Snowmobile Arctic Cat (2004 year). Manual - part 53

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4

When the MENU SELECT buttons are pressed, there
will be three modes: First mode, ARCTCO, second
mode, KOKUSAN, and third mode, KOKUSAN SPE-
CIAL, which is used only to retrieve special informa-
tion (explained earlier) found on the 2004 batteryless
EFI system ECU.

At this point, select KOKUSAN SPECIAL on the dis-
play by pushing the TEST button. The entire system
can now be tested by moving to the next test using the
MENU SELECT buttons.

If the analyzer is turned off during the test procedure,
the test function on the display will automatically start
over at the top of the list when turned back on. This
means the selection of the system being tested must be
repeated before continuing.

Once a test has been completed, press the TEST button
again to cancel the test, which allows the selection of a
different test using one of the MENU SELECT but-
tons.

Kokusan Special Mode

The 2004 batteryless EFI system has an updated ECU.
The snowmobile can be run with either regular gaso-
line or oxygenated gasoline. Special instructions
located on top of the tool box lid will instruct to dis-
connect two wires located in front of the ECU if oxy-
genated gasoline is used. If regular gasoline is to be
used, the two wires in front of the ECU must remain
connected or the mixture will be too rich.

734-482A

Menu List Organization
(Kokusan Special Mode)

1. Throttle Adjust - given in both volts and degree.

2. Fuel Change Number - number of times fuel leads

have been switched between regular gasoline and
oxygenated gasoline.

3. Last Gasoline Type - in case of engine failure,

what the system was last set for - regular gasoline
or oxygenated gasoline.

4. Other Rom Check - (for 2001 and earlier models

except 2001 600 cc) will indicate if the EPROM
chip has been changed. If none appears on the
display, the EPROM chip has not been changed
since the ECU was assembled.

5. Maximum Revolutions by Temperature - provides

a range in increments of 10° from -30° C to -101°
C. Will show engine RPM for each temperature
range and if the engine has been operated in the
range.

6. Total Running Time - will show total hours on the

engine.

7. Barometric Pressure - provides current air

pressure.

To test an batteryless EFI system using the EFI Ana-
lyzer, follow all instructions carefully and completely.

Analyzer Setup

1. Before connecting the analyzer to the snowmobile,

always check to make sure the analyzer is OFF;
then connect the analyzer batteryless test harness
(equipped with red and black external leads) to the
ECU diagnosis connector.

2. Attach the red external lead to the positive

terminal of a 12-volt battery; then connect the
negative external lead to the negative post.

3. Press the ON button of the analyzer. At this point,

the power light of the analyzer must be
illuminated.

4. To retrieve information found under Kokusan

Special Mode, push MENU SELECT button until
KOKUSAN SPECIAL mode appears on the
display; then push the TEST button. The analyzer
is now ready to test the special areas shown on the
menu list under KOKUSAN SPECIAL mode.

„

NOTE: When testing the batteryless EFI system,

KOKUSAN SPECIAL mode must be on the display.
Once the TEST button is pressed with KOKUSAN
SPECIAL mode on the display, the analyzer will
stay in this mode until it is turned OFF.

„

NOTE: Each time the analyzer is turned OFF,

reselection of the KOKUSAN SPECIAL mode is
necessary. 

EFI Components Not
Tested by Analyzer

When troubleshooting the EFI system with the EFI
Analyzer, there are EFI components the analyzer will
NOT diagnose. These components, (in the following
list) must be tested using a good digital volt/ohmmeter
or a fuel pressure gauge using recommended proce-
dures in this sub-section and in Section 5.

1. Fuel Pump Coil - Injection Coil - Timing Sensor.

2. Ignition Primary Coil.

3. Ignition Secondary Coil.

4. Fuel Pressure Regulator - Maintains fuel pressure

at specified psi.

4-48

5. Electric Fuel Pump - Located in the gas tank.

Supplies fuel under pressure to fuel injectors.

6. Switches and Stator Coils - Supplies all systems

with electrical current.

7. Servomotor.

Recommended EFI

Troubleshooting

Sequence

(Kokusan Mode)

When troubleshooting the batteryless EFI system, use
the following troubleshooting sequence to locate prob-
lems quickly and efficiently.

EXISTING PROBLEM DIAGNOSIS TEST

This should be the first test made. In this mode, the
analyzer tests the following components all at once.

A. Throttle Position Sensor

B. Intake Air Temperature Sensor

C. Water Temperature Sensor

D. Barometric Pressure Sensor

E. Fuel Injectors

After pushing the TEST button on the analyzer, the
display will indicate either SENSORS ALL O.K. or
which of the sensors are defective. Check these com-
ponents individually using the recommended proce-
dures in this sub-section.

