Snowmobile Arctic Cat (2004 year). Manual - part 67

5-35

5

Testing High 

Temperature Sensor

1. Disconnect the main wiring harness connector

from the temperature sensor.

2. Connect an ohmmeter between the sensor terminal

and any convenient chassis ground (or any brown
wire). The ohmmeter must read less than 20 ohms
of resistance with the water temperature more than
+230°F. The ohmmeter must read no resistance
with the water temperature less than +190°F.

„

NOTE: It may be easier to remove the sensor

from the water manifold for testing purposes.
Immerse the sensor body (only up to the threads)
in automatic transmission fluid and slowly heat
the fluid. The ohmmeter must indicate the above
resistances when connected between the sensor
terminal and the sensor body/chassis.

Testing

High Temperature 

Warning Light

1. Disconnect the main wiring harness connector

from the temperature sensor.

2. Temporarily place a jumper wire from the main

wiring harness sensor connector to any convenient
chassis ground (or any brown wire).

3. If the high temperature warning light is not

illuminated with the engine running (and the
harness terminal grounded), test the light bulb. An
ohmmeter must read less than 10 ohms across the
bulb filament.

4. If the bulb does not illuminate even when tested

good, use the ohmmeter to test the bulb harness.
Also test the red/white wire continuity from the
temperature sensor connector to the bulb
connector.

Testing Fuel Gauge

1. Disconnect the fuel gauge from the hood wiring

harness.

2. Connect the positive lead of a 12-volt power

supply to the yellow wire and the negative lead of
the 12-volt power supply to the brown wire.

3. The fuel gauge needle should peg in the negative

(empty) direction.

4. With the fuel gauge still connected to the 12-volt

power supply (from step 2), install a jumper wire
(such as a paper clip) between the brown wire and
the gray wire.

5. The fuel gauge needle should peg in the positive

(full) direction.

„

NOTE: A fuel gauge failing these testing proce-

dures is defective and must be replaced.

Testing

Fuel Gauge Sender

1. Remove the hardware securing the console to the

fuel tank and frame; then move the console out of
the way.

2. Disconnect the fuel gauge sender unit (black two-

wire connector) from the main wiring harness.

3. Connect the ohmmeter leads to the two sender

wires.

4. Compare the reading to the chart following.

Testing

Electric Fuel Pump

1. Remove the hardware securing the console to the

gas tank and frame; then move the console out of
the way.

2. Disconnect the fuel pump (white two-wire

connector on standard EFI models or the black
two-wire connector on the F-chassis EFI models)
from the main wiring harness.

3. Connect the positive lead of a 12-volt power

supply to the red wire and the negative lead of the
12-volt power supply to the black wire.

4. The pump should operate (it would be heard

running).

„

NOTE: If the fuel pump fails to operate, the pump

is defective and must be replaced.

Fuel Gauge Sender

Position

Ohms

Full

4-6

1/2

37.6-56.4

Empty

76-114

5-36

Solenoid 

(Electric Start Models)

TESTING

„

NOTE: The electric start solenoid may be tested

using either one of the following methods.

Method #1

1. Disconnect the electric start harness from the main

wiring harness.

2. Place the ohmmeter leads across the solenoid coil

terminals (brown wire and red/white wire).

3. The ohmmeter must read between 3 and 5 ohms.

Method #2

1. Connect the battery to the solenoid coil terminals

(brown wire and red/white wire).

2. A loud, audible “click” should be heard as the

solenoid internal contacts make connection.

3. Disconnect the battery from the solenoid.

4. A loud, audible “click” should be heard as the

solenoid internal contacts release.

„

NOTE: An in-line ammeter would measure

between 2 and 4 amps of solenoid coil current flow
with the battery connected.

Charging Diode

(Electric Start Models)

TESTING

1. Disconnect the electric start harness from the main

wiring harness.

2. Connect the ohmmeter positive lead (red) to the

diode yellow wire and the ohmmeter negative lead
(black) to the diode red wire. The ohmmeter must
read between 300 and 700 ohms.

3. Connect the ohmmeter positive lead (red) to the

diode red wire and the ohmmeter negative lead
(black) to the diode yellow wire. The ohmmeter
must read OPEN (infinite resistance).

Fuse

(Electric Start Models)

TESTING

1. Remove the fuse from the fuse holder.

2. Connect the ohmmeter across the fuse end-caps.

3. The ohmmeter must read less than 1 ohm of

resistance.

