SnowmobileSnowmobile Operator’sOperator’s Manual · PDF fileLIMITED WARRANTY Arctic Cat Inc. (hereinafter referred to as Arctic Cat) extends a limited warranty on each new Arctic

p/n 2257-929

SnowmobileSnowmobileOperator’sOperator’sManual Manual

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) YEARfrom 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 replacement parts.

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 instructed todo 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........................................4-33

Snowmobile Identification ............................ 4Control Locations......................................... 4Tipped Snowmobile (660 cc Models)........... 7Gasoline-Oil ................................................. 8Engine Break-In (2-Stroke Models) ........... 10Engine Break-In

(660 cc/1100 cc Models)......................... 10Indicator Lights (Carbureted/Bearcat W/T

Non-Turbo/Panther 660 Models) ............. 10Low Oil Warning Light

(Standard 2-Stroke Models) ................... 11Low Oil Pressure Warning Light

(Bearcat W/T Non-Turbo/ Panther 660 Models).............................. 11

Coolant Temperature Warning Light (Bearcat W/T Non-Turbo/Panther 660 Models)............................... 11

Charging System Warning Light (660 cc Models) ..................................... 12

Check Engine Light (Bearcat W/T Non-Turbo/Panther 660 Models) ............ 12

Speedometer/Tachometer IndicatorIcons (Bearcat W/T Turbo/T660 Models) .......................................... 12

Speedometer/Tachometer Indicator Icons (Standard Gauge) ................................... 14

Speedometer/Tachometer Indicator Icons (Permium Gauge) ................................... 16

Diagnostic Codes/ (Standard/Premium Gauges) ................. 19

Diagnostic Codes (Crossfire/F-Series/M-Series/T-Series Models)...................... 19

Diagnostic Codes (Jaguar Z1/TZ1 Models) ......................... 19

Diagnostic Codes/Check Engine Light(660 cc Models) ...................................... 20

Handlebar Tilt ............................................ 20Handlebar Tilt

(F-Series/T-Series - STD Models)........... 21Handlebar Tilt (LXR/Sno Pro/Jaguar Z1/

TZ1 Models)............................................ 21Exhaust System......................................... 22Air-Intake Silencer ..................................... 23Battery (Electric Start Models)................... 23Cooling System (Liquid) ............................ 23Drive Clutch and Driven Pulley .................. 24Drive Clutch/Driven Pulley Alignment ........ 24Drive Chain Tension................................... 24Fuel Pump ................................................. 25Gas Tank Shut-Off Valve (370 cc Model)... 25Shock Absorbers (Standard Gas).............. 25Shock Absorbers (Rebuildable Gas) ......... 25Deep-Lug Track ......................................... 26Standard-Lug Track ................................... 26Track Studs ................................................ 26Reverse Transmission

(Lever Style Models) ............................... 27Reverse Transmission

(Switch Button Style Models) .................. 28Towing........................................................ 29Adjustable Backrest .................................. 29Removable Rear Seat

(Bearcat W/T Models) ............................. 29

Removable Rear Seat (T-Series)................30Removable Seat

(Crossfire/M-Series Models) ....................30Adjustable Seat (TZ1 LXR Model)..............31Removable/Adjustable Seat

(F-Series/Jaguar Z1 Models) ...................31Arctic Power Valve (APV) System ..............32Exhaust Controlled Timing (ECT)

System (600/800/1000 cc Models) ..........33Operating Instructions ..................................34-40

Starting and Stopping Engine....................... 34High RPM Operation (660 cc Models)........37Braking (Hydraulic Brake Models) ..............37Emergency Stopping ..................................38Throttle/Ignition Monitor Switch

(2-Stroke/Jaguar Z1/TZ1 Models)...........38Varying Altitude Operation..........................40

Lubrication....................................................41-45Standard Chain Case .................................41ACT Drive Gear Case.................................41Front Suspension .......................................44Speedometer Drive Adapter .......................44Rear Suspension........................................45

Maintenance.................................................46-87Periodic Maintenance Checklist .................46Fuel System ...............................................47Checking Engine Oil Level

(660 cc Models) ......................................48Checking Engine Oil Level

(1100 cc Models) .....................................48Changing Engine Oil (660 cc Models)........49Changing Engine Oil/Filter

(1100 cc Models) .....................................50Adjusting Carburetor (Single) .....................51Adjusting Carburetors (Twin) ......................53Selecting Carburetor Main Jet(s)................57Spark Plugs (1100 cc Models) ...................58Spark Plugs ................................................58Checking/Adjusting Valve Clearance

(660 cc/1100 cc Models).........................60Battery (Electric Start Models) ...................60Fuses (660 cc Models) ...............................62Fuses (1100 cc Models) .............................64Engine Heater (660 cc Models) ..................64Mechanical Brake System..........................64Hydraulic Brake System .............................66Drive Belt ....................................................69Track Tension..............................................72Track Alignment ..........................................74Suspension.................................................75Lights..........................................................79Ski Wear Bars.............................................84Adjusting Ski Stance(M-Series/

Crossfire/Bearcat 570 Models) ................85Rail Wear Strips..........................................86Axial Fan Belt (370 cc Model).....................86Accessory Belt (660 cc Models) .................87

Performance Tips .............................................. 88Preparation For Storage...............................89-91Preparation After Storage.............................92-93U.S. EPA Emission Control

Statement/Warranty Coverage ..................... 94Change of Address, Ownership,

or Warranty Transfer ..................................... 95Maintenance Record ....................................97-98Warranty 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 untilit is too 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 ACCESSORIES

When in need of replacement parts, oil, or accessories for your Arctic CatSnowmobile, be sure to only use GENUINE ARCTIC CAT PARTS, OIL,AND ACCESSORIES. Only genuine Arctic Cat parts, oil, and accessories areengineered to meet the standards and requirements of your Arctic Cat Snow-mobile. For a complete list of accessories, refer to the current Arctic CatAccessory Catalog. An Illustrated Parts Manual is available through your localArctic Cat Snowmobile dealer.

1

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.

© 2007 Arctic Cat Inc.

Printed in U.S.A.

2

DECLARATION OF CONFORMITYApplication of council directives: EMC Directive 89/336/EEC

EC Machinery Directive 98/37/ECIssued by European Commission.

Type of Equipment: SnowmobileBrand Name: Arctic CatModel Numbers:

Standards to which conformity is declared:EMC: EN 50082-1/ 1992, EN 50081-1

MACHINERY: EN 292-1, EN 292-2, EN 953, EN 1050, EN 954-1Manufacturer (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 conforms to the directive(s) and standard(s) as specified.

Fred Bernier Manager, Product Testing & Certification

S2008ACAAAUSG S2008F6DLXUSB S2008F1LEFUSB S2008CFHSPUSOS2008ACAAAUSP S2008F6DLXUSP S2008F1LEFUSG S2008CFHSPOSOS2008BCDLTUSR S2008F6DLXUSG S2008F1LEFUSO S2008M8HSPUSWS2008BCDLTNAR S2008F6DLXUSO S2008F1LEPUSB S2008M8H3EUSBS2008BCDLTOSR S2008F6DEPUSB S2008F1LEPUSG S2008M8H3EUSOS2008PAFTOSUB S2008F6DEPUSG S2008F1LEPUSO S2008M8HEKUSBS2008PAAFCUSB S2008F6DEPUSO S2008F1LEPOSB S2008M8HEKUSOS2008PAAFCNAB S2008F6DEPOSG S2008F1LLXUSB S2008T5CTOUSBS2008PAAFCOSB S2008F6DEFUSB S2008F1LLXUSG S2008TZNLXUSRS2008BCFWTUSR S2008F6DEFUSG S2008F1LLXUSO S2008TZNTOUSBS2008BCFWTNAR S2008F6DEFUSO S2008Z1NJGUSB S2008TZNTOOSBS2008BCFWTOSR S2008M6D3EUSB S2008Z1NJGUSG S2008T5DTOUSBS2008BCFTWUSR S2008CFD36USB S2008Z1NJGOSG S2008T5DTOOSBS2008BCFTWNAR S2008CFDSPOSB S2008Z1NJGOSB S2008F5DFCUSBS2008BCFTWOSR S2008CFC36USB S2008F8HLXUSB S2008F5DFCUSGS2008BCFAWUSR S2008CFC36OSB S2008F8HLXUSG S2008F5DFCUSOS2008BCFAWNAR S2008CFL36USB S2008F8HLXUSO S2008M8HNFUSBS2008BCFAWOSR S2008M1L3EUSB S2008F8HEPUSB S2008M1LNFUSBS2008F5CEFUSB S2008M1L3EUSO S2008F8HEPUSG S2008CFHNFUSBS2008F5CEFUSG S2008M1LEKUSB S2008F8HEPUSO S2008CFLNFUSBS2008F5CEFUSO S2008M1LEKUSO S2008F8HEPOSO S2008Z1NNFUSBS2008F5CLXUSB S2008CFLSPUSO S2008F8HEFUSB S2008F1LNFUSBS2008F5CLXUSG S2008CFLSPOSO S2008F8HEFUSG S2008F8HNFUSBS2008F5CLXUSO S2008M1LSPUSW S2008F8HEFUSO S2008ACFTOUSBS2008F5CLXOSG S2008M1LSEUSW S2008CFH36USB

SNOWMOBILE SAFETY RULES 3

SNOWMOBILE SAFETY RULES

4 GENERAL INFORMATION

GENERAL INFORMATION

SNOWMOBILE IDENTIFICATION

The Arctic Cat Snowmobile has twoimportant identification numbers. TheVehicle Identification Number (VIN)is stamped into the tunnel near theright-side footrest. The Engine SerialNumber (ESN) is stamped into thecrankcase 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 snowmobilename, VIN, and ESN when contactingan authorized Arctic Cat Snowmobiledealer for parts, service, accessories,or warranty. If the complete enginemust be replaced, ask the dealer tonotify Arctic Cat for correct registra-tion information.

CONTROL LOCATIONS

Shown are the typical control loca-tions for Arctic Cat snowmobiles.Location of a specific control willvary according to model.

Panther 370 Model

739-592D

GENERAL INFORMATION 5

F5/F 570 - T500/T570 Models

742-456A

F6/F8/F1000/Jaguar Z1/TZ1 Models

741-375B

Crossfire/M-Series Models

741-633A


Bearcat Wide Track Turbo/T660 Models

0742-473

Bearcat 570 Model

740-586A

Bearcat Wide Track Non-Turbo/Panther 660 Models

0742-458


TIPPED SNOWMOBILE (660 cc Models)

Tipping a snowmobile on its side issometimes desirable for maintenancepurposes; however, on a 660 cc model,Arctic Cat recommends NOT TIP-PING IT ON ITS SIDE IN EXCESSOF A 70° ANGLE.

If a 660 cc model is tipped on its sidein excess of a 70° angle or if it hasbeen upside down at all, return thesnowmobile to the upright positionand use the following procedure:

1. With the ignition switch in theOFF position, remove the engineto air-intake silencer hose at theengine. If oil is present, proceedto step 2. If no oil is present,install the hose and start theengine.

AO224B

2. Remove the air-intake silencerfrom the engine. If oil is presentin the air-intake silencer, proceedto step 3. If no oil is present,install the air-intake silencer andthe engine to air-intake silencerhose; then start the engine.

NOTE: Prior to doing step 3,clean the air silencer thoroughly.

3. Remove the spark plugs from theengine and cover the spark plugholes with a rag (see Spark Plugsin this manual). With the emer-gency stop button in the down(OFF) position, turn the ignitionswitch to the START position.

4. Allow the engine to turn over forapproximately 10 seconds. If oilwas noted coming from the sparkplug holes during this procedure,repeat the process until all oil hasbeen discharged from the cylin-ders.

5. Install the spark plugs, spark plugwires, air-intake silencer, and theengine to air-intake silencer hose.

NOTE: The engine should nowbe safe to operate.

! CAUTIONThe 660 cc models should not betipped on their sides in excess ofa 70° angle for any reason, asengine oil may seep into theupper engine through the air-intake system. Severe enginedamage could result if the engineis run with oil in the upper engine.

! CAUTIONCare must be taken when install-ing the hose that it does not sagbelow the entrance/exit ends. Ifthere is a “valley” in the hose,freezing may occur.


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 regu-lar unleaded.

NOTE: On the 2-stroke EFIengine models for optimum per-formance, do not exceed the rec-ommended 87 octane gasoline.Using a higher octane gasolinewill not increase overall perfor-mance.

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

Oxygenated gasolines containing upto 10% ethanol or up to 15% MTBEare acceptable gasoline. Do not usegasolines 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 (660 cc STD)

NOTE: See the accompanyingSpecifications sheet for specificdetails on recommended engineoil.

The recommended oil to use is amulti-grade oil calibrated to the ambi-ent temperature at which the engine isrun. See the viscosity chart for details.

! 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 rec-ommended oil could cause seri-ous engine damage.

! CAUTIONAny oil used in place of the rec-ommended oil may cause seriousdamage.


OILCHARTD

After the engine break-in period, theengine oil should be changed every2500-3000 miles on standard 660 ccmodels.

Recommended Engine Oil (660 cc Turbo/1100 cc Models)

The recommended oil to use is Syn-thetic Turbo 0W-40 Oil (p/n 3639-510).

After the engine break-in period, theengine oil should be changed every2500-3000 miles on the 1100 cc mod-els and every 2000 miles on 660 ccTurbo 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 toa warm area.

Also, if the snowmobile is to remainon a trailer after filling the gas tank,the bed of the trailer must be main-tained level to prevent gasoline fromdraining out through the gas tank venthose.

NOTE: The F-Series/Jaguar Z1/T-Series/TZ1 models are notequipped with a gas tank venthose.

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. approved22.7 l (6 U.S. gal.) gasoline containerfor mixing the gasoline and oil. Toproperly mix the fuel at a 100:1 ratio,use the following procedure:

1. Pour gasoline into the gasolinecontainer until approximately halffull.

2. Pour 236 ml (8 fl oz) of the rec-ommended 2-cycle oil into thegasoline 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 fromthe gasoline container into thesnowmobile gas tank.

! WARNINGAlways fill the gas tank in a well-ventilated area. Never add gaso-line to the snowmobile gas tanknear any open flames or with theengine running. DO NOT SMOKEwhile filling the gas tank. Do notsit on the snowmobile withoutfirst installing the gas tank cap.

! CAUTIONNever mix oil and gasoline in thesnowmobile gas tank.


ENGINE BREAK-IN(2-Stroke Models)

The Arctic Cat engine (when new orrebuilt) requires a short break-inperiod before the engine is subjectedto heavy load conditions. Arctic Catrequires that the first tankful of fuel bepremixed at a 100:1 ratio in all oil-injection 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 isat the discretion and the expense of thesnowmobile owner.

ENGINE BREAK-IN (660 cc/1100 cc Models)

The Arctic Cat engine (when new orrebuilt) requires a short break-inperiod before the engine is subjectedto heavy load 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-in guidelines will be beneficial.

