Content .. 63 64 65 66 ..

Snowmobile Arctic Cat (2002 year). Manual - part 65

4-53

734-482A

Menu List Organization

(Kokusan Special Mode)

1. Throttle Adjust - given in both volts and degree.

2. Fuel Change Number - number of times fuel leads

have been switched between regular gasoline and

oxygenated gasoline.

3. Last Gasoline Type - in case of engine failure,

what the system was last set for - regular gasoline

or oxygenated gasoline.

4. Other Rom Check - will indicate if the EPROM

chip has been changed. If none appears on the

display, the EPROM chip has not been changed

since the ECU was assembled.

5. Maximum Revolutions by Temperature - provides

a range in increments of 10° from -30° C to -101°

C. Will show engine RPM for each temperature

range and if the engine has been operated in the

range.

6. Running Time by Temperature - will indicate how

long the engine has been run in each temperature

range from 40° C to 101° C in increments of 10°.

7. Total Running Time - will show total hours on the

engine.

8. Barometric Pressure - provides current air

pressure.

To test an batteryless EFI system using the EFI Ana-

lyzer, follow all instructions carefully and completely.

Analyzer Setup

1. Before connecting the analyzer to the snowmobile,

always check to make sure the analyzer is OFF;

then connect the analyzer batteryless test harness

(equipped with red and black external leads) to the

ECU diagnosis connector.

2. Attach the red external lead to the positive

terminal of a 12-volt battery; then connect the

negative external lead to the negative post.

3. Press the ON button of the analyzer. At this point,

the power light of the analyzer must be

illuminated.

4. Push either MENU SELECT button on the

analyzer until KOKUSAN mode appears on the

display; then push the TEST button. The analyzer

is now ready to test the batteryless EFI system.

5. To retrieve information found under Kokusan

Special Mode, push Menu Select button until

Kokusan Special Mode appears on the display;

then push the TEST button. The analyzer is now

ready to test the special areas shown on the menu

list under Kokusan Special Mode.

NOTE: When testing the batteryless EFI system,

KOKUSAN mode must be on the display. Once the
TEST button is pressed with KOKUSAN mode on
the display, the analyzer will stay in this mode until
it is turned OFF.

NOTE: Each time the analyzer is turned OFF,

reselection of the KOKUSAN mode is necessary.
The ARCTCO mode, which will also appear on the
display when the MENU SELECT buttons are
pressed, is for testing an EFI (battery system).

EFI Components Not

Tested by Analyzer

When troubleshooting the EFI system with the EFI

Analyzer, there are EFI components the analyzer will

NOT diagnose. These components, (in the following

list) must be tested using a good digital volt/ohmmeter

or a fuel pressure gauge using recommended proce-

dures in this sub-section and in Section 5.

1. Fuel Pump Coil - Injection Coil - Timing Sensor.

2. Ignition Primary Coil.

3. Ignition Secondary Coil.

4. Fuel Pressure Regulator - Maintains fuel pressure

at 37.9 ± 2.2 psi (600 cc) and 48 ± 2.2 psi (800 cc).

5. Electric Fuel Pump - Located in the gas tank.

Supplies fuel under pressure to fuel injectors.

6. Switches and Stator Coils - Supplies all systems

with electrical current.

Recommended EFI

Troubleshooting

Sequence

(Kokusan Mode)

When troubleshooting the batteryless EFI system, use

the following troubleshooting sequence to locate prob-

lems quickly and efficiently.

EXISTING PROBLEM DIAGNOSIS TEST

This should be the first test made. In this mode, the

analyzer tests the following components all at once.

4-54

A. Throttle Position Sensor

B. Intake Air Temperature Sensor

C. Water Temperature Sensor

D. Barometric Pressure Sensor

E. Fuel Injectors

After pushing the TEST button on the analyzer, the

display will indicate either SENSORS ALL O.K. or

which of the sensors are defective. Check these com-

ponents individually using the recommended proce-

dures in this sub-section.

MEMORY PROBLEM DIAGNOSIS TEST

This should be the second test made. In this mode, the

analyzer will reveal any problems in the sensor area

which might have occurred intermittently as the snow-

mobile was being operated.

If there were any such intermittent problems, the prob-

lem area will be shown on the display. Check the indi-

cated area for a wire connection problem or loose or

corroded connections.

Testing Individual EFI

Components

NOTE: For all of the following tests using the EFI

Analyzer, the analyzer power light must be illumi-
nated. If not illuminated, the problem must be cor-
rected before proceeding. Also the analyzer must
be properly connected to a 12-volt battery.

EXISTING PROBLEM DIAGNOSIS TEST

(Engine Off) FUNCTION

NOTE: When using an analyzer which has been

updated with the new EPROM chip, first select
KOKUSAN by pressing the TEST button. This will
allow the testing of the batteryless EFI system.

