Greetings,

I am having a problem with my 2006 Arctic Cat 4x4 Manual Shift FIS.

The starter motor would not fully turn over the engine. I have replaced the Starter and put in a new Battery.

The starter still will not turn over the engine unless you tug on the pull starter. Tugging on the pull rope while engaging the electric start will bring the engine to life immediatley. Once started it runs fine. It does not matter if the engine is warm or cold. I still need the assistance of the pull starter.

The only other thing I can think of looking into is the Starter clutch, which I think the manual calls the secondary clutch.

If anyone has any ideas, I would value your input.

Thanks...

 

did you check all your connections? may be corroded and just not getting good contact somewhere. Id also check to make sure the new battery is a good one,it may not be any good. Ive seen that happen a number of times. your starter solenoid maybe too?

 

I agree with Mudslinginfool. More than likely a loose or corroded connection at the battery, selenoid or starter. It could also be a weak battery (going bad) or a bad starter selenoid.

My AC400 does this quite often. Usually it is either a cable connection or a bad selenoid. I ride on a saltwater beach so things corrode up fast even when you try to clean them.

Good luck

Swampy

 

The Secondary Clutch plates are rusted. It will spin freely with your hand, but it binds up in one spot. I think this may be my problem...

 

Toddub,
I had this exact same problem. I tried a new battery, checked connections, new starter, nothing helped. My starter would actually start smoking, but it couldn't turn the motor over.
The problem was the automatic compression release in the cam. It has a spring loaded centrifical (sp?) weight that opens up the exhaust valve just a skosh when the engine is not running. As the cam spins, the centrifical weight is pulled away from the cam and the exhaust valve closes normally. The spring pulls the weight back in when the engine stops and therefore the exhaust valve is once again slightly open. This allows the engine to spin easily and therefore start easily. In my 2000 Arctic 500 manual 4X4, the spring got tired and the weight was not pulled back in when the engine stopped. Hence the starter motor (or the me pulling on the rope) had to overcome the full compression of the engine. The starter motor was just not strong enough to do that. The entire mechanism can not be pulled apart to just replace the spring. You have to buy a whole new cam (about $135 if I remember correctly). I put a new cam in the motor and everything was right with the world again.
It was a pain in the @$$, but I did the job myself in one afternoon.

Bill the Dog