Snowmobile Arctic Cat (2004 year). Manual - part 60

5-7

Electrical

Specifications

(EFI Models)

NOTE: The ignition system is a Normally Open Ignition (NOI).

Peak Voltage Tests were made with connectors plugged in, spark plugs removed and grounded, and by pull-
ing the recoil starter rope briskly.

NOTE: Lighting coil output is unregulated voltage.

Description

Resistance Test

Test Value

+ Test Connections -

Ignition Coil

Primary
Secondary

0.24-0.36 ohm

6800-10,200 ohms

black/orange

high tension wire

orange/black

high tension wire

Charge Coil (1)

13.6-20.4 ohms

black/red

green/red

Charge Coil (2)

13.6-20.4 ohms

brown/white

green/red

Lighting Coil

0.08-0.12 ohm

yellow

Ignition Timing Sensor

81-121 ohms

green/white

brown

Ignition Timing Sensor

(600 “Laydown”)

152-228 ohms

green/white

brown

Injection Coil

15.2-22.8 ohms

blue/white

Fuel Pump Coil

1.52-2.28 ohms

orange

Spark-Plug Cap

4000-6000 ohms

cap end

Description

Test Value

+ Test Connections -

Voltage Regulator

1.7-1.9 AC Volts

blue

brown

Low Oil-Light Sending

Unit

Less than 1 ohm

(float end down)

terminal

High Temperature

Sensor

Open (water temperature

lower than 190°F)

terminal

ground

Up to 20 ohms

(water temperature

higher than 230°F)

terminal

ground

High Temperature

Warning Light

Less than 10 ohms

terminal

Ignition Switch

Less than 1 ohm

(key in OFF position)

terminal

Description

Peak Voltage Test

+ Test Connections -

Primary Coil

151-176V

black/orange

orange/black

Charge Coil (1)

100-110V

black/red

green/red

Charge Coil (2)

85-94V

brown/white

green/red

Lighting Coil

5.4-5.8V

yellow

Ignition Timing Sensor

4.4V

green/white

brown

Injection Coil

12V

blue/white

Fuel Pump Coil

12.3V

orange

5-8

Electrical

Specifications

(600/700 cc “Laydown” Carb)

NOTE: The ignition system is a Normally Open Ignition (NOI).

Peak Voltage Tests were made with connectors plugged in, spark plugs removed and grounded, and by pull-
ing the recoil starter rope briskly.

NOTE: Lighting coil output is unregulated voltage.

Description

Resistance Test

Test Value

+ Test Connections -

Ignition Coil

Primary
Secondary

0.27-0.41 ohm

6800-10,200 ohms

orange

high tension wire

black

high tension wire

DC Power Coil

0.71-1.07 ohms

red/yellow

yellow/red

Lighting Coil

0.08-0.12 ohm

yellow

Ignition Timing Sensor

148-222 ohms

green/white

brown/green

Spark-Plug Cap

4000-6000 ohms

cap end

Description

Test Value

+ Test Connections -

Voltage Regulator

1.2-1.3 AC Volts

yellow

brown

Low Oil-Light Sending

Unit

Less than 1 ohm

(float end down)

terminal

High Temperature

Sensor

Open (water temperature

lower than 190°F)

terminal

ground

Up to 20 ohms

(water temperature

higher than 230°F)

terminal

ground

High Temperature

Warning Light

Less than 10 ohms

terminal

Ignition Switch

Less than 1 ohm

(key in OFF position)

terminal

Description

Peak Voltage Test

+ Test Connections -

CDI/External Coil

229V

orange

black

DC Power Coil

10V

red/yellow

yellow/red

Lighting Coil

yellow

Ignition Timing Sensor

1.4-1.6V

green/white

brown/green

5-9

Electrical

Specifications

(900 cc - Carb)

NOTE: The ignition system is a Normally Open

Ignition (NOI).

Peak Voltage Tests were made with connectors plugged in, spark plugs removed and grounded, and by
pulling the recoil starter rope briskly.

NOTE: Lighting coil output is unregulated voltage.

