Snowmobile Snowmobile Operator’s Operator’s · PDF fileSnowmobile Snowmobile Operator’s Operator’s Manual Manual p/n 2258-236 p/n 2258-236

Snowmobile Snowmobile Operator’s Operator’s

Manual Manual

p/n 2258-236 p/n 2258-236

LIMITED WARRANTYArctic Cat Inc. (hereinafter referred to as Arctic Cat) extends a limited warranty on each new Arctic CatSnowmobile it manufactures and on each part and accessory manufactured or sold by Arctic Cat. Thewarranty is extended to the original retail purchaser only on parts and accessories sold through anauthorized Arctic Cat Snowmobile dealer. Warranty on snowmobiles is extended to the original retailpurchaser; however, the balance of the unused warranty may be transferred to a second party.

Arctic Cat warrants only the products it manufactures and/or sells and does not warrant that otherproducts will function properly when used with an Arctic Cat Snowmobile or will not damage the ArcticCat Snowmobile. Arctic Cat does not assume any liability for incidental or consequential damages.

Arctic Cat will repair or replace, at its option, free of charge (including any related labor charges), anyparts that are found to be warrantable in material or workmanship. This repair work MUST be done byan authorized Arctic Cat Snowmobile dealer. No transportation charges, rental charges, orinconvenience costs will be paid by Arctic Cat. The warranty is validated upon examination of said partsby Arctic Cat or an authorized Arctic Cat Snowmobile dealer. Arctic Cat reserves the right to inspectsuch parts at its factory for final determination if warranty should apply.

The warranty periods are as follows:

1. For snowmobiles used for recreational purposes:—If purchased between May 1 and November 30, warranty expires ONE (1) YEAR fromDecember 1 of the current year.—If purchased between December 1 and April 30, ONE (1) YEAR from the date of sale.

2. For snowmobiles used for commercial purposes (including rental operations), ONE (1)YEAR from the date of sale and/or 5000 MILES whichever comes first.

3. THIRTY (30) DAYS from date of sale of snowmobile on all batteries.

4. THIRTY (30) DAYS from date of sale for all dealer installed service parts and accessories.

5. UNTIL EXPIRATION OF THE NEW PRODUCT WARRANTY for all eligible replacementparts.

Exclusions to this warranty include normal wear, abuse (i.e. a track run on marginal snow conditionswithout proper lubrication or additional idler wheels), and the following parts:

Fuel Filter Light Bulbs Windshield Torn or Punctured UpholsteryDrive Belt Wear Bars Water Pump Belt Brake PadsFan Belt Spark Plugs Wear Strips Drive Clutch/Driven Pulley Wear Parts

The following will VOID Arctic Cat’s warranty:

1. Failure to perform the proper break-in procedure and all operator related maintenance,storage procedures, and service as recommended in the Operator’s Manual.

2. Repairs and/or adjustments by anyone other than an authorized Arctic Cat Snowmobiledealer.

3. Use of an improper fuel mixture ratio.

4. Use of improper carburetor main jets.

5. Use of improper gasoline, lubricating oils, or spark plugs.

6. An accident or subjecting the snowmobile to misuse, abuse, or negligent operation.

7. Any modification or removal of parts (i.e. air-intake silencer, muffler, etc.) unless instructedto do so by Arctic Cat.

8. Use of the snowmobile in any way for racing purposes.

9. Removal of the engine for use in another vehicle.

10. Removal or mutilation of the Vehicle Identification Number or Engine Serial Number.

11. Use of parts not sold or approved by Arctic Cat.

12. Track and tunnel damage resulting from either ice stud or hooker plate installation.

13. Damage due to improper transportation.

In consideration of the foregoing, any implied warranty is limited in duration to the various warrantyperiods set forth. This warranty gives you specific legal rights, and you may also have other rights whichvary from state to state and country to country. Some states do not allow limitations on how long animplied warranty lasts, so the above limitations may not apply to you.

Table of ContentsLimited Warranty ......... Inside Front CoverForeword ................................................ 1Declaration of Conformity....................... 2Snowmobile Safety Rules ...................... 3General Information .......................... 4-27

Snowmobile Identification.................. 4Control Locations............................... 4Gasoline-Oil....................................... 6Engine Break-In (2-Stroke Models) ... 7Engine Break-In (1100 cc Models) .... 8Speedometer/Tachometer Indicator

Icons (Standard Gauge) ................. 8Speedometer/Tachometer Indicator

Icons (Premium Gauge) ............... 11Diagnostic Codes

(Standard/Premium Gauges) ...... 14Handlebar Tilt

(Bearcat/Crossfire/M-Series Models) ......................... 15

Handlebar Tilt (F-Series/T-Series - STD Models) ................................ 15

Handlebar Tilt (Cam Lever Style) .... 16Telescopic Handlebar (Crossfire/

M-Series Sno Pro/Sno Pro LE Models)......................................... 17

Exhaust System............................... 17Air-Intake Silencer ........................... 17Battery (Electric Start Models) ........ 17Cooling System (Liquid) .................. 18Drive Clutch and Driven Pulley........ 18Drive Clutch/Driven Pulley

Alignment ..................................... 18Fuel Pump ....................................... 18Shock Absorbers (Standard Gas).... 19Shock Absorbers

(Rebuildable Gas)......................... 19Deep-Lug Track ............................... 19Standard-Lug Track ......................... 20Track Studs...................................... 20Reverse Transmission

(Lever Style Models)..................... 21Reverse Transmission

(Switch Button Style Models) ....... 22Towing ............................................. 22Adjustable/Movable Backrest

(T-Series Models) ......................... 22Removable Rear Seat

(Bearcat XT Models) .................... 23Removable Rear Seat

(T-Series Models) ......................... 23Removable Seat

(Crossfire/M-Series Models)......... 24Removable/Adjustable Seat

(TZ1 Turbo/LXR Models) .............. 24

Removable/Adjustable Seat(F-Series/Z1 Models) ....................25

Arctic Power Valve (APV) System....26Exhaust Controlled Timing (ECT)

System (600/800/1000 cc Models) .........................................27

Operating Instructions .....................28-34Starting and Stopping Engine ..........28Braking.............................................30Emergency Stopping........................32Throttle/Ignition Monitor Switch........32Varying Altitude Operation ...............34

Lubrication .......................................35-38ACT Drive Gear Case ......................35Front Suspension .............................37Rear Suspension .............................38

Maintenance ....................................39-71Periodic Maintenance Checklist .......39Air Cleaner/Filter (1100 cc Turbo) ....40Fuel System .....................................40Checking Engine Oil Level

(1100 cc Models) ..........................42Changing Engine Oil/Filter

(1100 cc Models) ..........................43Coolant Level ...................................44Adjusting Carburetors ......................45Selecting Carburetor Main Jets........48Spark Plugs (1100 cc Models) .........48Spark Plugs (2-Stroke Models) ........49Checking/Adjusting Valve Clearance

(1100 cc Models) .........................50Battery (Electric Start Models) .........50Fuses (Electric Start Models)...........52Hydraulic Brake System...................53Drive Belt .........................................56Track Tension ...................................58Track Alignment................................60Suspension ......................................61Lights ...............................................65Ski Wear Bars ..................................70Adjusting Ski Stance (M-Series/

Crossfire/Bearcat 570/570 XT/Bearcat Z1 XT Models) .................70

Rail Wear Strips ...............................71Performance Tips .................................72Preparation For Storage ..................73-74Preparation After Storage................75-76U.S. EPA Emission Control

Statement/Warranty Coverage......78Change of Address, Ownership,

or Warranty Transfer......................79Warranty Procedure/Owner

Responsibility....... Inside Back Cover

REFERENCE INFORMATION

Write the appropriate information for your Arctic Cat Snowmobile in the spacesbelow.

Always use these numbers when referring to your snowmobile.

Model: _________________________________________________Date of Purchase: ________________________________________Vehicle Identification Number: ______________________________Engine Serial Number: ____________________________________Your Arctic Cat Dealer: __________________________________Address: ______________________________________________Phone: ________________________________________________

! WARNINGA snowmobile is a very high performance vehicle. Because it does accel-erate rapidly and is capable of very high speeds, it should not be oper-ated by a novice or an inexperienced operator. Never accelerate rapidlyor drive at high speed beyond the limits of visibility or without beingtotally familiar with the terrain and what lies in front of you. Obey speedlimits and never operate at speeds that do not allow adequate maneuver-ing and stopping distances. Read and study the entire Operator’s Manualand Safety Handbook.Failure to follow this warning could result in personal injury to yourselfor others.

PERSONAL INJURY• To avoid injury to yourself and others, NEVER operate the snowmobile without

first reading and understanding this manual and the Snowmobile Safety Hand-book; then follow the instructions and heed the warnings given.

• USE COMMON SENSE.• DON’T DRINK and DRIVE.• STAY IN CONTROL at ALL TIMES.• TELL YOUR FRIENDS. If you see a friend operating a snowmobile recklessly, at

excessive speeds, while intoxicated, or in other unsafe ways, don’t wait until it istoo late to warn of the consequences of snowmobile misuse. Such conductendangers everyone. TAKE AN ACTIVE ROLE IN THE SAFETY OF YOUR-SELF AND OTHERS.

PARTS AND ACCESSORIESWhen in need of replacement parts, oil, or accessories for your Arctic CatSnowmobile, be sure to only use GENUINE ARCTIC CAT PARTS, OIL, ANDACCESSORIES. Only genuine Arctic Cat parts, oil, and accessories are engi-neered to meet the standards and requirements of your Arctic Cat Snowmobile.For a complete list of accessories, refer to the current Arctic Cat Accessory Cat-alog. To aid in service and maintenance procedures on these snowmobiles, anIllustrated Parts Manual and a Service Manual are available through your localArctic Cat Snowmobile dealer.

FOREWORDCongratulations! You have chosen a quality Arctic Cat Snowmobile designedand manufactured to give dependable service. Be sure, as the owner/operator ofan Arctic Cat Snowmobile, to become thoroughly familiar with its basic opera-tion, maintenance, and off-season storage procedures. Read this manual and theaccompanying Snowmobile Safety Handbook before operating the snowmobileto learn safe and proper use of your new Arctic Cat Snowmobile. Always operatethe snowmobile within your level of skill and current terrain conditions.

The Operator’s Manual, Snowmobile Safety Handbook, and Snowmobile Decalsdisplay the words Warning, Caution, and Note to emphasize important informa-tion. The symbol ! WARNING identifies personal safety-related informa-tion. Be sure to follow the directive because it deals with the possibility of severepersonal injury or even death. The symbol ! CAUTION identifies unsafepractices which may result in snowmobile-related damage. Follow the directivebecause it deals with the possibility of damaging part or parts of the snowmobile.The symbol NOTE: identifies supplementary information worthy of particu-lar attention.

This manual covers operator-related maintenance, operating instructions, andoff-season storage instructions. If major repair or service is ever required, contactan authorized Arctic Cat Snowmobile dealer for professional service.

At the time of publication, all information and illustrations were technically cor-rect. Some illustrations used in this manual are used for clarity purposes only andare not designed to depict actual conditions. Because Arctic Cat Inc. constantlyrefines and improves its products, no retroactive obligation is incurred.

This Operator’s Manual should be considered a permanent part of the snowmo-bile and must remain with the snowmobile at the time of resale. If the snowmo-bile changes ownership more than once, contact Arctic Cat Inc., ServiceDepartment, P.O. Box 810, Thief River Falls, MN 56701, for proper registrationinformation. This manual was prepared by the Product Service and WarrantyDepartment of Arctic Cat Inc.

Every Arctic Cat Snowmobile meets or exceeds the standards of the SnowmobileSafety and Certification Committee and displays the SSCC decal. Arctic Cat Inc.endorses and encourages the safe use of all snowmobiles. Always wear a helmetand eye protection. Drive with caution, observe all state and local regulations,and respect the rights of others. ISMA members like Arctic Cat do their part toimprove trails, sponsor events, and generally support the sport of snowmobiling.As a member of the National Snowmobile Foundation, Arctic Cat Inc. promotessnowmobiling through education, charity, and research programs.

© 2008 Arctic Cat Inc.

Printed in U.S.A.

1

DECLARATION OF CONFORMITYApplication of council directives:Issued by European Commission.

EMC Directive 89/336/EECEC Machinery Directive 98/37/EC

Type of Equipment: SnowmobileBrand Name: Arctic CatModel Numbers:

S2009F5DFCUSG S2009TZNPKUSG S2009BCNWTUSL S2009F8HLXUSG

S2009F5DFCOSG S2009TZNLXUSB S2009BCNWTOSL S2009F8HLEUSB

S2009T5CTOUSG S2009TZNLXOSB S2009BCNWTUSB S2009F1LEPUSG

S2009T5CTOOSG S2009TZNTXUSB S2009F5CEFUSG S2009F1LEPUSO

S2009T5DFCUSG S2009TZNTLUSB S2009F5CLXUSG S2009Z1NEFUSG

S2009T5DFCOSG S2009TZNTLOSB S2009F6DEPUSG S2009Z1NLXUSB

S2009TZNTOUSG S2009BCDFCUSL S2009F6DEPUSO S2009Z1NTBUSB

S2009TZNTOOSG S2009BCDFCOSL S2009F8HEFUSG S2009Z1NTSUSB

S2009CFD1EUSB S2009BCDWTUSL S2009F8HEPUSG S2009Z1NTXUSB

S2009CFH1EUSB S2009BCDWTOSL S2009F8HEPUSO S2009CFC1EUSB

S2009CFHSPUSW S2009CFHLEOSB S2009CFLLEOSB S2009M8HEKUSB

S2009CFHLEUSB S2009CFL1EUSB S2009M6D3EUSB S2009M8HSPUSW

S2009M8HLEOSB S2009CFLSPUSW S2009M6D3EOSB S2009M8HSEUSW

S2009M1L3EUSB S2009CFLLEUSB S2009M8H3EUSB S2009M8HLEUSB

S2009M1LSEUSW S2009M1LEKUSB S2009M1LSPOSW S2009M1LSEOSW

S2009M1LLEUSB S2009M1LSPUSW S2009CFHEXUSB S2009CFHRCUSB

S2009CFHRCUSO S2009CFLEXUSB S2009CFLRCUSB S2009CFLRCUSO

S2009F1LEPOSG S2009F6DEPOSG S2009F8HEPOSO S2009Z1NTXOSB

Standards to which conformity is declared:EMC:MACHINERY:

EN 50082-1/ 1992, EN 50081-1EN 292-1, EN 292-2, EN 953, EN 1050, EN 954-1

Manufacturer (if not issuing agent): Arctic Cat Inc.601 Brooks Ave. S.Thief River Falls, MN56701 USA

I, the undersigned, hereby declare that the equipment specified above conformsto the directive(s) and standard(s) as specified.

Fred BernierManager, Product Testing & Certification

2

SNOWMOBILE SAFETY RULES

SNOWMOBILE SAFETY RULES 3

GENERAL INFORMATIONSNOWMOBILE IDENTIFICATION

The Arctic Cat Snowmobile has twoimportant identification numbers. TheVehicle Identification Number (VIN) isstamped into the tunnel near the right-side footrest. The Engine Serial Num-ber (ESN) is stamped into the crank-case of the engine.

0726-383

NOTE: The VIN also appears ona decal beneath the seat (Cross-fire/M-Series) or attached to theright-side tunnel (remaining mod-els). The decal also displays perti-nent production information.

These numbers are required by thedealer to complete warranty claimsproperly. No warranty will be allowedby Arctic Cat Inc. if the engine serialnumber or VIN is removed or muti-lated in any way.

Always provide the snowmobile name,VIN, and ESN when contacting anauthorized Arctic Cat Snowmobiledealer for parts, service, accessories, orwarranty. If the complete engine mustbe replaced, ask the dealer to notifyArctic Cat for correct registrationinformation.

CONTROL LOCATIONS

Shown are the typical control locationsfor Arctic Cat snowmobiles. Locationof a specific control will vary accord-ing to model.

Bearcat 570/570 XT/F 570 - T500/T570 Models

742-456A

4 GENERAL INFORMATION

Bearcat Z1 XT/F5/F6/F8/F1000/Z1/TZ1 Models

0743-518

Crossfire 500/600/800/1000/M-Series Models

741-633A

Crossfire 800R/1000R

0743-441

GENERAL INFORMATION 5

GASOLINE-OIL

Recommended Gasoline (Carbureted Models)

The recommended gasoline to use inthese snowmobiles is 87 octane regularunleaded. In many areas, oxygenates(either ethanol or MTBE) are added tothe gasoline. Oxygenated gasolinescontaining up to 10% ethanol or up to15% MTBE are acceptable gasolines;however, whenever using oxygenatedgasolines, the carburetor main jet mustbe one size larger than the main jetrequired for regular unleaded gasoline.For example, if a 400 main jet is rec-ommended for regular unleaded gaso-line, a 410 main jet must be installed ifusing an oxygenated gasoline.

When using ethanol blended gasoline,it is not necessary to add a gasolineantifreeze since ethanol will preventthe accumulation of moisture in thefuel system.

Recommended Gasoline (EFI Models)

The recommended gasoline to use inthese snowmobiles is 87 octane regularunleaded.

NOTE: On the 2-stroke EFIengine models for optimum perfor-mance, do not exceed the recom-mended 87 octane gasoline. Usinga higher octane gasoline will notincrease overall performance.

NOTE: The Z1 Turbo models willdetect lower octane gasoline andreduced engine performance willresult. It is recommended that 91octane (minimum) gasoline beused in these models.

In many areas, oxygenates (either etha-nol or MTBE) are added to the gaso-line.

Oxygenated gasolines containing up to10% ethanol or up to 15% MTBE areacceptable gasoline. Do not use gaso-lines containing methanol.

Recommended Injection Oil

The recommended oil to use in the oil-injection system is Arctic Cat 50:1Injection Oil (for standard models) orArctic Cat Synthetic APV 2-Cycle Oil(for APV models). These oils are spe-cially formulated to be used either asan injection oil or as a pre-mix oil (forbreak-in) and meets all of the lubrica-tion requirements of the Arctic Catsnowmobile engine.

Recommended Engine Oil (1100 cc Models)

The recommended oil to use is Syn-thetic Turbo 0W-40 Oil (p/n 5639-173).

! CAUTIONDo not use white gas or gasolinescontaining methanol. Only ArcticCat approved gasoline additivesshould be used.

! CAUTIONDo not use white gas or gasolinecontaining methanol. Only ArcticCat approved gasoline additivesshould be used.

! CAUTIONAny oil used in place of the recom-mended oil could cause seriousengine damage.


After the engine break-in period, theengine oil should be changed every2500-3000 miles on the 1100 cc STDmodels or 1500-2000 miles on the 1100cc Turbo models and before prolongedstorage.

Filling Gas Tank

Since gasoline expands as its tempera-ture increases, the gas tank must befilled to its rated capacity only. Expan-sion room must be maintained in thetank particularly if the tank is filledwith cold gasoline and then moved to awarm area.

Also, if the snowmobile is to remain ona trailer after filling the gas tank, thebed of the trailer must be maintainedlevel to prevent gasoline from drainingout through the gas tank vent hose.

Break-In Gas/Oil Mixing Instructions(2-Stroke Models)

Before mixing gasoline and oil, makesure the oil is at room temperature (20°C/68° F). Use a U.L. approved 22.7 l (6U.S. gal.) gasoline container for mix-ing the gasoline and oil. To properlymix the fuel at a 100:1 ratio, use thefollowing procedure:

1. Pour gasoline into the gasolinecontainer until approximately halffull.

2. Pour 236 ml (8 fl oz) of the recom-mended 2-cycle oil into the gaso-line container.

3. Install cap on gasoline containerand shake the mixture vigorously.

4. Fill the gasoline container withgasoline; then cap the gasolinecontainer and shake the mixturevigorously.

5. Using a fine-mesh screened fun-nel, pour the fuel mixture from thegasoline container into the snow-mobile gas tank.

ENGINE BREAK-IN(2-Stroke Models)

The Arctic Cat engine (when new orrebuilt) requires a short break-in periodbefore the engine is subjected to heavyload conditions. Arctic Cat requiresthat the first tankful of fuel be pre-mixed at a 100:1 ratio in all oil-injec-tion models.

During the break-in period, a maxi-mum of 1/2 throttle is recommended;however, brief full-throttle accelera-tions and variations in driving speedscontribute to good engine break-in.After one (1) tankful break-in period,the snowmobile may be taken to anauthorized Arctic Cat Snowmobiledealer for a checkup. This checkup is atthe discretion and the expense of thesnowmobile owner.

