Snowmobile Operator's Manual

2006Snowmobile

Operator’s

Manual

p/n 2257-327

LIMITED WARRANTY Arctic Cat Inc. (hereinafter referred to as Arctic Cat) extends a limited warranty on each new ArcticCat Snowmobile it manufactures and on each part and accessory manufactured or sold by Arctic Cat.The warranty is extended to the original retail purchaser only on parts and accessories sold throughan authorized Arctic Cat Snowmobile dealer. Warranty on snowmobiles is extended to the originalretail purchaser; 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 saidparts by Arctic Cat or an authorized Arctic Cat Snowmobile dealer. Arctic Cat reserves the right toinspect such 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 (i.e. rental operations and power and lightcompanies), NINETY (90) DAYS from the date of sale.

3. SIX (6) MONTHS from date of sale for batteries on a full exchange basis and 50% exchange forthe remaining SIX (6) MONTHS of the first year.

4. THIRTY (30) DAYS from date of sale for all dealer installed 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 bogie wheels), and the following parts:

Fuel Filter Light Bulbs Windshield Cracks or gouges in Body Parts and Hoods

Drive Belt Wear Bars Water Pump Belt Brake Pads

Wear Strips Fan Belt Spark Plugs Clutch Wear Parts (bushings, etc.)

The following will VOID Arctic Cat’s warranty:

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

2. Repair by anyone other than an authorized Arctic Cat Snowmobile dealer.

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 to doso 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.

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 rightswhich vary from state to state and country to country. Some states do not allow limitations on howlong an implied 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 ......................................4-25

Snowmobile Identification .........................4Control Locations......................................4Tipped Snowmobile ..................................5Gasoline-Oil..............................................6Engine Break-In (2-Stroke Models)...........9Engine Break-In (660 cc Models)..............9Indicator Lights (Standard Models) .........10Low Oil Warning Light

(Standard 2-Stroke Models) ................10Low Oil Pressure Warning Light

(660 cc Models)...................................10High Temperature Warning Light (Standard Liquid Cooled Models) .........10Charging System Warning Light

(660 cc Models)...................................11Check Engine Light (660 cc Models).......11Speedometer/Tachometer ......................11Handlebar Tilt .........................................13Handlebar Tilt

(Firecat/ZR 900/Turbo ST) ..................14Exhaust System......................................14Air-Intake Silencer ..................................14Battery (Electric Start Models) ................15Cooling System (Liquid)..........................15Drive Clutch and Driven Pulley................15Drive Clutch/Driven Pulley Alignment .................................16Drive Chain Tension

(Automatic System).............................16Drive Chain Tension (Adjustable System) ............................16Fuel Pump ..............................................17Gas Tank Shut-Off Valve.........................17Shock Absorbers (Standard Gas) ...........17Shock Absorbers (Rebuildable Gas) .......17Deep-Lug Track (Sno Pro Models) ..........18Attack 20 Track (M-Series/King

Cat Models).........................................18Track Studs .............................................19Reverse Transmission ............................20Towing ....................................................20Adjustable Backrest ...............................21Removable Rear Seat.............................21Removable Seat (M-Series/King Cat/

Sabercat Models)................................22Arctic Power Valve (APV) System ...........22Exhaust Controlled Timing

(ECT) System (Firecat 500) ................24

Operating Instructions.................................26-33Starting and Stopping Engine .................26High RPM Operation

(660 cc Models) ..................................29Braking (Hydraulic Brake Models)...........29Emergency Stopping ..............................31Throttle/Ignition Monitor Switch

(2-Stroke Models) ...............................31Varying Altitude Operation ......................33

Lubrication ..................................................34-37Standard Chain Case .............................34ACT Drive Gear Case .............................35Front Suspension ...................................36Speedometer Drive Adapter ...................36Rear Suspension ....................................36

Maintenance ...............................................38-78Periodic Maintenance Checklist..............38Fuel System............................................39Checking Oil-Injection System

(2-Stroke Models) ...............................40Checking Engine Oil Level

(660 cc Models) ..................................41Changing Engine Oil (660 cc Models).....41Adjusting Carburetor -

VM-Style (Single)................................42Adjusting Carburetors - VM-Style (Twin) .44Adjusting Carburetors - TM-Style............48Selecting Carburetor Main Jet(s) ............50Spark Plugs ............................................51Charging Battery

(Electric Start Models) ........................53Fuses (660 cc Models)............................55Engine Heater (660 cc Models)...............56Mechanical Brake System ......................56Hydraulic Brake System .........................57Drive Belt ................................................61Track Tension..........................................64Track Alignment ......................................66Suspension.............................................67Lights......................................................71Ski Wear Bars.........................................74Adjusting Ski Stance(M-Series/ King Cat/Bearcat 570 Models) ...........76Rail Wear Strips......................................76Axial Fan Belt (370/440 cc Models).........77Accessory Belt (660 cc Models)..............77

Performance Tips.............................................79Preparation For Storage..............................80-82Preparation After Storage ...........................83-84U.S. EPA Emission Control Statement/

Warranty Coverage .............................86Change of Address, Ownership,

or Warranty Transfer ...............................87Warranty Procedure/Owner Responsibility ......89

REFERENCE INFORMATIONWrite the appropriate information for your Arctic Cat Snowmobile in the spaces below. 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: __________________________________________________

PERSONAL INJURYTo avoid injury to yourself and others, NEVER operate the

snowmobile without first reading and understanding this manual and the Snowmobile Safety Handbook; then follow the instructions and heed the warnings given.

USE COMMON SENSE.

DON’T DRINK and DRIVE.

STAY IN CONTROL at ALL TIMES.

TELL YOUR FRIENDS. If you see a friend operating a snowmobile recklessly, at excessive speeds, while intoxicated, or in other unsafe ways, don’t wait until it is too late to warn of the consequences of snowmobile misuse. Such conduct endangers everyone. TAKE AN ACTIVE ROLE IN THE SAFETY OF YOURSELF AND OTHERS.

PARTS AND ACCESSORIESWhen in need of replacement parts, oil, or accessories for yourArctic Cat Snowmobile, be sure to only use GENUINE ARCTICCAT PARTS, OIL, AND ACCESSORIES. Only genuine Arctic Catparts, oil, and accessories are engineered to meet the standardsand requirements of your Arctic Cat Snowmobile. For a completelist of accessories, refer to the current Arctic Cat Accessory Cata-log. An Illustrated Parts Manual is available through your localArctic Cat Snowmobile dealer.

! WARNINGA snowmobile is a very high performance vehicle. Because it doesaccelerate rapidly and is capable of very high speeds, it should not beoperated by a novice or an inexperienced operator. Never acceleraterapidly or drive at high speed beyond the limits of visibility or withoutbeing totally familiar with the terrain and what lies in front of you.Obey speed limits and never operate at speeds that do not allow ade-quate maneuvering and stopping distances. Read and study the entireOperator’s Manual and Safety Handbook.Failure to follow this warning could result in personal injury to your-self or others.

4 GENERAL INFORMATION

GENERAL INFORMATIONSNOWMOBILE IDENTIFICATIONThe Arctic Cat Snowmobile has twoimportant identification numbers.The Vehicle Identification Number(VIN) is stamped into the tunnelnear the right-side footrest. TheEngine Serial Number (ESN) isstamped into the crankcase of theengine.

0726-383

These numbers are required by thedealer to complete warranty claimsproperly. No warranty wil l beallowed by Arctic Cat Inc. if theengine serial number or VIN isremoved or mutilated in any way.Always provide the snowmobilename, VIN, and ESN when contact-ing an authorized Arctic Cat Snow-mobile dealer for parts, service,accessories, or warranty. If the com-plete engine must be replaced, askthe dealer to notify Arctic Cat forcorrect registration information.

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

Panther Models

739-592C

Z Models

734-268A

ZR 900 Models

739-582B

GENERAL INFORMATION 5

Crossfire/M-Series Models

0739-609

T660/Bearcat Wide Track Models

740-587A

Bearcat 570 Models

740-586A

Firecat/Sabercat Models

739-696A

TIPPED SNOWMOBILETipping a snowmobile on its side issometimes desirable for mainte-nance purposes; however, on Fire-cat/Sabercat models, Arctic Catrecommends NOT TIPPING ITON ITS RIGHT SIDE FOR ANYEXTENDED PERIOD OF TIME,and on a 660 cc model, Arctic Catrecommends NOT TIPPING ITON ITS SIDE IN EXCESS OF A70° 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:

! CAUTIONThe Firecat/Sabercat modelsshould not be tipped on theirright sides for any extendedperiod of time, as air bubblesmay form in the oil hose. If airbubbles form in the oil hose, theoil injection system must bebled. Take the snowmobile to anauthorized Arctic Cat snowmo-bile dealer for this service. Thisservice is at the discretion andexpense of the snowmobileowner.

! CAUTIONThe 660 cc models should notbe t ipped on their s ides inexcess of a 70° angle for anyreason, as engine oil may seepinto the upper engine throughthe air-intake system. Severeengine damage could result ifthe engine is run with oil in theupper engine.


1. With the ignition switch in theOFF posi t ion , remove theengine to air-intake silencerhose at the engine. If oil ispresent, proceed to step 2. If nooil is present, install the hoseand start the engine.

AO224B

2. Remove the air-intake silencerfrom the engine. If oil is presentin the air-intake silencer, pro-ceed to step 3. If no oil ispresent, install the air-intakesilencer and the engine to air-intake silencer hose; then startthe engine.

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

3. Remove the spark plugs fromthe engine and cover the sparkplug holes with a rag (seeSpark Plugs in this manual).With the emergency stop buttonin the down (OFF) position,turn the ignition switch to theSTART position.

4. Allow the engine to turn overfor approximately 10 seconds.If oil was noted coming fromthe spark plug holes during thisprocedure, repeat the processuntil all oil has been dischargedfrom the cylinders.

5. Install the spark plugs, sparkplug wires, air-intake silencer,and the engine to air-intakesilencer hose.

NOTE: The engine should nowbe safe to operate.

GASOLINE-OIL

Recommended Gasoline (Carbureted Models)The recommended gasoline to use inthese snowmobiles is 87 minimumoctane regular unleaded. In manyareas, oxygenates (either ethanol orMTBE) are added to the gasoline.Oxygenated gasolines containing upto 10% ethanol or up to 15% MTBEare acceptable gasolines; however,whenever using oxygenated gaso-lines, the carburetor main jet mustbe one size larger than the main jetrequired for regular unleaded gaso-line. For example, if a 400 main jeti s r ecommended fo r r egu l a runleaded gasoline, a 410 main jetmust be installed if using an oxygen-ated gasoline.When using ethanol blended gaso-line, it is not necessary to add a gas-oline antifreeze since ethanol willprevent the accumulation of mois-ture in the fuel system.

! CAUTIONCare must be taken wheninstalling the hose that it doesnot sag below the entrance/exitends. If there is a “valley” in thehose, freezing may occur.

! CAUTIONDo not use white gas or gaso-lines containing methanol. OnlyArctic Cat approved gasolineadditives should be used.


Recommended Gasoline(EFI Models)NOTE: The 660 cc models arenot equipped with a fuel designa-tion connector.

The recommended gasoline to use inthese snowmobiles is 87 minimumoctane regular unleaded, and theFuel Designation Connector at theECU must be connected. In manyareas, oxygenates (either ethanol orMTBE) are added to the gasoline.Oxygenated gasolines containing upto 10% ethanol or up to 15% MTBEare acceptable gasolines; however, ifoxygenated gasoline is used, the fueldesignation connector at the ECUmust be disconnected. Do not usegasolines containing methanol.

NOTE: In order for the ECU tochange modes, the engine mustbe OFF when connecting or dis-connecting the fuel designationconnector.

Recommended Injection OilThe recommended oil to use in theoil-injection system is Arctic Cat50:1 Injection Oil (for standardmodels) or Arctic Cat SyntheticAPV 2-Cycle Oil (for APV models).These oils are specially formulatedto be used either as an injection oilor as a pre-mix oil (for break-in) andmeets all of the lubrication require-ments of the Arctic Cat snowmobileengine.

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 theambient temperature at which theengine is run. See the viscosity chartfor details.

GEN-0048A

! CAUTIONDo not use white gas or gaso-line containing methanol. OnlyArctic Cat approved gasolineadditives should be used.

! CAUTIONIf oxygenated gasoline is to beused, it is extremely importantthat the fuel designation con-nector at the ECU is discon-nected . I f not when us ingoxygenated gasoline, severeengine damage may occur.

! 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 seri-ous damage.

Multi-Grade


Recommended Engine Oil(660 cc Turbo)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 standard 660 ccmodels and every 2000 miles on660 cc Turbo models and beforeprolonged storage.

Filling Gas TankSince gasoline expands as its tem-perature increases, the gas tank mustbe filled to its rated capacity only.Expansion room must be maintainedin the tank particularly if the tank isfilled with cold gasoline and thenmoved to a warm area. Also, if thesnowmobile is to remain on a trailerafter filling the gas tank, the bed ofthe trailer must be maintained levelto prevent gasoline from drainingout through the gas tank vent hose.

Break-In Gas/Oil Mixing Instructions (2-Stroke Models)Before mixing gasoline and oil,make sure the oil is at room temper-ature (20° C/68° F). Use a U.L.approved 22.7 l (6 U.S. gal.) gaso-line container for mixing the gaso-line and oil. To properly mix the fuelat a 100:1 ratio, use the followingprocedure:

1. Pour gasoline into the gasolinecontainer until approximatelyhalf full.

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

3. Install cap on gasoline con-tainer and shake the mixturevigorously.

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

5. Using a fine-mesh screenedfunnel, pour the fuel mixturefrom the gasoline container intothe snowmobile 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 withthe engine running. DO NOTSMOKE while filling the gastank. Do not sit on the snowmo-bile without first installing thegas tank cap.

! CAUTIONNever mix oil and gasoline inthe snowmobile 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 withthe engine running. DO NOTSMOKE while mixing fuel or fill-ing the gas tank.


ENGINE BREAK-IN(2-Stroke Models)The Arctic Cat 2-stroke engine(when new or rebuilt) requires ashort break-in period before theengine is subjected to heavy loadconditions. Arctic Cat requires thatthe first tankful of fuel be premixedat a 100:1 ratio in all oil-injectionmodels.During the break-in period, a maxi-mum of 1 /2 throt t le i s recom-mended; however, brief full-throttleaccelerations and variations in driv-ing speeds contribute to good enginebreak-in. After one (1) tankfulbreak-in period, the snowmobilemay be taken to an authorized ArcticCa t Snowmobi le dea le r fo r acheckup. This checkup is at the dis-cretion and the expense of the snow-mobile owner.

ENGINE BREAK-IN (660 cc Models)The Arctic Cat 660 cc engine (whennew or rebuilt) requires a shortbreak-in period before the engine issubjected to heavy load conditions.This engine does not require anypre-mixed fuel during the break-inperiod.

To ensure trouble-free operation,careful adherence to the followingbreak-in guidelines will be benefi-cial.

* With occasional full-throttle operation.To ensure proper engine break-in onstandard models, Arctic Cat recom-mends that the engine oil and filterbe changed after 600 miles or afterone month, whichever comes first.This service is at the discretion andexpense of the snowmobile owner.To ensure proper engine break-in onTurbo models, Arctic Cat recom-mends that the engine oil and filterbe changed after 200-500 miles.This service is at the expense of thesnowmobile owner.

