Snowmobile Arctic Cat (2004 year). Manual - part 61

5-11

5

IGNITION KEY SWITCH

1. Disconnect the ignition key switch connectors;

then connect the ohmmeter leads to each of the
ignition key switch terminals.

2. With the switch in the OFF position, the meter

must read less than 1 ohm of resistance.

3. With the switch in the ON position, the meter must

read OL (infinite resistance).

THROTTLE CONTROL SWITCH

1. Verify that the throttle cable has free-play between

the throttle lever and control housing.

2. Disconnect the throttle control switch connector;

then connect one ohmmeter lead to the brown wire
and the other lead to the black/white wire of the
emergency stop switch.

3. With the throttle lever in the idle position and the

emergency stop knob in the up (RUN) position,
the meter must read no resistance (open). If the
meter reads resistance (closed), replace the switch.

4. With the throttle lever in the idle position and the

emergency stop knob in the down (STOP)
position, the meter must read resistance (closed).
If the meter reads no resistance (open), replace the
switch. With the emergency stop knob still in the
down (STOP) position, move the throttle lever to
the wide open position. The meter must read no
resistance (open). If the meter reads resistance
(closed), replace the switch.

5. Connect one ohmmeter lead to the brown wire and

the other lead to the violet wire. With the
emergency stop knob in the down (STOP)
position, the meter must read resistance (closed).
If the meter reads no resistance (open), replace the
switch. With the emergency stop knob in the up
(RUN) position, the meter must read no resistance
(open). If the meter reads resistance (closed),
replace the switch.

Troubleshooting

Ignition System

(Fan Cooled 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.

„

NOTE: On all models, there must be 0.75-1.5 mm

(0.030-0.060 in.) free-play between the throttle
lever and the control housing.

733-081C

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

! 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.

5-12

C. Grounded or shorted 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. If no spark is present,
proceed to Arctic Cat Ignition Analyzer in this sec-
tion.

Testing Ignition System

(Single Carburetor F/C Models)

„

NOTE: The throttle control is equipped with a

two-wire throttle control switch connector. There
must be 0.75-1.5 mm (0.030-0.060 in.) throttle cable
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 throttle control switches. The
two-wire 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 four-wire

connector coming from the engine stator
assembly. Disconnecting the 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 CDI unit. If the
engine starts, the problem is with the switches,
main wiring harness, or throttle cable free-play.

MAIN HARNESS

1. Disconnect the main wiring harness four-wire

connector coming from the engine stator
assembly. Connect one ohmmeter lead to the
violet wire and the other lead to the brown wire on
the chassis side of the main wiring harness four-
wire connector. With all switches in the RUN
position, the meter must read no resistance (open).

2. If the meter reads resistance (closed), test the

Ignition Key Switch and Throttle Control Switch
independently of each other.

IGNITION KEY SWITCH

1. Disconnect the ignition key switch connectors;

then connect the ohmmeter leads to each of the
ignition key switch terminals.

2. With the key switch in the OFF position, the meter

must read resistance (closed). If the meter reads no
resistance (open), the switch must be replaced.

THROTTLE CONTROL SWITCH

„

NOTE: The throttle control has a two-wire wiring

harness connector located on the front side of the
steering post. Whenever working with a two-wire
throttle control switch, the throttle cable must be
adjusted so there is 0.75-1.5 mm (0.030-0.060 in.)
free-play between the throttle lever and control
housing.

1. Verify that the throttle cable has the specified

amount of free-play between the throttle lever and
control housing.

2. Disconnect the two-wire throttle control switch

connector; then connect the ohmmeter leads to
each of the switch wires.

3. With the throttle lever in the idle position and the

emergency stop knob in the down (STOP)
position, the meter must read resistance (closed).
If the meter reads no resistance (open), replace the
switch.

4. Depress the throttle lever with the emergency stop

knob in the up (RUN) position. The meter must
read no resistance (open). If the meter reads
resistance (closed), replace the switch.

5. With the throttle lever depressed and the

emergency stop knob in the down (STOP)
position, the meter must read resistance (closed).
If the meter reads no resistance (open), replace the
switch.

5-13

5

Testing Ignition System

(Twin Carburetor F/C Models)

„

NOTE: There must be 0.75-1.5 mm (0.030-0.060

in.) free-play between the throttle lever and the
control housing (see Section 4 - Adjusting Carbu-
retors).

MAIN WIRING AND SAFETY 
SWITCHES

1. Check the wire connections at the ignition key

switch and at the emergency stop switch. This
connector is located on the front side of the
steering post. If any of the connections appear
dirty or corroded, clean with fine sandpaper and
compressed air; then connect all wires and squeeze
connections with a pliers for added tightness.

2. Disconnect the main wiring harness connector

coming from the engine. Using an ohmmeter,
connect one lead to the black wire in the connector
of the main harness. Connect the remaining
ohmmeter lead to the brown wire in the connector
of the main harness.

3. With all switches in the RUN position, the meter

must read resistance (closed). If the meter reads no
resistance (open), proceed to testing Emergency
Stop/Throttle Switch, Carburetor Safety Switches,
and Ignition Key Switch.

EMERGENCY STOP/
THROTTLE SWITCH

1. If the meter read no resistance (open) in the

previous test, locate the wiring harness coming
from the emergency stop/throttle switch assembly.

2. Disconnect the three-wire connector. Using an

ohmmeter, connect one meter lead to the black
wire and the other meter lead to the black/red wire
in the connector.

3. With the emergency stop knob, located on top of

the throttle control, in the ON (pulled up) position
and the throttle lever compressed, the meter must
read resistance (closed).

