Snowmobile Arctic Cat (2007 year). Manual - part 51

5-8

„ NOTE: On the 1100 cc Z1, it is necessary to
install the air silencer. Proceed to Servicing Air
Silencer (1100 cc Z1) sub-section in Section 3 and
follow steps 3-12 of INSTALLING.

Ignition Switch -

Electric Start Function

(660 cc/1100 cc Z1)

 

TESTING RESISTANCE

1. Disconnect the wiring harness from the ignition

switch; then remove the switch from the con-

sole.

2. Using the ohmmeter, test the connections indi-

cated in the following chart. If the meter reads

more than one ohm of resistance, the switch

must be replaced.

0742-118

„ NOTE: If the ignition switch tests good, verify
battery voltage to the harness side of the switch
plug-in. If there is no voltage, troubleshoot the bat-
tery, switch fuse, or starter relay.

If battery voltage is present at the plug-in and the

starter fails to activate, use the  following procedure:

1. With the ignition switch plugged in, place the

emergency stop switch to the OFF position.

2. Connect the red tester lead to the black/yellow

wire; then connect the black tester lead to a suit-

able ground.

3. Rotate the key to the START position and verify

battery voltage.

„ NOTE: If no battery voltage is present, trouble-
shoot the harness and/or the starter solenoid.

Emergency Stop Switch

(660 cc/1100 cc Z1)

RESISTANCE

1. Remove the four torx-head cap screws securing

the front/rear throttle control housing assembly

to the handlebar.

2. Set the selector to the OHMS position.

3. Connect one tester lead to pin A; then connect

the other tester lead to pin C.

ZJ252A

4. With the key in the OFF position, the meter

must read OL (infinite resistance).

5. With the key in the RUN position, the meter

must read less than 1 ohm resistance.

„ NOTE: If the meter shows more than 1 ohm of
resistance, troubleshoot or replace the switch/
component, the connector, or the switch wiring
harness.

! CAUTION

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

Test #

Key 

Position

Connector

1

ON

Yellow

Red/Blue

2

ON

Red/Black

Red/White

3

START

Yellow

Red/Blue

4

START

Red/White

Black

5-9

5

Starter Motor

(660 cc/1100 cc Z1)

REMOVING (660 cc)

1. Remove the drive belt; then remove the driven

pulley.

„ NOTE: On turbo models to remove these compo-
nents, proceed to Removing/Installing Drive Belt
(ACT Roller Driven Pulley); then proceed to ACT
Roller Driven Pulley (Turbo Models) in Section 8 of
this manual.

2. Remove the two cap screws securing the starter

motor; then remove the starter motor.

MD1437

3. Remove the starter solenoid connector and

starter motor cable.

REMOVING (1100 cc Z1)

1. Remove the negative cable from the battery.

„ NOTE: To remove the starter motor, it will be
necessary to remove the air silencer. Proceed to
Section 3 - Servicing Air Silencer (1100 cc Z1) sub-
section and follow steps 1-12 of REMOVING.

2. Remove cap screw (A) securing the positive

cable to the starter motor; then remove the two

cap screws (B) and remove the starter motor.

ZJ139A

DISASSEMBLING (660 cc)

1. Remove the solenoid nut securing the starter

wire strap to the solenoid.  Pull the wire strap

away from the cap screws securing the solenoid

to the starter motor. 

AO281

2. Remove the two cap screws securing the sole-

noid to the starter motor.

AO282

3. Tip the solenoid back and unhook the pinion

lever; then pull the solenoid out and away from

the starter motor. 

5-10

AO283

4. Remove the two through-bolts securing the end

cap to the commutator case; then remove the

end cap.

AO284

AO285

5. Check for corresponding alignment marks on

the commutator case and the commutator cap

for assembling purposes.   

„ NOTE: The alignment mark on the commutator
case must align with its corresponding mark on
the commutator cap during assembling. If no
alignment marks exist, scribe corresponding
alignment marks on the case and cap.

AO286

6.  Remove the commutator cap from the commuta-

tor case.

AO287

7. Remove the pinion-stop nut from the armature

shaft taking note that the lip of the pinion stop

nut faces inward. 

AO288

8. Remove the armature from the commutator

case. 

5-11

5

AO289

DISASSEMBLING (1100 cc Z1)

1. Secure the starter motor in a suitable clamping

device; then remove the two long cap screws

from the starter motor.

ZJ140A

2. For assembling purposes, make alignment

marks on the bearing housing, magnet housing,

and brush assembly.

ZJ152A

3. Remove the bearing housing (A) and the magnet

housing (B) with armature from the brush

assembly (C).

ZJ141A

4. With the armature removed from the magnet

housing, remove snap ring (D) from the arma-

ture. Account for shim (E) and locking plate (F).

5. Using a flat-blade screwdriver, carefully remove

the seal from the bearing housing.

ZJ142A

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

armature and brushes in parts-cleaning solvent;

then dry with compressed air.

2. Inspect all threaded areas for damaged or

stripped threads.

3. Inspect the brush holder assembly and brushes

for damage or wear. Using a caliper, measure the

length of the brushes. If brush measurement is

less than 10.1 mm (0.40 in.), replace with new

brushes and brush springs as a set.

! CAUTION

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