ATV Arctic Cat 2002. Service Manual

5-19

BC015

BC004

8. Place the front cover onto the starter housing

making sure it seats properly.

9. Apply red Loctite #271 to the threads of the two

long cap screws and install. Tighten to 0.8-1.2

kg-m (6-9 ft-lb).

AR653D

10. Apply a small amount of grease to the O-ring seal

on the starter; then install the starter into the

crankcase. Secure with two cap screws and wiring

forms.

11. Secure the positive cable to the starter with the

nut.

12. Connect the battery.

TESTING VOLTAGE

Perform this test on the starter motor positive terminal.

To access the terminal, slide the boot away.

NOTE: The ignition switch must be in the ON

position, the emergency stop switch in the RUN
position, the reverse lever (on manual transmis-
sion models) in the FORWARD position, and the
shift lever (on automatic transmission models) in
the NEUTRAL position.

1. Set the meter selector to the D.C. Voltage position.

2. Connect the red tester lead to the starter terminal;

then connect the black tester lead to ground.

3. With the starter button depressed, the meter must

show battery voltage and the starter motor should

operate.

AR607D

NOTE: If the meter showed battery voltage but

the starter did not operate or operated slowly,
inspect battery voltage (at the battery), starter
motor condition, and/or ground connections.

NOTE: If the meter showed no battery voltage,

inspect the main fuse, ground connections, starter
motor lead, battery voltage (at the battery), or the
switches.

Starter Relay

(250/300)

RESISTANCE

1. Disconnect the battery; then verify that the

ignition fuse is good. Disconnect all wires from

the solenoid.

2. Set the meter selector to the OHMS position.

3. Connect the tester leads to each of the heavy posts

of the solenoid.

4. The meter must show an open circuit.

! CAUTION

Always disconnect the battery when performing
resistance tests to avoid damaging the
multimeter.

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5-20

CH099D

NOTE: Leave the tester leads connected to the

solenoid posts for the following procedure.

NOTE: An external 12-volt power supply

“jumper” (positive and negative connections)
must be used for this test. Also, it is very impor-
tant that the meter leads and power supply con-
nections are made to the appropriate terminals of
the relay or damage to the multimeter will result.

5. Connect the power supply leads to each small

terminal of the solenoid. There should be an

audible “click” from the relay, and the meter must

show less than 1 ohm.

CH100D

NOTE: If there was no audible “click” from the

relay or if the meter shows more than 1 ohm, it
must be replaced. If there was a “click,” continue
to test resistance.

6. With the 12-volt power supply still connected,

connect the red tester lead to the heavy battery

cable terminal; then connect the black tester lead

to the heavy starter motor cable terminal.

7. The meter must show less than 1 ohm.

8. With the 12-volt power supply disconnected,

connect the tester leads to each small terminal of

the solenoid.

9. The meter must show 4.3 ohms ± 20%.

NOTE: If the meter shows no resistance, the

relay is out of tolerance or it must be replaced.

Starter Relay

(375/400/500)

0732-513

RESISTANCE

1. Disconnect the battery; then verify that the starter

relay 30-amp fuse is good.

2. Set the meter selector to the OHMS position.

3. Connect the red tester lead to terminal #1; then

connect the black tester to terminal #2.

4. The meter must show an open circuit.

NOTE: Leave the tester leads connected to the

terminals for the following procedure.

NOTE: An external 12-volt power supply

5. Connect the power supply (positive) to terminal

#3; then connect the power supply (negative) to

terminal #4. There should be an audible “click”

from the relay, and the meter must show less than

1 ohm.

NOTE: If there was no audible “click” from the

relay or if the meter shows more than 1 ohm, it
must be replaced. If there was a “click,” continue
to test resistance.

6. With the 12-volt power supply still connected,

then connect the red tester lead to the heavy

battery cable terminal; then connect the black

tester lead to the heavy starter motor cable

terminal.

! CAUTION

Always disconnect the battery when performing
resistance tests to avoid damaging the
multimeter.

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5-21

7. The meter must show less than 1 ohm.

8. With the 12-volt power supply disconnected,

connect the red tester lead to terminal #3; then

connect the black tester lead to terminal #4.

9. The meter must show 3.6 ohms ± 20%.

NOTE: If the meter shows no resistance, the

relay is out of tolerance or it must be replaced.

CDI Unit

(250/300)

The CDI is located beneath the right rear fender panel

near the battery.

The CDI is rarely the cause for electrical problems;

however, if the CDI is suspected, test resistance values

thoroughly and completely. Also, if the CDI is sus-

pected (resistance test values are slightly out of speci-

fication), substitute another CDI unit to verify the

suspected one is defective.

RESISTANCE

1. Set the meter selector to the OHMS position.

2. Test each combination as found in the following

chart. Write down each test value for each test for

comparison with the value in the chart.

NOTE: As an example, connect the red tester

lead to terminal #2; then connect the black tester
lead to terminal #3. The meter must show 20-100
k-ohms.