! WARNINGAlways fill the gas tank in a well-ventilated area. Never add gasolineto the snowmobile gas tank nearany open flames or with the enginerunning. DO NOT SMOKE while fill-ing the gas tank. Do not sit on thesnowmobile without first installingthe gas tank cap.

! CAUTIONNever mix oil and gasoline in thesnowmobile gas tank.

! WARNINGAlways fill the gas tank in a well-ventilated area. Never add gasolineto the snowmobile gas tank nearany open flames or with the enginerunning. DO NOT SMOKE whilemixing fuel or filling the gas tank.


ENGINE BREAK-IN (1100 cc Models)

The Arctic Cat engine (when new orrebuilt) requires a short break-in periodbefore the engine is subjected to heavyload conditions.

This engine does not require any pre-mixed fuel during the break-in period.

To ensure trouble-free operation, care-ful adherence to the following break-inguidelines will be beneficial.

* With occasional full-throttle operation.To ensure proper engine break-in, Arc-tic Cat recommends that the engine oiland filter be changed after 500 miles.This service is at the discretion andexpense of the snowmobile owner.

SPEEDOMETER/TACHOMETER INDICATOR ICONS (Standard Gauge)

Certain models are equipped with astandard gauge combination speedom-eter/tachometer. Indicator icons areincorporated within the speedometer/tachometer. Also incorporated into thespeedometer/tachometer is a digitalreadout screen.

FZ003C

A. Oil Pressure/Low Oil

B. Coolant Temperature

C. Low Fuel

D. Fuel Level

E. Service

F. High Beam

G. Charging System (1100 cc)

RPM/MPH (kph)

By pushing the left button once, theRPM and MPH will be displayed (oneon the readout screen and one with theneedle). By pushing the button onceagain, the functions will be reversed.

By pushing the left button (with speedbeing displayed) for more than twoseconds, the display will changebetween standard mph or metric kph.Release the button when desired dis-play appears.

! CAUTIONDO NOT exceed the one (1) tankfullimitation of a 100:1 gas/oil break-in mixture. Continuous use of agas/oil mixture, unless consis-tently operating in extremely coldconditions (-26°C/-15°F or colder),could cause spark plug fouling andexcessive carbon buildup. A 100:1gas/oil mixture must be used inconjunction with the oil-injectionsystem to ensure adequate enginelubrication in extremely cold con-ditions.

! CAUTIONDO NOT use premixed fuel in thesnowmobile gas tank. Engine dam-age will occur.

0-200 miles 1/2 Throttle (45 MPH-max)

200-400 miles 1/2-3/4 Throttle

400-600 miles 1/2-3/4 Throttle *


With RPM displayed on the readoutscreen by pushing and holding the leftbutton, maximum RPM will be dis-played on the readout screen. The max-imum RPM readout will reset when theright button is pushed (while maximumRPM is displayed).

Odometer/Trip-Meter (1)/Trip-Meter (2)/Hour-Meter/Clock

NOTE: The clock is available onelectric start models only.

By pushing the right button, the read-out screen will display odometer, trip-meter (1), trip-meter (2), hour-meter,and clock. To reset the trip meter withthe trip meter displayed, push and holdthe right button until the display iscleared. The hour-meter readout willnot reset.

Clock(Electric Start Models)With the clock selected on the readoutscreen by pushing and holding the rightbutton for two seconds, the option ofselecting the 12-hour or 24-hour clockis available. Push the left button for 12-hour display; push the right button for24-hour display. At this point, thehours and minutes will begin to flash.Push the left button to change the hourdisplay; push the right button to changethe minute display (either tap the but-tons for individual number display orpush and hold the buttons for rapidnumber display).

NOTE: During clock setting ifneither button (left, right) ispushed within a 5-second timeperiod, the clock-setting mode willbe exited with changes saved.

Service Icon On electric start models, the icon shouldilluminate each time the key is turned toRUN or START, and it should go outwhen the engine starts. If the icon staysilluminated (on electric start models) orit illuminates while the engine is run-ning, the system is receiving input thatis outside of its established parameters.If the icon illuminates indicating anerror, take the snowmobile to an autho-rized Arctic Cat Snowmobile dealer forservice. If not under warranty, this ser-vice is at the discretion and expense ofthe snowmobile owner.

Coolant Temperature Warning Icon

If the coolant temperature is at orabove the maximum running tempera-ture of 80° C (176° F), the coolant tem-perature warning icon will flash awarning (alert). If the coolant tempera-ture is at or above the maximum run-ning temperature of 93° C (200° F), thecoolant temperature warning icon willcease flashing and will remain con-stantly illuminated.

Steady Flash(Coolant Temperature Icon)

Coolant Temperature Above 80° C (176° F).

Constant On(Coolant Temperature Icon)

Coolant Temperature Above 93° C (200° F).

! CAUTIONAt this point, take precautionarymeasures such as changing toloose snow terrain, shutting theengine off (allowing the engine tocool down), and checking coolantlevel. If unable to either determineor remedy the problem, take thesnowmobile to an authorized Arc-tic Cat Snowmobile dealer for ser-vice. If not under warranty, thisservice is at the discretion andexpense of the snowmobile owner.


Charging System Warning Icon (1100 cc Models)

The Charging System Warning Icon isdesigned to warn the operator if thebattery charging system is not func-tioning. The icon should illuminateeach time the key is turned to RUN orSTART, and it should go out when theengine starts. If the icon stays illumi-nated or it illuminates while the engineis running, the battery is not beingcharged, and the snowmobile is run-ning on battery reserve power only.

If the Charging System Warning Iconilluminates, you should, as soon as pos-sible, take the snowmobile to an autho-rized Arctic Cat Snowmobile dealer forservice. If not under warranty, this ser-vice is at the discretion and expense ofthe snowmobile owner. The engineWILL NOT RUN without batterypower.

Low Oil Warning Icon(2-Stroke Models)The Low Oil Warning Icon is designedto alert the snowmobile operator whenthe oil in the oil injection reservoir getsbelow a prescribed level; however, it ishighly recommended that a visual veri-fication of the oil level in the reservoirbe done prior to operating the snowmo-bile. Once the Low Oil Warning Iconilluminates during operation of thesnowmobile, the operator must periodi-cally monitor the level of oil in the res-ervoir and must fill the reservoir thenext time gasoline is added to the gastank. The “alert level” of the Low OilWarning Icon is approximately equal to1 tankful of gasoline under normaloperating conditions.

Oil Pressure Warning Icon (1100 cc Models)

The Oil Pressure Warning Icon indi-cates engine oil pressure, not the oillevel; however, if the oil level is low, itmay affect oil pressure.

The icon should illuminate each timethe ignition switch is turned to RUN orSTART, and it should go out when theengine starts. If the icon illuminateswhile the engine is running, oil pres-sure has been lost and the engine willautomatically shut off.

If oil pressure is lost, use the followingprocedure to check the oil level:

1. With the engine off, remove theengine oil level stick and wipe itclean. Without screwing it in, setthe stick back in the oil tank.Remove it and observe the oillevel on the stick. If the oil level isat or below the ADD mark on theoil level stick, add only enoughrecommended oil to raise the levelto the NORMAL range. DO NOToverfill the reservoir with oil.

2. Open the air bleed bolt located onthe oil pump (beneath the coolanttank) to purge air from the oilhose.

ZJ004A

NOTE: When air can no longerbe heard purging from oil pumpbleed, tighten the bleed bolt to 7.5ft-lb.

3. Start the engine. The warning lightshould go out within five seconds.


4. If the warning light does not goout, shut the engine off immedi-ately and repeat step 2; then repeatstep 3.

If the warning light does not go out orif the engine does not start, take thesnowmobile to an authorized ArcticCat Snowmobile dealer. If not underwarranty, this service is at the discre-tion and expense of the snowmobileowner.

SPEEDOMETER/TACHOMETER INDICATOR ICONS (Premium Gauge)

Certain models are equipped with apremium gauge combination speedom-eter/tachometer. Indicator icons areincorporated within the speedometer/tachometer. Also incorporated into thespeedometer/tachometer is a digitalreadout screen.

FZ001A

A. High Beam

B. Oil Pressure/Low Oil

C. Coolant Temperature

D. Increment Button

E. Select Button

F. Decrement Button

G. Service

H. Charging System (1100 cc)

RPM/MPH (kph)

By pushing the increment button once,the RPM and MPH will be displayed(one on the readout screen and onewith the needle). By pushing the buttononce again, the functions will bereversed.

By pushing the increment button (withspeed being displayed) for more thantwo seconds, the display will changebetween standard mph or metric kph.

With RPM displayed on the readoutscreen by pushing and holding theincrement button, maximum RPM willbe displayed on the readout screen. Themaximum RPM readout will resetwhen the decrement button is pushed(while maximum RPM is displayed).

Odometer/Trip-Meter (1)/Trip-Meter (2)/Hour-Meter

By pushing the decrement button, thereadout screen will display odometer,trip-meter (1), trip-meter (2), and hour-meter. To reset the trip meter with thetrip meter displayed, push and hold thedecrement button until the display iscleared. The hour-meter readout willnot reset.

Clock/Altimeter

NOTE: The altimeter is availableon the 800/1000/1100 cc modelsonly.

By pushing the select button, the read-out screen will display clock, altimeter,and maximum altimeter.

With clock selected on the display bypushing and holding the select buttonfor two seconds, the option of selectingthe 12-hour or 24-hour clock mode isavailable. Push the increment button totoggle between the 12-hour display andthe 24-hour display. When desiredmode is displayed, push the select but-ton.


At this point, the hours display willbegin to flash. Push the increment but-ton to increase the hours; push the dec-rement button to decrease the hours.Pushing and holding a button willaccelerate the number display. Whendesired hour number is displayed, pushthe select button.

At this point, the minutes display willbegin to flash. Push the increment but-ton to increase the minutes; push thedecrement button to decrease the min-utes. Pushing and holding a button willaccelerate the number display. Whendesired minute number is displayed,push the select button.

NOTE: During clock setting if nobutton (increment, decrement,select) is pushed within a 5-sec-ond time period, the clock-settingmode will be exited with changessaved.

The altimeter readout is based off baro-metric pressure and may require cali-bration as weather conditions change.

To calibrate the altimeter to an estab-lished altitude with altimeter selectedon the display screen by pushing andholding the select button for a mini-mum of two seconds, the acronymCAL will be displayed on the readoutscreen for one second; then the altitudevalue will flash. Push the incrementbutton to increase the displayed alti-tude; push the decrement button todecrease the displayed altitude. Push-ing and holding a button will acceleratethe number display.

NOTE: If MPH has been selectedin the speed readout, the altitudevalue will be displayed in feet. Ifkph has been selected in thespeed readout, the altitude valuewill be displayed in meters.

To reset the maximum altimeter read-out with the maximum altimeter dis-played, push and hold the select buttonfor a minimum of two seconds.

Service Icon

On electric start models, the iconshould illuminate each time the key isturned to RUN or START, and it shouldgo out when the engine starts. If theicon stays illuminated (on electric startmodels) or it illuminates while theengine is running, the system is receiv-ing input that is outside of its estab-lished parameters. If the system iconilluminates indicating an error, take thesnowmobile to an authorized ArcticCat Snowmobile dealer for service. Ifnot under warranty, this service is at thediscretion and expense of the snowmo-bile owner.

Coolant Temperature Warning Icon

If the coolant temperature is at orabove the maximum running tempera-ture, the coolant temperature warningicon will flash a warning (alert). If thecoolant temperature is at or above themaximum running temperature, thecoolant temperature warning icon willcease flashing and will remain con-stantly illuminated.

Crossfire/F-Series/M-Series/T500Steady Flash (Coolant Temperature Icon)

Coolant Tempera-ture Above 80° C (176° F).



Z1/TZ1Steady Flash(Coolant Temperature Icon)





NOTE: On the Z1/TZ1 models ifthe coolant temperature icon isconstantly on, the engine will shutoff if vehicle speed is reduced to1.5 kph (0.9 MPH) or slower.

Charging System Warning Icon (1100 cc Models)

The Charging System Warning Icon isdesigned to warn the operator if thebattery charging system is not func-tioning. The icon should illuminateeach time the key is turned to RUN orSTART, and it should go out when theengine starts. If the icon stays illumi-nated or it illuminates while the engineis running, the battery is not beingcharged, and the snowmobile is run-ning on battery reserve power only.

If the Charging System Warning Iconilluminates, you should, as soon as pos-sible, take the snowmobile to an autho-rized Arctic Cat Snowmobile dealer forservice. If not under warranty, this ser-vice is at the discretion and expense ofthe snowmobile owner. The engineWILL NOT RUN without batterypower.

Low Oil Warning Icon

The Low Oil Warning Icon is designedto alert the snowmobile operator whenthe oil in the oil injection reservoir getsbelow a prescribed level; however, it ishighly recommended that a visual veri-fication of the oil level in the reservoirbe done prior to operating the snowmo-bile. Once the Low Oil Warning Iconilluminates during operation of thesnowmobile, the operator must periodi-cally monitor the level of oil in the res-ervoir and must fill the reservoir thenext time gasoline is added to the gastank. The “alert level” of the Low OilWarning Icon is approximately equal to1 tankful of gasoline under normaloperating conditions.

Oil Pressure Warning Icon (1100 cc Models)

The Oil Pressure Warning Icon indi-cates engine oil pressure, not the oillevel; however, if the oil level is low, itmay affect oil pressure.

The icon should illuminate each timethe ignition switch is turned to RUN orSTART, and it should go out when theengine starts. If the icon illuminateswhile the engine is running, oil pres-sure has been lost and the engine willautomatically shut off.

If oil pressure is lost, use the followingprocedure to check the oil level:

1. With the engine off, remove theengine oil level stick and wipe itclean. Without screwing it in, setthe stick back in the oil tank.Remove it and observe the oillevel on the stick. If the oil level isat or below the ADD mark on theoil level stick, add only enoughrecommended oil to raise the levelto the NORMAL range. DO NOToverfill the reservoir with oil.

! CAUTIONAt this point, take precautionarymeasures such as changing toloose snow terrain, shutting theengine off (allowing the engine tocool down), and checking coolantlevel. If unable to either determineor remedy the problem, take thesnowmobile to an authorized Arc-tic Cat Snowmobile dealer for ser-vice. If not under warranty, thisservice is at the discretion andexpense of the snowmobile owner.



ZJ004A


3. Start the engine. The warning lightshould go out within five seconds.

4. If the warning light does not goout, shut the engine off immedi-ately and repeat step 2; then repeatstep 3.

If the warning light does not go out orif the engine does not start, take thesnowmobile to an authorized ArcticCat Snowmobile dealer. If not underwarranty, this service is at the discre-tion and expense of the snowmobileowner.

DIAGNOSTIC CODES (Standard/Premium Gauges)

Diagnostic codes are activated by theECU and may be displayed on thereadout screen for a number of reasons.

If a code is displayed while the engineis running, the ECU is receiving inputthat is outside of its established param-eters. If a code has been activated, takethe snowmobile to an authorized ArcticCat Snowmobile dealer for service. Ifnot under warranty, this service is at thediscretion and expense of the snowmo-bile owner.

Crossfire/F-Series/M-Series/T500 Models

Additional codes are displayed on thereadout screen. Refer to the followingchart for diagnostic codes.

* On certain models.

Bearcat Z1 XT/Z1/TZ1 Models

These diagnostic codes are displayedon the readout screen incorporatedwithin the speedometer/tachometer.Refer to the following chart for diag-nostic codes.

Code Trouble2 Failure in injector(s).

4 Open or short circuit in barometric pressure sensor.

5 Open or short circuit in intake air temperature sensor.

6 Open or short circuit in water tem-perature sensor.

7 Open or short circuit in throttle position sensor.

12 Failure in ignition coil.

16* Incorrect adjustment/failure in APV cable.

17* Failure in exhaust temperature sensor.

18* Failure in servomotor.

21* Failure in knock sensor.

23* Fail-safe mode activated in knock control system.

Code Trouble1 Failure in the fuel system.

2 Failure in injector (#2).

3 Failure in injector (#1).

4 Failure in barometric pressure sen-sor.

5 Open or short circuit in intakemanifold air temperature sensor.

6 Open or short circuit in watertemperature sensor.

7 Open or short circuit in throttleposition sensor.

8 Open or short circuit in manifold air pressure sensor.


* Turbo models

HANDLEBAR TILT (Bearcat/Crossfire/M-Series Models)

The handlebar can be adjusted to theposition providing the operator withthe most comfort. To adjust the handle-bar, use the following procedure:

NOTE: It may be necessary toremove the handlebar cover forthis procedure.

1. Loosen the four lock nuts (Allen-head cap screws on models with atelescoping handlebar) securingthe handlebar caps and block tothe steering post.

0743-442

0743-467

2. Adjust the handlebar up or downto operator’s desired tilt; thentighten the lock nuts/cap screwsevenly and securely. Check steer-ing for maximum right/left turningcapabilities.

3. Recheck lock nuts/cap screws;tighten securely.

NOTE: Recommended torquevalue of lock nuts is 18 ft-lb. Rec-ommended torque value for theAllen-head cap screws is 20 ft-lb.

NOTE: Do not adjust the handle-bar to a position that allows thebrake fluid to be below the lowmark on either side of the mastercylinder.

HANDLEBAR TILT (F-Series/T-Series - STD Models)

The handlebar can be adjusted to theoperator’s preference. To adjust the han-dlebar, use the following procedure:

1. Loosen the eight cap screws secur-ing the handlebar caps to the riserand the riser to the steering post.

9 Failure in crankshaft position sen-sor.

11 Failure in speed sensor.

12 Failure in coil (#1).

13 Failure in coil (#2).

14 Failure in ISC valve.

15 Failure in oxygen sensor.

19 Failure in camshaft position sen-sor.

21 Failure in knock sensor.

22* Failure in coil (#1 secondary).

23* Failure in coil (#2 secondary).

OCTN* Low octane gasoline.

Code Trouble

! WARNINGTighten lock nuts according tospecifications to prevent unex-pected “movement” of the handle-bar during operation over roughterrain and DO NOT position han-dlebar so steering (maximum right/left turning capabilities) or throttleand brake controls are affected.


741-708A

2. Adjust the handlebar up or downto operator’s desired tilt, tightenthe cap screws evenly to 25 ft-lb,and check steering for maximumright/left turning capabilities.

NOTE: Do not adjust the handle-bar to a position that allows thebrake fluid to be below the lowmark on either side of the mastercylinder.

HANDLEBAR TILT (Cam Lever Style)

The handlebar can be adjusted to theoperator’s preference. To adjust the han-dlebar, use the following procedure:

1. Press inward on the lock pin torelease the cam lever and “flip” thecam lever up.

0741-427

2. Adjust the handlebar up or downand/or rotate the handlebar to oper-ator’s desired position; then pressdown on the cam lever until thelock pin is properly positioned andlocked. Check steering for maxi-mum right/left turning capabilities.

NOTE: At this point, gently liftthe cam lever without pressing inon the lock pin. If the cam levercannot be lifted, the lock pin issecure.

NOTE: Do not rotate the handle-bar to a position that allows air toenter the brake system.

3. Test the handlebar to ensure that itdoes not rotate within the riserblock. If it does not rotate, proceedto step 4. If it does rotate, releasethe cam lever and rotate the camlever clockwise; then press downon the cam lever until the lock pinis properly positioned and locked.Repeat this procedure until thehandlebar is properly secured.

4. After the handlebar is “locked” inposition, release the cam lever androtate it one turn clockwise; thenpress down on the cam lever until it“locks” in place.

NOTE: At this point, gently liftthe cam lever without pressing inon the lock pin. If the cam levercannot be lifted, the lock pin issecure.

! WARNINGTighten cap screws according tospecifications to prevent unexpected“movement” of the handlebar dur-ing operation over rough terrain. DONOT offset the handlebar so steering(maximum right/left turning capabili-ties) are altered or throttle and brakecontrols will be affected.

! CAUTIONIf at any time the lock pin will notengage into the locked position, doNOT operate the snowmobile. Takethe snowmobile to an authorizedArctic Cat dealer for service.


TELESCOPIC HANDLEBAR (Crossfire/M-Series Sno Pro/Sno Pro LE Models)

1. From each side of the steeringpost, compress the locking tabs tounlock the handlebar.

0743-463

2. With the tabs compressed, adjustthe handlebar up or down to thedesired position; then release thetabs to lock the handlebar in place.

EXHAUST SYSTEM

The exhaust system is designed toreduce noise and to improve the totalperformance of the engine. If anyexhaust system component is removedfrom the engine and the engine is run,severe engine damage will result.

