Snowmobile Arctic Cat (2008 year). Instruction - part 83

 

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Snowmobile Arctic Cat (2008 year). Instruction - part 83

 

 

5

5-13

AK051D

4. Ignition coil primary resistance must be between

0.26-0.35 ohm.

IGNITION COIL (Secondary)

1. Remove the spark-plug caps from the high tension

wires.

2. Set the selector in the OHMS position.

3. Connect the red meter lead to one high tension

wire; then connect the black meter lead to the

other high tension wire.

AK050D

4. Ignition coil secondary resistance must be between

6800-10,200 ohms.

CHARGE COIL (1)

1. Disconnect the three-wire plug from the CDI unit

to the magneto.

2. Set the selector in the OHMS position.

3. Connect the red meter lead to the black/red wire in

the plug; then connect the black meter lead to the

green/red wire in the plug.

AK014

4. Charge coil (1) resistance must be between 12-18

ohms.

CHARGE COIL (2)

1. Disconnect the three-wire plug from the CDI unit

to the magneto.

2. Set the selector in the OHMS position.

3. Connect the red meter lead to the brown/white

wire in the plug; then connect the black meter lead

to the green/red wire in the plug.

AK013

4. Charge coil (2) resistance must be between 12-18

ohms.

IGNITION TIMING SENSOR

1. Disconnect the green/white and brown wires from

the timing sensor to the main harness.

AO102D

5-14

2. Set the selector in the OHMS position.

3. Connect the red tester lead to the green/white wire;

then connect the black tester lead to the brown

wire.

4. Ignition timing sensor resistance must be between

148-222 ohms.

LIGHTING COIL

1. Disconnect the main wiring harness from the

engine.

2. Set the selector in the OHMS position.

3. Connect the two meter leads to each of the yellow

leads in the connector from the engine.

AK015

4. Lighting coil resistance must be between 0.12-

0.18 ohm.

SPARK-PLUG CAP

1. Remove the spark-plug caps from the high tension

wires.

2. Set the selector in the OHMS position.

3. In turn on each cap, touch a tester lead to each end

of the spark-plug cap.

B170

4. Spark-plug cap resistance must be between 4000-

6000 ohms.

IGNITION SWITCH

1. Remove the main wiring harness connectors from

the ignition switch.

2. Rotate the key to the OFF position.

3. The meter must read less than 1 ohm resistance

between the ignition switch terminals.

4. Rotate the key to the RUN position.

5. The meter must read OL (infinite resistance).

Voltage Regulator Test 

(Carbureted Models)

„NOTE: The following test should be made using
MaxiClips and the Fluke Model 73 Multimeter set to
the AC Volt scale.

This test should be made at the accessory connector of

the hood harness.

1. Connect the red maxiclip and meter lead to the

yellow wire in the connector; then connect the

black maxiclip and meter lead to the brown wire in

the connector.

2. Start the engine and allow it to idle. Meter reading

must be within specification.

Chassis Control Unit 

(CCU)/Codes

The CCU performs two important functions on the

snowmobile. Its main function is to distribute regu-

lated DC power to the chassis electrical systems. Its

other function is to control the forward/reverse shifting

of the ACT drive to ensure safe operation.

The CCU has two DC outputs used for lighting cir-

cuits. Both outputs have a circuit breaker (self reset-

ting devices) which protects components from over-

current and short circuit situations. If a system stops

working, it is likely a short has occurred and the sys-

tem has shut itself off much like a fuse will blow if a

circuit is shorted to ground. However, unlike a fuse if

the short is resolved, the CCU will reset the output and

the system will return to normal operation.

! WARNING

Most voltages generated by the ignition system are
sufficient to interrupt pacemakers! All technicians,
especially those using pacemakers, must avoid con-
tact with all electrical connections after the engine
has been started.

5

5-15

The first output, labeled the High Power DC Output,

supplies power for the headlights and handwarmers.

This output is on only while the engine is running.

This output is turned off during shifting to allow maxi-

mum power transfer to the ACT drive.

The second output, labeled the Low Power DC Output,

supplies power to the gauge, speed sensor, taillight,

accessory plugs, and APV servomotor via the Engine

Control Unit. This output is on only while the engine is

running. It is not turned off during shifting.

„NOTE: The supply of power to the ECU for the
APV servomotor is the only power transfer
between the CCU and ECU. The power for the fuel
pump, injectors, and spark plugs is generated
through separate windings in the stator and con-
trolled only by the ECU. Because of this, the
engine will run without the power input from the
CCU, but the APV servomotor will not be able to
operate the exhaust valves causing the ECU to
enter a “fail safe” mode.

„NOTE: If the engine will not run, the problem is
not related to the CCU.

SERVICE ICON

The Service Icon is controlled by the CCU/ECU and

may illuminate for a number of reasons. The icon

should illuminate each time the engine is started, and it

should go out after a few seconds. If the icon stays illu-

minated while the engine is running, the CCU/ECU is

receiving input that is outside of its established param-

eters.

