Content .. 67 68 69 70 ..

Snowmobile Arctic Cat 2-Stroke (2007 year). Manual - part 69

5-6

Electrical

Specifications

(800/1000 cc Models)

NOTE: The ignition system is a Normally Open Ignition (NOI).

Main harness plugged in

Peak Voltage Tests were made at room temperature with the MaxiClips (p/n 0744-041), Fluke Model 73 Multime-

ter (p/n 0644-191) set to the DC Volt scale, and the Peak Voltage Reading Adapter (p/n 0644-307). Also, the main

harness connectors must be unplugged (except on primary coil/CCU tests), the spark plugs removed and grounded,

and by pulling the recoil starter rope briskly.

NOTE: Lighting coil output is unregulated voltage.

Description

Resistance Test

Test Value

+ Test Connections -

Ignition Coil
Primary
Secondary

0.24-0.36 ohm
5040-7560 ohms

black/white
high tension wire

white/blue
high tension wire

Charge Coil (1)

7.20-10.8 ohms

black/red

green/red

Charge Coil (2)

7.20-10.8 ohms

brown/white

green/red

Lighting Coil

0.08-0.12 ohms

yellow

Ignition Timing Sensor (1)

148-222 ohms

blue/white

brown/green

Ignition Timing Sensor (2)

142-222 ohms

green/white

brown/green

Injection Coil

15.2-22.8 ohms

blue/white

Fuel Pump Coil

1.52-2.28 ohms

orange

Spark-Plug Cap

4000-6000 ohms

cap end

Description

Test Value

+ Test Connections -

Chassis Control Unit*

10-15 DC Volts

red/blue (low power)
red/black (high power)

brown (low power)
black (high power)

Servomotor

12 DC Volts

red/black (counter-
clockwise)
black/red (clockwise)

black/red (counter-
clockwise)
red/black (clockwise)

Low Oil-Light Sending Unit

Less than 1 ohm (float end down)

terminal

Coolant Temperature Sensor

Open
(coolant temperature lower than 190°F)

terminal

ground

Up to 20 ohms
(coolant temperature higher than 230°F)

terminal

ground

Coolant Temperature Warning Light Less than 10 ohms

terminal

Ignition Switch

Less than 1 ohm (key in OFF position)

terminal

Description

Peak Voltage Test

+ Test Connections -

MAG Primary Coil (Harness Side)* 125-137V

orange/red

orange/black

PTO Primary Coil (Harness Side)*

126-139V

white/red

white/black

Charge Coil (1)

13.6-14.8

black/red

green/red

Charge Coil (2)

13.5-14.6

brown/white

green/red

Lighting Coil

5.4-5.8V

yellow

Ignition Timing Sensor (1)

4.3V

blue/white

brown/green

Ignition Timing Sensor (2)

4.4V

green/white

brown/green

Injection Coil

12V

blue/white

Fuel Pump Coil

12.3V

orange

Lighting Coil

14.8-22.2V (@ 2000 RPM)

yellow

brown

! WARNING

Most voltages generated by the ignition system are sufficient to interrupt pacemakers! All technicians, espe-
cially those using pacemakers, must avoid contact with all electrical connections when pulling the recoil starter
rope or after the engine has been started.

5-7

Testing Electrical

Components

All tests of the engine electrical components should be

made using the digital Fluke Model 73 Multimeter (p/

n 0644-191). Replace any component that does not

have a test value within specifications.

NOTE: Whenever using a digital-style tester,
“open (infinite resistance)” denotes an overload
and the meter reading will be OL since the meter is
not calibrated to register resistance values of that
magnitude.

NOTE: Whenever testing switches, less than 1
ohm is desirable with the switch in the activated
position.

Troubleshooting

Ignition System

(EFI 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.

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

C. Corroded or loose wire connection at the throt-

tle-control housing or main wiring harness

D. Defective ignition switch

NOTE: To check these possible causes, proceed
to Testing Ignition System.

Testing Ignition System

(EFI Models)

NOTE: There must be 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 emergency stop switches. The

throttle control switch connector is located on the

front side of the steering post. If any of the con-

nections 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 connector

coming from the engine stator assembly. Discon-

necting this 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 prob-

lem is with the coils mounted on the engine, high

tension coil assembly, or the ECU. If the engine

starts, the problem is with the switches, main wir-

ing harness, or throttle cable free-play.

IGNITION KEY SWITCH

1. Disconnect the ignition key switch connectors;

then connect the ohmmeter leads to each of the

ignition key switch terminals.

! 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.

5-8

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) posi-

tion, 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 emer-

gency 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

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.

! CAUTION

Never crank the engine over without grounding the
spark plugs. Damage to coils and/or CDI unit may
result.

5-9

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 con-

nector 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 install-

ing 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 prob-

lem 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 con-

nector 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 Igni-

tion Key Switch and Throttle Control Switch inde-

pendently 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) posi-

tion, 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 resis-

tance (closed), replace the switch.

5. With the throttle lever depressed and the emer-

gency stop knob in the down (STOP) position, the

meter must read resistance (closed). If the meter

reads no resistance (open), replace the switch.

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 con-

nector is located on the front side of the steering

post. If any of the connections appear dirty or cor-

roded, clean with fine sandpaper and compressed

air; then connect all wires and squeeze connec-

tions with a pliers for added tightness.

2. Disconnect the main wiring harness connector

coming from the engine. Using an ohmmeter, con-

nect one lead to the black wire in the connector of

the main harness. Connect the remaining ohmme-

ter lead to the brown wire in the connector of the

main harness.

Content .. 67 68 69 70 ..