! CAUTIONDO NOT exceed the one (1) tank-ful limitation of a 100:1 gas/oilbreak-in mixture. Continuoususe of a gas/oil mixture, unlessconsis tent ly operat ing inextremely cold conditions (-26°C/-15°F or colder), couldcause spark plug fouling andexcessive carbon buildup. A100:1 gas/oil mixture must beused in conjunction with the oil-injection system to ensure ade-quate engine lubrication inextremely cold conditions.

! CAUTIONDO NOT use premixed fuel inthe snowmobi le gas tank .Engine damage will occur.

0-200 miles1/2 Throttle

(45 MPH-max)

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

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


INDICATOR LIGHTS (Standard Models)Indicator lights are incorporatedwithin the speedometer.

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 pre-scribed level; however, it is highlyrecommended that a visual verifica-tion of the oil level in the reservoirbe done prior to operating the snow-mobile. Once the Low Oil WarningLight illuminates during operationof the snowmobile, the operatormust periodically monitor the levelof oil in the reservoir and must fillthe reservoir the next time gasolineis added to the gas tank. The “alertlevel” of the Low Oil Warning Lightis approximately equal to 1 tankfulof gasoline under normal operatingconditions.

LOW OIL PRESSURE WARNING LIGHT (660 cc Models)The Low Oil Pressure WarningLight indicates engine oil pressure,not the oil level; however, if the oillevel is low, it may affect oil pres-sure. The light should illuminateeach time the ignition switch isturned to RUN or START, and itshould go out when the enginestarts. If the light illuminates whilethe engine is running, oil pressurehas been lost and the engine willautomatically shut off. If oil pressure is lost, use the follow-ing procedure:

1. Check the oil level.

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

2. If the oil level is below thelower mark on the oil levelstick, add only enough recom-mended oil to raise the levelbetween the upper and lowermarks. DO NOT overfill thecrankcase with oil.

3. After adding oil if the enginestarts, oil pressure should benormal.

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

HIGH TEMPERATURE WARNING LIGHT (Standard Liquid Cooled Models)The High Temperature WarningLight is designed to alert the snow-mobile operator when the tempera-ture of the engine coolant exceeds asafe operating temperature. If theHigh Temperature Warning Lightilluminates during operation of thesnowmobile, immediately shut offthe engine and determine the natureof the problem (low coolant level,etc.). If unable to either determine orremedy the problem, take the snow-mobile to an authorized Arctic CatSnowmobile dealer for service. Ifnot under warranty, this service is atthe discretion and expense of thesnowmobile owner. NOTE: Operating the snowmo-bile at slow speed over minimalsnow or hard pack terrain maycause excessive engine heatbuild-up. If the High TemperatureWarning Light illuminates underthese conditions, immediatelychange to a loose snow terrain.


CHARGING SYSTEM WARNING LIGHT (660 cc Models)The Charging System WarningLight is designed to warn the opera-tor if the battery charging system isnot functioning. The light shouldilluminate each time the key isturned to RUN or START, and itshould go out when the enginestarts. If the light stays illuminatedor it illuminates while the engine isrunning, the battery is not beingcharged, and the snowmobile is run-ning on battery reserve power only.If the Charging System WarningLight illuminates, you should, assoon as possible, take the snowmo-bile to an authorized Arctic CatSnowmobile dealer for service. Ifnot under warranty, this service is atthe discretion and expense of thesnowmobile owner. The engineWILL NOT RUN without batterypower.

CHECK ENGINE LIGHT(660 cc Models)The Check Engine Light is con-trolled by the ECU and may illumi-nate for a number of reasons. Thelight should illuminate each time thekey is turned to RUN or START, andit should go out when the enginestarts. If the light stays illuminatedor it illuminates while the engine isrunning, the ECU is receiving inputthat is outside of its establishedparameters. If the Check EngineLight illuminates, take the snowmo-bile to an authorized Arctic CatSnowmobile dealer for service. Ifnot under warranty, this service is atthe discretion and expense of thesnowmobile owner.

SPEEDOMETER/TACHOMETER Some models are equipped with acombination speedometer/tachome-ter. Also incorporated into thespeedometer/tachometer are a digi-tal readout screen and indicatorlights (battery, low oil, high beam,check engine, and high tempera-ture). NOTE: The functions of the dig-ital readout and indicator lightswill vary from model to model.

Top ButtonBy pushing the top button once(lower right-hand side of the speed-ometer/tachometer), the RPM andMPH will be displayed (one on thereadout screen and one with the nee-dle). By pushing the button onceagain, the functions will be reversed. By pushing the top button (withspeed being displayed) for morethan two seconds, the display willshow between standard mph or met-ric kph. Release the button whendesired display appears.By pushing and holding the top but-ton, maximum RPM will be dis-played on the readout screen. Themaximum RPM readout will resetwhen the engine is shut off.

Bottom ButtonBy pushing the bottom button once,the readout screen will display hour-meter or trip-meter/odometer; bypushing the button once again, thetwo functions will be reversed. Thehour-meter readout will not reset.


Low Oil Warning LightThe Low Oil Warning Light isdesigned to alert the snowmobileoperator when the oil in the oil-injection reservoir gets below a pre-scribed level; however, it is highlyrecommended that a visual verifica-tion of the oil level in the reservoirbe done prior to operating the snow-mobile.Once the Low Oil Warning Lightilluminates during operation of thesnowmobile, the operator must peri-odically monitor the level of oil inthe reservoir and must fill the reser-voir the next time gasoline is addedto the gas tank. The “alert level” ofthe Low Oil Warning Light i sapproximately equal to 1 tankful ofgasoline under normal operatingconditions.

High BeamOn the Firecat/Sabercat/ ZR 900models, the headlight HIGH/LOWbeam switch is incorporated into thebrake lever. Pushing the lever for-ward will activate the switch. Whenon HIGH beam, the high beam indi-cator light will be illuminated.

Diagnostic Codes/Check Engine/High Temperature Warning Light (Carbureted Models) On the Firecat 500 if exhaust pipetemperature is excessively high, thecheck engine light will flash a warn-ing (alert). Immediately shut off theengine and determine the nature ofthe problem (see Exhaust ControlledTiming (ECT) System in this man-ual).The High Temperature WarningLight is designed to alert the snow-mobile operator when the tempera-ture of the engine coolant exceeds asafe operating temperature.

If the coolant temperature is at orabove 80° C (176° F), the high tem-perature warning light will flash awarning (alert). If the coolant tem-perature is at or above 93° C (200°F), the high temperature warninglight will cease flashing and willremain constantly illuminated. NOTE: At this point, the opera-tor should take precautionarymeasures such as changing toloose snow terrain and/or check-ing coolant level.

Additional codes are flashed by thecheck engine light and high temper-ature warning light. Refer to the fol-lowing chart for diagnostic codesequences.

! CAUTIONIf unable to either determine orremedy the problem, take thesnowmobile to an authorizedArctic Cat Snowmobile dealerfor service.

Number of Flashes Trouble

1(Check Engine

Light)

Open or short circuit in throttle position sensor.

2(Check Engine

Light)

Open or short circuit in water temperature sensor.

6(Check Engine

Light)Failure in servomotor.

Steady Flash(High Temp

Light)

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

Constant On(High Temp

Light)



Diagnostic Codes/Check Engine (EFI Models)If the coolant temperature is at orabove 80° C (176° F), the checkengine light will flash a warning(alert). If the coolant temperature isat or above 93° C (200° F), thecheck engine light will cease flash-ing and will remain constantly illu-minated. NOTE: At this point, the operatorshould take precautionary mea-sures such as changing to loosesnow terrain and/or checking cool-ant level.

Additional codes are flashed by thecheck engine light. Refer to the fol-lowing chart for diagnostic codesequences.

HANDLEBAR TILTThe 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 andblock to the steering post.

0734-406

2. Adjust the handlebar up ordown to operator’s desired tilt;then t ighten the lock nutsevenly and securely. Checksteering for maximum right/leftturning capabilities.

3. Recheck lock nuts; tightensecurely.

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


1(Check Engine

Light)

Open or short circuit in throttle position sensor.

2(Check Engine

Light)

Open or short circuit in water temperature sensor.

3(Check Engine

Light)

Open or short circuit in intake air temperature sensor.

4(Check Engine

Light)

Open or short circuit in barometric pressure sensor.

5(Check Engine

Light)Failure in injector(s).

6(Check Engine

Light)Failure in servomotor.

7(Check Engine

Light)

Failure in exhaust temperature sensor.

Steady Flash(Check Engine

Light)


Constant On(Check Engine

Light)




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 (Firecat/ZR 900/Turbo ST)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 tothe riser and the riser to thesteering post.

735-501B

2. Adjust the handlebar up ordown to operator’s desired tilt,tighten the cap screws evenly to3.5 kg-m (25 ft-lb), and checksteering for maximum right/leftturning capabilities.

NOTE: Do not adjust the han-dlebar to a position that allowsthe brake fluid to be below thelow mark on either side of themaster cylinder.

EXHAUST SYSTEMThe exhaust system is designed toreduce noise and to improve the totalperformance of the engine. If anyexhaus t sys tem component i sremoved from the engine and theengine is run, severe engine damagewill result.

AIR-INTAKE SILENCERUsed in conjunction with the fuelintake system is a specially designedair-intake silencer. The purpose ofthe silencer is to quiet the intake offresh air. Since the fuel intake sys-tem is calibrated with the air-intakesilencer in place, the engine mustnever be run with the s i lencerremoved. Performance will not beimproved if the air-intake silencer isremoved. In contrast, severe enginedamage will occur.

! WARNINGTighten lock nuts according tospecifications to prevent unex-pected “movement” of the han-dlebar during operation overrough terrain and DO NOT posi-tion handlebar so steering (max-imum r ight / le f t tu rn ingcapabilities) or throttle andbrake controls are affected.

! WARNINGTighten cap screws accordingto specifications to preventunexpected “movement” of thehandlebar during operation overrough terrain. DO NOT offset thehandlebar so steering (maxi-mum right/left turning capabili-ties) are altered or throttle andbrake controls will be affected.

! CAUTIONThese snowmobiles are notdesigned to be operated industy conditions. Operating thesnowmobile in dusty condi-tions will result in severe enginedamage.


BATTERY (Electric Start Models)It is extremely important that thebattery be maintained at full chargeat all times and that the battery con-nections be clean and tight. If charg-ing the battery becomes necessary,refer to Charging Battery section ofthis manual.

COOLING SYSTEM (Liquid)Some snowmobiles are equippedwith a closed liquid cooling systemfor engine cooling. The cooling sys-tem should be inspected daily forleakage and damage. Also, the cool-ant level should be checked daily. Ifleakage or damage is detected, takethe snowmobile to an authorizedArctic Cat Snowmobile dealer forservice. If not under warranty, thisservice is at the discretion andexpense of the snowmobile owner.When filling the cooling system, usea coolant/water mixture which willsat isfy the coldest anticipatedweather conditions of your area inaccordance with the coolant manu-facturer’s recommendations. Whilethe cooling system is being filled, airpockets may develop; therefore, runthe engine for five to ten minutesafter the initial fill, shut the engineoff, and then fill the cooling systemto approximately 51 mm (2 in.)below the filler neck on 2-strokemodels or to just below the FULLmark on 660 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 (andwith the tank cap on and tight),open the bleed screw slightly toal low trapped air to escape.Continue until no air is apparent;then tighten the screw.

AO353A

NOTE: Use a good quality, gly-col-based, automotive-type anti-freeze.

DRIVE CLUTCH AND DRIVEN PULLEYThe drive clutch and driven pulleydo not require lubrication; there-fore, no special maintenance isrequired by the snowmobile owner.However, the drive clutch anddriven pulley should be disassem-bled, cleaned, and inspected by anauthorized Arctic Cat Snowmobiledealer after every 800 miles of oper-ation or at the end of the snowmobil-ing season whichever occurs first.This service is at the discretion andexpense of the snowmobile owner.When operating the snowmobile athigh altitudes, it may be necessary tochange certain component parts ofthe drive clutch. See an authorizedArctic Cat Snowmobile dealer forfurther information.

! CAUTIONAfter operating the snowmobilefor the initial 5-10 minutes, stopthe engine, allow the engine tocool down, and check the cool-ant level. Add coolant as neces-sary.


DRIVE CLUTCH/DRIVEN PULLEY ALIGNMENTThe parallel ism and the offsetbetween the drive clutch and drivenpulley are set at the factory. Nor-mally, no adjustment is necessary aslong as neither the drive clutch northe driven pulley is removed or dis-assembled. However, if prematuredrive belt wear is experienced or ifthe drive belt turns over, the driveclutch/driven pulley alignment mustbe checked. Take the snowmobile toan authorized Arctic Cat Snowmo-bile dealer for this service. If notunder warranty, this service is at thediscretion and expense of the snow-mobile owner.

DRIVE CHAIN TENSION (Automatic System)The drive chain must be properlytensioned for proper operation toprevent “ratcheting” and unneces-sary chain/sprocket wear. The chaintensioner in the drive system is auto-matic; therefore, no adjustment isrequired by the snowmobile owner/operator. Arctic Cat recommendsthat the chain, sprockets, and chaintensioner be checked for wear andthe chain for proper tension everyyear, 1000 miles, or whenever adrive chain related problem is sus-pected. Take the snowmobile to anauthorized Arctic Cat Snowmobiledealer for this service. If not underwarranty, this service is at the dis-cretion and expense of the snowmo-bile owner.

DRIVE CHAIN TENSION (Adjustable System)The drive chain must be properlytensioned for proper operation toprevent “ratcheting” and unneces-sary chain/sprocket wear. On thesesnowmobiles, there are two differentchain tensioners in the chain case.One chain tensioner is automaticand one is manual. The automaticchain tensioner will take up the slackin the chain under most operatingconditions; however, every 500miles or whenever repeated hardaccelerations will occur, the manualchain tensioner should be adjusted.Arctic Cat recommends that thechain, sprockets, and chain tensionerbe checked for wear and properalignment and adjustment everyyear, 1000 miles, or whenever adrive chain related problem is sus-pected. Take the snowmobile to anauthorized Arctic Cat Snowmobiledealer for this service. If not underwarranty, this service is at the dis-cretion and expense of the snowmo-bile owner. To adjust the manualdrive chain tensioner, use the fol-lowing 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.The drive clutch and driven pul-ley must be serviced by anauthorized Arctic Cat Snowmo-bile dealer only.


NOTE: If the adjustment boltwill not 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 diffi-cult to turn by hand, the drivechain is properly tensioned.

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

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 PUMPThe fuel pump is designed to pro-vide adequate amount of gas to thecarburetors (on carbureted models)or to the injectors (on EFI models) atall throttle settings. If a fuel deliv-ery problem is suspected, take thesnowmobile to an authorized ArcticCat Snowmobile dealer. If not underwarranty, this service is at the dis-cretion and expense of the snowmo-bile owner.

GAS TANK SHUT-OFF VALVEOn certain models, a shut-off valveis incorporated into the gas hosecoming from the gas tank. The valveshould be turned to the CLOSEDposition when trailering or storingthe snowmobile. Turn the valve tothe OPEN position before attempt-ing to start the engine.

NOTE: On all remaining mod-els, there is an automatic shut-offvalve incorporated into the fuelpump which prevents gasolineflow when the engine is off.

