Snowmobile Arctic Cat (2008 year). Manual - part 77

4-24

EFI Analyzer/

Diagnostic Tool

„NOTE: For testing the 800/1000 cc EFI system,
refer to the EFI Diagnostic System Manual, which
accompanies Laptop Diagnostic Tool and Laptop
Diagnostic Test Kit.

„NOTE: To aid in testing the 500/600 cc EFI sys-
tem, refer to the EFI Analyzer Usage Manual, which
accompanies EFI Analyzer Kit.

Throttle Body

Assembly

741-871A

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.

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

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

! 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.

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

4

4-25

„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).

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 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

0742-027

! CAUTION

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

! 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

4-26

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.

„NOTE: Some EFI models are equipped with a
control rod activated oil pump. If it must be
removed, the rod simply snaps off and on at the
control arm.

INSTALLING/ADJUSTING

1. Install the throttle cable into the throttle switch

assembly making sure the cable snaps into place.

2. Install the throttle cable end on the throttle lever.

3. Route the throttle cable from the throttle switch

assembly to the throttle body assembly and oil-

injection pump; avoid any sharp bends or moving

components.

4. Attach the throttle cable to the pulley on the throt-

tle body shaft.

5. On the 500 cc, install the oil-injection cable

adjuster on the oil-injection pump; secure with the

jam nuts.

6. On the 500 cc, install the oil-injection cable on the

control arm; secure with a washer and E-clip.

7. Secure the throttle cable to the handlebar and

steering post with cable ties.

8. On the other models, install the handlebar pad and

the console (if applicable).

9. Adjust the throttle cable tension by turning the jam

nuts in the appropriate direction until there is 0.75-

1.5 mm (0.030-0.060 in.) free-play in the throttle

lever and the butterfly completely opens and

closes. Tighten the jam nuts securely.

0741-518

10. Synchronize the oil-injection pump.

! CAUTION

Compress the throttle control lever to ensure free
movement. If the throttle cable sticks or binds, cor-
rect the problem before starting the engine.

4

4-27

EFI Component Voltage/Resistance Chart - 

Air Temperature

TEMP/C

TEMP/F

VOLTAGE

OHMS

100

212

0.113

555

98

208

0.121

595

96

205

0.128

635

94

201

0.136

675

92

198

0.143

715

90

194

0.151

755

88

190

0.162

819

86

187

0.173

883

84

183

0.184

947

82

180

0.195

1011

80

176

0.206

1075

78

172

0.222

1160

76

169

0.238

1245

74

165

0.253

1330

72

162

0.269

1415

70

158

0.285

1500

68

154

0.308

1640

66

151

0.331

1780

64

147

0.353

1920

62

144

0.376

2060

60

140

0.399

2200

58

136

0.432

2410

56

133

0.465

2620

54

129

0.498

2830

52

126

0.531

3040

50

122

0.564

3250

48

118

0.612

3595

46

115

0.659

3940

44

111

0.707

4285

42

108

0.754

4630

40

104

0.802

4975

38

100

0.869

5490

36

97

0.937

6005

34

93

1.004

6520

32

90

1.072

7035

30

86

1.139

7550

TEMP/C

TEMP/F

VOLTAGE

OHMS

28

82

1.230

8540

26

79

1.322

9530

24

75

1.413

10520

22

72

1.505

11510

20

68

1.596

12500

18

64

1.716

14020

16

61

1.836

15540

14

57

1.955

17060

12

54

2.075

18580

10

50

2.195

20100

8

46

2.323

23060

6

43

2.452

26020

4

39

2.580

28980

2

36

2.709

31940

0

32

2.837

34900

-2

28

2.969

39940

-4

25

3.101

44980

-6

21

3.233

50020

-8

18

3.365

55060

-10

14

3.497

60100

-12

10

3.610

76080

-14

7

3.722

92060

-16

3

3.835

108040

-18

-0.4

3.947

124020

-20

-4

4.060

140000

-22

-8

4.142

156000

-24

-11

4.224

172000

-26

-15

4.306

188000

-28

-18

4.388

204000

-30

-22

4.470

220000

-32

-26

4.522

261000

-34

-29

4.574

302000

-36

-32

4.625

343000

-38

-36

4.677

384000

-40

-40

4.729

425000