Snowmobile Arctic Cat (2004 year). Manual - part 32

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2

Troubleshooting Engine 

(Carbureted Models)

Problem: Engine Does Not Start (No Spark at Spark Plugs)

Condition

Remedy

1. Ignition switch malfunctioning — not in RUN 

position

2. Wiring harness shorting
3. Emergency stop switch knob in DOWN 

position — malfunctioning

4. Throttle/ignition monitor switch (TM-style)

adjusted too loose — malfunctioning

5. Throttle/ignition monitor switch (VM-style) 

adjusted too tight — malfunctioning

6. Carburetor safety switches (VM-style)

adjusted incorrectly — malfunctioning

7. Spark plugs fouled — damaged
8. Spark-plug caps damaged — leaking —

shorting

9. High tension wires/coil loose — grounded —

faulty

10. CDI unit faulty
11. Charge coil (1) faulty
12. Charge coil (2) faulty
13. Flywheel magnets weak
14. Flywheel key sheared

1. Replace ignition switch — turn switch to RUN 

position

2. Repair — replace wiring harness
3. Move knob to UP position — replace throttle 

switch

4. Adjust (tighten) throttle cable — replace throttle 

switch

5. Adjust (loosen) throttle cable — replace throttle 

switch

6. Adjust — replace carburetor safety switches

7. Clean — gap — replace spark plugs
8. Replace spark-plug caps

9. Service — replace high tension wires/coil

10. Replace CDI unit
11. Replace coil
12. Replace coil
13. Replace flywheel
14. Replace key

Problem: Engine Does Not Start (No Fuel at Cylinders)

Condition

Remedy

1. Gas tank empty
2. Shut-off valve (VM-style) closed
3. Fuel hose broken — pinched
4. Gas-tank vent — hose obstructed
5. In-line fuel filter obstructed — damaged
6. Fuel pump malfunctioning — faulty
7. Impulse hose cracked — broken — pinched —

disconnected

8. Carburetors adjusted incorrectly — dirty —

damaged

9. Primary compression (crankcase) absent

1. Fill tank
2. Open shut-off valve
3. Replace — service hose
4. Remove obstruction — replace vent — hose
5. Remove obstruction — replace in-line fuel filter
6. Replace — repair — clean fuel pump
7. Replace — connect impulse hose

8. Troubleshoot — clean — replace carburetors

9. Repair — replace damaged — worn engine 

components

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Problem: Engine Overheats

Condition

Remedy

1. Spark plug heat range too hot
2. Coolant low — absent
3. Carburetors adjusted incorrectly — jetted 

incorrectly — dirty

4. Carburetor-to-cylinder air leak

5. Heat exchangers no snow for cooling

6. Rings/grooves carboned
7. Exhaust ports obstructed
8. Muffler obstructed
9. Gas/air mixture incorrect

10. Oil-injection pump malfunctioning — adjusted 

incorrectly

11. Primary compression (crankcase) low —

absent

12. Ignition timing adjusted incorrectly
13. Gasoline octane too low
14. Water pump — thermostat damaged — faulty

1. Install lower heat-range spark plugs
2. Add coolant
3. Troubleshoot — clean carburetors — jet 

correctly

4. Replace — repair gaskets — intake flanges —

service intake ports

5. Select new trail — install ice studs to chew up 

hard packed snow and ice

6. Clean — replace rings — pistons
7. Remove obstruction
8. Remove obstruction
9. Replace jets — adjust jet needle E-clip position

10. Replace — bleed — adjust oil-injection pump

11. Repair — replace damaged — worn engine 

components

12. Time ignition
13. Use 87 minimum octane gasoline
14. Replace — rebuild water pump — replace 

thermostat

Problem: Engine Backfires

Condition

Remedy

1. Throttle/ignition monitor switch adjusted 

incorrectly

2. Spark plugs fouled — damaged
3. Spark plug heat range too hot
4. High tension wires/coil shorting
5. Carburetor-to-cylinder air leak

6. Carburetors adjusted incorrectly — dirty —

damaged — loose

7. Gas/air mixture incorrect — too lean
8. Oil-injection pump malfunctioning — adjusted 

incorrectly

1. Adjust throttle cable free-play — service spring

2. Clean — gap — replace spark plugs
3. Install lower heat-range spark plugs
4. Service — replace high tension wires/coil
5. Repair — replace gaskets — intake flanges 

service intake ports

6. Troubleshoot — tighten carburetors

7. Adjust jetting
8. Replace — bleed — adjust oil-injection pump

Problem: Engine Four-Cycles (Floods Excessively)

