Arctic Cat Wildcat EFI 1994 Service Manual Download Page 1

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Summary of Contents for Wildcat EFI 1994

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Page 2: ...94 Wildcat EFI and Wildcat EFI Mountain Cat components When servicing the technician should use discretion as to how much disassem bly is needed to correct any given condition All Arctco publications...

Page 3: ...ngine 3 Fuel System 4 Drive System 5 Electrical System 6 Steering and Body 7 Track Suspension 8 Recoil Starter 9 Aids for Maintenance 10 Troubleshooting Page 1 5 II 7 41 B 43 87 I 89 118 II 119 136 I...

Page 4: ...SECTION 1 GENERAL INFORMATION TABLE OF CONTENTS Specifications 2 Break In Procedure 3 Recommended Gasoline 3 Recommended Oil 3 Genuine Parts 3 Summer Storage 3 Preparation After Storage 4 II...

Page 5: ...41 CHASSIS Length wlSkis cm 282 299 in 111 118 Height wlWindshield cm 116 2 in 45 75 Overall Width cm 114 3 in 45 Ski Center to Center cm 99 Distance in 39 MISCELLANY Curb Weight approx kg 277 288 Ib...

Page 6: ...ce ethanol will pre vent the accumulation of moisture in the fuel system Do not use white gas or gasolines containing methanol Only Arctco approved gasoline additives may be used Recommended Oil The c...

Page 7: ...post bush ing pivot bushings of the ski frame and plung ers of the shock absorbers 12 Lubricate the front and rear suspension spindles ball jOints and speedometer drive adapter witt a low temperature...

Page 8: ...amine fuel hoses and connections for dete rioration tightness and cracks replace as nec essary 6 Fill the oil injection tank with Arctco 50 1 Injec tion Oil 7 Check the coolant level and all coolant l...

Page 9: ...nstalling Outer Crankshaft Bearings 23 Pinion Drive 23 Reed Valves 24 Measuring Critical Components 24 Cylinder Trueness 24 Piston Skirt Cylinder Clearance 24 Piston Ring End Gap 25 Piston Pin and Pis...

Page 10: ...the clutch bore Remove the driven pulley Account i for all washers and key Fig 2 1 I Piston Ring End Gap Range mm 0 20 0 80 in I 0 008 0 031 Piston Skirt Cylinder mm I 0 095 0 150 Clearance Range in i...

Page 11: ...p securing the throttle body then remove the throttle body from the flanges 9 Disconnect the main wiring harness from the engine harness Disconnect the spark plug caps from the spark plugs and the CDI...

Page 12: ...remove the recoil from the engine Leave the recoil in the engine com partment 14 Remove the four cap screws securing the engine to the front end Note the position of the shims on the left rear mount...

Page 13: ...aft keyway starter pulley Remove the starter pulley Fig 2 13 Fig 2 11 I I AJ015 Before applying excessive pressure to the center flywheel puller bolt check to make sure puller bolt is pulling straight...

Page 14: ...lance hoses 10 Compress and slide the clamp securing the bypass hose away from the end of the hose then pull the hose from the thermostat housing 11 Remove the three cap screws securing the thermostat...

Page 15: ...assem bly Mark the MAG cylinder 1 and PTO cylinder 12 AJ023 16 Remove the oil injection line from each cylinder nozzle 17 Remove the eight cylinder base nuts and four flange nuts securing the cylinde...

Page 16: ...iston pin circlip from the PTO side piston remove the MAG side piston pin circlip from the MAG side piston 14 21 Using the Piston Pin Puller pin 0144 003 remove the piston pins from both pistons f NOT...

Page 17: ...me from the top mounting hole of the oil injection pump It must be installed in the same location 25 Remove the two screws securing the oil injec tion pump retainer to the crankcase Gently tap on the...

Page 18: ...ods as the top half of the crankcase is removed Do not allow them to drop onto the sealing surface of the bottom case half 16 DO NOT drive any tool between halves to separate the crankcase Damage to t...

Page 19: ...any signs of leakage are present remove impel ler and shaft and replace seals Fig 2 36 NOTE For instructions on bearing and seal replacement see Assembling Engine section of this manual Only complete...

Page 20: ...1 Using a non metallic carbon removal tool remove any carbon buildup from the combus tion chambers being careful not to nick scrape or damage the combustion chambers or the sealing surfaces 2 Inspect...

Page 21: ...il is not available use a lightweight petroleum based oil Thoroughly clean cylin ders after honing using detergent soap and hot water and dry with compressed air then immediately apply oil to the cyli...

Page 22: ...ry to replace the piston 5 Inspect the perimeter of each piston for signs of excessive blowby Excessive blowby indi cates either worn piston rings or an out of round cylinder CRANKCASE 1 Wash the cran...

Page 23: ...nto position using your thumbs Fig 2 50 AJ048 5 Inspect the water pump drivesr a j s e 1 Nf gear for any signs of chipping r 1X lIII I roughness If either condition is o rc v a JIiiIC2 the driveshaft...

Page 24: ...u contact an experienced crankshaft rebuilder or the Arctco Service Department if you decide to rebuild a crankshaft 6 Visually inspect the two crankshaft sealing rings for wear or any signs of cracks...

Page 25: ...late covered with oil or by squirting oil into the bearing and using a pro pane torch to heat the inner race of the bearing until a slight smoke is noted coming from the bearing 4 Lubricate the PTa be...

Page 26: ...nce must be less than 0 20 mm 0 008 in If clearance is not within specifications replace the reeti valve see Assembling Engine section for instructions 24 AJ156 Measuring Critical Components CYLINDER...

