snowmobile operator’s manual - arctic cat · pdf filesnowmobile operator’s manual...

20072007Snowmobile

Operator’sManual

p/n 2257-617

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

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

Arctic Cat will repair or replace, at its option, free of charge (including any related labor charges), anyparts that are found to be warrantable in material or workmanship. This repair work MUST be done byan authorized Arctic Cat Snowmobile dealer. No transportation charges, rental charges, orinconvenience costs will be paid by Arctic Cat. The warranty is validated upon examination of 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 (including rental operations), ONE (1) YEARfrom 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 service parts and accessories.

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

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

Fuel Filter Light Bulbs Windshield Drive Clutch/Driven Pulley Wear Parts

Drive Belt Wear Bars Water Pump Belt Brake Pads

Wear Strips Fan Belt Spark Plugs Torn or Punctured Upholstery

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. Repairs and/or adjustments 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.

13. Damage due to improper transportation.

In consideration of the foregoing, any implied warranty is limited in duration to the various warrantyperiods set forth. This warranty gives you specific legal rights, and you may also have other rightswhich vary from state to state and country to country. Some states do not allow limitations on how longan 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 ...................................4-30

Snowmobile Identification...........................4Control Locations .......................................4Tipped Snowmobile ....................................7Gasoline-Oil ...............................................8Engine Break-In (2-Stroke Models)...........10Engine Break-In (660 cc/1100 cc Z1 Models) ...........................................10Indicator Lights (Carbureted Models/ Bearcat W/T Non-Turbo/ Panther 660).........................................11Low Oil Warning Light (Standard 2-Stroke Models)..................11Low Oil Pressure Warning Light (Bearcat W/T Non-Turbo/ Panther 660 Models) ............................11Coolant Temperature Warning Light (Carbureted Models/ Bearcat W/T Non-Turbo/ Panther 660).........................................12Charging System Warning Light (660 cc Models) ....................................12Check Engine Light (Bearcat W/T Non-Turbo/Panther 660 Models)...........12Speedometer/Tachometer Indicator Lights (Crossfire/F-Series/Jaguar Z1/ M-Series/660 cc Turbo Models) ............12Diagnostic Codes/Check Engine (2-Stroke Models) .................................15Diagnostic Codes/Check Engine (Jaguar Z1) ...........................................16Handlebar Tilt ...........................................17Handlebar Tilt (F-Series - STD) ....................................17Handlebar Tilt (F-Series LXR/Sno Pro/ Jaguar Z1) ............................................18Exhaust System .......................................19Air-Intake Silencer ....................................19Battery (Electric Start Models)..................19Cooling System (Liquid) ...........................20Drive Clutch and Driven Pulley .................20Drive Clutch/Driven Pulley Alignment...................................21Drive Chain Tension..................................21Fuel Pump ................................................22Gas Tank Shut-Off Valve...........................22Shock Absorbers (Standard Gas) .............22Shock Absorbers (Rebuildable Gas).........22Deep-Lug Track ........................................23Hacksaw Track..........................................23Track Studs...............................................23Reverse Transmission ..............................24Reverse Transmission (Crossfire/ F-Series/Jaguar Z1/ M-Series Models) .................................25Towing ......................................................26Adjustable Backrest .................................26Removable Rear Seat ..............................26Removable Seat (Crossfire/M-Series Models) ................................................27

Removable/Adjustable Seat (F-Series/Jaguar Z1) ............................27Arctic Power Valve (APV) System.............28Exhaust Controlled Timing (ECT) System (600/800/1000 cc) .........29

Operating Instructions..............................31-39Starting and Stopping Engine ...................31High RPM Operation (660 cc Models) ....................................35Braking (Hydraulic Brake Models) ............35Emergency Stopping ................................36Throttle/Ignition Monitor Switch (2-Stroke/Jaguar Z1 Models) ................37Varying Altitude Operation........................39

Lubrication ...............................................40-45Standard Chain Case ...............................40ACT Drive Gear Case ...............................41Front Suspension .....................................43Speedometer Drive Adapter .....................44Rear Suspension......................................45

Maintenance ............................................46-93Periodic Maintenance Checklist................46Fuel System .............................................47Checking Engine Oil Level (660 cc Models) ....................................48Checking Engine Oil Level (Jaguar Z1).....49Changing Engine Oil (660 cc Models) ....................................49Changing Engine Oil/Filter (Jaguar Z1).....50Adjusting Carburetor (Single) ...................52Adjusting Carburetors (Twin) ....................54Selecting Carburetor Main Jet(s) ..............58Spark Plugs (1100 cc Z1) .........................59Spark Plugs ..............................................59Checking/Adjusting Valve Clearance (660 cc/1100 cc Z1) ..............................62Charging Battery (Electric Start Models) ..........................62Fuses (660 cc Models) .............................64Fuses (1100 cc Z1) ...................................65Engine Heater (660 cc Models) ................66Mechanical Brake System ........................66Hydraulic Brake System ...........................68Drive Belt ..................................................72Track Tension............................................76Track Alignment ........................................78Suspension ..............................................79Lights........................................................83Ski Wear Bars...........................................89Adjusting Ski Stance(M-Series/ Bearcat 570 Models) ............................90Rail Wear Strips........................................91Axial Fan Belt (370 cc Models)..................91Accessory Belt (660 cc Models)................92

Performance Tips..........................................94Preparation For Storage...........................95-97Preparation After Storage ........................98-99U.S. EPA Emission Control

Statement/Warranty Coverage ...............100Change of Address, Ownership,

or Warranty Transfer ...............................101Warranty Procedure/

Owner Responsibility....... Inside Back Cover

REFERENCE INFORMATIONWrite the appropriate information for your Arctic Cat Snowmobile in the spacesbelow. Always use these numbers when referring to your snowmobile.

Model: ________________________________________________Date of Purchase: _______________________________________Vehicle Identification Number: _____________________________Engine Serial Number: ___________________________________

Your Arctic Cat Dealer: _____________________________________Address: ________________________________________________Phone: __________________________________________________

PERSONAL INJURY

• To 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 exces-

sive 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 ACCESSORIES

When in need of replacement parts, oil, or accessories for your Arctic Cat Snowmo-bile, be sure to only use GENUINE ARCTIC CAT PARTS, OIL, AND ACCESSO-RIES. Only genuine Arctic Cat parts, oil, and accessories are engineered to meet thestandards and requirements of your Arctic Cat Snowmobile. For a complete list ofaccessories, refer to the current Arctic Cat Accessory Catalog. An Illustrated PartsManual is available through your local Arctic Cat Snowmobile dealer.

! WARNINGA snowmobile is a very high performance vehicle. Because it does acceler-ate rapidly and is capable of very high speeds, it should not be operated bya novice or an inexperienced operator. Never accelerate rapidly or drive athigh speed beyond the limits of visibility or without being totally familiarwith the terrain and what lies in front of you. Obey speed limits and neveroperate at speeds that do not allow adequate maneuvering and stoppingdistances. Read and study the entire Operator’s Manual and Safety Hand-book.Failure to follow this warning could result in personal injury to yourself orothers.

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

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

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

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

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

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

© 2006 Arctic Cat Inc.

Printed in U.S.A.

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

EC Machinery Directive 98/37/ECIssued by European Commission.Type of Equipment: SnowmobileBrand Name: Arctic CatModel Numbers:

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

MACHINERY: EN 292-1, EN 292-2, EN 953, EN 1050, EN 954-1Manufacturer (if not issuing agent): Arctic Cat Inc.

601 Brooks Ave. S.Thief River Falls, MN56701 USA

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

Fred Bernier Manager, Product Testing & Certification

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SNOWMOBILE SAFETY RULES

SNOWMOBILE SAFETY RULES 3

GENERAL INFORMATIONSNOWMOBILE IDENTIFICATION

The Arctic Cat Snowmobile has twoimportant identification numbers. TheVehicle Identification Number (VIN)is stamped into the tunnel near theright-side footrest. The Engine SerialNumber (ESN) is stamped into thecrankcase of the engine.

0726-383

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

Always provide the snowmobilename, VIN, and ESN when contactingan authorized Arctic Cat Snowmobiledealer for parts, service, accessories,or warranty. If the complete enginemust be replaced, ask the dealer tonotify Arctic Cat for correct registra-tion information.

CONTROL LOCATIONS

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

Panther 370 Model

739-592D

4 GENERAL INFORMATION

Z Models

734-268A

F-Series/Jaguar Z1 Models

741-375B

Crossfire/M-Series Models

741-633A

GENERAL INFORMATION 5

T660/Bearcat Wide Track Models

741-632A

Bearcat 570 Model

740-586A

Panther 570/660 Models

741-634A


TIPPED SNOWMOBILE

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

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

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

AO224B

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

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

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

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

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

NOTE: The engine shouldnow be safe to operate.