* With occasional full-throttle operation.

To ensure proper engine break-in onthe 1100 cc and 660 cc models, ArcticCat recommends that the engine oiland filter be changed after 200-500miles. This service is at the expense ofthe snowmobile owner.

INDICATOR LIGHTS (Carbureted/Bearcat W/T Non-Turbo/Panther 660 Models)

Indicator lights are incorporatedwithin the speedometer.

! WARNINGAlways fill the gas tank in a well-ventilated area. Never add gaso-line to the snowmobile gas tanknear any open flames or with theengine running. DO NOT SMOKEwhile mixing fuel or filling the gastank.

! CAUTIONDO NOT exceed the one (1) tank-ful limitation of a 100:1 gas/oilbreak-in mixture. Continuous useof a gas/oil mixture, unless con-sistently operating in extremelycold conditions (-26°C/-15°F orcolder), could cause spark plugfouling and excessive carbonbuildup. A 100:1 gas/oil mixturemust be used in conjunction withthe oil-injection system to ensureadequate engine lubrication inextremely cold conditions.

! CAUTIONDO NOT use premixed fuel in thesnowmobile gas tank. Enginedamage 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 *


LOW OIL WARNING LIGHT (Standard 2-Stroke Models)

The Low Oil Warning Light isdesigned to alert the snowmobileoperator when the oil in the oil injec-tion reservoir gets below a prescribedlevel; however, it is highly recom-mended that a visual verification ofthe oil level in the reservoir be doneprior to operating the snowmobile.Once the Low Oil Warning Light illu-minates during operation of the snow-mobile, the operator must periodicallymonitor the level of oil in the reservoirand must fill the reservoir the nexttime gasoline is added to the gas tank.The “alert level” of the Low Oil Warn-ing Light is approximately equal to 1tankful of gasoline under normal oper-ating conditions.

LOW OIL PRESSURE WARNING LIGHT (Bearcat W/T Non-Turbo/Panther 660 Models)

The Low Oil Pressure Warning Lightindicates engine oil pressure, not theoil level; however, if the oil level islow, it may affect oil pressure. Thelight should illuminate each time theignition switch is turned to RUN orSTART, and it should go out when theengine starts. If the light 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:

1. Check the oil level.

NOTE: To ensure an accuratereading, the snowmobile shouldbe on level ground.

2. If the oil level is below the lowermark on the oil level stick, addonly enough recommended oil toraise the level between the upperand lower marks. DO NOT over-fill the crankcase with oil.

3. After adding oil if the enginestarts, oil pressure should be nor-mal.

If the engine does not start, take thesnowmobile to an authorized ArcticCat Snowmobile dealer.

COOLANT TEMPERATURE WARNING LIGHT (Bearcat W/T Non-Turbo/Panther 660 Models)

If the coolant temperature is at themaximum running temperature, theCoolant Temperature Warning Lightwill flash a warning (alert). If the cool-ant temperature is above the maxi-mum running temperature, the lightwill cease flashing and will remainconstantly illuminated.

! 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.


CHARGING SYSTEM WARNING LIGHT (660 cc Models)

The Charging System Warning Lightis designed to warn the operator if thebattery charging system is not func-tioning. The light should illuminateeach time the key is turned to RUN orSTART, and it should go out when theengine starts. If the light stays illumi-nated or it illuminates while theengine is running, the battery is notbeing charged, and the snowmobile isrunning on battery reserve power only.

If the Charging System Warning Lightilluminates, you should, as soon aspossible, take the snowmobile to anauthorized Arctic Cat Snowmobiledealer for service. If not under war-ranty, this service is at the discretionand expense of the snowmobile owner.The engine WILL NOT RUN with-out battery power.

CHECK ENGINE LIGHT(Bearcat W/T Non-Turbo/Panther 660 Models)

The Check Engine Light is controlledby the ECU and may illuminate for anumber of reasons. The light shouldilluminate each time the key is turnedto RUN or START, and it should goout when the engine starts. If the lightstays illuminated or it illuminateswhile the engine is running, the ECUis receiving input that is outside of itsestablished parameters. If the CheckEngine Light illuminates, take thesnowmobile to an authorized ArcticCat Snowmobile dealer for service. Ifnot under warranty, this service is atthe discretion and expense of thesnowmobile owner.

SPEEDOMETER/TACHOMETER INDICATOR ICONS (Bearcat W/T Turbo/T660 Models)

These snowmobiles are equipped witha combination speedometer/tachome-ter. Indicator icons are incorporatedwithin the speedometer/tachometer.Also incorporated into the speedome-ter/tachometer is a digital readoutscreen.

ZJ001C

A. Charging System

B. Oil Pressure/Low Oil

C. High Beam

D. Check Engine

E. Coolant Temperature

Top Button

By pushing the top button once (lowerright-hand side of the speedometer/tachometer), the RPM and MPH willbe displayed (one on the readoutscreen and one with the needle). Bypushing the button once again, thefunctions will be reversed.

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


By pushing and holding the top but-ton, maximum RPM will be displayedon the readout screen. The maximumRPM readout will reset when the bot-tom button is pushed (while maximumRPM is displayed).

Bottom Button

By pushing the bottom button once,the readout screen will display hour-meter or trip-meter/odometer; bypushing the button once again, the twofunctions will be reversed. To reset thetrip meter with the trip meter dis-played, push and hold the bottom but-ton until the display is cleared. Thehour-meter readout will not reset.

Charging System Warning Icon

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 theengine is running, the battery is notbeing charged, and the snowmobile isrunning on battery reserve power only.

If the Charging System Warning Iconilluminates, you should, as soon aspossible, take the snowmobile to anauthorized Arctic Cat Snowmobiledealer for service. If not under war-ranty, this service is at the discretionand expense of the snowmobile owner.The engine WILL NOT RUN with-out battery power.

Coolant Temperature Warning Icon

If the coolant temperature is at themaximum running temperature, thecoolant temperature warning icon willflash a warning (alert). If the coolanttemperature is above the maximumrunning temperature, the coolant tem-perature warning icon will cease flash-ing and will remain constantlyilluminated.

Oil Pressure/Low Oil Warning Icon

The Oil Pressure/Low Oil WarningIcon indicates engine oil pressure, notthe oil level; however, if the oil levelis low, it may affect oil pressure.

The icon should illuminate each timethe ignition switch is turned to RUNor START, and it should go out whenthe engine starts. If the icon illumi-nates while the engine is running, oilpressure has been lost and the enginewill automatically shut off.

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

NOTE: To ensure an accuratereading, the snowmobile shouldbe on level ground.



1. Check the oil level. If the oil levelis below the lower mark on the oillevel stick, add only enough rec-ommended oil to raise the levelbetween the upper and lowermarks. DO NOT overfill thecrankcase with oil.

2. Start the engine. The warningicon should go out within fiveseconds.

If the engine does not start, take thesnowmobile to an authorized ArcticCat Snowmobile dealer.

Check Engine Icon

The Check Engine Icon is controlledby the ECU and may illuminate for anumber of reasons.

NOTE: The icon should illumi-nate each time the key is turned toRUN or START, and it should goout when the engine starts.

If the icon stays illuminated or it illu-minates while the engine is running,the ECU is receiving input that is out-side of its established parameters. Ifthe Check Engine Icon illuminates,take the snowmobile to an authorizedArctic Cat Snowmobile dealer for ser-vice. If not under warranty, this ser-vice is at the discretion and expense ofthe snowmobile owner.

SPEEDOMETER/TACHOMETER INDICATOR ICONS (Standard Gauge)

This snowmobile is equipped with acombination speedometer/tachometer.Indicator icons are incorporated withinthe speedometer/tachometer. Alsoincorporated into the speedometer/tachometer is a digital readout screen.

FZ003A

A. Low Oil

B. Coolant Temperature

C. Low Fuel

D. Fuel Level

E. Service

F. High Beam

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.

With RPM displayed on the readoutscreen by pushing and holding the leftbutton, maximum RPM will be dis-played on the readout screen. Themaximum RPM readout will resetwhen the right button is pushed (whilemaximum RPM 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 theright button for two seconds, theoption of selecting the 12-hour or 24-hour clock is available. Push the leftbutton for 12-hour display; push theright button for 24-hour display. Atthis point, the hours and minutes willbegin to flash. Push the left button tochange the hour display; push the rightbutton to change the minute display(either tap the buttons for individualnumber display or push and hold thebuttons for rapid number 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 iconshould illuminate each time the key isturned to RUN or START, and itshould go out when the engine starts.If the icon stays illuminated (on elec-tric start models) or it illuminateswhile the engine is running, the sys-tem is receiving input that is outside ofits established parameters. If the iconilluminates indicating an error, takethe snowmobile to an authorized Arc-tic Cat Snowmobile dealer for service.If not under warranty, this service is atthe discretion and expense of thesnowmobile owner.


If the coolant temperature is at orabove the maximum running tempera-ture of 80° C (176° F), the coolanttemperature warning icon will flash awarning (alert). If the coolant temper-ature is at or above the maximum run-ning temperature of 93° C (200° F),the coolant temperature warning iconwill cease flashing and will remainconstantly illuminated.

Steady Flash(Coolant Temperature Icon)

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

Constant On(Coolant Temperature Icon)



! CAUTIONIf unable to either determine orremedy the problem, take thesnowmobile to an authorized Arc-tic Cat Snowmobile dealer for ser-vice.


Low Oil Warning Icon

The Low Oil Warning Icon is designedto alert the snowmobile operator whenthe oil in the oil injection reservoirgets below a prescribed level; how-ever, it is highly recommended that avisual verification of the oil level inthe reservoir be done prior to operat-ing the snowmobile. Once the Low OilWarning Icon illuminates during oper-ation of the snowmobile, the operatormust periodically monitor the level ofoil in the reservoir and must fill thereservoir the next time gasoline isadded to the gas tank. The “alert level”of the Low Oil Warning Icon isapproximately equal to 1 tankful ofgasoline under normal operating con-ditions.

SPEEDOMETER/TACHOMETER INDICATOR ICONS (Premium Gauge)

This snowmobile is equipped with acombination speedometer/tachometer.Indicator icons are incorporated withinthe speedometer/tachometer. Alsoincorporated into the speedometer/tachometer is a digital readout 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 but-ton once 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.The maximum 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), andhour-meter. To reset the trip meterwith the trip meter displayed, push andhold the decrement button until thedisplay is cleared. The hour-meterreadout will not reset.

Clock/Altimeter

NOTE: The altimeter is avail-able on the 800/1000/1100 cc mod-els only.

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


With clock selected on the display bypushing and holding the select buttonfor two seconds, the option of select-ing the 12-hour or 24-hour clock modeis available. Push the increment buttonto toggle between the 12-hour displayand the 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 thedecrement button to decrease thehours. Pushing and holding a buttonwill accelerate the number display.When desired hour number is dis-played, push the 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 buttonwill accelerate the number display.When desired minute number is dis-played, 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 offbarometric pressure and may requirecalibration as weather conditionschange.

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 alti-tude value will flash. Push the incre-ment button to increase the displayedaltitude; push the decrement button todecrease the displayed altitude. Push-ing and holding a button will acceler-ate the 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 itshould go out when the engine starts.If the icon stays illuminated (on elec-tric start models) or it illuminateswhile the engine is running, the sys-tem is receiving input that is outside ofits established parameters. If the sys-tem icon illuminates indicating anerror, take the snowmobile to anauthorized Arctic Cat Snowmobiledealer for service. If not under war-ranty, this service is at the discretionand expense of the snowmobile owner.


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-SeriesSteady Flash(Coolant Temperature Icon)





Charging System Warning Icon (1100 cc)

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 theengine is running, the battery is notbeing charged, and the snowmobile isrunning on battery reserve power only.

If the Charging System Warning Iconilluminates, you should, as soon aspossible, take the snowmobile to anauthorized Arctic Cat Snowmobiledealer for service. If not under war-ranty, this service is at the discretionand expense of the snowmobile owner.The engine WILL NOT RUN with-out battery power.

Low Oil Warning Icon

The Low Oil Warning Icon is designedto alert the snowmobile operator whenthe oil in the oil injection reservoirgets below a prescribed level; how-ever, it is highly recommended that avisual verification of the oil level inthe reservoir be done prior to operat-ing the snowmobile. Once the Low OilWarning Icon illuminates during oper-ation of the snowmobile, the operatormust periodically monitor the level ofoil in the reservoir and must fill thereservoir the next time gasoline isadded to the gas tank. The “alert level”of the Low Oil Warning Icon isapproximately equal to 1 tankful ofgasoline under normal operating con-ditions.

Oil Pressure Warning Icon (1100 cc)

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 RUNor START, and it should go out whenthe engine starts. If the icon illumi-nates while the engine is running, oilpressure has been lost and the enginewill automatically 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 levelis at or below the ADD mark onthe oil level stick, add onlyenough recommended oil to raisethe level to the NORMAL range.DO NOT overfill the reservoirwith oil.

Jaguar Z1/TZ1Steady Flash(Coolant Temperature Icon)







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 to1.05 kg-m (7.5 ft-lb).

3. Start the engine. The warninglight should go out within fiveseconds.

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

If the warning light does not go out orif the engine does not start, take thesnowmobile to an authorized ArcticCat Snowmobile dealer.

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 establishedparameters. If a code has been acti-vated, take the snowmobile to anauthorized Arctic Cat Snowmobiledealer for service. If not under war-ranty, this service is at the discretionand expense of the snowmobile owner.

DIAGNOSTIC CODES (Crossfire/F-Series/M-Series/T-Series Models)

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

* On certain models.

DIAGNOSTIC CODES (Jaguar 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 Trouble1-2 Failure in ignition coil.

1-6* Incorrect adjustment/failure in APV cable.

1-7* Failure in exhaust temperature sensor.

1-8* Failure in servomotor.

2 Failure in injector(s).

2-1* Failure in knock sensor.

2-3* Fail-safe mode activated in knock control system.

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.


DIAGNOSTIC CODES/CHECK ENGINE LIGHT (660 cc Models)

These diagnostic codes are flashed bythe check engine light incorporatedwithin the speedometer/tachometer(Bearcat W/T Turbo model) or withinthe gauge hole plate (Bearcat WideTrack Non-Turbo/Panther 660 mod-els). Refer to the following chart fordiagnostic code sequences.

NOTE: On these double-digitcodes (1-1, 1-3, etc.), the firstnumber indicated will flash in anuninterrupted sequence, there willbe a short pause, and the secondnumber indicated will flash in anuninterrupted sequence.

HANDLEBAR TILT

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

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

1. Loosen the four lock nuts secur-ing the handlebar caps and blockto the steering post.

Code Trouble1 Failure in the fuel system.

1-1 Failure in speed sensor.

1-2 Failure in coil (#1).

1-3 Failure in coil (#2).

1-4 Failure in ISC valve.

