97 EXT 600 EFI Electrical Problem. - Snowmobile Forum: Your #1 Snowmobile Forum

SnoCat800 · 10-25-2009, 02:41 AM

Bought this Arctic Cat today for $475. Don't run, has electrical problem. The PO said the headlite came on when coming back from Michigan on the trailer, stopped and disconnected the battery, found two wires shorted together coming from the stator. Now it has no spark. Haven't checked anything out yet.
Anybody got any idea's what it could be? Hope it's not the ECU.

**kccats** · 10-25-2009, 07:04 AM

Stator, have it rewound, like $200 or less and much better than new!

Blaine1 · 10-25-2009, 08:12 AM

Quote:

Originally Posted by SnoCat800

Bought this Arctic Cat today for $475. Don't run, has electrical problem. The PO said the headlite came on when coming back from Michigan on the trailer, stopped and disconnected the battery, found two wires shorted together coming from the stator. Now it has no spark. Haven't checked anything out yet.
Anybody got any idea's what it could be? Hope it's not the ECU.

This is how you test and replace the stator. If it is bad, I rewind stators.

Stator testing out of a sled
YouTube - Stator Testing a 2 Stroke Stator

Stator testing in a sled:
YouTube - Stator Testing in a sled

Stator removal:
YouTube - Installing a Stator Pt.1 Removing it

Stator reinstall:
YouTube - Installing a Stator Pt.2 Putting Everything Back Together

SnoCat800 · 10-25-2009, 10:26 AM

Thanks guy's for the info. Will let you know the results after checking.

SnoCat800 · 10-28-2009, 11:36 PM

Finally got the stator out. Flywheel popped loose with a bang, almost hit the side of the sled. Took a 18" breaker bar to pop it loose, was afraid the little 8mm (?) bolts were going to break. Was a little confused by the wiring hookup. This only has three wires from it, all yellow with red -- blue and brown strips, but got resistance reading OK, looks like new, no burnt coils. What I did find is that the ignition coil trigger sensor is open. Furthur update when it's back together .

catrider199 · 10-28-2009, 11:46 PM

hey snocat i dont kno if you have gotten my message but my sled is a 1994 arctic cat ext 580

Blaine1 · 10-29-2009, 06:11 AM

This is what SnoCat800 Tested. Much cheaper to replace than a Stator:

YouTube - Pulser Coil Testing

**kccats** · 10-29-2009, 08:40 AM

Nice video! Have you done one for the stator too?

SnoCat800 · 10-29-2009, 11:25 AM

Look at post #3 in this thread. Look at the sticky on manuals in the Arctic Cat threads, it includes 90 to 98 sleds in general, it's 500 pages long in Adobe pdf format. It's a little confusing because of so many different engines in those years, but it's good info never the less.

Blaine1 · 10-29-2009, 11:31 AM

Quote:

Originally Posted by SnoCat800

Look at post #3 in this thread.

You beat me to it. Maybe this weekend I can get my other videos done showing how to bypass the tss switch.

SnoCat800 · 10-29-2009, 11:51 PM

Quote:

Originally Posted by SnoCat800

Finally got the stator out. Flywheel popped loose with a bang, almost hit the side of the sled. Took a 18" breaker bar to pop it loose, was afraid the little 8mm (?) bolts were going to break. Was a little confused by the wiring hookup. This only has three wires from it, all yellow with red -- blue and brown strips, but got resistance reading OK, looks like new, no burnt coils. What I did find is that the ignition coil trigger sensor is open. Furthur update when it's back together .

Here is the stator I took out

Here is a used stator purchased WRONG ONE

Must be for a ZR model. Returned it.

Here is the connection to the CDI from stator with burnt wires.

Any ideas what could have caused this?

Here is the Ignition Trigger coil Sensor that is defective. No continuity.

Here is the ECU

Installed a battery today, now when I turn the key on the RED light next to the ECU flashes in tune with the fuel pump running, NO fuel in the tank to pump up pressure. Will put some fuel in and try it again, to see if the light goes out.

Since I'm only allowed 5 pictures I'll continue in a next post

SnoCat800 · 10-30-2009, 12:01 AM

Continueing post from 97 EXT 580 EFI Electrical Problem.

Here are three connectors under the speedo and tach. Anyone know what these might be used for? Could they cause the wires to the CDI to heat up if they shorted to the brake line?

They are a little difficult to see in the pic.

JheLrey · 10-30-2009, 11:55 AM

Just for different sleds or options... they use one wire harness to save $$$

SnoCat800 · 11-02-2009, 01:44 AM

Quote:

Originally Posted by JheLrey

Just for different sleds or options... they use one wire harness to save $$$

My oversight, yup the 2-6 wire connectors plug into each other and the 4-wire connector like you say is for other options.

SnoCat800 · 11-06-2009, 12:18 AM

Whoooo Hooooo

Correction: it's a 580 EFI.

Well after tearing almost everything apart, checking all the component resistance and finding nothing wrong. I was kinda mislead by getting a back voltage to the key switch (8.5 volts), fuel pump would run slowly, and check lite would flash in tune to the pump. Finally removed the seat and gas tank and tore into the main harness, WALLA, found the battery supply wire to the key switch badly corroded where it was spliced to two other wires, just touching it it broke off. Needless to say, it's soldered together and shrink wrapped now. One pull and VROOOOM, holy chit the smoke tho.