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

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


GASOLINE-OIL

Recommended Gasoline (Carbureted Models)

The recommended gasoline to use inthese snowmobiles is 87 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 gasolines,the carburetor main jet must be onesize larger than the main jet requiredfor regular unleaded gasoline. Forexample, if a 400 main jet is recom-mended for regular unleaded gasoline,a 410 main jet must be installed ifusing an oxygenated gasoline.

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

Recommended Gasoline (EFI Models)

The recommended gasoline to use inthese snowmobiles is 87 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 gasoline. Do not usegasolines containing methanol.

Recommended Injection Oil

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

Recommended Engine Oil (660 cc STD)

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

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

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

! CAUTIONDo not use white gas or gasolinecontaining methanol. Only Arc-tic Cat approved gasoline addi-tives should be used.

! CAUTIONAny oil used in place of the rec-ommended oil could cause seri-ous engine damage.


OILCHARTD

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

Recommended Engine Oil (660 cc Turbo/1100 cc Z1)

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

After the engine break-in period, theengine oil should be changed every2500-3000 miles on the 1100 cc Z1model and every 2000 miles on 660 ccTurbo models and before prolongedstorage.

Filling Gas Tank

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

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

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

Before mixing gasoline and oil, makesure the oil is at room temperature(20° C/68° F). Use a U.L. approved22.7 l (6 U.S. gal.) gasoline containerfor mixing the gasoline and oil. Toproperly mix the fuel at a 100:1 ratio,use the following procedure:

1. Pour gasoline into the gasolinecontainer until approximately halffull.

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

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

! CAUTIONAny oil used in place of the rec-ommended oil may cause seri-ous damage.

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

! CAUTIONNever mix oil and gasoline in thesnowmobile gas tank.


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

5. Using a fine-mesh screened fun-nel, pour the fuel mixture fromthe gasoline container into thesnowmobile gas tank.

ENGINE BREAK-IN(2-Stroke Models)

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

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

ENGINE BREAK-IN (660 cc/1100 cc Z1 Models)

The Arctic Cat engine (when new orrebuilt) requires a short break-inperiod before the engine is subjectedto heavy load conditions.

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

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

* With occasional full-throttle operation.

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

! CAUTIONDO NOT exceed the one (1) tank-ful limitation of a 100:1 gas/oilbreak-in mixture. Continuoususe of a gas/oil mixture, unlessconsistently operating inextremely cold conditions (-26°C/-15°F or colder), could causespark plug fouling and excessivecarbon buildup. A 100:1 gas/oilmixture must be used in con-junction with the oil-injectionsystem to ensure adequateengine lubrication in extremelycold conditions.

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

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

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

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


To ensure proper engine break-in onthe 1100 cc Z1 and 660 cc models,Arctic Cat recommends that theengine oil and filter be changed after200-500 miles. This service is at theexpense of the snowmobile owner.

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

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

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

The Low Oil Pressure Warning Lightindicates engine oil pressure, not theoil level; however, if the oil level islow, it may affect oil pressure. Thelight should illuminate each time theignition switch is turned to RUN orSTART, and it should go out when theengine starts. If the light illuminateswhile the engine is running, oil pres-sure has been lost and the engine willautomatically shut off.

If oil pressure is lost, use the followingprocedure:

1. Check the oil level.

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

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

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

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


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

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

CHARGING SYSTEM WARNING LIGHT (660 cc Models)

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

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

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

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

SPEEDOMETER/TACHOMETER INDICATOR LIGHTS (Crossfire/F-Series/Jaguar Z1/M-Series/660 cc Turbo Models)

This snowmobile is equipped with acombination speedometer/tachometer.Indicator lights are incorporatedwithin the speedometer/tachometer.Also incorporated into the speedome-ter/tachometer is a digital readoutscreen.

! CAUTIONAt this point, take precautionarymeasures such as changing toloose snow terrain, shutting theengine off (allowing the engine tocool down), and checking cool-ant level. If unable to either deter-mine or remedy the problem,take the snowmobile to an autho-rized Arctic Cat Snowmobiledealer for service.


ZJ001A

A. Chassis Control Unit

B. Oil Pressure/Low Oil

C. High Beam

D. Check Engine

E. Coolant Temperature

Top Button

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

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

By pushing and holding the top but-ton, maximum RPM will be displayedon the readout screen. The maximumRPM readout will reset when theengine is shut off.

Bottom Button

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

Chassis Control Unit

On electric start models, the iconshould illuminate each time the key isturned to RUN or START, and itshould go out when the engine starts.If the light stays illuminated (on elec-tric start models) or it illuminateswhile the engine is running, the CCUis receiving input that is outside of itsestablished parameters. If the CCUicon illuminates indicating an error,take the snowmobile to an authorizedArctic Cat Snowmobile dealer for ser-vice. If not under warranty, this ser-vice is at the discretion and expense ofthe snowmobile owner.

Coolant Temperature Warning Light

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


Low Oil Warning Light (Crossfire/F-Series/M-Series Models)

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

Oil Pressure Warning Light (Jaguar Z1/660 cc Turbo Models)

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

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

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

NOTE: On the 660 cc Turbomodels, to ensure an accuratereading, the snwomobile shouldbe on level ground.

1. On the 660 cc Turbo models,check the oil level. If the oil levelis below the lower mark on the oillevel stick, add only enough rec-ommended oil to raise the levelbetween the upper and lowermarks. DO NOT overfill thecrankcase with oil.

2. On the Jaguar Z1 with the engineoff, remove the engine oil levelstick and wipe it clean. Withoutscrewing it in, set the stick backin the oil tank. Remove it andobserve the oil level on the stick.If the oil level is at or below theADD mark on the oil level stick,add only enough recommendedoil to raise the level to the NOR-MAL range. DO NOT overfill thereservoir with oil.

3. On the Jaguar Z1, open the airbleed bolt located on the oil pump(beneath the coolant tank) topurge air from the oil hose.

! CAUTIONAt this point, take precautionarymeasures such as changing toloose snow terrain, shutting theengine off (allowing the engine tocool down), and checking cool-ant level. If unable to either deter-mine or remedy the problem,take the snowmobile to an autho-rized Arctic Cat Snowmobiledealer for service.


ZJ004A

NOTE: When air can no longerbe heard, purging from oil pumpbleed, tighten the bleed bolt to1.05 kg-m (7.5 ft-lb).

4. Start the engine. The warninglight shuld go out within five sec-onds.

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

Check Engine Light

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

NOTE: The light should illumi-nate each time the key is turnedto RUN or START, and it shouldgo out when the engine starts.

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

DIAGNOSTIC CODES/CHECK ENGINE (2-Stroke Models)

If the coolant temperature is at orabove 80° C (176° F), the coolant tem-perature light will flash a warning(alert). If the coolant temperature is ator above 93° C (200° F), the checkengine light will cease flashing andwill remain constantly illuminated.

NOTE: At this point, the opera-tor should take precautionarymeasures such as changing toloose snow terrain and/orchecking coolant level.

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

NOTE: On single-digit codes(2, 4, etc.), the number indicatedwill flash in an uninterruptedsequence. On double-digitcodes (1-2, 2-1, etc.), the firstnumber indicated will flash in anuninterrupted sequence, therewill be a short pause, and thesecond number indicated willflash in an uninterruptedsequence.

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


DIAGNOSTIC CODES/CHECK ENGINE (JAGUAR Z1)

These diagnostic codes are flashed bythe check engine light. Refer to thefollowing chart for diagnostic codesequences.

NOTE: On single-digit codes(2, 3, etc.), the number indicatedwill flash in an uninterruptedsequence. On double-digitcodes (1-1, 1-2, etc.), the firstnumber indicated will flash in anuninterrupted sequence, therewill be a short pause, and thesecond number indicated willflash in an uninterruptedsequence.

Number of Flashes Trouble

1-2(Check

Engine Light)

Failure in ignition coil.

1-6(Check

Engine Light)

Incorrect adjustment/failure in APV cable.

1-7(Check

Engine Light)

Failure in exhaust tem-perature sensor.

1-8(Check

Engine Light)

Failure in servomotor.

2(Check

Engine Light)

Failure in injector(s).

2-1(Check

Engine Light)

Failure in knock sen-sor.

2-3(Check

Engine Light)

Failure in knock con-trol system.

4(Check

Engine Light)

Open or short circuit in barometric pressure

sensor.