MEMORY PROBLEM DIAGNOSIS TEST

This should be the second test made. In this mode, the
analyzer will reveal any problems in the sensor area
which might have occurred intermittently as the snow-
mobile was being operated.

If there were any such intermittent problems, the prob-
lem area will be shown on the display. Check the indi-
cated area for a wire connection problem or loose or
corroded connections.

Testing Individual EFI 

Components

„

NOTE: For all of the following tests using the EFI

Analyzer, the analyzer power light must be illumi-
nated. If not illuminated, the problem must be cor-
rected before proceeding. Also the analyzer must
be properly connected to a 12-volt battery.

EXISTING PROBLEM DIAGNOSIS TEST 
(Engine Off) FUNCTION

„

NOTE: Select KOKUSAN SPECIAL by pressing

the TEST button. This will allow the testing of the
batteryless EFI system.

1. With the analyzer OFF, connect its harness to the

diagnosis test plug. Connect the external leads of
the harness to a good 12-volt battery.

2. Switch the analyzer ON.

3. With analyzer power light illuminated, press the

MENU SELECT buttons repeatedly until the
words Existing Problem Diagnosis Test appear on
the display.

4. Press the TEST button. If all sensors are good,

SENSORS ALL O.K. will appear on the display.
If any of the sensors listed under Existing Problem
Diagnosis Test are defective, that sensor will be
indicated on the display. Proceed then to check the
defective sensor individually as covered in this
section.

„

NOTE: If proceeding to another test, first press

the TEST button once again to cancel the present
test. To select a different test function, use the
MENU SELECT buttons.

MEMORY PROBLEM DIAGNOSIS TEST 
(Engine Off) FUNCTION

„

NOTE: Select KOKUSAN SPECIAL by pressing

the TEST button. This will allow the testing of the
batteryless EFI system.

1. With the analyzer OFF, connect its wiring harness

to the diagnosis test plug. Connect the external
leads of the harness to a good 12-volt battery.

2. Switch the analyzer ON.

3. With both indicator lights illuminated, press the

MENU SELECT buttons repeatedly until Memory
Problem Diagnosis Test appears on the display.

4. Press the analyzer TEST button. If there has been

an intermittent problem in a sensor, that sensor
will be indicated on the display. Make necessary
repairs.

„

NOTE: If proceeding to another test, first press

the TEST button once again to cancel the present
test. To select a different test function, use the
MENU SELECT buttons.

Existing Problem Diagnosis TEST

Memory Problem Diagnosis TEST

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CLEARING MEMORY

1. With the analyzer harness attached to the

diagnosis test plug, press the MENU SELECT
buttons until the words Diagnosis Memory Clear
appear on the display.

2. Press the analyzer TEST button and the words

Please Key Off should appear on the LCD; then
turn the analyzer switch to the OFF position.
Immediately turn the analyzer switch to the ON
position and the memory should now be clear.

„

NOTE: To check if the memory is clear, perform

Memory Problem Diagnosis Test to see if all sen-
sors test good. If a problem still remains on mem-
ory, repeat Clearing Memory procedure.

THROTTLE VALVE ANGLE TEST 
(Degrees/Volts) FUNCTION

The correct throttle valve angle is extremely important
for proper engine operation. If the throttle valve angle
isn’t correct in the idle position, the engine may be
very difficult to start “cold.” If the throttle valve angle
isn't correct in any of the off-idle positions, engine
damage or poor performance may result because of an
incorrect mixture.

„

NOTE: Select KOKUSAN by pressing the TEST

button. This will allow the testing of the batteryless
EFI system.

1. Connect the analyzer harness to the diagnosis test

plug. Make sure the analyzer is OFF.

2. Switch the analyzer ON.

3. With the analyzer power light illuminated, press

the MENU SELECT buttons on the analyzer
repeatedly until the words Throttle Valve Angle
appear on the display.

„

NOTE: When performing the Throttle Valve

Angle Test, test both the idle and full-open throttle
positions. Specifications are given for both posi-
tions in degrees and volts.

4. With the throttle in the “idle” position (engine not

running), press the analyzer TEST button. The
throttle valve angle should now appear on the
display.

5. If the “idle” position throttle valve angle or

voltage isn't within test specifications, push down
on the throttle shaft to make sure it is fully closed.
If the test specifications are now within tolerance,
loosen the throttle cable.

6. If the “idle” position throttle valve angle test

specification remains out of tolerance, adjust the
idle speed screw. If the throttle valve angle cannot
be corrected by either an idle speed screw or cable
adjustment, replace the throttle body assembly.