ATV0099A

= Infinity

Regulator/Rectifier

(250/300)

The regulator/rectifier is located near the battery.

RESISTANCE

1. Set the meter selector to the OHMS position.

2. Test each combination as found in the following

chart.

NOTE: As an example, connect the red tester

lead to the R terminal; then connect the black
tester lead to a Y terminal. The meter must show
7-k ohms.

! CAUTION

Always disconnect the battery when performing
resistance tests to avoid damaging the
multimeter.

! CAUTION

Before determining the CDI unit is defective,
perform every test combination shown in the
chart.

CDI UNIT ELECTRICAL TEST

SPECIFICATIONS (k-ohms)

Positive Meter Lead To:

gativ

ad T

—

2-10

50-150

2-10

—

20-80

20-100

—

20-100

1-7

50-150

—

1-7

20-80

—

20-80

—

! CAUTION

Always disconnect the battery when performing
resistance tests to avoid damaging the
multimeter.

! CAUTION

Before determining the regulator/rectifier is
defective, perform every test combination shown
in the chart.

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5-22

ATV1087B

= Infinity

CDI Unit

(375/400/500)

The CDI is located beneath the seat and fender panel

near the battery.

The CDI is rarely the cause for electrical problems;

however, if the CDI is suspected, test resistance values

thoroughly and completely. Also, if the CDI is sus-

pected (resistance test values are slightly out of speci-

fication), substitute another CDI unit to verify the

suspected one is defective.

RESISTANCE

1. Set the meter selector to the OHMS position.

2. Test each combination as found in the following

chart. Write down each test value for each test for

comparison with the value in the chart.

NOTE: As an example, connect the red tester

lead to terminal #1; then connect the black tester
lead to terminal #3. The meter must show 5-22
k-ohms.

ATV-009

REGULATOR/RECTIFIER SPECIFICATIONS

(k-ohms)

Positive Meter Lead To:

Nega

tive

ter

ead

B/W

—

B/W

30-50

—

! CAUTION

Always disconnect the battery when performing
resistance tests to avoid damaging the
multimeter.

! CAUTION

Before determining the CDI unit is defective,
perform every test combination shown in the
chart.

CDI UNIT ELECTRICAL TEST SPECIFICATIONS (k-ohms)

Positive Meter Lead To:

r Le

—

5-22

11-45

60-400

300~

—

5-22

11-45

5-22

60-400

300~

5-22

—

60-400

300~

15-60

24-100

—

80-500

300~

—

5-22

11-45

—

60-500

300~

5-22

11-45

—

60-500

300~

1-6

9-35

22-90

1-7

—

300~

2-9

10-40

26-100

2-9

80-500

—

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5-23

Regulator/Rectifier

(375/400/500)

The regulator/rectifier is located beneath the seat near

the air-cleaner housing.

RESISTANCE

1. Set the meter selector to the OHMS position.

2. Test each combination as found in the following

chart.

NOTE: As an example, connect the red tester

lead to the B/R terminal; then connect the black
tester lead to a B terminal. The meter must show
1-10 k-ohms.

0735-352

= Infinity

REG/REC SPEC

Neutral Start Relay

The connector is the white 4-prong one near the bat-

tery.

VOLTAGE (Connector)

NOTE: The ignition switch must be in the ON

position.

1. Set the meter selector to the D.C. Voltage position.

2. Connect the red tester lead to the orange wire; then

connect the black tester lead to ground.

3. The meter must show battery voltage.

NOTE: If the meter shows no battery voltage,

inspect the fuses, wiring harness, connectors, or
ignition switch.

NOTE: In the following test, the ignition switch

must be in the ON position and the emergency
stop switch must be in the RUN position.

4. With the black tester lead still connected to

ground, connect the red tester lead to the

yellow/green wire.

5. Depress the starter button. The meter must show

battery voltage.

NOTE: If the meter shows no battery voltage,

inspect fuses, wiring harness, connectors, and
switches.

RESISTANCE (Relay - Brass Terminals)

NOTE: An external 12-volt power supply

1. Set the meter selector to the OHMS position.

2. Connect the power supply (positive) to one copper

terminal; then connect the power supply (negative)

to the other copper terminal. There should be an

audible “click” from the relay.

! CAUTION

Always disconnect the battery when performing
resistance tests to avoid damaging the
multimeter.

! CAUTION

Before determining the regulator/rectifier is
defective, perform every test combination shown
in the chart.

REGULATOR/RECTIFIER SPECIFICATIONS

(k-ohms)

Positive Meter Lead To:

gativ

ad T

B/R

B/W

Body

B/R

—

1−10

—

1−10

—

1−10

—

B/W

3-15

1-10

—

Body

—

REGULATOR/RECTIFIER TERMINALS

!CAUTION

Always disconnect the battery when performing
resistance tests to avoid damaging the
multimeter.

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5-24

ATV-1075

NOTE: If there was no audible “click” from the

relay, it must be replaced. If there was a “click,”
continue to test resistance.

