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
CAUTION On the 5000, 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.
A number of special tools must be available to the technician when servicing the electrical systems.
NOTE: Make sure the ignition switch and the emergency stop switch are in the ON position.
NOTE: When indicated for use, each special tool will be identified by its specific name, as shown in the chart below, and capitalized.
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.
Description
p/n
Arctic Cat Diagnostic System Manual
2256-974
Laptop Diagnostic Tool
0744-048
Actuator Test Harness
0644-518
Fluke Model 77 Multimeter
0644-559
MaxiClips
0744-041
Throttle Position Sensor (TPS) Adjustment Tool Kit
3639-891
CCU Diagnostic Test Kit
0644-517
NOTE: Special tools are available from the Arctic Cat Service Parts Department.
Ignition System NOTE: There must be 0.030-0.060 in. free-play between the throttle lever and the control housing.
3. On the 2000, 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. 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 (2000). Corroded or loose wire connection at the handlebar, hood, or main wiring harness. D. Defective ignition switch. TESTING Throttle Control Switch
1. Disconnect the handlebar harness connector; then connect the ohmmeter leads as shown below. 2000 3000/7000
Black/White Green/Yellow
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.
741-518B
TROUBLESHOOTING
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.
3. Move the throttle lever to the wide open position. The meter must read OL (infinite resistance). If the meter reads less than 1000 ohms, replace the control assembly. 4. Connect the ohmmeter leads as shown below. 2000 3000/7000
Black Red/Green
Violet/Red Red/Violet
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