Snowmobile Arctic Cat (2004 year). Manual - part 33

 

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Snowmobile Arctic Cat (2004 year). Manual - part 33

 

 

2-119

2

Problem: Engine Does Not Start (Fuel Does Not Ignite)

Condition

Remedy

1. ECU LED trouble code
2. Spark absent

3. Primary compression low
4. Secondary compression low
5. Engine flooded
6. Gasoline contaminated

1. Service — replace problem component
2. Check for spark — see No Spark at Spark Plugs 

sub-section

3. Service engine
4. Service engine
5. Clear engine (hold throttle full-open)
6. Clean tank and entire fuel system

Problem: Engine Does Not Idle

Condition

Remedy

1. ECU LED trouble code
2. Throttle position sensor idle adjustment

incorrect

3. Injector(s) faulty
4. Fuel pressure regulator faulty
5. Air-intake silencer obstructed

1. Service — replace problem component
2. Adjust idle RPM to specifications

3. Replace injector(s)
4. Replace regulator — hose
5. Clean air-intake silencer

Problem: Engine Loses Power or Runs on One Cylinder

Condition

Remedy

1. Sensor faulty

2. Spark plug fouled
3. External coil faulty
4. Gas tank vent — hose obstructed
5. Secondary compression low
6. Fuel pressure regulator faulty
7. Pick-up valve(s) obstructed — out of position
8. Oil-injection pump malfunctioning — adjusted 

incorrectly

9. Throttle bodies out of synchronization

10. Injector faulty
11. Dropping resistor faulty

1. Check LED for trouble code — repair — replace 

problem circuit or sensor

2. Replace spark plugs
3. Service — replace coil
4. Service — replace vent hose
5. Service engine
6. Replace regulator
7. Replace — relocate pick-up valve(s)
8. Replace — bleed — adjust oil-injection pump

9. Replace throttle bodies from a similar engine — 

if problem is corrected, replace the original 
assembly

10. Replace injector
11. Test resistor — replace as necessary

2-120

Problem: Engine Overheats

Condition

Remedy

1. Spark plug heat range too hot
2. Coolant low — absent
3. Heat exchanger obstructed
4. Intake flange to cylinder air leak
5. Drive system (drive clutch — driven pulley — 

track — drive belt) adjusted incorrectly — worn 
— damaged

6. Rings/grooves carboned
7. Exhaust ports obstructed
8. Expansion chamber obstructed
9. Oil-injection pump malfunctioning — adjusted 

incorrectly

10. Primary compression low — absent

11. Gasoline octane too low
12. Water pump — thermostat damaged — faulty

1. Install lower heat-range spark plugs
2. Add coolant
3. Remove obstruction
4. Replace — seal intake flange(s)
5. Troubleshoot — adjust drive system

6. Clean — replace rings — pistons
7. Remove obstruction
8. Remove obstruction
9. Replace — bleed — adjust oil-injection pump

10. Repair — replace damaged — worn engine 

components

11. Use 87 minimum octane gasoline
12. Replace water pump — thermostat

Problem: Engine Backfires

Condition

Remedy

1. LED trouble code
2. Throttle/ignition monitor switch adjusted 

incorrectly

3. Spark plugs fouled — damaged
4. High tension leads/coil shorting
5. ECU faulty — damaged
6. Fuel mixture lean
7. Oil-injection pump malfunctioning — adjusted 

incorrectly

1. Service — replace problem component
2. Adjust throttle cable tension — service spring

3. Clean — replace spark plugs
4. Service — replace high tension leads/coil
5. Replace ECU
6. Repair fuel regulator — injector(s)
7. Replace — bleed — adjust oil-injection pump

Problem: Engine Four-Cycles (Floods Excessively)

Condition

Remedy

1. LED trouble code
2. Fuel pressure too high
3. Injector faulty
4. Throttle position sensor faulty
5. Air-intake silencer obstructed

1. Service — replace problem component
2. Replace regulator — hose
3. Replace injector
4. Replace throttle body assembly
5. Remove obstruction

2-121

2

Problem: Engine Stops Suddenly

Condition

Remedy

1. Gas tank empty
2. Spark absent
3. LED trouble code
4. CDI relay faulty
5. Fuel filter(s) obstructed
6. Fuel pressure low
7. Fuel pump faulty
8. Fuel pump relay faulty
9. Gas tank vent hose obstructed

10. ECU faulty
11. Fuel hose obstructed — broken — pinched

12. Ignition coil faulty
13. Engine seized
14. Throttle/ignition monitor switch — throttle 

cable tension faulty — adjusted incorrectly

1. Fill tank
2. See No Spark at Spark Plugs sub-section
3. Service — replace problem component
4. Replace CDI relay
5. Replace filter(s)
6. Replace regulator — hose
7. Service — replace fuel pump
8. Replace relay
9. Service vent hose

10. Replace ECU
11. Remove obstruction — repair — replace fuel 

hose

12. Replace ignition coil
13. Overhaul engine
14. Replace throttle control — adjust throttle cable

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

Condition

Remedy

1. ECU shorted to ground
2. Engine wiring harness connections wet

1. Replace ECU
2. Clean — dry connections

2-122

Engine Information

Table of Contents

Piston Replacement Guide ................................. 2-122
Cylinder Head Volume Tests ............................... 2-123
Crankshaft Repair ............................................... 2-124

Piston Replacement Guide

* Not a Service Part

ENGINE SIZE

YEAR

PISTON

RING

PISTON & RING SET

370 cc

2004

*

3004-825

3005-913

440 cc

2004

*

3002-742

3005-920

500 cc w/APV

2004

*

3005-828

3006-427

500 cc w/o APV

2004

*

3005-828

3006-746

550 cc

2004

*

3003-760

3006-685

570 cc

2004

*

3006-004

3006-528

600 cc (STD)

2004

*

3005-749

3005-445

600 cc (“Laydown”)

2004

*

3006-004

3006-645

800 cc

2004

*

3005-865

3006-029

900 cc

2004

*

3006-394

3006-393

700 cc

2004

*

3006-500

3006-499

 

 

 

 

 

 

 

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