FZ001D

FZ003B

„NOTE: If the icon illuminates while the engine is
running and no code is present on the readout
screen, the CCU is receiving input that is outside
of its established parameters.

Accessing CCU Codes

1. Connect the appropriate harness from CCU Diag-

nostic Test Kit to the diagnostic port.

2. Start the engine.

3. After approximately 5 seconds, the service icon on

the gauge will begin flashing.

4. When all error codes have been output, the service

icon flashes twice quickly.  The readout screen

will display an error code as CCU followed by a

number. 

„NOTE: Refer to the CCU Diagnostic Codes chart
for descriptions. 

Clearing Fault Codes

1. Connect the appropriate harness from CCU Diag-

nostic Test Kit to the diagnostic port.

2. Start the engine. 

3. Press and hold the shift button for 5 seconds.

„NOTE: Two quick flashes of the service icon indi-
cate the codes have been cleared.

CCU Diagnostic Codes

Code

Trouble

Cause

CCU 32 High power DC output 

over current.

Headlight and Hand Warmer
(Red/Black) circuit current 
greater than 20 Amps.

CCU 33 High power DC output 

shorted.

Headlight and Hand Warmer
(Red/Black) circuit shorted to 
ground.

CCU 34 Low power DC output 

over current.

Gauge, Taillight, and APV
Servo Power (Red/Blue)
circuit current greater than
20 Amps.

CCU 35  Low power DC output 

shorted.

Gauge, Taillight, and APV
Servo Power (Red/Blue)
circuit shorted to ground.

CCU 37  System over voltage.

Spike in battery voltage -
excessive gear case shifting.

CCU 38  Gear shift actuator 

failure.

Wires to reverse actuator
 damaged or shorted to 
ground.

CCU 42 Tachometer input fail-

ure (engine running - no 
tachometer signal 
present).

Tachometer signal wire 
shorted to ground.

CCU 43 Gear position switch 

failure.

Gear position switch
damaged or unplugged - 
reverse actuator not
working correctly.

CCU 44 CCU over temperature. Internal CCU temperature 

over 105° C (221° F).

5-16

VOLTAGE TEST

„NOTE: The T500 model does not have a CCU.

„NOTE: The following test should be made using
MaxiClips and the Fluke Model 73 Multimeter set to
the DC Volt scale.

„NOTE: The CCU tests were made with the con-
nectors plugged in, spark plugs removed and
grounded, and by pulling the recoil starter rope
briskly.

LOW POWER

1. Connect the red maxiclip and meter lead to the

red/blue lead of the connector; then connect the

black maxiclip and meter lead to the black lead of

the connector.

2. Pull the recoil starter rope briskly.

3. Meter reading must be within specification.

„NOTE: Repeat test three times to confirm results.

HIGH POWER

1. Connect the red maxiclip and meter lead to the

red/black lead; then connect the black maxiclip

and meter lead to the black lead.

2. Pull the recoil starter rope briskly.

3. Meter reading must be within specification.

„NOTE: Repeat this test three times to confirm
results.

Servomotor Test

„NOTE: A 12-volt battery and test leads will be
needed for this test.

1. Remove the servomotor from the snowmobile.

2. Contact the red/black servo terminal with the bat-

tery positive lead; then contact the black/red servo

terminal with the battery negative lead.

3. The servo should rotate when the negative lead

contacts the black/red terminal. Note the direction

of rotation.

4. Reverse the connections on the servo terminals:

positive lead to black/red and negative lead to red/

black. The servomotor should rotate in the oppo-

site direction.

5. Install the servomotor.

„NOTE: If the servo operates correctly in the
above test but fails to operate when connected to
the ECU/CDI at the designated RPM, proceed to
Potentiometer Test.

POTENTIOMETER TEST

„NOTE: The following test should be made using
MaxiClips and the Fluke Model 73 Multimeter set to
the ohms scale.

1. Remove the servomotor from the snowmobile.

2. Connect the red maxiclip and meter lead to the

black/white servo terminal; then connect the black

maxiclip and meter lead to the yellow servo termi-

nal.

3. Rotate the servo pulley counterclockwise. The

ohms should increase as the pulley is rotated until

it reaches 4700-5000 ohms.

4. Continue the pulley rotation, and there will be a

small area in the rotation at which the ohm reading

will disappear; then it will return again.

5. Continue the pulley rotation, and the ohms should

appear at a very low value but will again increase

to 4700-5000 ohms. This is normal operation.

FZ088A

6. Install the servomotor.

„NOTE: If the servo operates correctly and the
potentiometer test is correct but fails to operate
when connected to the ECU/CCU at the designated
RPM, see Troubleshooting Servomotor chart in
this section.

! WARNING

Most voltages generated by the ignition system are
sufficient to interrupt pacemakers! All technicians,
especially those using pacemakers, must avoid con-
tact with all electrical connections after the engine
has been started.

! CAUTION

Care must be taken not to contact the servo yellow,
orange, or black/white terminals, or damage to the
potentiometer circuit will result.

 

 

 

 

 

 

 

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