AIR-INTAKE SILENCER

Used in conjunction with the fuelintake system is a specially designedair-intake silencer. The purpose of thesilencer is to quiet the intake of freshair. Since the fuel intake system is cali-brated with the air-intake silencer inplace, the engine must never be runwith the silencer removed. Perfor-mance will not be improved if the air-intake silencer is removed. In contrast,severe engine damage will occur.

BATTERY

(Electric Start Models)

It is extremely important that the bat-tery be maintained at full charge at alltimes and that the battery connectionsbe clean and tight. If charging the bat-tery becomes necessary, refer to Bat-tery sub-section in the Maintenancesection of this manual.

! WARNINGCare must be taken to securelylock the handlebar cam lever toprevent unexpected “movement”of the handlebar during operationover rough terrain. DO NOT offsetthe handlebar so steering (maxi-mum right/left turning capabilities)are altered or throttle and brakecontrols will be affected.

! CAUTIONThese snowmobiles are notdesigned to be operated in dustyconditions. Operating the snow-mobile in dusty conditions willresult in severe engine damage.

! CAUTIONOn the 1100 cc models, always turnthe ignition switch key to the OFFposition when the snowmobile isnot being used. Leaving the ignitionswitch in the ON position will resultin discharging the battery and pos-sible damage to the battery.


COOLING SYSTEM (Liquid)

Some snowmobiles are equipped with aclosed liquid cooling system for enginecooling. The cooling system should beinspected daily for leakage and damage.Also, the coolant level should bechecked daily. If leakage or damage isdetected, take the snowmobile to anauthorized Arctic Cat Snowmobiledealer for service. If not under warranty,this service is at the discretion andexpense of the snowmobile owner.

When filling the cooling system reser-voir, use an ethylene glycol-based cool-ant/water mixture which will satisfy thecoldest anticipated weather conditionsof your area in accordance with the cool-ant manufacturer’s recommendations.

For checking/filling cooling system,refer to Coolant Level sub-section inthe Maintenance section of this man-ual.

DRIVE CLUTCH AND DRIVEN PULLEY

The drive clutch and driven pulley donot require lubrication; therefore, nospecial maintenance is required by thesnowmobile owner.

However, the drive clutch and drivenpulley should be disassembled,cleaned, and inspected by an autho-rized Arctic Cat Snowmobile dealerafter every 800 miles of operation or atthe end of the snowmobiling seasonwhichever occurs first. This service isat the discretion and expense of thesnowmobile owner.

When operating the snowmobile athigh altitudes, it may be necessary tochange certain component parts of thedrive clutch and/or the driven pulley.See an authorized Arctic Cat Snowmo-bile dealer for further information.

DRIVE CLUTCH/DRIVEN PULLEY ALIGNMENT

The parallelism and the offset betweenthe drive clutch and driven pulley areset at the factory. Normally, no adjust-ment is necessary as long as neither thedrive clutch nor the driven pulley isremoved or disassembled. However, ifpremature drive belt wear is experi-enced or if the drive belt turns over, thedrive clutch/driven pulley alignmentmust be checked. Take the snowmobileto an authorized Arctic Cat Snowmobiledealer for this service. If not under war-ranty, this service is at the discretion andexpense of the snowmobile owner.

FUEL PUMP

The fuel pump is designed to provideadequate amount of gas to the carbure-tors (on carbureted models) or to theinjectors (on EFI models) at all throttlesettings. If a fuel delivery problem issuspected, take the snowmobile to anauthorized Arctic Cat Snowmobiledealer. If not under warranty, this ser-vice is at the discretion and expense ofthe snowmobile owner.

! CAUTIONDO NOT attempt to service thedrive clutch and driven pulley. Thedrive clutch and driven pulley mustbe serviced by an authorized Arc-tic Cat Snowmobile dealer only.


SHOCK ABSORBERS (Standard Gas)

Each shock absorber should be visiblychecked weekly for fluid leakage,cracks or breaks in the lower case, or abent plunger. If any one of these condi-tions is detected, replacement is neces-sary. Take the snowmobile to anauthorized Arctic Cat Snowmobiledealer for this service. If not under war-ranty, this service is at the discretion andexpense of the snowmobile owner.

NOTE: When the snowmobile isoperated in extremely cold weather(-23° C/-10° F or colder), a smallamount of leakage may be present.Unless the leakage is excessive,replacement is not necessary.

SHOCK ABSORBERS (Rebuildable Gas)

NOTE: The presence of an ACTidentifier (decal or embossed) on ashock absorber body indicates a“rebuildable” shock absorber.

NOTE: The frequency of servicingrebuildable shock absorbers willvary according to the types of con-ditions and terrain the snowmobilehas been subjected to. If ridingquality deteriorates (or seems to bedeteriorating), take the snowmobileto an authorized Arctic Cat Snow-mobile dealer for shock absorberevaluation and/or servicing. Thisservice is at the discretion andexpense of the snowmobile owner.

Servicing rebuildable shock absorbersis considered normal maintenance andis the responsibility of the owner. Takethe snowmobile to an authorized ArcticCat Snowmobile dealer for this service.This service is at the discretion andexpense of the snowmobile owner. Kitsare available to either stiffen or softengas shock valving. If changes in shockvalving are desired, see an authorizedArctic Cat Snowmobile dealer. Thisservice is at the discretion and expenseof the snowmobile owner.

Each shock absorber should be visiblychecked weekly for fluid leakage,cracks or breaks in the lower case, or abent plunger. If any one of these condi-tions is detected, replacement is neces-sary. Take the snowmobile to anauthorized Arctic Cat Snowmobiledealer for this service. If not under war-ranty, this service is at the discretion andexpense of the snowmobile owner.

NOTE: When the snowmobile isoperated in extremely cold weather(-23° C/-10° F or colder), a smallamount of leakage may be present.Unless the leakage is excessive,replacement is not necessary.

DEEP-LUG TRACK

Some models are equipped with a deep-lug track which is specially designed foruse in powder snow riding conditions.When the deep-lug track is operated inhard-packed snow conditions, it will runslightly slower than a standard-lug trackand it will accelerate wear strip wear. Todecrease the amount of wear strip wear,slower speeds must be maintained whenoperating on hard-packed trails. Accel-erated wear strip wear caused by operat-ing a deep-lug track on hard-packedsnow conditions is NOT covered underArctic Cat Inc. warranty policy.


NOTE: If operating on ice or hard-packed snow conditions with aCrossfire model (except the Cross-fire R) or with an M-Series model, itis recommended that Ice Scratch-ers (p/n 4639-958) be installed toreduce wear strip and engine over-heating.

STANDARD-LUG TRACK

Accelerated wear strip wear caused byoperating on hard-packed snow condi-tions is NOT covered under Arctic CatInc. warranty policy.

TRACK STUDS

NOTE: Stud or hooker plateinstallation will void track and tun-nel warranty.

NOTE: Stud installation can beperformed by the snowmobileowner if qualified to do so. If theowner does not feel qualified, takethe snowmobile to an authorizedArctic Cat Snowmobile dealer forthis service. This service is at thediscretion and expense of thesnowmobile owner.

NOTE: To prevent tunnel damagefrom the studs, Tunnel Protector Kit(p/n 4639-771) for F 570/T 570 mod-els, (p/n 4639-968) for Crossfire mod-els, or (p/n 5639-143) for the BearcatZ1 XT model must be installed.

For proper installation, use the follow-ing procedure:

1. Using appropriate stud template(see chart), mark the desired studpattern to be used.

2. Using the proper-sized stud holedrill bit, drill out the stud holes.

3. Push the stud through the holefrom inside the track; then placethe domed support plate and locknut on the exposed stud.

4. Using a wrench to secure the stud,tighten the lock nut on the exposedstud.

It is also recommended that wheneverstuds are installed on a track, carbidewear bars should be installed on theskis. Carbide wear bars complementthe track studs to balance steering con-trol under these conditions. The lengthof the carbide on the wear bars shouldbe proportionate to the number of trackstuds (i.e. small number of track studs— short length of carbide...many trackstuds — long length of carbide). Theproper proportion between the numberof studs and carbide length on the wearbar will maintain steering balance.

! CAUTIONIf installing studs on the Crossfireor F-Series Sno Pro models with asingle ply track, studs with a headdiameter of at least 28.6 mm (1.125in.) must be used.

! WARNINGWhen installing studs on a singleply track, it is important to use Arc-tic Cat-approved studs (properhead diameter). If approved studs(proper head diameter) are notused, studs could tear free of thetrack causing possible injury oreven death. Consult an authorizedArctic Cat Snowmobile dealer forinformation.

! CAUTIONIf installing studs on the F-Series orZ1 models, a short Snowflap (p/n4706-462) or on the Crossfire mod-els (p/n 5639-232) must be installedor component damage will occur.

Stud Template ChartTrack Length p/n

128 in. 4639-443136 in. 4639-344141 in. 4639-991144 in. 5639-160


REVERSE TRANSMISSION(Lever Style Models)

The reverse transmission offers theoperator the convenience of being ableto back up the snowmobile rather thanhaving to turn the snowmobile aroundby hand. This feature, under most situ-ations, should not be used to free astuck snowmobile as it will tend to digthe skis deeper into the snow. Beforestarting the snowmobile, be sure theshift lever is in the desired position foreither forward or reverse operation.

Always use minimal speed when oper-ating in reverse and come to a completestop before shifting from either for-ward to reverse or reverse to forward.Once you have shifted to a new gear,apply slight throttle until positiveengagement of the shift has beenobserved. To shift the reverse transmis-sion, use the following procedure:

1. Come to a complete stop.

2. Pull the shift lever outward anddownward (from the forward posi-tion) to lock into the reverse posi-tion; then apply slight throttle untilpositive engagement of the shifthas been observed.

0742-499

No special maintenance is required forthe reverse transmission; however, ifchattering is experienced when thetransmission is shifted into reverse, thelinkage may have to be adjusted. ArcticCat recommends taking the snowmo-bile to an authorized Arctic Cat Snow-mobile dealer for this service. If notunder warranty, this service is at thediscretion and expense of the snowmo-bile owner.

NOTE: A warning buzzer willsound when the transmission is inthe reverse position; however,always check the position of theshift lever before accelerating.

! WARNINGAlways balance the snowmobilewith the proper proportionbetween the number of studs andcarbide length on the wear bars.Do not “over drive” conditions;use common sense in all operatingconditions.

! CAUTIONDo not use studs that are morethan 9.525 mm (0.375 in.) longerthan the track lug height.

! WARNINGDo not operate a snowmobile withloose studs as they may be thrownfrom the track. Always use ashielded safety stand wheneverperforming any maintenance oradjustments.

! WARNINGDO NOT stand behind the snowmo-bile or near the rotating track.NEVER run the track at high speedwhen the track is suspended.

! WARNINGUse caution and minimal speedwhen operating the snowmobile inreverse. Be sure the shift lever is inthe desired lever position.


REVERSE TRANSMISSION (Switch Button Style Models)

The reverse transmission offers theoperator the convenience of being ableto back up the snowmobile rather thanhaving to turn the snowmobile aroundby hand. This feature, under most situ-ations, should not be used to free astuck snowmobile as it will tend to digthe skis deeper into the snow. Alwaysuse minimal speed when operating inreverse and come to a complete stopbefore shifting from either forward toreverse or reverse to forward. To shiftthe reverse transmission, use the fol-lowing procedure:

1. Come to a complete stop.

NOTE: The snowmobile must beat a complete stop and the enginerunning under 3000 RPM beforethe system will allow shifting.

2. With the engine at idle (under 3000RPM), press the reverse switch but-ton; then release the button. Thereverse selection will be complete.

741-438A

NOTE: The system will not shiftuntil the button is released.

3. To shift into forward, stop thesnowmobile and allow the engineto idle (under 3000 RPM); thenpress the button and release. Theforward selection will be complete.

NOTE: A warning buzzer willsound when the transmission is inthe reverse position.

TOWING

If the snowmobile is to be towed byanother snowmobile, do not tow usingthe loops in the skis. The tow ropeshould be attached to the spindles.

ADJUSTABLE/MOVABLE BACKREST(T-Series Models)

The backrest is designed for maximumcomfort and safety. When riding dou-ble, the backrest must be in the rear-ward position.

When riding single, the backrest can bemoved to the forward position.

0742-494

To change the height of the backrest,push the adjuster down, adjust thebackrest up or down, and raise theadjuster to lock the backrest in place.

! WARNINGUse caution and minimal speedwhen operating the snowmobile inreverse. Be sure the button is inthe desired position.

! WARNINGMoving the backrest to the forwardposition limits the seating capacityto one person only.

T-Series Models


To move the backrest, push the adjusterdown, pull the backrest up and out ofthe slots, slide the backrest into thedesired position, and raise the adjusterto lock the backrest in place.

REMOVABLE REAR SEAT (Bearcat XT Models)These snowmobiles are equipped witha removable rear seat to allow for addi-tional cargo space when no passengeris being carried.

NOTE: If additional cargo isbeing added, maximum weight onthe snowmobile (operator/passen-ger/cargo) should not exceed themaximum limitation set for eachsnowmobile. See the chart in theSuspension - Overload Springssub-section of this manual fordetails. Also, the overload springsshould be engaged.

To remove the rear seat, use the follow-ing procedure:

1. Remove the four pins securing therear seat to the seat/Speedrackmount.

0743-329

2. Lift on the back of the seat andmove it rearward to remove itfrom the mount.

To install the rear seat, use the follow-ing procedure:

1. Place the seat into position on themount making sure the four pinholes are properly aligned with themounting location on mount.

2. Install the four pins making surethey are properly seated.

REMOVABLE REAR SEAT (T-Series Models)

These snowmobiles are equipped witha removable rear seat to allow for addi-tional cargo space when no passengeris being carried.

NOTE: If additional cargo isbeing added, maximum weight onthe snowmobile (operator/passen-ger/cargo) should not exceed themaximum limitation set for eachsnowmobile. See the chart in theSuspension - Overload Springssub-section of this manual fordetails. Also, the overload springsshould be engaged.

To remove the rear seat, use the follow-ing procedure:

NOTE: On LXR models, the lug-gage bag must be removed.

1. Rotate the seat latch either clock-wise or counterclockwise and holdit in that position; then lift the seatand move it rearward far enough toaccess the electrical connector.

! CAUTIONIf moving the backrest to the for-ward position, the rear seat mustbe removed.

! WARNINGMake sure the rear seat is securelylocked in place with the four pinsbefore carrying a passenger orpersonal injury may result.


0742-593

2. Unplug the electrical connector;then remove the seat from the tun-nel.

To install the seat, use the followingprocedure:

1. Place the seat into position on thetunnel; then plug in the electricalconnector.

2. Rotate the seat latch either clock-wise or counterclockwise and holdit in that position; then slide theseat forward, allow it to settle intoposition, and release the latch tolock the seat securely.

REMOVABLE SEAT (Crossfire/M-Series Models)

These snowmobiles are equipped witha removable seat. To remove the seat,use the following procedure:

1. Inside the rear storage compart-ment on the bottom of the seat-base, rotate the latch cover awayfrom the right-side locking pin.

2. Lift on the back of the seat andmove it rearward to remove itfrom the tunnel.


1. Slide the front of the seat intoposition on the tunnel; then lowerthe rear of the seat onto the lock-ing pins.

2. Press down on the rear of the seatuntil the retaining clips snap intoplace on the locking pins; then rotatethe latch cover until it snaps intoplace on the right-side locking pin.

REMOVABLE/ADJUSTABLE SEAT (TZ1 Turbo/LXR Models)

These snowmobiles are equipped witha removable/adjustable operator seat.

To remove the seat, use the followingprocedure:

1. Adjust the seat to the lowest posi-tion; then while lifting on the topforward part of the seat, remove theself-tapping screw from the rightside of the seat support assembly.

2. Press in on the left-end of the seatadjuster lever at the rear storagecompartment; then pull out on theseat adjuster lever.

3. Lift on the back of the seat andmove it forward and upward toremove it from the chassis.


! WARNINGMake sure the rear seat is securelylocked in place before carrying apassenger or personal injury mayresult.

! WARNINGMake sure the seat is securelylocked in place or personal injurymay result.

! CAUTIONDo not use the adjuster lever to liftthe seat.


1. With the seat adjuster lever pulledout, slide the front of the seat intoposition on the chassis; then withseat position selected, lower therear of the seat onto the rear stor-age compartment.

2. Press down on the rear of the seat;then secure the seat by releasingthe seat adjuster lever.

3. With the seat adjusted to the low-est position, install the self-tappingscrew into the right side of the seatsupport assembly.

To adjust the seat, use the followingprocedure:

1. Remove the rear seat.

2. Pull up on the operator seatadjuster.

0742-592

3. Lift up on the back of the seat;then move the front of the seat upor down into one of the sevenavailable positions.

4. Press down on the rear of the seat;then secure the seat by releasingthe seat adjuster.

5. Install the rear seat.

REMOVABLE/ADJUSTABLE SEAT(F-Series/Z1 Models)

These snowmobiles are equipped witha removable/adjustable seat. To adjustthe seat, use the following procedure:

1. Press in on the left-end of the seatadjuster lever at the rear storagecompartment; then pull out on theseat adjuster lever at the rear stor-age compartment.

741-434A

2. Lift up on the back of the seat;then move the front of the seat upor down into one of the sevenavailable positions.


To remove the seat, use the followingprocedure:

! WARNINGMake sure the self-tapping screwis securely tightened and the seatis securely locked in place or per-sonal injury may result.

! WARNINGMake sure the seats are securelylocked in place or personal injurymay result.


! WARNINGMake sure the seat is securelylocked in place or personal injurymay result.


1. Adjust the seat to the lowest posi-tion; then while lifting on the topforward part of the seat, remove theself-tapping screw from the rightside of the seat support assembly.

741-718A

2. Press in on the left-end of the seatadjuster lever at the rear storagecompartment; then pull out on theseat adjuster lever.

3. Lift on the back of the seat andmove it forward and upward toremove it from the chassis.


1. With the seat adjuster lever pulledout, slide the front of the seat intoposition on the chassis; then withseat position selected, lower therear of the seat onto the rear stor-age compartment.


3. With the seat adjusted to the low-est position, install the self-tappingscrew into the right side of the seatsupport assembly.

ARCTIC POWER VALVE (APV) SYSTEM

This RPM controlled servomotor(servo) actuated system adjusts the sizeof the exhaust ports to provide peak per-formance throughout the RPM range.

The system consists of an exhaustvalve assembly mounted to the exhaustside of each cylinder and connected byadjustable cables to an electronic servomounted beneath the hood.

NOTE: The mounting location ofthe servo will vary from model tomodel.

739-152F

At low RPM, the exhaust valves areheld in the DOWN position by returnsprings. This gives the engine a “lowport” exhaust design calibrated to pro-vide maximum low RPM power andimprove fuel economy at trail speeds.


! WARNINGMake sure the self-tapping screwis securely tightened and the seatis securely locked in place or per-sonal injury may result.

! CAUTIONThe correct engine oil to use isArctic Cat Synthetic APV 2-CycleOil (p/n 4639-348). Any substitutemay cause an APV malfunction.


739-152G

At high RPM, the exhaust valves areraised. This creates a “high port”exhaust design calibrated to providemaximum performance at high RPM.

739-152H

NOTE: The RPM ranges will varyfrom model to model.

NOTE: If the servomotor cyclesthree times and then shuts down,the exhaust valve cables are notadjusted correctly. The exhaustvalves may also be sticking.

NOTE: APV cleaning may bedone by the snowmobile owner ifqualified to do so. If the ownerdoes not feel qualified, take thesnowmobile to an authorized Arc-tic Cat Snowmobile dealer for thisservice. This service is at the dis-cretion and expense of the snow-mobile owner.

EXHAUST CONTROLLED TIMING (ECT) SYSTEM (600/800/1000 cc Models)

This system automatically adjusts theignition timing to provide maximumperformance through a variety of oper-ating conditions. The ECU receivesinput on engine RPM (demand) andexhaust pipe temperature (engine con-dition) and adjusts the ignition timingaccordingly. This system is not adjust-able and is maintenance free.

If a system fault is suspected, use anohmmeter to check continuity of theexhaust pipe temperature sensorlocated in the expansion chamber. Areading of either 0 ohm or infinity indi-cates a failed sensor.

0737-314

NOTE: A disabled ECT systemWILL NOT cause engine damage;however, a failed ECT system willhave slower throttle response andmay produce slightly less top-endperformance.