1. With the analyzer OFF, connect its harness to the

diagnosis test plug. Connect the external leads of

the harness to a good 12-volt battery.

2. Switch the analyzer ON.

3. With analyzer power light illuminated, press the

MENU SELECT buttons repeatedly until the

words Existing Problem Diagnosis Test appear on

the display.

4. Press the TEST button. If all sensors are good,

SENSORS ALL O.K. will appear on the display.

If any of the sensors listed under Existing Problem

Diagnosis Test are defective, that sensor will be

indicated on the display. Proceed then to check the

defective sensor individually as covered in this

section.

NOTE: If proceeding to another test, first press

the TEST button once again to cancel the present
test. To select a different test function, use the
MENU SELECT buttons.

MEMORY PROBLEM DIAGNOSIS TEST

(Engine Off) FUNCTION

NOTE: When using an analyzer which has been

updated with the new EPROM chip, first select
KOKUSAN by pressing the TEST button. This will
allow the testing of the batteryless EFI system.

1. With the analyzer OFF, connect its wiring harness

to the diagnosis test plug. Connect the external

leads of the harness to a good 12-volt battery.

2. Switch the analyzer ON.

3. With both indicator lights illuminated, press the

MENU SELECT buttons repeatedly until Memory

Problem Diagnosis Test appears on the display.

4. Press the analyzer TEST button. If there has been

an intermittent problem in a sensor, that sensor

will be indicated on the display. Make necessary

repairs.

NOTE: If proceeding to another test, first press

the TEST button once again to cancel the present
test. To select a different test function, use the
MENU SELECT buttons.

CLEARING MEMORY

1. With the analyzer harness attached to the

diagnosis test plug, press the MENU SELECT

buttons until the words Diagnosis Memory Clear

appear on the display.

2. Press the analyzer TEST button and the words

Please Key Off should appear on the LCD; then

turn the analyzer switch to the OFF position.

Immediately turn the analyzer switch to the ON

position and the memory should now be clear.

NOTE: To check if the memory is clear, perform

Memory Problem Diagnosis Test to see if all sen-
sors test good. If a problem still remains on mem-
ory, repeat Clearing Memory procedure.

Existing Problem Diagnosis TEST

Memory Problem Diagnosis TEST

Diagnosis Memory Clear

Please Key Off

4-55

THROTTLE VALVE ANGLE TEST

(Degrees/Volts) FUNCTION

The correct throttle valve angle is extremely important

for proper engine operation. If the throttle valve angle

isn’t correct in the idle position, the engine may be

very difficult to start “cold.” If the throttle valve angle

isn't correct in any of the off-idle positions, engine

damage or poor performance may result because of an

incorrect mixture.

NOTE: When using an analyzer which has been

updated with the new EPROM chip, first select
KOKUSAN by pressing the TEST button. This will
allow the testing of the batteryless EFI system.

1. Connect the analyzer harness to the diagnosis test

plug. Make sure the analyzer is OFF.

2. Switch the analyzer ON.

3. With the analyzer power light illuminated, press

the MENU SELECT buttons on the analyzer

repeatedly until the words Throttle Valve Angle

appear on the display.

NOTE: When performing the Throttle Valve

Angle Test, test both the idle and full-open throttle
positions. Specifications are given for both posi-
tions in degrees and volts.

4. With the throttle in the “idle” position (engine not

running), press the analyzer TEST button. The

throttle valve angle should now appear on the

display.

5. If the “idle” position throttle valve angle or

voltage isn't within test specifications, push down

on the throttle shaft to make sure it is fully closed.

If the test specifications are now within tolerance,

loosen the throttle cable.

6. If the “idle” position throttle valve angle test

specification remains out of tolerance, adjust the

idle speed screw. If the throttle valve angle cannot

be corrected by either an idle speed screw or cable

adjustment, replace the throttle body assembly.

7. Compress the throttle lever to the “full-open”

position (engine not running). The test

specification must be within the tolerance shown

in chart. If the test specification is out of tolerance,

grasp the throttle cable next to the throttle shaft

and pull on the cable. If the test specification is

now within tolerance, adjust the throttle cable. If

the throttle valve angle remains out of tolerance,

replace the throttle body assembly.

8. If the specifications listed below ARE

DISPLAYED during the test, replace the throttle

body assembly.

NOTE: If the Throttle Position Sensor should fail,

the ECU will go into the “limp home” mode and the
above readings in the idle position will be dis-
played.

NOTE: If proceeding to another test, first press

the TEST button once again to cancel the present
test. To select a different test function, use the
MENU SELECT buttons.

INTAKE AIR TEMPERATURE SENSOR

(Engine Off) FUNCTION

NOTE: When using an analyzer which has been

updated with the new EPROM chip, first select
Kokusan by pressing the TEST button. This will
allow the testing of batteryless EFI system.

