Snowmobile Arctic Cat (2008 year). Manual - part 85

5

5-21

Solenoid 

(Electric Start Models)

TESTING

„NOTE: The electric start solenoid may be tested
using either one of the following methods.

Method #1

1. Disconnect the electric start harness from the main

wiring harness.

2. Place the ohmmeter leads across the solenoid coil

terminals (brown wire and red/white wire).

3. The ohmmeter must read between 3 and 5 ohms.

Method #2

1. Connect the battery to the solenoid coil terminals

(brown wire and red/white wire).

2. A loud, audible “click” should be heard as the

solenoid internal contacts make connection.

3. Disconnect the battery from the solenoid.

4. A loud, audible “click” should be heard as the

solenoid internal contacts release.

„NOTE: An in-line ammeter would measure
between 2 and 4 amps of solenoid coil current flow
with the battery connected.

Fuse 

(Electric Start Models)

TESTING

1. Remove the fuse from the fuse holder.

2. Connect the ohmmeter across the fuse end-caps.

3. The ohmmeter must read less than 1 ohm of resis-

tance.

Ignition Switch -

Electric Start Function 

(Electric Start Models)

TESTING

1. Disconnect the wiring harness from the ignition

switch; then remove the switch from the console.

2. Using the ohmmeter, test the connections indi-

cated in the following chart. If the meter does not

read as specified or has more than one ohm of

resistance, the switch must be replaced.

0000-126

„NOTE: Some ignition-switch terminals may not
be labeled (-M, +M, A, B, or S). Refer to the wiring
harness diagram of the ignition switch when con-
necting the ohmmeter.

Starter Motor

REMOVING (Panther 370)

1. Disconnect the battery.

2. Remove the expansion chamber.

! CAUTION

NEVER connect an in-line ammeter with the large
starter cables because the 200 amps of current flow
will instantly damage most ammeters.

! CAUTION

To prevent ohmmeter damage when testing circuits
on snowmobiles equipped with an electric start, be
sure to disconnect the battery before testing.

Position

Lead to 

Terminal

Lead to 

Terminal

Meter 

Reading

OFF

-M

+M

CLOSED

ON

-M

+M

OPEN

ON

B

A

CLOSED

START

-M

+M

OPEN

START

B

S

CLOSED

5-22

3. Remove the nut and washer(s) securing the posi-

tive cable; then remove cable from the starter

motor.

4. Remove the drive clutch.

5. Remove the hardware securing the starter motor

and end plate/drive cap assembly to the bracket;

then remove the starter motor assembly.

REMOVING (Bearcat 570)

1. Disconnect the battery.

2. Remove the nut and washer(s) securing the posi-

tive cable; then remove cable from the starter

motor.

3. Loosen the two Allen-head screws securing the

flex-drive shaft to the pinion drive; then remove

the hardware securing the starter motor to the

bracket. Remove the starter motor assembly.

REMOVING (F 570/T570)

1. Disconnect the battery.

2. Remove the springs securing the expansion cham-

ber to the exhaust manifold and resonator and

remove the expansion chamber.

3. Remove the positive lead from the starter motor;

then remove the two cap screws securing the

MAG-side starter motor bracket to the engine.

Remove the bracket and starter motor and account

for the rubber dampers.

REMOVING
(500/600 cc LXR Models)

1. Disconnect the battery.

2. Remove the lock nuts securing the cables to the

starter motor; then remove cables from the starter

motor.

3. Loosen the two Allen-head screws securing the

flex-drive shaft to the pinion drive.

4. Remove the lock nut securing the starter mounting

bracket to the chassis.

5. Remove the lock nuts securing the mounting

bracket to the starter motor and remove the

bracket.

REMOVING
(800/1000 cc LXR Models)

„NOTE: To remove the starter motor, the air
silencer must be removed. Proceed to the appro-
priate Air-Intake Silencer sub-section in Section 4.