Page 27: ...g squarely in each cylinder 2 Using a feeler gauge measure each piston ring end gap Acceptable ring end gap must fall within specifications Fig 2 63 AJ068 PISTON RING END GAP RANGE mm in 0 20 0 80 0 0...

Page 28: ...e amount of crankshaft runout total indicator reading 3 Position the indicator contact pOint against the crankshaft 35 0 mm 1 377 in in from the MAG end of the crankshaft Zero the indicator and rotate...

Page 29: ...e seal 4 Using the seal driver gently drive the seal down into position against the snap ring Check the seal after the first couple of taps to make sure it is started straight AJ152 5 Apply a thin eve...

Page 30: ...ly examine the seal surface to make sure it hasn t been damaged AJ090 Care must be used when installing the water pump shaft or the small spring could be forced out of its position on the inner seal S...

Page 31: ...ide seal 13 Apply Arctco 50 1 Injection Oil to all of the crankshaft bearings then install the crankshaft into the upper crankcase halt Be sure the alignment hole in each bearing is pOSitioned over it...

Page 32: ...ng sure that the pinion gear and water pump gear mesh properly 30 18 Install the 18 crankcase cap screws securing the crankcase halves Make sure the cap screws are in the proper holes Tighten the cap...

Page 33: ...to the four screws and tighten securely Make sure the slot of the oil injection pump shaft is aligned with the shaft in the crankcase before installing the two oil pump mounting screws If not aligned...

Page 34: ...rd the cylinder exhaust port or both the cylinder and piston will be severely damaged NOTE The arrow is found up inside the piston or on the piston dome 26 Install the circlips so the open end is dire...

Page 35: ...In turn on each cylinder place a piston holder or suitable substitute beneath the piston skirt and square the piston with respect to the crank case then using a ring compressor or the fingers compres...

Page 36: ...aler pin 0636 069 to the two thermostat manifold gaskets Place the gaskets and housing into position and secure with four cap screws and washers Torque the four cap screws in a crisscross pat tern to...

Page 37: ...and cap into position Secure with three cap screws Torque to 0 7 1 0 kg m 5 7 ft Ib AJ123 40 Apply a thin coat of silicone sealer to the crank I II case water pump housing sealing surface g Fig 2 105...

Page 38: ...45 Route the coil ring wiring harness through the magneto backing plate and install the rubber grommet around the harness Place the coil ring into position and secure with three screws coated with LO...

Page 39: ...K N SEAL Torque to 1 8 2 2 kg m 13 16 ft Ib 53 Place the front and right rear mounting brackets into position on the crankcase Secure with cap screws coated with LOCTITE LOCK N SEAL then torque the ca...

Page 40: ...en the flange clamps securely Fig 2 117 b Place a rubber plug and cover on eaclt exhaust port and secure c Remove one of the plugs in the crankca 21 61 21 7 1 1 122 71 22 81 2 21 I I 21 71 21 8 1 2 22...

Page 41: ...re of the tem perature warning light to the sensor 6 Place the throttle body into position and secure with the flange clamps Be sure each boot is properly positioned and not folded into the throttle b...

Page 42: ...p screws and lock nuts 40 17 Fill the cooling system see Filling Cooling Sy tem If the engine had a major overhaul or if any major part was replaced proper engine break in procedures must be followed...

Page 43: ...S qt 7 Remove the green cap from the coolant holding tank and fill the tank 3 4 full of coolant 8 Test ride the snowmobile 5 to 6 minutes and recheck the coolant level INSPECTING THERMOSTAT 1 Inspect...

Page 44: ...51 ECU 52 Testing Individual Components 54 Throttle Position Sensor 54 Injectors 56 Crankshaft Position Sensor 57 Ignition Timing Sensor 58 Fuse Link 59 Electric Fuel Pump 60 Fuel Pressure Regulator 6...

Page 45: ...ols required are the EFI Diagnostic Test Harness pin 0644 181 and a digital volt ohmmeter Arctco recommends the Fluke Model 73 Multimeter pin 0644 191 AR001 EFI FEATURES 1 Automatic compensation for t...

Page 46: ...sition and crank the engine over until it starts and clears itself Release the parking brake FUEL SYSTEM The EFlfuel systeOl consists of the following com ponents A Fuel tank B Electric fuel pump C Tw...

Page 47: ...By observing the code the technician can determine the problem sensor by comparing the code flashed with the trouble code chart Fig 3 4 0730 174 46 Each time the key is turned on the LED will provide...

Page 48: ...to ground From this measurement the ECU determines the air tempera ture and calculates the fuel air mixture ratio A010l This sensor is very sensitive to temperature change Resistance will drop as the...

Page 49: ...he throttle sensor detects the opening or closing speed of the throttle valve and feeds that rate of voltage change to the ECU A0100 The input from the throttle position sensor is one of the main inpu...

Page 50: ...ioned in the top of each throt tle body O rings seal the top and bottom of each injector and they are held in position by the fuel rail I AK03II The injector is an electromagnet injection valve contro...

Page 51: ...ood working order With all switches turned ON the fuel pump should run for a period of five seconds then stop This indicates normal operation If you do not hear the fuel pump cycle for the five second...

Page 52: ...ction until you have read and recorded all codes being flashed Once you have determined the problem area check the components involved using a test har ness pIn 0644 181 and the Fluke Multimeter pIn 0...

Page 53: ...ests good and the light does not illuminate pro ceed to step 4 4 Check the brown EFI relay If the relay tests good and the light does not illuminate proceed to step 5 5 Check the wire connections at t...