OPERATING INSTRUCTIONSSTARTING AND STOPPING ENGINE

It is imperative that the brake systembe checked for wear and proper opera-tion and that all safety checks found inthe accompanying Snowmobile SafetyHandbook be performed beforeattempting to start the engine. Also, oncarbureted models, be sure the cor-rect carburetor main jets for theoperating temperature, altitude,and gasoline are being used. Afterthe engine has been started, check theheadlights (high and low beam), tail-light, and brakelight to be sure they areworking properly and adjusted cor-rectly. Make sure all lights are clean toprovide maximum illumination. Theheadlight and taillight must be cleanand must be illuminated whenever theengine is running.

NOTE: If equipped with reverseshift lever, make sure the lever isin the forward position beforestarting the engine.

1. Test the operation of the brake sys-tem by compressing the brakelever. The brake lever must feelfirm when compressed; then whileholding the brake lever in the com-pressed position, measure the dis-tance between the brake lever andthe handlebar. The distance mustbe greater than 2.54 cm (1 in.).

741-328C

2. Check the fluid level in the reser-voir. The brake fluid level must bevisible in the sight glass. Add Arc-tic Cat approved brake fluid asnecessary.

741-328A

NOTE: If the sight glass appearsdark, there is a sufficient amountof fluid in the reservoir.

3. Test the throttle control lever bycompletely compressing andreleasing it several times. Thelever MUST return to the idleposition quickly and completely.

4. Move the emergency stop switchto the UP or RUN position.

5. Insert key into ignition switch;then rotate key to the RUN posi-tion.

! WARNINGDo not start the engine if the brakesystem is not functioning properly.Service the brake system or have itproperly repaired prior to operat-ing the snowmobile. Serious per-sonal injury or even death mayoccur if the brake system is notoperating properly.

! CAUTIONOn liquid cooled models, alwayscheck the coolant level beforestarting the engine.

28 OPERATING INSTRUCTIONS

6. On carbureted models for a coldengine, move the choke lever tothe full-choke position. If theengine is warm, choking is nor-mally not necessary.

0725-001

NOTE: On carbureted modelswhen the engine is being startedwith aid of the choke, DO NOTCOMPRESS THE THROTTLE CON-TROL LEVER. If the throttle controllever is compressed, the enginewill not start because the gas/airmixture will be too lean. To start awarm engine, however, the throttlecontrol lever may have to be com-pressed slightly.

NOTE: On EFI models when acold engine is being started, DONOT COMPRESS THE THROTTLECONTROL LEVER. If the throttlecontrol lever is compressed, theengine will not start because thefuel/air mixture will be too lean.

NOTE: On 2-stroke EFI modelswhen a warm engine is beingstarted, the throttle control levermay have to be compressedslightly.

7. On manual start models, pull therecoil handle slowly until resis-tance is felt; then give a shortquick pull. Repeat until the enginestarts.

NOTE: On large-displacementengines in extremely cold weather,pull the recoil handle slowly two tothree times to begin the startingprocedure.

NOTE: On electric start models,rotate the key to the START posi-tion; then when the engine starts,release the key.

8. On carbureted models when theengine starts, allow it to warm upfor approximately 30 seconds withthe choke lever in the full-chokeposition. After the 30-secondwarm-up, move the choke lever tothe middle position. The chokelever should be moved to the OFFposition when engine is warm.Slight throttle control lever com-pression may be necessary afterthe engine starts and during warm-up. Idle the engine several minutesuntil the engine has reached nor-mal operating temperature.

9. On EFI models when the enginestarts, allow it to warm up prop-erly. Idle the engine several min-utes until the engine has reachednormal operating temperature. Donot idle the engine for excessivelylong periods of time.

! CAUTIONTo avoid damaging the recoilstarter, DO NOT pull the recoil ropeto its limit or release the recoil han-dle from an extended position.Allow the rope to rewind slowly.

! CAUTIONDo not continuously run the starterfor more than 5 seconds at a time.

OPERATING INSTRUCTIONS 29

10. Flooding — On carbureted modelsif the engine does not start whenthe choke is being used but seemsready to start, move the chokelever to the OFF position. Engagethe brake lever lock; then com-press the throttle control leverfully and try to start the engine.When the engine starts, release thethrottle control lever immediately.After the warm-up, release thebrake lever lock.

NOTE: Continued choking willcause the engine to flood more.

11. Flooding — On EFI models if theengine does not start but seemsready to start, engage the brakelever lock; then compress the throt-tle control lever fully and try tostart the engine. When the enginestarts, release the throttle controllever immediately. After the warm-up, release the brake lever lock.

NOTE: On EFI models except the1100 cc models if the engine failsto start during the attempt with thethrottle control lever compressed,remove the spark plugs and cleanand dry them thoroughly or installa new set of properly gapped, rec-ommended spark plugs.

NOTE: On the 1100 cc models ifspark plugs must be replaced, takethe snowmobile to an authorizedArctic Cat Snowmobile dealer forinspection and service. This ser-vice is at the discretion andexpense of the snowmobile owner.

12. To shut off the engine, turn theignition key to the OFF position orpush the emergency stop switch tothe DOWN position.

BRAKING

The following items are items that theoperator must be familiar with whenoperating this snowmobile and itshydraulic brake system. Importantadditional information on the propermaintenance of the brake system isfound in the maintenance section ofthis manual.

1. Use the brakes wisely. Each timethe brakes are applied in allhydraulic brake systems (includingautomotive applications), heat istransferred to the brake fluid. Theamount of heat transferred duringhigh speed stops and/or repetitiveuse may be high enough to boil thebrake fluid and cause the brakes toeither fade or may cause an unex-pected loss of brakes.

! CAUTIONIt is extremely important that theengine is properly warmed upbefore subjecting the engine tohigh speed operation or heavyloads. The engine should beallowed to idle at least 3-4 minutesbefore it is operated at more than1/2 throttle. In extremely cold con-ditions, the warm-up time will belonger. Cold seizure and pistonscuffing caused by insufficientwarm-up will not be covered bywarranty. Also, do not idle theengine for excessively long peri-ods of time.

! CAUTIONOn the 1100 cc models, alwaysturn the ignition switch key to theOFF position when the snowmo-bile is not being used. Leaving theignition switch in the ON positionwill result in discharging the bat-tery and possible damage to thebattery.


If this occurs, the brake fluidrequires a cool-down period beforethe brakes will again functionproperly. This cool-down periodwill vary depending upon theambient air temperature and thetemperature of the brake fluid. Ifloss of brakes has occurredbecause of high fluid tempera-tures, do not operate the snowmo-bile until the cool-down period hasexpired and brake lever firmnesshas returned.

2. Be sure to maintain the brake fluidat the proper level and take carenot to get any moisture in the sys-tem as moisture in the brake fluidlowers the boiling point. If thebrake fluid is ever boiled (by highspeed stops or repetitive use) or ifmoisture is allowed to enter thesystem, it must be changed. Neversubstitute or mix different types orgrades of brake fluid.

3. Never ride the brake. Even main-taining minimal pressure on thebrake lever will cause the brakepads to drag on the disc and mayoverheat the brake fluid.

4. The brake lever lock is not a park-ing brake and should not beapplied for periods exceeding 5minutes. NEVER OPERATE THESNOWMOBILE WITH THEBRAKE LEVER LOCKENGAGED.

5. Pumping the brake lever is permis-sible; however, if pumping thebrake lever more than twice is nec-essary to obtain the necessarystopping power, immediately takethe snowmobile to an authorizedArctic Cat Snowmobile dealer forservice. If not under warranty, thisservice is at the discretion andexpense of the snowmobile owner.

6. When new brake pads areinstalled, a “burnishing” process isrequired. Drive the snowmobileslowly and compress the brakelever several times until the padsjust start to heat up; then allowthem to thoroughly cool down.This process stabilizes the padmaterial and extends the life of thepads.

! WARNINGExcessive repetitive use of thehydraulic brake for high speedstops will cause overheating of thebrake fluid and premature brakepad wear which will result in anunexpected loss of brakes.

! WARNINGUse only Arctic Cat approvedbrake fluid. Never substitute or mixdifferent types or grades of brakefluid. Brake loss can result. Checkbrake fluid level and pad wearbefore each use. Brake loss canresult in severe injury or evendeath.

! WARNINGThe brake lever lock is not a park-ing brake and should not beapplied for periods exceeding 5minutes. The brake lever lockmaintains the brake lever in thecompressed position and main-tains pressure against the brakedisc; however, after a period oftime, the pressure applied to thebrake disc may relax below theamount required to hold the snow-mobile stationary.


EMERGENCY STOPPING

There are several methods of stoppingor slowing the snowmobile under avariety of situations. Identified in thefollowing chart are the ways a snow-mobile may be brought to a stop andthe effectiveness under normal condi-tions.

THROTTLE/IGNITION MONITOR SWITCH

The throttle control is equipped with amonitor switch for safety purposeswhich will stop the engine when a lossof return spring force occurs. If iceforms in the throttle system or if thereis some other malfunction of the throt-tle system resulting in a loss of returnspring force, the monitor switch willstop the engine when the throttle con-trol lever is released.

If the snowmobile engine stopsabruptly when the throttle control leveris released and the activation of themonitor switch is suspected, use thefollowing procedure:

1. Rotate the ignition key to the OFFposition.

2. Remove ice and snow from thethrottle system and wait 5-10 min-utes for the engine heat to thaw icefrom the throttle system.

3. Test the throttle control lever bycompressing and releasing it sev-eral times. The lever MUST returnto the idle position quickly andcompletely.

NOTE: If the throttle control leveroperates properly and the enginedoes not start, compress the throt-tle lever slightly (approximately 1/8throttle) and try starting theengine. If the engine now startsand stops when the throttle lever isreleased, take the snowmobile toan authorized Arctic Cat Snowmo-bile dealer for service. If not underwarranty, this service is at the dis-cretion and expense of the snow-mobile owner.

4. If the throttle control lever oper-ates properly, rotate the ignitionkey to the RUN position and gothrough normal starting proce-dures.

ITEM FUNCTION CONDITIONEmergency Stop Switch

interrupts igni-tion circuit

ALL

Throttle/Igni-tion Monitor

Switch


ALL

Ignition Switch


ALL

Brake slows the ACT drive

ALL

Choke (car-bureted models)

floods the engine

1/2 throttle or less

! WARNINGIf any malfunction of the throttlesystem occurs (such as freezing influffy snow) and the monitor switchdoes not shut off the engine, pressdown on the emergency stopswitch IMMEDIATELY to stop theengine. DO NOT start the engineuntil the malfunction in the throttlesystem has been located and cor-rected.

! WARNINGIf the throttle control lever does notwork properly, DO NOT ATTEMPTTO START THE ENGINE.


NOTE: On fan-cooled models ifthe throttle control lever operatesproperly and the engine does notstart, either a malfunctioning mon-itor switch or a misadjusted mag-netic carburetor switch may be theproblem. Take the snowmobile toan authorized Arctic Cat Snowmo-bile dealer for service. If not underwarranty, this service is at the dis-cretion and expense of the snow-mobile owner. However, if a direemergency exists wherein theengine must be started, discon-nect the carburetor safety switchconnectors. If disconnection of thecarburetor safety switch connec-tors is needed to start the engine,take the snowmobile to an autho-rized Arctic Cat Snowmobile dealerfor service as soon as possible. Ifnot under warranty, this service isat the discretion and expense ofthe snowmobile owner.

NOTE: To access the switch con-nectors, open the left-side accesspanel and remove the belt guard;then locate the switch on the left-side of the carburetor and tracethe wire to the connector.

0743-448

NOTE: On liquid-cooled modelsif the throttle control lever oper-ates properly and the engine doesnot start, a malfunctioning monitorswitch may be the problem. Takethe snowmobile to an authorizedArctic Cat Snowmobile dealer forservice. If not under warranty, thisservice is at the discretion andexpense of the snowmobile owner.However, if a dire emergencyexists wherein the engine must bestarted, disconnect the throttlemonitor switch located in the right-side handlebar control.

NOTE: On liquid-cooled modelsif disconnection of the throttlemonitor switch is needed to startthe engine, take the snowmobile toan authorized Arctic Cat Snowmo-bile dealer for service as soon aspossible. If not under warranty,this service is at the discretion andexpense of the snowmobile owner.

NOTE: The monitor switch isnow bypassed. With exception ofthe monitor switch and the emer-gency stop switch, all other igni-tion/electrical features (ignitionswitch, headlight, taillight, andbrakelight) will operate properly.

! WARNINGUnder no circumstances shoulddisconnection of the throttle con-trol wiring harness be used as asubstitute for the monitor switchduring normal operation of thesnowmobile. Personal injury anddamage could occur if the throttlesystem malfunctions or if the oper-ator is unable to stop the engine inan emergency. If the snowmobilemust be operated with a discon-nected throttle control wiring har-ness, EXTREME CAUTION MUSTBE TAKEN. NEVER EXCEED 10MPH WITH THE THROTTLE CON-TROL WIRING HARNESS DISCON-NECTED.


VARYING ALTITUDE OPERATION

Operating a snowmobile at varyingaltitudes requires changes in perfor-mance components. These changesaffect drive train components (on allmodels) and carburetion components(on carbureted models).

The altitude information decal islocated beneath the hood of the snow-mobile. On carbureted models, theinformation is incorporated into theCarburetor Main Jet Chart decal.

NOTE: Just as important as cali-brating the snowmobile for higheraltitudes is recalibrating the snow-mobile when going to lower alti-tudes. Always consult the altitudedecal beneath the hood of thesnowmobile.

M-Series models are initially set up atthe factory for operation between6000-9000 feet.

NOTE: Carburetion and drivetrain changes can be made by thesnowmobile owner if qualified todo so. If the owner does not feelqualified, take the snowmobile toan authorized Arctic Cat Snowmo-bile dealer for this service. Thisservice is at the discretion andexpense of the snowmobile owner.

! CAUTIONOn carbureted models, carefullyfollow the Main Jet Chart recom-mendations for proper main jetselection for altitude, temperature,and gasoline being used.


LUBRICATIONACT DRIVE GEAR CASE (Each Season Prior to Storage)

NOTE: Flushing the gear caseand replacing the lubricant can bedone by the snowmobile owner ifqualified to do so. If the ownerdoes not feel qualified, take thesnowmobile to an authorized Arc-tic Cat dealer for this service. Thisservice is at the discretion andexpense of the snowmobile owner.

It is very important that the gear casebe flushed and the lubricant bereplaced after each season of use. Arc-tic Cat recommends that the flushingand replacing be done prior to off-sea-son storage.

To flush the gear case and replace thelubricant, use the following procedure:

NOTE: Gear case profiles willvary from model to model. Deter-mine which style is being servicedand refer to the appropriate illus-tration.

1. Open the left-side access panel;then remove the panel and the beltguard.

2. Remove the drive belt (see DriveBelt sub-section); then remove thedriven pulley.

NOTE: If excessive oil depositsare noticed, take the snowmobileto an authorized Arctic Cat Snow-mobile dealer for service. If notunder warranty, this service is atthe discretion and expense of thesnowmobile owner.

3. Tip the snowmobile onto its rightside and place a piece of cardboardunderneath to protect the finish onthe hood and belly pan.

NOTE: It is recommended thatthe gas tank be nearly empty (lessthan 1/4 full) when tipping thesnowmobile.

4. Remove the drain plug from thegear case; then install a drainadapter fitting with hose into thedrain plug hole.

0743-456

741-636A

NOTE: To aid in draining thelubricant, it is advisable to fashiona drain adapter by acquiring a fit-ting - Gear Case Drain Fitting (p/n0644-508) - and a length of 3/8-in.hose.

5. Tip the snowmobile back to theupright position; then place a drainpan on the floor next to the drainhose and tip the snowmobiletoward its left side far enough toallow the lubricant to drain fromthe gear case into the drain pan.

NOTE: It is critical that the snow-mobile is on a level surface toensure the lubricant drains prop-erly and completely.

LUBRICATION 35

6. Secure the snowmobile in thisposition until the lubricant is com-pletely drained.

7. When the lubricant has completelydrained form the gear case, tip thesnowmobile back to the uprightposition, remove the drain adapter,and install and securely tighten thedrain plug; then remove the check/fill plug.

8. Pour the recommended amount ofArctic Cat ACT Drive Flush Fluid(p/n 4639-333) into the check/fillhole; then install the plug. Tightensecurely.

9. Install the driven pulley; theninstall the drive belt (see DriveBelt sub-section) and the beltguard.

10. Install the left-side access panel;then close the access panel.

11. Position the tips of the skis againsta wall; then using a shielded safetystand, raise the rear of the snow-mobile off the floor making surethe track is free to rotate.

12. Start the engine and accelerateslightly. Use only enough throttleto turn the track several revolu-tions. SHUT ENGINE OFF.

13. Open the left-side access panel;then remove the panel and the beltguard.

14. Remove the drive belt (see DriveBelt sub-section); then remove thedriven pulley.

15. Tip the snowmobile onto its rightside and place a piece of cardboardunderneath.

16. Remove the drain plug from thegear case; then install the drainadapter fitting with hose into thedrain plug hole.

17. Tip the snowmobile back to theupright position; then place a drainpan on the floor next to the drainhose and tip the snowmobiletoward its left side far enough toallow the flush fluid to drain fromthe gear case into the drain pan.

18. Secure the snowmobile in thisposition until the flush fluid iscompletely drained.

! CAUTIONIt is critical that all of the old lubri-cant be drained from the gear caseprior to flushing the gear case.

! CAUTIONDo Not add more or less than therecommended amount of flushfluid to the gear case.

! WARNINGThe tips of the skis must be posi-tioned against a wall or similarobject.


! CAUTIONIt is critical that all of the flush fluidbe drained from the gear case priorto filling with new lubricant.

36 LUBRICATION

19. When the fluid has completelydrained from the gear case, tip thesnowmobile back to the uprightposition, remove the drain adapter,and install and securely tighten thedrain plug; then remove the check/fill plug.

20. Pour the exact amount (see specifi-cation sheet) of Arctic Cat Syn-thetic ACT Gear Case Fluid intothe check/fill hole; then install theplug. Tighten securely.

21. Install the driven pulley; theninstall the drive belt (see DriveBelt sub-section) and the beltguard.

22. Install the left-side access panel;then close the access panel.

FRONT SUSPENSION

NOTE: Arctic Cat recommendsthat Arctic Cat Low-Temp Grease(p/n 4639-365) be used for this pro-cedure.

It is very important that the front sus-pension is greased on a monthly basisusing low-temperature grease. Thefront suspension should also be greasedafter trailering the snowmobile on anopen trailer. Pump grease into the spin-dle grease fitting (both sides) untilgrease is noted coming out of the topand bottom of the spindle. Wipe excessgrease from the spindle.

Crossfire/M-Series Models

0737-294

Bearcat/F-Series/Z1/T-Series/TZ1 Models

741-335A

On the Crossfire/M-Series models,pump grease into the upper steeringshaft grease fitting (located on eachside of the snowmobile directly belowthe inner cap screw securing the upperA-arm to the chassis) until grease isnoted coming out of the bottom of theshaft. Wipe excess grease from theshaft.

! CAUTIONThe correct lubricant to use in thegear case is Arctic Cat SyntheticACT Gear Case Fluid (p/n 4639-628).Any substitute may cause seriousdamage to the drive system.

! CAUTIONDo not add more or less than therecommended amount of lubricantto the gear case or damage to thegear case will occur. Oil levelshould be at the Oil Fill Level onthe gear case cover.

LUBRICATION 37

Crossfire/M-Series Models

0743-219

On the Bearcat/F-Series/Z1/T-Series/TZ1 models, turn the handlebar to theright; then from the right side, pumpgrease into the steering arms untilgrease is noted coming out of eitherend of the arms. Wipe excess greasefrom the arms.

Bearcat/F-Series/Z1/T-Series/TZ1 Models

0741-440

REAR SUSPENSION (Every 40 Operating Hours)

NOTE: Arctic Cat recommendsthat Arctic Cat Low-Temp Grease(p/n 4639-365) be used for this pro-cedure.

NOTE: Illustrated are the generallocations of grease fittings. Actuallocations will vary from model tomodel.

1. Shut engine off and wait for allmoving parts to stop.

2. With the gas tank nearly empty(less than 1/4 full), lay the snow-mobile on its left side. A piece ofcardboard should be used to pro-tect the finish on the hood andbelly pan.

