

0 cc

57

0 cc

600

 cc EF

I

600

 c

c

 

C

a

rb (

Trip

le

)

600

 c

c

 

Ca

rb

 (

T

w

in)

8

0

cc

 C

a

rb

80

cc

 E

F

I

10

0

cc

En

gi

ne

 M

ode

l N

umb

er

AA

12A

1

AA3

7A4

AS4

4A5

A

U

50

L6

A

C

B

55L3

AA5

6A1

A

D6

0L

6

A

G

60L8

AF

60L

6

AA78L2

A

B

78L2

A

A

10

L5

D

isp

la

ce

me

nt

cc 

cu

. i

n.

11

7.

3

36

22

.4

1

431 

26

.3

49

30

.3

55

33

.5

6

56

34

.5

59

36

.5

4

59

36

.2

4

59

36

.5

4

785

 

47.

9

785 

47

.9

99

60

.9

6

N

o.

 o

C

yl

in

de

rs

1222222322

23

Bo

re 

·

 m

m

 ·

 in

.

60

 

2.

4

60

 

2.

36

2

65

 

2.

55

9

71

 

2.

800

73

.4

 

2.

890

73

.8 

2.

91

0

78 

3.

07

1

66

.5

 

2.

61

8

78 

3.

07

1

81 

3.

188

81 

3.1

88

81 

3.1

9

St

ro

ke

· 

mm

· 

in

.

42

 

1.

7

65

 

2.

55

9

65

 

2.

55

9

62

.7

 

2.

46

9

65

 

2.

55

9

66

 

2.

59

8

62

.7

 

2.

46

9

57

 

2.

24

0

62

.7

 

2.

46

9

76 

2.

99

2

76

 

2.9

92

64

.6

 

2.5

4

Co

m

pr

es

si

on

 R

at

io

8.

2:1

6.

3:1

6.

5:

1

6.

74

:1

6.

6:

1

6.4

:1

6.

55

:1

6.

4:

1

6.5

5:

1

6.2

9:

1

6.2

9:

1

6.4

:1

C

oo

ling 

Sy

st

em

Fa

C

ool

ed

Fa

Co

ol

ed

Fa

Co

ol

ed

Li

qu

id

 C

oo

le

d

Li

qu

id

 C

oo

led

Fa

Co

ole

d

Li

qu

id 

C

ool

ed

Li

qui

C

ool

ed

Liq

ui

C

oo

le

d

Liq

ui

C

oo

le

d

Liq

ui

Co

ol

ed

Li

qu

id

 C

oo

le

d

G

as

o

lin

O

ct

an

(m

in

)

87

87

87

87878787878787

87

87

Fue

l M

ix

tu

re

N/A

O

il I

nj

ec

tio

n

Oi

l Inj

ec

tio

n

O

il 

Inj

ec

tio

n

Oi

l In

je

ct

io

n

O

il 

In

je

cti

on

Oi

l In

je

ct

io

n

O

il In

je

ct

io

n

O

il In

je

ct

io

n

O

il In

je

ct

io

n

O

il In

je

ct

io

n

O

il I

nj

ec

tio

n

Ign

iti

on

 Ti

m

in

de

gr

ee

s

 ·

 m

m

· 

in

.

Fi

xe

d

18

i

*

2.

01

0.

07

9

18

i

*

2.

01

0.

07

9

25

i

 

3.

67

0.

14

5

33

i

*

6.

556 

0.

25

8

 1

8

i

*

 

2.

04

0.

081

24

f

3.

39

0.

13

3

18

i

2.

01

0.

07

9

24

i

3.

39

0.

13

3

14

i

1.

41

0.

05

6

26

k

4.7

96

0.1

89

16

e

1.

556

 

0.

061

Sp

ark 

Plu

(N

G

K)

BP

R

6ES

BR

9EY

A

BR

9EY

A

BR

9EY

A

BR

9EY

A

BR

9EY

A

BR

9E

YA

BR

9E

YA

BR

9E

YA

BR

9E

YA

B

R

9E

YA

B

R

9E

YA

Sp

ark 

Plu

G

ap

· 

mm

· 

in

.

0.

7-

0.

0.

02

8-

0.0

31

0.

7-

0.

8 0.

02

8-

0.0

31

0.

7-

0.

0.

02

8-

0.0

31

0.

7-

0.

0.

02

8-

0.0

31

0.

7-

0.

0.