Page 54: ...avoid damage to electrical components all switches must be in the OFF position and the battery disconnected before servicing any EFI electrical component 1 Disconnect the battery then disconnect the t...

Page 55: ...the ECU frame NOTE Both the EPROM chip and its mounting plate are notched When install ing the chip the notched end must align with the notch in the mounting plate 1 Insert the back row of pins into t...

Page 56: ...t measure 12 6 12 8 volts Charge battery if low B Check to ensure all switches are ON and that the throttle monitor low speed switch is activated The battery light on the console should be ON at this...

Page 57: ...satisfac tory 4 If no voltage is found check the battery condi tion and connections the brown fusible link the brown EFI relay and the wire connections at the ECU NOTE The injector should click when...

Page 58: ...Leave clearance 01 3 7 mm 12 28 In from hose end 0729 325 5 Connect the wiring harness to the injectors making sure the number 1 harness is con nected to the MAG side injector 6 Connect the battery ca...

Page 59: ...Remove the two screws securing the crank shaft position sensor to the magneto housing 3 Remove the sensor from the engine compart ment Installing 1 Using two screws coated with LOCTITE 242 secure the...

Page 60: ...e timing sensor wiring harness through the magneto housing Connect the timing sen sor to the main wiring harness then close the rubber boot 2 Using two screws coated with LOCTITE 242 secure the inject...

Page 61: ...OFF two times to con firm the reading 7 If correct voltage is indicated and the fuel pump fails to operate check the fuel pump connector and fuel pump continuity Remove the main har ness connector fr...

Page 62: ...and spill seal Disconnect the fuel pump wiring harness from the fuel pump Label the fuel lines supply and return then loosen the clamps and remove the fuel hoses WARNING The fuel supply hose may be un...

Page 63: ...el line connections to ensure they are tight and properly connected Fig 3 52 For a short studded end pipe fit the hose to completely cover the pipe as shown I Leave clearance of r 3 7 mm 12 28 in from...

Page 64: ...f valve to the OFF position Observe the gauge for several minutes and note if there is any loss of pressure If pressure begins to drop the cause may be a ruptured diaphragm worn spring or leaking valv...

Page 65: ...ing harness connec tors to ensure they are corrosion free 1 Attach the wiring harness connector to the com ponent being installed 2 Using lock nut s secure the component to the ECU mounting bracket 3...

Page 66: ...e volt position test between pins 113 and 121 The reading indicates battery voltage 0729 602 3 Turn the ignition switch to the ON position While the fuel pump is cycling there will be no voltage readi...

Page 67: ...ain harness dropping resistor fuse link injector lead or the injector s 1 Turn the ignition switch to the OFF position 2 Disconnect the smaller of the two harness con nectors from the ECU 3 With the m...

Page 68: ...Chart on page 87 for the correct voltage specification in relationship to the coolant temperature Fig 3 65 0729 602 1 Turn the ignition switch to the OFF position then install the EFI test harness 2 T...

Page 69: ...st probes together when in contact with the two test harness pins Damage to the ECU may result 2 Turn the ignition switch to the ON position Using the multimeter set on the DC volt scale perform the v...

Page 70: ...e function selected push the TEST button Once the test has been completed push the TEST button again to cancel the test and allow you to select a different test from the menu list Menu List Organizati...

Page 71: ...analysis test plug If all switches are ON and the analyzer test plug is properly con nected test the following components using a good digital volt ohmmeter a Battery condition and all cable connecti...

Page 72: ...rs wire connections are clean and tight Make necessary repairs and clear the memory following the procedures pro 1ided in this section proceed to testing individual EFI components Testing Individual E...

Page 73: ...fely operate on is 9 0 volts 6 If the battery voltage is low and the voltage does come up after starting the engine this could indicate one of the following a A voltage draw on the battery when the en...

Page 74: ...er and the dis play should indicate the increased engine RPM NOTE If you are now going to proceed to another test you must first press the Test button once again to cancel the present test To select a...

Page 75: ...ly until the words Diagnosis Test 1 appear on the display AR213 4 ush the T ST button If all sensors are good sensors ok Will appear on the display If any of the s ensors listed under Existing Problem...

Page 76: ...ors test good proceed to the remaining Memory Prob lem Diagnosis Test Clearing Memory 1 With the analyzer attached to the analysis test plug push the MENU SELECT button until Diagnosis Memory Clear ap...

Page 77: ...adjust the idle screw If the throttle angle cannot be corrected by either an idle screw or cable adjustment the Throttle Position Sensor must be replaced 7 Squeeze the throttle lever to the full open...

Page 78: ...e analyzer in the OFF position connect its harness to the snowmobile analysis plug 2 Turn ON all snowmobile switches and then the analyzer switch Both the snowmobile charge indicator light and the ana...

Page 79: ...m close to the coolant temperature the sensor should be replaced If the water temperature sensor has failed the ECU will automatically indicate the specifications shown below for each RPM If these spe...

Page 80: ...d remove the sensor TPS Installation 1 Apply a light coat of silicone grease to the area around the outside of the TPS flange 2 Install the new TPS onto the throttle shaft by aligning its flat with th...

Page 81: ...OSITION setting If the CLOSED POSITION setting is correct replace the sen sor Throttle Body Flange REMOVING To avoid damage to electrical components all switches must be in the OFF position and the ba...

Page 82: ...towel around the connection to absorb fuel 6 Loosen the flange clamps 7 Slide the throttle body out of the flanges then loosen the jam nut securing the throttle cable and remove 8 Remove the throttle...