5(Check

Engine Light)

Open or short circuit in intake air temperature

sensor.

6(Check

Engine Light)

Open or short circuit in water temperature

sensor.

7(Check

Engine Light)

Open or short circuit in throttle position sen-

sor.

Steady Flash(Coolant

Temperature Light)

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

Constant On(Coolant

Temperature Light)

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


1(Check Engine

Light)

Failure in the fuel sys-tem.

1-1(Check Engine

Light)

Failure in speed sen-sor.

1-2(Check Engine

Light)

Failure in coil (#1).

1-3(Check Engine

Light)

Failure in coil (#2).

1-4(Check Engine

Light)

Failure in ISC valve.

1-5(Check Engine

Light)

Failure in oxygen sen-sor.

1-9 (Check Engine

Light)

Failure in camshaft position sensor.

2(Check Engine

Light)

Failure in injector (#2).


HANDLEBAR TILT

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

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

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

0734-406

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

3. Recheck lock nuts; tightensecurely.

NOTE: Recommended torquevalue of lock nuts is 2.5 kg-m (18ft-lb).

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.

HANDLEBAR TILT (F-Series - STD)

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

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

3(Check Engine

Light)

Failure in injector (#1).

4(Check Engine

Light)

Failure in barometric pressure sensor.

5(Check Engine

Light)

Open or short circuit in intake manifold air tem-

perature sensor.

6(Check Engine

Light)

Open or short circuit in water temperature sen-

sor.

7(Check Engine

Light)

Open or short circuit in throttle position sensor.

8(Check Engine

Light)

Open or short circuit in manifold air pressure

sensor.

9(Check Engine

Light)

Failure in crankshaft position sensor.


! 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 (maxi-mum right/left turning capabili-ties) or throttle and brake con-trols are affected.


735-501B

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

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

HANDLEBAR TILT (F-Series LXR/Sno Pro/Jaguar Z1)

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

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

0741-427

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

NOTE: At this point, gently liftthe cam lever without pressingin on the lock pin. If the camlever cannot be lifted, the lockpin is secure.

NOTE: Do not rotate the han-dlebar to a position that allowsair to enter the brake system.

3. Test the handlebar to ensure that itdoes not rotate within the riserblock. If it does not rotate, pro-ceed to step 4. If it does rotate,release the cam lever and rotatethe cam lever clockwise; thenpress down on the cam lever untilthe lock pin is properly positionedand locked. Repeat this procedureuntil the handlebar is properlysecured.

! WARNINGTighten cap screws according tospecifications to prevent unex-pected “movement” of the han-dlebar 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.


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

NOTE: At this point, gently liftthe cam lever without pressingin on the lock pin. If the camlever cannot be lifted, the lockpin is secure.

EXHAUST SYSTEM

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

AIR-INTAKE SILENCER

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

BATTERY (Electric

Start Models)

It is extremely important that the bat-tery be maintained at full charge at alltimes and that the battery connectionsbe clean and tight. If charging the bat-tery becomes necessary, refer toCharging Battery section of this man-ual.

! CAUTIONIf at any time the lock pin willnot engage into the locked posi-tion, do NOT operate the snow-mobile. Take the snowmobile toan authorized Arctic Cat dealerfor service.

! WARNINGCare must be taken to securelylock the handlebar cam lever toprevent unexpected “move-ment” of the handlebar duringoperation over rough terrain. DONOT offset the handlebar sosteering (maximum right/leftturning capabilities) are alteredor throttle and brake controlswill be affected.

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


COOLING SYSTEM (Liquid)

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

When filling the cooling system, usean ethylene glycol-based coolant/water mixture which will satisfy thecoldest anticipated weather condi-tions of your area in accordance withthe coolant manufacturer’s recommen-dations. While the cooling system isbeing filled, air pockets may develop;therefore, run the engine for five to tenminutes after the initial fill, shut theengine off, and then fill the coolingsystem to approximately 51 mm (2 in.)below the filler neck on 2-stroke mod-els or to just below the FULL mark on660 cc/1100 cc Z1 models.

NOTE: The 660 cc models areequipped with a coolant “bleedscrew” on the purge tank(located on the front-top of theengine). After starting theengine (and with the tank cap onand tight), open the bleed screwslightly to allow trapped air toescape. Continue until no air isapparent; then tighten thescrew.

AO353A

NOTE: Use a good quality, eth-ylene glycol-based, automotive-type antifreeze.

DRIVE CLUTCH AND DRIVEN PULLEY

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

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

! 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.


When operating the snowmobile athigh altitudes, it may be necessary tochange certain component parts of thedrive clutch. See an authorized ArcticCat Snowmobile dealer for furtherinformation.

DRIVE CLUTCH/DRIVEN PULLEY ALIGNMENT

The parallelism and the offset betweenthe drive clutch and driven pulley areset at the factory. Normally, no adjust-ment is necessary as long as neitherthe drive clutch nor the driven pulleyis removed or disassembled. However,if premature drive belt wear is experi-enced or if the drive belt turns over,the drive clutch/driven pulley align-ment must be checked. Take the snow-mobile to an authorized Arctic CatSnowmobile dealer for this service. Ifnot under warranty, this service is atthe discretion and expense of thesnowmobile owner.

DRIVE CHAIN TENSION

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

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

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

0730-323

! CAUTIONDO NOT attempt to service thedrive clutch and driven pulley.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 the chaincase.

NOTE: When the head of theadjustment bolt bottoms on thejam nut, the drive chain is inneed of being replaced. See anauthorized Arctic Cat Snowmo-bile dealer for this service.

FUEL PUMP

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

GAS TANK SHUT-OFF VALVE

On certain models, a shut-off valve isincorporated into the gas hose comingfrom the gas tank. The valve should beturned to the CLOSED position whentrailering or storing the snowmobile.Turn the valve to the OPEN positionbefore attempting to start the engine.

NOTE: On all remaining mod-els, there is an automatic shut-off valve incorporated into thefuel pump which prevents gaso-line flow when the engine is off.

SHOCK ABSORBERS (Standard Gas)

Each shock absorber should be visiblychecked weekly for fluid leakage,cracks or breaks in the lower case, or abent plunger. If any one of these con-ditions is detected, replacement is nec-essary. Take the snowmobile to anauthorized Arctic Cat Snowmobiledealer for this service. If not underwarranty, this service is at the discre-tion and expense of the snowmobileowner.

NOTE: When the snowmobileis operated in extremely coldweather (-23° C/-10° F or colder),a small amount of leakage maybe present. Unless the leakageis excessive, replacement is notnecessary.

SHOCK ABSORBERS (Rebuildable Gas)

NOTE: The presence of an ACTidentifier (decal or embossed)on a shock absorber body indi-cates a “rebuildable” shockabsorber.


NOTE: The frequency of ser-vicing rebuildable shock absorb-ers will vary according to thetypes of conditions and terrainthe snowmobile has been sub-jected to. If riding quality deteri-orates (or seems to be deterio-rating), take the snowmobile toan authorized Arctic Cat Snow-mobile dealer for shockabsorber evaluation and/or ser-vicing. This service is at the dis-cretion and expense of thesnowmobile owner.

Servicing rebuildable shock absorbersis considered normal maintenance andis the responsibility of the owner. Takethe snowmobile to an authorized Arc-tic Cat Snowmobile dealer for this ser-vice. This service is at the discretionand expense of the snowmobile owner.Kits are available to either stiffen orsoften gas shock valving. If changes inshock valving are desired, see anauthorized Arctic Cat Snowmobiledealer. This service is at the discretionand expense of the snowmobile owner.

Each shock absorber should be visiblychecked weekly for fluid leakage,cracks or breaks in the lower case, or abent plunger. If any one of these con-ditions is detected, replacement is nec-essary. Take the snowmobile to anauthorized Arctic Cat Snowmobiledealer for this service. If not underwarranty, this service is at the discre-tion and expense of the snowmobileowner.

NOTE: When the snowmobileis operated in extremely coldweather (-23° C/-10° F or colder),a small amount of leakage maybe present. Unless the leakageis excessive, replacement is notnecessary.

DEEP-LUG TRACK

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

HACKSAW TRACK

Accelerated wear strip wear caused byoperating a Hacksaw Track on hard-packed snow conditions is NOT cov-ered under Arctic Cat Inc. warrantypolicy.

TRACK STUDS

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


NOTE: Stud installation can beperformed by the snowmobileowner if qualified to do so. If theowner does not feel qualified,take the snowmobile to anauthorized Arctic Cat Snowmo-bile dealer for this service. Thisservice is at the discretion andexpense of the snowmobileowner.