3. Remove ice and snow buildupfrom the skid frame to expose thegrease fittings.

0741-376

4. Lubricate the grease fittings withlow-temperature grease.

38 LUBRICATION

MAINTENANCEPERIODIC MAINTENANCE CHECKLIST

ITEM INTERVAL PAGE REMARKSBrake System (Hydraulic) Daily 53 Check for binding, leakage, and proper opera-

tion; lever firmness, travel, caliper, disc, and padsCooling System - Liquid Daily 18,44 Check for leakage, damage, obstructions, cool-

ant levelOil System Daily 42-44 Check for leakage, damage, and injection/engine

oil levelEngine Oil (1100 cc STD) 2500 miles/

Seasonal42 Change oil and filter

Engine Oil (1100 cc Turbo) 2000 miles/seasonal

42 Change oil and filter

Battery Daily 17,50 Check for proper charge and tight connectionsStop Switch Daily — Check for proper operationHoses Daily — Check for damage, leakage, and routingHeadlight & Taillight/Brakelight Daily 65-69 Check for proper operation and cleanlinessSteering System Daily — Check for proper operation, tightness of bolts,

and bindingThrottle Control System Daily 32 Check for binding, sticking, proper operation,

throttle cable tension, and routingDrive Belt Daily

Monthly56 Check for wear, cracks, and fraying

Check length and width dimensionsSki Wear Bars Daily 70 Check for wear and damageCarburetors - Main Jets - Adjustment Screws

Daily Weekly

4845-47

Install proper main jetsAdjust according to specifications

Electrical Wiring Weekly — Check for wear, damage, tight connections, and routing

Exhaust System Weekly 17 Check for damage, leakage, and obstructionsNuts, Bolts, Fasteners Weekly — Check tightness Recoil Starter Weekly — Check rope for wear, fraying, and proper operationShock Absorbers Weekly 19 Check for fluid leakage and damageSpark Plugs (2-Stroke) Weekly 49 Check center electrode insulator color, carbon,

and gapValve Clearance (1100 cc) 5000 miles/

Seasonal50 Check/adjust

Suspension Weekly 61 Check for damage, loose components, and proper adjustment

Track Tension/Alignment Weekly 58,60 Check/adjust as necessaryWear Strips Weekly 71 Check for wear and damageWires & Cables Weekly — Check for wear, damage, and routingFuel System - Tank, Pump, In-Line Filter, & Vent Hose

Weekly — Check for damage, wear, obstructions, and leak-age

Fuel Filter (1100 cc) 5000 miles/2 years

— Replace

Air Cleaner/Filter (1100 cc Turbo)

Weekly/Seasonal

40 Check/Replace

APV System Monthly 26 Check/adjust as necessaryACT Drive Gear Case Seasonal 35 Change drive fluid prior to storageHeat Exchangers Monthly — Check for wear, leakage, and damageDrive Clutch/Driven Pulley Monthly 18 Check for damage, abnormal noise, vibration,

binding, and sticking and clean off drive belt deposits

Front & Rear Suspension Monthly 37,38 Grease

MAINTENANCE 39

The longevity and safety of the snow-mobile can be increased by makingperiodic checks of the items in the pre-ceding checklist.

If, at any time, abnormal noises, vibra-tions, or improper working conditionsof any component of this snowmobileare detected, DO NOT OPERATETHE SNOWMOBILE. Take the snow-mobile to an authorized Arctic CatSnowmobile dealer for inspection andadjustment or repair. If not under war-ranty, this service is at the discretionand expense of the snowmobile owner.

The snowmobile should be taken to anauthorized Arctic Cat Snowmobiledealer at the end of each snowmobilingseason for general inspection and foroff-season storage servicing. Thisinspection and servicing is at theexpense of the snowmobile owner.

AIR CLEANER/FILTER(1100 cc Turbo)

The air filter inside the air cleanerhousing must be kept clean to providegood engine power and gas mileage. Ifthe snowmobile is used under normalconditions, inspect the filter weeklyand replace the filter at the intervalsspecified. If operated in adverse condi-tions, inspect and service the filtermore frequently. Use the followingprocedure to remove the filter and toinspect and/or clean/replace it.

1. Remove the air cleaner cover; thenremove the air filter.

2. Clean the foam filter with warmsoapy water; then allow it to drythoroughly.

3. Clean any debris from inside theair intake plenum.

4. Place the filter into the plenum.

5. Secure the air cleaner cover ontothe plenum.

FUEL SYSTEM

! CAUTIONFailure to inspect the air filter fre-quently if the snowmobile is usedin adverse conditions can damagethe turbocharger/engine.

! CAUTIONDo not use compressed air to drythe filter. Damage to the filter mayoccur.

! CAUTIONA torn air filter can cause damageto the turbocharger/engine. Con-taminants may get inside the turbo-charger/engine if the filter is torn.Carefully examine the filter forholes or tears before and aftercleaning it. Replace the filter with anew one if it is torn.

! CAUTIONDo not run the engine without theair filter installed. Severe damage tothe turbocharger/engine will occur.

! WARNINGWhenever any maintenance orinspection is made on the fuel sys-tem in which there may be fuelleakage, there should be no weld-ing, smoking, open flames, etc., inthe area.

40 MAINTENANCE

In-Line Fuel Filter (Carbureted Models)

Arctic Cat recommends that the in-linefuel filter be checked weekly. The in-line fuel filter is located just in front ofthe fuel pump inlet fitting. The filtermust be clean to allow the fuel hose totransmit the amount of gasolinerequired.

If the in-line fuel filter is obstructed,gasoline flow will be restricted; there-fore, the filter must be replaced. Toremove and install the in-line fuel fil-ter, use the following procedure:

1. Pinch off the fuel hose between thegas tank and fuel filter.

2. Remove the clamps; then pry thefuel hoses off the in-line fuel filterand remove the filter.

NOTE: The in-line fuel filter mustbe replaced if obstructed. Filtersare available from an authorizedArctic Cat Snowmobile dealer.

3. Install the in-line fuel filter in thefuel hose so the arrow on the filterpoints toward the fuel pump. Makesure the fuel hoses fit tightly onthe filter. If the existing fuel hosedoes not fit tightly on the filter, cut6 mm (1/4 in.) from the end of thefuel hose; then install on the filterand secure with the clamps.

728-272B

In-Line Fuel Filter (1100 cc Models)

Arctic Cat recommends that the in-linefuel filter be checked weekly andreplaced every 5000 miles. The in-linefuel filter is located just inside the left-side access panel. The filter must beclean to allow the fuel hose to transmitthe amount of gasoline required.

If the in-line fuel filter is obstructed,gasoline flow will be restricted; there-fore, the filter must be replaced. Toremove and install the in-line fuel fil-ter, use the following procedure:

NOTE: Before removing the fuelfilter, take note of the filter inletand outlet for installing purposes.

1. Open the left-side access panel;then remove the fuel filter fromthe bracket.

! WARNINGThe fuel hoses must fit tightly onthe fuel filter. If the fuel hose lengthdoesn’t permit this procedure,replace the fuel hose. Also, afterinstalling the fuel hoses on the fil-ter, check to be sure that the fuelhoses do not contact any hot orrotating components.

! WARNINGSince the fuel supply hose may beunder pressure, always wearsafety glasses when removing thefuel hoses.

! CAUTIONSince the fuel supply hose may beunder pressure, remove it slowlyto release the pressure. Place anabsorbent towel around the con-nection to absorb the fuel.

MAINTENANCE 41

2. Remove the hose clamps and dis-card; then slowly remove the fuelhoses from the fuel filter. Disposeof the excess fuel from the filterproperly.

3. Inspect the fuel hoses thoroughlyfor any signs of cracking, cuts, orwear points.

4. Place the new hose clamps on thefuel hoses; then with the fuelpump inlet and outlet noted, con-nect the fuel hoses to the fuel filter.Secure with the hose clamps.

5. Secure the fuel filter to the fuel fil-ter bracket; then start the engineand inspect the fuel hoses and fil-ter for any signs of leaks.

Gasoline Additives

Fuel de-icer can be used for all models.Also, periodic use of an injectorcleaner for EFI models is recom-mended especially in the last tank ofgasoline before storage. Arctic CatFuel Stabilizer (p/n 0436-907) shouldalso be added to the last tank of gaso-line before storage.

Fuel Pickup Valves

All 2-Stroke EFI models are equippedwith fuel pickup valves in the gas tank.If ever there is a restricted fuel flowand a pickup valve is suspected, takethe snowmobile to an authorized ArcticCat Snowmobile dealer for this service.If not under warranty, this service is atthe discretion and expense of the snow-mobile owner.

CHECKINGENGINE OIL LEVEL(1100 cc Models)

1. Park the snowmobile on a levelsurface; then start the engine andallow it to warm up for 5-10 min-utes, or if the snowmobile wasoperated, allow the engine to idlefor approximately 30 seconds.

NOTE: The snowmobile must beon a level surface for this proce-dure.

2. Shut the engine off; then removethe oil level stick from the oil res-ervoir. Wipe the stick clean.

ZJ002A

3. Insert the oil level stick into the oilreservoir without threading it inand remove. Read the oil levelshown on the stick. The oil levelshould be near the middle of or onthe high end of the NORMALrange on the stick.

0741-490

NOTE: To attain an accurate oillevel reading, do not thread thestick into the reservoir.

4. If step 1 was followed and the oillevel is at or below the ADD mark,add up to 1/2 qt of recommendedengine oil.

NOTE: Care must be taken not toover-fill the reservoir with oil.

5. Repeat steps 3-4 until the oil levelis within the recommended rangeon the oil level stick.

42 MAINTENANCE

CHANGING ENGINE OIL/FILTER (1100 cc Models)

NOTE: Recycle or properly dis-pose of the used engine oil.

1. Using a putty knife, remove thebelly pan plug.

2. Park the snowmobile on a levelsurface; then start the engine andallow it to warm up for 5-10 min-utes, or if the snowmobile wasoperated, allow the engine to idlefor approximately 30 seconds.

3. Shut the engine off; then placedrain pans beneath both engine oildrain plugs (crankcase and oil res-ervoir).

ZJ003A

4. Remove the drain plugs and allowthe oil to drain completely.

NOTE: At this point, remove thestrainer from the oil reservoir toallow the oil to drain completely.

5. After the oil has drained com-pletely, install the oil strainer,drain plugs, and washers andtighten to 15 ft-lb.

NOTE: Always install a new OilPan Drain Plug Gasket (p/n 3402-011) and a new Reservoir DrainPlug O-Ring (p/n 1670-926) whenchanging the oil.

6. Install a new belly pan plug.

7. Using Oil Filter Wrench (p/n0644-389), loosen (but do notremove) the oil filter and allow theoil to drain from the filter; thenremove the filter.

8. Apply a light coat of fresh engineoil to the seal of the new oil filter.

9. Install the new oil filter by turningthe oil filter by hand until the sealhas contacted the oil filter mount-ing surface; then tighten the oil fil-ter to 15 ft-lb.

10. Pour 2.9 l (3 U.S. qt) of the recom-mended engine oil into the oil res-ervoir.


ZJ004A


12. Without starting the engine, placethe handlebar emergency stopswitch to the RUN position andthe ignition switch to the ON posi-tion. The Oil Pressure WarningIcon should illuminate.

! WARNINGCare must be taken if a hot drainplug is removed by hand. Burningcould occur.

MAINTENANCE 43

NOTE: If the warning icon doesnot illuminate, take the snowmo-bile to an authorized Arctic CatSnowmobile dealer for service. Ifnot under warranty, this service isat the discretion and expense ofthe snowmobile owner.

13. If the warning icon illuminates(from step 12), start the engine.The warning icon should go outwithin five seconds. If it does, pro-ceed to step 14.

NOTE: If the warning icon doesnot go out, shut the engine offimmediately and repeat step 11;then place the ignition switch to theON position and repeat step 13. Ifthe warning icon does not go out,take the snowmobile to an autho-rized Arctic Cat Snowmobile dealerfor service. If not under warranty,this service is at the discretion andexpense of the snowmobile owner.

14. Shut the engine off and pour theremaining amount (0.9 l or 1 U.S.qt) of recommended oil into the oilreservoir; then proceed to theChecking Engine Oil Level (1100cc Models) sub-section to verifyand finalize the procedure.

COOLANT LEVEL

NOTE: Use a good quality, ethyl-ene glycol-based, automotive-typeantifreeze.

500/600/800/1000 cc

NOTE: Always check the coolantlevel with the engine cold.

Locate the appropriate FULL mark onthe coolant reservoir. If coolant isbelow the FULL mark, add antifreezeto the FULL mark.

On the F-Series/T-Series if addingcoolant, the console must be removed.For Removing/Installing the console,use the following procedure.

1. Remove the two torx-head screwssecuring the console to the chassis;then lift up the rearward end of theconsole and disconnect the consoleharness plug-in.

0743-428

2. Remove the console.

3. Place the console into position onthe headlight support bracket; thenconnect the console harness con-nector.

4. Secure the console to the chassiswith the two torx-head screws.

1100 cc

NOTE: Always check the coolantlevel with the engine cold.

NOTE: The hood must beremoved for this procedure.

Locate the FULL COLD mark on thecoolant reservoir (located in the for-ward engine compartment below thehood hinge bracket).

If the coolant is below the FULLCOLD mark, add antifreeze to theFULL COLD mark.

! CAUTIONAfter operating the snowmobile forthe initial 5-10 minutes, stop theengine, allow the engine to cooldown, and check the coolant level.Add coolant as necessary.

44 MAINTENANCE

ADJUSTING CARBURETORS

The carburetors have been calibrated atthe factory for average riding condi-tions; however, altitude, temperature,and general wear may necessitate cer-tain carburetor adjustments. Be surethe correct carburetor main jetsfor the operating temperature, alti-tude, and type of gasoline are beingused (see Selecting CarburetorMain Jets sub-section). Since carbu-retor adjustments critically affectengine performance, Arctic Cat recom-mends that all changes in internal car-buretor calibration and piston valvesynchronization be made by an autho-rized Arctic Cat Snowmobile dealer;however, four external adjustments canbe made on each carburetor.

These are the choke cable travel, pistonvalves, pilot air screws, and idle speedscrews.

NOTE: Carburetor adjustmentsand changing main jets may bedone by the snowmobile owner ifqualified to do so. If the ownerdoes not feel qualified, take thesnowmobile to an authorized Arc-tic Cat Snowmobile dealer for thisservice. This service is at the dis-cretion and expense of the snow-mobile owner.

Adjusting Choke Cable

1. Be sure the ignition switch key isin the OFF position and the brakelever lock is set.

2. Loosen the jam nut securing eachchoke cable adjuster. Rotate eachchoke cable adjuster clockwiseuntil it bottoms against the brassplunger cap.

0727-156

3. Slowly rotate one choke cableadjuster counterclockwise whilechecking the choke lever for free-play. As soon as all free-play hasbeen removed from the end of thelever, stop rotating the adjuster.

4. With free-play removed from thelever, slowly rotate each chokecable adjuster once again clock-wise while checking the chokecable lever for free-play. Adjustuntil 3 mm (1/8 in.) free-playbetween front bottom edge of leverand housing is attained. Securelytighten the adjuster jam nut.

732-848B

! CAUTIONAfter operating the snowmobile forthe initial 5-10 minutes, stop theengine, allow the engine to cooldown, and check the coolant level.Add coolant as necessary.

! CAUTIONMake sure to perform these adjust-ment/synchronization procedureson all carburetors.

MAINTENANCE 45

NOTE: If a carburetor chokecable is adjusted too tight, theengine will only operate on onecylinder at idle.

Synchronizing Piston Valves

1. Remove the air-intake silencerboots from the silencer to accessthe intake bores.

2. Rotate the idle speed screws coun-terclockwise until all spring ten-sion is removed.

0727-156

3. Loosen the jam nut securing eachthrottle cable swivel adapter; thenrotate each swivel adapter clock-wise until each piston valve bot-toms in the piston valve bore.

4. In turn on each carburetor, place afinger lightly against the side ofthe piston valve; then rotate thecarburetor swivel adapter counter-clockwise until slight upwardmovement of the valve is noted.

5. Check to make sure the valvesstart to open at the exact samemoment by placing a thumb andfinger against the valves; thenlightly compress the throttle lever.

NOTE: If an individual pistonvalve starts to open beforeanother, rotate the swivel adapteron the valve which is lifting firstclockwise, just enough to synchro-nize the valves. Recheck by repeat-ing steps 2-5.

6. With the piston valves synchro-nized, tighten the swivel adapterjam nuts securely. Slide the rubberthrottle cable caps down over theswivel adapters.

NOTE: There must be free-playin the throttle lever on all models.

7. In turn on each carburetor, place afinger against the piston valve.Rotate the idle speed screw clock-wise until it contacts the valve.

8. Compress the throttle lever to thefull-open position; then rotate eachidle speed screw clockwise 2 com-plete turns. Release the throttle lever.

NOTE: There must be 0.75-1.5mm (0.030-0.060 in.) free-playbetween the throttle lever and thecontrol housing.

9. At this point, there must be 0.75-1.5 mm (0.030-0.060 in.) of cablefree-play gap in the throttle lever.If there is no cable free-play in thethrottle lever, the throttle safetyswitches will not function prop-erly, and the engine will cut out inthe idle position.

0741-518

! WARNINGBe sure to tighten the swiveladapter jam nuts securely. If aswivel adapter jam nut is not tight-ened, the adjuster can rotate out ofthe carburetor cap causing the pis-ton valve not to return to the full-closed position.

46 MAINTENANCE

NOTE: If cable free-play gap isnot correct, rotate each swiveladapter an equal amount until rec-ommended free-play is achieved.Each piston valve must be restingagainst the tip of its idle speedscrew.

NOTE: If throttle cable free-playis incorrect, the carburetor safetyswitches will be activated prema-turely and the engine will not start.

Fine-Tuning Pilot Air Screws and Idle Speed Screws

1. While counting the rotations, care-fully rotate the pilot air screwsclockwise until lightly seated.

2. Rotate the pilot air screws counter-clockwise the exact number ofrotations ± 1/4 turn from the seatedposition as an initial setting.

3. Install the air-intake silencer bootstaking care that the boots are prop-erly positioned and that the bootsare not “folded” in the air-intakesilencer causing a restriction of airflow.

4. With the snowmobile on ashielded safety stand, start theengine, release the brake leverlock, and thoroughly warm up.

NOTE: Make engine idle adjust-ment only after the engine hasreached running temperature.Since the idle speed screws havenot been fine-tuned, slight throttlepressure may be necessary tokeep the engine running. Allowengine to warm up for 2-3 minutes.

5. After the engine has been thor-oughly warmed up, fine-tune thepilot air screws (equally) and theidle speed screws (equally) untilthe engine runs smoothly.

NOTE: Engine idle RPM shouldbe approximately 1500.

6. Test the throttle control lever bycompressing and releasing it sev-eral times. The lever must return tothe idle position quickly and com-pletely.

! CAUTIONDo not force a pilot air screw whenrotating it clockwise; damage tothe pilot air screw needle tip willresult.


! WARNINGIf a tachometer is not available,care must be taken not to adjustengine idle speed too high.

! CAUTIONIt is important that the pilot airscrews are adjusted equally andthat the idle speed screws areadjusted equally.

! WARNINGDO NOT operate the snowmobilewhen any component in the throt-tle system is damaged, frayed,kinked, worn, or improperlyadjusted. If the snowmobile isoperated when the throttle systemis not functioning properly, per-sonal injury could result.

MAINTENANCE 47

SELECTING CARBURETOR MAIN JETS

Altitude, temperature, and the use ofoxygenated gasoline affect the carbure-tion needed for optimum engine perfor-mance. The carburetor main jets mustbe changed in conjunction with changesin operating altitude, oxygenated gaso-line usage, and temperature. As theambient temperature rises or as thesnowmobile is operated at a higher alti-tude, the main jets must be replacedwith leaner main jets. The originalequipment (production) main jets mayneed to be changed (depending on thetype of gasoline you are using, youroperating altitude, and temperature). AMain Jet Chart decal is located beneaththe hood of the snowmobile. It shouldbe noted that when selecting the propermain jets, it is better to be too rich ratherthan too lean. To change carburetormain jets, use the following procedure:

NOTE: Carburetor main jets maybe changed by the snowmobileowner if qualified to do so. If theowner does not feel qualified, takethe snowmobile to an authorizedArctic Cat Snowmobile dealer forthis service. This service is at thediscretion and expense of thesnowmobile owner.

1. Loosen each carburetor flangeclamp and remove each carburetorfrom the intake flange and boot.

2. Remove each drain plug and O-ring from the carburetor floatchamber and drain the gas into asmall container or shop towels.

3. Using the main jet wrench (fromthe tool kit), thread the main jetout of each carburetor. Account forthe baffle ring/washer. Install thenew main jet and the existing baf-fle ring/washer. Tighten the mainjet securely.