4. If the meter reads no resistance (open) and the

lever/control housing free-play is correct, replace
the throttle switch.

5. If the meter reads resistance (closed) but the

engine will not start, with the ohmmeter leads still
connected, alternately release and compress the
throttle lever; then move the emergency stop knob
down and up.

6. The meter must read no resistance (open) when the

throttle lever is released and the emergency stop
knob is in either the UP or the DOWN position.

7. If the meter reads resistance (closed), replace the

throttle switch.

8. Connect one meter lead to the black/red wire and

the other meter lead to the black/white wire.

9. With the throttle lever released (idle position) and

the emergency stop knob in the DOWN position,
the meter must read no resistance (open).

10. If above tests were good, proceed to testing

Carburetor Safety Switches and Ignition Key
Switch.

CARBURETOR SAFETY SWITCHES

1. If the meter read no resistance (open) in the

previous test, disconnect the carburetor safety
switches one at time and test for a closed circuit.

2. Attach the two ohmmeter leads to the two leads

coming from each carburetor switch. The meter
must read resistance (closed).

3. If the meter reads no resistance (open), the switch

must either be adjusted or replaced (see
Synchronizing Carburetor Safety Switches in this
sub-section). If the meter reads resistance (closed),
proceed to testing Ignition Key Switch.

IGNITION KEY SWITCH

1. If the meter read resistance (closed) in the

previous test, disconnect the ignition key switch
connectors and connect the ohmmeter leads to
each of the leads from the switch.

2. With the key switch in the OFF position, the meter

must read resistance (closed). If the meter reads no
resistance (open), replace the switch.

SYNCHRONIZING CARBURETOR 
SAFETY SWITCHES

Before synchronizing the carburetor safety switches,
check to make certain the carburetor idle speed screws
are adjusted equally and the piston valves are synchro-
nized. The carburetor safety switches affect ignition
spark at idle only. If ignition spark problems are
observed at partial or full-throttle positions, the prob-
lem is not with the carburetor safety switches.

„

NOTE: There must be 0.75-1.5 mm (0.030-0.060

in.) free-play between the throttle lever and the
control housing.

1. Inspect the cable free-play gap between the

throttle lever and the control housing at idle.
Adjust the throttle cable swivel adapter at the top
of each carburetor for 0.75-1.5 mm (0.030-0.060
in.) cable free-play gap between the throttle lever
“nibs” and the control housing. While observing if
there is any cable free-play gap, apply slight
pressure to the throttle lever to take up any cable
slack that may be present. However, do not apply
enough pressure to actually raise the carburetor
slides during this adjustment. After cable free-play
is properly adjusted, tighten the jam nut on each
carburetor securely.

5-14

733-081C

2. To determine which switch needs adjusting,

disconnect both carburetor safety switches from
the main wiring harness connector.

3. Connect a digital ohmmeter to one carburetor

safety switch connector; then compress the throttle
lever while observing the meter reading and
measure the gap between the throttle lever and
control housing at the moment the meter reading
changes from open to closed. Repeat this step for
the other carburetor safety switch.

„

NOTE: The correct throttle lever/housing gap

should be in a range of 9.5 - 12.7 mm (0.375-0.500
in.) the moment the meter reading changes from
open to closed. A switch that changes from open
to closed before the other one is the switch that
must be raised to attain safety switch synchroniza-
tion.

733-082A

4. If an adjustment is necessary, loosen the switch

bracket screws, move the switch up, tighten the
screws, and then reset using step 3.

„

NOTE: After completion of any adjustments,

throttle lever “side pressure” should not cause an
ignition miss at idle. Carburetor switches set too
low or an excessively tight throttle cable makes
the shutdown system very sensitive to throttle
lever “side pressure” near idle. To test carburetor
safety switch synchronization, follow steps 5-9.

5. Reconnect the carburetor safety switch

connectors. Place the rear of the snowmobile on a
shielded safety stand; then start the engine and
allow it to warm up for 3-4 minutes.

6. Hold both the top and bottom of the throttle lever

pin so that depression of the throttle lever does not
move the lever pin in its control slot.

0728-916

7. Slowly depress the throttle lever to increase engine

RPM.

„

NOTE: It is very important that engine RPM be

allowed to increase slowly, since most engines
have a “rich area” at approximately 2500 RPM.

8. Observe the tachometer and the drive clutch to

determine the moment the carburetor safety
switches shut down the ignition. Since retaining
the throttle lever pin prevents the switch in the
throttle control housing from closing, the
carburetor safety switches should shut down the
ignition at or slightly after clutch engagement.

9. Repeat steps 6-8 several times. If ignition

shutdown always occurs at or slightly after clutch
engagement, the carburetor safety switches are
synchronized.

10. Again, inspect the gap between the throttle lever

and the control housing at idle. Adjust the throttle
cable swivel adapter at the top of each carburetor
for 0.75-1.5 mm (0.030-0.060 in.) cable free-play
gap between the throttle lever “nibs” and the
control housing. While observing if there is any
cable free-play gap, apply slight pressure to the
throttle lever to take up any cable slack that may
be present. However, do not apply enough
pressure to actually raise the carburetor slides
during this adjustment. After cable free-play is
properly adjusted, tighten the jam nut on each
carburetor securely.

„

NOTE: After completion of any adjustments,

throttle lever “side pressure” should not cause an
ignition miss at idle. Carburetor safety switches
set too low or an excessively tight throttle cable
makes the shutdown system very sensitive to
throttle lever “side pressure” near idle.