Snowmobile Arctic Cat (2008 year). Manual - part 80

5-1

SECTION 5 — ELECTRICAL SYSTEMS

TABLE OF

CONTENTS

Electrical Systems................................................... 5-2
Testing Electrical Components................................ 5-2
Ignition System

EFI Models........................................................... 5-2
Fan Cooled Models .............................................. 5-3
Single Carburetor F/C Model ............................... 5-4
Twin Carbutetor F/C Models ................................ 5-5

Throttle Position Sensor (EFI Models) .................... 5-7
Testing Electrical Resistances

500/600 cc Models............................................... 5-8
800/1000 cc Models............................................. 5-9
370 cc Model ..................................................... 5-11
570 cc Models.................................................... 5-12

Voltage Regulator Test (Carbureted Models) ........ 5-14
Chassis Control Unit/Codes .................................. 5-14
Servomotor Test .................................................... 5-16
Peak Voltage Tests (Carbureted Models) .............. 5-17
Peak Voltage Tests (500/600 cc Models) .............. 5-17
Peak Voltage Tests (800/1000 cc Models) ............ 5-18
Testing Low-Oil Light Sensor ................................ 5-19
Testing High Temperature Sensor......................... 5-19
Testing High Temperature Warning Light .............. 5-20
Testing Fuel Gauge ............................................... 5-20
Testing Fuel Gauge Sender .................................. 5-20
Testing Electric Fuel Pump ................................... 5-20

Electric Start Components

Solenoid ............................................................. 5-21
Fuse ................................................................... 5-21
Ignition Switch - Electric Start Function ............. 5-21
Starter Motor ...................................................... 5-21
Troubleshooting Electric Start ............................ 5-29

Ignition Timing ....................................................... 5-29
Brakelight Switch................................................... 5-29
Headlight Dimmer Switch ...................................... 5-30
Testing Handlebar Warmer Elements ................... 5-31
Testing Thumb Warmer Element........................... 5-32
Testing Handlebar Warmer Switch

(Bearcat 570/Panther 370)................................. 5-32

Testing Handlebar Warmer/Thumb Warmer

Switch (EFI Models/F 570/T570) ....................... 5-32

Testing Thumb Warmer Switch

(Bearcat 570/Panther 370)................................. 5-33

Testing Passenger Handwarmer Switch................ 5-33
Testing Passenger Handwarmer Elements ........... 5-33
Testing Speedometer Sensor

(EFI Models/F 570/T570) ................................... 5-34

Testing Reverse Alarm Switch............................... 5-34
Testing Shift Actuator Switch

(Electronic Reverse Models) .............................. 5-35

Testing Shift Actuator

(Electronic Reverse Models) .............................. 5-35

Troubleshooting Servomotor ................................. 5-36

5-2

Electrical Systems

NOTE: Critical electrical specifications can be
found in Section 1 of this manual.

NOTE: Some illustrations and photographs used
in this section are used for clarity purposes only
and are not designed to depict actual conditions.

SPECIAL TOOLS

A number of special tools must be available to the

technician when servicing the electrical systems.

NOTE: Special tools are available from the Arctic
Cat Service Parts Department.

Testing Electrical

Components

All tests of the electrical components should be made

using the digital Fluke Model 73 Multimeter. 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.

Ignition System

(EFI Models)

TROUBLESHOOTING

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

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.

Description

p/n

Fluke Model 73 Multimeter

0644-191

MaxiClips

0744-041

Peak Voltage Reading Adapter

0644-307

Starter Assembly Tool

0644-052

Throttle Position Sensor Adjustment Tool Kit

3639-891

Test Harness

0686-999

! 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.

5-3

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.

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.

Ignition System

(Fan Cooled Models)

TROUBLESHOOTING

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.

! CAUTION

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

5-4

0741-518

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 hous-

ing

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.

Ignition System

(Single Carburetor F/C Model)

TESTING

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.

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.

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