Snowmobile Arctic Cat 2-Stroke (2007 year). Manual - part 49

2-182

Problem: Engine Does Not Idle

Condition

Remedy

1. ECU/CCU LED trouble code

1. Service — replace problem component

2. Throttle position sensor idle adjustment incorrect

2. Adjust idle RPM to specifications

3. Injector(s) faulty

3. Replace injector(s)

4. Fuel pressure regulator faulty

4. Replace regulator — hose

5. Air-intake silencer obstructed

5. Clean air-intake silencer

Problem: Engine Loses Power or Runs on One Cylinder

Condition

Remedy

1. Sensor faulty

1. Check LED for trouble code — repair — replace prob-

lem circuit or sensor

2. Spark plug fouled

2. Replace spark plugs

3. External coil faulty

3. Service — replace coil

4. Gas tank vent — hose obstructed

4. Service — replace vent hose

5. Secondary compression low

5. Service engine

6. Fuel pressure regulator faulty

6. Replace regulator

7. Pick-up valve(s) obstructed — out of position

7. Replace — relocate pick-up valve(s)

8. Oil-injection pump malfunctioning — adjusted incor-

rectly

8. Replace — bleed — adjust oil-injection pump

9. Throttle bodies out of synchronization

9. Replace throttle bodies from a similar engine — if prob-

lem is corrected, replace the original assembly

10. Injector faulty

10. Replace injector

11. Dropping resistor faulty

11. Test resistor — replace as necessary

Problem: Engine Overheats

Condition

Remedy

1. Spark plug heat range too hot

1. Install lower heat-range spark plugs

2. Coolant low — absent

2. Add coolant

3. Heat exchanger obstructed

3. Remove obstruction

4. Intake flange to cylinder air leak

4. Replace — seal intake flange(s)

5. Drive system (drive clutch — driven pulley — track

— drive belt) adjusted incorrectly — worn — damaged

5. Troubleshoot — adjust drive system

6. Rings/grooves carboned

6. Clean — replace rings — pistons

7. Exhaust ports obstructed

7. Remove obstruction

8. Expansion chamber obstructed

8. Remove obstruction

9. Oil-injection pump malfunctioning — adjusted incor-

rectly

9. Replace — bleed — adjust oil-injection pump

10. Primary compression low — absent

10. Repair — replace damaged — worn engine compo-

nents

11. Gasoline octane too low

11. Use 87 minimum octane gasoline

12. Water pump — thermostat damaged — faulty

12. Replace water pump — thermostat

2-183

2

Problem: Engine Backfires

Condition

Remedy

1. ECU/CCU LED trouble code

1. Service — replace problem component

2. Throttle/ignition monitor switch adjusted incorrectly

2. Adjust throttle cable tension — service spring

3. Spark plugs fouled — damaged

3. Clean — replace spark plugs

4. High tension leads/coil shorting

4. Service — replace high tension leads/coil

5. ECU/CCU faulty — damaged

5. Replace ECU/CCU

6. Fuel mixture lean

6. Repair fuel regulator — injector(s)

7. Oil-injection pump malfunctioning — adjusted incor-

rectly

7. Replace — bleed — adjust oil-injection pump

Problem: Engine Four-Cycles (Floods Excessively)

Condition

Remedy

1. ECU LED trouble code

1. Service — replace problem component

2. Fuel pressure too high

2. Replace regulator — hose

3. Injector faulty

3. Replace injector

4. Throttle position sensor faulty

4. Replace throttle body assembly

5. Air-intake silencer obstructed

5. Remove obstruction

Problem: Engine Stops Suddenly

Condition

Remedy

1. Gas tank empty

1. Fill tank

2. Spark absent

2. See No Spark at Spark Plugs sub-section

3. ECU/CCU LED trouble code

3. Service — replace problem component

4. CDI relay faulty

4. Replace CDI relay

5. Fuel filter(s) obstructed

5. Replace filter(s)

6. Fuel pressure low

6. Replace regulator — hose

7. Fuel pump faulty

7. Service — replace fuel pump

8. Fuel pump relay faulty

8. Replace relay

9. Gas tank vent hose obstructed

9. Service vent hose

10. ECU/CCU faulty

10. Replace ECU/CCU

11. Fuel hose obstructed — broken — pinched

11. Remove obstruction — repair — replace fuel hose

12. Ignition coil faulty

12. Replace ignition coil

13. Engine seized

13. Service engine

14. Throttle/ignition monitor switch — throttle cable

tension faulty — adjusted incorrectly

14. Replace throttle control — adjust throttle cable

Problem: Engine Fails to Stop (Continues to Run, Even with All Switches Off)

Condition

Remedy

1. ECU/CCU shorted to ground

1. Replace ECU/CCU

2. Engine wiring harness connections wet

2. Clean — dry connections

3-1

3

SECTION 3 — 

ENGINE-RELATED ITEMS

TABLE OF

CONTENTS

Axial Fan/Belt (370 cc) ............................................ 3-2
Repairing Water Pump (500/600 cc) ....................... 3-4
Repairing Water Pump (800/1000 cc) ..................... 3-8
Pressure Testing Engine ....................................... 3-12
Liquid Cooling System .......................................... 3-12
Cooling System Schematics ................................. 3-15
Recoil Starter (370/500/600 cc) ............................ 3-17
Recoil Starter (570/800/1000 cc) .......................... 3-19
Arctic Power Valve (APV) System ......................... 3-22
Exhaust Controlled Timing (ECT) System ............ 3-29

3-2

Axial Fan/Belt 

(370 cc)

REMOVING FAN

1. Remove the four cap screws securing the recoil

starter to the fan case.

2. Remove the three cap screws securing the recoil

starter pulley and fan drive pulley to the flywheel;

then remove the recoil starter pulley and fan drive

pulley.

3. Remove the cap screws and flange nuts securing

the fan case assembly to the engine; then remove

the fan case from the engine compartment.

DISASSEMBLING

1. Remove the fan cover; then remove the belt.

2. Using the Fan Spanner Wrench (p/n 0644-139),

remove the nut, lock washer, and washer securing

pulley halves.

AB102

3. Slide the outer pulley half, shim(s), fan belt, and

inner pulley half off the shaft and account for the

key and the fan belt.

A908

4. Remove the fan with shaft.

5. Drive the bearings from the fan case and account

for the spacer between the bearings.

A910

„NOTE: A circlip is positioned between the bear-
ings. The bearings must be driven from the center
to the outside of the fan case.

6. Remove the circlip from the fan case.

A911

CLEANING AND INSPECTING

„NOTE: Whenever a part is worn excessively,
cracked, or damaged in any way, replacement is
necessary.

1. Clean all axial fan components.

2. Inspect the fan case and shaft threaded areas for

damage or stripped threads; then check the shaft

keyway and key for excessive wear.

3. Inspect the fan for broken, bent, or damaged

vanes.

4. Inspect the bearings for smooth rotation.

5. Inspect the pulley halves for cracks, gouges, or

other damage.

6. Inspect the fan belt for cracks, tears, or fraying.