TROUBLESHOOTING
Electrical Systems All tests of the electrical components should be made using the digital Fluke Model 77 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: Always check the appropriate fuse before testing a component for failure.
SPECIAL TOOLS A number of special tools must be available to the technician when servicing the electrical systems. Description Arctic Cat Diagnostic System Manual Laptop Diagnostic Tool Actuator Test Harness Fluke Model 77 Multimeter MaxiClips Throttle Position Sensor (TPS) Adjustment Tool Kit CCU Diagnostic Test Kit
p/n 2256-974 0744-048 0644-518 0644-559 0744-041 3639-891 0644-517
NOTE: Special tools are available from the Arctic Cat Service Parts Department.
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 to the engine.
CAUTION On the 4-stroke, do not ground the spark plug on the cylinder head cover. The cover is made of magnesium and any contact with spark or electrical arc will severely pit the surface.
CAUTION Before checking for spark, place all the engine switches in the deactivated position. In the event the engine could be flooded, engage the starter 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/ECM may result.
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.
Ignition System
3. On the 570, if no spark is present, disconnect the main wiring harness 4-pin connector from the engine. Crank the engine over. If spark is present, the problem is either one or more of A-D below.
NOTE: There must be 0.030-0.060 in. free-play between the throttle lever and the control housing.
4. If still no spark is present, the problem is either one or more of A-D below. A. Defective emergency stop switch B. Defective safety switch in throttle-control housing C. Grounded or shorted wire connection at the throttle-control housing or main wiring harness (570 cc). Corroded or loose wire connection at the handlebar, hood, or main wiring harness. D. Defective ignition switch TESTING Throttle Control Switch
741-518B
1. Disconnect the handlebar harness connector; then connect the ohmmeter leads as shown below. Engine 500 570 cc 1100 cc
Wire Black/White Black/White Green/Yellow
Wire Black/Blue Violet/Red Red/Green
2. With the throttle lever in the idle position, the meter must read less than 1 ohm. If the meter reads OL (infinite resistance), replace the control assembly.
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