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    HELP!!!! Relay Switch Sticks - 660 4 stroke Acrtic Cat

    4 replies
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    • Member since
      January, 2010
    HELP!!!! Relay Switch Sticks - 660 4 stroke Acrtic Cat
    Posted by Gordon George on Friday, January 01, 2010 12:35 PM

    For the past 3 or 4 years now, whenever it is extremely cold outside, I start my 2002 Arctic Cat 660 4 stroke and run it, but the first time I stop and turn off the engine, let it coll down a bit, and then try to start it again, it won't start.

    It turns over fine but it doesn't start becasue the relay swtich for the fuel pump "sticks".

    It is always the same relay. As soon as take out the "problem relay" and pop it a "spare", I can hear the fuel pump prime and the machine starts first crack. It only happens in cold weather after the machine has run the first time that day.

    I don't have a problem carrying a spare (warm) relay and putting it in, but surely there is a #$%$%$! permanent solution for this.

    My dealer tells me everyone running Arctic Cat 660 4 strokes (mine is an extremely well maintained 2002) has the same issue. Yet I didn't have this problem when the machine was new the first couple of years.

    Can anyone help? Surely there is a more permanent solution????

    Thank you

    • Member since
      January, 2011
    Posted by Duck2 on Thursday, January 20, 2011 8:16 AM

    Gordon,  I have had this exact same problem with my 2002 Arctic Cat 660, but have never gotten a dealer to acknowledge it as a reported problem with the Arctic Cat 660.  Has anyone responded to your post?  I hate to emerge from my ice fishing house in the cold and dark only to confront a sled that wont start.  Except for the starting problem, i love the machine.

    If I was to buy a spare relay, do you happen to know the part number? 


    • Member since
      January, 2011
    Posted by Roodjr on Monday, January 31, 2011 11:12 PM

    I have a 2006 660 Bearcat,  Intermittent start problem is due to defective relays.  No help yet from AC on a permanent solution.  If you put the relays in your pocket and warm them up, magic, it will start.  This is BS and AC needs to find a permanant solution. 


    • Member since
      March, 2014
    Posted by acsnogoer on Thursday, March 13, 2014 9:32 PM

    I have yet to have a problem with my turbo 660 and its an 05.Hope reading this post does not cause me problems .LOL

    • Member since
      January, 2018
    Posted by Fromthekitchen on Friday, January 26, 2018 3:32 PM
    There is. Had the same issue til I found Yamaha relay (part # YAM 8GN-81950-00-00). The relay needs to have the plastic 'skirt' around the contacts taken off, then it fits fine. At about $15 and change I replaced the fuel pump and main ignition relays and have not had an issue since. Yamaha had issues with their relays early on, but unlike Cat, they made solid state models.

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