SHOCK ABSORBERS (Standard Gas)Each shock absorber should be visi-bly checked weekly for fluid leak-age, cracks or breaks in the lowercase, or a bent plunger. If any one ofthese conditions is detected, replace-ment is necessary. Take the snow-mobile to an authorized Arctic CatSnowmobile dealer for this service.If not under warranty, this service isat the discretion and expense of thesnowmobile owner. NOTE: When the snowmobile isoperated in ex t remely co ldweather (-23° C/-10° F or colder),a small 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 indicatesa “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 absorb-ers is considered normal mainte-nance and is the responsibility of theowner. Take the snowmobile to anauthorized Arctic Cat Snowmobiledealer for this service. This serviceis at the discretion and expense ofthe snowmobile owner. Kits areavailable to either stiffen or softengas shock valving. If changes inshock valving are desired, see anauthorized Arctic Cat Snowmobiledealer. This service is at the discre-tion and expense of the snowmobileowner.Each shock absorber should be visi-bly checked weekly for fluid leak-age, cracks or breaks in the lowercase, or a bent plunger. If any one ofthese conditions is detected, replace-ment is necessary. Take the snow-mobile to an authorized Arctic CatSnowmobile dealer for this service.If not under warranty, this service isat the discretion and expense of thesnowmobile owner. NOTE: When the snowmobile isoperated in ex t remely co ldweather (-23° C/-10° F or colder),a small amount of leakage may bepresent. Unless the leakage isexcessive, replacement is notnecessary.

DEEP-LUG TRACK (Sno Pro Models)The Sno Pro models are equippedwith a deep-lug track which is spe-cially designed for use in powdersnow riding conditions. When thedeep-lug track is operated in hard-packed snow conditions, it will runslightly slower than a standard-lugtrack and it will accelerate wear stripwear. To decrease the amount ofwear strip wear, slower speeds mustbe maintained when operating onhard-packed trails. Accelerated wearstrip wear caused by operating adeep-lug track on hard-packed snowconditions is NOT covered underArctic Cat Inc. warranty policy.

ATTACK 20 TRACK (M-Series/King Cat Models)These models are equipped with aspecially designed, directional trackfor different operating conditions.Install the track either with the DeepSnow arrow positioned toward thedirection of track rotation or with theHill Climbing arrow positionedtoward the direction of track rota-tion.NOTE: The t rack may beremoved/installed by the snow-mobile owner if qualified to do so.If the owner does not feel quali-fied, take the snowmobile to anauthorized Arctic Cat Snowmo-bile dealer for this service. Thisservice is at the discretion andexpense of the snowmobi leowner.

0726-208


TRACK STUDS

0726-207

Studs must be installed only on thecenter belt using the pattern illus-trated. For proper installation, usethe following procedure:

1. Measure 38 mm (1 1/2 in.) infrom the edge of the center belt;then drill the stud hole using theproper-sized hole drill.

2. Push the stud through the holefrom inside the track; then placethe domed support plate andlock nut on the exposed stud.

3. Using a wrench to secure thestud, tighten the lock nut on theexposed stud.

It is also recommended that when-ever studs are installed on a track,ca rb ide wea r b a r s sh ou ld beinstalled on the skis. Carbide wearbars complement the track studs tobalance steering control under theseconditions. The length of the carbideon the wear bars should be propor-tionate to the number of track studs(i.e. small number of track studs —short length of carbide...many trackstuds — long length of carbide). Theproper proportion between the num-ber of studs and carbide length onthe wear bar will maintain steeringbalance.

NOTE: Stud or hooker plateinstallation will void track andtunnel warranty.

! CAUTIONTo protect the tunnel from pos-sible damage from the studs, itis recommended that Stud Pro-tection Wear Strips be installedon those models not soequipped.

! WARNINGAlways balance the snowmo-bile with the proper proportionbetween the number of studsand carbide length on the wearbars. Do not “over drive” condi-tions; use common sense in alloperating conditions.

! CAUTIONDo not use studs that are morethan 9.525 mm (0.375 in.) longerthan the track lug height. Also,do not install studs in the outertrack belts.

! WARNINGDo not operate a snowmobilewith loose studs as they may bethrown from the track. Alwaysuse a shielded safety standwhenever performing any main-tenance or adjustments.


REVERSE TRANSMISSIONThe reverse transmission offers theoperator the convenience of beingable to back up the snowmobilerather than having to turn the snow-mobile around by hand. This fea-ture, under most situations, shouldnot be used to free a stuck snowmo-bile as it will tend to dig the skisdeeper into the snow. Before startingthe snowmobile, be sure the shiftlever is in the desired position foreither forward or reverse operation.Always use minimal speed whenoperating in reverse and come to acomplete stop before shifting fromeither forward to reverse or reverseto forward. Once you have shifted toa new gear, apply slight throttle untilpositive engagement of the shift hasbeen observed. To shift the reversetransmission, use the following pro-cedure:

1. Come to a complete stop.2. Either push or pull the shift

lever to the desired position;then apply slight throttle untilpositive engagement of the shifthas been observed.

737-831A

No special maintenance is requiredfor the reverse transmission; how-ever, if chattering is experiencedwhen the transmission is shifted intoreverse, the linkage may have to beadjusted. Arctic Cat recommendstaking the snowmobile to an autho-rized Arctic Cat Snowmobile dealerfor this service. If not under war-ranty, this service is at the discretionand expense of the snowmobileowner. NOTE: A warning buzzer willsound when the transmission isin the reverse position; however,always check the position of theshift lever before accelerating.

TOWINGIf the snowmobile is to be towed byanother snowmobile, do not towusing the loops in the skis. The towrope should be attached to the spin-dles.

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

! WARNINGUse caution and minimal speedwhen operating the snowmo-bile in reverse. Be sure the shiftlever is in the desired lever posi-tion.


ADJUSTABLE BACKRESTThe adjustable backrest is designedfor maximum comfort and safety.When riding double, the backrestmust be adjusted to the most rear-ward position. When riding single,the backrest should be moved for-ward to a position comfortable to theoperator. Be sure to maintain thebackrest pad in a vertical position inall locations. Also, be sure to tightenall retaining knobs securely afteradjusting the backrest.

0734-425

REMOVABLE REAR SEATSome snowmobiles are equippedwith a removable rear seat to allowfor additional cargo space when nopassenger is being carried. Toremove the rear seat, use the follow-ing procedure:

1. Move and lock the adjustablebackrest in the forward posi-tion.

2. Pull back on the seat latch han-dle located at the bottom rear ofthe seat.

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 fol-lowing procedure:

1. Place the seat into position onthe tunnel making sure the twopins on the front of the rear seatare properly engaged with thereceiving tabs on the rear of thefront seat.

2. Pull back on the seat latch han-dle; then with the seat latchhandle pulled back, push therear seat forward and down andrelease the seat latch handle.

! WARNINGMoving the backrest forwardlimits the seating capacity toone person only.

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

! WARNINGMake sure the rear seat issecurely locked in place beforecarrying a passenger or per-sonal injury may result.


REMOVABLE SEAT (M-Series/King Cat/Sabercat Models)These snowmobiles are equippedwith a removable seat. To removethe seat, use the following proce-dure:

1. On the Sabercat, remove therear storage compartment.

2. On the bottom of the seat-base,press the retaining clips awayfrom locking pins.

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

To install the seat, use the followingprocedure:

1. Slide the front of the seat intoposition on the tunnel; thenlower the rear of the seat ontothe locking pins.

2. Press down on the rear of theseat until the retaining clipssnap into place on the lockingpins.

3. On the Sabercat, install the rearstorage compartment.

ARCTIC POWER VALVE (APV) SYSTEMThis RPM controlled servomotor(servo) actuated system adjusts thesize of the exhaust ports to providepeak performance throughout theRPM range. The system consists ofan exhaust valve assembly mountedto the exhaust side of each cylinderand connected by adjustable cablesto an electronic servo mountedbeneath the hood.

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

739-152E

0739-152

At low RPM, the exhaust valves areheld in the DOWN position byreturn springs. This gives the enginea “low port” exhaust design cali-brated to provide maximum lowRPM power and improve fuel econ-omy at trail speeds.

739-152C

! WARNINGMake sure the seat is securelylocked in place or personalinjury may result.


739-152A

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

739-152D

739-152B

NOTE: The RPM ranges willvary from 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/cableadjustments may be done by thesnowmobile owner if qualified todo so. If the owner does not feelqualified, take the snowmobile toan authorized Arctic Cat Snow-mobile dealer for this service.This service is at the discretionand expense of the snowmobileowner.To adjust the APV System, use thefollowing prcedure:

1. Remove the cover from theservo; then remove the actuat-ing cables from the servo.

2. While holding the cable hous-ing, lightly pull on one cableend to remove any slack.

3. Measure the amount of exposedcable from the cable housing tothe end of the cable.

0735-516

4. Repeat steps 2 and 3 for eachcable; then compare the mea-surements.

APV CABLE LENGTHENGINE MODEL

CENTER± 1 mm (0.039 in.)

500 cc 34.5 mm(1.35 in.)

600 cc 34.5 mm(1.35 in.)

700 cc 34.5 mm(1.35 in.)

900 cc 39.5 mm (1.56 in.)


NOTE: The measurements mustbe equal and within the specifica-tions from the chart. If the mea-surements are within speci-fications, no adjustment is neces-sary. If they are not within specifi-cations, proceed to step 5.

5. Loosen the jam nut on the cablehousing to be adjusted; thenus ing t he ad ju s t i ng n u t s ,lengthen or shorten the housingas needed.

738-232B

0739-715

739-581A

6. While holding the adjusting nutin place, tighten the jam nutsecurely.

7. Install the actuating cables tothe servo; then install the servocover.

EXHAUST CONTROLLED TIMING (ECT) SYSTEM (Firecat 500)This system automatically adjuststhe ignition timing to provide maxi-mum performance through a varietyof operating conditions. The CDIunit receives input on engine RPM(demand) and exhaust pipe tempera-ture (engine condition) and adjuststhe ignition timing accordingly. Thissystem is not adjustable and is main-tenance free.

Firecat/Sabercat

Crossfire/M-Series

! CAUTIONThe correct engine oil to use isArctic Cat Synthetic APV 2-Cycle Oil (p/n 2639-512). Anysubstitute may cause an APVmalfunction.

King Cat/ZR


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.

26 OPERATING INSTRUCTIONS

OPERATING INSTRUCTIONSSTARTING AND STOPPING ENGINEIt is imperative that the brake systembe checked for wear and properoperation and that all safety checksfound in the accompanying Snow-mobile Safety Handbook be per-formed before attempting to start theengine. Also, on carbureted mod-els, be sure the correct carburetormain jet(s) for the operating tem-perature, altitude, and gasolineare being used, and on 2-strokeEFI models, be sure the correctfuel designation connection/ dis-connection (for the type of gaso-line being used) has been selected.

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 alllights are clean to provide maximumillumination. The headlight and tail-light must be clean and must be illu-minated whenever the engine isrunning. NOTE: If equipped with reverse,make sure the reverse shift leveris in the forward position beforestarting the engine.

1. Test the operation of the brakesystem by compressing thebrake lever. The brake levermust fee l f i rm when com-pressed; then while holding thebrake lever in the compressedposition, measure the distancebetween the brake lever and thehandlebar (on hydraulic brakemodels) or between the brakel ev e r and l eve r s t op (onmechanical brake models). Thedistance must be greater than2.54 cm (1 in.) on hydraulicbrake models or within a rangeof 6-13 mm (1/4-1/2 in.) onmechanical brake models.

734-505A

727-451A

! CAUTIONOn 2-stroke EFI models, be surean adequate amount of gasolineis in the gas tank. If you run outof gasoline, engine damage mayoccur.

OPERATING INSTRUCTIONS 27

2. On hydraulic brake models,check the fluid level in the res-ervoir. The brake fluid levelmust be just below the highmark in the brake fluid reser-voir or visible in the sight glass.Add Arctic Cat approved brakefluid as necessary.

740-159A

0740-588

3. Test the throttle control lever bycompletely compressing andreleasing it several times. Thelever MUST return to the idleposi t ion quickly and com-pletely.

4. Move the emergency stopswitch to the UP or RUN posi-tion.

5. Insert key into ignition switch;then rotate key to the RUNposition.

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.To start a warm engine, however,the throttle control lever mayhave to be compressed slightly.

! 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 thebrake system is not operatingproperly.

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


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, pullthe recoil handle slowly untilresistance is felt; then give ashort quick pull. Repeat untilthe engine starts.

NOTE: On large-displacementengines in ex t remely co ldweather, pull the recoil handleslowly two to three times to beginthe starting procedure.

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

8. On carbureted models when theengine starts, allow it to warmup for approximately 30 sec-onds with the choke lever in thefull-choke position. After the30-second warm-up, move thechoke lever to the middle posi-tion. The choke lever should bemoved to the OFF positionwhen engine is warm. Slightthrottle control lever compres-sion may be necessary after theengine starts and during warm-up. Idle the engine several min-u t e s u n t i l t h e e n g i n e h a sreached normal operating tem-perature.

9. On EFI models when the enginestarts, allow it to warm up prop-erly. Idle the engine severalminutes until the engine hasreached normal operating tem-perature. Do not idle the enginefor excessively long periods oftime.

! CAUTIONTo avoid damaging the recoilstarter, DO NOT pull the recoilrope to its limit or release therecoil handle from an extendedposit ion. Al low the rope torewind slowly.

! CAUTIONDo not continuously run thestarter for more than 5 secondsat a time.

! 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 atmore than 1 /2 throt t le . Inextremely cold conditions, thewarm-up time will be longer.Cold seizure and piston scuffingcaused by insufficient warm-upwill not be covered by warranty.Also, do not idle the engine forexcessively long periods oftime.


10. Flooding — On carburetedmodels if the engine does notstart when the choke is beingused but seems ready to start,move the choke lever to theOFF position. Engage the brakelever lock; then compress thethrottle control lever fully andtry to start the engine. When theengine starts, release the throttlecontrol lever immediately. Afterthe warm-up, release the brakelever lock.

NOTE: Continued choking willcause the engine to flood more.

11. Flooding — On EFI models ifthe engine does not start butseems ready to start, engage thebrake lever lock; then compressthe throttle control lever fullyand try to start the engine.When the engine starts, releasethe throttle control lever imme-diately. After the warm-up,release the brake lever lock.

NOTE: If the engine fails to startduring the attempt with the throt-tle control lever compressed,remove the spark plugs and cleanand dry them thoroughly or installa new set of properly gapped, rec-ommended spark plugs.

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

NOTE: On 660 cc models ,ensure that the ignition switchkey is in the OFF position whenthe engine is not running. Leav-ing the ignition switch in the ONposition allows the lights to be onand will drain power from the bat-tery. The engine WILL NOT STARTwithout battery 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, theidle RPM may be slightly higherthan usual for a brief period of time.This higher RPM is a normal oil-cooling function and should not beof concern.

BRAKING (Hydraulic Brake Models)Operat ing a snowmobi le wi thhydraulic brakes is different fromopera t ing a snowmobi le wi thmechanical brakes. The followingitems are items that the operatormust be familiar with when operat-ing this snowmobile and its hydrau-l i c b r ak e s y s t e m . I m p o r t a n tadditional information on the propermaintenance of the brake system isfound in the maintenance section ofthis manual.

1. Use the brakes wisely. Eachtime the brakes are applied inall hydraulic brake systems(including automotive applica-tions), heat is transferred to thebrake fluid. The amount of heattransferred during high speedstops and/or repetitive use maybe high enough to boil the brakefluid and cause the brakes toeither fade or may cause anunexpected loss of brakes.


If this occurs, the brake fluidrequires a cool-down periodbefore the brakes will againfunction properly. This cool-down period will vary depend-ing upon the ambient air tem-perature and the temperature ofthe brake fluid. If loss of brakeshas occurred because of highfluid temperatures, do not oper-ate the snowmobile until thecool-down period has expiredand brake lever firmness hasreturned.