For proper installation, use the follow-ing procedure:

1. Using Stud Template (p/n 2639-903), mark the desired stud pat-tern to be used.

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

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

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

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

REVERSE TRANSMISSION

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

! WARNINGAlways balance the snowmobilewith 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.

! 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.

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


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

1. Come to a complete stop.

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

737-831A

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

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

REVERSE TRANSMISSION(Crossfire/F-Series/Jaguar Z1/M-Series Models)

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

1. Come to a complete stop.

NOTE: The snowmobile mustbe at a complete stop and theengine at idle before the systemwill allow shifting.

2. With the engine at idle, press thereverse switch button; then releasethe button. The reverse selectionwill be complete.

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


0741-438

NOTE: The system will notshift until the button is released.

3. To shift into forward, stop thesnowmobile and allow the engineto idle; then press the button andrelease. The forward selection willbe complete.

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

TOWING

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

ADJUSTABLE BACKREST

The adjustable backrest is designedfor maximum comfort and safety.When riding double, the backrest mustbe adjusted to the most rearward posi-tion.

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

0734-425

REMOVABLE REAR SEAT

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

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

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

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

! WARNINGUse caution and minimal speedwhen operating the snowmo-bile in reverse. Be sure the but-ton is in the desired position.

! WARNINGMoving the backrest forward lim-its the seating capacity to oneperson only.


0735-854

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

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

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

REMOVABLE SEAT (Crossfire/M-Series Models)

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

1. Inside the rear storage compart-ment on the bottom of the seat-base, pull the retaining clips awayfrom locking pins.

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

To install the seat, use the followingprocedure:

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

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

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

This snowmobile is equipped with aremovable/adjustable seat. To adjustthe seat, use the following procedure:

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

741-434A

! 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 personalinjury may result.

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


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

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

To remove the seat, use the followingprocedure:

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

741-718A

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

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

To install the seat, use the followingprocedure:

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

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

3. With the seat adjusted to the low-est position, install the self-tap-ping screw into the right side ofthe seat support assembly.

ARCTIC POWER VALVE (APV) SYSTEM

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

! CAUTIONDo not use the adjuster lever tolift the seat.

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

! CAUTIONDo not use the adjuster lever tolift the seat.

! WARNINGMake sure the self-tappingscrew is securely tightened andthe seat is securely locked inplace or personal injury mayresult.

! CAUTIONThe correct engine oil to use isArctic Cat Synthetic APV 2-CycleOil (p/n 2639-512). Any substitutemay cause an APV malfunction.


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

NOTE: The mounting locationof the servo will vary from modelto model.

739-152F

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

739-152G

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

739-152H

NOTE: The RPM ranges willvary from model to model.

NOTE: If the servomotorcycles three times and thenshuts down, the exhaust valvecables are not adjusted cor-rectly. The exhaust valves mayalso be sticking.

NOTE: APV cleaning may bedone by the snowmobile ownerif qualified to do so. If the ownerdoes not feel qualified, take thesnowmobile to an authorizedArctic Cat Snowmobile dealerfor this service. This service isat the discretion and expense ofthe snowmobile owner.

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

This system automatically adjusts theignition timing to provide maximumperformance through a variety ofoperating conditions. The ECUreceives input on engine RPM(demand) and exhaust pipe tempera-ture (engine condition) and adjusts theignition timing accordingly. This sys-tem is not adjustable and is mainte-nance free.


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

0737-314

NOTE: A disabled ECT systemWILL NOT cause engine dam-age; however, a failed ECT sys-tem will have slower throttleresponse and may produceslightly less top-end perfor-mance.


OPERATING INSTRUCTIONSSTARTING AND STOPPING ENGINE

It is imperative that the brake systembe checked for wear and proper opera-tion and that all safety checks found inthe accompanying Snowmobile SafetyHandbook be performed beforeattempting to start the engine. Also,on carbureted models, be sure thecorrect carburetor main jet(s) forthe operating temperature, alti-tude, and gasoline are being used.After the engine has been started,check the headlights (high and lowbeam), taillight, and brakelight to besure they are working properly andadjusted correctly. Make sure all lightsare clean to provide maximum illumi-nation. The headlight and taillightmust be clean and must be illuminatedwhenever the engine is running.

NOTE: If equipped withreverse shift lever, make surethe lever is in the forward posi-tion before starting the engine.

1. Test the operation of the brakesystem by compressing the brakelever. The brake lever must feelfirm when compressed; thenwhile holding the brake lever inthe compressed position, mea-sure the distance between thebrake lever and the handlebar (onhydraulic brake models) orbetween the brake lever and leverstop (on mechanical brake mod-els). The distance must be greaterthan 2.54 cm (1 in.) on hydraulicbrake models or within a range of6-13 mm (1/4-1/2 in.) on mechan-ical brake models.

734-505A

727-451A

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

OPERATING INSTRUCTIONS 31

740-159A

0740-588

NOTE: On models with a sightglass if the sight glass appearsdark, there is a sufficientamount of fluid in the reservoir.

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

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

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

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

0725-001

! 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 i f thebrake system is not operatingproperly.

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

32 OPERATING INSTRUCTIONS

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, how-ever, the throttle control levermay have to be compressedslightly.

NOTE: On EFI models whenthe engine is being started, DONOT COMPRESS THE THROT-TLE CONTROL LEVER. If thethrottle control lever is com-pressed, the engine will not startbecause the fuel/air mixture willbe too lean.

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

NOTE: On large-displacementengines in extremely coldweather, pull the recoil handleslowly two to three times tobegin the starting procedure.

NOTE: On electric start mod-els, rotate the key to the STARTposition; then when the enginestarts, release the key.

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

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

To avoid damaging the recoilstarter, DO NOT pull the recoilrope to its limit or release therecoil handle from an extendedposition. Allow the rope torewind slowly.

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


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

NOTE: Continued choking willcause the engine to flood more.

11. Flooding — On EFI models if theengine does not start but seemsready to start, engage the brakelever lock; then compress thethrottle control lever fully and tryto start the engine. When theengine starts, release the throttlecontrol lever immediately. Afterthe warm-up, release the brakelever lock.

NOTE: On EFI models exceptthe 1100 cc Z1 if the engine failsto start during the attempt withthe throttle control lever com-pressed, remove the sparkplugs and clean and dry themthoroughly or install a new setof properly gapped, recom-mended spark plugs.

NOTE: On the Crossfire/F-Series/M-Series if spark plugsmust be cleaned or replaced,see Spark Plugs in the Mainte-nance sub-section of this man-ual.

NOTE: On the 1100 cc Z1 ifspark plugs must be replaced,take the snowmobile to anauthorized Arctic Cat Snowmo-bile dealer for inspection andservice. If not under warranty,this service is at the discretionand expense of the snowmobileowner.

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 beon and will drain power from thebattery. The engine WILL NOTSTART without battery power.

! CAUTIONIt is extremely important that theengine is properly warmed upbefore subjecting the engine tohigh speed operation or heavyloads. The engine should beallowed to idle at least 3-4 min-utes before it is operated at morethan 1/2 throttle. In extremelycold conditions, the warm-uptime will be longer. Cold seizureand piston scuffing caused byinsufficient warm-up will not becovered by warranty. Also, donot idle the engine for exces-sively long periods of time.


HIGH RPM OPERATION(660 cc Models)

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

BRAKING (Hydraulic Brake Models)

Operating a snowmobile with hydrau-lic brakes is different from operating asnowmobile with mechanical brakes.The following items are items that theoperator must be familiar with whenoperating this snowmobile and itshydraulic brake system. Importantadditional information on the propermaintenance of the brake system isfound in the maintenance section ofthis manual.

1. Use the brakes wisely. Each timethe brakes are applied in allhydraulic brake systems (includ-ing automotive applications), heatis transferred to the brake fluid.The amount of heat transferredduring high speed stops and/orrepetitive use may be high enoughto boil the brake fluid and causethe brakes to either fade or maycause an unexpected loss ofbrakes.

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

.

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

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

! WARNINGUse only Arctic Cat approvedbrake fluid. Never substitute ormix different types or grades ofbrake fluid. Brake loss canresult. Check brake fluid leveland pad wear before each use.Brake loss can result in severeinjury or even death.


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

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

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

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

EMERGENCY STOPPING

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

! 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.

ITEM FUNCTION CONDITION

Emer-gency Stop

Switch

interrupts ignition cir-

cuit

ALL

Throttle/Ignition Monitor Switch


cuit

ALL

Ignition Switch


cuit

ALL

Brake slows the driven

shaft/ACT drive

ALL

Choke (car-bureted models)

floods the engine

1/2 throttle or less


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 beon and will drain power from thebattery. The engine WILL NOTSTART without battery power.