1-5 Failure in oxygen sensor.

1-9 Failure in camshaft position sensor.

2 Failure in injector (#2).

3 Failure in injector (#1).

4 Failure in barometric pressure sensor.

5 Open or short circuit in intake manifold air temperature sensor.

6 Open or short circuit in water temperature sensor.

7 Open or short circuit in throttle position sensor.

8 Open or short circuit in manifold air pressure sensor.

9 Failure in crankshaft position sensor.

Number of Flashes Trouble

1-1(Check Engine

Light)

Open or short circuit in manifold air pressure

sensor.

1-3(Check Engine

Light)

Open or short circuit inthrottle position sensor.

1-4(Check Engine

Light)

Failure in oxygen sensor.

1-5(Check Engine

Light)

Failure in crankshaft position sensor.

1-6 (Check Engine

Light)

Failure in speed sensor.

1-7 (Check Engine

Light)

Open or short circuit inknock sensor.

1-8 (Check Engine

Light)

Open or short circuit in intake

manifold air temperature sensor.

1-9 (Check Engine

Light)

Open or short circuit inwater temperature sen-

sor.

2-7(Check Engine

Light)

Failure in coil.

2-9(Check Engine

Light)

Failure in barometricpressure sensor.


0734-406

2. Adjust the handlebar up or downto operator’s desired tilt; thentighten the lock nuts evenly andsecurely. Check steering for maxi-mum right/left turning capabilities.

3. Recheck lock nuts; tightensecurely.

NOTE: Recommended torquevalue of lock nuts is 2.5 kg-m (18ft-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 thehandlebar, use the following proce-dure:

1. Loosen the eight cap screwssecuring the handlebar caps to theriser and the riser to the steeringpost.

735-501B

2. Adjust the handlebar up or downto operator’s desired tilt, tightenthe cap screws evenly to 3.5 kg-m(25 ft-lb), and check steering formaximum right/left turning capa-bilities.

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 (LXR/Sno Pro/Jaguar Z1/TZ1 Models)

The handlebar can be adjusted to theoperator’s preference. To adjust thehandlebar, use the following proce-dure:

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

! 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.

! WARNINGTighten cap screws according tospecifications to prevent unex-pected “movement” of the han-dlebar during operation overrough terrain. DO NOT offset thehandlebar so steering (maximumright/left turning capabilities) arealtered or throttle and brake con-trols will be affected.


0741-427

2. Adjust the handlebar up or downand/or rotate the handlebar tooperator’s desired position; thenpress down on the cam lever untilthe lock pin is properly positionedand locked. Check steering formaximum right/left turning capa-bilities.

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, pro-ceed to step 4. If it does rotate,release the cam lever and rotatethe cam lever clockwise; thenpress down on the cam lever untilthe lock pin is properly positionedand locked. Repeat this procedureuntil the handlebar is properlysecured.

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

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.

! CAUTIONIf at any time the lock pin will notengage into the locked position,do NOT operate the snowmobile.Take the snowmobile to an autho-rized Arctic Cat dealer for service.

! 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 capabili-ties) are altered or throttle andbrake controls will be affected.


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 cal-ibrated 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 in the Maintenance section of thismanual.

COOLING SYSTEM (Liquid)

Some snowmobiles are equipped witha closed liquid cooling system forengine cooling. The cooling systemshould be inspected daily for leakageand damage. Also, the coolant levelshould be checked daily. If leakage ordamage is detected, take the snowmo-bile to an authorized Arctic Cat Snow-mobile dealer for service. If not underwarranty, this service is at the discre-tion and expense of the snowmobileowner.

When filling the cooling system, usean ethylene glycol-based coolant/water mixture which will satisfy thecoldest anticipated weather condi-tions of your area in accordance withthe coolant manufacturer’s recommen-dations. While the cooling system isbeing filled, air pockets may develop;therefore, run the engine for five to tenminutes after the initial fill, shut theengine off, and then fill the coolingsystem to approximately 51 mm (2 in.)below the filler neck on 2-stroke mod-els or to just below the FULL mark on660 cc/1100 cc models.

NOTE: The 660 cc models areequipped with a coolant “bleedscrew” on the purge tank (locatedon the front-top of the engine).After starting the engine (and withthe tank cap on and tight), openthe bleed screw slightly to allowtrapped air to escape. Continueuntil no air is apparent; thentighten the screw.

AO353A

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

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

! CAUTIONAfter operating the snowmobilefor the initial 5-10 minutes, stopthe engine, allow the engine tocool down, and check the coolantlevel. Add coolant as necessary.


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 orat the 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 Snow-mobile 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 neitherthe drive clutch nor the driven pulleyis removed or disassembled. However,if premature drive belt wear is experi-enced or if the drive belt turns over,the drive clutch/driven pulley align-ment must be checked. Take the snow-mobile to an authorized Arctic CatSnowmobile dealer for this service. Ifnot under warranty, this service is atthe discretion and expense of thesnowmobile owner.

DRIVE CHAIN TENSION

The drive chain must be properly ten-sioned for proper operation to prevent“ratcheting” and unnecessary chain/sprocket wear. On these snowmo-biles, there are two different chain ten-sioners in the chain case. One chaintensioner is automatic and one is man-ual. The automatic chain tensionerwill take up the slack in the chainunder most operating conditions; how-ever, every 500 miles or wheneverrepeated hard accelerations will occur,the manual chain tensioner should beadjusted. Arctic Cat recommends thatthe chain, sprockets, and chain ten-sioner be checked for wear and properalignment and adjustment every year,1000 miles, or whenever a drive chainrelated problem is suspected. Take thesnowmobile to an authorized ArcticCat Snowmobile dealer for this ser-vice. If not under warranty, this ser-vice is at the discretion and expense ofthe snowmobile owner. To adjust themanual drive chain tensioner, use thefollowing procedure:

1. Loosen the jam nut on the chaintensioner adjustment bolt.

2. Tighten the adjustment bolt fin-ger-tight.

0730-323

! 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.


NOTE: If the adjustment bolt willnot turn using the fingers(because of dirty threads), use awrench to loosen the bolt; thenusing the fingers, adjust the boltuntil it is finger-tight. Once theadjustment bolt becomes difficultto turn by hand, the drive chain isproperly tensioned.

3. Lock the adjustment by bottom-ing the jam nut against the chaincase.

NOTE: When the head of theadjustment bolt bottoms on thejam nut, the drive chain is in needof being replaced. See an autho-rized Arctic Cat Snowmobiledealer for this service.

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 throt-tle settings. If a fuel delivery problemis suspected, take the snowmobile toan authorized Arctic Cat Snowmobiledealer. If not under warranty, this ser-vice is at the discretion and expense ofthe snowmobile owner.

GAS TANK SHUT-OFF VALVE (370 cc Model)

A shut-off valve is incorporated intothe gas hose coming from the gas tank.The valve should be turned to theCLOSED position when trailering orstoring the snowmobile. Turn thevalve to the OPEN position beforeattempting to start the engine.

NOTE: On all remaining models,there is a valve incorporated intothe fuel pump which preventsgasoline flow when the engine isoff.

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 discretionand expense of the snowmobile owner.

NOTE: When the snowmobile isoperated in extremely coldweather (-23° C/-10° F or colder), asmall amount of leakage may bepresent. Unless the leakage isexcessive, replacement is notnecessary.

SHOCK ABSORBERS (Rebuildable Gas)

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

NOTE: The frequency of servic-ing rebuildable shock absorberswill vary according to the types ofconditions and terrain the snow-mobile has been subjected to. Ifriding quality deteriorates (orseems to be deteriorating), takethe snowmobile to an authorizedArctic Cat Snowmobile dealer forshock absorber evaluation and/orservicing. This service is at thediscretion and expense of thesnowmobile owner.


Servicing rebuildable shock absorbersis considered normal maintenance andis the responsibility of the owner. Takethe snowmobile to an authorized Arc-tic Cat Snowmobile dealer for this ser-vice. This service is at the discretionand expense of the snowmobile owner.Kits are available to either stiffen orsoften gas shock valving. If changes inshock valving are desired, see anauthorized Arctic Cat Snowmobiledealer. This service is at the discretionand expense of 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 con-ditions is detected, replacement is nec-essary. Take the snowmobile to anauthorized Arctic Cat Snowmobiledealer for this service. If not underwarranty, this service is at the discre-tion and expense of the snowmobileowner.

NOTE: When the snowmobile isoperated in extremely coldweather (-23° C/-10° F or colder), asmall amount of leakage may bepresent. Unless the leakage isexcessive, replacement is notnecessary.

DEEP-LUG TRACK

Some models are equipped with adeep-lug track which is speciallydesigned for use in powder snow rid-ing conditions. When the deep-lugtrack is operated in hard-packed snowconditions, it will run slightly slowerthan a standard-lug track and it willaccelerate wear strip wear. Todecrease the amount of wear stripwear, slower speeds must be main-tained when operating on hard-packedtrails. Accelerated wear strip wearcaused by operating a deep-lug trackon hard-packed snow conditions isNOT covered under Arctic Cat Inc.warranty policy.

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 dam-age from the studs, Tunnel Protec-tor Kit (p/n 4639-771) for F 570/T570 models or (p/n 4639-338) forCrossfire models must beinstalled.

For proper installation, use the follow-ing procedure:

1. Using Stud Template (p/n 4639-443) for 128-in. track models or(p/n 4639-344) for 136-in. trackmodels, 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 theexposed stud.


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 oftrack studs (i.e. small number of trackstuds — short length of carbide...manytrack studs — long length of carbide).The proper proportion between thenumber of studs and carbide length onthe wear bar will maintain steeringbalance.

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 com-plete stop before shifting from eitherforward to reverse or reverse to for-ward. Once you have shifted to a newgear, apply slight throttle until positiveengagement of the shift has beenobserved. To shift the reverse trans-mission, use the following procedure:

1. Come to a complete stop.

2. Either push or pull the shift leverto the desired position; then applyslight throttle until positiveengagement of the shift has beenobserved.

737-831A

NOTE: On the F 570/T500/T570models, the lever must be pulledoutward and pushed downward toengage reverse gear and to lockthe lever into position.

! 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 operat-ing conditions.

! 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 bethrown from the track. Always usea shielded safety stand wheneverperforming any maintenance oradjustments.

! WARNINGDO NOT stand behind the snow-mobile or near the rotating track.NEVER run the track at highspeed when the track is sus-pended.


0742-499

No special maintenance is required forthe reverse transmission; however, ifchattering is experienced when thetransmission is shifted into reverse,the linkage may have to be adjusted.Arctic Cat recommends taking thesnowmobile to an authorized ArcticCat Snowmobile dealer for this ser-vice. If not under warranty, this ser-vice is at the discretion and expense ofthe snowmobile owner.

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

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 (under3000 RPM), press the reverseswitch button; then release the but-ton. The reverse selection will becomplete.

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.

! WARNINGUse caution and minimal speedwhen operating the snowmobilein reverse. Be sure the shift leveris in the desired lever position.


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 BACKREST

The adjustable backrest is designed formaximum comfort and safety. Whenriding double, the backrest must beadjusted to the most rearward position.

When riding single, the backrestshould be moved forward to a positioncomfortable to the operator. Be sure tomaintain the backrest pad in a verticalposition in all locations. Also, be sureto tighten all retaining knobs securelyafter adjusting the backrest.

0734-425

0742-494

REMOVABLE REAR SEAT (Bearcat W/T Models)

These snowmobiles are equipped witha removable rear seat to allow foradditional cargo space when no pas-senger is being carried. To remove therear seat, use the following procedure:

1. Move and lock the adjustablebackrest in the forward position.

2. Pull back on the seat latch handlelocated at the bottom rear of theseat.

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

0735-854

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

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

! WARNINGMoving the backrest forward lim-its the seating capacity to one per-son only.

Bearcat/Panther/T660 Models

! CAUTIONOn models equipped with a seatwarmer, disconnect the warmerwiring harness prior to fullyremoving the seat.

T-Series Models


1. Place the seat into position on thetunnel making sure the two pinson the front of the rear seat areproperly engaged with the receiv-ing tabs on the rear of the frontseat.

2. Pull back on the seat latch handle;then with the seat latch handlepulled back, push the rear seatforward and down and release theseat latch handle.

REMOVABLE REAR SEAT (T-Series)

These snowmobiles are equipped witha removable rear seat to allow foradditional cargo space when no pas-senger is being carried. To remove therear seat, use the following procedure:

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

1. Rotate the seat latch either clock-wise or counterclockwise andhold it in that position; then liftthe seat and move it rearward farenough to access the electricalconnector.

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 andhold it in that position; then slidethe seat forward, allow it to settleinto position, and release the latchto lock 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, pull the retaining clips awayfrom locking pins.

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.

! WARNINGMake sure the rear seat issecurely locked in place beforecarrying a passenger or personalinjury may result.

! WARNINGMake sure the rear seat issecurely locked in place beforecarrying a passenger or personalinjury may result.


2. Press down on the rear of the seatuntil the retaining clips snap intoplace on the locking pins.

ADJUSTABLE SEAT (TZ1 LXR Model)

This snowmobile is equipped with anadjustable operator seat. To adjust theseat, use the following procedure:

1. Remove the rear seat; see Remov-able Rear Seat (T-Series) sub-sec-tion.

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.

REMOVABLE/ADJUSTABLE SEAT (F-Series/Jaguar 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 storagecompatement; 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.

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

To remove the seat, use the followingprocedure:

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


! CAUTIONDo not use the adjuster lever to liftthe seat.



1. Adjust the seat to the lowest posi-tion; then while lifting on the topforward part of the seat, removethe self-tapping screw from theright side of the seat supportassembly.

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.

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-tap-ping screw into the right side ofthe seat support assembly.

ARCTIC POWER VALVE (APV) SYSTEM

This RPM controlled servomotor(servo) actuated system adjusts thesize of the exhaust ports to providepeak performance throughout theRPM range.

The system consists of an exhaustvalve assembly mounted to theexhaust side of each cylinder and con-nected by adjustable cables to an elec-tronic servo mounted beneath thehood.

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.

! CAUTIONDo not use the adjuster lever tolift the seat.

! 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 4639-349). 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 ofoperating conditions. The ECUreceives input on engine RPM(demand) and exhaust pipe tempera-ture (engine condition) and adjusts theignition timing accordingly. This sys-tem is not adjustable and is mainte-nance 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 infinityindicates 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.

34 OPERATING INSTRUCTIONS

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,on carbureted models, be sure thecorrect carburetor main jet(s) forthe operating temperature, alti-tude, and gasoline are being used.After the engine has been started,check the headlights (high and lowbeam), taillight, and brakelight to besure they are working properly andadjusted correctly. Make sure all lightsare clean to provide maximum illumi-nation. The headlight and taillightmust be clean and must be illuminatedwhenever the engine 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 brakesystem by compressing the brakelever. The brake lever must feelfirm when compressed; thenwhile holding the brake lever inthe compressed position, mea-sure the distance between thebrake lever and the handlebar (onhydraulic brake models) orbetween the brake lever and leverstop (on mechanical brake mod-els). The distance must be greaterthan 2.54 cm (1 in.) on hydraulicbrake models or within a range of6-13 mm (1/4-1/2 in.) on mechan-ical brake models.