2. Be sure to maintain the brakefluid at the proper level andtake care not to get any mois-ture in the system as moisture inthe brake fluid lowers the boil-ing point. If the brake fluid isever boiled (by high speed stopsor repetitive use) or if moistureis allowed to enter the system, itmust be changed. Never substi-tute or mix different types orgrades of brake fluid.

3. Never ride the brake. Evenmaintaining minimal pressureon the brake lever will cause thebrake pads to drag on the discand may overheat the brakefluid.

4. The brake lever lock is not aparking brake and should not beapplied for periods exceeding 5minutes. NEVER OPERATETHE SNOWMOBILE WITHTHE BRAKE LEVER LOCKENGAGED.

5. Pumping the brake lever is per-missible; however, if pumpingthe brake lever more than twiceis necessary to obtain the neces-sary stopping power, immedi-ately take the snowmobile to anauthorized Arctic Cat Snowmo-bile dealer for service. If notunder warranty, this service is atthe discretion and expense ofthe snowmobile owner.

! 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 f luid. Brake loss canresult. Check brake fluid leveland pad wear before each use.Brake loss can result in severeinjury or even death.

! WARNINGThe brake lever lock is not aparking 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.


6. When new brake pads areinstalled, a “burnishing” pro-cess is required. Drive thesnowmobile slowly and com-press the brake lever severaltimes until the pads just start toheat up; then allow them tothoroughly cool down. Thisprocess stabilizes the pad mate-rial and extends the life of thepads.

EMERGENCY STOPPINGThere are several methods of stop-ping or slowing the snowmobileunder a variety of situations. Identi-fied in the following chart are theways a snowmobile may be broughtto a stop and the effectiveness undernormal conditions.

NOTE: On 660 cc models ,ensure that the ignition switchkey is in the OFF position whenthe engine is not running. Leav-ing the ignition switch in the ONposition allows the lights to be onand will drain power from the bat-tery. The engine WILL NOT STARTwithout battery power.

THROTTLE/IGNITION MONITOR SWITCH (2-Stroke Models)The throttle control is equipped witha monitor switch for safety purposeswhich will stop the engine when aloss of return spring force occurs. Ifice forms in the throttle system or ifthere is some other malfunction ofthe throttle system resulting in a lossof return spring force, the monitorswitch will stop the engine when thethrottle control lever is released.

If the snowmobile engine stopsabruptly when the throttle controllever is released and the activationof the monitor switch is suspected,use the following procedure:

1. Rotate the ignition key to theOFF position.

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

3. Test the throttle control lever bycompressing and releasing itseveral times. The lever MUSTreturn to the idle posi t ionquickly and completely.

ITEM FUNCTION CONDITION

Emergency Stop Switch

interrupts ignition circuit

ALL

Throttle/Ignition Monitor Switch


ALL

Ignition Switch


ALL

Brakeslows the

driven shaft/ACT drive

ALL

Choke (carbureted

models)

floods the engine

1/2 throttle or less

! WARNINGIf any malfunction of the throttlesystem occurs (such as freezingin fluffy snow) and the monitorswitch does not shut off theengine, press down on theemergency stop switch IMMEDI-ATELY to stop the engine. DONOT start the engine until themalfunction in the throttle sys-tem has been located and cor-rected.


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 ArcticCat Snowmobile dealer for ser-vice. If not under warranty, thisservice is at the discretion andexpense of the snowmobi leowner.

4. If the throttle control leveroperates properly, rotate theignition key to the RUN posi-tion and go through normalstarting procedures.

NOTE: If the throttle controllever operates properly and theengine does not start, either amalfunctioning monitor switch ora misadjusted magnetic carbure-tor switch (on twin VM-style car-buretor models) may be theproblem. Take the snowmobile toan 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 whereinthe engine must be started, dis-connect the throttle control wiringharness located below the han-dlebar pad and next to the steer-ing post. If disconnection of thethrottle control wiring harness isneeded to start the engine, takethe snowmobile to an authorizedArctic Cat Snowmobile dealer forservice as soon as possible. Ifnot under warranty, this service isat the discretion and expense ofthe snowmobile owner.

0734-481

738-156A

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.

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

! WARNINGUnder no circumstances shoulddisconnection of the throttlecontrol wiring harness be usedas a substitute for the monitorswitch during normal operationof the snowmobile. Personalinjury and damage could occurif the throttle system malfunc-tions or if the operator is unableto stop the engine in an emer-gency. If the snowmobile mustbe operated with a discon-nected throttle control wiringharness, EXTREME CAUTIONMUST BE TAKEN. NEVEREXCEED 10 MPH WITH THETHROTTLE CONTROL WIRINGHARNESS DISCONNECTED.


VARYING ALTITUDE OPERATIONOperating a snowmobile at varyingaltitudes requires changes in perfor-mance components. These changesaffect drive train components (on allmodels) and carburetion compo-nents (on carbureted models).The altitude information decal islocated beneath the hood of thesnowmobile. On carbureted models,the information is incorporated intothe Main Jet Chart decal. NOTE: Just as important as cal-ibrat ing the snowmobi le forhigher altitudes is recalibratingthe snowmobile when going tolower altitudes. Always consultthe altitude decal beneath thehood of the snowmobile.

Crossfire, M-Series, and King Catmodels are initially set up at the fac-tory for operation between 6000-9000 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 Snow-mobile dealer for this service.This service is at the discretionand expense of the snowmobileowner.

! CAUTIONOn carbureted models, care-fully follow the Main Jet Chartrecommendations for propermain jet selection for altitude,temperature, and gasoline beingused.

! CAUTIONOn the ZR 900 and King Cat, theCDI must be replaced or repro-grammed for altitude change.

34 LUBRICATION

LUBRICATIONSTANDARD CHAIN CASE (Every 40 Operating Hours)The recommended amount of trans-mission lube in the chain case is 236ml (8 fl oz) for models withoutreverse and 354 ml (12 fl oz) formodels with reverse. Adding moretransmission lube to the chain case(above the recommended amount)may result in leakage. To check thetransmission lube level, use the fol-lowing procedure:

1. With the snowmobile level,shut engine off and wait for allmoving parts to stop; then openthe hood.

2. Remove the oil level stick fromthe chain case cover. Wipe theoil level stick clean; then threadthe oil level stick completelyback into the chain case (with-out reverse) or install the oillevel stick completely back intothe chain case (with reverse).Remove the oil level stick againand check the lubricant level.

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3. If the lubricant level is abovethe AD D mark (w i th ou treverse) or above the LOWmark (with reverse), the lubri-cant level is satisfactory. If thelubricant level is at or below themark, proceed to step 4.

4. If oil is low, remove the fillerplug and add transmission lubethrough the filler plug hole.When the oil level is correct,install both the filler plug andthe oil level stick.

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.

! CAUTIONThe correct lubricant to use inthe chain case is Arctic CatTransmission Lube (p/n 0636-817). Any substitute may causepremature chain failure or seri-ous damage to the chain drivesystem.

LUBRICATION 35

ACT DRIVE GEAR CASE (Each Season Prior to Storage)NOTE: Changing gear case fluidcan be done by the snowmobileowner if qualified to do so. If theowner does not feel qualified,take the snowmobile to an autho-rized Arctic Cat dealer for thisservice. If not under warranty,this service is at the discretionand expense of the snowmobileowner.

It is very important that the gear casefluid be changed after each season ofuse. Arctic Cat recommends that thefluid be changed prior to off-seasonstorage.To change the gear case lubricant,use the following procedure:

1. Place a drain pan beneath thegear case; then from the back-side of the case, remove thedrain/fill plug.

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NOTE: It is critical that thesnowmobile is on a level surfaceto ensure the fluid drains properlyand completely.

2. Tip the snowmobile onto its leftside and place a piece of card-board underneath to protect thefinish on the hood and bellypan.

NOTE: It is recommended thatthe gas tank be nearly empty(less than 1/4 full) when tippingthe snowmobile.

3. Secure the snowmobile in thisposition.

4. Pour the exact amount (seespecification sheet) of ArcticCat ACT Drive Fluid into thedrain/fill hole; then install theplug. Tighten securely.

5. Tip the snowmobile back to theupright position.

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.

! CAUTIONDo not over-fill the gear case. Ifthe gear case is over-filled withfluid, damage to the gear casecould occur.

! CAUTIONThe correct lubricant to use inthe gear case is Arctic Cat ACTDrive Fluid. Any substitute maycause serious damage to thedrive system.

! CAUTIONIt is critical that all of the oldfluid be drained from the gearcase prior to filling with newfluid.

! CAUTIONDo Not add more or less thanthe recommended amount ofdrive fluid to the gear case ordamage to the gear case willoccur.

36 LUBRICATION

FRONT SUSPENSION NOTE: Arctic Cat recommendsthat Arctic Cat Low-Temp Grease(p/n 0636-593) be used for thisprocedure.

It is very important that the frontsuspension is greased on a monthlybasis using low-temperature grease.The front suspension should also begreased after trailering the snowmo-bile on an open trailer. Pump greaseinto the spindle grease fitting (bothsides) until grease is noted comingout of the top and bottom of thespindle. Wipe excess grease fromthe spindle.

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On the AWS VI and M-Series mod-els, pump grease into the uppersteering shaft grease fitting (locatedon the right-side of the snowmobiledirectly above the forward part ofthe upper A-arm) until grease isnoted coming out of the bottom ofthe shaft. Wipe excess grease fromthe shaft.

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SPEEDOMETER DRIVE ADAPTER (Semi-Annually) NOTE: Arctic Cat recommendsthat Arctic Cat Low-Temp Grease(p/n 0636-593) be used for thisprocedure.

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

2. Using low-temperature grease,lubricate the fit t ing on thespeedometer drive adapter untilgrease is noted coming outalong the edge of the driveadapter.

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REAR SUSPENSION (Every 40 Operating Hours) NOTE: Arctic Cat recommendsthat Arctic Cat Low-Temp Grease(p/n 0636-593) be used for thisprocedure. 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.

LUBRICATION 37

2. With the gas tank nearly empty(less than 1/4 full), lay thesnowmobile on its left side. Apiece of cardboard should beused to protect the finish on thehood and belly pan.

3. Remove ice and snow buildupfrom the skid frame to exposethe grease fittings.

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4. Lubricate the grease fittingswith low-temperature grease.

! CAUTIONThe Firecat/Sabercat modelsshould not be tipped on theirright sides for any extendedperiod of time, as air bubblesmay form in the oil hose. If airbubbles form in the oil hose, theoil injection system must bebled. Take the snowmobile to anauthor iz ed Arct ic Catsnowmobile dealer for thisservice. This service is at thediscretion and expense of thesnowmobile owner.

! CAUTIONThe 660 cc models should notbe tipped on their sides for anyreason, as engine oil may seepinto the upper engine throughthe air-intake system. Severeengine damage could result ifthe engine is run with oil in theupper engine.

38 MAINTENANCE

MAINTENANCEPERIODIC MAINTENANCE CHECKLIST

ITEM INTERVAL REFER TO REMARKSAir Filter

(660 cc Turbo) 2000 miles/Seasonal

__ Replace

Brake System (Hydraulic) Daily Page 57 Check for binding, leakage, and proper operation; lever firmness, travel, caliper, disc, and pads

Brake System (Mechanical) Daily Page 56 Check for binding, sticking, and proper operation; lever travel, cable, spring, caliper, and disc

Cooling System - Liquid Daily Page 15 Check for leakage, damage, obstructions, coolant level

Cooling System - Fan Belt Monthly Page 77 Check tightness and for wear, damage, and obstructions

Charging System - Accessory Belt (660 cc)

Monthly Page 77 Check tightness and for wear, damage, and obstructions

Oil System Daily Page 40-42 Check for leakage, damage, and injection/engine oil level

Engine Oil (660 cc Standard)

2500-3000 miles/

Seasonal

Page 41 Change oil and filter

Engine Oil(660 cc Turbo)

2000 miles/Seasonal

Page 41 Change oil and filter

Battery Daily Page 15Page 53

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 Page 71 Check for proper operation and cleanliness

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

Throttle Control System Daily Page 31 Check for binding, sticking, proper operation, throttle cable tension, and routing

Drive Belt DailyMonthly

Page 61 Check for wear, cracks, and frayingCheck length and width dimensions

Ski Wear Bars Daily Page 74 Check for wear and damage

Carburetors - Main Jets - Adjustment Screws

Daily Weekly

Page 50Page 42-50

Install proper main jetsAdjust according to specifications

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

Exhaust System Weekly Page 14 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 Page 17 Check for fluid leakage and damage

Spark Plugs(2-Stroke)

Weekly Page 51 Check center electrode insulator color, carbon, and gap

Suspension Weekly Page 67 Check for damage, loose components, and proper adjustment

Track Tension/Alignment Weekly Page 64 Page 66

Check/adjust as necessary

Wear Strips Weekly Page 76 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)

5000 miles/2 years

__ Replace

APV System Monthly Page 22 Check/adjust as necessary

Standard Chain Case Monthly Page 34 Check lube level and for leakage

ACT Drive Gear Case Seasonal Page 35 Change drive fluid prior to storage

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

Drive Clutch/Driven Pulley Monthly Page 15-16 Check for damage, abnormal noise, vibration, binding, and sticking and clean off drive belt deposits

Front & Rear Suspension Monthly Page 36 Grease

MAINTENANCE 39

The longevity and safety of thesnowmobile can be increased bymaking periodic checks of the itemsin the preceding checklist.If, at any time, abnormal noises,vibrations, or improper workingconditions of any component of thissnowmobile are detected, DO NOTOPERATE THE SNOWMOBILE.Take the snowmobile to an autho-rized Arctic Cat Snowmobile dealerfor inspection and adjustment orrepair.The snowmobile should be taken toan authorized Arctic Cat Snowmo-bile dealer at the end of each snow-mob i l i ng s ea son fo r g ene ra linspection and for off-season stor-age servicing. This inspection andservicing is at the expense of thesnowmobile owner.

FUEL SYSTEM

In-Line Fuel Filter (Carbureted Models)Arctic Cat recommends that the in-line fuel filter be checked weekly.The in-line fuel filter is located justin front of the fuel pump inlet fitting.The filter must be clean to allow thefuel hose to transmit the amount ofgasoline required. If the in-line fuelfilter is obstructed, gasoline flowwill be restricted; therefore, the filtermust be replaced. To remove andinstall the in-line fuel filter, use thefollowing procedure:

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

1. On models with a gas tank shut-off valve, turn the gas tank shut-off valve to the CLOSED posi-tion.

2. Using a screwdriver, pry thefuel hoses off the in-line fuelfilter and remove the filter.

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NOTE: The in-line fuel filtermust be replaced if obstructed.Fi l ters are available from anauthorized Arctic Cat Snowmo-bile dealer.

3. Install the in-line fuel filter inthe fuel hose so the arrow onthe filter points toward the fuelpump. Make sure the fuel hosesfit tightly on the filter. If a fuelhose does not fit tightly, cut 6mm (1/4 in.) from the end of thefuel hose; then install on the fil-ter.

! WARNINGWhenever any maintenance orinspection is made on the fuelsystem in which there may befuel leakage, there should be nowelding, smoking, open flames,etc., in the area.

40 MAINTENANCE

4. If applicable, turn the gas tankshut-off valve to the OPENposition.

Gasoline AdditivesFuel 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 0638-165)should also be added to the last tankof gasoline before storage.

Fuel Pickup ValvesA l l 2 - St r o k e E F I m o d e l s a r eequipped with fuel pickup valves inthe gas tank. If ever there is arestricted fuel flow and a pickupvalve is suspected, take the snow-mobile to an authorized Arctic CatSnowmobile dealer for this service.If not under warranty, this service isat the discretion and expense of thesnowmobile owner.