02

8-

0.

03

1

0.

7-

0.

0.

02

8-

0.

03

1

0.

7-

0.

0.

02

8-

0.

031

0.

7-

0.

0.

02

8-

0.0

31

0.

7-

0.

0.

02

8-

0.0

31

0.

7-

0.

0.

02

8-

0.0

31

0.7

 -

0.8

0.

02

8-

0.

031

0.7

-0.

0.

028-

0.

031

Li

gh

tin

C

oi

l O

utp

ut

12

V/

55

W

12V/

185W

12

V/

185W

12

V/

21

0W

12

V/

180W

12

V/

210

W

12

V

/175

W

12

V

/2

10

W

12

V

/2

10

W

12V

/2

10

W

12V/

190

W

12V/

18

5W

Ign

iti

on

 T

yp

e

Tr

an

si

st

or

iz

ed

C

D

I/N

OI

CD

I/N

OI

CD

I/N

OI

C

D

I/NOI

C

DI/

N

OI

C

D

I/NOI

C

DI

/NOI

C

D

I/NO

I

C

DI

/NO

I

CDI

/N

O

I

C

D

I/N

OI

Pi

st

on

 Sk

ir

t/C

yl

in

der

 

·

 m

Cl

ear

an

ce

 R

ang

e

·

 in.

0.

02

0-

0.

12

0

0.

00

08-

0.

00

47

0.

06

0-

0.

15

0

0.

00

24

-0

.0

05

9

0.

080-

0.

15

0

0.

00

31

-0

.0

05

9

0.

083

-0.

15

0

0.

00

33

-0

.00

59

0.

095-

0.

15

0

0.

0037

-0

.0

059

0.

09

5-

0.

15

0

0.

00

37

-0

.0

059

0.

083-

0.

150

0.

00

33

-0

.0

05

9

0.

085-

0.

15

0

0.

00

34

-0

.0

05

9

0.

083-

0.

15

0

0.

00

33

-0

.0

05

9

0.

083-

0.

15

0

0.

00

33-

0.

00

59

0.

083-

0.

15

0

0.

00

33-

0.

00

59

0.

095

-0

.1

50

0.

003

7-

0.

005

9

Pi

st

on

 R

in

End

·

 m

G

ap 

R

ang

e

·

 in.

0.

20

-0

.7

0

0.

00

79

-0

.0

280

0.

15

-0

.80

0.

00

6-

0.

03

1

0.

15

-0

.83

0.

00

6-

0.

03

3

0.

20

-0

.83

0.

00

8-

0.0

33

0.

20

-0

.83

0.

00

8-

0.

03

3

0.

20

-0

.83

0.

00

8-

0.

03

3

0.

20

-0

.83

0.

00

8-

0.

033

0.

20

-0

.83

0.

00

8-

0.0

33

0.

20

-0

.83

0.

00

8-

0.0

33

0.

30

-0

.5

0

0.

01

2-

0.

02

0

0.3

0-

0.5

0

0.

01

2-

0.

02

0

0.

20-

0.

83

0.

008-

0.

033

C

yli

nd

er

 T

ru

en

es

s

·

 m

Li

m

it (

m

ax

)

· 

in

.

0.

03

 

0.

00

12

0.

0.

00

4

0.

0.

00

4

0.

0.

00

4

0.

0.

00

4

0.

0.

00

4

0.

0.

00

4

0.

0.

00

4

0.

0.

00

4

0.

0.

00

4

0.1

 

0.0

04

0.1

 

0.

004

Pi

st

on

 P

in

· 

mm

Di

ame

te

R

ange

·

 in

.

14

.9

80

-14

.9

95

0.

5898-

0.

59

04

17

.9

95

-1

8.0

00

0.

70

85

-0.

70

87

15

.9

95

-1

6.

00

0

0.

62

97

-0

.6

29

9

19

.9

95

-2

0.0

00

0.

7872

-0

.7874

19

.995

-2

0.

000

0.

7872

-0

.7

874

17

.9

95

-1

8.

000

0.

70

85

-0.

70

87

19

.9

95

-2

0.

00

0

0.

7872

-0

.7

874

17

.9

95

-1

8.0

00

0.

70

85

-0.

70

87

19

.9

95

-2

0.

00

0

0.

7872

-0

.7

874

23.

995-

24.

00

0

0.

94

47-

0.

94

49

23

.9

95-

24

.0

00

0.