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

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

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

1. Rotate the ignition key to the OFFposition.

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

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

NOTE: If the throttle controllever operates properly and theengine does not start, compressthe throttle lever slightly(approximately 1/8 throttle) andtry starting the engine. If theengine now starts and stopswhen the throttle lever isreleased, take the snowmobileto an authorized Arctic CatSnowmobile dealer for service.If not under warranty, this ser-vice is at the discretion andexpense of the snowmobileowner.

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

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

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


NOTE: On fan-cooled modelsif the throttle control lever oper-ates properly and the enginedoes not start, either a malfunc-tioning monitor switch or a mis-adjusted magnetic carburetorswitch (on twin carburetor mod-els) may be the problem. Takethe snowmobile to an authorizedArctic Cat Snowmobile dealerfor service. If not under war-ranty, this service is at the dis-cretion and expense of thesnowmobile owner. However, if adire emergency exists whereinthe engine must be started, dis-connect the throttle control wir-ing harness located below thehandlebar pad and next to thesteering post. If disconnectionof the throttle control wiring har-ness is needed to start theengine, take the snowmobile toan authorized Arctic Cat Snow-mobile dealer for service assoon as possible. If not underwarranty, this service is at thediscretion and expense of thesnowmobile owner.

NOTE: On F-Series/Jaguar Z1models if the throttle controllever operates properly and theengine does not start, a mal-functioning monitor switch maybe the problem. 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 snowmobileowner. However, if a dire emer-gency exists wherein the enginemust be started, disconnect thethrottle monitor switch locatedin the right-side handlebar con-trol.

NOTE: On F-Series/Jaguar Z1models if disconnection of thethrottle monitor switch is neededto start the engine, take the snow-mobile to an authorized Arctic CatSnowmobile dealer for service assoon as possible. If not underwarranty, this service is at the dis-cretion and expense of the snow-mobile owner.


NOTE: The monitor switch isnow bypassed. With exceptionof the monitor switch and theemergency stop switch, all otherignition/ electrical features (igni-tion switch, headlight, taillight,and brakelight) will operateproperly.

VARYING ALTITUDE OPERATION

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

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

NOTE: Just as important ascalibrating the snowmobile forhigher altitudes is recalibratingthe snowmobile when going tolower altitudes. Always consultthe altitude decal beneath thehood of the snowmobile.

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

NOTE: Carburetion and drivetrain changes can be made bythe snowmobile owner if quali-fied to do so. If the owner doesnot feel qualified, take the snow-mobile to an authorized ArcticCat Snowmobile dealer for thisservice. This service is at thediscretion and expense of thesnowmobile owner.

! WARNINGUnder no circumstances shoulddisconnection of the throttle con-trol wiring harness be used as asubstitute for the monitor switchduring normal operation of thesnowmobile. Personal injury anddamage could occur if the throt-tle system malfunctions or if theoperator is unable to stop theengine in an emergency. If thesnowmobile must be operatedwith a disconnected throttle con-trol wiring harness, EXTREMECAUTION MUST BE TAKEN.NEVER EXCEED 10 MPH WITHTHE THROTTLE CONTROL WIR-ING HARNESS DISCONNECTED.

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


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 without reverseand 354 ml (12 fl oz) for models withreverse. Adding more transmissionlube to the chain case (above the rec-ommended amount) may result inleakage. To check the transmissionlube level, use the following proce-dure:

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

2. Remove the oil level stick fromthe chain case cover. Wipe the oillevel stick clean; then thread theoil level stick completely backinto the chain case (withoutreverse) or install the oil levelstick completely back into thechain case (with reverse).Remove the oil level stick againand check the lubricant level.

728-948A

0737-715

3. If the lubricant level is above theADD mark (without reverse) orabove the LOW mark (withreverse), the lubricant level is sat-isfactory. If the lubricant level isat or below the mark, proceed tostep 4.

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

NOTE: If excessive oil depos-its are noticed, 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 snowmobileowner.

! 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.

40 LUBRICATION

ACT DRIVE GEAR CASE (Each Season Prior to Storage)

NOTE: Flushing the gear caseand replacing the lubricant canbe done by the snowmobileowner if qualified to do so. If theowner does not feel qualified,take the snowmobile to anauthorized Arctic Cat dealer forthis service. If not under war-ranty, this service is at the dis-cretion and expense of thesnowmobile owner.

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

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

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

NOTE: On the Crossfire/M-Series, remove the belt guard.

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

NOTE: If excessive oil depos-its are noticed, 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 snowmobileowner.

F-Series/Jaguar Z1

0741-334

Crossfire/M-Series

741-636A

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

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

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

NOTE: To aid in draining thelubricant, it is advisable to fash-ion a drain adapter by acquiringa fitting and a length of 3/8-in.hose.

LUBRICATION 41

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

NOTE: It is critical that thesnowmobile is on a level surfaceto ensure the lubricant drainsproperly and completely.

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

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

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

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

NOTE: On the Crossfire/M-Series, install the belt guard.

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

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

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



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

! CAUTIONIt is critical that all of the oldlubricant be drained from thegear case prior to flushing thegear case.

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

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


42 LUBRICATION

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

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

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

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

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

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

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


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

FRONT SUSPENSION

NOTE: Arctic Cat recommendsthat Arctic Cat Low-TempGrease (p/n 0636-593) be usedfor this procedure.

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

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

! CAUTIONThe correct lubricant to use inthe gear case is Arctic Cat ACTDrive Fluid (p/n 4639-362) formodels with reverse or (p/n 4639-361) for models without reverse.Any substitute may cause seri-ous damage to the drive system.

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

LUBRICATION 43

0739-724

F-Series/Jaguar Z1

741-335A

On the Crossfire/F-Series/M-Series/Jaguar Z1 models, pump grease intothe upper steering shaft grease fitting(located on the right-side of the snow-mobile directly above the forward partof the upper A-arm) until grease isnoted coming out of the bottom of theshaft. Wipe excess grease from theshaft.

Crossfire/M-Series

0737-294

F-Series/Jaguar Z1

0741-440

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


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

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

0727-472

44 LUBRICATION

REAR SUSPENSION (Every 40 Operating Hours)


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

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

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

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

0741-376

4. Lubricate the grease fittings withlow-temperature grease.

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

LUBRICATION 45

MAINTENANCEPERIODIC MAINTENANCE CHECKLIST

ITEM INTERVAL PAGE REMARKSAir Filter

(660 cc Turbo) 2000 miles/Seasonal

__ Replace

Brake System (Hydraulic) Daily 68 Check for binding, leakage, and proper operation; lever firmness, travel, caliper, disc, and pads

Brake System (Mechanical) Daily 66 Check for binding, sticking, and proper operation; lever travel, cable, spring, caliper, and disc

Cooling System - Liquid Daily 20 Check for leakage, damage, obstructions, coolant level

Cooling System - Fan Belt Monthly 91 Check tightness and for wear, damage, and obstructions

Charging System - Accessory Belt (660 cc)

Monthly 92 Check tightness and for wear, damage, and obstructions

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

Engine Oil (660 cc Standard)

2500-3000 miles/Seasonal

49 Change oil and filter

Engine Oil(660 cc Turbo)

2000 miles/Seasonal


Engine Oil (Jaguar Z1) 2500 miles/Seasonal


Battery Daily 1962

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 83 Check for proper operation and cleanliness

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

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

Drive Belt DailyMonthly

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

Ski Wear Bars Daily 89 Check for wear and damage

Carburetors - Main Jets - Adjustment Screws

Daily Weekly

5852-58

Install proper main jetsAdjust according to specifications

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

Exhaust System Weekly 19 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 22 Check for fluid leakage and damage

Spark Plugs(2-Stroke)

Weekly 59 Check center electrode insulator color, carbon, and gap

Valve Clearance (660 cc) 3500 miles/Seasonal

62 Check/adjust

Valve Clearance (1100 cc Z1) 5000 miles/Seasonal

62 Check/adjust

Suspension Weekly 79 Check for damage, loose components, and proper adjustment

Track Tension/Alignment Weekly 7678

Check/adjust as necessary

Wear Strips Weekly 91 Check for wear and damage

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

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

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

Fuel Filter(660 cc/1100 cc Z1)

5000 miles/2 years

__ Replace

APV System Monthly 28 Check/adjust as necessary

Standard Chain Case Monthly 40 Check lube level and for leakage

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

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

Drive Clutch/Driven Pulley Monthly 20-21 Check for damage, abnormal noise, vibration, binding, and sticking and clean off drive belt deposits

Front & Rear Suspension Monthly 4345

Grease

46 MAINTENANCE

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

If, at any time, abnormal noises, vibra-tions, or improper working conditionsof any component of this snowmobileare detected, DO NOT OPERATETHE SNOWMOBILE. Take thesnowmobile to an authorized ArcticCat Snowmobile dealer for inspectionand adjustment or repair.