Description

Resistance Test

Test Value

+ Test Connections -

Ignition Coil

Primary
Secondary

0.24-0.36 ohm

6800-10,200 ohms

orange

high tension wire

black

high tension wire

DC Power Coil

0.52-0.78 ohm

red/yellow

yellow/red

Ignition Timing Sensor

148-228 ohms

green/white

brown

Lighting Coil

0.08-0.12 ohm

yellow

Spark-Plug Cap

4000-6000 ohms

cap end

Description

Test Value

+ Test Connections -

Voltage Regulator

1.2-1.3 AC Volts

yellow

brown

Low Oil-Light Sending

Unit

Less than 1 ohm

(float end down)

terminal

Ignition Switch

Less than 1 ohm

(key in OFF position)

terminal

Description

Peak Voltage Test

+ Test Connections -

Primary Coil

185-204V

orange

black

DC Power Coil

14.0-15.5V

red/yellow

yellow/red

Ignition Timing Sensor

1.4-1.6V

green/white

brown

Lighting Coil

7.0-7.7V

yellow

5-10

Testing Electrical

Components

All tests of the engine electrical components should be
made using the digital Fluke Model 73 Multimeter
(p/n 0644-191). Replace any component that does not
have a test value within specifications.

NOTE: Whenever using a digital-style tester,

“open (infinite resistance)” denotes an overload
and the meter reading will be OL since the meter is
not calibrated to register resistance values of that
magnitude.

NOTE: Whenever testing switches, less than 1

ohm is desirable with the switch in the activated
position.

Troubleshooting

Ignition System

(EFI Models)

When troubleshooting the standard “normally open”
ignition system, use the following procedure.

1. Remove the spark plugs and visually check their

condition. Replace any fouled plug. Attach the
spark plugs to the high tension leads and ground
them on the cylinder heads.

NOTE: Make sure the ignition switch and the

emergency stop switch are in the ON position.

2. Crank the engine over and check for spark. If no

spark is present, check to make sure the throttle
cable is properly tensioned. Compress the throttle
control and while holding the throttle control in
this position, crank the engine over and check for
spark. If spark is now present, adjust the throttle
cable tension.

3. If no spark is present, disconnect the main wiring

harness from the engine. Crank the engine over. If
spark is present, the problem is either one or more
of the following:

A. Defective emergency stop switch

B. Defective safety switch in throttle-control

housing

C. Corroded or loose wire connection at the

throttle-control housing or main wiring harness

D. Defective ignition switch

NOTE: To check these possible causes, proceed

to Testing Ignition System.

Testing Ignition System

(EFI Models)

NOTE: There must be free-play between the

throttle lever and the control housing.

MAIN WIRING AND SAFETY
SWITCHES

1. Check the wiring connections coming from the

ignition key and emergency stop switches. The
throttle control switch connector is located on the
front side of the steering post. If any of the
connections appear dirty or corroded, clean them
with fine sandpaper and compressed air; then
connect all wires and squeeze the connections with
a pliers for additional tightness.

2. Disconnect the main wiring harness connector

coming from the engine stator assembly.
Disconnecting this connector will bypass the main
wiring harness and all switches which will not
allow the engine to be shut off without first
installing an additional auxiliary ground wire.

3. Insert an auxiliary ground wire into the black wire

of the four-wire main harness connector on the
engine side. To stop the engine once it has been
started, touch the auxiliary ground wire to the
engine.

4. Support the rear of the snowmobile up on a

shielded safety stand; then set the brake lever lock.
Inspect the complete throttle mechanism to assure
that it's working properly.

5. Attempt to start the engine. To stop the engine (if

the engine starts), touch the auxiliary ground wire
installed into the four-wire connector to a ground
on the engine. If the engine fails to start, the
problem is with the coils mounted on the engine,
high tension coil assembly, or the ECU. If the
engine starts, the problem is with the switches,
main wiring harness, or throttle cable free-play.

! CAUTION

Before checking for spark, place all the engine
switches in the deactivated position. In the event
the engine could be flooded, pull the starter rope
(slowly at first) several times to clear the engine
of excess fuel.

! CAUTION

Never crank the engine over without grounding
the spark plugs. Damage to coils and/or CDI unit
may result.

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