Complete and comprehensive FACTORY service manual for ALL the 1978 Arctic Cat models. Includes all variations of the Pantera, Panther, Cheeta, Jag and Lynx!. Over 230 pages in PDF file form for download. You can download the FREE preview file, then download the entire manual here instantly!

TROUBLESHOOTING

Brakes Squeal / Poor Brake Performance

• Air in system
• Water in system (brake fluid contaminated)
• Caliper/disc misaligned
• Caliper dirty or damaged
• Brake line damaged or lining ruptured
• Worn disc and/or friction pads
• Incorrectly adjusted stationary pad
• Worn or damaged master cylinder or components
• Damaged break pad noise insulator

Pedal Vibration

• Disc damaged
• Disc worn (runout or thickness variance exceeds service limit)

Caliper Overheats (Brakes Drag)

• Compensating port plugged
• Pad clearance set incorrectly
• Parking brake lever incorrectly adjusted
• Brake pedal binding or unable to return fully
• Parking brake left on
• Residue build up under caliper seals
• Operator riding brakes

Brakes Lock

• Alignment of caliper to disc
• Caliper pistons sticking
• Improper assembly of brake system components

Ignition System Troubleshooting

No Spark, Weak or Intermittent Spark

• Spark plug gap incorrect
• Fouled spark plug
• Faulty spark plug cap or poor connection to high tension lead
• Related wiring loose, disconnected, shorted, or corroded
• Faulty ignition switch
• Wire harness or connections wet, corroded.
• Poor ignition coil ground (e.g. coil mount loose or corroded)
• Faulty stator (measure resistance of all ignition related windings)
• Incorrect wiring (inspect color coding in connectors etc.)
• Faulty ignition coil winding (measure resistance of primary and secondary)
• Worn magneto (RH) end Crankshaft bearings
• Sheared flywheel key
• Flywheel loose or damaged
• Trigger coil air gap too wide (where applicable) - should be .016 - .030 (.4 - .75 mm)
• Excessive crankshaft runout on magneto (RH) end - should not exceed .0024”
• Faulty CDI module

Troubleshooting

Starter Motor Does Not Run

• Battery discharged - Low specific gravity
• Loose or faulty battery cables or corroded connections (see Voltage Drop Tests)
• Related wiring loose, disconnected, or corroded
• Poor ground connections at battery cable, starter motor or starter solenoid (see Voltage Drop Tests)
• Faulty key switch
• Faulty starter solenoid or starter motor
• Engine problem - seized or binding (can engine be rotated easily)

Starter Motor Turns Over Slowly

• Battery discharged - low specific gravity
• Excessive circuit resistance - poor connections (see Voltage Drop Test)
• Engine problem - seized or binding (can engine be rotated easily)
• Faulty or worn brushes in starter motor

Starter Motor Turns - Engine Does Not Rotate

• Faulty starter drive
• Faulty starter drive gears or starter motor gear
• Faulty flywheel gear or loose flywheel

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