734-505A

727-451A

2. On hydraulic brake models, checkthe fluid level in the reservoir.The brake fluid level must be justbelow the high mark in the brakefluid reservoir or visible in thesight glass. Add Arctic Catapproved brake fluid as necessary.

740-159A

0740-588

OPERATING INSTRUCTIONS 35

NOTE: On models with a sightglass 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.

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 THROTTLECONTROL LEVER. If the throttlecontrol lever is compressed, theengine will not start because thegas/air mixture will be too lean. Tostart a warm engine, however, thethrottle control lever may have tobe compressed slightly.

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

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

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.

! WARNINGDo not start the engine if thebrake system is not functioningproperly. Service the brake sys-tem or have it properly repairedprior to operating the snowmo-bile. Serious personal injury oreven death may occur if the brakesystem is not operating properly.

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

! CAUTIONTo avoid damaging the recoilstarter, DO NOT pull the recoilrope to its limit or release therecoil handle from an extendedposition. Allow the rope to rewindslowly.

! CAUTIONDo not continuously run thestarter for more than 5 seconds ata time.


8. On carbureted models when theengine starts, allow it to warm upfor approximately 30 secondswith the choke lever in the full-choke position. After the 30-sec-ond warm-up, move the chokelever to the middle position. Thechoke lever should be moved tothe OFF position when engine iswarm. Slight throttle control levercompression may be necessaryafter the engine starts and duringwarm-up. Idle the engine severalminutes until the engine hasreached normal operating temper-ature.

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.

10. Flooding — On carbureted mod-els if the engine does not startwhen the choke is being used butseems ready to start, move thechoke lever to the OFF position.Engage the brake lever lock; thencompress the throttle control leverfully and try to start the engine.When the engine starts, releasethe throttle control lever immedi-ately. After the warm-up, releasethe brake 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 thethrottle control lever fully and tryto start the engine. When theengine starts, release the throttlecontrol lever immediately. Afterthe warm-up, release the brakelever lock.

NOTE: On EFI models exceptthe 1100 cc models if the enginefails to start during the attemptwith the throttle control lever com-pressed, remove the spark plugsand clean and dry them thor-oughly or install a new set ofproperly gapped, recommendedspark plugs.

NOTE: On the 1100 cc models ifspark plugs must be replaced,take the snowmobile to an autho-rized Arctic Cat Snowmobiledealer for inspection and service.If not under warranty, this serviceis at the discretion and expense ofthe snowmobile owner.

12. To shut off the engine, turn theignition key to the OFF positionor push the emergency stopswitch to the DOWN position.

! 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 min-utes before it is operated at morethan 1/2 throttle. In extremely coldconditions, the warm-up time willbe longer. 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.


NOTE: On 660 cc models,ensure that the ignition switch keyis in the OFF position when theengine is not running. Leaving theignition switch in the ON positionallows the lights to be on and willdrain power from the battery. Theengine WILL NOT START withoutbattery power.

HIGH RPM OPERATION(660 cc Models)

On a 660 cc model when the enginespeed returns to idle after a sustainedperiod of high RPM operation, the idleRPM may be slightly higher thanusual for a brief period of time. Thishigher RPM is a normal oil-coolingfunction and should not be of concern.

BRAKING (Hydraulic Brake Models)

Operating a snowmobile with hydrau-lic brakes is different from operating asnowmobile with mechanical brakes.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 (includ-ing automotive applications), heatis transferred to the brake fluid.The amount of heat transferredduring high speed stops and/orrepetitive use may be high enoughto boil the brake fluid and causethe brakes to either fade or maycause an unexpected loss ofbrakes.

If this occurs, the brake fluidrequires a cool-down periodbefore the brakes will again func-tion properly. This cool-downperiod will vary depending uponthe ambient air temperature andthe temperature of the brake fluid.If loss of brakes has occurredbecause of high fluid tempera-tures, do not operate the snowmo-bile until the cool-down periodhas expired and brake lever firm-ness has returned

2. Be sure to maintain the brakefluid at the proper level and takecare not to get any moisture in thesystem as moisture in the brakefluid lowers the boiling point. Ifthe brake fluid is ever boiled (byhigh speed stops or repetitive use)or if moisture is allowed to enterthe system, it must be changed.Never substitute or mix differenttypes or grades 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.

! WARNINGExcessive repetitive use of thehydraulic brake for high speedstops will cause overheating ofthe brake fluid and prematurebrake pad wear which will resultin an unexpected loss of brakes.

! WARNINGUse only Arctic Cat approvedbrake fluid. Never substitute ormix different types or grades ofbrake fluid. Brake loss can result.Check brake fluid level and padwear before each use. Brake losscan result in severe injury or evendeath.


4. The brake lever lock is not a park-ing brake and should not be appliedfor periods exceeding 5 minutes.NEVER OPERATE THE SNOW-MOBILE WITH THE BRAKELEVER LOCK ENGAGED.

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” processis required. 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 ofthe pads.

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.

NOTE: On 660 cc models,ensure that the ignition switch keyis in the OFF position when theengine is not running. Leaving theignition switch in the ON positionallows the lights to be on and willdrain power from the battery. Theengine WILL NOT START withoutbattery power.

THROTTLE/IGNITION MONITOR SWITCH (2-Stroke/Jaguar Z1/TZ1 Models)

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.

! 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 thesnowmobile stationary.

ITEM FUNCTION CONDITIONEmergency Stop Switch

interrupts igni-tion circuit

ALL

Throttle/Igni-tion Monitor

Switch


ALL

Ignition Switch


ALL

Brake slows the driven shaft/ACT drive

ALL

Choke (car-bureted models)

floods the engine

1/2 throttle or less


If the snowmobile engine stopsabruptly when the throttle controllever is released and the activation ofthe monitor switch is suspected, usethe following procedure:

1. Rotate the ignition key to the OFFposition.

2. Remove ice and snow from thethrottle system and wait 5-10minutes for the engine heat tothaw ice from the throttle system.

3. Test the throttle control lever bycompressing and releasing it sev-eral times. The lever MUSTreturn to the idle position quicklyand completely.

NOTE: If the throttle controllever operates properly and theengine does not start, compressthe throttle lever slightly (approxi-mately 1/8 throttle) and try start-ing the engine. If the engine nowstarts and stops when the throttlelever is released, take the snow-mobile to an authorized Arctic CatSnowmobile dealer for service. Ifnot under warranty, this service isat the discretion and expense ofthe snowmobile owner.

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

NOTE: On fan-cooled models ifthe throttle control lever operatesproperly and the engine does notstart, either a malfunctioningmonitor switch or a misadjustedmagnetic carburetor switch (ontwin carburetor models) may bethe problem. 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. However, if adire emergency exists wherein theengine must be started, discon-nect the throttle control wiringharness located below the handle-bar pad and next to the steeringpost. If disconnection of the throt-tle control wiring harness isneeded to start the engine, takethe snowmobile to an authorizedArctic Cat Snowmobile dealer forservice as soon as possible. If notunder warranty, this service is atthe discretion and expense of thesnowmobile owner.

NOTE: On F-Series/Jaguar Z1/T-Series/TZ1 models if the throttlecontrol lever operates properlyand the engine does not start, amalfunctioning monitor switchmay be 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 snowmobileowner. However, if a dire emer-gency exists wherein the enginemust be started, disconnect thethrottle monitor switch located inthe right-side handlebar control.

! WARNINGIf any malfunction of the throttlesystem occurs (such as freezingin fluffy snow) and the monitorswitch does not shut off theengine, press down on the emer-gency stop switch IMMEDIATELYto stop the engine. DO NOT startthe engine until the malfunction inthe throttle system has beenlocated and corrected.

! WARNINGIf the throttle control lever doesnot work properly, DO NOTATTEMPT TO START THE ENGINE.


NOTE: On F-Series/Jaguar Z1/T-Series/TZ1 models if disconnec-tion of the throttle monitor switchis needed to start the engine, takethe snowmobile to an authorizedArctic Cat Snowmobile dealer forservice as soon as possible. If notunder warranty, this service is atthe discretion and expense of thesnowmobile 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.

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 thesnowmobile when going to loweraltitudes. Always consult the alti-tude decal beneath the hood ofthe snowmobile.

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.

! 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 theoperator is unable to stop theengine in an emergency. If thesnowmobile must be operatedwith a disconnected throttle con-trol wiring harness, EXTREMECAUTION MUST BE TAKEN.NEVER EXCEED 10 MPH WITHTHE THROTTLE CONTROL WIR-ING HARNESS DISCONNECTED.

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

LUBRICATION 41

LUBRICATION

STANDARD CHAIN CASE (Every 40 Operating Hours)

The recommended amount of trans-mission lube in the chain case is 354ml (12 fl oz). Adding more transmis-sion lube to the chain case (above therecommended amount) may result inleakage. To check the transmissionlube level, use the following proce-dure:

1. With the snowmobile level, shutengine off and wait for all movingparts to stop; then open the hood.

2. Remove the oil level stick fromthe chain case cover. Wipe the oillevel stick clean; then install theoil level stick completely backinto the chain case. Remove theoil level stick again and check thelubricant level.

0737-715

3. If the lubricant level is above theLOW mark, the lubricant level issatisfactory. If the lubricant levelis at or below the mark, proceedto step 4.

4. If oil is low, remove the filler plugand add transmission lubethrough the filler plug hole. Whenthe oil level is correct, install boththe filler plug and the oil levelstick.

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.

ACT 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. Ifnot under warranty, this service isat the discretion and expense ofthe 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:

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

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

! CAUTIONThe correct lubricant to use in thechain case is Arctic Cat Transmis-sion Lube (p/n 0636-817). Anysubstitute may cause prematurechain failure or serious damage tothe chain drive system.

42 LUBRICATION

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.

F5/F 570 - T500/T570

742-476A

F-Series 6/8/1000 - Jaguar Z1/TZ1

0741-334

Crossfire/M-Series

741-636A

3. Tip the snowmobile onto its rightside and place a piece of card-board underneath to protect thefinish on the 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.

NOTE: To aid in draining thelubricant, it is advisable to fashiona drain adapter by acquiring a fit-ting and a length of 3/8-in. hose.

5. Tip the snowmobile back to theupright position; then place adrain pan on the floor next to thedrain hose 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 thesnowmobile is on a level surfaceto ensure the lubricant drainsproperly and completely.

6. Secure the snowmobile in thisposition until the lubricant iscompletely drained.

7. When the lubricant has com-pletely drained form the gearcase, tip the snowmobile back tothe upright position, remove thedrain adapter, and install andsecurely tighten the drain plug;then remove the check/fill plug.

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

! CAUTIONIt is critical that all of the old lubri-cant be drained from the gearcase prior to flushing the gearcase.

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

LUBRICATION 43

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

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

11. Position the tips of the skisagainst a wall; then using ashielded safety stand, raise therear of the snowmobile off thefloor making sure the track is freeto 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 removethe driven pulley.

15. Tip the snowmobile onto its rightside and place a piece of card-board underneath.

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 adrain pan on the floor next to thedrain hose 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.

19. When the fluid has completelydrained from the gear case, tip thesnowmobile back to the uprightposition, remove the drainadapter, and install and securelytighten the drain plug; thenremove the check/fill plug.

20. Pour the exact amount (see speci-fication sheet) of Arctic Cat ACTDrive Fluid lubricant into thecheck/fill hole; then install theplug. Tighten securely.

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

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


! CAUTIONIt is critical that all of the flushfluid be drained from the gearcase prior to filling with new lubri-cant.

! CAUTIONThe correct lubricant to use in thegear case is Arctic Cat ACT DriveFluid (p/n 4639-628). Any substi-tute may cause serious damage tothe drive system.

! CAUTIONDo Not add more or less than therecommended amount of lubri-cant to the gear case or damageto the gear case will occur.

44 LUBRICATION

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 thisprocedure.

It is very important that the front sus-pension is greased on a monthly basisusing low-temperature grease. Thefront suspension should also begreased after trailering the snowmo-bile on an open trailer. Pump greaseinto the spindle grease fitting (bothsides) until grease is noted coming outof the top and bottom of the spindle.Wipe excess grease from the spindle.

0739-724

F-Series/JaguarZ1/T-Series/TZ1 Models

741-335A

On the Crossfire/F-Series/M-Series/Jaguar Z1/TZ1 models, pump greaseinto the upper steering shaft grease fit-ting (located on the right-side of thesnowmobile directly above the for-ward part of the upper A-arm) untilgrease is noted coming out of the bot-tom of the shaft. Wipe excess greasefrom the shaft.

Crossfire/M-Series Models

0737-294

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

0741-440

SPEEDOMETER DRIVE ADAPTER - Bearcat W/T Non-Turbo/Bearcat 570/Panther/Z Models (Semi-Annually)


1. Shut the engine off and wait forall moving parts to stop; thenopen the hood.

LUBRICATION 45

2. Using low-temperature grease,lubricate the fitting on the speed-ometer drive adapter until greaseis noted coming out along theedge of the drive adapter.

0727-472

REAR SUSPENSION (Every 40 Operating Hours)


NOTE: Determine which stylerear suspension is being lubri-cated and locate the grease fit-tings accordingly.

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.

! CAUTIONThe 660 cc models should not betipped on their sides for any rea-son, as engine oil may seep intothe upper engine through the air-intake system. Severe enginedamage could result if the engineis run with oil in the upper engine.