7. Compress the throttle lever to the “full-open”

position (engine not running). The test
specification must be within the tolerance shown
in chart. If the test specification is out of tolerance,
grasp the throttle cable next to the throttle shaft
and pull on the cable. If the test specification is
now within tolerance, adjust the throttle cable. If
the throttle valve angle remains out of tolerance,
replace the throttle body assembly.

8. If the specifications listed below ARE

DISPLAYED during the test, replace the throttle
body assembly.

„

NOTE: If the Throttle Position Sensor should fail,

the ECU will go into the “fail safe” mode and the
above readings in the idle position will be dis-
played.

„

NOTE: If proceeding to another test, first press

the TEST button once again to cancel the present
test. To select a different test function, use the
MENU SELECT buttons.

Diagnosis Memory Clear

Please Key Off

Throttle Valve Angle

Throttle Valve Angle - Degrees

Model

Idle

Full-Open

600 cc 

STD

3.715°-4.065°

77.265°-86.135°

600/

700 cc 

“Laydown”

5.100°-5.600°

82.500°-87.200°

800/900 

cc

5.100°-5.600°

82.500°-87.200°

Throttle Valve Angle - Voltage

Model

Idle (Volts)

Full-Open 

(Volts)

600 cc STD

0.625-0.647

3.575-3.937

600/700 cc 

“Laydown”

0.685-0.707

3.750-3.937

800/900 cc

0.685-0.707

3.750-3.937

Throttle Valve Angle - Degrees/Volts

Degrees/Volts

RPM Range

2.25/0.570

Idle to 3000

4-50

INTAKE AIR TEMPERATURE SENSOR
(Engine Off) FUNCTION

„

NOTE: When using an analyzer which has been

updated with the new EPROM chip, first select
Kokusan by pressing the TEST button. This will
allow the testing of batteryless EFI system.

1. With the analyzer OFF, connect its harness to the

diagnosis test plug. Connect the external leads of
the harness to a good 12-volt battery.

2. Switch the analyzer ON.

3. With the analyzer power light illuminated, press

the MENU SELECT buttons repeatedly until
Intake Air Temperature appears on the display.

4. Press the analyzer TEST button and the intake air

temperature will be indicated on the display.

„

NOTE: Intake air temperature will be displayed in

both °C and °F.

„

NOTE: The temperature indicated should be

close to room temperature if the snowmobile
hasn't recently been run. Consider what tempera-
ture the snowmobile is actually at.

5. If when testing the intake air temperature sensor,

an indicated temperature of -40° C and °F is noted
and the actual snowmobile temperature isn't close
to this temperature, replace the sensor. The ECU
will automatically go to -40° C and °F when the
intake air temperature sensor fails.

„

NOTE: If proceeding to another test, first press

the TEST button once again to cancel the present
test. To select a different test function, use the
MENU SELECT buttons.

BAROMETRIC PRESSURE SENSOR 
TEST (Engine Off) FUNCTION

„

NOTE: Select KOKUSAN SPECIAL by pressing

the TEST button. This will allow the testing of the
batteryless EFI system.

1. With the analyzer OFF, attach its harness to the

diagnosis test plug.

2. Switch the analyzer ON.

3. With the analyzer power light illuminated, press

the MENU SELECT buttons repeatedly until the
words Barometric Pressure appear on the display.

4. Press the analyzer TEST button and actual area

barometric pressure will be indicated.

„

NOTE: Actual area barometric pressure can be

obtained from a local airport, radio station, etc.

5. If the barometric pressure sensor has failed, the

ECU will automatically go to the barometric
pressure shown below. If these readings APPEAR
on the display, replace the ECU.

Peak Voltage Tests 

and Specifications

„

NOTE: For peak voltage testing procedures, see

Section 5 in this Volume.

Throttle

Position Sensor

It is not possible to replace the throttle position sensor
on the batteryless EFI system. If the sensor should
malfunction, the complete throttle body assembly must
be replaced.

„

NOTE: It is important to order a throttle body

assembly with the same symbol marking on the
injectors as the ones being replaced. The symbol
is located on the side of the injector top.

Throttle Body

Flange

REMOVING

1. Loosen the clamps securing the throttle body

assembly to the throttle body flanges.

2. Remove the throttle body assembly from the

flanges.

3. In turn on each flange, remove the two nuts, lock

washers, and flat washers securing the intake
flange to the cylinder; then remove the flange.

INSTALLING

1. Apply a thin coat of high-temperature silicone to

the cylinder side of each flange; then attach each
flange to a cylinder and secure each with two flat
washers, lock washers, and nuts. Tighten to 1.5-
1.9 kg-m (11-14 ft-lb).

Intake Air Temperature

Barometric Pressure

Model

Barometric Pressure

600/700 cc

880 mm/hg

(34.65 in./hg)

800/900 cc

880 mm/hg

(34.65 in./hg)