0728-054

4. Install each drain plug and O-ring;then tighten securely.

5. Install and secure the carburetors.

SPARK PLUGS(1100 cc Models)

NOTE: If spark plugs must bereplaced, take the snowmobile toan authorized Arctic Cat Snowmo-bile dealer for inspection and ser-vice. This service is at thediscretion and expense of thesnowmobile owner.

! CAUTIONUse only GENUINE Mikuni brassmain jets. Also, if using an oxygen-ated gasoline (up to 10% ethanolor up to 15% MTBE), the carburetormain jet must be one size largerthan the main jet required for regu-lar unleaded gasoline.

! CAUTIONA main jet which is too small willcause severe engine damage.Engine damage caused by lean jet-ting WILL NOT BE covered by Arc-tic Cat warranty policy.

! WARNINGWhenever any maintenance is per-formed on the fuel system, thereshould be no welding, smoking,open flames, etc., in the area.

48 MAINTENANCE

SPARK PLUGS(2-Stroke Models)

NOTE: Always use the recom-mended spark plugs in the engine.See the appropriate specificationschart for correct spark plug gap.

Varying terrain conditions and operat-ing usage may require spark plugs of adifferent heat range. For example, sus-tained cross-country riding will usuallyrequire colder heat-range spark plugswhile trail riding or other continualslow speed operation will usuallyrequire hotter heat-range spark plugs.

Removing/Installing Spark Plugs (Crossfire/M-Series Models)

1. Remove the springs securing theexpansion chamber to the exhaustmanifold and resonator; then movethe expansion chamber out of theway to access the spark plugs.

2. Remove the spark plug caps fromthe plugs.

3. Using a spark plug wrench,remove the plugs.

4. Install the plugs and finger-tighten.

5. Tighten the spark plugs to 19 ft-lb;then install the spark plug caps.

6. Place the expansion chamber intoposition and secure to the exhaustmanifold and resonator with thesprings.

Removing/Installing Spark Plugs (Bearcat 570/570 XT - F-Series/T-Series Models)

1. Remove the two torx-head screwssecuring the console to the head-light support bracket.

0743-428

2. Lift the rearward end of the con-sole and disconnect the main/hoodharness connector; then removethe console.

3. Remove the spark plug caps fromthe plugs.

4. Using a spark plug wrench,remove the plugs.

5. Install the plugs and finger-tighten.

6. Tighten the spark plugs to 19 ft-lb;then install the spark plug caps.

7. Place the console into position onthe headlight support bracketkeeping the rearward end slightlyelevated; then connect the main/hood harness connector.

8. Lower the rearward end of theconsole into position; then installthe two torx-head screws. Tightensecurely.

Checking Spark Plugs (2-Stroke Models)

To see if the spark plugs being used areof the proper heat range (after thesnowmobile has been operated undernormal driving conditions), remove thespark plugs and examine the conditionof the center electrode insulator of eachspark plug.

MAINTENANCE 49

AO352A

A. TAN or LIGHT BROWN insu-lator indicates correct sparkplugs (heat range).

B. LIGHT GRAY or WHITEinsulator indicates over-heatingof the engine. This condition iscaused by a too lean conditionor incorrect spark plugs (heatrange too hot).

C. BLACK insulator indicatesfuel in the combustion chamberis not burning completely. Thiscondition is caused by a toorich condition, too much oil, orincorrect spark plugs (heatrange too cold).

NOTE: If the center electrodeinsulators are light gray, white, orblack and if the carburetor adjust-ments (on carbureted models), oil-injection pump synchronization,and ignition timing are correct, dif-ferent heat-range spark plugs maybe necessary. Authorized Arctic CatSnowmobile dealers have detailedspark plug information. Consult adealer before changing spark plugs,as incorrect heat-range spark plugscould cause poor engine perfor-mance or engine damage.

CHECKING/ADJUSTING VALVE CLEARANCE(1100 cc Models)

After 5000 miles or prior to seasonalstorage, valve clearance should bechecked and adjusted as necessary.

NOTE: Take the snowmobile toan authorized Arctic Cat Snowmo-bile dealer for inspection and ser-vice. This service is at thediscretion and expense of thesnowmobile owner.

BATTERY (Electric Start Models)

These standard and sealed batteriesafter being in service require regularcleaning and recharging in order todeliver peak performance and maxi-mum service life. The following proce-dures are recommended for cleaningand maintaining standard and sealedbatteries. Always read and followinstructions provided with battery char-gers and battery products.

! CAUTIONIf a spark plug is light gray, white,or black and another is tan or lightbrown, take the snowmobile to anauthorized Arctic Cat Snowmobiledealer for inspection and service. Ifnot under warranty, this service isat the discretion and expense ofthe snowmobile owner.

! CAUTIONIt is critical that the checking/adjusting valve clearance be doneat the recommended intervals orsevere engine damage may occur.

50 MAINTENANCE

NOTE: Battery maintenance maybe done by the snowmobile ownerif qualified to do so. If the ownerdoes not feel qualified, take thesnowmobile to an authorized Arc-tic Cat Snowmobile dealer for thisservice. This service is at the dis-cretion and expense of the snow-mobile owner.

To remove and charge the battery, usethe following procedure:

1. Remove the negative batterycable; then remove the positivecable and on the standard battery,the battery vent tube. Remove thebattery from the snowmobile. Careshould be taken not to damage thevent tube.

2. Thoroughly wash the battery withsoap and water.

NOTE: If battery posts or cableends have a build-up of white/green powder residue, apply waterand baking soda to neutralize acid;then flush off with warm soapywater.

3. Using a wire brush, clean the bat-tery posts and cable ends removingall corrosive buildup. Replacedamaged cables or cable ends.

4. On a standard battery, add cleandistilled water to bring fluid levelto the UPPER level line.

5. Using a multimeter, test the batteryvoltage. The meter must read noless than 12.5 DC Volts for a fullycharged battery.

NOTE: At this point if the meterreads as specified, the battery maybe returned to service (see step 9).

6. If the meter reads less than speci-fied voltage, charge the batteryusing the following guidelines.

A. When using an automatic bat-tery charger, always follow thecharger manufacturer’s instruc-tions.

! WARNINGAny time service is performed on abattery, the following must beobserved: Keep sparks, openflame, cigarettes, or any otherflame away. Always wear safetyglasses. Protect skin and clothingwhen handling batteries. Whenservicing battery in enclosedspace, keep the area well-venti-lated. Make sure battery venting isnot obstructed.

! WARNINGBattery posts, terminals, andrelated accessories contain leadand lead compounds, chemicalsknown to the state of California tocause cancer and reproductiveharm. Wash hands after handling.

! WARNINGAvoid spillage and contact withskin, eyes, and clothing.

! CAUTIONDo not charge the battery while itis in the snowmobile with the bat-tery terminals connected.

! CAUTIONDo not remove seal strip on asealed battery.

! WARNINGBattery acid is harmful if it con-tacts eyes, skin, or clothing. Caremust be taken whenever handlinga battery.

! CAUTIONNever use electrolyte (sulfuricacid) to “top off” the battery. Useonly distilled water or severe bat-tery damage may occur.

MAINTENANCE 51

B. When using a constant-currentbattery charger, use the follow-ing Battery Charging Chart.

NOTE: If the battery voltage is11.5 DC Volts or less, some char-gers may “cut off” and fail tocharge. If this occurs, connect afully charged booster battery inparallel (positive to positive andnegative to negative) for a shortperiod of time with the chargerconnected. After 10-15 minutes,disconnect the booster batteryleaving the charger connected andthe charger should continue tocharge. If the charger “cuts off,”replace the battery.

7. After charging the battery for thespecified time, remove the batterycharger and allow the battery to sitfor 1-2 hours.

8. Connect the multimeter and testthe battery voltage. The metershould read no less than 12.5 DCVolts. If the voltage is as specified,the battery is ready for service.

NOTE: If voltage in step 8 isbelow specifications, charge thebattery an additional 1-5 hours;then retest. Recheck electrolytelevel (standard battery) and thebattery is ready for service.

9. Place the battery into position inthe snowmobile; then coat the bat-tery posts and cable ends with alight coat of multi-purpose grease.

10. Connect the battery cables (posi-tive cable first).

FUSES(Electric Start Models)

Fuses protect the snowmobile electricalsystem from overloading. If electricalparts in the snowmobile are not work-ing, the system may have been over-loaded and caused a blown fuse.Before repairing or replacing any elec-trical part, check the appropriate fuses.If a fuse blows (opens a circuit), all theparts of the snowmobile that use thatcircuit will not work.

! CAUTIONNever exceed the standard charg-ing rate.

! WARNINGAn overheated battery couldexplode causing severe injury ordeath. Always monitor chargingtimes and charge rates carefully.Stop charging if the batterybecomes very warm to the touch.Allow it to cool before resumingcharging.

Battery Charging Chart (Constant-Current Charger)

Battery Voltage

(DC)

ChargeState

Charge Time Required(at 1.5-2.0

Amps)

12.5(minimum)

100% None

12.2-12.4 75%-99% 3-6 hours

12.0-12.2 50%-74% 5-11 hours

11.0-11.9 25%-49% 13 hours (minimum)

11.5 or less 0-24% 20 hours (minimum)

! CAUTIONBefore installing the battery, makesure the ignition switch is in theOFF position.

! CAUTIONConnecting cables in reverse (pos-itive to negative and negative topositive) can cause serious dam-age to the electrical system.

52 MAINTENANCE

Once which fuse to check has beendetermined, perform the followingsteps:

1. Open the right-side access panel;then on 4-stroke models, removethe fuse panel cover (the fusepanel is located behind the bat-tery). On 2-stroke models, discon-nect the fuse connector harness.

ZJ005A

ZJ306A

NOTE: On 4-stroke models, thereare spare fuses inside the fusepanel.

2. Remove the suspected fuse.

3. Look through the clear side of thefuse to see if the metal wire insideis separated. If it is, the fuse isblown and should be replaced witha fuse of the correct amperage rat-ing.

4. Install the fuse panel cover.

Even after replacing a fuse, it may con-tinue to blow if the cause of the over-load is not determined. If the fusecontinues to blow, take the snowmobileto an authorized Arctic Cat Snowmo-bile dealer for service. If not underwarranty, this service is at the discre-tion and expense of the snowmobileowner.

HYDRAULIC BRAKE SYSTEM

Arctic Cat recommends that the brakesystem (brake lever, fluid reservoir,hose, caliper, pads, and brake disc) bechecked daily for fluid leakage, wear,or damage and for proper operation.Also, the brake fluid level must bechecked every time before starting theengine. The brake fluid must be visiblein the sight glass.

Checking/Adding Brake Fluid

1. With sight glass reservoir in alevel position, check the fluidlevel. The brake fluid level mustbe visible in the sight glass.

NOTE: If the sight glass appearsdark, there is a sufficient amountof fluid in the reservoir.

! WARNINGAlways replace a fuse with onehaving the same specified amper-age rating. Using a fuse with ahigher rating can cause severewire damage and could start a fire.

! WARNINGDO NOT operate the snowmobilewhen the brake lever lock isengaged or when any componentin the brake system is damaged,worn, or adjusted improperly. If thesnowmobile is operated and thebrake system is not functioningproperly, severe personal injurycould result.

MAINTENANCE 53

741-328A

2. If the brake fluid is not visible inthe sight glass, remove the reser-voir cover and add Arctic Catapproved brake fluid until the fluidis at the recommended level.Install and secure the reservoircover. Do not allow moisture tocontaminate the brake system.

Changing Brake Fluid

The brake fluid must be changed on aregular basis and whenever the brakefluid has been overheated or contami-nated. The brake fluid should bechanged every 1000 miles or at the endof the snowmobiling season, which-ever occurs first. Take the snowmobileto an authorized Arctic Cat Snowmo-bile dealer for this service. This serviceis at the discretion and expense of thesnowmobile owner.

Checking Brake Lever Travel

Before each use, check the brake levertravel using the following procedure:

1. Compress the brake lever fully.

NOTE: Do not pump the brakelever as it will produce an inaccu-rate reading.

2. Measure the distance between thebrake lever and the handlebar. Thedistance must be greater than 2.54cm (1 in.).

741-328B

3. If the resultant distance is less thanspecified, take the snowmobile toan authorized Arctic Cat Snowmo-bile dealer for service. If not underwarranty, this service is at the dis-cretion and expense of the snow-mobile owner.

Bleeding Brake System

If the brake lever feels spongy whenapplied, the brake system may need tobe bled. To bleed the brake, use the fol-lowing procedure:

! CAUTIONBrake fluid is highly corrosive. Donot spill brake fluid on any surfaceof the snowmobile.

! WARNINGDo not overfill the brake fluid res-ervoir. Overfilling the reservoirmay cause the brake system tohydraulically lock. Use only ArcticCat approved brake fluid. Neversubstitute or mix different types orgrades of brake fluid. Brake losscan result. Brake loss can result insevere injury or even death. ! WARNING

Do not operate the snowmobile ifthe compressed distance betweenthe brake lever and the handlebaris less than 2.54 cm (1 in.). Brakeloss may occur. Brake loss canresult in severe personal injury.

54 MAINTENANCE

NOTE: The brake system may bebled by the snowmobile owner ifqualified to do so. If the ownerdoes not feel qualified, take thesnowmobile to an authorized Arc-tic Cat Snowmobile dealer for thisservice. This service is at the dis-cretion and expense of the snow-mobile owner.

1. Remove the reservoir cover andfill the reservoir with Arctic Catapproved brake fluid.

2. Slide a piece of flexible tubingover the ball of the bleeder valveand direct the other end into a con-tainer.

739-269B

3. Slowly compress the brake leverand hold. Open the bleeder valveto release the fluid and air. Whenthe fluid stops, close the bleedervalve; then release the brake lever.

4. Repeat step 3 until the brake fluidflows free of air bubbles.

NOTE: It may be necessary torefill the reservoir during thebleeding process.

5. When the brake fluid is free of allair and the brake lever feels firmwhen compressed, fill the reser-voir; then install and secure thecover. Remove the tube from thebleeder valve.

Checking/Changing Brake Pads

The condition of the brake pads mustbe checked daily and changed if wornor damaged. To check and change thebrake pads, use the following proce-dure:

NOTE: The brake pads may bechanged by the snowmobile ownerif qualified to do so. If the ownerdoes not feel qualified, take thesnowmobile to an authorized Arc-tic Cat Snowmobile dealer for thisservice. This service is at the dis-cretion and expense of the snow-mobile owner.

NOTE: When installing newbrake pads, always install them asa set. Never install just one pad oruse brake pads which have beenused in another snowmobile.

1. Measure the thickness of bothbrake pads. The brake pad thick-ness must be greater than 5.0 mm(0.20 in.). If the brake pad thick-ness is less than specified, replace-ment of both pads is necessary.

0739-269

2. Remove the pin/hairpin clip secur-ing the brake pads to the caliperassembly.

! CAUTIONBrake fluid is highly corrosive. Donot spill brake fluid on any surfaceof the snowmobile.

! WARNINGUse only Arctic Cat approvedbrake fluid. Any substitute mayresult in a loss of brakes.

MAINTENANCE 55

3. Remove the brake fluid reservoircover; then remove most of thebrake fluid from the reservoir.Install the cover.

NOTE: The above procedure willallow room for the fluid from thecaliper when the pistons arepushed into the caliper for install-ing new brake pads. Replacing thecover will prevent fluid spillage.

4. Using a pair of pliers, pull onebrake pad out of the caliper assem-bly.

NOTE: Changing one pad at atime will prevent one piston frompushing out the other piston fromthe caliper.

5. Using a flat-blade tool, slowly andcarefully push the piston into thecaliper.

6. Position the new brake pads intothe caliper.

7. Repeat steps 4-6 for the other pad;then secure the pads with the pin/hairpin clip.

8. Remove the reservoir cover andremove the remaining fluid; thenfill the reservoir with fresh fluidand install the cover.

9. Pump the brake lever to ensurecorrect positioning of the brakepads; then release.

10. Remove the reservoir cover andfill the reservoir to the proper levelwith fresh brake fluid; then installthe cover.

NOTE: When new brake pads areinstalled, a “burnishing” processis required. Drive the snowmobileslowly and compress the brakelever several times until the padsjust start to warm up; then allowthem to cool down. This procedurestabilizes the pad material andextends the life of the pads.

DRIVE BELT

The drive belt transfers power from thedrive clutch to the driven pulley. If thebelt is worn, cracked, or stretched,maximum power will not be transmit-ted and the belt could also fail andtherefore must be replaced. Periodicchecks (at least once a month undernormal usage) of two drive belt specifi-cations are essential.

1. Measure the outside circumferenceof the drive belt. The belt shouldbe within the recommended rangein circumference.

2. Measure the outside width of thedrive belt. The belt should be withinthe recommended range in width.

3. Check the belt for cracking, fray-ing, etc.

If any of the specifications or condi-tions are unsatisfactory, replace thedrive belt.

NOTE: Drive belts should be pur-chased from an authorized ArcticCat Snowmobile dealer, as ArcticCat drive belts are made to exactspecifications and of quality mate-rial. Belts made by other manufac-turers may not be of the samespecifications or quality and,therefore, usage could result inpoor performance and prematurebelt failure.

Before starting the snowmobile inextremely cold temperatures, the drivebelt should be removed and warmed upto room temperature. Once the drivebelt is at room temperature, install thedrive belt.

! CAUTIONNever run the engine with the drivebelt removed. Excessive revving ofthe engine could result in seriousengine damage and drive clutchfailure.

56 MAINTENANCE

Also, drive belts have a break-in periodof approximately 20 miles. Afterinstalling a new drive belt, drive thesnowmobile for 20 miles at 1/2 throttleor less. This will allow the drive belt togain its optimum flexibility and willextend drive belt life.

Checking/Adjusting Drive Belt Deflection

0743-319

The drive belt must have the proper fitin the drive clutch and driven pulley.To check for proper drive belt fit, usethe following procedure.

1. Place a straightedge on the top ofthe drive belt. The straightedgeshould reach from the drive clutchto the top of the driven pulley.

NOTE: Make sure the drive beltis all the way out in the driven pul-ley before checking drive belt fit.

2. Using a stiff ruler centeredbetween the drive clutch anddriven pulley, push down on thedrive belt just enough to removeall slack and note the amount ofdeflection. The deflection shouldbe within the range of 28.5-31.8mm (1 1/8-1 1/4 in.).

3. To correct drive belt deflection,remove the sheave adjuster fromthe pulley, remove or add shimwashers to the adjuster, and installthe adjuster.

NOTE: Adding shim washers willdecrease belt deflection and remov-ing shim washers will increase beltdeflection. Available shim washersfrom Arctic Cat are p/n 0648-714(0.090 in.) - one included in the toolkit, p/n 0648-715 (0.030 in.), and p/n0648-716 (0.060 in.).

NOTE: Removing/adding shimwashers may be done by the snow-mobile owner if qualified to do so.If the owner does not feel qualified,take the snowmobile to an autho-rized Arctic Cat Snowmobile dealerfor this service. This service is atthe discretion and expense of thesnowmobile owner.

Removing Drive Belt

NOTE: Changing a drive belt canbe done by the snowmobile ownerif qualified to do so. If the ownerdoes not feel qualified, take thesnowmobile to an authorized Arc-tic Cat Snowmobile dealer for thisservice. This service is at the dis-cretion and expense of the snow-mobile owner.

1. Turn ignition key to the OFF posi-tion and wait for all moving partsto stop.

2. Set the brake lever lock.

3. Open the left-side access panel;then remove the belt guard.

4. Remove the cap screw, lockwasher, washer, and sheaveadjuster from the end of the drivenpulley.

NOTE: Assure that the shimsand O-ring are not removed fromthe adjuster.

MAINTENANCE 57

0743-395

5. Remove the cap screw (w/lockwasher and washer) from theadjuster, turn the adjuster around(reverse it), and insert the capscrew (w/lock washer and washer)into the adjuster.

0743-396

6. Install the sheave adjuster and capscrew (w/lock washer and washer)onto the driven pulley; thentighten the cap screw until themovable sheave opens far enoughto allow the belt to be removed.

NOTE: Before installing the drivebelt, use a suitable cleaning sol-vent to thoroughly clean thesheaves.

7. Remove the drive belt from thedriven pulley first; then from thedrive clutch.

Installing Drive Belt

1. Place the drive belt (so the partnumber can be read) between thesheaves of the drive clutch first;then between the sheaves of thedriven pulley.

2. Remove the sheave adjuster andinstall it in its original position(beveled side out); then install thecap screw, lock washer, washer,and sheave adjuster back into thedriven pulley. Tighten the capscrew to 32 ft-lb.