CHECKING OIL-INJECTION SYSTEM (2-Stroke Models)The oil-injection system has beensynchronized at the factory; how-ever, Arctic Cat recommends peri-odic checking of the oil-injectionsystem synchronization. The syn-chronization and maintenance mustbe done by an authorized Arctic CatSnowmobile dealer. If not underwarranty, this service is at the dis-cretion and expense of the snowmo-b i l e owner. To check the o i l -injection system synchronization,use the following procedure:NOTE: On the “Laydown”engine models to access the oilpump, tip the snowmobile onto itsleft side; then using a torx-bit,remove the screws securing thecenter belly pan (skid plate) to thefront end.

1. With the engine off and theignition key in the OFF posi-tion, move the throttle controllever to the full-open position.

2. In the full-open position, thealignment mark on the controlarm must align with the station-ary alignment mark on thepump boss.

727-185C

! WARNINGThe fuel hoses must fit tightlyon the fuel filter. If the fuel hoselength doesn’t permit this pro-cedure, replace the fuel hose.Also, after installing the fuelhoses on the filter, check to besure that the fuel hoses do notcontact any hot or rotating com-ponents.

MAINTENANCE 41

738-338A

3. Make sure the cable/linkage rodjam nuts are tight.

CHECKING ENGINE OIL LEVEL (660 cc Models) NOTE: The snowmobile mustbe on a level surface for this pro-cedure.

1. Open the hood and pull up onthe oil level stick until the topmark on the stick is even withthe top of the oil level sticktube. Wait 30 seconds beforeproceeding.

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

2. After 30 seconds, remove theoil level stick and wipe it with aclean cloth. Insert the oil levelstick fully into the engine andremove. Read the oil levelshown on the oil level stick.The oil level must be betweenthe two marks on the bottomend of the stick.

AA054B

3. If the oil level is at or below thebottom mark on the oil levelstick, add recommended oiluntil the oil level is slightlybelow the top mark on the bot-tom end of the stick.

NOTE: It takes 800 ml (27 fl oz)to raise the oil level from thelower mark to the upper mark onthe bottom end of the stick.

CHANGING ENGINE OIL (660 cc Models) NOTE: The o i l should bechanged when the engine iswarm to allow all oil to drain fromthe crankcase.

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

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

! CAUTIONOnly an authorized Arctic CatSnowmobi le dealer shouldadjust the oil-injection systemsynchronizat ion. Improperadjustment of the oil-injectionpump cable may result in throt-tle/ignition monitor switch fail-ure creating a risk of personalinjury or may result in insuffi-cient oil flow causing severeengine damage.

! WARNINGCare must be taken if a hot drainplug is removed by hand. Burn-ing could occur.

42 MAINTENANCE

2. Place a drain pan beneath thebe l ly pan p lug ho le ; thenremove the oil drain plug andwasher from the underside ofthe crankcase.

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 2.3kg-m (16.5 ft-lb).

5. Install a new belly pan plug. 6. Remove the oil filter using Oil

Filter Wrench (p/n 0644-389).

0644-389

7. Apply a light coat of freshengine oil to the gasket of thenew oil filter.

8. Install the new oil filter by turn-ing the oil filter by hand untilthe gasket has contacted the oilfilter mounting surface; thentighten the oil filter 3/4 turn byhand.

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

ADJUSTING CARBURETOR — VM-STYLE (Single)The carburetor has been calibratedat the factory for average riding con-ditions; however, altitude, tempera-t u r e , and gene ra l wea r maynecessitate certain carburetor adjust-ments. Be sure the correct carbu-retor main jet for the operatingtemperature, altitude, and type ofgasoline is being used (see Select-ing Carburetor Main Jet(s) sec-tion). Since carburetor adjustmentscrit ically affect engine perfor-mance, Arctic Cat recommends thatall changes in internal carburetorcalibration be made by an autho-rized Arctic Cat Snowmobile dealer;however, four external adjustmentscan be made on the carburetor.These are the choke cable travel,piston valve, pilot air screw, and idlespeed screw. Due to cable “stretch,”it is recommended to check throttlecable tension periodically and adjustthe swivel adapter as necessary.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 Cable1. Be sure the ignition switch key

is in the OFF position and theparking brake is set.

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

MAINTENANCE 43

3. Slowly rotate the choke cableadjuster counterclockwisewhile checking the choke leverfor free-play. As soon as allfree-play has been removedfrom the end of the lever, stoprotating the adjuster.

4. With free-play removed fromthe lever, slowly rotate thechoke cable adjuster once againclockwise while checking thechoke cable lever for free-play.Adjust until 3 mm (1/8 in.) free-play between front bottom edgeof lever and housing is attained.Securely tighten the adjusterjam nut.

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Adjusting Piston Valve1. Remove the air-intake silencer

boot; then rotate the idle speedscrew counterclockwise untilall spring tension is removed.

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2. Loosen the jam nut securing thethrottle cable swivel adapter;then rotate the swivel adapterclockwise until the piston valvebottoms in the piston valvebore.

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 screwclockwise until it contacts thevalve.

5. Compress the throttle lever tothe full-open position; thenrotate the idle speed screwclockwise 2 complete turns.Release the throttle lever.

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

6. At this point, there must becable free-play gap in the throt-tle lever.

733-081C

NOTE: If no cable free-play gapis detected, rotate the swiveladapter unt i l f ree-p lay isachieved. The piston valve mustbe resting against the tip of itsidle speed screw.

44 MAINTENANCE

Adjusting Pilot Air Screw1. While counting the rotations,

carefully rotate the pilot airscrew clockwise until lightlyseated.

2. Rotate the pilot air screw coun-terclockwise the exact numberof rotations ± 1/4 turn from theseated position for an initial set-ting.

3. Install the air-intake silencerboot taking care that the boot isproperly positioned and that theboot is not “folded” in the air-intake silencer causing a restric-tion of air flow.

Adjusting Engine Idle Speed1. With the snowmobile on a

shielded safety stand, start theengine, release the parkingbrake, and thoroughly warm up.“Fine-tune” the idle speedscrew and the pilot air screwuntil the engine idles smoothlyat the desired RPM (1500 RPMis recommended).

NOTE: Make engine idle adjust-ment only after the engine hasreached running temperature. NOTE: If the engine does notstart after the carburetor hasbeen adjusted, repeat steps 2-6 ofAdjusting Piston Valve sub-sec-tion. If all cable slack is “takenup,” the throttle/ignition monitorswitch will prevent the ignitionsystem from firing the sparkplugs.

ADJUSTING CARBURETORS — VM-STYLE (Twin)The carburetors have been cali-brated at the factory for averageriding conditions; however, alti-tude, temperature, and general wearmay necessitate certain carburetoradjustments. Be sure the correctcarburetor main jets for the oper-ating temperature, altitude, andtype of gasoline are being used(see Selecting Carburetor MainJet(s) section). Since carburetoradjustments critically affect engineperformance, Arctic Cat recom-mends that all changes in internalcarburetor calibration and pistonvalve synchronization be made byan authorized Arctic Cat Snowmo-bile dealer; however, four externaladjustments can be made on eachcarburetor. These are the chokecable travel, piston valves, pilot airscrews, and idle speed screws.

! 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 rotat ingtrack. NEVER run the track athigh speed when the track issuspended.

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

! WARNINGDO NOT operate the snowmo-bile when any component in thethrottle system is damaged,frayed, kinked, worn, or improp-erly adjusted. If the snowmobileis operated when the throttlesystem is not functioning prop-er ly, personal in jury couldresult.

MAINTENANCE 45

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 expense is at thediscretion and expense of thesnowmobile owner.


is in the OFF position and thebrake lever lock is set.

2. Loosen the jam nut securingeach choke cable adjuster.Ro ta t e e ach chok e cab l eadjuster clockwise until it bot-toms against the brass plungercap.

0727-156

3. Slowly rotate one choke cableadjuster counterclockwisewhile checking the choke leverfor free-play. As soon as allfree-play has been removedfrom the end of the lever, stoprotating the adjuster.

4. With free-play removed fromthe lever, slowly rotate eachchoke cable adjuster once againclockwise while checking thechoke cable lever for free-play.Adjust until 3 mm (1/8 in.) free-play between front bottom edgeof lever and housing is attained.Securely tighten the adjusterjam nut.

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, theair-intake silencer is a one-pieceunit, and the silencer boots canbe removed to access the intakebores. Remove the boots; thenproceed to step 4. NOTE: On some models, theair-intake silencer includes acover/tool tray assembly and abaffle/resonator, and the silencerboot cannot be removed toaccess the intake bores. Proceedto 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 for-ward and out of its slots andremove the assembly.

! CAUTIONMake sure to perform theseadjustment/synchronizationprocedures on all carburetors.

46 MAINTENANCE

3. Using a large flat-blade screw-driver, remove the baffle/reso-nator tabs from the air-intakesilencer slots and remove thebaffle/resonator to access theintake bores.

NOTE: The baffle/resonator canbe removed more eas i ly byremoving the back tabs first.

4. Rotate the idle speed screwscounterclockwise unt i l a l lspring tension is removed.

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5. Loosen the jam nut securingeach throt t le cable swiveladapter; then rotate each swiveladapter clockwise until eachpiston valve bottoms in the pis-ton valve bore.

6. In turn on each carburetor,place a finger lightly against theside of the piston valve; thenrotate the carburetor swiveladapter counterclockwise untilslight upward movement of thevalve 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 throttlelever.

NOTE: If an individual pistonva lve s tar ts 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-n i zed , t i gh t en t he swive ladapter jam nuts securely. Slidethe rubber throttle cable capsdown over the swivel adapters.

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

9. In turn on each carburetor,place a finger against the pistonvalve. Rotate the idle speedscrew clockwise until it con-tacts the valve.

10. Compress the throttle lever tothe full-open position; thenrotate each idle speed screwclockwise 2 complete turns.Release the throttle lever.

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

11. At this point, there must be0.75-1.5 mm (0.030-0.060 in.)of cable free-play gap in thethrottle lever. If there is nocable free-play in the throttlel ev e r, t h e t h r o t t l e s a f e tyswitches will not function prop-erly, and the engine will cut outin the idle position.

! WARNINGBe sure to tighten the swiveladapter jam nuts securely. If aswivel adapter jam nut is nottightened, the adjuster canrotate out of the carburetor capcausing the piston valve not toreturn to the full-closed posi-tion.

MAINTENANCE 47

733-081C

NOTE: If cable free-play gap isnot correct, rotate each swiveladapter an equal amount untilrecommended f ree-p lay isachieved. Each piston valve mustbe resting against the tip of itsidle speed screw. 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,carefully rotate the pilot airscrews clockwise until lightlyseated.

2. Rotate the pilot air screwscounterclockwise the exactnumber of rotations ± 1/4 turnfrom the seated position as aninitial setting.

3. On some models, install the air-intake silencer boots taking carethat the boots are properly posi-tioned and that the boots are not“fo lded” in the a i r- in takesilencer causing a restriction ofair flow.

4. On some models, install thebaffle/resonator and the cover/tool tray 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 throt-tle pressure 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-tunethe pilot air screws (equally)and the id le speed screws(equally) until the engine runssmoothly.

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

! 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 rotatingtrack. NEVER run the track athigh speed when the track issuspended.


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

48 MAINTENANCE

7. Test the throttle control lever bycompressing and releasing itseveral times. The lever mustreturn to the idle posi t ionquickly and completely.

ADJUSTING CARBURETORS — TM-STYLEThe carburetors have been cali-brated at the factory for averageriding conditions; however, alti-tude, temperature, and general wearmay necessitate certain carburetoradjustments. Be sure the correctcarburetor main jets for the oper-ating temperature, altitude, andtype of gasoline are being used(see Selecting Carburetor MainJet(s) section). Since carburetoradjustments critically affect engineperformance, Arctic Cat recom-mends that all changes in internalcarburetor calibration be made by anauthorized Arctic Cat Snowmobiledealer; however, four externaladjustments can be made on eachcarburetor. These are the chokecable travel, fuel mixture screws, airscrews, and idle speed screw. 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.


is in the OFF position and thebrake lever lock is set.

2. Loosen the jam nut securingeach choke cable adjuster onthe side of the carburetor.

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3. Slowly rotate one choke cableadjuster while checking thechoke lever for free-play. Assoon as all free-play has beenremoved from the end of thelever, stop rotating the adjuster.

4. With free-play removed fromthe lever, slowly rotate theadjus ter once again whi lechecking the choke lever forfree-play. Adjust until 3 mm (1/8 in.) free-play between frontbottom edge of lever and hous-ing is attained. Securely tightenthe jam nut.

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5. Repeat steps 3 and 4 on theother carburetor.


MAINTENANCE 49

Fine-Tuning Fuel Mixture Screws, Air Screws, and Idle Speed Screw

1. While counting the rotations,carefully rotate the fuel mixturescrews clockwise until lightlyseated.

0735-774

2. Rotate the fuel mixture screwscounterclockwise the exactnumber of rotations ± 1/4 turnfrom the seated position as aninitial setting.

3. While counting the rotations,carefully rotate the air screwsclockwise until lightly seated.

4. Rotate the air screws counter-clockwise the exact number ofrotations ± 1/4 turn from theseated position as an initial set-ting.

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.Allow engine to warm up for 2-3minutes.

6. After the engine has been thor-oughly warmed up, fine-tunethe idle speed screw until theengine idles smoothly.

NOTE: If a tachometer is beingused, engine idle speed shouldbe approximately 1500 RPM.

! CAUTIONDo not force a fuel mixturescrew when rotating it clock-wise; damage to the fuel mix-ture screw taper will result.

! CAUTIONThe fuel mixture screw setting isvery critical to engine perfor-mance; therefore, do not rotatethe fuel mixture screws lessthan the recommended numberof turns counterclockwise orengine damage will occur.

! CAUTIONDo not force an air screw whenrotating it clockwise; damage tothe air screw will result.

! WARNINGIt is important that the rear ofthe snowmobile is on a shieldedsafety stand. If not, personalinjury could result.



50 MAINTENANCE

7. Test the throttle control lever bycompressing and releasing itseveral times. The lever mustreturn to the idle posi t ionquickly and completely.

SELECTING CARBURETOR MAIN JET(S)Altitude, temperature, and the use ofoxygenated gasoline affect the car-buretion needed for optimum engineperformance. The carburetor mainjet(s) must be changed in conjunc-tion with changes in operating alti-tude, oxygenated gasoline usage,and temperature. As the ambienttemperature rises or as the snowmo-bile is operated at a higher altitude,the main jet(s) must be replaced withleaner main jet(s). The originalequipment (production) main jet(s)may need to be changed (dependingon the type of gasoline you areusing, your operating altitude, andtemperature). A Main Jet Chartdecal is located beneath the hood ofthe snowmobile. It should be notedthat when selecting the proper mainjet(s), it is better to be too rich ratherthan too lean. To change carburetormain jet(s), use the following proce-dure:

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 snowmobi leowner.

Changing Main Jet(s) (VM-Style)1. Loosen each carburetor flange

clamp and remove each carbu-retor from the intake flange andboot.

2. Remove each drain plug and O-ring from the carburetor floatchamber and drain the gas intoa small container or shop tow-els.


! CAUTIONUse only GENUINE Mikuni brassmain jets. Also, if using an oxy-genated gasoline (up to 10%ethanol or up to 15% MTBE), thecarburetor main jet must be onesize larger than the main jetrequired for regular unleadedgasoline.

