Snowmobile Arctic Cat 2-Stroke (2007 year). Manual - part 64

4-30

IGNITION TIMING SENSOR

0729-627

Testing Resistance

1. Disconnect the two leads from the sensor to the

main wiring harness.

2. Set the meter selector to the OHMS scale.

3. Test between the green/white and brown leads

from the sensor. Test specification is 152-228

ohms.

„NOTE: This sensor is located inside the mag-
neto case next to the flywheel, and the recoil
starter and the flywheel must be removed to
access the sensor (see Section 2).

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 from the main wiring

harness.

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

ply 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 run-

ning).

„NOTE: If the fuel pump fails to operate, the
pump is defective and must be replaced.

TESTING FUEL PRESSURE 
REGULATOR 

1. Using the Fuel Pressure Test Kit (p/n 0644-493),

connect the tester to the regulator fuel inlet.

AO053

„NOTE: A short piece of 3/8 in. I.D. hose will be
needed to make the above connections.

2. Pressurize the regulator to 2.0-2.2 kg/cm² (28-31.3

psi). Turn the pressure tester shut off valve to the

OFF position. Observe the gauge for several min-

utes and note if there is any loss of pressure. If

pressure begins to drop, the cause may be a rup-

tured diaphragm, worn spring, or leaking valve. If

the regulator fails to build or maintain pressure,

replace the regulator.

„NOTE: If there is a drop in pressure, check the
hose connections to ensure there are no leaks.

COOLANT TEMPERATURE SENSOR

Testing Resistance

„NOTE: The coolant temperature sensor is very
sensitive to temperature change. Before the resis-
tance test is conducted, it is important to know the
coolant temperature. If the engine has been oper-
ated recently and the coolant is warm, the resis-
tance will measure lower than if the coolant was at
room temperature or colder. For accurate test
results, check the coolant temperature in the filler
neck using a thermometer.

1. Disconnect the coolant temperature sensor wiring

harness from the main harness.

2. Set the meter selector to the OHMS position and

test the resistance between the two leads from the

sensor.

3. Compare the resistance reading to the EFI Compo-

nent Voltage/Resistance Chart - Water Tempera-

ture in this sub-section. If resistance is not within

the specification, replace the sensor.

„NOTE: A coolant temperature sensor voltage
test can be made using the EFI Analyzer. 

„NOTE: The coolant temperature sensor is
located at the lower half of the crankcase. To
remove the sensor, the engine must be removed
(see Section 2).

4

4-31

INTAKE AIR TEMPERATURE 
SENSOR

Testing Resistance

„NOTE: It is very important to know the compo-
nent temperature before conducting this test.
Allow the engine to reach room temperature.

1. Disconnect the wiring harness from the intake air

temperature sensor.

AO135D

2. Set the meter selector in the OHMS position and

test the two leads located in the sensor connector.

Compare with the EFI Component Voltage/Resis-

tance Chart - Air Temperature in this sub-section.

„NOTE: The intake air temperature sensor
employs a thermistor, which is very sensitive to
temperature changes. Resistance will change as
temperature varies.

Removing

1. Disconnect the wiring harness from the intake air

temperature sensor.

2. Using a standard screwdriver, pry the sensor end

to end to remove it from the air-intake silencer.

Account for two push pins.

Installing

1. Place the sensor into position in the air-intake

silencer and secure with push pins.

2. Connect the wiring harness to the intake air tem-

perature sensor. Secure the sensor leads with cable

ties so they do not rub on any other components.

EFI Analyzer/

Diagnostic Tool

„NOTE: For testing the 800/1000 cc EFI system,
refer to the EFI Diagnostic System Manual (p/n
2257-850), which accompanies Laptop Diagnostic
Tool (p/n 0744-048) and Laptop Diagnostic Test Kit
(p/n 0744-050).

„NOTE: To aid in testing the 500/600 cc EFI sys-
tem, refer to the EFI Analyzer Usage Manual (p/n
2259-020), which accompanies EFI Analyzer Kit (p/
n 0744-049).

Peak Voltage Tests 

and Specifications

„NOTE: For peak voltage testing procedures, see
Section 5 in this manual.

