Snowmobile Arctic Cat (2002 year). Manual - part 80

5-39

5

Testing

Electric Fuel Pump

1. Remove the hardware securing the console to the

gas tank and frame; then move the console out of

the way.

2. Disconnect the fuel pump (white two-wire

connector) from the main wiring harness.

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

supply to the red wire and the negative lead of the

12-volt power supply to the black wire.

4. The pump should operate (it would be heard

running).

„

NOTE: If the fuel pump fails to operate, the pump

is defective and must be replaced.

Solenoid 

(Electric Start Models)

TESTING

„

NOTE: The electric start solenoid may be tested

using either one of the following methods.

Method #1

1. Disconnect the electric start harness from the main

wiring harness.

2. Place the ohmmeter leads across the solenoid coil

terminals (brown wire and red/white wire).

3. The ohmmeter must read between 3 and 5 ohms.

Method #2

1. Connect the battery to the solenoid coil terminals

(brown wire and red/white wire).

2. A loud, audible “click” should be heard as the

solenoid internal contacts make connection.

3. Disconnect the battery from the solenoid.
4. A loud, audible “click” should be heard as the

solenoid internal contacts release.

„

NOTE: An in-line ammeter would measure

between 2 and 4 amps of solenoid coil current flow
with the battery connected.

Charging Diode

(Electric Start Models)

TESTING

1. Disconnect the electric start harness from the main

wiring harness.

2. Connect the ohmmeter positive lead (red) to the

diode yellow wire and the ohmmeter negative lead

(black) to the diode red wire. The ohmmeter must

read between 300 and 700 ohms.

3. Connect the ohmmeter positive lead (red) to the

diode red wire and the ohmmeter negative lead

(black) to the diode yellow wire. The ohmmeter

must read OPEN (infinite resistance).

Fuse 

(Electric Start Models)

TESTING

1. Remove the fuse from the fuse holder.
2. Connect the ohmmeter across the fuse end-caps.
3. The ohmmeter must read less than 1 ohm of

resistance.

Ignition Switch -

Electric Start Function 

(Electric Start Models)

TESTING

1. Disconnect the wiring harness from the ignition

switch; then remove the switch from the console.

! CAUTION

NEVER connect an in-line ammeter with the large
starter cables because the 200 amps of current
flow will instantly damage most ammeters.

! CAUTION

To prevent ohmmeter damage when testing
circuits on snowmobiles equipped with an
electric start, be sure to disconnect the battery
before testing.

! CAUTION

To prevent ohmmeter damage when testing
circuits on snowmobiles equipped with an
electric start, be sure to disconnect the battery
before testing.

5-40

2. Using the ohmmeter, test the connections

indicated in the following chart. If the meter does

not read as specified or has more than one ohm of

resistance, the switch must be replaced.

0000-126

„

NOTE: Some ignition-switch terminals may not

be labeled (-M, +M, A, B, or S). Refer to the wiring
harness diagram of the ignition switch when con-
necting the ohmmeter.

Starter Motor

REMOVING

1. Disconnect the battery.
2. Remove the expansion chamber(s).
3. Remove the nut and washer(s) securing the

positive cable; then remove cable from the starter

motor.

4. Remove the drive clutch.
5. Remove the hardware securing the starter motor

and end plate/drive cap assembly to the bracket;

then remove the starter motor assembly.

DISASSEMBLING

„

NOTE: For assembly purposes, scribe a refer-

ence line on the end plate/drive cap, commutator
cap, and the case.

1. If applicable, remove the snap ring securing the

primary gear to the starter motor; then remove the

gear and account for the spring washer.

2. Remove the two long through-bolts. As the bolts

are being removed, hold pressure against the

commutator cap.

AI050

3. Slowly remove the cap and account for the four

brush holder springs.

AI026

4. Using a plastic hammer, tap the end plate/drive

cap free of the starter case and slide the cap free

from the armature shaft. Account for any  washers.

AI027

5. Slide the armature free of the starter case.

Position

Lead to 

Terminal

Lead to 

Terminal

Meter 

Reading

OFF

-M

+M

CLOSED

ON

-M

+M

OPEN

ON

B

A

CLOSED

START

-M

+M

OPEN

START

B

S

CLOSED

5-41

5

AI028

6. Lift all brushes from the brush holder and account

for the four brush springs.

7. Using a 5/16-in. socket, remove the two cap

screws securing the ground brushes to the

commutator cap. Remove the brushes and brush

holder from the cap.

AI036

8. Using a 7/16-in. wrench, remove the nut securing

the cable stud to the cap. Account for the number

of and the position of washers.

AI037

9. While holding the brush wires, pull the stud from

the end cap. Account for the plastic insulator.

CLEANING AND INSPECTING

„

NOTE: Whenever a part is worn excessively,

cracked, or damaged in any way, replacement is
necessary.

1. Thoroughly clean all components except the

armature and brushes in parts-cleaning solvent;

then dry with compressed air.

AI029

2. Inspect all threaded areas for damaged or stripped

threads.

3. Inspect the brush holder assembly and brushes for

damage or wear. Using a calipers, measure the

length of the brushes. If brush measurement is less

than 7.5 mm (0.30 in.), replace brushes as a set

along with new brush springs.

AI030

4. Inspect brush leads for cracks, wear, or fraying. If

any of these conditions exist, replace the brushes

as a set along with new brush springs.

5. Inspect the commutator cap bushing for wear.

Using a calipers, measure inner diameter at the cap

bushing. If found to be 8.6 mm (0.338 in.) or

larger, replace the cap.

! CAUTION

Do not wash the armature and brushes in any
kind of solvent. Use only compressed air and
clean dry cloth in cleaning these components.

5-42

AI031

6. Inspect the end plate/drive cap bushing for wear.

Using a calipers, measure the inner diameter of the

cap bushing. If found to be 13.2 mm (0.523 in.) or

larger, replace the cap.

AI032

7. Inspect the brass commutator end of the armature

for any burned spots or damage. If the commutator

is slightly burned or damaged, the armature must

be replaced. This is a molded commutator and no

attempt to turn it down in a lathe should be tried.

8. Inspect the commutator for buildup in the grooves.

Buildup in the grooves must be removed to

prevent any chance of arcing between individual

sections of the commutator. Carefully remove any

buildup using a thinly ground hacksaw blade. Do

not cut any deeper than the original groove which

can be seen by looking at the commutator from the

side.

AI033

„

NOTE: After cleaning any buildup from the com-

mutator, use compressed air to clean.

9. Inspect the armature for shorting. Use the

multitester and the following procedure:
A. Set the selector on the X1K position; then touch

the leads and zero the meter.

B. Touch the black tester lead to the armature

shaft.

C. Using the red tester lead, probe the commutator

end of the armature. The meter indicator should

not move. If the indicator needle moves, the

armature must be replaced.

AI034

10. Inspect the armature for shorting. Use a “growler”

and the following procedure:
A. Place the armature in the “growler.”

B. While holding a metal strip over the armature,

rotate the armature an entire revolution. If the

metal strip vibrates at any point on the

armature, the armature is shorted and must be

replaced.

! CAUTION

Do not use emery cloth to clean the commutator
as emery particles will become imbedded in the
brass commutator resulting in a short circuit.
Use only #00 grit sandpaper.