Fuel Systems; Fuel System; Individual Components - Arctic Cat 2015 ZR 5000 Service Manual

Fuel Systems

This section has been organized for servicing the fuel
systems; however, some components may vary from
model to model. The technician should use discretion and
sound judgment when removing/disassembling and
assembling/installing components.
Whenever any maintenance or inspection is made on the
fuel system where fuel leakage may occur, there should
be no welding, smoking, or open flames in the area.
WARNING
Since the fuel supply hose may be under pressure,
remove it slowly to release the pressure. Place an
absorbent towel around the connection to absorb gas-
oline; then remove the hose slowly to release the pres-
sure. Always wear safety glasses when removing the
fuel hoses.
 NOTE: Whenever a part is worn excessively,
cracked, or damaged in any way, replacement is nec-
essary.
SPECIAL TOOLS
A number of special tools must be available to the techni-
cian when servicing the fuel systems.
Description
EFI Analyzer
EFI Diagnostic System Manual
EFI Diagnostic System Manual (Instructions)
Fluke Model 77 Multimeter
Fuel Hose Clamp Tool
Fuel Pressure Test Kit
Vacuum Test Pump
Fuel Pump Installation Tool Kit
Laptop Diagnostic Test Kit
Laptop Diagnostic Tool
Oil Injection Usage Tool
 NOTE: Special tools are available from the Arctic
Cat Service Parts Department.

Fuel System

INTRODUCTION
The Arctic Cat EFI System operates off a series of coils
located on the stator and is made up of the following
components.
1. An engine control module (ECM) calculates input
from sensors (air temperature sensor, coolant tem-
perature sensor, throttle position sensor, and a knock
sensor) to provide the engine with the correct fuel
mixture and timing for optimum operation.
2. Charge coils (1 and 2), located on the stator, provide
AC voltage to the ECM/regulator/rectifier where AC
voltage is converted to DC voltage.
114
3. A fuel pump coil located on the stator operates the
low voltage, high output fuel pump. At cranking
speed, the high output fuel pump provides enough
fuel to charge the fuel rail.
4. An injector coil located on the stator provides the
injectors with DC voltage for operation through the
ECM.
FLOODED ENGINE
If the engine should become flooded, set the brake lever
lock, compress the throttle lever to the full-open position,
and crank the engine over until it starts and clears itself.
Release the brake lever lock.
FUEL SYSTEM
The fuel is first drawn into the electric fuel pump through
multiple pick-up valves and hoses. The fuel is then
routed through a high-pressure fuel hose to the fuel rail.
The fuel pressure is maintained in the fuel rail by the fuel
regulator. With the fuel pressure maintained at a constant
psi, the ECM evaluates the information it receives from
the electrical sensors and opens the injectors for precise
periods of time (pulse widths) to meet engine demands.
 NOTE: The entire EFI system depends on all coils
functioning properly on the stator.

Individual Components

p/n
ECM
0744-049
2257-850
The ECM is the brain of the EFI system. It uses sensor
2259-020 inputs to determine the correct fuel/air ratio for the engine
given the existing conditions of altitude and temperature.
0644-559
0644-545
If any of the sensors should fail while the engine is run-
0644-493
ning, the ECM will sense a problem and go into a "fail
0644-131
safe" mode. This is an over-rich condition and will greatly
0744-074
reduce performance. However, the engine will be pro-
0744-050
tected from a possible lean condition and engine damage.
0744-060
The ECM is equipped with a self-diagnostic system uti-
0644-007
lizing the service icon in the speedometer/tachometer and
remains illuminated when a problem exists with any of
the sensors. The technician can determine the problem
sensor by reading the code shown on the readout screen
and applying it to the ECM Diagnostic Codes chart (see
Self-Diagnostic System/Codes in this section).
 NOTE: The ECM cannot be repaired.
Removing (5000/9000)
1. Remove the left-side access panel; then remove the
snap ring securing the lower console.
2. Remove the two wiring connectors from the ECM;
then remove the ECM mounting bracket from the
belt guard.
3. Remove the two torx-head screws securing the ECM
to the mounting bracket.
Installing (5000/9000)
1. Secure the ECM to mounting bracket using the exist-
ing two torx-head screws. Tighten securely.