Snowmobile Arctic Cat (2004 year). Manual - part 75

Harness N

(p/n 0686-853)

Firecat 600 EFI (EB)

0738-196

5-67

6-1

6

SECTION 6 — CHASSIS 

ELECTRICAL SYSTEMS

TABLE OF

CONTENTS

Brakelight Switch (Hydraulic System) ..................... 6-2
Brakelight Switch (Mechanical System) .................. 6-2
Headlight Dimmer Switch ........................................ 6-3
Testing Handlebar Warmer Elements 
   (ON/OFF Function) .............................................. 6-4
Testing Thumb Warmer Element
   (ON/OFF Function) .............................................. 6-4
Testing Handlebar Warmer Elements 
   (HI/OFF/LO Function - Standard Models) ............ 6-4
Testing Handlebar Warmer Elements
   (AWS VI Models) .................................................. 6-4
Testing Thumb Warmer Element
   (HI/OFF/LO Function - Standard Models) ............ 6-4
Testing Thumb Warmer Element
   (AWS VI Models) .................................................. 6-5
Testing Handlebar Warmer Switch

(ON/OFF Function) .............................................. 6-5

Testing Handlebar Warmer Switch

(HI/OFF/LO Function - Standard Models)............ 6-5

Testing Handlebar Warmer Switch
   (AWS VI Models) .................................................. 6-5
Testing Thumb Warmer Switch

(OFF/ON Function) .............................................. 6-6

Testing Thumb Warmer Switch

(HI/OFF/LO Function - Standard Models)............ 6-6

Testing Thumb Warmer Switch
   (AWS VI Models) .................................................. 6-6
Testing Passenger Handwarmer Switch.................. 6-6
Testing Passenger Handwarmer Elements ............. 6-7
Wiring Diagram Index (Main and Hood) .................. 6-9
Wiring Diagrams.................................................... 6-10

6-2

Brakelight Switch

(Hydraulic System)

TESTING/REMOVING

„

NOTE: On AWS VI models, the servomotor  must

be removed from the mounting bracket to access
the brakelight switch harness connector.

1. Disconnect the wiring harness from the brake

control.

2. To test the brakelight switch, connect one tester

lead to the #1 (yellow) terminal; then connect the
other lead to the #4 (red) terminal.

727-650A

3. With the brake lever compressed, the meter must

read resistance. With the brake lever released, the
meter must read no resistance. If the meter does
not read as specified, the brakelight switch is
defective and must be replaced.

4. On standard models to remove the switch, use a

small screwdriver to compress the plastic locking
tabs by pushing in on the tabs; then slide the
switch free of the brake control.

AF201D

5. On AWS VI models to remove the switch, remove

the Allen-head cap screw from beneath the master
cylinder and free the switch from the master
cylinder assembly.

INSTALLING

1. On standard models, slide the brakelight switch

into the brake control assembly until the self-
locking tabs snap into position. Give the switch
body a light pull to make sure the switch is
properly secured.

2. On AWS VI models, place the switch into position

beneath the master cylinder assembly making sure
the alignment pins are properly positioned; then
secure the switch with the Allen-head screw.

3. Connect the switch harness to the main wiring

harness. Position the wires so they will not be
either pinched or come in contact with any moving
components. Start the engine and check the switch
for proper operation.

Brakelight Switch

(Mechanical System)

TESTING/REMOVING

1. Disconnect the wiring harness from the brake

control.

2. Connect one tester lead to the #1 terminal; then

connect the other lead to the #4 terminal.

727-650A

3. With the brake lever compressed, the meter must

read less than 1 ohm of resistance. With the brake
lever released, the meter must read no resistance.
If the meter does not read as specified, the
brakelight switch is defective and must be
replaced.

Terminal

Corresponding Wire 

Color

Wire Usage

1

Yellow

Power Supply

2

Blue

Headlight - 

High Beam

3

White

Headlight - 

Low Beam

4

Red

Brakelight

6-3

6

4. Use a small screwdriver to compress the plastic

locking tabs by pushing in on the tabs; then slide
the switch free of the brake control.

AF907D

INSTALLING

1. Slide the brakelight switch into the brake control

assembly until the self-locking tabs snap into
position. Give the switch body a light pull to make
sure the switch is properly secured.

2. Connect the switch harness to the main wiring

harness. Position the wires so they will not be
either pinched or come in contact with any moving
components. Start the engine and check the switch
for proper operation.

Headlight

Dimmer Switch

TESTING

1. Disconnect the headlight dimmer switch plug

(located next to the air-intake silencer on standard
models or behind the servomotor on AWS VI
models).

2. Use the tester connections indicated in the

following chart. If the meter does not read as
specified, the headlight dimmer switch is defective
and must be replaced.

REMOVING (Standard Models)

1. Remove the handlebar pad.

2. Remove the screws from the cover plate securing

the dimmer switch.

AF908D

3. Remove the plate and lift the switch free of the

control.

AF909D

INSTALLING (Standard Models)

1. Place the dimmer switch into the control and

secure with the cover plate and screws.

2. Connect the four-prong plug; then install and

secure the handlebar pad.

REMOVING (AWS VI Models)

1. Remove the Allen-head cap screw from beneath

the master cylinder.

2. Free the switch from the master cylinder

assembly.

INSTALLING (AWS VI Models)

1. Place the switch into position beneath the master

cylinder assembly making sure the alignment pins
are properly positioned; then secure the switch
with the Allen-head screw.

2. Connect the four-prong plug.

Position

Lead to 

Terminal 

(Wire Color)

Lead to 

Terminal 

(Wire Color)

Meter

Reading

High Beam

1 (Yellow)

2 (Blue)

Less than 1 

ohm

High Beam

1 (Yellow)

3 (White)

OL

Low Beam

1 (Yellow)

2 (Blue)

OL

Low Beam

1 (Yellow)

3 (White)

Less than 1 

ohm

6