94

47-

0.

94

49

19

.9

95

-2

0.

00

0

0.7

872

-0

.7

874

Pi

st

on

 Pi

B

or

· 

mm 

 

Di

ame

te

R

ange

·

 in

.

15

.0

06

-1

5.

03

0

0.

59

08-

0.

59

17

17

.9

98-

18.0

06

0.

70

86

-0.

70

89

15

.9

96

-1

6.

00

4

0.

62

98-

0.

63

01

20

.0

02

-2

0.0

10

0.

7875

-0

.7878

20

.002

-2

0.

010

0.

7875

-0

.7

878

17

.9

98-

18.

006

0.

70

86

-0.

70

89

20

.0

02

-2

0.

01

0

0.

7875

-0

.7

878

18.0

02

-1

8.0

08

0.

70

87

-0.

70

90

20

.0

02

-2

0.

01

0

0.

7875

-0

.7

878

24.

002-

24.

01

0

0.

94

50-

0.

94

53

24

.0

02-

24

.0

10

0.

94

50-

0.

94

53

20

.0

02

-2

0.

01

0

0.7

875

-0

.7

878

Co

nn

ec

tin

R

od

·

 mm

 

Smal

l En

Bore

·

 in

.

 D

ia

met

er 

R

an

ge

15

.0

06

-1

5.

03

0

0.

59

08-

0.

59

17

23

.0

03

-2

3.

01

1

0.

90

56

-0

.9

05

9

21

.0

03

-2

1.

01

1

0.

826

9-

0.

827

2

26

.0

03

-2

6.0

11

1.

02

37

-1

.02

41

26

.003

-2

6.

011

1.

0237

-1

.0

241

23

.0

03

-2

3.

011

0.

90

56

-0

.9

059

26

.0

03

-2

6.

01

1

1.

02

37

-1

.0

24

1

23

.0

03

-2

3.

01

1

0.

90

56

-0

.9

05

9

26

.0

03

-2

6.

01

1

1.

02

37

-1

.0

24

1

29.

003-

29.

01

1

1.

14

10-

1.

14

20

29

.0

03-

29

.0

11

1.

14

10-

1.

14

20

26

.0

03

-2

6.

01

1

1.

023

7-

1.

024

1

Co

nn

ec

tin

R

od

·

 mm

 

Ra

dia

l P

la

R

an

ge

·

 in.

0.

01

5-

0.

07

0

0.

00

06

-0

.0

02

8

0.

02

-0

.0

3

0.

00

08-

0.

00

12

0.

02

-0

.0

3

0.

00

08-

0.

00

12

0.

02

-0

.0

3

0.

00

08-

0.00

12

0.

02

-0

.0

3

0.

0008-

0.

0012

0.

02

-0

.0

3

0.

00

08-

0.

0012

0.

02

-0

.0

3

0.

00

08-

0.

00

12

0.

02

-0

.0

3

0.

00

08-

0.

00

12

0.

02

-0

.0

3

0.

00

08-

0.

00

12

0.

00

3-

0.

02

0

0.

00

01-

0.

00

08

0.

00

3-

0.

02

0

0.

00

01-

0.

00

08

0.

02-

0.

03

0.

000

8-

0.

001

2

Cr

an

ks

ha

ft R

un

ou

t

·

 m

m

 

(t

.i.r

.)

·

 in

.

0.

10

 

0.

00

4

0.

05

 

0.

00

2

0.

05

 

0.

00

2

0.

05

 

0.

00

2

0.

05

 

0.

00

2

0.

05

 

0.

00

2

0.

05

 

0.

00

2

0.

05

 

0.

00

2

0.

05

 

0.

00

2

0.

05

 

0.

00

2

0.0

5

0.0

02

0.

05 

0.

002

Cr

an

ks

ha

ft E

nd

·

 m

m

 

P

la

y R

an

ge

· 

in

.

0.

05

-0

.1

0

0.

00

2-

0.

00

4

0.

05

-0

.1

0

0.

00

2-

0.

00

4

0.

05

-0

.1

0

0.

00

2-

0.

00

4

0.

05

-0

.1

0

0.

00

2-

0.

00

4

0.

05

-0

.1

0

0.

002-

0.

00

4

0.

05

-0

.1

0

0.

00

2-

0.

00

4

0.

05

-0

 

 

 

 

 

 

 

Content   ..  39  40  41  42   ..