46 MAINTENANCE

MAINTENANCE

PERIODIC MAINTENANCE CHECKLISTITEM INTERVAL PAGE REMARKS

Air Filter (660 cc Turbo) 2000 miles/Seasonal __ Replace

Brake System (Hydraulic) Daily 66 Check for binding, leakage, and proper operation; lever firmness, travel, caliper, disc, and pads

Brake System (Mechanical) Daily 64 Check for binding, sticking, and proper operation; lever travel, cable, spring, caliper, and disc

Cooling System - Liquid Daily 23 Check for leakage, damage, obstructions, coolant level

Cooling System - Fan Belt Monthly 86 Check tightness and for wear, damage, and obstructions

Charging System - Accessory Belt (660 cc)

Monthly 87 Check tightness and for wear, damage, and obstructions

Oil System Daily 48-49 Check for leakage, damage, and injection/engine oil level

Engine Oil (660 cc Standard) 2500-3000 miles/Seasonal

49 Change oil and filter

Engine Oil (660 cc Turbo) 2000 miles/Seasonal 49 Change oil and filter

Engine Oil (1100 cc) 2500 miles/Seasonal 50 Change oil and filter

Battery Daily 2360

Check for proper charge and tight connections

Stop Switch Daily — Check for proper operation

Hoses Daily — Check for damage, leakage, and routing

Headlight & Taillight/Brakelight Daily 79-84 Check for proper operation and cleanliness

Steering System Daily — Check for proper operation, tightness of bolts, and binding

Throttle Control System Daily 37 Check for binding, sticking, proper operation, throttle cable tension, and routing

Drive Belt DailyMonthly

69 Check for wear, cracks, and frayingCheck length and width dimensions

Ski Wear Bars Daily 84 Check for wear and damage

Carburetors - Main Jets - Adjustment Screws

Daily Weekly

5751-57

Install proper main jetsAdjust according to specifications

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

Exhaust System Weekly 22 Check for damage, leakage, and obstructions

Nuts, Bolts, Fasteners Weekly — Check tightness

Recoil Starter Weekly — Check rope for wear, fraying, and proper operation

Shock Absorbers Weekly 25 Check for fluid leakage and damage

Spark Plugs (2-Stroke) Weekly 59 Check center electrode insulator color, carbon, and gap

Valve Clearance (660 cc) 3500 miles/Seasonal 60 Check/adjust

Valve Clearance (1100 cc) 5000 miles/Seasonal 60 Check/adjust

Suspension Weekly 75 Check for damage, loose components, and proper adjustment

Track Tension/Alignment Weekly 7274

Check/adjust as necessary

Wear Strips Weekly 86 Check for wear and damage

Wires & Cables Weekly — Check for wear, damage, and routing

Fuel System - Tank, Pump, In-Line Filter, & Vent Hose

Weekly — Check for damage, wear, obstructions, and leakage

Fuel Filter (660 cc/1100 cc) 5000 miles/2 years __ Replace

APV System Monthly 32 Check/adjust as necessary

Standard Chain Case Monthly 41 Check lube level and for leakage

ACT Drive Gear Case Seasonal 41 Change drive fluid prior to storage

Heat Exchangers Monthly — Check for wear, leakage, and damage

Drive Clutch/Driven Pulley Monthly 24 Check for damage, abnormal noise, vibration, binding, and sticking and clean off drive belt deposits

Front & Rear Suspension Monthly 4445

Grease

MAINTENANCE 47

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 thesnowmobile to an authorized ArcticCat Snowmobile dealer for inspectionand adjustment or repair.

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

FUEL SYSTEM

In-Line Fuel Filter (Carbureted Models)

Arctic Cat recommends that the in-line fuel filter be checked weekly. Thein-line fuel filter is located just in frontof the 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:

NOTE: Determine which stylein-line fuel filter is being replacedand remove and install accord-ingly.

1. On models with a gas tank shut-offvalve, turn the gas tank shut-offvalve to the CLOSED position.

2. Using a screwdriver, pry the fuelhoses off the in-line fuel filter andremove the filter.

726-065A

728-272B

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.Make sure the fuel hoses fittightly on the filter. If a fuel hosedoes not fit tightly, cut 6 mm (1/4in.) from the end of the fuel hose;then install on the filter.

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

48 MAINTENANCE

4. If applicable, turn the gas tankshut-off valve to the OPEN posi-tion.

Gasoline Additives

Fuel de-icer can be used for all mod-els. 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 gastank. If ever there is a restricted fuelflow and a pickup valve is suspected,take the snowmobile to an authorizedArctic Cat Snowmobile dealer for thisservice. If not under warranty, this ser-vice is at the discretion and expense ofthe snowmobile owner.

CHECKING ENGINE OIL LEVEL (660 cc Models)

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

1. Open the hood and pull up on theoil level stick until the top markon the stick is even with the top ofthe oil level stick tube. Wait 30seconds before proceeding.

NOTE: Failure to perform step 1as stated will result in an inaccu-rate reading.

2. After 30 seconds, remove the oillevel stick and wipe it with aclean cloth. Insert the oil levelstick fully into the engine andremove. Read the oil level shownon the oil level stick. The oil levelmust be between the two markson the bottom end of the stick.

AA054B

3. If the oil level is at or below thebottom mark on the oil level stick,add recommended oil until the oillevel is slightly below the topmark on the bottom end of thestick.

NOTE: It takes 800 ml (27 fl oz)to raise the oil level from the lowermark to the upper mark on thebottom end of the stick.

CHECKING ENGINE OIL LEVEL (1100 cc Models)

1. Park the snowmobile on a levelsurface; then start the engine andallow it to warm up for 10-15minutes, or if the snowmobilewas operated, allow the engine toidle for approximately 30 sec-onds.

NOTE: The snowmobile mustbe on a level surface for this pro-cedure.

! WARNINGThe fuel hoses must fit tightly onthe fuel filter. If the fuel hoselength doesn’t permit this proce-dure, replace the fuel hose. Also,after installing the fuel hoses onthe filter, check to be sure that thefuel hoses do not contact any hotor rotating components.

MAINTENANCE 49

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 theoil reservoir without threading itin and 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 ADDmark, add up to 1/2 qt of recom-mended engine oil.

NOTE: Care must be taken notto over-fill the reservoir with oil.

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

CHANGING ENGINE OIL (660 cc Models)

NOTE: The oil should bechanged when the engine is warmto allow all oil to drain from thecrankcase.

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

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

2. Place a drain pan beneath thebelly pan plug hole; then removethe oil drain plug and washerfrom the underside of the crank-case.

3. Remove the oil fill cap from thetop of the engine.

4. After the oil has drained com-pletely, install the oil drain plugand washer and tighten to 2.3 kg-m (16.5 ft-lb).

5. Install a new belly pan plug.

6. Remove the oil filter using OilFilter Wrench (p/n 0644-389).

7. Apply a light coat of fresh engineoil to the gasket of the new oil fil-ter.

8. Install the new oil filter by turningthe oil filter by hand until the gas-ket has contacted the oil filtermounting surface; then tighten theoil filter 3/4 turn by hand.

9. Pour 2.9 l (3 U.S. qt) of the rec-ommended engine oil into the oilfill tube; then check the oil level.

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

50 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 10-15minutes, or if the snowmobilewas operated, allow the engine toidle for approximately 30 sec-onds.

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 2.1 kg-m (15 ft-lb).

NOTE: Always install a newcrankcase drain plug Washer (p/n3007-101) and a new reservoirWasher (p/n 1670-845) 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 allowthe oil to drain from the filter;then remove 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 oilfilter to 2.1 kg-m (15 ft-lb).

10. Pour 2.9 l (3 U.S. qt) of the rec-ommended engine oil into the oilreservoir.

11. 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 to1.05 kg-m (7.5 ft-lb).

12. Without starting the engine, placethe handlebar emergency stopswitch to the RUN position andthe ignition switch to the ONposition. The Oil Pressure Warn-ing Icon should illuminate.

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

MAINTENANCE 51

NOTE: If the warning icon doesnot illuminate, take the snowmo-bile to an authorized Arctic CatSnowmobile dealer for service.

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

NOTE: If the warning icon doesnot go out, shut the engine offimmediately and repeat step 11;then place the ignition switch tothe ON position and repeat step13. If the warning icon does not goout, take the snowmobile to anauthorized Arctic Cat Snowmobiledealer for service.

14. Shut the engine off and pour theremaining amount (0.9 l or 1 U.S.qt) of recommended oil into theoil reservoir; then proceed to theappropriate Checking Engine OilLevel sub-section to verify andfinalize the procedure.

ADJUSTING CARBURETOR (Single)

The carburetor has 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 jet forthe operating temperature, altitude,and type of gasoline is being used(see Selecting Carburetor MainJet(s) section). Since carburetoradjustments critically affect engineperformance, Arctic Cat recommendsthat all changes in internal carburetorcalibration be made by an authorizedArctic Cat Snowmobile dealer; how-ever, four external adjustments can bemade on the carburetor. These are thechoke cable travel, piston valve, pilotair screw, and idle speed screw. Due tocable “stretch,” it is recommended tocheck throttle cable tension periodi-cally and adjust the swivel adapter asnecessary.

NOTE: Carburetor adjustmentsand changing the main jet 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 park-ing brake is set.

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

52 MAINTENANCE

3. Slowly rotate the 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 the 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 oflever and housing is attained.Securely tighten the adjuster jamnut.

732-848B

Adjusting Piston Valve

1. Remove the air-intake silencerboot; then rotate the idle speedscrew counterclockwise until allspring tension is removed.

0727-156

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

3. Place a finger lightly against theside of the valve; then rotate thecarburetor swivel adapter coun-terclockwise until slight upwardmovement of the valve is noted.

4. Place a finger against the valve.Rotate the idle speed screw clock-wise until it contacts the valve.

5. Compress the throttle lever to thefull-open position; then rotate theidle speed screw clockwise 2complete turns. Release the throt-tle lever.

NOTE: There must be free-playbetween the throttle lever and thecontrol housing.

6. At this point, there must be cablefree-play gap in the throttle lever.

733-081C

NOTE: If no cable free-play gapis detected, rotate the swiveladapter until free-play is achieved.The piston valve must be restingagainst the tip of its idle speedscrew.

Adjusting Pilot Air Screw

1. While counting the rotations,carefully rotate the pilot air screwclockwise until lightly seated.

! CAUTIONDo not force a pilot air screwwhen rotating it clockwise; dam-age to the pilot air screw needletip will result.

MAINTENANCE 53

2. Rotate the pilot air screw counter-clockwise the exact number ofrotations ± 1/4 turn from theseated position for an initial set-ting.

3. Install the air-intake silencer boottaking care that the boot is prop-erly positioned and that the bootis not “folded” in the air-intakesilencer causing a restriction ofair flow.

Adjusting Engine Idle Speed

1. With the snowmobile on ashielded safety stand, start theengine, release the parking brake,and thoroughly warm up. “Fine-tune” the idle speed screw and thepilot air screw until the engineidles smoothly at the desiredRPM (1500 RPM is recom-mended).

NOTE: Make engine idle adjust-ment only after the engine hasreached running temperature.

NOTE: If the engine does notstart after the carburetor has beenadjusted, repeat steps 2-6 ofAdjusting Piston Valve sub-sec-tion. If all cable slack is “taken up,”the throttle/ignition monitor switchwill prevent the ignition systemfrom firing the spark plugs.

ADJUSTING CARBURETORS (Twin)

The carburetors have been calibratedat the 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,altitude, and type of gasoline arebeing used (see Selecting Carbure-tor Main Jet(s) section). Since car-buretor adjustments critically affectengine performance, Arctic Cat rec-ommends that all changes in internalcarburetor calibration and piston valvesynchronization be made by an autho-rized Arctic Cat Snowmobile dealer;however, four external adjustmentscan be made on each carburetor.

These are the choke cable travel, pis-ton valves, pilot air screws, and idlespeed screws.

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.


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

! 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.

54 MAINTENANCE

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 oflever and housing is attained.Securely tighten the adjuster jamnut.

732-848B

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

Synchronizing Piston Valves

NOTE: On some models, the air-intake silencer is a one-piece unit,and the silencer boots can beremoved to access the intakebores. Remove the boots; thenproceed to step 4.

NOTE: On some models, the air-intake silencer includes a cover/tool tray assembly and a baffle/resonator, and the silencer bootcannot be removed to access theintake bores. Proceed to step 1.

1. Open the air-intake silencercover; then remove the screwssecuring the cover/tool trayassembly to the silencer.

2. Close the cover; then tip thecover/tool tray assembly forwardand out of its slots and remove theassembly.

3. Using a large flat-blade screw-driver, remove the baffle/resona-tor tabs from the air-intakesilencer slots and remove the baf-fle/resonator to access the intakebores.

NOTE: The baffle/resonator canbe removed more easily by remov-ing the back tabs first.

! CAUTIONMake sure to perform theseadjustment/synchronization pro-cedures on all carburetors.

MAINTENANCE 55

4. Rotate the idle speed screwscounterclockwise until all springtension is removed.

0727-156

5. 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.

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

7. 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 syn-chronize the valves. Recheck byrepeating steps 4-7.

8. With the piston valves synchro-nized, tighten the swivel adapterjam nuts securely. Slide the rub-ber throttle cable caps down overthe swivel adapters.

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

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

10. Compress the throttle lever to thefull-open position; then rotateeach idle speed screw clockwise 2complete turns. Release the throt-tle lever.

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

11. 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.

733-081C

! WARNINGBe sure to tighten the swiveladapter jam nuts securely. If aswivel adapter jam nut is nottightened, the adjuster can rotateout of the carburetor cap causingthe piston valve not to return tothe full-closed position.

56 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 notstart.

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 coun-terclockwise the exact number ofrotations ± 1/4 turn from theseated position as an initial set-ting.

3. On some models, install the air-intake silencer boots taking carethat the boots are properly posi-tioned and that the boots are not“folded” in the air-intake silencercausing a restriction of air flow.

4. On some models, install the baf-fle/resonator and the cover/tooltray assembly.

5. 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 min-utes.

6. 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: If a tachometer is beingused, engine idle RPM should beapproximately 1500.

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

! CAUTIONDo not force a pilot air screwwhen rotating it clockwise; dam-age to the pilot air screw needletip will result.

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

! 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.

MAINTENANCE 57

SELECTING CARBURETOR MAIN JET(S)

Altitude, temperature, and the use ofoxygenated gasoline affect the carbure-tion needed for optimum engine perfor-mance. The carburetor main jet(s) mustbe changed in conjunction withchanges in operating altitude, oxygen-ated gasoline usage, and temperature.As the ambient temperature rises or asthe snowmobile is operated at a higheraltitude, the main jet(s) must bereplaced with leaner main jet(s). Theoriginal equipment (production) mainjet(s) may need to be changed (depend-ing on the type of gasoline you areusing, your operating altitude, and tem-perature). A Main Jet Chart decal islocated beneath the hood of the snow-mobile. It should be noted that whenselecting the proper main jet(s), it isbetter to be too rich rather than toolean. To change carburetor main jet(s),use the following procedure:

NOTE: Carburetor main jet(s)may be changed by the snowmo-bile owner if qualified to do so. Ifthe owner does not feel qualified,take the snowmobile to an autho-rized Arctic Cat Snowmobiledealer for this service. This ser-vice is at the discretion andexpense of the snowmobileowner.

1. Loosen each carburetor flangeclamp and remove each carbure-tor from the intake flange andboot.

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. Accountfor the baffle ring/washer. Installthe new main jet and the existingbaffle ring/washer. Tighten themain jet securely.

! 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.

! CAUTIONUse only GENUINE Mikuni brassmain jets. Also, if using an oxygen-ated gasoline (up to 10% ethanolor up to 15% MTBE), the carbure-tor main jet must be one sizelarger than the main jet requiredfor regular unleaded gasoline.

! CAUTIONA main jet which is too small willcause severe engine damage.Engine damage caused by leanjetting WILL NOT BE covered byour warranty policy.

! WARNINGWhenever any maintenance isperformed on the fuel system,there should be no welding,smoking, open flames, etc., in thearea.

