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Help rebuilding 2-stroke engine from snowmobile (kitty kat)

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Help rebuilding 2-stroke engine from snowmobile (kitty kat)

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Old 11-05-2009, 06:18 AM
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Default Help rebuilding 2-stroke engine from snowmobile (kitty kat)

I'm working on re-building a 1972 Arctic Cat Kitty Kat. I've had it since I was a little kid. I've got the body and mechanical work just about done... engine is last. I priced just buying a replacement, but thought i might give a try to repairing the existing engine. The engine ran when it was put away (so I'm told), but it sat for at least 15 years. My thought is to do just a little bit of work and throw a little $$ at it to see how it runs. I want to do this both to try to save a little money, and for my own benefit... just interested in learning something.

The engine is a Kawasaki T5A, 60cc, 1972.

So, here's where I'm at. I am missing a piece of the ignition system, however I'm not sure what it is. I know the basic mechanical parts of the 2-stroke, I rebuild a '79 engine once. However, I dont know much about the ignition. There is a cover over the flywheel...



On top of the cover there is a "port". A pair of wires went through this hole and are connected to a "disc." This is where I assume the part is missing. When i first started messing with this engine, i found i had no spark. So, I pulled the cover and all that fell out of there was a spring. There are other holes in the cover... so whatever was attached to the disc probably fell out years ago. Here's the disc...



One wire from the disc (marked M+) goes back into the engine through the same hole that the spark plug wire comes out of. I assume there is a stator and points in there. The other wire (M-) is grounded to the engine block.



So, I'm hoping that i can identify this part that is missing so that I can order one. If I still have no spark, I'll pull the flywheel and see what's going on in there.

Any help is appreciated. Reading this back, I sound like a complete dope. I am pretty good with engines though... this is just the first time I've messed with a small 2-stroke.

Thanks

Last edited by timo14; 11-05-2009 at 06:28 AM.
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Old 11-05-2009, 09:59 AM
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I believe that disc would be part of a magneto.
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Old 11-05-2009, 10:26 AM
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I'm pretty sure all the parts of the magneto are under the flywheel. I tried to look up the parts on line, but the oldest Kitty Kat I could find listed was a 78 so the parts may be different AND it didn't show the engine cover.

I can't see it that well, but is it possible that 'port' in the engine cover used to be a key switch? The back of a key switch would have a disk with wires attached to different locations that would be connected at a certain position of the switch.

Ken
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Old 11-05-2009, 10:30 AM
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I checked another place and found it! That IS a key switch on the engine cover but yours is apparently broken. Check out this site for parts diagrams of the 1972 Kitty Kat:

http://alpha-sports.com/arctic_cat_parts.htm

BTW - that puppy actually uses points - so dirt between the contacts or a bad condenser could be killing your spark. There is one wire that looks like it leads from the magneto to the keyswitch. That wire will either need to open (not connected to anything) or grounded for the spark to work. No harm in trying it both ways.

Ken
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Old 11-05-2009, 01:30 PM
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Originally Posted by kchace View Post
I checked another place and found it! That IS a key switch on the engine cover but yours is apparently broken. Check out this site for parts diagrams of the 1972 Kitty Kat:

http://alpha-sports.com/arctic_cat_parts.htm

BTW - that puppy actually uses points - so dirt between the contacts or a bad condenser could be killing your spark. There is one wire that looks like it leads from the magneto to the keyswitch. That wire will either need to open (not connected to anything) or grounded for the spark to work. No harm in trying it both ways.

Ken
Ken, you are the man!!! I looked all over on the internet for diagrams. That link is sweet.

The way that the disc was oriented when i took it apart, i had assumed that there was a missing piece that extended down and touched the flywheel. There is a terminal on the disc that was completely worn off... and there was a matching wear mark on the flywheel. I guess it must have just fallen into the flywheel and wore a groove in it by mistake. Wierd.

I'm going get rid of that switch tonight and see if i cant get a spark. You probably just saved me alot of time and probably quite a few dollars. I definately owe you one!

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Old 11-06-2009, 07:35 AM
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No problem. Always happy to help out a fellow sled owner. Kitty Kats are great.

Ken
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Old 11-06-2009, 08:33 AM
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Never got a chance to work on the engine last night... wife had to work late and kids had me pretty beat up by the time she got home. I'll definately get on it this weekend. I've had this kitty kat since i was about 8, I'm 33 right now. My sister ran it, a cousin had it, neighbors used it... needless to say it's a little beat up. Hoping to get it running by the winter which usually shows up in January in my neck of the woods. My boy is 3, barely old enough to ride, but figured i might as well give him a shot.

By the way, I'm very jealous of your boat. The Tolman's are "home-made" boats aren't they?

Thanks again for the info!
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