Page 83: ...the cable to the throttle switch assembly then remove the cable from the throttle switch assembly INSTALLING 1 Install the throttle cable into the throttle switch assembly Secure with a retaining ring...

Page 84: ...ly aligned with the slot of the oil injection pump shaft 2 Secure the pump with two screws lock wash ers and washers Tighten screws to 0 7 kg m 5 ft Ib The short mounting bolt must be installed in the...

Page 85: ...Boss IG l i N J1i 13 Control Arm tY c O I jJID c 16J u Ir Oil Bleed Plug Bleeding Oil Injection System 0727 115 1 Fill the oil reservoir with Arctco 50 1 Injection Oil 2 Place an absorbent towel below...

Page 86: ...nt of oil used with the specifications on the chart OIL CONSUMPTION FULL OPEN 2 Minutes I b __ ____ __ 00 12 1 17 700 8 If the Oil injection pump does not meet the specifications see Testing Oil Injec...

Page 87: ...6 x 2 Effective area equivalent to 40 Diameter of the bore Throttle system Type of valve Butterfly type Operating angle 80 full closed angle 10 Radius of drum I R25 at wire center Throttle adjusting s...

Page 88: ...4 016 I 4 076 I 4 134 4 190 4 242 4 292 4 339 4 383 4 425 4 464 4 450 4 533 i 4 565 4 593 4 620 I 4 645 4 668 4 689 4 7091 4 728 4 747 4 765 4 783 I 4 802 TEMP F OHMS 82 1933 79 2065 75 72 r _2359 68...

Page 89: ...Installing 103 Drive Clutch Driven Pulley 103 Checking Parallelism Offset 103 Correcting Offset 104 Adjusting Center To Center Distance 104 Drive Belt Deflection 104 Drive Train 105 Disassembling 105...

Page 90: ...ugh the system ONLY ARCTCO ARCTIC CAT DRIVE BELTS SHOULD BE USED Different brands of belts may not have the same construction causing either more friction or more slippage when the belt is wedged betw...

Page 91: ...ch compression retainer REMOVING Clutch retainer position 0728 853 1 Open the clutch shield and remove the drive belt 2 Remove the retainer plug and washer then using a 1 2 in 12 point socket remove t...

Page 92: ...sheave Before removing the original cover plate note which button tower of the movable sheave the words ARCTIC CAT on the cover plate are nearest to Mark the tower with a mark ing pen for assembly pu...

Page 93: ...nuts securing the cam arms to the movable sheave then remove the cam arms with washers CLEANING 1 Using parts cleaning solvent wash grease dirt and foreign matter off all parts dry with com pressed ai...

Page 94: ...g Chart below SPRING COMET DRIVE pIn Color Rate Rate 2318 in 1 3 8 in 0646 154 Purple 136 254 0146 526 Yellow Green 134 264 0646 083 h 0646 097 IRed 92 68 222 197 0646 084 White I 78 178 0646 096 Silv...

Page 95: ...n the mov able sheave then secure with the arm pin and nut coated with LOCTITE STUD N BEARING MOUNT Carefully tighten the lock nut to apoint just ensuring free cam arm movement Repeat procedure on the...

Page 96: ...er slides freely Secondly grasp the movable sheave and lift it upward then release it It must move freely and not bind at any point If any binding is noted one or more of the cam arm pins may be too t...

Page 97: ...tion 1 ___3_rd_ REMOVING 1 Open the hood then open the clutch shield 2 Remove the drive belt 3 Remove the cap lock screw and washer then account for and note the position of any align ment washers 7 I...

Page 98: ...in driven pulley servicing use a roll of duct tape as a work fixture The work fixture will increase stability of the pulley and decrease the spring tension during the repair procedure 3 Remove the th...

Page 99: ...e the sheaves to be gouged thus the drive belt may not slide properly between sheaves Decreased performance and possible accelerated drive belt wear will result INSPECTING NOTE Whenever a part is worn...

Page 100: ...ngs Clear ance between the shaft and the respective bearing must not exceed 0 5 mm 0 020 in If the clearance exceeds the specification the bearing must be replaced Fig 4 36 B466 B467 BEARINGS Removing...

Page 101: ...he retainer bracket 2 Place the torque bracket into position on the stationary sheave making sure the degree num ber on the torque bracket aligns with the part number on the stationary sheave Install...

Page 102: ...t 8 While holding the sheaves to prevent them from rotating grasp the retainer bracket and rotate t approximately 1200 clockwise until the mount ing holes align then push retainer bracket intc positio...

Page 103: ...ary 5 Install the drive belt and check drive belt deflec tion Secure the clutch shield and side pod Drive Clutchl Driven PulIey CHECKING PARALLELISM OFFSET If premature drive belt failure is experienc...

Page 104: ...Allen head wrench loosen the rear PTO side motor mount bolt 3 Move the required number of shim plates for ward to achieve the 28 9 cm 11 375 in ceD ter to center distance between the drive clutch and...

Page 105: ...ashers 4 Slide the driven pulley off the driven shaft then remove the driven pulley from the engine com partment Remove the key alignment washers and stub shaft from the driven shaft NOTE If the drive...

Page 106: ...he driven shaft If heat is used examine the bearing seal for any dama 1 before installation 10 Loosen the set screw on the PTO side drive shaft collar Drive the collar clockwise opposite shaft rotatio...