58 MAINTENANCE

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. If not under warranty, thisservice is at the discretion andexpense of the snowmobile owner.

SPARK PLUGS

NOTE: Always use the recom-mended spark plugs in theengine. See the appropriate speci-fications chart for correct sparkplug gap.

Varying terrain conditions and operat-ing usage may require spark plugs of adifferent heat range. For example, sus-tained cross-country riding will usu-ally require colder heat-range sparkplugs while trail riding or other con-tinual slow speed operation will usu-ally require hotter heat-range sparkplugs.

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

1. Remove the springs securing theexpansion chamber to the exhaustmanifold and resonator; thenmove the expansion chamber outof the way to access the sparkplugs.

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 2.5-2.8kg-m (18-20 ft-lb); then install thespark plug caps.

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

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

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

741-722A

2. Lift the rearward end of the con-sole and disconnect the main/hood harness connector; thenremove the console.

MAINTENANCE 59





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.

Removing/Installing Spark Plugs (Fan-Cooled Models)





Removing/Installing Spark Plugs (660 cc Models)

1. Remove the spark plug/coil cover.

2. Remove the cap screws securingthe spark plug coils to the engine;then remove the coils.



5. Tighten the spark plugs to 2.1 kg-m (15 ft-lb); then install the sparkplug coils and secure them withcap screws.

6. Install the spark plug/coil cover.

Checking Spark Plugs (2-Stroke Models)

To see if the spark plugs being usedare of the proper heat range (after thesnowmobile has been operated undernormal driving conditions), removethe spark plugs and examine the con-dition of the center electrode insulatorof each spark plug.

AO352A

A. TAN or LIGHT BROWNinsulator indicates correctspark plugs (heat range).

B. LIGHT GRAY or WHITEinsulator indicates over-heat-ing of the engine. This condi-tion is caused by a too leancondition or incorrect sparkplugs (heat range too hot).

C. BLACK insulator indicatesfuel in the combustion cham-ber is not burning completely.This condition is caused by atoo rich condition, too muchoil, or incorrect spark plugs(heat range too cold).

60 MAINTENANCE

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,different heat-range spark plugsmay be necessary. AuthorizedArctic Cat Snowmobile dealershave detailed spark plug informa-tion. Consult a dealer beforechanging spark plugs, as incor-rect heat-range spark plugs couldcause poor engine performanceor engine damage.

CHECKING/ADJUSTING VALVE CLEARANCE (660 cc/1100 cc Models)

After 3500 miles (660 cc)/5000 miles(1100 cc) or prior to seasonal storage,valve clearance should be checked andadjusted as necessary.

NOTE: Take the snowmobile toan authorized Arctic Cat Snowmo-bile dealer for inspection and ser-vice. If not under warranty, thisservice is at the discretion andexpense of the snowmobile 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 pro-cedures are recommended for cleaningand maintaining standard and sealedbatteries. Always read and followinstructions provided with batterychargers and battery products.

NOTE: Battery maintenancemay be done 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.

To remove and charge the battery, usethe following procedure:

! 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.If not under warranty, this serviceis at the discretion and expenseof the snowmobile owner.

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

! WARNINGAny time service is performed ona battery, 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 ventingis not obstructed.

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

MAINTENANCE 61

1. Remove the negative batterycable; then remove the positivecable and on the standard battery,the battery vent tube. Remove thebattery from the snowmobile.Care should be taken not to dam-age the vent 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 remov-ing all 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 bat-tery voltage. The meter must read12.5-13.0 DC Volts for a fullycharged battery.

NOTE: At this point, if the meterreads as specified, the batterymay be returned to service (seestep 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.

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

! 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.

! 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.

62 MAINTENANCE

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 connectedand the charger should continueto charge. If the charger “cuts off,”replace the battery.

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

8. Connect the multimeter and testthe battery voltage. The metershould read 12.5-13.0 DC Volts.If the voltage is as specified, thebattery 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 thebattery posts and cable ends witha light coat of multi-purposegrease.

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

FUSES (660 cc Models)

Fuses protect the snowmobile electri-cal system from overloading. If elec-trical parts in the snowmobile are notworking, the system may have beenoverloaded and caused a blown fuse.Before repairing or replacing any elec-trical part, check the appropriate fuses.The following illustration showswhich fuse protects each electricalpart on the snowmobile. If a fuseblows (opens a circuit), all the parts ofthe snowmobile that use that circuitwill not work.

Battery Charging Chart (Constant-Current Charger)

Battery Voltage

(DC)

ChargeState

Charge Time Required(at 1.5-2.0

Amps)

12.5-13.0 100% 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(positive to negative and nega-tive to positive) can cause seriousdamage to the electrical system.

MAINTENANCE 63

736-448A

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

1. Open the hood and remove thefuse panel cover. The fuse panelis located on the right side of theengine compartment near the bat-tery (for standard models) orbehind the intake manifold (forTurbo models).

NOTE: There is a fuse pullingtool along with spare fuses insidethe fuse panel.

AO352A

NOTE: If the battery/alternatorfuse (80 Amp) must be replaced,the cap screw securing the powercable to the fuse panel must beremoved. This procedure 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.

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 replacedwith a fuse of the correct amper-age rating.

4. Install the fuse panel cover.

Even after replacing a fuse, it maycontinue to blow if the cause of theoverload is not determined. If the fusecontinues to blow, take the snowmo-bile to an authorized Arctic Cat Snow-mobile dealer for service. If not underwarranty, this service is at the discre-tion and expense of the snowmobileowner.

! 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 afire.

64 MAINTENANCE

FUSES (1100 cc Models)

Fuses protect the snowmobile electri-cal system from overloading. If elec-trical parts in the snowmobile are notworking, the system may have beenoverloaded 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.

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

1. Open the right-side access panel;then remove the fuse panel cover.The fuse panel is located behindthe battery.

ZJ005A

NOTE: There are spare fusesinside the fuse panel.

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 replacedwith a fuse of the correct amper-age rating.

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 under war-ranty, this service is at the discretionand expense of the snowmobile owner.

ENGINE HEATER (660 cc Models)

The engine heater will help provideeasier starting in cold weather. ArcticCat recommends that the heater beplugged in any time the temperature isexpected to get below -15°F. Theheater cord is stored on the left rear ofthe engine compartment just above theair-intake vent.

MECHANICAL BRAKE SYSTEM

Arctic Cat recommends that the brakesystem (brake lever, brake lever travel,cable, caliper, spring, and disc) bechecked daily for wear or damage,smooth operation, and proper adjust-ment.

! 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 parking brake isengaged or when any componentin the brake system is damaged,worn, or adjusted improperly. Ifthe snowmobile is operated andthe brake system is not function-ing properly, severe personalinjury could result.

MAINTENANCE 65

Checking Brake Lever Travel

1. Rotate the brake disc alternatelyforward and backward whileslowly compressing the brakelever.

2. At the point where the disc islocked, check the distancebetween the brake lever and thelever stop. The distance must bewithin a range of 6-13 mm (1/4-1/2 in.).

727-451A

3. If distance is not within specifica-tions, adjust the brake levertravel.

Adjusting Brake Lever Travel

1. To decrease brake lever travel (setup brakes), pull out on the brakeadjustment knob and rotate theknob clockwise. As you rotate theknob, periodically check thebrake lever travel distance untilthe correct travel distance isattained. Once the correct brakelever travel has been obtained,release the adjustment knob into asecured position.

NOTE: If the brake adjustmentknob has reached its maximumadjustment (cannot be rotated anyfurther clockwise), both brakepads must be replaced.

730-151A

2. To increase brake lever travel(loosen the brake), pull out on thebrake adjustment knob and rotatethe knob counterclockwise whilechecking the brake lever travel.Once the desired brake levertravel is obtained, release theadjustment knob into a securedposition.

! WARNINGBefore making any adjustment,make certain the brake adjust-ment knob isn’t hot. If the snow-mobile has just been used, youmust allow some time for thebrake adjustment knob to cool orburns may occur.

! WARNINGDO NOT attempt to adjust thebrake with the flange nuts on thebrake cable bracket. Incorrectbrake adjustment may occurcausing possible brake failure.

66 MAINTENANCE

NOTE: When adjusting thebrake, do not accidentally closethe gas tank shut-off valve.

NOTE: When new brake padsare installed, a “burnishing” pro-cess is required. Drive the snow-mobile slowly and compress thebrake lever several times until thepads just start to warm up; thenallow them to cool down. This pro-cedure stabilizes the pad materialand extends the life of the pads.

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 main-tained at a level just below the highmark on the fluid reservoir.

Checking/Adding Brake Fluid

1. With the fluid reservoir/sightglass reservoir in a level position,check the fluid level. The brakefluid level must be just below thehigh mark in the brake fluid reser-voir or visible in the sight glass.

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

740-159A

0740-588

2. If the brake fluid level is belowthe low mark or not visible in thesight glass, remove the reservoircover and add Arctic Catapproved brake fluid until thefluid is at the recommended level.Install and secure the reservoircover. Do not allow moisture tocontaminate the brake system.

! WARNINGWhen the brake adjustment knobhas reached its maximum adjust-ment, both brake pads MUST BEREPLACED. Take the snowmobileto an authorized Arctic Cat Snow-mobile dealer for this service.This service is at the discretionand expense of the snowmobileowner.

! WARNINGDO NOT operate the snowmobilewhen the brake lever lock isengaged or when any componentin the brake system is damaged,worn, or adjusted improperly. Ifthe snowmobile is operated andthe brake system is not function-ing properly, severe personalinjury could result.

! CAUTIONBrake fluid is highly corrosive. Donot spill brake fluid on any sur-face of the snowmobile.

MAINTENANCE 67

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 theend of the snowmobiling season,whichever occurs first. Take the snow-mobile to an authorized Arctic CatSnowmobile dealer for this service.This service is at the discretion andexpense of the snowmobile 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.The distance must be greater than2.54 cm (1 in.).

740-159B

741-328B

3. If the resultant distance is lessthan specified, take the snowmo-bile to an authorized Arctic CatSnowmobile dealer for service.This service is at the discretionand expense of the snowmobileowner.

Bleeding Brake System

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

NOTE: The brake system maybe bled 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. Remove the reservoir cover andfill the reservoir to the high markwith Arctic Cat approved brakefluid.

! 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.

! WARNINGDo 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.

68 MAINTENANCE

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

730-434H

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 brakelever.

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 to a level just below the highmark; 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 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: 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 3.2 mm(0.125 in.) on the standard caliperor greater than 5.0 mm (0.20 in.)on the ACT drive caliper. If thebrake pad thickness is less thanspecified, replacement of bothpads is necessary.

730-434F

! CAUTIONBrake fluid is highly corrosive. Donot spill brake fluid on any sur-face of the snowmobile.

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

STD

ACT

MAINTENANCE 69

0739-269

2. Remove the pin/hairpin clipsecuring the brake pads to the cal-iper assembly.

3. Remove the brake fluid reservoircover; then remove most of thebrake fluid from the reservoir.Replace 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 caliperassembly.

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

5. Using a flat-blade tool, slowlyand carefully push the piston intothe caliper.

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 fluid.

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

10. Fill the reservoir to the properlevel with fresh brake fluid.

NOTE: When new brake padsare installed, a “burnishing” pro-cess is required. Drive the snow-mobile slowly and compress thebrake lever several times until thepads just start to warm up; thenallow them to cool down. This pro-cedure stabilizes the pad materialand extends the life of the pads.

DRIVE BELT

The drive belt transfers power fromthe drive clutch to the driven pulley. Ifthe belt 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 speci-fications are essential.

1. Measure the outside circumfer-ence of the drive belt. The beltshould be within the recom-mended range in circumference.

2. Measure the outside width of thedrive belt. The belt should bewithin the recommended range inwidth.

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 bepurchased from an authorizedArctic Cat Snowmobile dealer, asArctic Cat drive belts are made toexact specifications and of qualitymaterial. Belts made by othermanufacturers may not be of thesame specifications or qualityand, therefore, usage could resultin poor performance and prema-ture belt failure.

70 MAINTENANCE

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

Also, drive belts have a break-inperiod of approximately 20 miles.After installing a new drive belt, drivethe snowmobile for 20 miles at 1/2throttle or less. This will allow thedrive belt to gain its optimum flexibil-ity and will extend drive belt life.

NOTE: On the ACT roller drivenpulley, adding shim washers willdecrease belt deflection andremoving shim washers willincrease belt deflection. Availableshim washers from Arctic Cat arep/n 0648-714 (0.090 in.) - oneincluded in the tool kit of the ACTdrive models, p/n 0648-715 (0.030in.), 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.

Removing Drive Belt (Standard Driven Pulley)

1. Turn ignition key to the OFFposition and wait for all movingparts to stop.

2. Set the brake lever lock.

3. Open the hood; then open the beltguard.

4. Grasp the driven pulley rollerplate and push against it whilerotating it clockwise.

5. When the sheaves are fully apart,hold the roller plate, pull up ondrive belt, and roll the belt overthe stationary sheave until it isfree of the driven pulley. Slowlyrelease the roller plate.

0742-466

6. When the belt is free of drivenpulley, remove the belt from thedrive clutch.

Installing Drive Belt (Standard Driven Pulley)

1. Place the belt (so the part numbercan be read) between the sheavesof the drive clutch.

2. Grasp the driven pulley rollerplate and push against it whilerotating it clockwise.

3. When the sheaves are fully apart,hold the roller plate, roll the beltover the stationary sheave, andslowly release the roller plate.

! CAUTIONNever run the engine with thedrive belt removed. Excessiverevving of the engine could resultin serious engine damage anddrive clutch failure.

MAINTENANCE 71

4. After the belt is installed properly,close and secure the belt guardand the hood.

5. Release the brake lever lock.

Removing Drive Belt (ACT Roller Driven Pulley)

NOTE: Changing a drive beltcan be done 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. Turn ignition key to the OFFposition and wait for all movingparts to stop.

2. Set the brake lever lock.

3. On the Bearcat W/T Turbo, openthe hood; then open the beltguard.

4. On remaining models, open theleft-side access panel; thenremove the panel and the beltguard.

5. On Style A using the spark plugwrench, screwdriver, and BeltDeflection Tool (p/n 0644-435)from the tool kit, remove thesheave adjuster from the end ofthe driven pulley. Account for andremove the O-ring and shimwashers. Note the orientation ofthe components for installing pur-poses.

NOTE: The sheave adjuster hasleft-hand threads.

739-267D

6. On Style B, remove the cap screwand sheave adjuster from the endof the driven pulley. Account forand remove the O-ring and shimwashers. Note the orientation ofthe components for installing pur-poses.

741-721B

7. On Style A with the O-ring andshim washers removed, carefullythread the sheave adjuster backinto the driven pulley; thentighten the adjuster with thedeflection tool/screwdriver/sparkplug wrench assembly until it bot-toms against the driven shaft.

NOTE: By bottoming the sheaveadjuster against the driven shaft,the sheaves of the driven pulleywill spread far enough to allow theremoval of the drive belt.