! CAUTIONA main jet which is too smallwill cause severe engine dam-age. Engine damage caused bylean jetting WILL NOT BE cov-ered by our warranty policy.

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

MAINTENANCE 51

3. Using the main jet wrench(from the tool kit), thread themain jet out of each carburetor.Account for the baffle ring/washer. Install the new main jetand the existing baffle ring/washer. Tighten the main jetsecurely.

0728-054

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

5. Install and secure the carbure-tors.

Changing Main Jets (TM-Style)1. Remove all components from

the front of the a ir- in takesilencer.

2. Remove the screws securing theair-intake silencer; then movethe silencer forward and out ofthe engine compartment.

3. Loosen the carburetor flangeclamps; then slide the carbure-tors out of the intake flanges.

4. Tilt the carburetors to access themain jets.

5. Remove each drain plug and O-ring from the carburetor floatchamber and drain the gas intoa small container or shop tow-els.

6. Using the main jet wrench(from the tool kit), thread themain jet out of each carburetor.Account for the washer. Installeach new main jet and the exist-ing washer. Tighten the main jetsecurely.

0734-280

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

8. Push the carburetors back intoposition and into the intakeflanges; then tighten the carbu-retor flange clamps securely.

9. Place the air-intake silencer intoposition in the engine compart-men t and secure wi th thescrews.

10. Install all components onto theair-intake silencer and securewith existing hardware.

SPARK PLUGS NOTE: Always use the recom-mended spark p lugs in theengine. See the appropriate spec-ifications chart for correct sparkplug gap.

Varying terrain conditions and oper-ating usage may require spark plugsof a different heat range. For exam-ple, sustained cross-country ridingwill usually require colder heat-range spark plugs while trail ridingor other continual slow speed opera-tion will usually require hotter heat-range spark plugs.

52 MAINTENANCE

Removing/Installing Spark Plugs (2-Stroke Models)

1. Remove the spark plug capsfrom the plugs.

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

3. Install the plugs and finger-tighten.

4. Tighten the spark plugs to 2.5-2.8 kg-m (18-20 ft-lb); theninstall the spark plug caps.

Removing/Installing Spark Plugs (660 cc Models)

1. Remove the spark plug/coilcover.

2. Remove the cap screws secur-ing the spark plug coils to theengine; then remove the coils.

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

4. Install the plugs and finger-tighten.

5. Tighten the spark plugs to 2.1kg-m (15 ft-lb); then install thespark plug coils and securethem with cap 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 (afterthe snowmobile has been operatedunder normal driving conditions),remove the spark plugs and exam-ine the condition of the center elec-trode insulator of each spark plug.

AO352A

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

B. LIGHT GRAY or WHITEinsulator indicates over-heating of the engine. Thiscondition is caused by a toolean condition or incorrectspark plugs (heat range toohot).

C. BLACK insulator indicatesfuel in the combustionchamber is not burningcompletely. This conditionis caused by a too richcondition, too much oil, orincorrect spark plugs (heatrange too cold).

NOTE: If the center electrodeinsulators are light gray, white, orblack and if the carburetor adjust-ments (on carbureted models),oil-injection pump synchroniza-tion, and ignition timing are cor-rect, different heat-range sparkplugs may be necessary. Autho-rized Arctic Cat Snowmobile deal-ers have detailed spark pluginformation. Consult a dealerbefore changing spark plugs, asincorrect heat-range spark plugscould cause poor engine perfor-mance or engine damage.

MAINTENANCE 53

CHARGING BATTERY (Electric Start Models)

Standard with Removable Caps NOTE: The level of the batteryfluid must be kept between theMAX and MIN level lines at alltimes. If the level drops below theMIN level line, add only distilledwater until it reaches MAX levelline.

To remove and charge the battery,use the following procedure:

1. Remove the negative batterycable; then remove the positivecable and the battery vent tube.Remove the battery from thesnowmobile. Care should betaken not to damage the venttube.

2. Remove the vent plugs; then (ifnecessary) fill the battery withdistilled water to the MAXlevel indicated on the battery.

3. Trickle charge the battery at 1.4amps for 10 hours.

4. After charging, check fluidlevel and fill with distilledwater as necessary; then installvent plugs.

! CAUTIONIf a spark plug is light gray,white, or black and another istan or l ight brown, take thesnowmobile to an authorizedArctic Cat Snowmobile dealerfor inspection and service. If notunder warranty, this service is atthe discretion and expense ofthe snowmobile owner.

! WARNINGBattery acid is harmful if it con-tacts eyes, skin, or clothing.Care must be taken wheneverhandling a battery.

! WARNINGAny time service is performedon a battery, the following mustbe observed: Keep sparks, openflame, cigarettes, or any otherflame away. Always wear safetyglasses. Protect skin and cloth-ing when handling batteries.When serv ic ing bat tery inenclosed space, keep the areawell-ventilated. Make sure bat-tery venting is not obstructed.

! WARNINGBattery posts, terminals, andrelated accessories contain leadand lead compounds, chemicalsknown to the state of Californiato cause cancer and reproduc-tive harm. Wash hands afterhandling.

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

! CAUTIONDo not charge the battery whileit is in the snowmobile with thebattery terminals connected.

! CAUTIONNever exceed the standardcharging rate.

! CAUTIONBefore installing the battery,make sure the ignition switch isin the OFF position.

54 MAINTENANCE

5. Place the battery into positionin the snowmobile and secure.

6. Attach the vent tube and checkthe vent tube to make sure it isnot crimped or obstructed inany way and that it is properlyrouted.

7. Clean the battery posts andcable ends by using a batterypost cleaning tool and/or a wirebrush to remove dirt, grease,and corrosion.

8. Connect cables to the properterminals: positive cable to thepositive terminal (+) and nega-tive cable to the negative termi-nal (-). Connect the negativecable last.

Sealed with Cap Strip

1. Remove the battery from thesnowmobile.

NOTE: This battery is perma-nently sealed. There is no need toremove the caps or to add elec-trolyte for the life of the battery. NOTE: Do not charge the bat-tery while it is in the snowmobilewith the battery cables connectedas damage to the electrical sys-tem may occur.

2. Using Arctic Cat BatteryCharger (p/n 0436-634), chargethe battery until the indicatorlight on the charger illuminates.

NOTE: Once charged, the bat-tery can be left connected to thecharger indefinitely.

3. Place the battery into positionin the snowmobile and secure.

4. Connect cables to the properterminals: positive cable to thepositive terminal (+) and nega-tive to the negative terminal (-).Connect the negative cable last.

! CAUTIONConnecting cables in reverse(positive to negative and nega-tive to positive) can cause seri-ous damage to the electricalsystem.

! CAUTIONThis maintenance-free batteryrequires periodic charging toprevent sulfiding. If the snow-mobile will be idle for extendedperiods of time, either run theengine or trickle charge fromtime to time. If the battery com-pletely discharges, permanentdamage will occur requiringreplacement.

! WARNINGAlways wear safety glasseswhen connecting or disconnect-ing a battery charger. Do notsmoke or allow open flamesnear a charging battery.

! CAUTIONImproper activation or exces-sive overcharging (possibly byequipment failure) could causedamage to the battery or snow-mobile by forcing acid out of thesafety valve.

! CAUTIONConnecting cables in reverse(i.e. positive to negative andnegative to positive) can causeserious damage to the electri-cal system.

MAINTENANCE 55

FUSES (660 cc Models)Fuses protect the snowmobile elec-trical system from overloading. Ifelectrical parts in the snowmobileare not working, the system mayhave been overloaded and caused ablown fuse. Before repairing orreplacing any electrical part, checkthe appropriate fuses. The followingillustration shows which fuse pro-tects each electrical part on thesnowmobile. If a fuse blows (opensa circuit), all the parts of the snow-mobile that use that circuit will notwork.

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 ofthe engine compartment nearthe battery (for standard mod-els) or behind the intake mani-fold (for Turbo models).

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

AO352A

2. Remove the suspected fuse.3. Look through the clear side of

the fuse to see if the metal wireinside is separated. If it is, thefuse is blown and should bereplaced with a fuse of the cor-rect amperage 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 thefuse continues to blow, take thesnowmobile to an authorized ArcticCat Snowmobile dealer for service.If not under warranty, this service isat the discretion and expense of thesnowmobile owner.

! WARNINGAlways replace a fuse with onehaving the same speci f iedamperage rating. Using a fusewith a higher rating can causesevere wire damage and couldstart a fire.

56 MAINTENANCE

ENGINE HEATER (660 cc Models)The engine heater will help provideeasier starting in cold weather. Arc-tic Cat recommends that the heaterbe plugged in any time the tempera-ture is expected to get below -15°F.The heater cord is stored on the leftrear of the engine compartment justabove the air-intake vent.

MECHANICAL BRAKE SYSTEMArctic Cat recommends that thebrake system (brake lever, brakelever travel, cable, caliper, spring,and disc) be checked daily for wearor damage, smooth operation, andproper adjustment.

Checking Brake Lever Travel1. Rotate the brake disc alternately

forward 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 specifi-cations, adjust the brake levertravel.

Adjusting Brake Lever Travel

1. To decrease brake lever travel(set up brakes), pull out on thebrake adjustment knob androtate the knob clockwise. Asyou rotate the knob, periodi-cally check the brake levertravel distance until the correcttravel distance is attained. Oncethe correct brake lever travelhas been obtained, release theadjustment knob into a securedposition.

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

! WARNINGDO NOT operate the snowmo-bile when the parking brake isengaged or when any compo-nent in the brake system is dam-aged, worn , or ad justedimproperly. If the snowmobile isoperated and the brake systemis not functioning properly,severe personal injury couldresult.

! 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 coolor burns may occur.

MAINTENANCE 57

730-151A

2. To increase brake lever travel(loosen the brake), pull out onthe brake adjustment knob androtate the knob counterclock-wise while checking the brakelever travel. Once the desiredbrake lever travel is obtained,release the adjustment knobinto a secured position.

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. Thisprocedure stabilizes the padmaterial and extends the life ofthe pads.

HYDRAULIC BRAKE SYSTEMArctic Cat recommends that thebrake system (brake lever, fluid res-ervoir, hose, caliper, pads, and brakedisc) be checked daily for fluid leak-age, wear, or damage and for properoperation. Also, the brake fluid levelmust be checked every time beforestarting the engine. The brake fluidmust be maintained at a level justbelow the high mark on the fluid res-ervoir.

Checking/Adding Brake Fluid1. With the fluid reservoir/sight

glass reservoir in a level posi-tion, check the fluid level. Thebrake fluid level must be justbelow the high mark in thebrake fluid reservoir or visiblein the sight glass.

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

! WARNINGDO NOT attempt to adjust thebrake with the flange nuts onthe brake cable bracket. Incor-rect brake adjustment mayoccur causing possible brakefailure.

! WARNINGWhen the brake adjustmentknob has reached its maximumadjustment, both brake padsMUST BE REPLACED. Take thesnowmobile to an authorizedArctic Cat Snowmobile dealerfor this service. This service isat the discretion and expense ofthe snowmobile owner.

! WARNINGDO NOT operate the snowmo-bile when the brake lever lock isengaged or when any compo-nent in the brake system is dam-aged, worn , or ad justedimproperly. If the snowmobile isoperated and the brake systemis not functioning properly,severe personal injury couldresult.

58 MAINTENANCE

740-159A

0740-588

2. If the brake fluid level is belowthe low mark or not visible inthe sight glass, remove the res-ervoir cover and add Arctic Catapproved brake fluid until thefluid is at the recommendedlevel. Install and secure the res-ervoir cover. Do not allowmoisture to contaminate thebrake system.

Changing Brake FluidThe brake fluid must be changed ona regular basis and whenever thebrake fluid has been overheated orcontaminated. The brake fluidshould be changed every 1000 milesor at the end of the snowmobilingseason, whichever occurs first. Takethe snowmobile to an authorizedArctic Cat Snowmobile dealer forthis service. This service is at thediscretion and expense of the snow-mobile owner.

Checking Brake Lever TravelBefore each use, check the brakelever travel using the following pro-cedure:

1. Compress the brake lever fully. NOTE: Do not pump the brakelever as it will produce an inaccu-rate reading.

2. Measure the distance betweenthe brake lever and the handle-bar. The dis tance must begreater than 2.54 cm (1 in.).

! CAUTIONBrake fluid is highly corrosive.Do not spill brake fluid on anysurface of the snowmobile.

! WARNINGDo not overfill the brake fluidreservoir. Overfilling the reser-voir may cause the brake sys-tem to hydraulically lock. Useonly Arctic Cat approved brakefluid. Never substitute or mixdifferent types or grades ofbrake f luid. Brake loss canresult. Brake loss can result insevere injury or even death.

MAINTENANCE 59

734-505A

3. If the resultant distance is lessthan specified, take the snow-mobile to an authorized ArcticCat Snowmobile dealer for ser-vice. This service is at the dis-cretion and expense of thesnowmobile owner.

Bleeding Brake SystemIf the brake lever feels spongy whenapplied, the brake system may needto be bled. To bleed the brake, usethe following 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 highmark with Arctic Cat approvedbrake fluid.

2. Slide a piece of flexible tubingover the ball of the bleedervalve and direct the other endinto a container.

0730-434

0739-269

! WARNINGDo not operate the snowmobileif the compressed distancebetween the brake lever and thehandlebar is less than 2.54 cm(1 in.). Brake loss may occur.Brake loss can result in severepersonal injury.

! CAUTIONBrake fluid is highly corrosive.Do not spill brake fluid on anysurface of the snowmobile.

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

60 MAINTENANCE

3. Slowly compress the brakel eve r and ho ld . Op en t h ebleeder valve to release thefluid and air. When the fluidstops, close the bleeder valve;then release the brake lever.

4. Repeat step 3 until the brakefluid flows free of air bubbles.

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

5. When the brake fluid is free ofall air and the brake lever feelsfirm when compressed, fill thereservoir to a level just belowthe high mark; then install andsecure the cover. Remove thetube from the bleeder valve.

Checking/Changing Brake PadsThe condition of the brake padsmust be checked daily and changedif worn or damaged. To check andchange the brake pads, use the fol-lowing procedure: NOTE: The brake pads may bechanged by the snowmobileowner if qualified to do so. If theowner 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 snowmobi leowner.NOTE: When install ing newbrake pads, always install themas a set. Never install just onepad or use brake pads whichhave been used in another snow-mobile.

1. Measure the thickness of bothbrake pads. The brake padthickness must be greater than3.2 mm (0.125 in.) on the stan-dard caliper or greater than 5.0mm (0.20 in.) on the ACT drivecaliper. If the brake pad thick-ness is less than specified,replacement of both pads isnecessary.

0730-434

0739-269

2. Remove the pin/hairpin clipsecuring the brake pads to thecaliper assembly.

3. Remove the brake fluid reser-voir cover; then remove most ofthe brake fluid from the reser-voir. 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. Replacingthe cover will prevent fluid spill-age.

MAINTENANCE 61

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 pistoninto the caliper.

6. Position the new brake padsinto the caliper.

7. Repeat steps 4-6 for the otherpad; then secure the pads withthe pin/hairpin clip.

8. Remove the reservoir cover andremove the remaining fluid;then fill the reservoir with freshfluid.

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. Thisprocedure stabilizes the padmaterial and extends the life ofthe pads.

DRIVE BELTThe drive belt transfers power fromthe drive clutch to the driven pulley.If the belt is worn, cracked, orstretched, maximum power will notbe transmitted and the belt couldalso fail and therefore must bereplaced. Periodic checks (at leastonce a month under normal usage)of two drive belt specifications areessential.

