ATV Arctic Cat 2001 Line. Service Manual

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

If any of these conditions exist, replace with new
brushes and brush springs as a set.

5. Inspect the rear cover bushing for wear.

6. Inspect the front cover bearing for wear.

7. Inspect the brass commutator end of the armature

for any burned spots or damage. If the commutator
is lightly burned or damaged, the armature must be
replaced. This is a molded commutator and turning
it down in a lathe should not be attempted.

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 #200 grit sandpaper.

8. Inspect the commutator end of the armature for

buildup in the grooves. Carefully remove any
buildup by undercutting using a thinly ground
hacksaw blade. Do not undercut any deeper than the
original groove which can be seen by looking at the
end of the commutator.

9. Using a caliper, measure the undercut. Maximum

undercut groove must be 0.2 mm (0.008 in.).

Fig. 5-36

ATV-1054

Buildup in the grooves must be removed to
prevent any chance of an electrical arc between
individual sections of the commutator.

10. Inspect the commutator for shorting using a

multimeter and the following procedure.
A. Set the selector to the OHMS position.
B. Touch the black lead to the armature shaft.
C. Using the red tester lead, probe the commutator

end of the armature. The meter indicator should
not change. If the indicator shows resistance, the
armature is shorted and must be replaced.

11. Inspect the armature for shorting using a “growler”

and the following procedure.
A. Place the armature in the “growler.”
B. While holding a metal strip on the armature,

rotate the armature an entire revolution. If the
metal strip vibrates at any point on the armature,
the armature is shorted and must be replaced.

Fig. 5-37

0725-653

12. Inspect the ground brushes to make sure they are

properly grounded. Use a multimeter and the
following procedure.
A. Set the selector to the OHMS position.
B. Touch the black tester lead to a ground brush.
C. Touch the red tester lead to the brush holder

assembly.

NOTE: If no resistance is indicated, check the

g ro u n d c o n n e c t i o n fo r t ig ht ne s s a n d for
cleanliness. If there is still no meter indication,
replace the brush assembly.

! CAUTION

5-18

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Fig. 5-49

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 transmission
models) in the FORWARD position, and the shift
lever (on automatic transmission model) 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;

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.

Fig. 5-50

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 cc)

RESISTANCE

Always disconnect the battery when performing
re s i s tance te sts to avoid dam aging the
multimeter.

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.

Fig. 5-51

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 important that the meter
leads and power supply connections are made to
the appropriate terminals of the relay or damage to
the multimeter will result.

! CAUTION

5-21

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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.

Fig. 5-52

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; 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

(400/500 cc)

Fig. 5-53

0732-513

RESISTANCE

Always disconnect the battery when performing
re s i s tance te sts to avoid dam aging the
multimeter.

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 “jumper”

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.

! CAUTION

5-22

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

connect the red tester lead to the heavy battery cable
terminal; 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 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 cc)

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
suspected (resistance test values are slightly out of
specification), substitute another CDI unit to verify the
suspected one is defective.

RESISTANCE

Always disconnect the battery when performing
re s i s t ance tes ts to avoi d d am ag in g t he
multimeter.

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.

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

Fig. 5-54

ATV0099A

CDI UNIT ELECTRICAL TEST

SPECIFICATIONS (k-ohms)

Positive Meter Lead To:

Lead

To:

—

2-10

50-150

∞

2-10

∞

—

20-80

∞

20-100

—

∞

20-100

∞

1-7

50-150

—

1-7

∞

20-80

∞

—

∞

20-80

∞

—

∞

= Infinity

Regulator/Rectifier

(250/300 cc)

The regulator/rectifier is located near the battery.

RESISTANCE

Always disconnect the battery when performing
re s i s tance te sts to avoid dam aging the
multimeter.

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

! CAUTION

5-23

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

Fig. 5-55

ATV1087B

REGULATOR/RECTIFIER SPECIFICATIONS

(k-ohms)

Positive Meter Lead To:

Nega

tiv

Mete

Lead

To:

B/W

—

∞

—

∞

—

∞

—

∞

B/W

30-50

—

∞

= Infinity

CDI Unit

(400/500 cc)

The CDI is located beneath the seat and fender panel
near the battery.