8. On Style B with the O-ring andshim washers removed, install thesheave adjuster and cap screwback into the driven pulley; thentighten the cap screw until thesheave adjuster bottoms againstthe input shaft.

! WARNINGNever operate the snowmobilewithout the belt guard secured inplace.

72 MAINTENANCE

NOTE: By bottoming the sheaveadjuster against the input shaft,the sheaves of the driven pulleywill spread far enough to allow theremoval of the drive belt.

9. Remove the drive belt from thedrive clutch and driven pulley.

Installing Drive Belt (ACT Roller Driven Pulley)

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. On Style A using the deflectiontool/screwdriver/spark plugwrench assembly, remove thesheave adjuster from the end ofthe driven pulley. Place the shimwashers and O-ring (as noted inremoving) onto the sheaveadjuster; then carefully thread thesheave adjuster back into thedriven pulley. Tighten the adjustersecurely using the deflection tool/screwdriver/spark plug wrenchassembly.

NOTE: Do not over-tighten thesheave adjuster. A torque value of2.1 kg-m (15 ft-lb) is recom-mended.

3. On Style B, place the shim wash-ers and O-ring (as noted inremoving) onto the sheaveadjuster; then install the capscrew and sheave adjuster backinto the driven pulley. Tighten thecap screw to 4.4 kg-m (32 ft-lb).

4. On the Bearcat W/T Turbo, closethe belt guard and the hood.

5. On remaining models, install thebelt guard; then install and closethe left-side access panel.

6. Release the brake lever lock.

TRACK TENSION

Track tension is directly related to theoverall performance of the snowmo-bile. If the track is too loose, it mayslap against the tunnel causing wear orit may “ratchet” on the track drivesprockets. If extremely loose, the idlerwheels may climb over the track lugsforcing the track against the tunnelcausing the track to “lock.” Arctic Catrecommends that the track tension bechecked daily during the first 300miles of operation and once a weekthereafter and adjusted according toneed. The track will stretch and take a“set” during break-in. Track deflectionmust be maintained within the recom-mended range.

Checking Track Tension

1. Remove excess ice and snowbuildup from the track, trackdrive sprockets, and the inside ofthe skid frame.

! 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.

! WARNINGDO NOT attempt to check oradjust track tension with enginerunning. Turn ignition key to theOFF position. Personal injurycould result from contact with arotating track.

MAINTENANCE 73

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 pulldown on the scale to the recom-mended pressure. Measure thedeflection (distance) between thebottom of the wear strip and theinside surface of the track clip.Compare the measurement withthe chart.

729-429E

729-429A

NOTE: On the M-Series, mea-surement is from the bottom ofthe wear strip at the point of theshock pad on the slide rail.

Adjusting Track Tension

1. Loosen the rear idler wheeladjusting bolt jam nuts.

739-636B

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

2. If the deflection (distancebetween the bottom of the wearstrip and the inside of the track)exceeds specifications, tighten theadjusting bolts to take up exces-sive slack in the track.

Model Setup Tension

After Break-In Tension

Panther/T660 Models @ 20 lb

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

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

T-Series/TZ1 Models @ 20 lb

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

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

Bearcat Models@ 20 lb

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

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

F-Series Models @ 20 lb

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

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

Jaguar Z1Model @ 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.)

74 MAINTENANCE

3. If the distance between the bot-tom of the wear strip and theinside surface of the track is lessthan specified, loosen the adjust-ing bolts to increase the slack inthe track.

4. Check track alignment (see TrackAlignment section).

5. When proper track tension isobtained, tighten the adjustingbolt jam nuts against the axlehousings.

NOTE: Since track tension andtrack alignment are interrelated,always check both even if onlyone adjustment 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 willoccur if the track is improperlyaligned. Arctic Cat recommends thatthe track alignment be checked once aweek or whenever the track tension isadjusted.

Checking Track Alignment

1. Remove excess ice and snowbuildup from the track, trackdrive sprockets, and the inside ofthe skid frame.

2. Position the tips of the skisagainst a wall; then using ashielded safety stand, raise therear of the snowmobile off thefloor making sure the track is freeto 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 coastto a stop. DO NOT apply the brakebecause it could produce an inac-curate alignment condition.

! 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 climbover the track lugs forcing thetrack against the tunnel causingthe track to “lock.” If a track“locks” during operation, severepersonal injury could result.

! WARNINGMake sure the ignition key is inthe OFF position and the track isnot rotating before checking oradjusting track alignment. Per-sonal injury could result if contactis made with a rotating track.

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


MAINTENANCE 75

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.

0727-729

0739-637

5. If the idler wheels are not cen-tered between the inner trackdrive lugs, an adjustment is nec-essary.

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 TrackTension section).

3. After proper track alignment isobtained, tighten the adjustingbolt jam nut against the axle hous-ing.

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 pref-erence of the operator.

The front shock springs determine theamount of ski pressure and the reac-tion of the front suspension to roughterrain. The amount of ski pressurecan also be changed by adjusting thelength of the skid frame front arm lim-iter straps.

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

76 MAINTENANCE

The rear springs influence the loadcarrying capability of the snowmobileand should be adjusted for the weightand riding preference of the operator.

Adjusting Front Shock Springs (STD)

NOTE: On some models, thefront shock springs are notadjustable.

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 thespring adjuster and the shock housingas an initial setting. Additional skipressure can be obtained by tighteningthe spring 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 frontend wants to pitch, relax the springtension on the side that is pitching. Ifboth sides are pitching, relax thespring tension 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 shocksmay be done 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.

The air shocks are individually adjust-able for the terrain conditions anddriving style of the operator. Theshocks are preset at the factory (seechart) as an initial setting; however, itis possible to “fine tune” the shocks tomatch the operator’s weight, ridingstyle, and terrain conditions.

NOTE: Care should be taken tohave equal pressure in the skishocks before operating thesnowmobile.

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

Initial Setting Chart

Model Ski Shock Rear Arm Shock

Crossfire Sno Pro/F-Series Sno Pro

4.6 kg/cm2

(65 psi)N/A

M-Series 4.2 kg/cm2

(60 psi)9.5-10.2 kg/cm2

(135-145 psi)

MAINTENANCE 77

NOTE: When adjusting air pres-sure, all weight must be removedfrom the front suspension, andthe shock 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 fromthe shock.

2. Thread the valve of Air ShockPump (p/n 2603-614) onto theshock air valve approximately sixrotations.

NOTE: As the pump is beingattached to the shock, the hosewill fill with air. This will result in alower gauge pressure 0.14-3.52kg/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 pres-sure is attained.

5. Remove the pump valve from theshock air valve.

NOTE: As the pump valve isbeing removed from the shock,the sound of air loss is from thepump hose, 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 as loose aspossible. Tightening the skid framefront arm shock spring may causeimproper balance and may ruin thehandling features 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 skidframe and 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 snowmo-bile. Some experimentation may berequired until the proper adjustmentfor the operator’s individual style isobtained.

! WARNINGDo not exceed 105 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.

78 MAINTENANCE

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 theride, rotate the cam so as to raise thespring end. Make the appropriateadjustment on the other cam.

Articulating Skid Fame (Bearcat Wide Track Models)

The rear articulating portion of theskid frame has two adjusters whichcontrol the amount of travel in the rearsuspension.

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.

0739-642

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.

MAINTENANCE 79

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. To eitherengage or disengage the spring tensionblocks, use the Spring Block Tool, aspark plug socket, and a screwdriverto adjust the spring block to thedesired 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, see theappropriate specifications sheet.

Removing and Installing Taillight/Brakelight Bulb (Bearcat/Panther/T660 Models)

1. Remove the screws securing thetaillight/brakelight lens; thenremove the lens.

728-384C

2. Push in on the bulb and rotate itcounterclockwise to remove itfrom the socket.

3. Install the new bulb in the socketby pushing it in and rotating itclockwise.

4. Install the lens and secure withthe screws.

Removing and Installing Taillight/Brakelight Bulb (Crossfire/F-Series/Jaguar Z1/M-Series/T-Series/TZ1 Models)

1. On the F-Series/Jaguar Z1/TZ1models from inside the rear storagecompartment, remove the self-tap-ping screws and washers securingthe taillight/brakelight housing.

741-680A

2. On the Crossfire/M-Series mod-els, remove the machine screwsecuring the taillight/brakelighthousing to the rear bumper; thenremove the two self-tappingscrws and washers securing thetaillight/brakelight to the housing.

80 MAINTENANCE

0742-338

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 lockinto place.

8. Connect the harness connector.

9. On the Crossfire/M-Series mod-els, secure the taillight/brakelightto the housing with the two self-tapping screws and washers; thensecure the housing to the rearbumper with the machine screw.

10. On the F-Series models, place thehousing into position; then frominside the rear storage compart-ment, secure with the self-tappingscrews and washers.

Removing Headlight Bulb (Bearcat 570/WT Non-Turbo/Panther Models)

NOTE: The bulb portion of theheadlight is fragile. HANDLEWITH CARE. When replacing theheadlight bulb, the bulb assemblymust first be removed from thehousing.

1. Pull the wiring harness retainingclip away from the headlight bulbbase and disconnect the wiringharness from the bulb.

0733-178

2. Rotate the headlight bulb basecounterclockwise and remove thebulb from the headlight housing.

Installing Headlight Bulb (Bearcat 570/WT Non-Turbo/Panther Models)

1. While holding the bulb by itsbase, insert the bulb into the head-light housing and rotate it clock-wise until it locks into thehousing.

2. Plug the wiring harness into theheadlight bulb base making surethe retaining clip locks onto thebase.

! CAUTIONDo not touch the glass portion ofthe bulb. If the glass portion istouched, it must be cleaned with adry cloth before installing.

MAINTENANCE 81

3. Check headlight aim (see Adjust-ing Headlight Aim in this sub-section).

Removing Headlight Bulb (Bearcat W/T Turbo/T660 Models)

NOTE: The bulb portion of theheadlight is fragile. HANDLEWITH CARE. When replacing theheadlight bulb, the bulb assemblymust first be removed from thehousing.

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

740-462A

Installing Headlight Bulb (Bearcat W/T Turbo/T660 Models)

1. Plug the wiring harness into theheadlight bulb.

2. Insert the bulb into the headlighthousing.


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 hous-ing. Do not touch the glass por-tion of the bulb. If the glass istouched, it must be cleaned with adry cloth before installing.

To access the headlight bulbs, use thefollowing procedure:

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

2. Carefully push the headlightlenses rearward far enough toremove the torx-head screwssecuring the air silencer plenumto 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.


! WARNINGDo not operate the snowmobileunless headlight beam is adjustedproperly. An incorrectly adjustedbeam will not provide the operatorthe optimum amount of light.



82 MAINTENANCE

0740-462

Installing Headlight Bulb (Crossfire/M-Series Models)



3. Press the air silencer plenum intoplace on the hood and secure withthe O-rings; then close the hood.

4. Carefully push the headlightlenses rearward far enough toinstall the torx-head screws.Tighten the screws securely.

5. Tighten the headlight adjustmentknobs.


Removing Headlight Bulb (F-Series/Jaguar Z1/T-Series/TZ1 Models)

NOTE: The bulb portion ofheadlight is fragile. HANDLEWITH CARE. When replacing theheadlight bulb, the bulb assemblymust first be removed from thehousing. Do not touch the glassportion of the bulb. If the glass istouched, it must be cleaned with adry cloth before installing.

To access the headlight bulbs, use thefollowing procedure:

1. Remove the two torx-head capscrews located to the outside ofthe headlight adjustment knobs;then remove the single torx-headcap screw from beneath the con-sole (located between the head-lights).

741-505A

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.




MAINTENANCE 83

741-329A

Installing Headlight Bulb (F-Series/Jaguar Z1/T-Series/TZ1 Models)



3. Lift the front of the consoleenough to allow the headlighthousing to be installed; theninstall the housing making surethe forks of the housing go intothe grommets on top of the air-intake silencer. Secure with thecap screw and lock nut.

741-505A

4. Position the console onto the air-intake silencer; then secure withthe single torx-head cap screwbeneath the console (locatedbetween the headlights).

5. Install the two torx-head capscrews located to the outside ofthe headlight adjustment knobs;then tighten securely.


Adjusting Headlight Aim

The headlight can be adjusted for ver-tical aim of the HIGH/LOW beam.The geometric center of HIGH beamzone is to be used for vertical aiming.

1. Position the snowmobile on alevel floor so the headlight isapproximately 8 m (25 ft) from anaiming surface (wall or similarsurface).

NOTE: There should be an“average” operating load on thesnowmobile when adjusting head-light aim.

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.



84 MAINTENANCE

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. On 3-bulb models, adjust theheadlight housing mountingscrews until correct aim isobtained. Shut the engine off;then disengage the brake leverlock.

8. On the Bearcat W/T Turbo/F-Series/Jaguar Z1/T-Series/TZ1models, adjust the headlight usingthe adjustment knobs until correctaim is obtained. Shut the engineoff; then disengage the brakelever lock.

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 mini-mize ski wear, and to maintain goodsteering control. If the snowmobile isoperated primarily in deep snow, skiwear bar wear will be minimal; how-ever, if the snowmobile is operated onterrain where the snow cover is mini-mal, the ski wear bar will wear faster.To maintain positive steering charac-teristics, Arctic Cat recommends thatthe ski wear bars be checked beforeeach use and replaced if worn beyond1/2 of the original diameter. Ski wearbars are available from an authorizedArctic Cat Snowmobile 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 and wash-ers (if applicable) securing thewear bar to the ski.

! WARNINGOperating the snowmobile withexcessively worn ski wear barsmay result in a loss of steeringcontrol.

MAINTENANCE 85

731-037D

0739-596

0739-016

4. Remove the wear bar from the skiand account for the location of thebushings (if applicable).

Installing Ski Wear Bars

1. If applicable, place the bushingsonto the studs; then move thewear bar into position on the bot-tom of the ski.

NOTE: If installing a double-off-set wear bar, the carbide edgemust be directed to the outside ofthe ski; however, on the T660Touring models, the carbide edgemust be directed to the inside ofthe ski.

2. Align the wear bar studs with theholes in the ski; then install thewashers (if applicable) and locknuts. Tighten to 1.5-2.1 kg-m (11-15 ft-lb).

ADJUSTING SKI STANCE (M-Series/Crossfire/Bearcat 570 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 assemblyto the spindle. Remove the ski.Account for the rubber damper,inserts, and washers.

3. To increase ski stance 2.5 cm (1in.), place both ski stance spacersto the outside of the spindle.

4. To decrease ski stance 2.5 cm (1in.), place both ski stance spacersto the inside of the spindle.

5. Apply a low-temperature greaseto the non-threaded portion of thecap screw; then slide the capscrew through the ski accountingfor the rubber damper, inserts, andwashers.

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 6.2 kg-m (45 ft-lb).