Page 107: ...prockets off the driveshaft 20 Remove the six socket head cap screws and lock nuts securing the brake disc to the hub then separate disc and hub CLEANING AND INSPECTING NOTE Whenever a part is worn ex...

Page 108: ...0 Ring 13 Sprocket 14 Washer 15 Screw 16 Chain 17 Washer 18 Bushing 19 Tightener Arm 20 Lock Nut 21 Roller 22 Bearing 23 Cotler Pin 24 Bearing 25 Flange Plate 26 Lock Nut 21 Washer 28 Sprocket 29 Seal...

Page 109: ...ess the sprockets on the driveshaft noting the 3 Assemble driveshaft components on the PTO scribed marks on the shaft and the timing mark end of the driveshaft Install bearing lock collar found on one...

Page 110: ...4174 to the bear ing seating area adjacen t to the shaft splines Install the bearing seal and flange plate and secure with three lock nuts Tighten to 2 2 2 5 kg m 16 18 ft Ib NOTE If washers were rem...

Page 111: ...oat is allowable 16 Check the alignment of the drive clutch driven pulley 17 Tip the snowmobile onto the PTO side using cardboard to prevent scratching the belly pan then install the rollers and sprin...

Page 112: ...cking and Adding Brake Fluid 1 With the master cylinder level look into the master cylinder reservoir The brake fluid level must be just below the high mark Fig 4 73 Brake fluid reservoir Low brake fl...

Page 113: ...OTE It may be necessary to refill the res ervoir several times to eliminate all con taminated brake fluid 4 When the brake fluid is free of all air and con tamination and the brake lever feels firm wh...

Page 114: ...sary Follow steps 2 6 to replace the brake pads Fig 4 76 Note Replace worn brake pads when they are wore to 0 125 of an inch from the backing plate on the pad Bleeder valve 0729 871 2 Remove the safet...

Page 115: ...r of fluid 3 Remove the brake hose from the caliper Use an absorbent towel to collect any remaining brake fluid Brake fluid is highly corrosive Do not spill brake fluid on any surface of the snowmobil...

Page 116: ...6 1 Inspect the brake piston for gouges cracks pit ting scuffing or corrosion If any of these con ditions exist replace the piston 2 To clean the piston outer surface use a Scotch Brite pad and clean...

Page 117: ...ring then install the O ring into the groove of the caliper 3 Assemble the two caliper halves Secure with the two socket head cap screws Do not tighten at this time INSTALLING 1 Install the caliper a...

Page 118: ...4 Bleed the brake system see Bleeding Brake System section If new brake pads were installed a bedding in process is required Drive the snowmobile slowly and compress the brake lever several times unt...

Page 119: ...trical Resistances 125 Ignition Coil Primary 125 Ignition Coil Secondary 126 Charge Coil 1 126 Charge Coil 2 126 Lighting Coil 126 Spark Plug Cap 127 Ignition Timing Sensor 127 Crankshaft Position Sen...

Page 120: ...n Timing Sensor Crankshaft Position Sensor Lighting Coil 85 HIGH 40 HIGH 75 HIGH 45 LOW 40 LOW 80 LOW Test Connections white high tension lead green red green red white black green white yellow red ye...

Page 121: ...k for spark If no spark is present proceed to step 3 3 Below are some causes that can create a no spark situation If no spark situation occurs refer to the causes below for assistance in locating the...

Page 122: ...ow reads CLOSED tension the throttle cable If the meter remains OPEN replace the throttle assembly 5 With the ohmmeter leads still connected com press the throttle lever to full open position The mete...

Page 123: ...be connected Also check to be sure all switches ignition switch and emergency stop switch are in the ON position and the tether switch cap is installed Ignition coil output may be tested by using eith...

Page 124: ...ight illumi nates charge coil output is satisfactory pro ceed to Testing Charge Coil 2 Output If the tester light fails to illuminate replace the charge coil Test three times for conclusive results Te...

Page 125: ...lighting coil wires should be checked for breaks corro sion and looseness If the connections are tight and free of corrosion replace the coil ring Testing Lighting Coil Output lighting System NOTE The...

Page 126: ...the green red lead connect the black meter lead to the brown white lead AK012 4 Ignition coil secondary resistance must be 6300 ohms 20 CHARGE COIL 1 1 Disconnect the triple wire plug from the COl uni...

Page 127: ...N SENSOR 1 Disconnect the white black and brown wires from the injector timing sensor to the main har ness 2 Set the ohmmeter on the X100 position and zero the meter 3 Connect the red tester lead to t...

Page 128: ...floor 2 Using a multitester connect the red tester lead to a yellow lead and the black tester lead to a brown lead in the accessory harness connector Testing Warning Light Posistor 1 Disconnect the p...

Page 129: ...brown wire The ohmmeter must read less than 20 ohms of resistance with the water tem perature higher than 230 F The ohmmeter must read OPEN infinite resistance with the water temperature lower than 19...

Page 130: ...specifi cations replace the thumb warmer element Testing Heater Switch The heater switch is designed to turn the thumb warmer on by itself or to turn on both the thumb warmer and handlebar warmers to...

Page 131: ...Replace if burnt If the fuse is good proceed to step 3 Fig 5 12 AK032 4 Place the multimeter on the AC volt position Slightly spread the main four prong wiring har ness connector Start the engine Tou...

Page 132: ...wiring harness to the recti fier regulator then secure it to the steering sup port with two washers and nuts 2 Install the battery and battery hold down Secure with a wing nut 3 Connect the positive...

Page 133: ...bar heater on off switch to the warmer indicator light The warmer light will illuminate when the handlebar heater switch connects the green wire to com mon ground COLOR FUNC q 6RW1 e Black Ignition Sy...