Ignition Switch -

Electric Start Function 

(Electric Start Models)

TESTING

1. Disconnect the wiring harness from the ignition

switch; then remove the switch from the console.

2. Using the ohmmeter, test the connections

indicated in the following chart. If the meter does
not read as specified or has more than one ohm of
resistance, the switch must be replaced.

! CAUTION

NEVER connect an in-line ammeter with the large
starter cables because the 200 amps of current
flow will instantly damage most ammeters.

! CAUTION

To prevent ohmmeter damage when testing
circuits on snowmobiles equipped with an
electric start, be sure to disconnect the battery
before testing.

! CAUTION

To prevent ohmmeter damage when testing
circuits on snowmobiles equipped with an
electric start, be sure to disconnect the battery
before testing.

Position

Lead to 

Terminal

Lead to 

Terminal

Meter 

Reading

OFF

-M

+M

CLOSED

ON

-M

+M

OPEN

ON

B

A

CLOSED

START

-M

+M

OPEN

START

B

S

CLOSED

5-37

5

0000-126

„

NOTE: Some ignition-switch terminals may not

be labeled (-M, +M, A, B, or S). Refer to the wiring
harness diagram of the ignition switch when con-
necting the ohmmeter.

Starter Motor

REMOVING (370/440 cc Models)

1. Disconnect the battery.

2. Remove the expansion chamber.

3. Remove the nut and washer(s) securing the

positive cable; then remove cable from the starter
motor.

4. Remove the drive clutch.

5. Remove the hardware securing the starter motor

and end plate/drive cap assembly to the bracket;
then remove the starter motor assembly.

REMOVING (570 cc/Pantera 
Models)

1. Disconnect the battery.

„

NOTE: On certain models, it may be necessary

to remove the expansion chamber.

2. Remove the nut and washer(s) securing the

positive cable; then remove cable from the starter
motor.

3. Loosen the two Allen-head screws securing the

flex-drive shaft to the pinion drive; then remove
the hardware securing the starter motor  to the
bracket. Remove the starter motor assembly.

REMOVING (AWS VI Models)

1. Disconnect the battery.

2. Remove the nut and washer(s) securing the

positive cable; then remove cable from the starter
motor.

3. Remove the lock nut securing the upper mounting

bracket to the steering support; then remove the
two lock nuts securing the starter motor  to the
lower bracket and remove the starter motor
assembly.

4. Loosen the two Allen-head screws securing the

flex-drive shaft to the pinion drive; then remove
the lock nuts securing the lower mounting bracket
and remove the bracket.

DISASSEMBLING

„

NOTE: For assembly purposes, scribe a refer-

ence line on the end plate/drive cap, commutator
cap, and the case.

1. If applicable, remove the snap ring securing the

primary gear to the starter motor; then remove the
gear and account for the spring washer.

2. Remove the two long through-bolts. As the bolts

are being removed, hold pressure against the
commutator cap.

AI050

3. Slowly remove the cap and account for the four

brush holder springs.

AI026

5-38

4. Using a plastic hammer, tap the end plate/drive

cap free of the starter case and slide the cap free
from the armature shaft. Account for any  washers.

AI027

5. Slide the armature free of the starter case.

AI028

6. Lift all brushes from the brush holder and account

for the four brush springs.

7. Using a 5/16-in. socket, remove the two cap

screws securing the ground brushes to the
commutator cap. Remove the brushes and brush
holder from the cap.

AI036

8. Using a 7/16-in. wrench, remove the nut securing

the cable stud to the cap. Account for the number
of and the position of washers.

AI037

9. While holding the brush wires, pull the stud from

the end cap. Account for the plastic insulator.

CLEANING AND INSPECTING

„

NOTE: Whenever a part is worn excessively,

cracked, or damaged in any way, replacement is
necessary.

1. Thoroughly clean all components except the

armature and brushes in parts-cleaning solvent;
then dry with compressed air.

AI029

2. Inspect all threaded areas for damaged or stripped

threads.

3. Inspect the brush holder assembly and brushes for

damage or wear. Using a calipers, measure the
length of the brushes. If brush measurement is less
than 7.5 mm (0.30 in.), replace brushes as a set
along with new brush springs.

! WARNING

When using compressed air to dry components,
always wear safety glasses.

! CAUTION

Do not wash the armature and brushes in any
kind of solvent. Use only compressed air and
clean dry cloth in cleaning these components.