Snowmobile Arctic Cat (2002 year). Manual - part 66

4-57

4

3. Test between the green/red and brown/white wires

in the triple plug connector from the stator. Pull

the recoil starter rope briskly. Reading should be

85-94 volts.

Charge Coil (1) Test (Static)

1. Remove the spark plugs and ground them to the

cylinder heads.

2. Unplug the triple plug connector from the ECU.

3. Test between the black/red and green/red wires in

the triple plug connector from the stator. Pull the

recoil starter rope briskly. Reading should be 100-

110 volts.

ECU Output To Secondary Coil 

(Static)

1. Remove the spark plugs and ground them to the

cylinder heads.

2. Contact one small lead with the black meter leads

and the other small lead with the red meter lead.

Pull the recoil starter rope briskly. Reading should

be 130-143 volts.

„

NOTE: If the CDI unit isn’t within specifications

and if the charge coil (1) and charge coil (2) read-
ings were within specifications, replace the ECU.

Ignition Timing Sensor Output (Static)

1. Remove the spark plugs and ground them to the

cylinder heads.

2. Unplug the 2-lead connector of the timing sensor

harness. Test between the green/white and brown

wires in the connector from the sensor.

3. Pull the recoil starter rope briskly. Reading should

be 1.5 volts or higher.

Air Temperature Sensor Output 

Voltage Test From ECU

1. Remove the spark plugs and ground them to the

cylinder heads.

2. Unplug the blue and black leads from the air

temperature sensor.

3. Test between the blue and black leads from the

ECU. Pull the recoil starter rope briskly. Reading

should be approximately 4.5 to 5 volts.

Water Temperature Sensor Output 

Voltage Test From ECU

1. Remove the spark plugs and ground them to the

cylinder heads.

2. Unplug the yellow and black leads from ECU to

the water temperature sensor. Test between the

yellow and black leads from the ECU. Pull the

recoil starter rope briskly. Reading should be

approximately 4.5 to 5 volts.

„

NOTE: If either the air temperature or water tem-

perature sensor output test is low, retest to con-
f i r m   r e s u l t s .   I f   e i t h e r   t e s t   r e m a i n s   o u t   o f
specification, replace the ECU.

Throttle

Position Sensor

It is not possible to replace the throttle position sensor

on the batteryless EFI system. If the sensor should

malfunction, the complete throttle body assembly must

be replaced.

„

NOTE: It is important to order a throttle body

assembly with the same symbol marking on the
injectors as the ones being replaced. The symbol
is located on the side of the injector top.

Throttle Body

Flange

REMOVING

1. Loosen the clamps securing the throttle body

assembly to the throttle body flanges.

2. Remove the throttle body assembly from the

flanges.

3. In turn on each flange, remove the two nuts, lock

washers, and flat washers securing the intake

flange to the cylinder; then remove the flange.

INSTALLING

1. Apply a thin coat of high-temperature silicone to

the cylinder side of each flange; then attach each

flange to a cylinder and secure each with two flat

washers, lock washers, and nuts. Tighten to 1.5-

1.9 kg-m (11-14 ft-lb).

2. Install the flange clamps on the flanges; then place

the throttle body assembly into the flanges and

secure with the clamps.

3. Secure all wires and hoses with cable ties.

4-58

Throttle Body

Assembly

0736-279

REMOVING

1. Disconnect the wiring harness from each injector

and from the throttle valve sensor connector.

2. Remove the coolant hose from the PTO-side of the

throttle body and plug it to prevent leakage.

3. Remove the fuel return hose (600 cc) and supply

hose from the fuel pressure regulator (600 cc) and

delivery pipe. Label for assembly.

4. Loosen the flange clamps.

5. Slide the throttle body assembly out of the flanges;

then loosen the jam nut securing the throttle cable

and remove.

6. Remove the throttle body.

AR113

INSTALLING

1. Attach the throttle cable to the throttle body.

Secure with jam nut.

2. Place the throttle body assembly into position.

Make sure the flanges and boots are positioned

properly. Secure with flange clamps.

3. Secure the fuel supply hose and return hose (600

cc) to the delivery pipe and regulator (600 cc).

KEY

1. Throttle Body Assembly
2. Fuel Pressure Regulator
3. Bolt
4. Delivery Pipe
5. Fuel Injector
6. Screw
7. Control Rod
8. Rod End
9. Spring Pin

10. Hose
11. Hose Clamp
12. O-Ring Set

600 cc

KEY

1. Throttle Body Assembly
2. Delivery Pipe
3. Fuel Injector
4. Screw
5. Hose
6. Hose Clamp
7. O-Ring Set

800 cc

! CAUTION

Since the fuel supply hose may be under
pressure, remove it slowly to release the
pressure. Place an absorbent towel around the
connection to absorb fuel.