Page 134: ...c l RLtur i Throttle body A it TUI trnturt 5u sov rnrm I Ctntrel unit tU I sensa t cmperaLure sensor I II 1 IGN swit h FU L UI I Harness e BATT fl en e m _ I cnUJ 0 I _ 1 aH Q 3 3...

Page 135: ...H a m R P c n t t o en 8 Co n 5 FLOAT OPTIONAL POSISTOR SPEEDOMETER LIGHT lEFI TAIL HARNESS 4 ft AC REGULATOR j J 111 11 11 OC REGU ATOR ro t CMS fH wN I ROIoi MATING 9 PFACE SLOE Z IrUILE PIN TU OoII...

Page 136: ...PUMP RELAY i IUE I 8 n _ m rl STOP THROTTLE SWITCH SPE EO ST fI C NOTES I CONTAC t CLOSURES VrYOLLa 5 ON l Y m CfI c D TI E en UI J S CC 3 J J Q J I JUI l UI Z CQMtC ltR SKlWN FRaN W TltoU SA l ACE Sl...

Page 137: ...ng Steering Tie Rod 151 Checking Ski Alignment 152 II Adjusting Ski Alignment 153 Removing Front Suspension Arms 153 Inspecting Front Suspension Arms 154 Installing Front Suspension Arms 154 Removing...

Page 138: ...from the handlebar 138 6 Disconnect the throttle switch harness from the main wiring harness at the front of the steering post 7 Remove the tapping screw securing the throttle switch to the handlebar...

Page 139: ...rip and using a rub ber hammer drive the grip into position WARNING Then handlebar adhesive is extremely flammable The product contains acetone and vapors released can be easily ignited Keep away from...

Page 140: ...CTING NorE Whenever a part is worn cracked defective or damaged in any way replace ment is necessary 1 Inspect the screw securing the brake lever for wear cracked stretched or damaged threads 2 Inspec...

Page 141: ...ut will cause the brake lever to bind The lever must work freely and fully return to its stop after installation 1 Apply Arctco approved high temperature brake fluid to the a ring seal then install on...

Page 142: ...s and cap screws securing the adjuster caps to the adjuster block then remove the caps handlebar assem bly and adjuster block Move the handlebar as sembly out of the way Position the handlebar assembl...

Page 143: ...the cap screw and lock nut Coat the threads of the cap screw with LOCTITE LOCK N SEAL before installing Tighten to 4 2 kg m 30 ft Ib Al055 2 On the lower end of the steering post place the bearing ha...

Page 144: ...see Installing Engine sec tion 10 Install the battery Attach the positive cable then the negative cable to the battery Removing Ski 1 Place the front of the snowmobile ona support stand 2 Remove the...

Page 145: ...sition enhances the handling charac teristics of the snowmobile 4 Secure each cap screw with a washer as needed and castle nut and torque to 9 7 11 1 kg m 70 80 ft Ib 5 Place a cotter pin through each...

Page 146: ...ing tie rod and rubber boot I I l Inspecting Drag Link 1 Inspect the entire drag link especially in the areas where the ball joints attach for any signs of cracks wear or damage 2 Inspect the bearings...

Page 147: ...rubber boot was removed Place the tie rod ball joint into posi tion and secure with cap screw flat washers and lock n ut The lock nut must be located on the backside of the drag link along with a fla...

Page 148: ...e ball joint to the drag link 2 Using the Tuning Fork pin 0644 098 and a hammer drive the tuning fork between the ball jOint and spindle arm and separate the ball joint from the spindle Fig 6 35 AL069...

Page 149: ...m nuts against the tie rod may cause loss of snowmobile control and possible personal injury 4 Remove the three cotter pins and slotted nuts securing the ball joints to the spindle 5 Raise the spindle...

Page 150: ...1 and 2 1 Press the upper suspension ball joint into the arm until it bottoms out and square the ball joint with the arm Apply LOCTITE LOCK N SEAL to the lock nut hold the ball joint parallel to the...

Page 151: ...1 4 If the tie rod assembly is to be disassembled measure the exact distance between the two ball jOint centers and write down measurement for assembly purposes To disassemble the tie rod loosen the t...

Page 152: ...I Check to make sure the handlebar and drag link are centered Adjust the tie rod as necessary then apply LOCTITE LOCK N SEAL to the tie rod jam nuts threaded area Tighten both jam nuts securely 152 6...

Page 153: ...NOTE The outside jam nuts are Ieft hand thread Care should be taken to rotate them in the proper direction Fig 6 46 Lock Nuts Upper Suspension Arm 0729 406 2 Adjust the ski alignment by rotating the...

Page 154: ...70 ft Ib 3 Install the ball joints and spindle see Install Spindle and Suspension Ball Joints 4 Place a bushing retainer and bushing onto the sway bar adjusting cap screw then slide it up through the...

Page 155: ...osed below the shock adjuster 3 Place the shock absorber into position threaded end up Install both cap screws from the front The short cap screw must be installed in the upper shock mount and the lon...

Page 156: ...ng Sway Bar section 156 Removing Console and Console Extension 1 Pull the recoil rope outward then tie a slip knot in the recoil rope near the recoil case Slowly allow the rope to retract to the knot...

Page 157: ...1 Remove the seat gas tank assembly 2 Remove the rod securing the front of the seat cover then using a sharp tool pry out all staples securing the seat cushion to the plastiC seat base Remove the cove...