Throttle Body

Assembly

741-871A

KEY

1. Throttle Body

2. Throttle Position Sensor

3. Screw

4. O-Ring

5. Fuel Rail

6. Bolt

7. Fuel Injector

8. Cushion

500 cc

4-32

0740-804

0741-330

REMOVING

„NOTE: The expansion chamber and air silencer
must be removed for this procedure (see Section
2).

1. Disconnect the wiring harness from each injector

and from the throttle position sensor connector.

2. Remove the coolant hoses from the throttle body

assembly and plug them to prevent leakage.

3. Remove the fuel supply hose from the fuel rail.

4. Loosen the flange clamps.

5. Slide the throttle body assembly out of the flanges;

then loosen the jam nut securing the throttle cable

and remove.

6. Where applicable, remove the oil pump control

rod.

7. Remove the throttle body assembly.

INSTALLING

1. Attach the throttle cable to the throttle body.

Secure with jam nut.

2. Place the throttle body assembly into position.

Make sure the flanges and boots are positioned

properly. Secure with flange clamps.

3. Where applicable, connect the oil pump control

rod.

„NOTE: The coolant hoses must be connected
first; then the throttle body assembly must be
installed.

4. Secure the coolant hoses to throttle body assem-

bly.

5. Connect the fuel supply hose to the fuel rail. 

0729-325

6. Connect the wiring harness to each injector and

throttle position sensor.

„NOTE: Install the air silencer and the expansion
chamber (see Section 2).

600 cc

KEY

1. Throttle Body

2. Fuel Rail

3. Fuel Injector

4. Screw

5. Hose

6. Clamp

7. O-Ring Set

8. Throttle 

Position 
Sensor

9. Screw

10. Control Rod

KEY

1. Throttle Body

2. Fuel Injector

3. Fuel Rail

4. O-Ring 

5. Hose

6. Clip

7. Screw

8. Throttle 

Position 
Sensor

9. Screw

10. Control Rod

800/1000 cc

! CAUTION

Since the fuel supply hose may be under pressure,
remove it slowly to release the pressure. Place an
absorbent towel around the connection to absorb
fuel.

! CAUTION

These hoses must be connected to the correct fit-
tings.

4

4-33

7. Place the rear of the snowmobile on a shielded

safety stand and start the engine without touching

the throttle. It may idle slowly and stop. Restart

using the same procedure until the engine starts

and builds RPM on its own. 

8. Check the cooling system.

9. Adjust the throttle cable as necessary.

Throttle Body Flange

REMOVING

1. Loosen the clamps securing the throttle body

assembly to the throttle body flanges.

2. Remove the throttle body assembly from the

flanges.

3. In turn on each flange, remove the two nuts, lock

washers, and flat washers securing the intake flange

to the cylinder; then remove the flange.

INSTALLING

1. Apply a thin coat of high-temperature silicone to

the cylinder side of each flange; then attach each

flange to a cylinder and secure each with two flat

washers, lock washers, and nuts. Tighten to 2.1

kg-m (15 ft-lb).

2. Install the flange clamps on the flanges; then place

the throttle body assembly into the flanges and

secure with the clamps.

3. Secure all wires and hoses with cable ties.

Throttle Cable

„NOTE: Determine which type of cable is being
replaced and remove and install accordingly.

741-982A

741-618A

742-027A

REMOVING

1. Loosen the throttle cable adjuster at the bracket.

2. Remove the throttle cable from the pulley on the

throttle body lever shaft.

3. On the 500 cc, remove the E-clip securing the oil-

injection cable to the oil-injection pump control

arm. Account for a washer.

4. On the 500 cc, loosen the oil-injection cable jam

nuts.

5. On the other models, remove the handlebar pad

and the console (if applicable).

6. Remove the cable ties securing the throttle cable.

7. Remove the throttle cable ends from the throttle

lever and from the throttle control housing.

! CAUTION

When installing the throttle bodies, make sure the
gasline hose is properly routed to avoid premature
wear and/or contact with exhaust components.

KEY

1. Throttle Cable

2. Cable Tie

3. E-Ring

4. Washer

KEY

1. Throttle Cable

2. Cable Tie

KEY

1. Throttle Cable

2. Cable Tie