3. Install the belt guard; then close theleft-side access panel.

4. Release the brake lever lock.

TRACK TENSION

Track tension is directly related to theoverall performance of the snowmobile.If the track is too loose, it may slapagainst the tunnel causing wear or itmay “ratchet” on the track drive sprock-ets. If extremely loose, the idler wheelsmay climb over the track lugs forcingthe track against the tunnel causing thetrack to “lock.” Arctic Cat recommendsthat the track tension be checked dailyduring the first 300 miles of operationand once a week thereafter and adjustedaccording to need. The track will stretchand take a “set” during break-in. Trackdeflection must be maintained withinthe recommended range.

! CAUTIONDo not apply Loctite to the drivenpulley cap screw or componentdamage may occur.

! WARNINGNever operate the snowmobilewithout the belt guard/accesspanel secured in place.

! WARNINGTrack tension must be properlymaintained. Personal injury couldresult if a track is allowed tobecome excessively loose.

58 MAINTENANCE

Checking Track Tension

1. Remove excess ice and snowbuildup from the track, track drivesprockets, and the inside of theskid frame.

2. Place the snowmobile up on ashielded safety stand. Check tomake sure the track is 5-8 cm (2-3in.) off the floor.

3. At mid-point of the track (on thebottom side), hook a spring scalearound a track clip; then pull downon the scale to the recommendedpressure. Measure the deflection(distance) between the bottom ofthe wear strip and the inside sur-face of the track clip. Compare themeasurement with the chart.

0743-188

0743-191

NOTE: On the M-Series, mea-surement is from the bottom of thewear strip at the point of the shockpad on the slide rail.

Adjusting Track Tension

1. Loosen the rear idler wheel adjust-ing bolt jam nuts.

739-636B

NOTE: To ensure proper tracktension adjustment, perform alladjustments on both sides of thesnowmobile.

2. If the deflection (distance betweenthe bottom of the wear strip andthe inside of the track) exceedsspecifications, tighten the adjust-ing bolts to take up excessive slackin the track.

! WARNINGDO NOT attempt to check or adjusttrack tension with engine running.Turn ignition key to the OFF posi-tion. Personal injury could resultfrom contact with a rotating track.

Model Setup Tension

After Break-In Tension

Bearcat 570/T-Series/TZ1 Models @ 20 lb

44-51 mm (1 3/4-2 in.)

51-57 mm(2-2 1/4 in.)

Bearcat XT Models @ 20 lb

38-44 mm(1 1/2-1 3/4in.)

38-44(1 1/2-1 3/4 in.)

F-Series Models @ 20 lb

44-51 mm(1 3/4-2 in.)

51-57 mm(2-2 1/4 in.)

Z1 Models @ 20 lb

44-51 mm(1 3/4-2 in.)

51-57 mm(2-2 1/4 in.)

Crossfire Models @ 20 lb

44-51 mm(1 3/4-2 in.)

51-57 mm(2-2 1/4 in.)

M-Series Models @ 10 lb

51-64 mm(2-2 1/2 in.)

51-64 mm(2-2 1/2 in.)

MAINTENANCE 59

3. If the distance between the bottomof the wear strip and the inside sur-face of the track is less than speci-fied, loosen the adjusting bolts toincrease the slack in the track.

4. Check track alignment (see TrackAlignment sub-section).

5. When proper track tension isobtained, tighten the adjusting boltjam nuts against the axle housings.

NOTE: Since track tension andtrack alignment are interrelated,always check both even if only oneadjustment seems necessary.

TRACK ALIGNMENT

Proper track alignment is obtainedwhen the rear idler wheels are equaldistance from the inner track drivelugs. Excessive wear to the idlerwheels, drive lugs, and track will occurif the track is improperly aligned. Arc-tic Cat recommends that the trackalignment be checked once a week orwhenever the track tension is adjusted.

Checking Track Alignment

1. Remove excess ice and snowbuildup from the track, track drivesprockets, and the inside of theskid frame.

2. Position the tips of the skis againsta wall; then using a shielded safetystand, raise the rear of the snow-mobile off the floor making surethe track is free to rotate.

3. Start the engine and accelerateslightly. Use only enough throttleto turn the track several revolu-tions. SHUT ENGINE OFF.

NOTE: Allow the track to coast toa stop. DO NOT apply the brakebecause it could produce an inac-curate alignment condition.

4. When the track stops rotating,check the relationship of the rearidler wheels and the inner trackdrive lugs. If the rear idler wheelsare centered between the innertrack drive lugs, no adjustment isnecessary.

! WARNINGIf jam nuts are not tightened prop-erly, the adjusting bolts couldloosen causing the track tobecome extremely loose and,under some operating conditions,allow the idler wheels to climb overthe track lugs forcing the trackagainst the tunnel causing thetrack to “lock.” If a track “locks”during operation, severe personalinjury could result.

! WARNINGMake sure the ignition key is in theOFF position and the track is notrotating before checking or adjust-ing track alignment. Personalinjury could result if contact ismade with a rotating track.

! WARNINGThe tips of the skis must be posi-tioned against a wall or similarobject.


60 MAINTENANCE

0727-729

0739-637

5. If the idler wheels are not centeredbetween the inner track drive lugs,an adjustment is necessary.

Adjusting Track Alignment

1. On the side of the track which hasthe inner track drive lugs closer tothe rear idler wheel, loosen theadjusting bolt jam nut; then rotatethe adjusting bolt clockwise 1 to 11/2 turns.

739-636B

2. Check track alignment and con-tinue adjustment until properalignment is obtained.

NOTE: Make sure correct tracktension is maintained after adjust-ing track alignment (see Track Ten-sion sub-section).

3. After proper track alignment isobtained, tighten the adjusting boltjam nut against the axle housing.

4. Field test the track under actualconditions.

5. After the field test, check thealignment of the track. If addi-tional adjustment is necessary,repeat Adjusting Track Alignmentprocedure.

SUSPENSION

The suspension should be adjusted forthe operational needs and riding prefer-ence of the operator.

The front shock springs determine theamount of ski pressure and the reactionof the front suspension to rough terrain.The amount of ski pressure can also bechanged by adjusting the length of theskid frame front arm limiter straps.

The rear springs influence the load car-rying capability of the snowmobile andshould be adjusted for the weight andriding preference of the operator.

Adjusting Front Shock Springs (STD)

NOTE: On some models, the frontshock springs are not adjustable.

! WARNINGIf a jam nut is not tightened prop-erly, the adjusting bolt couldloosen causing the track tobecome dangerously loose.

MAINTENANCE 61

The front shock springs are individu-ally adjustable for the terrain condi-tions and driving style of the operator.The spring adjuster has been set at thefactory so the correct amount ofthreads are exposed between the springadjuster and the shock housing as aninitial setting. Additional ski pressurecan be obtained by tightening thespring tension; ski pressure can bedecreased by relaxing spring tension.

NOTE: Equal adjustmentsshould be maintained on bothsides of the snowmobile.

To adjust spring tension, rotate theentire spring in whichever direction isdesired. If after adjusting spring ten-sion you note the snowmobile front endwants to pitch, relax the spring tensionon the side that is pitching. If bothsides are pitching, relax the spring ten-sion on both sides.

NOTE: The spring adjuster willnormally rotate with the spring.

734-501B

734-500B

Adjusting Shocks (Fox Air Shocks)

NOTE: It is recommended tomonitor the air pressure in the airshocks once every month.

NOTE: Adjusting air shocks maybe done by the snowmobile ownerif qualified to do so. If the ownerdoes not feel qualified, take thesnowmobile to an authorized Arc-tic Cat Snowmobile dealer for thisservice. This service is at the dis-cretion and expense of the snow-mobile owner.

The air shocks are individually adjust-able for the terrain conditions and driv-ing style of the operator. The shocksare preset at the factory (see chart) asan initial setting; however, it is possibleto “fine tune” the shocks to match theoperator’s weight, riding style, and ter-rain conditions.

Checking and adjusting air pressuremust be done at riding temperature(outside). Also, it is advisable to checkair pressure when the outside tempera-ture varies more than 25°.

NOTE: Care should be taken tohave equal pressure in the front(ski) shocks before operating thesnowmobile.

To increase or decrease air pressure,use the following procedure.

Initial Setting Chart

ModelFront Shock (Ski)

Rear Arm Shock

Crossfire Sno Pro

4.6 kg/cm2

(65 psi)9.5-10.2 kg/cm2

(135-145 psi)

F-Series Sno Pro/Z1 Sno Pro

3.9 kg/cm2

(55 psi) N/A

M-Series 4.2 kg/cm2

(60 psi)9.5-10.2 kg/cm2 (135-145 psi)

62 MAINTENANCE

NOTE: When adjusting air pres-sure, all weight must be removedfrom the suspension, and theshock absorbers must be fullyextended.

NOTE: Adding air pressure willincrease the air spring force;reducing air pressure willdecrease air spring force.

1. Remove the air valve cap from theshock.

2. Thread the valve of ShockAbsorber Air Pump (p/n 2603-614) onto the shock air valveapproximately six rotations.

NOTE: As the pump is beingattached to the shock, the hosewill fill with air. This will result in alower gauge pressure 0.14-3.52 kg/cm2 (2-5 psi).

3. To decrease air pressure in theshock, press the black bleed valvebutton half way down and holduntil desired pressure is attained.

NOTE: Pressing the button fullydown and releasing it will allowonly a small amount of air toescape (micro-adjust).

4. To increase air pressure in theshock, pump until desired pressureis attained.

5. Remove the pump valve from theshock air valve.

NOTE: As the pump valve isbeing removed from the shock, thesound of air loss is from the pumphose, not from the shock.

6. Install the air valve cap onto theshock.

Skid Frame Front Arm

NOTE: On some models, thefront arm limiter straps are notadjustable.

The skid frame front arm shock springand limiter straps are adjustable. How-ever, Arctic Cat recommends that theshock spring be maintained at the fac-tory preset of 1/8-1/4 in. preload.Tightening the skid frame front armshock spring may cause improper bal-ance and may ruin the handling fea-tures of the snowmobile.

The length adjustment of the front armlimiter straps determines the weightdistribution between the front of theskid frame and the skis. Tightening thelimiter strap (shortening the strap) willpull up on the front of the skid frameand will increase ski pressure. Loosen-ing the limiter strap (lengthening thestrap) lowers the front of the skid frameand decreases ski pressure.

When customizing the amount of skipressure, be sure to adjust both strapsequally and do not over-adjust the lim-iter straps to adversely affect steeringand operator control of the snowmobile.Some experimentation may be requireduntil the proper adjustment for the oper-ator’s individual style is obtained.

NOTE: If the limiter straps areadjusted, it is highly recom-mended that at least a minimum of1/8 in. preload on the shock springbe maintained.

! WARNINGDo not exceed 10.5 kg/cm2 (150psi) in the shock.

! WARNINGDo not adjust the front arm limiterstraps to a point at which steeringand operator control of the snow-mobile are adversely affected.

MAINTENANCE 63

Adjusting Rear Spring Pre-Load

Proper adjustment of rear spring pre-load is necessary to get the most com-fortable ride. The chart is designed tohelp in setting up rear spring pre-load;however, riding style is the singlegreatest factor in determining rearspring requirements.

NOTE: These cam position set-tings are suggestions only. Per-sonal riding style will greatlyinfluence cam position settings.Spend time to determine settingpreferences.

Rear spring pre-load adjustment isaccomplished by rotating the adjustingcams. Position 3 provides the stiffestride, and position 1 is for the lightdriver or slow-speed trail riding. Posi-tion 2 is for the average operator undernormal conditions. Always rotate thecam from the lighter position to theheavier position.

741-450A

To rotate an adjusting cam, use thespark plug wrench from the tool kit.Rotate the wrench until the cam is inthe desired position. To stiffen the ride,rotate the cam so as to raise the springend. Make the appropriate adjustmenton the other cam.

Articulating Skid Frame (Bearcat XT Models)

The rear articulating portion of the skidframe has two adjusters which controlthe amount of travel in the rear suspen-sion.

These two adjusters have been pre-setat the factory and should require nofurther adjustment.

If adjustment is ever required, rotatethe two adjusters equally to permit12.5-25 mm (1/2-1 in.) travel of thearticulating portion of the suspension.

0743-323

Overload Springs

Some models have overload springsbuilt into the rear suspension. Wheneither carrying a heavy load or riding2-up, the overload springs should beengaged by rotating the spring tensionblocks to the UP position. The springtension blocks lock in an over-centerposition when engaged.

NOTE: Arctic Cat recommendsthat the overload springs beengaged whenever a load on thesnowmobile (operator/passenger/cargo) exceeds 136 kg (300 lb).

Rider Weight (lb) Cam Position

Up to 180 1

180-240 2

Over 240 3

! CAUTIONNever force the adjustment camsfrom the low position to the highposition. Cam damage may occur.

64 MAINTENANCE

To either engage or disengage thespring tension blocks, use the SpringBlock Tool, a spark plug socket, and ascrewdriver to adjust the spring blockto the desired position. Make sure bothspring blocks are in the same position(either engaged or disengaged).

0739-625

LIGHTS

For the correct headlight bulb and/ortaillight/brakelight bulb/LED, see theappropriate specifications sheet.

Removing and Installing Taillight/Brakelight (Bearcat XT Models)

These models are equipped with anLED taillight/brakelight. If the LEDfails, it must be replaced. To removeand install the LED, use the followingprocedure.

1. Remove the four pins securing therear seat to the seat/Speedrackmount; then remove the seat.

0743-329

2. Compress the latch on the rightside of the front seat and lift thefront seat away; then disconnectthe taillight harness connector.

0743-444

3. Loosen (but do not remove) thethree right-side seat/Speedrackmount cap screws.

4. Carefully route the harness con-nector through the hole in the stor-age compartment panel; thenremove the harness from beneaththe seat/Speedrack mount.

! CAUTIONThere are weight limitations forthese snowmobiles. If additionalcargo is being added, maximumweight on the snowmobile (opera-tor/passenger/cargo) should notexceed the maximum limitation setfor each snowmobile. See chart fordetails. Also, the overload springsshould be engaged.

Maximum Weight Limitations

Bearcat 570 170 kg 375 lb

Bearcat 570 XT 272 kg 600 lb

Bearcat Z1 XT 272 kg 600 lb

T-Series 170 kg 375 lb

MAINTENANCE 65

5. Remove the two self-tappingscrews securing the taillight to thebumper; then route the harness outof the bumper and remove the tail-light.

6. Route the taillight harness throughthe bumper; then secure the tail-light to the bumper with the twoself-tapping screws.

7. Carefully route the harnessbeneath the Speedrack mount andthrough the hole in the storagecompartment panel; then connectthe harness connector.

8. Tighten the three right-side mountcap screws; then lower the frontseat.

9. Place the rear seat into position onthe mount making sure the fourpin holes are properly aligned withthe mounting location on themount.

10. Install the four pins making surethey are properly seated.

Removing and Installing Taillight/Brakelight (Crossfire/M-Series Models)

These models are equipped with anLED taillight/brakelight. If the LEDfails, it must be replaced. To removeand install the LED, use the followingprocedure.

1. Drill out the rivets securing thesnowflap to the tunnel end cap.

0743-320

2. Disconnect the taillight harnessconnector.

3. Remove the two self-tappingscrews securing the taillight to thesnowflap.

4. Secure the taillight to the snowflapwith the two self-tapping screws;then connect the taillight connector.

5. Secure the snowflap to the tunnelend cap with rivets.

Removing and Installing Taillight/Brakelight Bulb (Bearcat 570/F-Series/Z1/T-Series/TZ1 Models)

1. On the F-Series/Z1 models frominside the rear storage compart-ment, remove the self-tappingscrews and washers securing thetaillight/brakelight housing.

741-680A

2. On the Bearcat 570/T-Series/TZ1models, remove the torx-head capscrews securing the taillight accesspanel.

! WARNINGMake sure the rear seat is securelylocked in place with the four pinsbefore carrying a passenger orpersonal injury may result.

66 MAINTENANCE

742-467A

3. Disconnect the harness connectorand remove housing.

4. Push in on the socket and rotate itcounterclockwise to remove itfrom the housing.

5. Remove the old bulb by pulling itstraight out of the socket.

6. Install the new bulb in the socketby pushing it straight in.

7. Push the socket into the housingand rotate it clockwise to lock intoplace.

8. Connect the harness connector.

9. On the F-Series/Z1 models, placethe housing into position; thenfrom inside the rear storage com-partment, secure with the self-tap-ping screws and washers.

10. On the Bearcat 570/T-Series/TZ1models, secure the access panelwith the torx-head cap screws.

Removing Headlight Bulb (Crossfire/M-Series Models)

NOTE: The bulb portion of head-light is fragile. HANDLE WITHCARE. When replacing the head-light bulb, the bulb assembly mustfirst be removed from the housing.Do not touch the glass portion ofthe bulb. If the glass is touched, itmust be cleaned with a dry clothbefore installing.

To access the headlight bulbs, use thefollowing procedure:

1. With the hood closed, loosen theheadlight adjustment knobs.

2. Carefully push the headlight lensesrearward far enough to remove thetorx-head screws securing the airsilencer plenum to the hood.

3. Open the hood; then remove theO-rings securing the air silencerplenum to the hood and removethe air silencer plenum to accessthe bulbs.

4. Remove the bulb from the head-light housing and disconnect thewiring harness from the bulb.

0740-462

Installing Headlight Bulb (Crossfire/M-Series Models)

1. Plug the wiring harness into theheadlight bulb.

2. Insert the bulb into the headlighthousing.

3. Press the air silencer plenum intoplace on the hood and secure withthe O-rings; then close the hood.

! CAUTIONDo not touch the glass portion ofthe bulb. If the glass portion istouched, it must be cleaned with adry cloth before installing.

MAINTENANCE 67

4. Carefully push the headlight lensesrearward far enough to install thetorx-head screws. Tighten thescrews securely.

5. Tighten the headlight adjustmentknobs.

6. Check headlight aim (see AdjustingHeadlight Aim in this sub-section).

Removing Headlight Bulb (Bearcat/F-Series/Z1/T-Series/TZ1 Models)

NOTE: The bulb portion of head-light is fragile. HANDLE WITHCARE. When replacing the head-light bulb, the bulb assembly mustfirst be removed from the housing.Do not touch the glass portion ofthe bulb. If the glass is touched, itmust be cleaned with a dry clothbefore installing.

To access the headlight bulbs, use thefollowing procedure:

1. Remove the two torx-head screwslocated to the outside of the head-light adjustment knobs; thenremove the single torx-head screwfrom beneath the console (locatedbetween the headlights).

743-439A

2. Remove the cap screw and locknut securing the front of the head-light assembly to the air-intakesilencer.

3. Lift the front of the consoleenough to allow the headlighthousing to be removed; thenremove the housing.

4. Remove the bulb from the head-light housing and disconnect thewiring harness from the bulb.

741-329A

Installing Headlight Bulb (Bearcat/F-Series/Z1/T-Series/TZ1 Models)

1. Plug the wiring harness into theheadlight bulb.

2. Insert the bulb into the headlighthousing.

3. Lift the front of the consoleenough to allow the headlighthousing to be installed; then installthe housing making sure the forksof the housing go into the grom-mets on top of the air-intakesilencer. Secure with the cap screwand lock nut.

! WARNINGDo not operate the snowmobileunless headlight beam is adjustedproperly. An incorrectly adjustedbeam will not provide the operatorthe optimum amount of light.

! CAUTIONDo not touch the glass portion ofthe bulb. If the glass portion istouched, it must be cleaned with adry cloth before installing.

68 MAINTENANCE

743-439A

4. Position the console onto the air-intake silencer; then secure with thesingle torx-head screw beneath theconsole (located between the head-lights).

5. Install the two torx-head screwslocated to the outside of the head-light adjustment knobs; thentighten securely.

6. Check headlight aim (see Adjust-ing Headlight Aim in this sub-sec-tion).

Adjusting Headlight Aim

The headlight can be adjusted for verti-cal aim of the HIGH/LOW beam. Thegeometric center of HIGH beam zoneis to be used for vertical aiming.

1. Position the snowmobile on a levelfloor so the headlight is approxi-mately 8 m (25 ft) from an aimingsurface (wall or similar surface).

NOTE: There should be an “aver-age” operating load on the snow-mobile when adjusting headlightaim.

2. Measure the distance from thefloor to midpoint of the headlight.

3. Using the measurement obtainedin step 2, make a horizontal markon the aiming surface.

4. Make a vertical mark which inter-sects the horizontal mark on theaiming surface directly in front ofthe headlight.

5. Engage the brake lever lock andstart the engine. Move the head-light dimmer switch to the HIGHbeam position. DO NOT USELOW BEAM.

