Content .. 77 78 79 80 ..

Snowmobile Arctic Cat (2002 year). Manual - part 79

5-35

AO102D

2. Set the selector in the X10 position.
3. Connect the red tester lead to the green/white wire;

then connect the black tester lead to the brown

wire.

4. Ignition timing sensor resistance must be between

148-222 ohms (570 cc) or 152-228 ohms (1000

cc).

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 0.12-

0.18 ohm.

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).

Peak Voltage Tests

(Fan Cooled Models)

NOTE: The following tests should be made using

the Fluke Model 73 Multimeter (p/n 0644-191) with
Peak Voltage Reading Adapter (p/n 0644-307).

NOTE: Peak voltage test specifications are on

the Electrical Specifications (Individual) pages in
this section.

The Fluke Multimeter w/Adapter can perform the fol-

lowing tests.

A. Stator/Charge Coil(s) Output

B. Lighting Coil Output

C. Primary/Secondary Coil Output

D. Voltage Regulator Output

!WARNING

Most voltages generated by the ignition system
are sufficient to interrupt pacemakers! All techni-
cians, especially those using pacemakers, must
avoid contact with all electrical connections
when making these tests.

5-36

STATOR (Charge) COIL OUTPUT

1. Connect the red meter lead to the red/white wire

from the stator; then connect the black meter lead

to the black/red wire from the stator.

2. Pull the recoil starter rope briskly. Meter reading

must be within specification.

LIGHTING COIL OUTPUT

1. Connect the red meter lead to one yellow wire;

then connect the black meter lead to the other

yellow wire.

2. Pull the recoil starter rope briskly. Meter reading

must be within specification.

CHARGE COIL (1) OUTPUT

1. Connect the red meter lead to the red/white wire

(440 cc) or to the black/red wire (570 cc); then

connect the black meter lead to the black/white

wire (440 cc) or to the green/red wire (570 cc).

2. Pull the recoil starter rope briskly. Meter reading

must be within specification.

CHARGE COIL (2) OUTPUT

1. Connect the red meter lead to the black/red wire

(440 cc) or to the brown/white wire (570 cc); then

connect the black meter lead to the red/white wire

(440 cc) or to the green/red wire (570 cc).

2. Pull the recoil starter rope briskly. Meter reading

must be within specification.

PRIMARY COIL OUTPUT

1. Connect the red meter lead to the orange wire;

then connect the black meter lead to the black

wire.

2. Pull the recoil starter rope briskly. Meter reading

must be within specification.

SECONDARY COIL OUTPUT

1. Connect the red meter lead to one high tension

wire; then connect the black meter lead to the

other high tension wire.

2. Pull the recoil starter rope briskly. Meter reading

must be within specification.

VOLTAGE REGULATOR OUTPUT

1. Connect the red meter lead to the yellow wire

from the regulator; then connect the black meter

lead to the brown wire from the regulator.

2. Pull the recoil starter rope briskly. Meter reading

must be within specification.

Peak Voltage Tests

(Carbureted APV Models)

NOTE: The following tests should be made using

the Fluke Model 73 Multimeter (p/n 0644-191) with
Peak Voltage Reading Adapter (p/n 0644-307).

NOTE: Peak voltage test specifications are on

the Electrical Specifications (Individual) pages in
this section.

The Fluke Multimeter w/Adapter can perform the fol-

lowing tests.

A. DC Power Coil Output

B. Voltage Regulator Output

C. Primary/Secondary Coil Output

D. Lighting Coil Output

DC POWER COIL OUTPUT

1. Connect the red meter lead to the red/yellow wire

from the stator; then connect the black meter lead

to the yellow/red wire from the stator.

2. Pull the recoil starter rope briskly. Meter reading

must be within specification.

VOLTAGE REGULATOR OUTPUT

1. Connect the red meter lead to the red wire from the

regulator; then connect the black meter lead to the

brown wire from the regulator.

2. Pull the recoil starter rope briskly. Meter reading

must be within specification.

PRIMARY COIL OUTPUT

1. Connect the red meter lead to the orange wire

(500/600/800 cc twin) or to the positive spade

terminal (600 cc triple); then connect the black

meter lead to the black wire (500/600/800 cc twin)

or to the negative spade terminal (600 cc triple).

2. Pull the recoil starter rope briskly. Meter reading

must be within specification.

SECONDARY COIL OUTPUT

1. Connect the red meter lead to one high tension

wire; then connect the black meter lead to the

other high tension wire.

! WARNING

5-37

2. Pull the recoil starter rope briskly. Meter reading

must be within specification.

LIGHTING COIL OUTPUT

1. Connect the red meter lead to one yellow wire;

then connect the black meter lead to the other

yellow wire.

2. Pull the recoil starter rope briskly. Meter reading

must be within specification.

Peak Voltage Tests

(EFI Models/550/1000 cc Models)

NOTE: The following tests should be made using

the Fluke Model 73 Multimeter (p/n 0644-191) with
Peak Voltage Reading Adapter (p/n 0644-307).

NOTE: Peak voltage test specifications are on

the Electrical Specifications (Individual) pages in
this section.

The Fluke Multimeter w/Adapter can perform the fol-

lowing tests.

A. Charge Coil (1) Output

B. Charge Coil (2) Output

C. Lighting Coil Output

D. Primary/Secondary Coil Output

E. Voltage Regulator Output

CHARGE COIL (1) OUTPUT

1. Connect the red meter lead to the black/red wire

(EFI/1000 cc) or to the red/white wire (550 cc);

then connect the black meter lead to the green/red

wire (EFI/1000 cc) or to the black/white wire (550

cc).