7. Place the cotter pin into the skicap screw and spread the pin.

8. Repeat procedure for the otherski.

86 MAINTENANCE

RAIL WEAR STRIPS

Arctic Cat recommends that the wearstrips be checked weekly and replacedas necessary. Measure the wear stripsat 25.4 cm (10 in.) intervals. Wearstrips must be 10.7 mm (0.42 in.) thickor thicker.

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 isat the discretion and expense of thesnowmobile 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 threetimes.

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.

0727-726

AXIAL FAN BELT(370 cc Model)

Arctic Cat recommends that the condi-tion of the axial fan belt be inspectedmonthly.

1. Be sure ignition key is in the OFFposition.

2. Lift the hood and remove thescrews securing the fan cover;then remove the fan cover.

3. Inspect axial fan belt for cracks,wear, and proper tension.

726-155A

4. Using the thumb and forefinger,check the tension (tightness) ofthe fan belt by squeezing the belttogether near mid-span. The max-imum belt deflection must notexceed 6 mm (1/4 in.).

NOTE: If the axial fan belt isdamaged or if the belt deflectionexceeds the specification, takethe snowmobile to an authorizedArctic Cat Snowmobile dealer forrepair or adjustment. This serviceis at the discretion and expense ofthe snowmobile owner.

5. Install the fan cover.

! WARNINGDO NOT inspect the axial fan beltwhile the engine is running. Con-tact with the axial fan belt, fanblades, or other moving parts maycause personal injury.

MAINTENANCE 87

ACCESSORY BELT (660 cc Models)

Arctic Cat recommends that the condi-tion of the accessory belt be inspectedmonthly.

Checking Belt Tension

1. Be sure ignition key is in the OFFposition.

2. On the standard models, removethe air cleaner assembly; on theturbo models, remove the inter-cooler assembly.

3. Remove the bolts securing thebelt guard to the engine; thenremove the belt guard from theengine compartment.

4. Inspect the belt for cracks, wear,and proper tension.

5. Using the thumb, check the ten-sion (tightness) of the belt bypressing down on the belt nearmid-span. The maximum beltdeflection must not exceed 9 mm(0.35 in.).

0736-564

Adjusting Belt Tension

1. Remove the bolts securing thebelt guard to the engine; thenremove the belt guard from theengine compartment.

2. On the alternator, loosen, but donot remove, the tension bolt (A)and the pivot bolt (B).

0736-553

3. Insert a wooden pry bar (such as ahammer handle) between theengine and the alternator, pry thealternator away from the engine,and tighten the accessory belt.

4. When the accessory belt is ten-sioned properly (see AccessoryBelt in this sub-section), tightenthe tension bolt (A) to 2.4 kg-m(17 ft-lb).

5. Tighten the pivot bolt (B) to 5.1kg-m (37 ft-lb).

6. Place the belt guard into positionand secure with the bolts.

7. On the standard models, installthe air cleaner assembly; on theturbo models, install the inter-cooler assembly.

! WARNINGDO NOT inspect the belt while theengine is running. Contact withthe belt, pulleys, or other movingparts may cause personal injury.

88 PERFORMANCE TIPS

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.Be sure, however, to thoroughly readand understand this entire manualespecially the section on spark plugs,track tension and alignment, and sus-pension.

DRIVE BELT — This link betweenthe engine and drive train is often themost neglected component. The drivebelt must have the proper fit in thedrive clutch and driven pulley. Properfit is when the top surface of the drivebelt is flush with the top or up to 1/16in. higher than the driven pulleysheaves (with the sheaves fullyclosed). If the belt sits below thislevel, the snowmobile will bog at slowspeeds and will have a slower maxi-mum speed. To correct this condition,first determine if the drive belt iswithin specifications (see Drive Beltsection) and replace if worn or toolong. Secondly, it may be necessary toremove a shim washer from betweenthe driven pulley sheaves to allow thedriven pulley to close tighter. On theACT roller driven pulley, adding shimwashers will decrease belt deflectionand removing shim washers willincrease belt deflection. Availableshim washers from Arctic Cat are p/n0648-714 (0.090 in.) - one included inthe tool kit on the ACT drive models,p/n 0648-715 (0.030 in.), and p/n0648-716 (0.060 in.).

NOTE: On ACT roller driven pul-ley, removing/adding shim washersmay be done 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.

Finally, always run the drive belt inthe same direction. Installing the drivebelt so the part number can be readwill ensure that the drive belt isalways run the same direction.

DRIVE CLUTCH AND DRIVENPULLEY — Keeping the driveclutch and driven pulley clean shouldbe the primary consideration of theoperator. The clutch sheaves can becleaned of any drive belt accumulationusing a clean cloth and parts-cleaningsolvent. All pivot points can be main-tained clean using compressed air.

CARBURETOR MAIN JET(S)(Carbureted Models) — Proper carbu-retion is absolutely necessary to obtainpeak performance. Since ambient tem-perature and operating altitude bothaffect the main jet size needed for opti-mum engine performance, the mainjet(s) MUST be changed whenever thetemperature changes 20° F or when-ever operating altitude varies by morethan 1000 feet. The Main Jet Chartbeneath the hood of the snowmobileidentifies the proper main jet(s) to useunder all operating temperatures andaltitudes. Follow the Main Jet Chartcarefully to obtain peak engine perfor-mance and avoid 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 willnot increase overall performance.

PREPARATION FOR STORAGE 89

PREPARATION FOR STORAGEPrior to storing the snowmobile, itmust be properly serviced to preventcorrosion and component deteriora-tion. An authorized Arctic Cat Snow-mobile dealer should perform thisservice; however, the owner/ operatorcan perform this service if desired.This service is at the discretion andexpense of the snowmobile owner. Toprepare the snowmobile for storage,Arctic Cat recommends the followingprocedure:

1. Clean the seat cushion with adamp cloth and Arctic Cat VinylProtectant (p/n 0638-313).

2. Clean the snowmobile thoroughlyby hosing dirt, oil, grass, andother foreign matter from the skidframe, tunnel, hood, and bellypan. Allow the snowmobile to drythoroughly. DO NOT get waterinto any part of the engine.

NOTE: On 4-stroke models,change the engine oil and cleanthe air filter; then proceed to step9.

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 for-ward; then spray Arctic CatEngine Storage Preserver (p/n0436-888) into the intakes untilthe engine exhaust starts to smokeheavily or until the engine startsto drop in RPM. Turn engine off.

NOTE: On the 500/600/800/1000cc engine models after step 4,proceed to step 9.

NOTE: On some standard mod-els, the air-intake silencer is aone-piece unit, and the silencerboot(s) can be removed to accessthe intake bore(s). Remove theboots; then proceed to step 8.

NOTE: On some standard mod-els, the air-intake silencerincludes a cover/tool tray assem-bly and a baffle/resonator, and thesilencer boot cannot be removedto access the intake bores. Pro-ceed to step 5.

5. Open the air-intake silencercover; then remove the Phillips-head screws securing the cover/tool tray assembly to the silencer.

6. Close the cover; then tip thecover/tool tray assembly forwardand out of its slots and remove theassembly.

7. Using a large flat-blade screw-driver, remove the baffle/resona-tor tabs from the air-intakesilencer slots and remove the baf-fle/resonator to access the intakebores.

NOTE: The baffle/resonator canbe removed more easily by remov-ing the back tabs first.

8. Start the engine and allow to idle.With the engine idling, spray Arc-tic Cat Engine Storage Preserver(p/n 0436-888) into the intake(s)until the engine exhaust starts tosmoke heavily or until the enginestarts to drop in RPM. Turnengine off.

NOTE: On some models, installthe air-intake silencer boot(s); onsome models, install the baffle/resonator and the cover/tool trayassembly.

90 PREPARATION FOR STORAGE

9. Plug the exhaust system outletwith a clean cloth.

10. With the ignition switch in theOFF position:

A. Disconnect the high tensionleads from the spark plugs;then remove the plugs, con-nect them to the leads, andground them on the cylinderheads.

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 andconnect the high tension leads.

11. On carbureted models, drain thegas from each carburetor floatchamber.

12. Fill the gas tank to its rated capac-ity; then add Arctic Cat Fuel Sta-bilizer (p/n 0436-907) to the gastank following directions on thecontainer for the stabilizer/gaso-line ratio. Tighten the gas tankcap securely.

13. On standard chain case models,drain the chain-case lubricant byremoving the chain-case drainplug located on the backside ofthe chain-case assembly. Removethe chain-case cover and inspectchain, sprockets, chain tensioner,and rollers for wear and the chainfor proper tension. Install thedrain plug, chain-case cover, andseal; then pour the recommendedamount of Arctic Cat Transmis-sion Lube (p/n 0636-817) into thefiller hole (see Lubrication sec-tion).

14. On ACT drive gear case models,flush the gear case and replace thelubricant (see Lubrication sec-tion).

15. Remove the drive belt from thedrive clutch/driven pulley. Laythe belt on a flat surface or slide itinto a cardboard sleeve to preventwarping or distortion during stor-age.

16. Clean and inspect the drive clutchand driven pulley.

17. Apply light oil to the upper steer-ing post bushing, ski spindles andbolts, front and rear pivot bush-ings of the skid frame, and plung-ers of the shock absorbers.

18. Lubricate the rear suspension,spindles, speedometer driveadapter, and driven shaft supportbearing with a low-temperaturegrease.

19. Tighten all nuts, bolts, and capscrews making sure all calibratednuts, bolts, and cap screws aretightened to specifications. Makesure all rivets holding the compo-nents together are tight. Replaceall loose rivets.

! CAUTIONDo not do step 10 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 unitmay result.

PREPARATION FOR STORAGE 91

20. Clean and polish the hood, con-sole, and chassis with Arctic CatHood and Windshield Cleaner/Polish (p/n 0636-174). DO NOTUSE SOLVENTS OR SPRAYCLEANERS. THE PROPEL-LANT WILL DAMAGE THEFINISH.

21. On electric start models, discon-nect the battery cables makingsure to disconnect the negativecable first; then clean the batteryposts and cables. Charge the bat-tery.

22. 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 tarpau-lin to protect it from dirt and dust.

23. 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 tracktension. Cover with a machinecover or a heavy tarpaulin to pro-tect it from dirt, dust, and rain.

! CAUTIONSealed batteries require chargingif left for extended non-start peri-ods. Arctic Cat recommendstrickle charging once a month.Follow the manufaturer’s instruc-tions and cautions.

! CAUTIONAvoid storing in direct sunlightand using a plastic cover as mois-ture may collect on the snowmo-bile causing corrosion.

92 PREPARATION AFTER 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 thor-oughly. Polish the exterior of thesnowmobile.

2. Clean the engine. Remove thecloth from the exhaust system.Check exhaust system and air-intake silencer/air filter forobstructions.

3. Inspect all control wires andcables for signs of wear or fray-ing. Replace if necessary. Usecable ties or tape to route wiresand cables away from hot or rotat-ing parts.

4. Inspect the drive belt for cracksand tears. Check belt specifica-tions. Replace if damaged orworn. 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 oilhoses for deterioration or cracks;replace if necessary. Make sure allconnections are tight; then on 2-stroke models, fill the oil-injec-tion reservoir with the recom-mended 2-cycle oil (see Gasoline-Oil sub-section).

NOTE: After prolonged storageof 2-stroke models, Arctic Cat rec-ommends one tankful of 100:1gas/oil mixture be used in con-junction with the oil-injection sys-tem to ensure proper lubrication.

7. On 2-stroke and 660 cc models,inspect the spark plugs. Replace,gap, or clean as necessary.

8. Verify the condition of and theadjustment of the carburetor(s)and choke cable on carburetedmodels and throttle cable on allmodels.

9. Tighten all nuts, bolts, and capscrews making sure all calibratednuts, bolts, and cap screws aretightened to specifications.

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.

! CAUTIONOn carbureted models if the gasin each carburetor float chamberwas not drained prior to storage,the carburetor(s) 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 slide notto return to the full-closed posi-tion.

PREPARATION AFTER STORAGE 93

12. On fan cooled models, clean theengine cooling fins and vents.

13. On electric start models, chargethe battery until fully charged;then connect the battery cablesmaking sure to connect the posi-tive cable first. Test the electricstart system.

14. Inspect the entire brake system,all controls, 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.

94

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 Valve

Ignition 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.

95

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) _________________

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

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

97

MAINTENANCE RECORDDATE MILEAGE SERVICE PERFORMED/NOTES

98

MAINTENANCE RECORDDATE MILEAGE SERVICE PERFORMED/NOTES

WARRANTY PROCEDURE/OWNER RESPONSIBILITY

At the time of sale, an Owner Registration form (included with each newsnowmobile) is to be completed by the selling dealer and consumer. Thereceipt of the registration form by Arctic Cat is a condition precedent towarranty coverage. It is the selling dealer’s responsibility to retain and/orsubmit the appropriate copies of the form to the appropriate place(s) toinitiate warranty coverage.

The dealer will furnish to the consumer a signed copy of the form whichmust be presented to the dealer when requesting warranty service. Theregistration form is the consumer’s proof of ownership andwarranty eligibility. The form is used by the dealer to validate thewarranty claim. Retain your copy of the form and keep it in a safe place.

When warranty repair is suspected, the snowmobile should be taken tothe selling dealer, who has the primary responsibility to perform warrantyrepairs. In the event the selling dealer has ceased to do business, youhave moved, or you are in a location away from your selling dealer,warranty may be performed by any authorized Arctic Cat Snowmobiledealer.

The authorized Arctic Cat Snowmobile dealer will examine thesnowmobile or part to determine if, in his opinion, a warrantablecondition exists. If a warrantable condition appears to exist, the dealerwill repair or replace, at Arctic Cat’s option, free of charge, including anyrelated labor costs, all parts that are found to be warrantable and anyother parts which the warrantable part caused to be damaged. You, theconsumer, will then be asked to sign a warranty form to ensure ArcticCat that the warranty work was actually performed.

It is the consumer’s responsibility to maintain and service thesnowmobile in accordance with Arctic Cat’s recommendations in theOperator’s Manual. To protect yourself and your snowmobile, follow allsafety and service tips. Arctic Cat will NOT warrant repairs requiredas a result of not performing standard operator maintenance,storage procedures, and service as outlined in the Operator’sManual.

Should you have any questions concerning the warranty, contact anauthorized Arctic Cat Snowmobile dealer.

Arctic Cat Inc., P.O. Box 810, Thief River Falls, MN 56701 (218) 681-8558

ARCTIC CAT®

Printed in U.S.A. Trademarks of Arctic Cat Inc. Thief River Falls, MN 56701 p/n 2257-929Phone: (218) 681-9851 - U.S./(204) 982-1772 - Canada

®TM

Documents

SnowmobileSnowmobile Operator’sOperator’s Manual · PDF fileLIMITED WARRANTY Arctic Cat Inc. (hereinafter referred to as Arctic Cat) extends a limited warranty on each new Arctic