3. Set the meter selector to the OHMS position.

4. With the power supply still connected, connect the

red tester lead to one brass terminal; then connect

the black tester lead to the other brass terminal.

5. The meter must show less than 1 ohm.

NOTE: If the meter shows more than 1 ohm

(even though the “click” was heard in the power
supply test), the relay must be replaced.

RESISTANCE

(Relay - Copper Terminals)

Always disconnect the battery when performing resis-

tance tests to avoid damaging the multimeter.

NOTE: The external power supply will not be

used for this test.

1. Set the meter selector to the OHMS position.

2. Connect the red tester lead to one copper terminal;

then connect the black tester lead to the other

copper terminal.

3. The meter must show 90 ohms ± 20%.

NOTE: If the meter shows no resistance, replace

the relay.

Headlights

The connectors are the two 3-prong ones secured to

the front bumper supports (one on each side) with

cable ties.

736-825A

BULB VERIFICATION

(Low and High Beam)

NOTE: Perform this test on each headlight bulb.

Also, a 12-volt external power supply w/jumpers
will be needed.

1. Disconnect the wiring harness from the bulb to be

tested.

2. Connect the power supply (positive) to one bulb

contact; then connect the power supply (negative)

to the remaining bulb contact.

3. The bulb should illuminate.

4. If the bulb fails to illuminate, it must be replaced.

VOLTAGE

NOTE: Perform this test in turn on the main har-

ness side of all four connectors. Also, the ignition
switch must be in the LIGHTS position.

NOTE: The LO beam is the inside bulb, and the

HI beam is the outside bulb.

1. Set the meter selector to the D.C. Voltage position.

2. Connect the red tester lead to one wire; then

connect the black tester lead to the other wire.

3. With the dimmer switch in the LO position, test

the two inside connectors (LO beam). The meter

must show battery voltage.

4. With the dimmer switch in the HI position, test the

two outside connectors (HI beam). The meter must

show battery voltage.

NOTE: If battery voltage is not shown in any test,

inspect the fuses, battery, main wiring harness,
connectors, or the left handlebar switch.

KEY

1. Lock Washer
2. Headlight Assy
3. Bulb
4. Machine Screw
5. Grille
6. Spacer
7. Nut
8. Yoke
9. Guard

10. Screen

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5-25

Taillight - Brakelight

The connector is the 3-prong one located under the

rear fender assembly.

BULB VERIFICATION

NOTE: Perform this test on the taillight-brake-

light side of the connector. Also, a 12-volt external
power supply (jumper) will be needed.

1. Connect the power supply (positive) to the yellow

wire; then connect the power supply (negative) to

the brown wire.

2. The taillight should illuminate.

3. With the negative power supply still connected,

connect the positive supply wire to the red wire.

4. The brakelight should illuminate.

NOTE: If either the taillight or brakelight fails to

illuminate, inspect the bulb, the connectors, or the
component wiring harness.

VOLTAGE (Taillight)

NOTE: Perform this test on the main harness

side of the connector. Also, the ignition switch
should be in the LIGHTS position.

1. Set the meter selector to the D.C. Voltage position.

2. Connect the red tester lead to the pink wire; then

connect the black tester lead to the black wire.

3. With the ignition key in the LIGHTS position, the

meter must show battery voltage.

NOTE: If the meter shows no voltage, inspect

fuses, wiring harness, connectors, and switches.

VOLTAGE (Brakelight)

NOTE: Perform this test on the main harness

side of the connector. Also, the ignition switch
should be in the ON position and the brake (either
foot pedal or hand lever) must be applied.

NOTE: Make sure the brake lever (hand) and

brake pedal (foot) are properly adjusted for this
procedure.

1. Set the meter selector to the D.C. Voltage position.

2. Connect the red tester lead to the red/blue wire;

then connect the black tester lead to the black

wire.

3. With either brake applied, the meter must show

battery voltage.

NOTE: If the meter shows no voltage, inspect

bulb, fuses, wiring harness, connectors, and
switches.

Ignition Timing

The ignition timing cannot be adjusted; however, veri-

fying ignition timing can aid in troubleshooting other

components. To verify engine timing, use the follow-

ing procedure.

1. Attach the engine Timing Light (p/n 0644-197) to

the spark plug high tension lead; then remove the

timing inspection plug from the left-side crankcase

cover.

2. With the Arctic Cat Engine Tachometer (p/n

0644-275) connected, start the engine and run at

the specified RPM.

3. Ignition timing should be according to

specifications.

4. Install the timing inspection plug.

If ignition timing cannot be verified, the rotor may be

damaged, the key may be sheared, the trigger coil

bracket may be bent or damaged, or the CDI unit may

be faulty.

Model

Timing

250

5° BTDC below 1800 RPM

35° BTDC above 3800 RPM

300

5° BTDC @ 1800 RPM

30° BTDC @ 3800 RPM

375

10° BTDC @ 3000 RPM

400/500

10° BTDC @ 1500 RPM

RepairPro Service Manual

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ATV Arctic Cat 2002. Service Manual - part 19