6. Observe the headlight beam aim.Proper aim is when the mostintense beam is centered on thevertical mark 5 cm (2 in.) belowthe horizontal mark on the aimingsurface.

0741-448

7. Adjust the headlight using theadjustment knobs until correct aimis obtained. Shut the engine off;then disengage the brake leverlock.

! WARNINGDo not operate the snowmobileunless headlight beam is adjustedproperly. An incorrectly adjustedbeam will not provide the operatorthe optimum amount of light.

MAINTENANCE 69

SKI WEAR BARS

The ski wear bar is a replaceable barattached to the underside of the ski.The purpose of the wear bar is to assistin turning the snowmobile, to minimizeski wear, and to maintain good steeringcontrol. If the snowmobile is operatedprimarily in deep snow, ski wear barwear will be minimal; however, if thesnowmobile is operated on terrainwhere the snow cover is minimal, theski wear bar will wear faster. To main-tain positive steering characteristics,Arctic Cat recommends that the skiwear bars be checked before each useand replaced if worn beyond 1/2 of theoriginal diameter. Ski wear bars areavailable from an authorized Arctic CatSnowmobile dealer.

Removing Ski Wear Bars

NOTE: Determine which type ofwear bar is being replaced andremove and install accordingly.

1. Remove ice and snow buildupfrom the ski.

2. Using a suitable safety stand orlift, elevate the front of the snow-mobile.

3. Remove the lock nuts securing thewear bar to the ski.

0743-185

4. Remove the wear bar from the ski.

Installing Ski Wear Bars

1. Move the wear bar into position onthe bottom of the ski.

NOTE: If installing a double-off-set wear bar, the carbide edgemust be directed to the outside ofthe ski.

2. Align the wear bar studs with theholes in the ski; then install thelock nuts. Tighten to 11-15 ft-lb.

ADJUSTING SKI STANCE (M-Series/Crossfire/Bearcat 570/570 XT/Bearcat Z1 XT Models)

NOTE: Ski stance can beincreased/decreased by 6.3 cm(2.5 in.) on Bearcat models or by2.5 cm (1.0 in.) on M-Series/Cross-fire models.

1. Place the front of the snowmobileon a support stand.

2. Remove the cotter pin; thenremove the slotted nut and capscrew securing the ski assembly tothe spindle. Remove the ski.Account for the rubber damper,inserts, and washers.

3. To increase ski stance, place bothski stance spacers to the outside ofthe spindle.

! WARNINGOperating the snowmobile withexcessively worn ski wear barsmay result in a loss of steeringcontrol.

70 MAINTENANCE

4. To decrease ski stance, place bothski stance spacers to the inside ofthe spindle.

5. Apply a low-temperature grease tothe non-threaded portion of the capscrew; then slide the cap screwthrough the ski accounting for therubber damper, inserts, and wash-ers.

NOTE: Install the cap screw sothe slotted nut will be located tothe inside of the ski.

6. Apply red Loctite #271 to thethreads of the cap screw; thentighten the nut to 45 ft-lb.

7. Place the cotter pin into the ski capscrew and spread the pin.

8. Repeat procedure for the other ski.

RAIL WEAR STRIPS

Arctic Cat recommends that the wearstrips be checked weekly and replacedas necessary. Measure the wear strips at25.4 cm (10 in.) intervals. Wear stripsmust be 10.7 mm (0.42 in.) thick orthicker.

If wear strip measurements are lessthan specified, replacement of bothwear strips is necessary to prevent pre-mature track clip wear and possibletrack damage. Take the snowmobile toan authorized Arctic Cat Snowmobiledealer for this service. This service is atthe discretion and expense of the snow-mobile owner.

Each time a new set of wear strips areinstalled, they should be tempered.Temper the wear strips by driving thesnowmobile for approximately a mileon a hard pack trail; then immediatelydrive into deep snow and allow thewear strips to cool. Repeat the proce-dure (warming up the wear strips; thencooling them down) two or three times.

NOTE: The rail wear strips willwear rapidly if the snowmobile isoperated on terrain on which thesnow cover is minimal. Loosesnow is required to cool and lubri-cate the wear strips and preventaccelerated wear.

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MAINTENANCE 71

PERFORMANCE TIPSOperating a high performance snow-mobile requires a special attention thatis not required by a low performancesnowmobile. Often, a minor adjust-ment will result in a large increase inperformance. This section is intendedto highlight minor conditions thatadversely affect performance and theadjustments needed to correct them. Besure, however, to thoroughly read andunderstand this entire manual espe-cially the section on spark plugs, tracktension and alignment, and suspension.

DRIVE BELT — This link between theengine and drive train is often the mostneglected component. The drive beltmust have the proper fit in the driveclutch and driven pulley. Proper fit iswhen the top surface of the drive belt isflush with the top or up to 1/16 in.higher than the driven pulley sheaves(with the sheaves fully closed). If thebelt sits below this level, the snowmo-bile will bog at slow speeds and willhave a slower maximum speed. To cor-rect this condition, first determine if thedrive belt is within specifications (seeDrive Belt sub-section) and replace ifworn or too long. Secondly, it may benecessary to remove a shim washer frombetween the driven pulley sheaves toallow the driven pulley to close tighter.Adding shim washers will decrease beltdeflection and removing shim washerswill increase belt deflection. Availableshim washers from Arctic Cat are p/n0648-714 (0.090 in.) - one included inthe tool kit, p/n 0648-715 (0.030 in.),and p/n 0648-716 (0.060 in.).

NOTE: Removing/adding shimwashers may be done by the snow-mobile owner if qualified to do so.If the owner does not feel qualified,take the snowmobile to an autho-rized Arctic Cat Snowmobile dealerfor this service. This service is atthe discretion and expense of thesnowmobile owner.

Finally, always run the drive belt in thesame direction. Installing the drive beltso the part number can be read willensure that the drive belt is always runthe same direction.

DRIVE CLUTCH AND DRIVENPULLEY — Keeping the drive clutchand driven pulley clean should be theprimary consideration of the operator.The clutch sheaves can be cleaned ofany drive belt accumulation using aclean cloth and parts-cleaning solvent.All pivot points can be maintainedclean using compressed air.

CARBURETOR MAIN JETS (Car-bureted Models) — Proper carburetionis absolutely necessary to obtain peakperformance. Since ambient tempera-ture and operating altitude both affectthe main jet size needed for optimumengine performance, the main jetsMUST be changed whenever the tem-perature changes 20° F or wheneveroperating altitude varies by more than1000 feet. The Main Jet Chart beneaththe hood of the snowmobile identifiesthe proper main jets to use under alloperating temperatures and altitudes.Follow the Main Jet Chart carefully toobtain peak engine performance andavoid engine damage.

GASOLINE (EFI Models) — On the2-stroke EFI engine models for opti-mum performance, do not exceed therecommended 87 octane gasoline.Using a higher octane gasoline will notincrease overall performance; however,the Z1 Turbo models will detect loweroctane gasoline and reduced engineperformance will result. It is recom-mended that 91 octane (minimum) gas-oline be used in these models.

72 PERFORMANCE TIPS

PREPARATION FOR STORAGEPrior to storing the snowmobile, itmust be properly serviced to preventcorrosion and component deterioration.An authorized Arctic Cat Snowmobiledealer should perform this service;however, the owner/ operator can per-form this service if desired. This ser-vice is at the discretion and expense ofthe snowmobile owner. To prepare thesnowmobile for storage, Arctic Catrecommends the following procedure:

1. Clean the seat cushion with adamp cloth and a Vinyl Protectant.

2. Clean the snowmobile thoroughlyby hosing dirt, oil, grass, and otherforeign matter from the skidframe, tunnel, hood, and belly pan.Allow the snowmobile to dry thor-oughly. DO NOT get water intoany part of the engine.

NOTE: On 4-stroke models,change the engine oil and cleanthe air filter; then proceed to step6.

3. Place the rear of the snowmobileup on a shielded safety stand.

4. On the 500/600/800/1000 ccengine models, start the engineand allow to idle. With the engineidling, pry the intake boot forward;then spray an Engine Storage Pre-server into the intakes until theengine exhaust starts to smokeheavily or until the engine starts todrop in RPM. Turn engine off.Install the intake boot.

5. On the 570 cc engine models,carefully pry the intake boots par-tially over the carburetor inlets;then start the engine and allow toidle. With the engine idling, sprayan Engine Storage Preserver intothe intakes until the engine exhauststarts to smoke heavily or until theengine starts to drop in RPM. Turnengine off. Install the intake boots.

6. Plug the exhaust system outletwith a clean cloth.

7. With the ignition switch in theOFF position:

A. Disconnect the high tensionleads from the spark plugs;then remove the plugs, connectthem to the leads, and groundthem on the cylinder heads.

B. Pour 29.5 ml (1 fl oz) of SAE#30 petroleum-based oil intoeach spark plug hole and pullthe recoil starter handle slowlyabout 10 times.

C. Install the spark plugs and con-nect the high tension leads.

! CAUTIONDo not run the engine without thebelt guard in place and secured.

! CAUTIONDo not do step 7 on the 4-strokemodels; severe engine damagecould result.

! CAUTIONNever crank the engine over with-out grounding the spark plugs.Damage to coils and/or CDI/ECUunit may result.

PREPARATION FOR STORAGE 73

8. On carbureted models, drain thegas from each carburetor floatchamber.

9. Fill the gas tank to its rated capac-ity; then add Arctic Cat Fuel Stabi-lizer (p/n 0436-907) to the gastank following directions on thecontainer for the stabilizer/gaso-line ratio. Tighten the gas tank capsecurely.

10. Flush the gear case and replace thelubricant (see Lubrication section).

11. Remove the drive belt from thedrive clutch/driven pulley. Lay thebelt on a flat surface or slide it intoa cardboard sleeve to preventwarping or distortion during stor-age.

12. Clean and inspect the drive clutchand driven pulley.

13. Apply light oil to the upper steer-ing post bushing, ski spindles andbolts, front and rear pivot bushingsof the skid frame, and plungers ofthe shock absorbers.

14. Lubricate the rear suspension,spindles, speedometer driveadapter, and driven shaft supportbearing with a low-temperaturegrease.

15. Tighten all nuts, bolts, and capscrews making sure all nuts, bolts,and cap screws are tightenedsecurely. Make sure all rivets hold-ing the components together aretight. Replace all loose rivets.

16. Clean and polish the hood, con-sole, and chassis with Arctic CatHood and Windshield Cleaner/Polish (p/n 4639-559). DO NOTUSE SOLVENTS OR SPRAYCLEANERS. THE PROPEL-LANT WILL DAMAGE THEFINISH.

17. On electric start models, discon-nect the battery cables making sureto disconnect the negative cablefirst; then clean the battery postsand cables. Charge the battery.

18. If possible, store the snowmobileindoors. Raise the track off thefloor by blocking up the back endmaking sure the snowmobile issecure. Loosen the track adjustingbolts to reduce track tension.Cover the snowmobile with amachine cover or a heavy tarpaulinto protect it from dirt and dust.

19. If the snowmobile must be storedoutdoors, position the snowmo-bile out of direct sunlight; thenblock the entire snowmobile offthe ground making sure the snow-mobile is secure. Loosen the trackadjusting bolts to reduce track ten-sion. Cover with a machine coveror a heavy tarpaulin to protect itfrom dirt, dust, and rain.

! CAUTIONSealed batteries require charging ifleft for extended non-start peri-ods. Arctic Cat recommends tricklecharging once a month. Follow themanufacturer’s instructions andcautions.

! CAUTIONAvoid storing in direct sunlight andusing a plastic cover as moisturemay collect on the snowmobilecausing corrosion.

74 PREPARATION FOR STORAGE

PREPARATION AFTER STORAGETaking the snowmobile out of storageand correctly preparing it for anotherseason will assure many miles andhours of trouble-free snowmobiling.Arctic Cat recommends the followingprocedure:

1. Clean the snowmobile thoroughly.Polish the exterior of the snowmo-bile.

2. Clean the engine. Remove thecloth from the exhaust system.Check exhaust system and air-intake silencer for obstructions.

3. Inspect all control wires and cablesfor signs of wear or fraying.Replace if necessary. Use cable tiesor tape to route wires and cablesaway from hot or rotating parts.

4. Inspect the drive belt for cracksand tears. Check belt specifica-tions. Replace if damaged or worn.Install the drive belt.

NOTE: If the old belt is worn butin reasonable condition, retain itwith the snowmobile as a spare incase of emergency.

5. On carbureted models, inspect thein-line fuel filter and replace ifnecessary.

6. Inspect all fuel hoses and oil hosesfor deterioration or cracks; replaceif necessary. Make sure all connec-tions are tight; then on 2-strokemodels, fill the oil-injection reser-voir with the recommended 2-cycle oil (see Gasoline-Oil sub-section).

NOTE: After prolonged storageof 2-stroke models, Arctic Cat rec-ommends one tankful of 100:1 gas/oil mixture be used in conjunctionwith the oil-injection system toensure proper lubrication.

7. On 2-stroke models, inspect thespark plugs. Replace, gap, or cleanas necessary.

8. Verify the condition of and theadjustment of the carburetors andchoke cable on carbureted modelsand throttle cable on all models.

9. Tighten all nuts, bolts, and capscrews making sure all nuts, bolts,and cap screws are tightenedsecurely.

10. Lubricate the rear suspension,spindles, speedometer driveadapter, and driven shaft supportbearing with a low-temperaturegrease.

11. On liquid cooled models, checkthe coolant level and all coolanthoses and connections for deterio-ration or cracks. Add properlymixed coolant as necessary.

12. On air cooled models, clean theengine cooling fins and vents.

! CAUTIONOn carbureted models if the gas ineach carburetor float chamber wasnot drained prior to storage, thecarburetors must be cleanedbefore starting the engine.

! WARNINGBe sure to tighten the swiveladapter jam nuts securely. If a jamnut isn’t tightened, the adjustercan rotate out of the carburetorcap causing the throttle valve notto return to the full-closed posi-tion.

PREPARATION AFTER STORAGE 75

13. On electric start models, chargethe battery until fully charged (seeBattery sub-section in the Mainte-nance section); then connect thebattery cables making sure to con-nect the positive cable first. Testthe electric start system.

14. Inspect the entire brake system, allcontrols, headlight, taillight,brakelight, ski wear bars, andheadlight aim; adjust or replace asnecessary.

15. Adjust the track to the proper ten-sion and alignment. Lock the jamnuts.

76 PREPARATION AFTER STORAGE

NOTES

77

U.S. EPA EMISSION CONTROL STATEMENT/WARRANTY COVERAGE

(U.S. Only)

STATEMENT/WARRANTYArctic Cat warrants to the original retail purchaser, and each subsequent purchaser, that all U.S. EPA-certified Arctic Cat snowmobiles are designed, built, and equipped to conform to all U.S. EPA EmissionControl Regulations. Please read the following information completely.

Your authorized Arctic Cat snowmobile dealer will repair or replace any defective emission-relatedcomponent at no cost to you during the warranty period. You may have non-warranty service performedby any repair establishment that uses equivalent components. The regulations provide significant civilpenalties for tampering that causes your snowmobile to no longer meet U.S. EPA emission standards.

Arctic Cat further warrants that the engine and its emission-related components are free from defects inmaterials or workmanship that could cause the engine to fail to comply with applicable regulationsduring the warranty period.

If you have any questions about this information, or the emission warranty coverage statement, contactyour local authorized Arctic Cat snowmobile dealer.

WARRANTY PERIODThe emission warranty period for this snowmobile begins on the same date as the standard warrantycoverage and continues for 30 months or 2500 miles, whichever comes first.

COMPONENTS COVERED

The emissions warranty covers major emissions control components and emission-related componentslisted as follows:

Engine Management and Sensors Fuel/Air SystemBarometric Pressure Sensor Fuel InjectorsCamshaft Position Sensor Fuel Pressure RegulatorEngine Control Unit (ECU) Fuel PumpEngine Coolant Temperature Sensor Carburetor(s)Intake Air Temperature Sensor Turbocharger AssemblyManifold Absolute Pressure Sensor Air Bypass ValveOxygen Sensor Turbo Waste Gate Control ValveThrottle Position Sensor Crankcase Ventilation System

ISC ValveIgnition System Miscellaneous Items Used Ignition Coil in Aforementioned SystemsKnock Sensor System ConnectorsSpark Plugs SwitchesCapacitive Discharge Ignition (CDI) Module GrommetsMagneto Pick-Up Clamps

HosesTiesGasketsWiring

OWNER'S RESPONSIBILITIESThe owner of any snowmobile warranted under this Arctic Cat Emission Control Statement isresponsible for the proper maintenance and use of the snowmobile as stated in the Operator's Manual.Proper maintenance generally includes replacement and service, at the owner's choosing, such itemsas air filter, oil and oil filter, or any other part, item, or device related to emissions control as specified inthe Operator's Manual. It is the owner's responsibility to ensure that the snowmobile is used in a mannerfor which it was designed.

78

CHANGE OF ADDRESS, OWNERSHIP, OR WARRANTY TRANSFER

Arctic Cat Inc. keeps on file the current name and address of theowner of this snowmobile. This will allow Arctic Cat to reach thecurrent owner with any important safety information which maybe necessary to protect customers from personal injury orproperty damage. Please make sure a copy of this form iscompleted and returned to Arctic Cat Inc. if you move or if thesnowmobile is sold to another party.

This form may also be used to transfer the unused portion of theoriginal warranty to a second party. In order to transfer warranty,fill out this form completely; then return a copy of this form toArctic Cat Inc. Arctic Cat will then process the application andissue warranty for the balance of the time remaining of theoriginal warranty.

❏ Address Change

❏ Ownership Change

❏ Warranty Transfer

CHANGE OF ADDRESS/OWNERSHIP/WARRANTY TRANSFER TO:

Name ________________________________________

Address ______________________________________

City/State (Province)/Zip Code (Postal Code) __________

Phone # ( )____________________________________

Year and Model Snowmobile ______________________

Vehicle Identification Number (VIN) _________________

79

Fold Back Once

CHANGE OF ADDRESS/OWNERSHIP

ARCTIC CAT INC.PRODUCT SERVICE AND

WARRANTY DEPT.P.O. BOX 810

THIEF RIVER FALLS, MN 56701

PlaceStampHere

NOTES

81

NOTES

82

WARRANTY PROCEDURE/OWNER RESPONSIBILITY

At the time of sale, an Owner Registration form is to be completed by the sell-ing dealer and consumer. The receipt of the registration form by Arctic Cat is acondition precedent to warranty coverage. It is the selling dealer’s responsibil-ity to retain and/or submit the appropriate copies of the form to the appropriateplace(s) to initiate warranty coverage.

The dealer will furnish to the consumer a signed copy of the form which mustbe presented to the dealer when requesting warranty service. The registrationform is the consumer’s proof of ownership and warranty eligibility. Theform is used by the dealer to validate the warranty claim. Retain your copyof the form and keep it in a safe place.

When warranty repair is suspected, the snowmobile should be taken to the sell-ing dealer, who has the primary responsibility to perform warranty repairs. Inthe event the selling dealer has ceased to do business, you have moved, or youare in a location away from your selling dealer, warranty may be performed byany authorized Arctic Cat Snowmobile dealer.

The authorized Arctic Cat Snowmobile dealer will examine the snowmobile orpart to determine if, in his opinion, a warrantable condition exists. If a warrant-able condition appears to exist, the dealer will repair or replace, at Arctic Cat’soption, free of charge, including any related labor costs, all parts that are foundto be warrantable and any other parts which the warrantable part caused to bedamaged. You, the consumer, will then be asked to sign a warranty form toensure Arctic Cat that the warranty work was actually performed.

It is the consumer’s responsibility to maintain and service the snowmobile inaccordance with Arctic Cat’s recommendations in the Operator’s Manual. Toprotect yourself and your snowmobile, follow all safety and service tips. ArcticCat will NOT warrant repairs required as a result of not performing stan-dard operator maintenance, storage procedures, and service as outlined inthe Operator’s Manual.

Should you have any questions concerning the warranty, contact an authorizedArctic Cat Snowmobile dealer.

Arctic Cat Inc., P.O. Box 810, Thief River Falls, MN 56701 (218) 681-8558

Printed in U.S.A. Trademarks of Arctic Cat Inc. Thief River Falls, MN 56701 p/n 2258-236Phone: (218) 681-9851 - U.S./(204) 982-1772 - Canada

®TM

ARCTIC CAT®

Documents

Snowmobile Snowmobile Operator’s Operator’s · PDF fileSnowmobile Snowmobile Operator’s Operator’s Manual Manual p/n 2258-236 p/n 2258-236