2004 T660 N/A No Start - ArcticChat.com - Arctic Cat Forum

4 Strokes Z1 Turbo / Z1 / T660

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post #1 of 37 Old 12-02-2016, 09:11 PM Thread Starter
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2004 T660 N/A No Start

Hi all...

I've been out of the sled world for a few years however just got a great deal on a 2004 T660. The PO stated it had two issues; The secondary clutch is bad and it doesn't start.

I'm not too concerned with the clutch as that's pretty straight forward. It needs to be replaced.

The no start is a bit more of a mystery.

Here's what I know so far;

Using a good 12v battery via jumper cables, I can get it to turn over and actually run on starting fluid. Yeah, I know I shouldn't, however I only did it to establish that I indeed have ignition.

When I key it, nothing happens. Nada. No lights, no fuel pump priming...nothing. The starter obviously engages and works and it sustains ignition...but nothing else. I checked all fuses and relays and they're fine.

The PO was very nice and honest. He stated that when the clutch went he stored it and when he went to fire it up...dead. So whatever "happened" did so while static. I have no reason to believe otherwise as the sled has always been serviced regularly at a dealer and has always been "mature" adult driven.

Could it simply be that the battery is faulty? I haven't gotten to the store to find a new one yet...but the old one is definitely toast.

Thanks for any replies...
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post #2 of 37 Old 12-02-2016, 09:54 PM
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So when you boost it, do you hear the fuel pump priming the system?

Current Sled rides
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post #3 of 37 Old 12-02-2016, 10:09 PM Thread Starter
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Quote:
Originally Posted by 660catman View Post
So when you boost it, do you hear the fuel pump priming the system?
No...not a thing. Battery will barely crank the engine over.
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post #4 of 37 Old 12-03-2016, 03:35 AM
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Quote:
Originally Posted by 660catman View Post
So when you boost it, do you hear the fuel pump priming the system?
Quote:
Originally Posted by Oshkosh1 View Post
No...not a thing. Battery will barely crank the engine over.
Theres your problem, the injection needs all the juice to pressurize the system besides just crank the motor. These aren't like a 53 Oldsmobile
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post #5 of 37 Old 12-03-2016, 05:05 AM
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But, with BOOST battery hooked up, he should hear pump priming if he turns off key (then turns back on while carefully listening)...

All "E/S" EFI sleds are that way... Cat/Yam/Poo/Doo...

Maybe the OP isn't "picking up" what 660 is saying...?

Edit: "barely cranks engine over"......?? Sounds like barely has 12.0vdc,,,, let alone 12.8 or more...

Trigger finger's getting itchy, so don't entice me....

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That is freeking sick man........
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post #6 of 37 Old 12-03-2016, 08:38 AM
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ATV: 03 400 4x4 auto FIS, 05 300 4x4
Is there a second smaller wire attached to the positive side of your battery? I know there is on my 06 T660 T/T. Without this, it will not fire up but still turn over as I made that mistake one year. It's a single loose wire that dropped out of site for me. How old is your battery? Is it a cheap one or is it a good AGM one. Test voltage when cranking and report on that.

Current Sled rides
2005 Sabercat 600 EFI LX
2006 T660 Turbo Touring
2016 Bearcat 2000XT

Past Sled rides
1993 Pantera 550 EFI
1980 El Tigre 6000

Current ATV rides
2005 A/C 300 manual 4x4
RTR Bushings & shock bushings


2003 A/C 400 auto 4x4 FIS
RTR Steerlites & Shock Bushings
Motobatt battery
26" Kenda Bearclaw HTR's


Past ATV rides
2003 A/C 400 manual ACT 4x4
RTR Shock Bushings
Rebuild Project started Mar 15 / 2017
Completed April 8 / 2017

Sold May 16 / 2017
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post #7 of 37 Old 12-03-2016, 09:24 AM
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Good question for this topic, without that (like you pointed out), no power to the fuse box for distribution to fuel system components.. Great idea to check on...

Trigger finger's getting itchy, so don't entice me....

Quote:
If it's cnote approved it will work good
Quote:
Originally Posted by DonoBBD View Post
That is freeking sick man........
Don
0637-185: '99 Sno-Pro APV (guide and button) update kit p/n...
0637-186: '99 Sno-Pro APV superseded valve inserts update kit p/n...
http://www.arcticchat.com/forum/z-zl...tml?highlight=

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post #8 of 37 Old 12-03-2016, 10:54 AM
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yes lets get a new battery in it. On my 660 I tossed it after 3 years
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post #9 of 37 Old 12-03-2016, 11:11 AM
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Good idea guud.....

Trigger finger's getting itchy, so don't entice me....

Quote:
If it's cnote approved it will work good
Quote:
Originally Posted by DonoBBD View Post
That is freeking sick man........
Don
0637-185: '99 Sno-Pro APV (guide and button) update kit p/n...
0637-186: '99 Sno-Pro APV superseded valve inserts update kit p/n...
http://www.arcticchat.com/forum/z-zl...tml?highlight=

"Arctic Chat is not affiliated with Arctic Cat Inc. in any way, shape or form. We are an enthusiast site run by fans."

(Are you experiencing issues with your local dealer? Feel free to call Cat Consumer Complaint @ 218-681-8558)
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post #10 of 37 Old 12-03-2016, 11:41 AM Thread Starter
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The battery was 4 years old. It was junk. I'm headed out to grab a new one.

I know on some vehicles I've owned, even when a good external 12v source was hooked to a truly "bad" battery(not simply discharged) that some of the systems would not power up.

All wires were attached as specified so no issues there...

As with a previous poster, I'm betting just the new battery will cure it.

Now, for the clutch.

The plastic rollers are broken. The rest of the clutch doesn't look too bad. How difficult is it to replace them? I have the clutch off and it appears that it's not too difficult, just need a small punch to get the pins out. In the manual I downloaded it states that I can simply use a roll of duct tape to set it on while doing the work...sound right or does anyone have a better more secure method?

Oh...Plugs. I know in my other small engines, NGK are the way to go. What say the jury? What's the popular brand/P/N? I haven't pulled them, however I like to replace that sort of thing(along with the fuel filter) so I know for sure how many miles I have on them.

You guys have been a great help so far...TIA!
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