Regulator/Rectifier; Start-In-Gear Relay - Arctic Cat ATV 250 Utility 2009 Service Manual

The CDI is rarely the cause for electrical problems;
however, if the CDI is suspected, substitute another
CDI unit to verify the suspected one is defective.
NOTE: Prior to replacing the CDI unit to assure
the CDI unit is defective, it is advisable to perform
a CDI peak voltage test (see Ignition Coil in this
section) and/or perform a continuity test of the wir-
ing harness from the CDI connector to the CDI
unit.

Regulator/Rectifier

The regulator/rectifier is located on the right side of
the frame. Verify all other charging system compo-
nents before the regulator/rectifier is replaced.
TESTING
1. Start the engine and warm up to normal operating
temperature; then connect a multimeter to the bat-
tery as follows.
2. Select the DC Voltage position; then connect the
red tester lead to the positive battery post and the
black tester lead to the negative battery post.
3. Start the engine and slowly increase RPM. The
voltage should increase with the engine RPM to a
maximum of 15.5 DC volts.
NOTE: If voltage rises above 15.5 DC volts, the
regulator is faulty or a battery connection is loose
or corroded. Clean and tighten battery connec-
tions or replace the regulator/rectifier. If voltage
does not rise, check Voltage (Stator Coil - No Load)
sub-section. If charging coil voltage is normal,
replace the regulator/rectifier.

Start-in-Gear Relay

NOTE: The relay schematic is embossed on the
relay housing for testing continuity.
NOTE: The module and wiring harness are not a
serviceable component and must be replaced as
an assembly.
TESTING
The start-in-gear relay is located under the seat below
the fuse block. To test the relay, use the following pro-
cedure.
1. Turn the ignition switch to the ON position; then
compress the brake lever or depress the auxiliary
brake pedal. There should be an audible "click"
from the start-in-gear relay.
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NOTE: The brakelight should illuminate when-
ever either brake is applied. If the brakelight does
not illuminate, troubleshoot the respective brake-
light switch.
2. Apply the opposite brake from step 1. There should
be an audible "click" from the start-in-gear relay.
3. Disconnect the four-wire connector from the
start-in-gear relay; then using a voltmeter, connect
the red tester lead to the green/yellow wire (1) and
the black tester lead to the green wire (3).
4. With the ignition switch in the ON position, select
the DC volts position on the tester; then apply
either brake. The meter must read battery voltage.
If battery voltage is observed and no audible
"click" was heard in step 1 or 2, remove the tester
leads and replace the start-in-gear relay.
5. Shift the gear selector out of neutral and connect a
jumper wire between the yellow/green wire (2)
and the green wire (4).
6. Momentarily depress the starter button. The starter
should engage. If the starter engages, replace the
start-in-gear relay. If the starter does not engage,
troubleshoot the battery connections, starter relay,
or starter connections.
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KM460A
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KM460A
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