2. Pull the recoil starter rope briskly. Meter reading

must be within specification.

CHARGE COIL (2) OUTPUT

1. Connect the red meter lead to the brown/white

wire (EFI/1000 cc) or to the black/red wire (550

cc); then connect the black meter lead to the green/

red wire (EFI/1000 cc) or to the red/white wire

(550 cc).

2. Pull the recoil starter rope briskly. Meter reading

must be within specification.

LIGHTING COIL OUTPUT

1. Connect the red meter lead to one yellow wire;

then connect the black meter lead to the other

yellow wire.

2. Pull the recoil starter rope briskly. Meter reading

must be within specification.

PRIMARY COIL OUTPUT

1. Connect the red meter lead to the orange wire

(EFI/550 cc) or to the positive spade terminal

(1000 cc); then connect the black meter lead to the

black wire (EFI/550 cc) or to the negative spade

terminal (1000 cc).

2. Pull the recoil starter rope briskly. Meter reading

must be within specification.

SECONDARY COIL OUTPUT

1. Connect the red meter lead to one high tension

wire; then connect the black meter lead to the

other high tension wire.

2. Pull the recoil starter rope briskly. Meter reading

must be within specification.

VOLTAGE REGULATOR OUTPUT

(550/1000 cc)

1. Connect the red meter lead to the yellow wire from

the regulator; then connect the black meter lead to

the brown wire from the regulator.

2. Pull the recoil starter rope briskly. Meter reading

must be within specification.

Testing Low-Oil

Light Sensor

The low-oil light sensor is a magnetic switch. Its oper-

ation is based on a magnet located around the inside

diameter of a 1/2 in. hole in a plastic float. The switch

located in the stem of the sending unit is positioned

through the hole in the float. When the float drops to

the lower part of the stem, the magnet closes the elec-

trical contacts (located in the stem) allowing the cur-

rent to pass on to the warning light.

If the sensor should fail, it must be replaced. To test

the sensor, use the following procedure.

1. Remove the sensor from the oil reservoir by

twisting and pulling upwards. Wipe excess oil

from the sensor.

2. Unplug the sensor from the wiring harness.
3. Using an ohmmeter, set the selector on the X1K

position.

! WARNING

5-38

4. Touch each of the meter leads to one of the two

wires coming from the sensor. With the sensor in

its normal position (float end down), the meter

should read resistance.

5. If the meter reads no resistance, check to make

sure good contact has been made with each of the

wires coming from the sensor. If the meter still

reads no resistance, replace the sensor.

6. While maintaining contact between the meter

leads and the sensor, raise the float. The meter

must read no resistance. If the meter reads

resistance, replace the sensor.

7. If the sensor tested out satisfactory but the light

doesn’t illuminate with only a small amount of oil

in the reservoir, check the bulb.

8. If the bulb is in good condition, check for voltage

at the connection where the sensor plugs into the

accessory wiring harness. Using a multimeter set

on the 50 ACV scale, start the engine and allow it

to idle. Touch the red lead of the voltmeter to the

red wire in the two-prong connector. Touch the

black lead to the black wire in the wiring harness.

At idle, the meter should read 5 to 6 volts (AC). If

no voltage is present but the lights on the

snowmobile operate normally, either check the

wiring harness for a broken wire or replace the

harness.

Testing High

Temperature Sensor

1. Disconnect the main wiring harness connector

from the temperature sensor.

2. Connect an ohmmeter between the sensor terminal

and any convenient chassis ground (or any brown

wire). The ohmmeter must read less than 20 ohms

of resistance with the water temperature more than

+230°F. The ohmmeter must read no resistance

with the water temperature less than +190°F.

NOTE: It may be easier to remove the sensor

from the water manifold for testing purposes.
Immerse the sensor body (only up to the threads)
in automatic transmission fluid and slowly heat
the fluid. The ohmmeter must indicate the above
resistances when connected between the sensor
terminal and the sensor body/chassis.

Testing

High Temperature

Warning Light

1. Disconnect the main wiring harness connector

from the temperature sensor.

2. Temporarily place a jumper wire from the main

wiring harness sensor connector to any convenient

chassis ground (or any brown wire).

3. If the high temperature warning light is not

illuminated with the engine running (and the

harness terminal grounded), test the light bulb. An

ohmmeter must read less than 10 ohms across the

bulb filament.

4. If the bulb does not illuminate even when tested

good, use the ohmmeter to test the bulb harness.

Also test the red/white wire continuity from the

temperature sensor connector to the bulb

connector.

Testing Fuel Gauge

1. Disconnect the fuel gauge from the hood wiring

harness.

2. Connect the positive lead of a 12-volt power

supply to the yellow wire and the negative lead of

the 12-volt power supply to the brown wire.

3. The fuel gauge needle should peg in the negative

(empty) direction.

4. With the fuel gauge still connected to the 12-volt

power supply (from step 2), install a jumper wire

(such as a paper clip) between the brown wire and

the gray wire.

5. The fuel gauge needle should peg in the positive

(full) direction.

NOTE: A fuel gauge failing these testing proce-

dures is defective and must be replaced.

Testing

Fuel Gauge Sender

1. Remove the hardware securing the console to the

fuel tank and frame; then move the console out of

the way.

2. Disconnect the fuel gauge sender unit (black two-

wire connector) from the main wiring harness.

3. Connect the ohmmeter leads to the two sender

wires.

4. Compare the reading to the chart following.

Fuel Gauge Sender

Position

Ohms

Full

4-6

1/2

37.6-56.4

Empty

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Content .. 77 78 79 80 ..