Page 158: ...On Mountain Cat models remove the tunnel extension cover Installing Rear Bumper and Snowflap Fig 6 52 KEY 1 Rear Bumper 2 Cap Screw 3 Washer 4 Lock Nut 5 Machine Screw 6 Snowflap 7 Machine Screw 8 De...

Page 159: ...ght Housing 1 Remove the four screws securing the taillight lens to the housing Account for a gasket 2 Remove the two lock nuts and washers secur ing the taillight housing Pull the housing free Instal...

Page 160: ...emoving Headlight Assembly NOTE The headlight assembly is secured at the top with a single plastic push rivet It is located at the top center of the assembly 1 To remove the headlight assembly first l...

Page 161: ...m The headlight can be adjusted vertically and hori zontally The geometric center of the HIGH beam light zone is to be used for vertical and horizontal aiming 1 Position the snowmobile on a level floo...

Page 162: ...73 Front Idler Wheels Bracket Front Shock Bracket and Front Arm Bracket 174 Front Shock Absorber 178 Rear Shock Absorber and Shock Rods 178 Rear Shock Pivot 180 Rear Inner Idler Wheels 181 Slide Rail...

Page 163: ...lock 39 Retaining Ring 7 Cap Screw 40 Cover 8 Washer 41 Spring 9 Lock Nut 42 Axle 10 Shock Absorber 43 Idler Wheel 11 Arm 44 Cap Screw 12 Bushing 45 Limiter Strap 13 Grease Fitting 46 Cap Screw 14 Spa...

Page 164: ...ew 49 Spring Sleeve 50 Lock Nut 51 Cap Screw 52 Retainer Nut 0729 778 Fig 7 4 KEY 1 Formed Rail 2 Axle 3 Lock Nut 4 Washer 5 Nosepiece 6 Cap Screw Wildcat EFI Mountain Cat 1 Machine Screw 13 Axle 19 W...

Page 165: ...ching Remove the skid frame Fig 7 6 Disassembling and Assembling Skid Frame NOTE This track and suspension system section has been written so each disas sembly and assembly procedure can be com pleted...

Page 166: ...r strip can also be driven off the slide rail using a block of wood and hammer however it is much quicker to use a pipe wrench Cleaning Inspecting NOTE Whenever a part is worn exces sively cracked def...

Page 167: ...rk the inside edge of the bearing 3 Slide the spring and the plastic sleeve off the rear arm 4 Repeat these steps for the other rear spring Inspecting NOTE Whenever a part is worn exces sively cracked...

Page 168: ...the idler wheel caps then remove the cap screws and large flat washers securing the outer idler wheels Remove the idler wheels from the shaft NOTE The large wheel insert is positioned next to the inne...

Page 169: ...the slide rails Secure each bracket with two cap screws and lock nuts Torque to 1 5 kg m 11 ft Ib Fig 7 19 AG077 2 Slide the axle through an axle bracket and in order place a short spacer idler wheel...

Page 170: ...e idler wheels Remove limiter strap Fig 7 26 3 Remove the cap screw and lock nut securing the upper shock eyelet to the rear arm AG311 6 Remove the lock nut and cap screw securing the lower arm to the...

Page 171: ...and secure with cap screw washers and lock nut 5 Position the shock rods into the upper hole of the rear arm bracket Place a spacer between the center of the brackets and push the cap screw through t...

Page 172: ...emove the two cap screws and lock nuts securing the front arm to the slide rail brackets 5 Remove the front arm and account for the axles Inspecting NOTE Whenever a part is worn exces sively cracked d...

Page 173: ...each side of the strap and lock nut Tighten securely Fig 7 37 3 Install the outer idler wneels on the idler wheel shaft and secure with flat washers and cap screws Tighten securely 4 Position the shoc...

Page 174: ...rear spring slide block and remove the spring slide block 6 Remove the cap screw and lock nut securing the lower shock eyelet to the front shock bracket Swing shock forward out of bracket cc6unf for a...

Page 175: ...e spacers and outer idler wheel on the inner axle and secure with a flat washer and cap screw 4 Slide the front idler wheel bracket onto the slide rail Install the two cap screws and lock nuts securin...

Page 176: ...0 Install the lock nut securing the wear strip to the slide rail Tighten securely 7 Install the bushing into the lower shock eyelet and place the lower shock eyelet into the lower shock bracket Instal...

Page 177: ...ect the shock absorber for any signs of oil leakage especially at the point where the shock ram enters the shock body 2 Inspect the shock absorber eyelet welds at each end for any cracks or signs of s...

Page 178: ...move the cap screw and lock nut securing the shock rods to the upper arm bracket 5 Examine the axle surfaces for any signs of cor Account for the two shock rod axles and wash rosion If corrosion is fo...

Page 179: ...screw and lock nut securing the lower shock absorber eyelet and shock rods to the pivot tube bracket Account for the two shock rod axles AG314 2 Remove cap screws and flat washer securing outer idler...

Page 180: ...r wheel bearings by hand and check for binding or roughness Assembling 1 Position the idler wheels with spacer and spacer washers one on each side of the idler wheel between the idler wheel brackets 2...

Page 181: ...ont arm cross brace 6 Remove the two cap screws and lock nuts securing the front arm crossbrace to the slide rail AG323 7 Remove the two cap screws and lock nuts securing the rear idler wheel bracket...

Page 182: ...t the slide rail for cracks or unusual bends 2 Inspect the wear strip for wear The wear strip must be 10 7 mm 0 42 in thick or thicker If the wear strip measurement is less than speci fied replacement...