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 ofthe drive belt. The belt shouldbe within the recommendedrange in width.

3. Check the belt for cracking,fraying, 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 qual-ity material. Belts made by othermanufacturers may not be of thesame specifications or qualityand, therefore, usage could resultin poor performance and prema-ture belt failure.

Before starting the snowmobile inextremely cold temperatures, thedrive belt should be removed andwarmed up to room temperature.Once the drive belt is at room tem-perature, install the drive belt.Also, drive belts have a break-inperiod of approximately 20 miles.After installing a new drive belt,drive the snowmobile for 20 miles at1/2 throttle or less. This will allowthe drive belt to gain its optimumflexibility and will extend drive beltlife.

! CAUTIONNever run the engine with thedrive belt removed. Excessiverevving of the engine couldresult in serious engine damageand drive clutch failure.

62 MAINTENANCE

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

belt guard.

0739-613

737-316A

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

5. When the sheaves are fullyapart, hold the roller plate, pullup on drive belt, and roll thebelt over the stationary sheaveuntil it is free of the driven pul-ley. Slowly release the rollerplate.

731-659A

737-317A

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 num-ber can be read) between thesheaves of the drive clutch.

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

3. When the sheaves are fullyapart, hold the roller plate, rollthe belt over the stationarysheave, and slowly release theroller plate.

MAINTENANCE 63

4. After the belt is installed prop-erly, close and secure the beltguard and 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,take the snowmobile to an autho-rized Arctic Cat Snowmobiledealer for this service. This ser-vice is at the discretion andexpense of the snowmobi leowner. NOTE: On M-Series models, thedrive belt can be removed andinstalled by removing the sidepanel and pushing in on thedriven torque bracket (cam) toseparate the sheaves.

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

belt guard.4. Remove the driven pulley plug

from the belly pan.5. Using the spark plug wrench,

screwdriver, and Belt Deflec-tion Tool (p/n 0644-435) fromthe tool kit, remove the sheaveadjuster from the end of thedriven pulley. Account for andremove the O-ring and shimwashers. Note the orientation ofthe components for installingpurposes.

739-266A

739-267A

6. With the O-ring and shim wash-ers removed, carefully threadthe sheave adjuster back intothe driven pulley; then tightenthe adjuster with the deflectiontool/screwdriver/spark plugwrench 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 allowthe removal of the drive belt.

7. 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) betweenthe sheaves of the drive clutchfirst; then between the sheavesof the driven pulley.

! WARNINGNever operate the snowmobilewithout the belt guard securedin place.

64 MAINTENANCE

2. Using the deflection tool/screw-dr ive r / spa rk p lug wrenchassembly, remove the sheaveadjuster from the end of thedriven pulley.

3. Place the shim washers and O-ring (as noted in removing)onto the sheave adjuster; thencarefully thread the sheaveadjuster back into the drivenpulley. Tighten the adjustersecurely using the deflectiontool/screwdriver/spark plugwrench assembly.

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

4. Close the belt guard; theninstall the driven pulley plug.

5. Release the brake lever lock.

TRACK TENSIONTrack tension is directly related tothe overall performance of thesnowmobile. If the track is tooloose, it may slap against the tunnelcausing wear or it may “ratchet” onth e t r a ck d r ive s p r o c k e t s . I fextremely loose, the idler wheelsmay climb over the track lugs forc-ing the track against the tunnel caus-ing the track to “lock.” Arctic Catrecommends that the track tensionbe checked daily during the first 300miles of operation and once a weekthereafter and adjusted according toneed. The track will stretch and takea “set” during break-in. Trackdeflection must be maintainedwithin the recommended range.

Checking Track Tension

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

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

3. At mid-point of the track (onthe bottom side), hook a springscale around a track clip; thenpull down on the scale to therecommended pressure. Mea-sure the deflection (distance)between the bottom of the wearstrip and the inside surface ofthe track clip. Compare themeasurement with the chart.

NOTE: On King Cat models andM-Series models, no pressureshould be applied to the track.

! WARNINGNever operate the snowmobilewithout the belt guard securedin place.

! WARNINGTrack tension must be properlymaintained. Personal injurycould result if a track is allowedto become 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 65

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 Tension1. Loosen the rear idler wheel

adjusting bolt jam nuts.

0727-456

739-636A

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, tightenthe adjusting bolts to take upexcessive slack in the track.

3. If the distance between the bot-tom of the wear strip and theinside surface of the track isless than specified, loosen theadjusting bolts to increase theslack in the track.

4. Check track alignment (seeTrack Alignment section).

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

Model Setup Tension

After Break-In Tension

Z/ZR Models @ 20 lb

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

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

Panther Models @ 20 lb

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

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

T660 Touring/Turbo Touring @ 20 lb

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

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

Turbo Trail/Turbo ST @ 20 lb

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

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

Bearcat Models@ 20 lb

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

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

Firecat Models/Sabercat (128 in. Track) @ 20 lb

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

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

Crossfire Models/Sabercat EXT@ 20 lb

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

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

King Cat Models/ M-Series Models @ 0 lb

51-64 mm(2-2 1/2 in.)No pressure

51-64 mm(2-2 1/2 in.)No pressure

66 MAINTENANCE

NOTE: Since track tension andtrack alignment are interrelated,always check both even if onlyone adjustment seems neces-sary.

TRACK ALIGNMENTProper 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 oncea week or whenever the track ten-sion is adjusted.

Checking Track Alignment

1. Remove excess ice and snowbuildup from the track, trackdrive sprockets, and the insideof the 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 isfree to rotate.

3. Start the engine and accelerateslightly. Use only enough throt-tle to turn the track several rev-olutions. SHUT ENGINE OFF.

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

4. When the track stops rotating,check the relationship of therear idler wheels and the innertrack drive lugs. If the rear idlerwheels are centered betweenthe inner track drive lugs, noadjustment is necessary.

0727-729

! WARNINGIf jam nuts are not tightenedproperly, the adjusting boltscould loosen causing the trackto become extremely loose and,under some operating condi-tions, allow the idler wheels toclimb over the track lugs forcingthe track against the tunnelcausing the track to “lock.” If atrack “locks” during operation,severe personal injury couldresult.

! WARNINGMake sure the ignition key is inthe OFF position and the trackis not rotating before checkingor adjusting track alignment.Personal injury could result ifcontact is made with a rotatingtrack.

! WARNINGThe tips of the skis must bepositioned against a wall orsimilar object.


MAINTENANCE 67

0739-637

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

Adjusting Track Alignment1. On the side of the track which

has the inner track drive lugscloser to the rear idler wheel,loosen the adjusting bolt jamnut; then rotate the adjustingbolt clockwise 1 to 1 1/2 turns.

0727-456

739-636A

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

NOTE: Make sure correct tracktens ion is mainta ined a f teradjusting track alignment (seeTrack Tension section).

3. After proper track alignment isobtained, tighten the adjustingbolt jam nut against the axlehousing.

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 Align-ment procedure.

SUSPENSIONThe suspension should be adjustedfor the operational needs and ridingpreference of the operator.The front shock springs determinethe amount of ski pressure and thereaction of the front suspension torough terrain. The amount of skipressure can also be changed byadjusting the length of the skidframe front arm limiter straps.The rear springs influence the loadcarrying capability of the snowmo-bile and should be adjusted for theweight and riding preference of theoperator.

Adjusting Front Shock Springs (STD) NOTE: On some models, thefront shock spr ings are notadjustable.

! WARNINGIf a jam nut is not tightenedproperly, the adjusting boltcould loosen causing the trackto become dangerously loose.

68 MAINTENANCE

The front shock springs are individ-ually adjustable for the terrain con-ditions and driving style of theoperator. The spring adjuster hasbeen set at the factory so the correctamount of threads are exposedbetween the spring adjuster and theshock housing as an initial setting.Additional ski pressure can beobtained by tightening the springt ens ion ; sk i p r e s su re can b edecreased by relaxing spring ten-sion. NOTE: Equal adjustmentsshould be maintained on bothsides of the snowmobile.

To adjust spring tension, rotate theentire spring in whichever directionis desired. If after adjusting springtension you note the snowmobilefront end wants to pitch, relax thespring tension on the side that ispitching. If both sides are pitching,relax the spring tension on bothsides. NOTE: The spring adjuster willnormally rotate with the spring.

734-501B

734-500B

Adjusting Front 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,take the snowmobile to an autho-rized Arctic Cat Snowmobiledealer for this service. This ser-vice is at the discretion andexpense of the snowmobi leowner.

The air shocks are individuallyadjustable for the terrain conditionsand driving style of the operator.The shocks are preset at 3.5 kg/cm2

(50 psi) as an initial setting (4.2 kg/cm2 (60 psi) on the M-7 LE); how-ever, it is possible to “fine tune” theshocks to match the operator ’sweight, riding style, and terrain con-ditions. NOTE: Care should be taken tohave equal pressure in theshocks before operating thesnowmobile.

To increase or decrease air pressure,use the following procedure. 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 a i r pressure wi l ldecrease air spring force.

1. Remove the air valve cap fromthe shock.

! WARNINGDo not exceed 105 kg/cm2 (150psi) in the shock.

MAINTENANCE 69

2. Thread the valve of Air ShockPump (p/n 2603-324) onto theshock air valve approximatelysix rotations.

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

3. To decrease air pressure in theshock, press the black bleedvalve button half way down andhold until desired pressure isattained.

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 fromthe shock 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 shockspring and limiter straps are adjust-able. However, Arctic Cat recom-mends that the shock spring bemaintained as loose as possible.Tightening the skid frame front armshock spring may cause improperbalance and may ruin the handlingfeatures of the snowmobile.

The length adjustment of the frontarm limiter straps determines theweight distribution between thefront of the skid frame and the skis.Tightening the limiter strap (short-ening the strap) will pull up on thefront of the skid frame and willincrease ski pressure. Loosening thelimiter strap (lengthening the strap)lowers the front of the skid frameand decreases ski pressure.When customizing the amount of skipressure, be sure to adjust bothstraps equally and do not over-adjustthe limiter straps to adversely affectsteering and operator control of thesnowmobile. Some experimentationmay be required until the properadjustment for the operator’s indi-vidual style is obtained.

0730-537

0739-714

! WARNINGDo not adjust the front arm lim-iter straps to a point at whichsteering and operator control ofthe snowmobile are adverselyaffected.

70 MAINTENANCE

Adjusting Rear Spring Pre-LoadProper adjustment of rear springpre-load is necessary to get the mostcomfortable r ide. The chart isdesigned to help in setting up rearspring pre-load; however, ridingstyle is the single greatest factor indetermining rear spring require-ments.

NOTE: These cam position set-tings are suggestions only. Personalriding style will greatly influencecam position settings. Spend timeto determine setting preferences.Rear spring pre-load adjustment isaccomplished by rotating the adjust-ing cams. Position 3 provides thestiffest ride, and position 1 is for thelight driver or slow-speed trailriding. Position 2 is for the averageoperator under normal conditions.Always rotate the cam from thelighter position to the heavier posi-tion.

727-720A

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 STD)The rear articulating portion of theskid frame has two adjusters whichcontrol the amount of travel in therear suspension.These two adjusters have been pre-set at the factory and should requireno further 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 suspen-sion.

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 71

Overload Springs Some models have overload springsbuilt into the rear suspension. Wheneither carrying a heavy load orriding 2-up, the overload springsshould be engaged by rotating thespring tension blocks to the UP posi-tion. The spring tension blocks lockin an over-center position whenengaged. To either engage or disen-gage the spring tension blocks, usethe Spring Block Tool, a spark plugsocket, and a screwdriver to adjustthe spring block to the desired posi-tion. Make sure both spring blocksare in the same position (eitherengaged or disengaged).

0739-625

LIGHTSThe correct taillight/brakelight bulbis p/n 0109-460. The correct head-light bulbs are p/n 0609-251 for thehigh beam and p/n 0609-252 for thelow beam. NOTE: On the Crossfire/M-Series models, the correct head-light bulb for low beam is p/n0609-693.

Removing and Installing Taillight/Brakelight Bulb

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

0728-239

0737-302

0739-712

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

3. Install the new bulb in thesocket by pushing it in androtating it clockwise.

4. Install the lens and secure withthe screws.

72 MAINTENANCE

Removing Headlight Bulb (3-Bulb Style) 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 retain-ing clip away from the head-light bulb base and disconnectthe wiring harness from thebulb.

0733-178

2. Rotate the headlight bulb basecounterclockwise and removethe bulb from the headlighthousing.

Installing Headlight Bulb (3-Bulb Style)

1. While holding the bulb by itsbase, insert the bulb into theheadlight housing and rotate itclockwise until it locks into thehousing.

2. Plug the wiring harness into theheadlight bulb base makingsure the retaining clip locksonto the base.

3. Check headlight aim (seeAdjusting Headlight Aim in thissub-section).

Removing Headlight Bulb (4-Bulb Style) 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 theheadlight housing and discon-nect the wiring harness from thebulb.

0740-462

Installing Headlight Bulb (4-Bulb Style)

1. Plug the wiring harness into theheadlight bulb.

! CAUTIONDo not touch the glass portionof the bulb. If the glass portionis touched, it must be cleanedwith a dry cloth before install-ing.

! WARNINGDo not operate the snowmobileunless headl ight beam isadjusted properly. An incor-rectly adjusted beam will notprovide the operator the opti-mum amount of light.


MAINTENANCE 73

2. Insert the bulb into the head-light housing.


Removing Headlight Bulb (Crossfire/M-Series 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, usethe following procedure.

1. With the hood closed, loosenthe headlight 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 a i r s i lencer p lenum toaccess the bulbs.

4. Remove the bulb from theheadlight housing and discon-nect the wiring harness from thebulb.

0740-462

Installing Headlight Bulb (Crossfire/M-Series Models)

1. Plug the wiring harness into theheadlight bulb.

2. Insert the bulb into the head-light housing.

3. Press the air silencer plenuminto place on the hood andsecure with the O-rings; thenclose the hood.

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

5. Tighten the headlight adjust-ment knobs.




74 MAINTENANCE

Adjusting Headlight AimThe headlight can be adjusted forvertical aim of the HIGH/LOWbeam. The geometric center ofHIGH beam zone is to be used forvertical aiming.

1. Position the snowmobile on alevel floor so the headlight isapproximately 8 m (25 ft) froman aiming surface (wall or simi-lar surface).

NOTE: There should be an“average” operating load on thesnowmobi le when adjust ingheadlight aim.

2. Measure the distance from thefloor to midpoint of the head-light.

3. Using the measurementobtained in step 2, make a hori-zontal mark on the aiming sur-face.

4. Make a vertical mark whichintersects the horizontal markon the aiming surface directlyin front of the headlight.

5. Engage the brake lever lock andstart the engine. Move the head-light dimmer switch to theHIGH beam position. DO NOTUSE LOW BEAM.

6. Observe the headlight beamaim. Proper aim is when themost intense beam is centeredon the vertical mark 5 cm (2 in.)below the horizontal mark onthe aiming surface.

740-153A

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

8. On 4-bulb models, adjust theheadlight using the adjustmentknobs unt i l correct a im isobtained. Shut the engine off;then disengage the brake leverlock.

SKI WEAR BARSThe ski wear bar is a replaceable barattached to the underside of the ski.The purpose of the wear bar is toassist in turning the snowmobile, tominimize ski wear, and to maintaingood steering control. If the snow-mobile is operated primarily in deepsnow, ski wear bar wear will be min-imal; however, if the snowmobile isoperated on terrain where the snowcover is minimal, the ski wear barwill wear faster. To maintain posi-tive steering characteristics, ArcticCat recommends that the ski wearbars be checked before each use andreplaced if worn beyond 1/2 of theoriginal diameter. Ski wear bars areavailable from an authorized ArcticCat Snowmobile dealer.