1. Disconnect the battery.

2. Remove the expansion chamber and the resonator.

3. Remove the lock nuts and washers securing the

cables to the starter motor; then remove the cables

from the starter motor.

4. Loosen the two Allen-head screws securing the

flex-drive shaft to the pinion drive.

5. Remove the cap screws and lock nuts securing the

starter motor brackets to the chassis and to the

upper frame. Remove the starter motor.

DISASSEMBLING

„NOTE: For assembly purposes, scribe a refer-
ence line on the end plate/drive cap, commutator
cap, and the case.

1. If applicable, remove the snap ring securing the

primary gear to the starter motor; then remove the

gear and account for the spring washer.

2. Remove the two long through-bolts. As the bolts

are being removed, hold pressure against the com-

mutator cap.

AI050

3. Slowly remove the cap and account for the four

brush holder springs.

AI026

4. Using a plastic hammer, tap the end plate/drive

cap free of the starter case and slide the cap free

from the armature shaft. Account for any washers.

5

5-23

AI027

5. Slide the armature free of the starter case.

AI028

6. Lift all brushes from the brush holder and account

for the four brush springs.

7. Using a 5/16-in. socket, remove the two cap

screws securing the ground brushes to the commu-

tator cap. Remove the brushes and brush holder

from the cap.

AI036

8. Using a 7/16-in. wrench, remove the nut securing

the cable stud to the cap. Account for the number

of and the position of washers.

AI037

9. While holding the brush wires, pull the stud from

the end cap. Account for the plastic insulator.

CLEANING AND INSPECTING

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

1. Thoroughly clean all components except the arma-

ture and brushes in parts-cleaning solvent; then

dry with compressed air.

AI029

2. Inspect all threaded areas for damaged or stripped

threads.

3. Inspect the brush holder assembly and brushes for

damage or wear. Using a calipers, measure the

length of the brushes. If brush measurement is less

than 7.5 mm (0.30 in.), replace brushes as a set

along with new brush springs.

! WARNING

When using compressed air to dry components,
always wear safety glasses.

! CAUTION

Do not wash the armature and brushes in any kind
of solvent. Use only compressed air and clean dry
cloth in cleaning these components.

5-24

AI030

4. Inspect brush leads for cracks, wear, or fraying. If

any of these conditions exist, replace the brushes

as a set along with new brush springs.

5. Inspect the commutator cap bushing for wear.

Using a calipers, measure inner diameter at the cap

bushing. If found to be 8.6 mm (0.338 in.) or

larger, replace the cap.

AI031

6. Inspect the end plate/drive cap bushing for wear.

Using a calipers, measure the inner diameter of the

cap bushing. If found to be 13.2 mm (0.523 in.) or

larger, replace the cap.

AI032

7. Inspect the brass commutator end of the armature

for any burned spots or damage. If the commutator

is slightly burned or damaged, the armature must

be replaced. This is a molded commutator and no

attempt to turn it down in a lathe should be tried.

8. Inspect the commutator for buildup in the grooves.

Buildup in the grooves must be removed to pre-

vent any chance of arcing between individual sec-

tions of the commutator. Carefully remove any

buildup using a thinly ground hacksaw blade. Do

not cut any deeper than the original groove which

can be seen by looking at the commutator from the

side.

AI033

„NOTE: After cleaning any buildup from the com-
mutator, use compressed air to clean.

9. Inspect the armature for shorting. Use the multit-

ester and the following procedure:

A. Set the selector on the OHMS position; then

touch the leads and zero the meter.

B. Touch the black tester lead to the armature

shaft.

C. Using the red tester lead, probe the commutator

end of the armature. The meter indicator should

not move. If the indicator needle moves, the

armature must be replaced.

! CAUTION

Do not use emery cloth to clean the commutator as
emery particles will become imbedded in the brass
commutator resulting in a short circuit. Use only #00
grit sandpaper.