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

FUEL SYSTEM

In-Line Fuel Filter (Carbureted Models)

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

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

NOTE: Determine which stylein-line fuel filter is beingreplaced and remove and installaccordingly.

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 the fuelhoses off the in-line fuel filter andremove the filter.

726-065A

728-272B

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

! 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.

MAINTENANCE 47

3. Install the in-line fuel filter in thefuel hose so the arrow on the filterpoints toward the fuel pump.Make sure the fuel hoses fittightly on the filter. If a fuel hosedoes not fit tightly, cut 6 mm (1/4in.) from the end of the fuel hose;then install on the filter.

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

Gasoline Additives

Fuel de-icer can be used for all mod-els. Also, periodic use of an injectorcleaner for EFI models is recom-mended especially in the last tank ofgasoline before storage. Arctic CatFuel Stabilizer (p/n 0638-165) shouldalso be added to the last tank of gaso-line before storage.

Fuel Pickup Valves

All 2-Stroke EFI models are equippedwith fuel pickup valves in the gastank. If ever there is a restricted fuelflow and a pickup valve is suspected,take the snowmobile to an authorizedArctic Cat Snowmobile dealer for thisservice. If not under warranty, this ser-vice is at the discretion and expense ofthe snowmobile owner.

CHECKING ENGINE OIL LEVEL (660 cc Models)

NOTE: The snowmobile mustbe on a level surface for thisprocedure.

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

NOTE: Failure to perform step1 as stated will result in an inac-curate reading.

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

AA054B

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

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

48 MAINTENANCE

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.

CHECKING ENGINE OIL LEVEL (Jaguar Z1)

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

NOTE: The snowmobile mustbe on a level surface for thisprocedure.

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

ZJ002A

3. Insert the oil level stick into theoil reservoir without threading itin and remove. Read the oil levelshown on the stick. The oil levelshould be near the middle of or onthe high end of the NORMALrange on the stick.

0741-490

NOTE: To attain an accurateoil level reading, do not threadthe stick into the reservoir.

4. If step 1 was followed and the oillevel is at or below the ADDmark, add up to 1/2 qt of recom-mended engine oil.

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

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

CHANGING ENGINE OIL (660 cc Models)

NOTE: The oil should bechanged when the engine iswarm to allow all oil to drainfrom the crankcase.

NOTE: Recycle or properlydispose of the used engine oil.

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

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

MAINTENANCE 49

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

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

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

5. Install a new belly pan plug.

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

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

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

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

CHANGING ENGINE OIL/FILTER (Jaguar Z1)

NOTE: Recycle or properlydispose of the used engine oil.

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

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

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

ZJ003A

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

NOTE: At this point, removethe strainer from the oil reser-voir to allow the oil to drain com-pletely.

5. After the oil has drained com-pletely, install the oil strainer,drain plugs, and washers andtighten to 2.1 kg-m (15 ft-lb).

NOTE: Always install a newcrankcase drain plug Washer (p/n 3007-101) and a new reservoirWasher (p/n 1670-845) whenchanging the oil.

6. Install a new belly pan plug.

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

50 MAINTENANCE

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

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

9. Install the new oil filter by turningthe oil filter by hand until the sealhas contacted the oil filter mount-ing surface; then tighten the oilfilter to 2.1 kg-m (15 ft-lb).

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

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

ZJ004A

NOTE: When air can no lon-ger be heard purging from oilpump bleed, tighten the bleedbolt to 1.05 kg-m (7.5 ft-lb).

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

NOTE: If the warning lightdoes not illuminate, take thesnowmobile to an authorizedArctic Cat Snowmobile dealerfor service.

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

NOTE: If the warning lightdoes not go out, shut the engineoff immediately and repeat step11; then place the ignitionswitch to the ON position andrepeat step 13. If the warninglight does not go out, take thesnowmobile to an authorizedArctic Cat Snowmobile dealerfor service.

14. Shut the engine off and pour theremaining amount (0.9 l or 1 U.S.qt) of recommended oil into theoil reservoir; then proceed toChecking Engine Oil Level sub-section to verify and finalize theprocedure.

MAINTENANCE 51

ADJUSTING CARBURETOR(Single)

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

NOTE: Carburetor adjust-ments and changing the main jetmay be done by the snowmobileowner if qualified to do so. If theowner does not feel qualified,take the snowmobile to anauthorized Arctic Cat Snowmo-bile dealer for this service. Thisservice is at the discretion andexpense of the snowmobileowner.

Adjusting Choke Cable

1. Be sure the ignition switch key isin the OFF position and the park-ing brake is set.

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

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

4. With free-play removed from thelever, slowly rotate the chokecable adjuster once again clock-wise while checking the chokecable lever for free-play. Adjustuntil 3 mm (1/8 in.) free-playbetween front bottom edge oflever and housing is attained.Securely tighten the adjuster jamnut.

732-848B

Adjusting Piston Valve

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

52 MAINTENANCE

0727-156

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

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

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

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

NOTE: There must be free-playbetween the throttle lever andthe control housing.

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

733-081C

NOTE: If no cable free-playgap is detected, rotate theswivel adapter until free-play isachieved. The piston valve mustbe resting against the tip of itsidle speed screw.

Adjusting Pilot Air Screw

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

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

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

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

MAINTENANCE 53

Adjusting Engine Idle Speed

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

NOTE: Make engine idleadjustment only after the enginehas reached running tempera-ture.

NOTE: If the engine does notstart after the carburetor hasbeen adjusted, repeat steps 2-6of Adjusting Piston Valve sub-section. If all cable slack is“taken up,” the throttle/ignitionmonitor switch will prevent theignition system from firing thespark plugs.

ADJUSTING CARBURETORS(Twin)

The carburetors have been calibratedat the factory for average riding condi-tions; however, altitude, temperature,and general wear may necessitate cer-tain carburetor adjustments. Be surethe correct carburetor main jetsfor the operating temperature,altitude, and type of gasoline arebeing used (see Selecting Carbure-tor Main Jet(s) section). Since car-buretor adjustments critically affectengine performance, Arctic Cat rec-ommends that all changes in internalcarburetor calibration and piston valvesynchronization be made by an autho-rized Arctic Cat Snowmobile dealer;however, four external adjustmentscan be made on each carburetor.

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


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

! WARNINGDO NOT operate the snowmobilewhen any component in thethrottle system is damaged,frayed, kinked, worn, or improp-erly adjusted. If the snowmobileis operated when the throttlesystem is not functioning prop-erly, personal injury could result.

54 MAINTENANCE

NOTE: Carburetor adjust-ments and changing main jetsmay be done by the snowmobileowner if qualified to do so. If theowner does not feel qualified,take the snowmobile to anauthorized Arctic Cat Snowmo-bile dealer for this service. Thisexpense is at the discretion andexpense of the snowmobileowner.

Adjusting Choke Cable

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

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

0727-156

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

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

732-848B

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

Synchronizing Piston Valves

NOTE: On some models, theair-intake silencer is a one-pieceunit, and the silencer boots canbe removed to access the intakebores. Remove the boots; thenproceed to step 4.

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

MAINTENANCE 55

NOTE: On some models, theair-intake silencer includes acover/tool tray assembly and abaffle/resonator, and thesilencer boot cannot beremoved to access the intakebores. Proceed to step 1.

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

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

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

NOTE: The baffle/resonatorcan be removed more easily byremoving the back tabs first.

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

0727-156

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

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

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

NOTE: If an individual pistonvalve starts to open beforeanother, rotate the swiveladapter on the valve which islifting first clockwise, justenough to synchronize thevalves. Recheck by repeatingsteps 4-7.

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

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

56 MAINTENANCE

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

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

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

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

733-081C

NOTE: If cable free-play gap isnot correct, rotate each swiveladapter an equal amount untilrecommended free-play isachieved. Each piston valvemust be resting against the tipof its idle speed screw.

NOTE: If throttle cable free-play is incorrect, the carburetorsafety switches will be activatedprematurely and the engine willnot start.

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

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

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

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

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

MAINTENANCE 57

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

NOTE: Make engine idleadjustment only after the enginehas reached running tempera-ture. Since the idle speedscrews have not been fine-tuned, slight throttle pressuremay be necessary to keep theengine running. Allow engine towarm up for 2-3 minutes.

