Snowmobile Arctic Cat (2002 year). Manual - part 76

5-23

5

4. Using TPS Adjustment Tool (p/n 0644-299),

connect its wiring harness to the TPS. Connect the

two digital voltmeter leads (red and black) using

the two pin jack adapters provided with the

adjustment tool to the white and black jacks of the

TPS adjustment tool.

5. With the throttle in the closed position (valve

resting on the pin gauge), compare the reading on

the voltmeter to the chart. If the reading is at the

prescribed specification, proceed to step 6. If the

reading is not at the prescribed specification,

proceed to Adjusting TPS (Carbureted Models) in

this sub-section.

6. Hold the throttle in the wide-open position; then

compare the reading on the voltmeter to the chart.

If the reading is not within the specification range,

recheck the closed position reading. If the closed

position reading is correct and the wide-open

position reading is not, the TPS is faulty and must

be replaced.

7. If both voltmeter readings are correct, remove the

test harness and pin gauge, install the carburetor

assembly (see Section 4), and connect the

snowmobile TPS harness to the TPS.

„

NOTE: Before installing the TPS harness con-

nector, apply dielectric grease to the connector
pins.

ADJUSTING TPS (Carbureted 

Models)

1. Using TPS Screwdriver (p/n 0644-344), loosen the

two retaining screws securing the TPS to the

carburetor.

2. Adjust the TPS to obtain the correct closed

position reading on the voltmeter.

3. Tighten the two retaining screws securely.
4. To verify TPS position is correct, proceed to steps

6 and 7 of Checking TPS (Carbureted Models) in

this sub-section.

CHECKING/ADJUSTING TPS

(EFI Models)

„

NOTE: Before using the TPS adjustment tool,

verify its battery condition. The battery used in the
tool is a 9-volt battery; also, the Test Harness (p/n
0686-627) must be plugged into the analyzer for
testing voltage.

To check battery condition, use a digital volt/ohmme-

ter set on DC volt scale. Test between the adjustment

tool black and red jacks. Insert the red lead of the digi-

tal voltmeter into the red jack of the adjustment tool

and the black lead of the digital voltmeter into the

black jack of the adjustment tool. If voltage is found

below 4.9 volts, replace the battery.

1. Using TPS Adjustment Tool (p/n 0644-299),

connect its wiring harness to the TPS. Connect the

two digital voltmeter leads (red and black) using

the two pin jack adapters provided with the

adjustment tool to the white and black jacks of the

TPS adjustment tool.

2. Ensure that the throttle cable has the  proper

amount of free-play.

3. With the throttle in the idle position, compare the

reading on the voltmeter to the chart. If the reading

is at the prescribed specification, proceed to step 6.

If the reading is not at the prescribed specification,

proceed to step 4.

4. Using TPS Screwdriver (p/n 0644-344), loosen the

two retaining screws securing the TPS to the

throttle body.

5. Adjust the TPS to obtain the correct idle position

reading; then tighten the two retaining screws

securely.

6. Depress the throttle lever slowly. The meter

reading should show a smooth rise all the way to

wide-open throttle. Repeat this step until it is

assured that there are no open areas or “peaks” in

the reading.

Engine

Closed 

Position 

Idle 

RPM

Wide-Open 

Position

500 cc

0.56V

1500

3.796-4.222V

600 cc (Twin)

0.56V

1500

3.796-4.222V

600 cc (Triple)

0.56V

1500

3.639-4.056V

800 cc

0.56V

1500

3.941-4.370V

1000 cc

0.56V

1500

3.796-4.222V

Engine

Idle 

Position

Wide-Open 

Position

600 cc

0.64V

3.575-3.937V

800 cc

0.69-

0.71V

3.575-3.937V

5-24

7. Disconnect the adjustment tool harness from the

TPS. Connect the snowmobile TPS harness to the

newly installed or adjusted TPS.

„

NOTE: Before installing the TPS harness con-

nector, apply dielectric grease to the connector
pins.

REPLACING TPS (All Models)

1. Disconnect the throttle cable from the throttle

shaft.

2. Turn the idle adjustment screw counterclockwise

until it is not in contact with the throttle lever.

3. Disconnect the TPS wiring harness connector.

Using TPS Screwdriver (p/n 0644-344), remove

the two retaining screws securing the TPS to the

carburetor/throttle body.

4. Install the new TPS and secure with two retaining

screws, flat washers, and lock washers.

5. Adjust the TPS using the appropriate procedures

in this sub-section.

FAIL-SAFE IGNITION TIMING

Engines equipped with the 3-D ignition system have a

protective feature called “fail-safe” ignition timing

which prevents engine damage should the TPS fail. If

the TPS does fail, the engine will run normally at low

RPM but will run poorly at high RPM. This will allow

the operator to get the snowmobile to safety with little

or no engine damage.

