Content .. 52 53 54 55 ..

Snowmobile Arctic Cat (2004 year). Manual - part 54

4-51

2. Install the flange clamps on the flanges; then place

the throttle body assembly into the flanges and
secure with the clamps.

3. Secure all wires and hoses with cable ties.

Throttle Body

Assembly

NOTE: Determine which type of assembly is

being replaced and remove and install accord-
ingly.

0736-279

0738-076

0736-975

REMOVING

1. Disconnect the wiring harness from each injector

and from the throttle valve sensor connector.

2. Remove the coolant hose from the PTO-side of the

throttle body and plug it to prevent leakage.

3. On the 600 cc STD model, remove the fuel return

hose and supply hose from the fuel pressure
regulator and delivery pipe. Label for assembly.

KEY

1. Throttle Body Assembly
2. Fuel Pressure Regulator
3. Bolt
4. Delivery Pipe
5. Fuel Injector
6. Screw
7. Control Rod
8. Rod End
9. Spring Pin

10. Hose
11. Hose Clamp
12. O-Ring Set

600 cc STD

! CAUTION

Since the fuel supply hose may be under
pressure, remove it slowly to release the
pressure. Place an absorbent towel around the
connection to absorb fuel.

600 cc “Laydown”/

700 cc

KEY

1. Throttle Body
2. Delivery Pipe
3. Fuel Injector
4. Screw
5. Hose
6. Clamp
7. O-Ring Set
8. Control Rod

KEY

1. Throttle Body Assembly
2. Delivery Pipe
3. Fuel Injector
4. Screw
5. Hose
6. Hose Clamp
7. O-Ring Set

800/900 cc

4-52

4. Loosen the flange clamps.

5. Slide the throttle body assembly out of the flanges;

then loosen the jam nut securing the throttle cable
and remove.

6. Remove the throttle body.

AR113

INSTALLING

1. Attach the throttle cable to the throttle body.

Secure with jam nut.

2. Place the throttle body assembly into position.

Make sure the flanges and boots are positioned
properly. Secure with flange clamps.

3. On the 600 cc STD model secure the fuel supply

hose and return hose to the delivery pipe and
regulator.

0729-325

4. Secure the coolant hose to throttle body assembly.

5. Connect the wiring harness to each injector and

throttle valve sensor.

6. Place the rear of the snowmobile on a shielded

safety stand and start the engine without touching
the throttle. It may idle slowly and stop. Restart
using the same procedure until the engine starts
and builds RPM on its own.

7. Check the cooling system.

8. Adjust the throttle cable as necessary.

Throttle Cable

NOTE: Determine which type of cable is being

replaced and remove and install accordingly.

738-064A

737-754A

737-973A

! CAUTION

These hoses must be connected to the correct
fittings.

! WARNING

Check all hose connections for leakage. Repair as
necessary.

KEY

1. Throttle Cable
2. E-Ring
3. Washer
4. Cable Tie
5. Locking Nut
6. Retaining Clip
7. Rubber Plug

4
5

KEY

1. Cable Tie
2. Throttle Cable
3. Jam Nut
4. E-Ring
5. O-Ring
6. Retaining Clip

1
2

KEY

1. Cable Tie
2. Throttle Cable
3. Locking Nut
4. Retaining Clip

4-53

REMOVING

1. Open the belt guard and remove the belt.

2. Remove the driven pulley.

3. Remove the E-clip securing the oil-injection cable

to the oil-injection pump control arm. Account for
a washer.

4. Loosen the oil-injection cable jam nuts.

5. Loosen the throttle cable jam nuts.

6. Remove the throttle cable from the throttle body

assembly.

7. Remove the handlebar pad.

8. Remove the cable ties securing the throttle cable.

9. Remove the throttle cable end from the throttle

lever.

10. Using Throttle Cable Removal Tool (p/n 1639-

963), push down on the throttle cable retaining
clip; then remove the cable from the throttle
switch assembly.

INSTALLING/ADJUSTING

1. Install the throttle cable into the throttle switch

assembly making sure the cable snaps into place.

2. Install the throttle cable end on the throttle lever.

3. Route the throttle cable from the throttle switch

assembly to the throttle body assembly and oil-
injection pump; avoid any sharp bends or moving
components.

4. Attach the throttle cable to the throttle body.

5. Install the oil-injection cable adjuster on the oil-

injection pump; secure with the jam nuts.

6. Install the oil-injection cable on the control arm;

secure with a washer and E-clip.

7. Secure the throttle cable to the steering post with

cable ties.

8. Install the handlebar pad.

9. Adjust the throttle cable tension by turning the jam

nuts in the appropriate direction until there is 0.75-
1.5 mm (0.030-0.060 in.) free-play in the throttle
lever and the butterfly completely opens and
closes. Tighten the jam nuts securely.

733-081C

10. Synchronize the oil-injection pump.

11. Install the driven pulley.

12. Install the belt and secure the belt guard.

! CAUTION

Compress the throttle control lever to ensure
free movement. If the throttle cable sticks or
binds, correct the problem before starting the
engine.

4-54

BASIC EFI SYSTEM INFORMATION

Item

Description

Basic system

Fuel supply system

Electronically controlled multi-point injection

Ignition system

(CDI system) Digital

Air/fuel flow

meter

System

O/N (throttle opening/engine revolution) system & atmospheric

pressure compensation

Component parts

Throttle opening sensor
Atmospheric pressure sensor

Injection system

One time simultaneous injection per revolution

(synchronized ignition)

Fuel system

Fuel pressure

Regulated specified pressure

Fuel return (600 cc STD)

Pressure regulated by pressure regulator. There are fuel

returns.

Throttle

system

System

1 stage x duplex (1 bore/cylinder)

Diameter of the bore

46 x 2 (Effective area equivalent to 40)

Type of valve

Butterfly type

Operating angle

See Testing Individual EFI Components in this section

Radius of drum

R25 (at wire center)

Adjusting system for idle revolution

Throttle adjusting screw type

Comp

one

nt par

nd spe

cification

Control unit

Fuel injection control

Fuel

system

Fuel pump

Electric

Injection

Side feed type

Pressure regulator (600 cc

STD)

Diaphragm type

Fuel filter

Fine screens on pick-up hose

Fuel piping

Regulated specified pressure

Throttle body

1 bore/cylinder x duplex

Sens

, et

Throttle sensor

Revolution scrubbing type potentiometer

Pressure sensor

Semiconductor type

Water temperature sensor

Thermistor type

Intake air temperature sensor

Thermistor type

Cable harness

Equivalent to current harness

Other

Batteryless EFI System

Content .. 52 53 54 55 ..