MAINTENANCE 75

Removing Ski Wear BarsNOTE: Determine which type ofwear bar is being replaced andremove and install accordingly.

1. Remove ice and snow buildupfrom the ski.

2. With the gas tank nearly empty(less than 1/4 full), lay thesnowmobile on its left side. Apiece of cardboard should beused to protect the finish on thehood and belly pan.

3. Remove the lock nuts and wash-ers (if applicable) securing thewear bar to the ski.

737-454A

731-037D

0739-596

0739-016

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

! CAUTIONThe “Laydown” engine modelsshould not be tipped on theirright sides for any extendedperiod of time, as air bubblesmay form in the oil hose. If airbubbles form in the oil hose, theoil injection system must bebled. Take the snowmobile toan authorized Arctic Cat snow-mobile dealer for this service.This service is at the discretionand expense of the snowmobileowner.

! CAUTIONThe 660 cc models should notbe t ipped on their s ides inexcess of a 70° angle for anyreason, as the engine oil mayseep into the upper enginethrough the air-intake system.Severe engine damage couldresult if the engine is run withoil in the upper engine.

76 MAINTENANCE

4. Remove the wear bar from theski and account for the locationof the bushings (if applicable).

Installing Ski Wear Bars1. If applicable, place the bushings

onto the studs; then move thewear bar into position on thebottom of the ski.

NOTE: If installing a double-off-set wear bar, the carbide edgemust be directed to the outside ofthe ski.

2. Align the wear bar studs withthe holes in the ski; then installthe washers (if applicable) andlock nuts. Tighten to 1.5-2.1 kg-m (11-15 ft-lb).

ADJUSTING SKI STANCE (M-Series/King Cat/Bearcat 570 Models)

1. Place the front of the snowmo-bile on 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 spac-ers to 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. Position the ski over the saddle.6. Apply a low-temperature grease

to the non-threaded portion ofthe cap screw; then slide the capscrew through the ski and sad-dle accounting for the rubberdamper, inserts, and washers.

NOTE: Install the cap screw sothe slotted nut will be located tothe inside of the ski.

7. Apply red Loctite #271 to thethreads of the cap screw; thentighten the nut to 6.2 kg-m (45ft-lb).

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

9. Repeat procedure for the otherski.

RAIL WEAR STRIPSArctic Cat recommends that thewear strips be checked weekly andreplaced as necessary. Measure thewear strips at 25.4 cm (10 in.) inter-vals. Wear strips must be 10.7 mm(0.42 in.) thick or thicker. If wearstrip measurements are less thanspecified, replacement of both wearstrips is necessary to prevent prema-ture track clip wear and possibletrack damage. Take the snowmobileto an authorized Arctic Cat Snow-mobile dealer for this service. Thisservice is at the discretion andexpense of the snowmobile owner.Each time a new set of wear stripsare installed, they should be tem-pered. Temper the wear strips bydriving the snowmobile for approxi-mately a mile on a hard pack trail;then immediately drive into deepsnow and allow the wear strips tocool. Repeat the procedure (warm-ing up the wear strips; then coolingthem down) two or three times. NOTE: The rail wear strips willwear rapidly if the snowmobile isoperated on terrain on which thesnow cover is minimal. Loosesnow is required to cool andlubricate the wear strips and pre-vent accelerated wear.

MAINTENANCE 77

0727-726

AXIAL FAN BELT (370/440 cc Models)Arctic Cat recommends that the con-di t ion of the axia l fan bel t beinspected monthly.

1. Be sure ignition key is in theOFF position.

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 thebelt together near mid-span.The maximum belt deflectionmust not exceed 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 expenseof the snowmobile owner.

5. Install the fan cover.

ACCESSORY BELT (660 cc Models)Arctic Cat recommends that the con-dition of the accessory belt beinspected monthly.

Checking Belt Tension1. Be sure ignition key is in the

OFF position.

2. On the standard models,remove the air cleaner assem-bly ; on the tu rbo model s ,remove the intercooler assem-bly.

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.

! WARNINGDO NOT inspect the axial fanbelt while the engine is running.Contact with the axial fan belt,fan blades, or other movingpar ts may cause personalinjury. !WARNING

DO NOT inspect the belt whilethe engine is running. Contactwith the belt, pulleys, or othermoving parts may cause per-sonal injury.

78 MAINTENANCE

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 9mm (0.35 in.).

0736-564

Adjusting Belt Tension1. Remove the bolts securing the

belt 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 (suchas a hammer handle) betweenthe engine and the alternator,pry the alternator away from theengine, and tighten the acces-sory 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 posi-tion and secure with the bolts.

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

PERFORMANCE TIPS 79

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 ful lyclosed). 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.), p/n 0648-715(0.030 in.), and p/n 0648-716 (0.060in.). See an authorized Arctic CatSnowmobile dealer for this service.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 dr iveclutch and driven pulley clean shouldbe the primary consideration of theoperator. The clutch sheaves can becleaned of any drive belt accumula-tion using a clean cloth and parts-cleaning solvent. All pivot points canbe maintained clean using compressedair.The setting of the driven pulley pre-load will vary the peak engine rpm.Peak engine rpm is the rpm at whichthe engine develops its maximumhorsepower. Optimum snowmobileperformance will result if the enginerpm (full throttle) is within 3% of thespecifications. To increase the peakrpm, increase the spring tension of thedriven pulley by moving the springend clockwise. To decrease the peakrpm, decrease the spring tension of thedriven pulley by moving the springend counterclockwise. Each hole posi-tion will change the peak engine rpmby approximately 200 rpm. On theACT roller driven pulley, spring ten-sion is adjusted using Spring Adjust-ment Tool (p/n 0644-413). CARBURETOR MAIN JET(S)(Carbureted Models) — Proper carbu-retion is absolutely necessary toobtain peak performance. Since ambi-ent temperature and operating altitudeboth affect the main jet size needed foroptimum engine performance, themain jet(s) MUST be changed when-ever the temperature changes 20° F orwhenever operating altitude varies bymore than 1000 feet. The Main JetChart beneath the hood of the snow-mobile identifies the proper mainjet(s) to use under all operating tem-peratures and altitudes. Follow theMain Jet Chart carefully to obtainpeak engine performance and avoidengine damage.

80 PREPARATION FOR STORAGE

PREPARATION FOR STORAGEPrior to storing the snowmobile, itmust be properly serviced to pre-vent corrosion and component dete-rioration. An authorized Arctic CatSnowmobile dealer should performthis service; however, the owner/operator can perform this service ifdesired. This service is at the discre-tion and expense of the snowmobileowner. To prepare the snowmobilefor storage, Arctic Cat recommendsthe following procedure:

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

2. Clean the snowmobile thor-oughly by hosing dirt , oil ,grass, and other foreign matterfrom the skid frame, tunnel,hood, and belly pan. Allow thesnowmobile to dry thoroughly.DO NOT get water into anypart of the engine.

NOTE: On 660 cc models,change the engine oil and cleanthe air filter; then proceed to step9.

3. Place the rear of the snowmo-bile up on a shielded safetystand.

4. On the “Laydown” engine mod-els, start the engine and allow toidle. With the engine idling, prythe intake boot forward; thenspray Arctic Cat Engine Stor-age Preserver (p/n 0636-177)into the intakes until the engineexhaust starts to smoke heavilyor until the engine starts to dropin RPM. Turn engine off.

NOTE: On the “Laydown”engine models after step 4, pro-ceed 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-e ls , the a i r - in take s i lencerincludes 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/t oo l t r ay a s sembly to t hesilencer.

6. Close the cover; then tip thecover/tool tray assembly for-ward and out of its slots andremove the assembly.

7. Using a large flat-blade screw-driver, remove the baffle/reso-nator tabs from the air-intakesilencer slots and remove thebaffle/resonator to access theintake bores.

NOTE: The baffle/resonator canbe removed more eas i ly byremoving the back tabs first.

8. Start the engine and allow toidle. With the engine idling,spray Arctic Cat Engine Stor-age Preserver (p/n 0636-177)into the intake(s) until theengine exhaust starts to smokeheavily or until the engine startsto drop in RPM. Turn engineoff.

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

PREPARATION FOR STORAGE 81

9. Plug the exhaust system outletwith a clean cloth.

10. With the ignition switch in theOFF position:A. Disconnect the high

tension leads from thespark plugs; then removethe plugs, connect them tothe leads, and ground themon the cylinder heads.

B. Pour 29.5 ml (1 fl oz) ofSAE #30 petroleum-basedoil into each spark plughole and pull the recoilstarter handle slowly about10 times.

C. Install the spark plugs andconnect the high tensionleads.

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

12. Fill the gas tank to its ratedcapacity; then add Arctic CatFuel Stabilizer (p/n 0638-165)to the gas tank following direc-tions on the container for thes t a b i l i ze r / g as o l i n e r a t i o .Ti gh t en t he g as t ank capsecurely.

13. On standard chain case models,drain the chain-case lubricantby removing the chain-casedrain plug located on the back-side of the chain-case assembly.Remove the chain-case coverand inspect chain, sprockets,chain tensioner, and rollers forwear and the chain for propertension. Install the drain plug,chain-case cover, and seal; thenpour the recommended amountof Arctic Cat TransmissionLube (p/n 0636-817) into thefiller hole (see Lubrication sec-tion).

14. On ACT drive gear case mod-els, change the gear case fluid(see Lubrication section).

15. Remove the drive belt from thedrive clutch/driven pulley. Laythe belt on a flat surface or slideit into a cardboard sleeve to pre-vent warping or distortion dur-ing storage.

16. Clean and inspect the driveclutch and driven pulley.

17. Apply light oil to the uppersteering post bushing, ski spin-dles and bolts, front and rearpivot bushings of the skidframe, and plungers of theshock absorbers.

18. Lubricate the rear suspension,spindles, speedometer driveadapter, and driven shaft sup-port bearing with a low-temper-ature grease.

19. Tighten all nuts, bolts, and capscrews making sure all cali-brated nuts, bolts, and capscrews are tightened to specifi-cations. Make sure all rivetsh o ld ing t h e comp onen t stogether are tight. Replace allloose rivets.

! CAUTIONDo not do step 10 on the 4-stroke models; severe enginedamage could result.

! CAUTIONNever crank the engine overwithout grounding the sparkplugs. Damage to coils and/orCDI unit may result.

82 PREPARATION FOR STORAGE

20. Clean and polish the hood, con-sole, and chassis with ArcticCat Hood and Windshie ldCleaner/ Polish (p/n 0636-174).DO NOT USE SOLVENTS ORSPRAY CLEANERS. THEPROPELLANT WILL DAM-AGE THE FINISH.

21. On electric start models, dis-connect the battery cables mak-ing sure to disconnect thenegative cable first; then cleanthe battery posts and cables.

22. If possible, store the snowmo-bile indoors. Raise the track offthe floor by blocking up theback end making sure the snow-mobile is secure. Loosen thetrack adjusting bolts to reducetrack tension. Cover the snow-mobile with a machine cover ora heavy tarpaulin to protect itfrom dirt and dust.

23. If the snowmobile must bestored outdoors, position thesnowmobile out of direct sun-light; then block the entiresnowmobile off the groundmaking sure the snowmobile issecure. Loosen the track adjust-ing bolts to reduce track ten-sion. Cover with a machinecover or a heavy tarpaulin toprotect it from dirt, dust, andrain.

! CAUTIONAvoid storing in direct sunlightand using a plastic cover asmoisture may collect on thesnowmobile causing corrosion.

PREPARATION AFTER STORAGE 83

PREPARATION AFTER STORAGETaking the snowmobile out of stor-age and correctly preparing it foranother season will assure manymiles and hours of trouble-freesnowmobiling. Arctic Cat recom-mends the following procedure:

1. Clean the snowmobile thor-oughly. Polish the exterior ofthe snowmobile.

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 orrotating 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, inspectthe in-line fuel filter and replaceif necessary.

6. Inspect all fuel hoses and oilhoses for deterioration or cracks;replace if necessary. Make sureall connections are tight; then on2-stroke models, fill the oil-injection reservoir with the rec-ommended 2-cycle oil (see Gas-oline-Oil sub-section).

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

7. Inspect the entire brake system,all controls, headlight, taillight,brakelight, ski wear bars, andheadlight aim; adjust or replaceas necessary.

8. Inspect the spark plugs.Replace, gap, or clean as neces-sary.

9. Adjust the track to the propertension and alignment. Lock thejam nuts.

10. Adjust the carburetor(s) andchoke cable on carbureted mod-els and throttle cable on allmodels.

11. Tighten all nuts, bolts, and capscrews making sure all cali-brated nuts, bolts, and capscrews are tightened to specifi-cations.

! CAUTIONOn carbureted models if the gasin each carburetor float cham-ber was not drained prior tostorage, the carburetor(s) mustbe cleaned before starting theengine.

! WARNINGOn VM-style carburetors, besure to t ighten the swive ladapter jam nuts securely. If ajam nut isn’t t ightened, theadjuster can rotate out of thecarburetor cap causing thethrottle slide not to return to thefull-closed position.

84 PREPARATION AFTER STORAGE

12. Lubricate the rear suspension,spindles, speedometer driveadapter, and driven shaft sup-port bearing with a low-temper-ature grease.

13. On liquid cooled models, checkthe coolant level and all coolanthoses and connections for dete-rioration or cracks. Add prop-erly mixed coolant as necessary.

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

15. On 2-stroke models, place therear of the snowmobile on ashielded safety stand; then startthe engine. Allow the engine toidle; then using a long stiff wirewith a hooked end, raise the oil-injection pump control arm tothe wide-open position until theengine starts to smoke heavily.Release the control arm andturn off the engine.

16. On electric start models, chargethe battery; then connect thebattery cables making sure toconnect the positive cable first.Test the electric start system.

NOTES 85

NOTES

86

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. EPAEmission Control 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 serviceperformed by any repair establishment that uses equivalent components. The regulations providesignificant civil penalties for tampering that causes your snowmobile to no longer meet U.S. EPAemission standards.

Arctic Cat further warrants that the engine and its emission-related components are free from defectsin materials 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,contact your 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 COVEREDThe emissions warranty covers major emissions control components and emission-relatedcomponents listed as follows:

Engine Management and SensorsBarometric Pressure SensorCamshaft Position SensorEngine Control Unit (ECU)Engine Coolant Temperature SensorIntake Air Temperature SensorManifold Absolute Pressure SensorOxygen SensorThrottle Position Sensor

Ignition SystemIgnition CoilKnock Sensor SystemSpark PlugsCapacitive Discharge Ignition (CDI) ModuleMagneto Pick-Up

Fuel/Air SystemFuel InjectorsFuel Pressure RegulatorCarburetor(s)Turbocharger AssemblyAir Bypass ValveTurbo Waste Gate Control ValveCrankcase Ventilation System

Miscellaneous Items Used in Aforementioned SystemsConnectorsSwitchesGrommetsClampsHosesTiesGasketsWiring

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'sManual. Proper maintenance generally includes replacement and service, at the owner's choosing,such items as air filer, oil and oil filter, or any other part, item, or device related to emissions control asspecified in the Operator's Manual. It is the owner's responsibility to ensure that the snowmobile isused in a manner for which it was designed.

Printed in U.S.A. Trademarks of Arctic Cat Inc. Thief River Falls, MN 56701 p/n 2257-327®TM

ARCTIC CAT®

Documents

Snowmobile Operator's Manual