Page 183: ...d frame into the track making sure the track is positioned above the track deflectors located in the tunnel Slide the inner axles through the upper and rear arms of the skid frame 3 Position the front...

Page 184: ...OTE The cap screws securing the rear idler wheels must be loosened when adjusting track tension Be sure to tighten after making the adjustment 10 Check track tension and alignment see Track Tension an...

Page 185: ...heels to the inner drive lugs is the same on both sides no adjustment is necessary Fig 7 88 Rear Idler Wheels _ _ _ Inner Track Drive Lugs 0727 729 4 If the distance from the idler wheels to the inner...

Page 186: ...can be obtained by tightening the spring ten sion ski pressure can be decreased by relaxing spring tension To adjust spring tension rotate the entire spring in whichever direction is desired Equal adj...

Page 187: ...bottom located under the lower rubber bushing Rotating the adjustment bolt clock wise will lower the side rotating the adjustment bolt counterclockwise will raise the side Fig 7 91 Sway Bar Sway Bar A...

Page 188: ...I SECTION 8 RECOIL STARTER TABLE OF CONTENTS Removing 190 Disassembling 190 Inspecting 191 Assembling 191 Installing 192 189...

Page 189: ...er counterclockwise until the notch of the roller is near the recoil rope guide in the case Guide the rope into the notch and slowly allow the roller to retract until all recoil spring tension is rele...

Page 190: ...acks or dam age 4 Inspect the recoil rope for breaks or fraying 5 Inspect the recoil spring for cracks crystal lization or abnormal bends 6 Inspect the handle for damage cracks or dete rioration KEY 1...

Page 191: ...242 to the threads then secure the drive plate with a washer and nut Tighten to 1 0 kg m 7 ft lb Fig 8 8 8526 11 With 50 cm 20 in of rope exposed hook the rope in the notch of the recoil roller 12 Ro...

Page 192: ...u SECTION 9 AIDS FOR MAINTENANCE Table Of Contents Special Tools 194 General Bolt Torque Specifications 195 Torque Conversions 195 Torque Specifications 196 Engine Torque Patterns 197 193...

Page 193: ...0644 169 0644 179 0644 181 0644 188 0644 191 0644 194 0644 197 0644 202 0644 203 0644 205 0644 206 0644 207 0686 069 0686 070 0686 071 0686 085 PIN 0133 043 0133 417 0144 003 0144 007 0144 109 0144 11...

Page 194: ...Ib 56 in Ib 10 ft Ib 86 in Ib 14 ft Ib 12 ft Ib 5 16 18 11 ft Ib 8 ft Ib 17 ft Ib 13 ft Ib 25 ft Ib 18 ft Ib 5 16 24 12 ft Ib 9 ft Ib 19 ft Ib 14 ft Ib 28 ft Ib 20 ft Ib 3 8 16 20 ft Ib 15 ft Ib 30 ft...

Page 195: ...g m 6 9 7 6 Mounts ft Ib 20 25 kg m 2 8 3 5 Spark Plug ft Ib 18 20 kg m 2 5 2 8 DRIVE Drive Clutch ft Ib 50 55 kg m 7 6 6 9 Spider ft Ib 250 kg m 34 5 Drive Clutch Cover ft Ib 7 Plate kg m 1 0 Retaine...

Page 196: ...Engine Torque Patterns CYLINDER HEAD 0727 158 CYLINDER BASE CRANKCASE 9 10 0727 491 197...

Page 197: ...SECTION 10 TROUBLESHOOTING TABLE OF CONTENTS Engine 200 Fuel System 204 Drive Clutch Driven Pulley 204 Drive Belt 206 Track 207 Light System 207 199...

Page 198: ...position 5 Repair replace connect wiring harness 6 Move switch to UP position replace throttle switch 7 Adjust throttle cable tension replace throttle body assembly 8 Connect replace tether switch 9 C...

Page 199: ...low 2 Bad sensor check L E O for trouble code 3 Spark plug fouled 4 External coil defective 5 Gas tank vent hose obstructed 6 Charge coil defective 7 Tether switch defective 8 Secondary compression lo...

Page 200: ...tch defective 1 Install lower heat range spark plugs 2 Add coolant 3 Remove obstruction 4 Replace seal intake flange s 5 Troubleshoot adjust drive system 6 Clean replace rings pistons 7 Remove obstruc...

Page 201: ...rottle cable adjusted incorrectly Problem Engine Fails To Stop Continues To Condition 1 COl unit shorted to ground 2 Engine wiring harness plug wet Remedy 1 Fill tank 2 See section on No Spark 3 Repai...

Page 202: ...emove obstruction 4 Fuel filter s obstructed 4 Replace fuel filter s 6 ECU defective 6 Replace ECU Drive Clutchl Driven Pulley Problem Drive Clutch Engagement Before Specified RPM Condition Remedy 1 S...

Page 203: ...worn damaged 1 Rep ace drive clutch spring 2 Replace driven pulley spring 3 Increase spring preload tension 4 Adjust center to center distance 5 Replace movable sheave Problem Midrange Shift up Too Sl...

Page 204: ...quate 2 Replace drive clutch spring 3 Drive clutch components dirty damaged 3 Clean replace drive clutch 4 Offset parallelism center to center 4 Adjust offset parallelism center to center distance adj...

Page 205: ...Adjust track alignment Light System Problem Bulbs Burn Out Repeatedly I Condition 1 Voltage regulator malfunctioning damaged 1 Replace connect regulator defective not connected 1 Wiring harness conne...

Page 206: ...NOTES...

Page 207: ......

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