RESISTANCE

Always disconnect the battery when performing
re s i s tance te sts to avoid dam aging the
multimeter.

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

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

Fig. 5-56

ATV-0099

! CAUTION

B/W

! CAUTION

5-24

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Regulator/Rectifier

(400/500 cc)

The regulator/rectifier is located beneath the seat near
the air-cleaner housing.

RESISTANCE

Always disconnect the battery when performing
re s i s t ance tes ts to avoi d d am ag in g t he
multimeter.

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

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

Fig. 5-57

0735-352

CDI UNIT ELECTRICAL TEST SPECIFICATIONS (k-ohms)

Positive Meter Lead To:

Negat

ive

Meter

ead

To:

—

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

—

∞

—

∞

—

∞

= Infinity

CDI Chart

! CAUTION

REGULATOR/RECTIFIER TERMINALS

REGULATOR/RECTIFIER

SPECIFICATIONS (k-ohms)

Positive Meter Lead To:

Negati

Meter

Lead

to:

B/R

B/W

Body

B/R

—

∞

1-10

—

∞

1-10

∞

—

∞

1-10

∞

—

∞

B/W

3-15

1-10

—

∞

Body

∞

—

∞

= Infinity

REG/REC SPEC

5-25

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Neutral Start

Relay

The connector is the white 4-prong one near the battery.

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 - Copper
Terminals)

Always disconnect the battery when performing
re s i s t ance tes ts to avoi d d am ag in g t he
multimeter.

NOTE: An external 12-volt power supply “jumper”

1. Set the meter selector to the OHMS position.

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

terminal; connect the power supply (negative) to the
other brass terminal. There should be an audible
“click” from the relay.

Fig. 5-58

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 copper terminal; then connect
the black tester lead to the other copper 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 - Brass Terminals)

Always disconnect the battery when performing
re s i s tance te sts to avoid dam aging 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 brass terminal;

then connect the black tester lead to the other brass
terminal.

3. The meter must show 90 ohms ± 20%.

NOTE: If the meter shows no resistance, replace

the relay.

! CAUTION

5-26

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Headlights

The connectors are the two 3-prong ones secured to the
front bumper supports (one on each side) with cable
ties.

Fig. 5-59

0735-353

BULB VERIFICATION (Low and High
Beam)

NOTE: Perform this test in turn on the headlight

side of both connectors. Also, a 12-volt external
power supply (jumper) will be needed.

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

wire; then connect the power supply (negative) to
the black wire.

2. The low beam of the headlight bulb should

illuminate.

3. With the negative power supply still connected,

connect the positive power supply to the yellow
wire.

4. The high beam of the headlight bulb should

illuminate.

NOTE: If the appropriate beam of the headlight

bulb did not illuminate, inspect the bulb, the
connectors, or the component wiring harness.

VOLTAGE (Headlights/Harnesses)

NOTE: Perform this test in turn on the main

harness side of both connectors. Also, the ignition
switch must be in the LIGHTS position.

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

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

connect the black tester lead to the black wire.

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

meter must show battery voltage.

4. With the black tester lead still connected, connect

the red tester lead to the yellow wire.

5. With the dimmer switch in the HI position, the

meter must show battery voltage.

NOTE: If battery voltage is not shown in either or

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

Taillight - Brakelight

The connector is the 3-prong one located under the rear
fender assembly.

BULB VERIFICATION

NOTE: Perform this test on the taillight-brakelight

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 gray 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.

KEY

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

10. Headlight Mount
11. Headlight Yoke
12. Screen
13. Nut

5-27

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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 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,
verifying ignition timing can aid in troubleshooting
other components. To verify engine timing, use the
following 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. I g n i t i o n t i m i n g s h o u l d b e a c c o r d i n g t o

specifications.

Model

Timing

250 cc

5° BTDC below 1800 RPM

35° BTDC above 3800 RPM

300 cc

5° BTDC @ 1800 RPM

30° BTDC @ 3800 RPM

400/500 cc

10° BTDC @ 1500 RPM

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.

5-28

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ATV Arctic Cat 2001 Line. Service Manual - part 20