Testing Fuel Gauge Sender; Emergency Stop Switch; Starter Relay Solenoid - Arctic Cat 2015 ZR 5000 Service Manual

This test should be made at the three-pin connector of the
regulator/rectifier.
! 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.
 NOTE: Test the connector that comes from the
engine.
1. Set the meter selector to the DC Voltage position.
2. Connect the red tester lead to the positive battery
post; then connect the black tester lead to the nega-
tive battery post.
3. With the engine running at 2500-3000 RPM, the
meter must show 12-14.5 DC volts.
4. Set the meter selector to the AC Voltage position.
5. Test between the three yellow wires for a total of
three tests.
6. With the engine running at 2500-3000 RPM, all wire
tests must be within 36-44 volts.
 NOTE: If tests failed, check all connections, etc.,
and test again. If no voltage is present, replace the
stator assembly.
Testing Fuel Gauge
Sender
 NOTE: Before testing the sender, verify the harness
from the sender to the gauge is satisfactory.
1. Remove the seat.
2. Disconnect the fuel gauge sender unit from the main
wiring harness; then connect the ohmmeter leads to
the two black sender wires.
3. Compare the reading to the chart following.
Full
1/2
Empty

Emergency Stop Switch

RESISTANCE
1. Remove the four torx-head cap screws securing the
front/rear throttle control housing assembly to the
handlebar.
2. Set the selector to the OHMS position.
3. Connect one tester lead to one pin; then connect the
other tester lead to the other pin.
<20 ohms
40-56 ohms
76-105 ohms
4. With the switch in the OFF position, the meter must
read OL (infinite resistance).
5. With the switch in the RUN position, the meter must
read less than 1 ohm resistance.
 NOTE: If the meter does not show as specified, trou-
bleshoot or replace the switch/component, the con-
nector, or the switch wiring harness.

Starter Relay Solenoid

TESTING
 NOTE: The electric start solenoid may be tested
using either one of the following methods.
Method #1
1. Disconnect the solenoid connector from the main
wiring harness.
2. Place the ohmmeter leads across the solenoid coil
terminals. The ohmmeter must read 3-5 ohms.
 NOTE: An in-line ammeter would measure between
2 and 4 amps of solenoid coil current flow with the
battery connected.
CAUTION
NEVER connect an in-line ammeter with the large
starter cables because the 200 amps of current flow
will instantly damage most ammeters.
Method #2
1. Using the multimeter set to the DC Voltage position,
check the relay as follows.
2. Connect the red tester lead to the positive battery ter-
minal; then connect the black tester lead to the starter
cable connection on the starter relay. The meter must
show battery voltage.
 NOTE: Engage the brake lever lock and place the
emergency stop switch in the RUN position.
3. Engage the starter while observing the multimeter.
The multimeter should drop to 0 volts and a "click"
should be heard from the relay.
 NOTE: If a "click" is heard and more than 1 volt is
indicated by the multimeter, replace the starter relay.
If no "click" is heard and the multimeter continues to
indicate battery voltage, proceed to step 4.
PC253A
135