„

NOTE: The engine will continue to operate this

way until the TPS is replaced.

Testing Main Wiring 

Harness

(120 cc Model)

„

NOTE: The main wiring harness test can be

made using the Fluke Model 73 Multimeter (p/n
0644-191).

1. Disconnect the engine wires from the main wiring

harness.

2. At the main wiring harness engine connector,

connect the red tester lead to the violet wire; then

connect the black tester lead to the engine ground

(brown wire).

3. With the ignition switch in the RUN position, the

emergency stop switch in the ON position, and the

tether cord connected, the meter must read no

resistance. If the meter reads resistance,

disconnect the ignition switch from the main

wiring harness. If the meter now reads no

resistance, replace the ignition switch.

725-704A

4. If the meter continues to read resistance with the

ignition switch disconnected, disconnect the

emergency stop switch. If the meter now reads no

resistance, replace the emergency stop switch.

5. If the meter continues to read resistance with both

the ignition switch and the emergency stop switch

disconnected, disconnect the wires to the tether

switch. If the meter now reads no resistance,

replace the tether switch.

6. If the meter continues to read resistance with all

three switches disconnected, replace the main

wiring harness.

Testing Electrical 

Resistances

(120 cc Model)

„

NOTE: The following test procedure starts by

testing the resistance of the spark plug cap and
working back to the stator under the flywheel.
Replace any component that does not have a test
value within specifications.

SPARK PLUG CAP

1. Remove the spark plug cap from the high tension

lead by rotating it counterclockwise.

2. Set the selector in the X1K position.
3. Connect one tester lead to one end of the cap and

the other tester lead to other end of the cap.

5-25

5

B170

4. Spark plug cap resistance must be between 4000-

6000 ohms.

LIGHTING COIL

1. Disconnect the two yellow wires from the main

wiring harness.

2. Set the selector to the OHMS position.
3. Connect the tester leads to the two yellow leads on

the engine-side connectors.

4. Lighting coil resistance must be between 0.46-

0.68 ohm.

Testing Electrical 

Resistances

(EFI Models)

„

NOTE: Resistance tests of the engine electrical

components should be made using the Fluke Mul-
timeter only. Analog-style multitesters may not be
accurate enough to use in these critical tests.
Replace any component that does not have a test
value within specifications.

IGNITION COIL (Primary)

1. Disconnect the double wire plug from the ECU to

the ignition coil.

2. Set the selector in the X1 position.
3. Connect the red meter lead to the orange lead; then

connect the black meter lead to the black lead.

AK051D

4. Ignition coil primary resistance must be between

0.24-0.36 ohm.

IGNITION COIL (Secondary)

1. Remove the spark-plug caps from the high tension

wires.

2. Set the selector in the X1K position.
3. Connect the red meter lead to one high tension

wire; then connect the black meter lead to the

other high tension wire.

AK050D

4. Ignition coil secondary resistance must be between

6800-10,200 ohms.

CHARGE COIL (1)

1. Disconnect the triple-wire plug from the ECU to

the magneto.

2. Set the selector in the X1 position.
3. Connect the red meter lead to the black/red wire

in the plug; then connect the black meter lead to

the green/red wire in the plug.

5-26

AK014

4. Charge coil (1) resistance must be between 13.6-

20.4 ohms. 

CHARGE COIL (2)

1. Disconnect the triple-wire plug from the ECU to

the magneto.

2. Set the selector in the X1 position.
3. Connect the red meter lead to the brown/white

wire in the plug; then connect the black meter lead

to the green/red wire in the plug.

AK013

4. Charge coil (2) resistance must be between 13.6-

20.4 ohms. 

LIGHTING COIL

1. Disconnect the main wiring harness from the

engine.

2. Set the selector in the X1 position.
3. Connect the two meter leads to each of the yellow

leads in the connector from the engine.

AK015

4. Lighting coil resistance must be between 0.08-

0.12 ohm.

IGNITION TIMING SENSOR

1. Disconnect the two timing sensor leads (green/

white and brown) from the ECU.

2. Set the selector in the X100 position; then connect

the meter leads to the sensor leads.

3. Ignition timing sensor resistance must be between

152-228 ohms.

SPARK-PLUG CAP

1. Remove the spark-plug caps from the high tension

wires.

2. Set the selector in the X1K position.
3. In turn on each cap, touch a tester lead to each end

of the spark-plug cap.

B170

4. Spark-plug cap resistance must be between 4000-

6000 ohms.

IGNITION SWITCH

1. Remove the main wiring harness connectors from

the ignition switch.

2. Rotate the key to the OFF position.
3. The meter must read less than 1 ohm resistance

between the ignition switch terminals.

4. Rotate the key to the RUN position.
5. The meter must read OL (infinite resistance).