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

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

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

SELECTING CARBURETOR MAIN JET(S)

Altitude, temperature, and the use ofoxygenated gasoline affect the carbu-retion needed for optimum engine per-formance. The carburetor main jet(s)must be changed in conjunction withchanges in operating altitude, oxygen-ated gasoline usage, and temperature.As the ambient temperature rises or asthe snowmobile is operated at a higheraltitude, the main jet(s) must bereplaced with leaner main jet(s). Theoriginal equipment (production) mainjet(s) may need to be changed(depending on the type of gasolineyou are using, your operating altitude,and temperature). 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:


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

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

! WARNINGDO NOT operate the snowmobilewhen any component in thethrottle system is damaged,frayed, kinked, worn, or improp-erly adjusted. If the snowmobileis operated when the throttlesystem is not functioning prop-erly, personal injury could result.

58 MAINTENANCE

NOTE: Carburetor main jet(s)may be changed by the snow-mobile owner if qualified to doso. If the owner does not feelqualified, take the snowmobileto an authorized Arctic CatSnowmobile dealer for this ser-vice. This service is at the dis-cretion and expense of thesnowmobile owner.

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

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

3. Using the main jet wrench (fromthe tool kit), thread the main jetout of each carburetor. Accountfor the baffle ring/washer. Installthe new main jet and the existingbaffle ring/washer. Tighten themain jet securely.

0728-054

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

5. Install and secure the carburetors.

SPARK PLUGS (1100 cc Z1)

NOTE: If spark plugs must bereplaced, take the snowmobileto an authorized Arctic CatSnowmobile dealer for inspec-tion and service. If not underwarranty, this service is at thediscretion and expense of thesnowmobile owner.

SPARK PLUGS

NOTE: Always use the recom-mended spark plugs in theengine. See the appropriatespecifications chart for correctspark plug gap.

! CAUTIONUse only GENUINE Mikuni brassmain jets. Also, if using an oxy-genated gasoline (up to 10% eth-anol 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 small willcause severe engine damage.Engine damage caused by leanjetting WILL NOT BE covered byour warranty policy.

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

MAINTENANCE 59

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

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

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

2. Remove the spark plug caps fromthe plugs.

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

4. Install the plugs and finger-tighten.

5. Tighten the spark plugs to 2.5-2.8kg-m (18-20 ft-lb); then install thespark plug caps.

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

Removing/Installing Spark Plugs (F-Series)

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

741-722A

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





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

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

Removing/Installing Spark Plugs (Fan-Cooled Models)



60 MAINTENANCE



Removing/Installing Spark Plugs (660 cc Models)

1. Remove the spark plug/coil cover.

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



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

6. Install the spark plug/coil cover.

Checking Spark Plugs (2-Stroke Models)

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

AO352A

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

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

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

NOTE: If the center electrodeinsulators are light gray, white,or black and if the carburetoradjustments (on carburetedmodels), oil-injection pump syn-chronization, and ignition timingare correct, different heat-rangespark plugs may be necessary.Authorized Arctic Cat Snowmo-bile dealers have detailed sparkplug information. Consult adealer before changing sparkplugs, as incorrect heat-rangespark plugs could cause poorengine performance or enginedamage.

MAINTENANCE 61

CHECKING/ADJUSTING VALVE CLEARANCE (660 cc/1100 cc Z1)

After 3500 miles (660 cc)/5000 miles(1100 cc Z1) or prior to seasonal stor-age, valve clearance should bechecked and adjusted as necessary.

NOTE: Take the snowmobile toan authorized Arctic Cat Snow-mobile dealer for inspection andservice. If not under warranty,this service is at the discretionand expense of the snowmobileowner.

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 belowthe MIN level line, add only dis-tilled water until it reaches MAXlevel line.

To remove and charge the battery, usethe following procedure:

! CAUTIONIf a spark plug is light gray,white, or black and another is tanor light brown, take the snowmo-bile to an authorized Arctic CatSnowmobile dealer for inspec-tion and service. If not underwarranty, this service is at thediscretion and expense of thesnowmobile owner.

! CAUTIONIt is critical that the checking/adjusting valve clearance bedone at the recommended inter-vals or severe engine damagemay occur.

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

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

62 MAINTENANCE

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 vent tube.

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

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

4. After charging, check fluid leveland fill with distilled water asnecessary; then install vent plugs.

5. Place the battery into position inthe snowmobile and secure.

6. Attach the vent tube and checkthe vent tube to make sure it is notcrimped or obstructed in any wayand that it is properly routed.

7. Clean the battery posts and cableends by using a battery postcleaning tool and/or a wire brushto remove dirt, grease, and corro-sion.

8. Connect cables to the proper ter-minals: positive cable to the posi-tive terminal (+) and negativecable to the negative terminal (-).Connect the negative cable last.

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

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

! CAUTIONDo not charge the battery while itis 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.

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

MAINTENANCE 63

Sealed with Cap Strip

1. Remove the battery from thesnowmobile.

NOTE: This battery is perma-nently sealed. There is no needto remove the caps or to addelectrolyte for the life of the bat-tery.

NOTE: Do not charge the bat-tery while it is in the snowmo-bile with the battery cablesconnected as damage to theelectrical system may occur.

2. Using Arctic Cat Battery Charger(p/n 0436-634), charge the batteryuntil the indicator light on thecharger illuminates.

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

3. Place the battery into position inthe snowmobile and secure.

4. Connect cables to the proper ter-minals: positive cable to the posi-tive terminal (+) and negative tothe negative terminal (-). Con-nect the negative cable last.

FUSES (660 cc Models)

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

! CAUTIONThis maintenance-free batteryrequires periodic charging toprevent sulfiding. If the snowmo-bile will be idle for extended peri-ods of time, 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 flames neara charging battery.

! CAUTIONImproper activation or excessiveovercharging (possibly by equip-ment failure) could cause dam-age to the battery or snowmobileby forcing acid out of the safetyvalve.

! CAUTIONConnecting cables in reverse (i.e.positive to negative and negativeto positive) can cause seriousdamage to the electrical system.

64 MAINTENANCE

736-448A

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

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

NOTE: There is a fuse pullingtool along with spare fusesinside the fuse panel.

AO352A

2. Remove the suspected fuse.

3. Look through the clear side of thefuse to see if the metal wire insideis separated. If it is, the fuse isblown and should be replacedwith a fuse of the correct amper-age rating.

4. Install the fuse panel cover.

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

FUSES (1100 cc Z1)

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

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

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

MAINTENANCE 65

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

ZJ005A

NOTE: There are spare fusesinside the fuse panel.

2. Remove the suspected fuse.

3. Look through the clear side of thefuse to see if the metal wire insideis separated. If it is, the fuse isblown and should be replacedwith a fuse of the correct amper-age rating.

4. Install the fuse panel cover.

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

ENGINE HEATER (660 cc Models)

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

MECHANICAL BRAKE SYSTEM

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

Checking Brake Lever Travel

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

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

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

66 MAINTENANCE

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

727-451A

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

Adjusting Brake Lever Travel

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

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

730-151A

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

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

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

! WARNINGWhen the brake adjustment knobhas reached its maximum adjust-ment, both brake pads MUST BEREPLACED. Take the snowmo-bile to an authorized Arctic CatSnowmobile dealer for this ser-vice. This service is at the discre-tion and expense of thesnowmobile owner.

MAINTENANCE 67

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

NOTE: When new brake padsare installed, a “burnishing”process is required. Drive thesnowmobile slowly and com-press the brake lever severaltimes until the pads just start towarm up; then allow them tocool down. This procedure sta-bilizes the pad material andextends the life of the pads.

HYDRAULIC BRAKE SYSTEM

Arctic Cat recommends that the brakesystem (brake lever, fluid reservoir,hose, caliper, pads, and brake disc) bechecked daily for fluid leakage, wear,or damage and for proper operation.Also, the brake fluid level must bechecked every time before starting theengine. The brake fluid must be main-tained at a level just below the highmark on the fluid reservoir.

Checking/Adding Brake Fluid

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

NOTE: If the sight glassappears dark, there is a suffi-cient amount of fluid in the res-ervoir.

740-159A

0740-588

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

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

68 MAINTENANCE

Changing Brake Fluid

The brake fluid must be changed on aregular basis and whenever the brakefluid has been overheated or contami-nated. The brake fluid should bechanged every 1000 miles or at theend of the snowmobiling season,whichever occurs first. Take the snow-mobile to an authorized Arctic CatSnowmobile dealer for this service.This service is at the discretion andexpense of the snowmobile owner.