! CAUTION

These hoses must be connected to the correct
fittings.

4-59

4

0729-325

4. Secure the coolant hose to throttle body assembly.

5. Connect the wiring harness to each injector and

throttle valve sensor.

6. Place the rear of the snowmobile on a shielded

safety stand and start the engine without touching

the throttle. It may idle slowly and stop. Restart

using the same procedure until the engine starts

and builds RPM on its own.

7. Check the cooling system.

8. Adjust the throttle cable as necessary.

Throttle Cable

REMOVING

1. Open the belt guard and remove the belt.

2. Remove the driven pulley.

3. Remove the E-clip securing the oil-injection cable

to the oil-injection pump control arm. Account for

a washer.

4. Loosen the oil-injection cable jam nuts.

5. Loosen the throttle cable jam nuts.

6. Remove the throttle cable from the throttle body

assembly.

7. Remove the handlebar pad.

8. Remove the cable ties securing the throttle cable.

9. Remove the throttle cable end from the throttle

lever.

10. Using Throttle Cable Removal Tool (p/n 1639-

963), push down on the throttle cable retaining

clip; then remove the cable from the throttle

switch assembly.

INSTALLING/ADJUSTING

1. Install the throttle cable into the throttle switch

assembly making sure the cable snaps into place.

2. Install the throttle cable end on the throttle lever.

3. Route the throttle cable from the throttle switch

assembly to the throttle body assembly and oil-

injection pump; avoid any sharp bends or moving

components.

4. Attach the throttle cable to the throttle body.

5. Install the oil-injection cable adjuster on the oil-

injection pump; secure with the jam nuts.

6. Install the oil-injection cable on the control arm;

secure with a washer and E-clip.

7. Secure the throttle cable to the steering post with

cable ties.

8. Install the handlebar pad.

9. Adjust the throttle cable tension by turning the jam

nuts in the appropriate direction until there is 0.75-

1.5 mm (0.030-0.060 in.) free-play in the throttle

lever and the butterfly completely opens and

closes. Tighten the jam nuts securely.

733-081C

10. Synchronize the oil-injection pump.

11. Install the driven pulley.

12. Install the belt and secure the belt guard.

! WARNING

Check all hose connections for leakage. Repair as
necessary.

! CAUTION

Compress the throttle control lever to ensure
free movement. If the throttle cable sticks or
binds, correct the problem before starting the
engine.

0736-975

4-60

BASIC EFI SYSTEM INFORMATION

Item

Description

Basic system

Fuel supply system

Electronically controlled multi-point injection

Ignition system

(CDI system) Digital

Air/fuel flow 

meter

System

O/N (throttle opening/engine revolution) system & atmospheric 

pressure compensation

Component parts

Throttle opening sensor 
Atmospheric pressure sensor

Injection system

One time simultaneous injection per revolution 

(synchronized ignition)

Fuel system

Fuel pressure

Regulated high pressure 37.9 ± 2.2 psi (600 cc)/ 48 ± 2.2 psi 

(800 cc)

Fuel return (600 cc)

Pressure regulated by pressure regulator. There are fuel 

returns.

Throttle 

system

System

1 stage x duplex (1 bore/cylinder)

Diameter of the bore

46 x 2 (Effective area equivalent to 40)

Type of valve

Butterfly type

Operating angle

80° (full closed angle 10°)

Radius of drum

R25 (at wire center)

Adjusting system for idle revolution

Throttle adjusting screw type

Comp

one

nt p

a

rt

s

 and

 s

pec

if

ic

ati

ons

Control unit

Fuel injection control

F

uel

 s

y

s

tem

Fuel pump

Gear type

Injection

Side feed type

Pressure regulator (600 cc)

Diaphragm type

Fuel filter

Fine screens on pick-up hose

Fuel piping

High pressure specification 37.9 ± 2.2 psi (600cc)/ 48 ± 2.2 psi 

(800 cc) 

Throttle body

1 bore/cylinder x duplex

S

ens

or

, e

tc.

Throttle sensor

Revolution scrubbing type potentiometer

Pressure sensor

Semiconductor type

Water temperature sensor

Thermistor type

Intake air temperature sensor

Thermistor type

Cable harness

Equivalent to current harness

Other

Batteryless EFI System