Condition

Remedy

1. Carburetors adjusted incorrectly — dirty —

damaged

2. Gas/air mixture incorrect
3. Oil-injection pump malfunctioning — adjusted 

incorrectly

4. Air-intake silencer obstructed

1. Troubleshoot — clean carburetors

2. Adjust jetting
3. Replace — bleed — adjust oil-injection pump

4. Remove obstruction

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2

Problem: Engine Stops Gradually

Condition

Remedy

1. In-line fuel filter obstructed — damaged
2. Fuel hose obstructed — broken — pinched

3. Head gasket(s) burned out

4. Cylinder head loosening
5. Spark plugs loose
6. Impulse hose cracked
7. High tension wires/coil faulty
8. Float bowl vent hose (TM-style) obstructed —

kinked — damaged

1. Remove obstruction — replace in-line fuel filter
2. Remove obstruction — replace — repair fuel 

hose

3. Replace head gasket(s) — service cylinders —

head

4. Tighten cylinder head cap screws
5. Tighten spark plugs
6. Replace impulse hose
7. Service — replace high tension wires/coil
8. Service — replace float bowl vent hose

Problem: Engine Stops Suddenly

Condition

Remedy

1. In-line fuel filter obstructed — damaged
2. Fuel hose obstructed — broken — pinched

3. CDI unit faulty
4. Ignition coil faulty
5. Charge coil (1) faulty
6. Charge coil (2) faulty
7. Gas-tank vent — hose obstructed — damaged
8. Engine seized
9. Throttle/ignition monitor switch faulty —

throttle cable adjusted incorrectly

1. Remove obstruction — replace in-line fuel filter
2. Remove obstruction — repair — replace fuel 

hose

3. Replace CDI unit
4. Replace ignition coil
5. Replace coil
6. Replace coil
7. Remove obstruction — replace vent — hose
8. Overhaul engine
9. Replace throttle control — adjust throttle cable 

free-play — adjust — connect — replace 
carburetor safety switches (VM-style)

Problem: Engine Fails to Stop (Continues to Run, Even with All Switches Off)

Condition

Remedy

1. CDI unit shorted to ground
2. Main wiring harness four-prong connector

disconnected

1. Replace CDI unit
2. Connect four-prong connector

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Troubleshooting

Engine

(EFI Models)

Problem: Engine Does Not Start (No Spark at Spark Plugs)

Condition

Remedy

1. Ground connections dirty — loose
2. Throttle/ignition monitor switch

malfunctioning — ignition switch not on

3. Wiring harness shorting — disconnected
4. Emergency stop switch in DOWN position — 

malfunctioning

5. Throttle/ignition monitor switch

malfunctioning

6. Spark plugs fouled — damaged
7. Spark-plug caps damaged — leaking — 

shorting

8. High tension leads/coil loose — grounded — 

faulty

9. ECU faulty

10. Ignition timing sensor faulty

1. Check all ground connections — clean and tight
2. Replace faulty switch — turn switch on

3. Repair — replace — connect wiring harness
4. Move switch to UP position — replace throttle 

control

5. Adjust throttle cable tension — replace throttle 

body assembly

6. Clean — replace spark plugs
7. Replace spark-plug caps

8. Service — replace high tension leads/coil

9. Replace ECU

10. Replace sensor

Problem: Engine Does Not Start (No Fuel at Cylinders)

Condition

Remedy

1. Gas tank empty
2. Injector dropping resistor faulty
3. Fuel pressure regulator faulty
4. Gasoline contaminated
5. Fuel pump faulty

6. Fuel hose broken — pinched
7. Gas-tank vent — hose obstructed
8. Pick-up valve(s) obstructed — damaged
9. Primary compression absent

10. ECU faulty

1. Fill tank
2. Replace dropping resistor
3. Replace regulator — hose
4. Replace gasoline
5. Service — replace fuel pump — connections — 

wires

6. Replace — service hose
7. Remove obstruction — replace vent — hose
8. Remove obstruction — replace pick-up valve(s)
9. Repair — replace damaged — worn engine 

components

10. Replace ECU