1. With the analyzer OFF, connect its harness to the

diagnosis test plug. Connect the external leads of

the harness to a good 12-volt battery.

2. Switch the analyzer ON.

3. With the analyzer power light illuminated, press

the MENU SELECT buttons repeatedly until

Intake Air Temperature appears on the display.

4. Press the analyzer TEST button and the intake air

temperature will be indicated on the display.

NOTE: Intake air temperature will be displayed in

both °C and °F.

NOTE: The temperature indicated should be

close to room temperature if the snowmobile
hasn't recently been run. Consider what tempera-
ture the snowmobile is actually at.

5. If when testing the intake air temperature sensor,

an indicated temperature of -40° C and °F is noted

and the actual snowmobile temperature isn't close

to this temperature, replace the sensor. The ECU

will automatically go to -40° C and °F when the

intake air temperature sensor fails.

Throttle Valve Angle

Throttle Valve Angle - Degrees

Model

Idle

Full-Open

800 cc

5.210°-5.720°

77.265°-86.135°

600 cc

3.715°-4.065°

77.265°-86.135°

Throttle Valve Angle - Voltage

Model

Idle (Volts)

Full-Open

(Volts)

800 cc

0.690-0.710 3.575-3.937

600 cc

0.625-0.647 3.575-3.937

Throttle Valve Angle - Degrees/Volts

Degrees/Volts

RPM Range

2.25/0.570

Idle to 3000

Intake Air Temperature

4-56

NOTE: If proceeding to another test, first press

the TEST button once again to cancel the present
test. To select a different test function, use the
MENU SELECT buttons.

BAROMETRIC PRESSURE SENSOR

TEST (Engine Off) FUNCTION

NOTE: When using an analyzer which has been

updated with the new EPROM chip, first select
KOKUSAN by pressing the TEST button. This will
allow the testing of the batteryless EFI system.

1. With the analyzer OFF, attach its harness to the

diagnosis test plug.

2. Switch the analyzer ON.

3. With the analyzer power light illuminated, press

the MENU SELECT buttons repeatedly until the

words Barometric Pressure appear on the display.

Barometric Pressure

4. Press the analyzer TEST button and actual area

barometric pressure will be indicated.

NOTE: Actual area barometric pressure can be

obtained from a local airport, radio station, etc.

5. If the barometric pressure sensor has failed, the

ECU will automatically go to the barometric

pressure shown below. If these readings APPEAR

on the display, replace the ECU.

Peak Voltage Tests

and Specifications

(2002 Models)

Fuel Pump Coil Test (Static)

1. Remove the spark plugs and ground them to the

cylinder heads.

2. Unplug orange leads from stator and test between

the two orange wires from the stator.

3. Pull the recoil starter rope briskly. Reading should

be 13 volts or higher.

Fuel Pump Coil Test (Running)

1. Connect the two orange leads from the stator to the

ECU.

2. Insert a paper clip into each orange wire connector

making contact with its terminal.

3. Start the engine and test between the two orange

leads. Reading should be approximately 13 to 15

volts.

ECU Output To Fuel Pump (Running)

1. With the engine running, test between the red and

black leads in the pump connector.

2. Reading should be 12 to 15 volts (600 cc) or 18-26

volts (800 cc).

NOTE: If the output between the orange leads to

the ECU are within tolerance but the ECU output is
low, replace the ECU. If the ECU output is within
specifications but the fuel pump fails to operate,
replace the fuel pump.

Injector Coil Output Test (Static)

1. Remove the spark plugs and ground them to the

cylinder heads.

2. Unplug the double lead connector at the ECU

having two blue/white wires.

3. Test between the two blue/white leads in the

connector harness from the stator plate.

4. Pull the recoil starter rope briskly. Reading should

be approximately 80 volts.

Injector Coil Output Test (Running)

1. Install the spark plugs and tighten securely.

2. Connect the double lead connector to the ECU

leaving just enough room to make contact with the

meter leads.

3. Start the engine and test between the two blue/

white leads in the double connector. Reading

should be approximately 20 to 22 volts.

ECU Output To The Injectors (Number

1 Injector)

1. Using two paper clips, insert them into the number

1 (MAG-side) connector (yellow and yellow/red

leads) at the injector from the back side. Leave the

connector attached to the injector. Touch red

meter lead to yellow and black meter lead to

yellow/red.

2. Start the engine. Reading should be approximately

20 volts.

NOTE: Repeat the same test as above for injec-

tor number 2. Switch meter leads to the green and
green/red leads. Reading should be approximately
20 volts.

Charge Coil (2) Test (Static)

1. Remove the spark plugs and ground them to the

cylinder heads.

2. Unplug the triple plug connector from the ECU.

Model

Barometric Pressure

800 cc

880 mm/hg

(34.65 in./hg)

600 cc

880 mm/hg

(34.65 in./hg)

Content .. 63 64 65 66 ..