Checking Brake Lever Travel

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

1. Compress the brake lever fully.

NOTE: Do not pump the brakelever as it will produce an inac-curate reading.

2. Measure the distance between thebrake lever and the handlebar.The distance must be greater than2.54 cm (1 in.).

740-159B

741-328B

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

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

! WARNINGDo not overfill the brake fluid res-ervoir. Overfilling the reservoirmay cause the brake system tohydraulically lock. Use only Arc-tic Cat approved brake fluid.Never substitute or mix differenttypes or grades of brake fluid.Brake loss can result. Brake losscan result in severe injury oreven death.

! WARNINGDo not operate the snowmobile ifthe compressed distancebetween the brake lever and thehandlebar is less than 2.54 cm (1in.). Brake loss may occur. Brakeloss can result in severe per-sonal injury.

MAINTENANCE 69

Bleeding Brake System

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

NOTE: The brake system maybe bled by the snowmobileowner if qualified to do so. If theowner does not feel qualified,take the snowmobile to anauthorized Arctic Cat Snowmo-bile dealer for this service. Thisservice is at the discretion andexpense of the snowmobileowner.

1. Remove the reservoir cover andfill the reservoir to the high markwith Arctic Cat approved brakefluid.

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

730-434F

0739-269

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

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

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

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

! 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.

70 MAINTENANCE

Checking/Changing Brake Pads

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

NOTE: The brake pads may bechanged by the snowmobileowner if qualified to do so. If theowner does not feel qualified,take the snowmobile to anauthorized Arctic Cat Snowmo-bile dealer for this service. Thisservice is at the discretion andexpense of the snowmobileowner.

NOTE: When installing newbrake pads, always install themas a set. Never install just onepad or use brake pads whichhave been used in anothersnowmobile.

1. Measure the thickness of bothbrake pads. The brake pad thick-ness must be greater than 3.2 mm(0.125 in.) on the standard caliperor greater than 5.0 mm (0.20 in.)on the ACT drive caliper. If thebrake pad thickness is less thanspecified, replacement of bothpads is necessary.

730-434F

0739-269

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

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

NOTE: The above procedurewill allow room for the fluid fromthe caliper when the pistons arepushed into the caliper forinstalling new brake pads.Replacing the cover will preventfluid spillage.

4. Using a pair of pliers, pull onebrake pad out of the caliperassembly.

NOTE: Changing one pad at atime will prevent one pistonfrom pushing out the other pis-ton from the caliper.

MAINTENANCE 71

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

6. Position the new brake pads intothe caliper.

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

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

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

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

NOTE: When new brake padsare installed, a “burnishing”process is required. Drive thesnowmobile slowly and com-press the brake lever severaltimes until the pads just start towarm up; then allow them tocool down. This procedure sta-bilizes the pad material andextends the life of the pads.

DRIVE BELT

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

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

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

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

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

NOTE: Drive belts should bepurchased from an authorizedArctic Cat Snowmobile dealer,as Arctic Cat drive belts aremade to exact specificationsand of quality material. Beltsmade by other manufacturersmay not be of the same specifi-cations or quality and, therefore,usage could result in poor per-formance and premature beltfailure.

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

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

72 MAINTENANCE

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

NOTE: On the ACT rollerdriven pulley, adding shimwashers will decrease beltdeflection and removing shimwashers will increase beltdeflection. Available shim wash-ers from Arctic Cat are p/n 0648-714 (0.090 in.), p/n 0648-715(0.030 in.), and p/n 0648-716(0.060 in.). See an authorizedArctic Cat Snowmobile dealerfor this service.

Removing Drive Belt (Standard Driven Pulley)

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

2. Set the brake lever lock.

3. Open the hood; then open the beltguard.

737-316A

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

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

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 numbercan be read) between the sheavesof the drive clutch.

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

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

MAINTENANCE 73

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

5. Release the brake lever lock.

Removing Drive Belt (ACT Roller Driven Pulley)

NOTE: Changing a drive beltcan be done by the snowmobileowner if qualified to do so. If theowner does not feel qualified,take the snowmobile to anauthorized Arctic Cat Snowmo-bile dealer for this service. Thisservice is at the discretion andexpense of the snowmobileowner.

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

2. Set the brake lever lock.

3. Open the hood; then open the beltguard (if applicable).



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

NOTE: The sheave adjusterhas left-hand threads.

741-445B

741-446B

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

! WARNINGNever operate the snowmobilewithout the belt guard secured inplace.

74 MAINTENANCE

741-721B

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

NOTE: By bottoming thesheave adjuster against thedriven shaft, the sheaves of thedriven pulley will spread farenough to allow the removal ofthe drive belt.

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

NOTE: By bottoming thesheave adjuster against the out-put shaft, the sheaves of thedriven pulley will spread farenough to allow the removal ofthe drive belt.

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

Installing Drive Belt (ACT Roller Driven Pulley)

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

2. On Style A using the deflectiontool/screwdriver/spark plug wrenchassembly, remove the sheaveadjuster from the end of the drivenpulley. Place the shim washers andO-ring (as noted in removing) ontothe sheave adjuster; then carefullythread the sheave adjuster back intothe driven pulley. Tighten theadjuster securely using the deflec-tion tool/screwdriver/spark plugwrench assembly.

NOTE: Do not over-tighten thesheave adjuster. A torque valueof 2.1 kg-m (15 ft-lb) is recom-mended.

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

4. Close the belt guard (if applica-ble); then install the left-sideaccess panel.


MAINTENANCE 75

5. Release the brake lever lock.

TRACK TENSION

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

Checking Track Tension

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

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

3. At mid-point of the track (on thebottom side), hook a spring scalearound a track clip; then pulldown on the scale to the recom-mended pressure. Measure thedeflection (distance) between thebottom of the wear strip and theinside surface of the track clip.Compare the measurement withthe chart.

729-429E

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

76 MAINTENANCE

729-429A

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

Adjusting Track Tension

1. Loosen the rear idler wheeladjusting bolt jam nuts.

739-636B

NOTE: To ensure proper tracktension adjustment, perform alladjustments on both sides ofthe snowmobile.

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

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

4. Check track alignment (see TrackAlignment section).

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

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

Model Setup Tension

After Break-In Tension

Z 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 @ 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.)

F-Series Models@ 20 lb

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

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

Jaguar Z1 @ 20 lb

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

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

Crossfire Models@ 20 lb

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

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

M-Series Models @ 10 lb

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

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

MAINTENANCE 77

TRACK ALIGNMENT

Proper track alignment is obtainedwhen the rear idler wheels are equaldistance from the inner track drivelugs. Excessive wear to the idlerwheels, drive lugs, and track willoccur if the track is improperlyaligned. Arctic Cat recommends thatthe track alignment be checked once aweek or whenever the track tension isadjusted.

Checking Track Alignment

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

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

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

NOTE: Allow the track to coastto a stop. DO NOT apply thebrake because it could producean inaccurate alignment condi-tion.

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

! WARNINGIf jam nuts are not tightenedproperly, the adjusting boltscould loosen causing the track tobecome extremely loose and,under some operating condi-tions, allow the idler wheels toclimb over the track lugs forcingthe track against the tunnel caus-ing the track to “lock.” If a track“locks” during operation, severepersonal injury could result.

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

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


78 MAINTENANCE

0727-729

0739-637

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

Adjusting Track Alignment

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

739-636B

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

NOTE: Make sure correct tracktension is maintained afteradjusting track alignment (seeTrack Tension section).

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

4. Field test the track under actualconditions.

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

SUSPENSION

The suspension should be adjusted forthe operational needs and riding pref-erence of the operator.

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

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

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

MAINTENANCE 79

Adjusting Front Shock Springs (STD)

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

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

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

To adjust spring tension, rotate theentire spring in whichever direction isdesired. If after adjusting spring ten-sion you note the snowmobile frontend wants to pitch, relax the springtension on the side that is pitching. Ifboth sides are pitching, relax thespring tension on both sides.

NOTE: The spring adjuster willnormally rotate with the spring.

734-501B

734-500B

Adjusting Front Shocks (Fox Air Shocks)

NOTE: It is recommended tomonitor the air pressure in theair shocks 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 anauthorized Arctic Cat Snowmo-bile dealer for this service. Thisservice is at the discretion andexpense of the snowmobileowner.

The air shocks are individually adjust-able for the terrain conditions anddriving style of the operator. Theshocks are preset at 4.6 kg/cm2 (65psi) as an initial setting on the Cross-fire/F-Series Sno Pro models or at 4.2kg/cm2 (60 psi) on the M-Series mod-els; however, it is possible to “finetune” the shocks to match the opera-tor’s weight, riding style, and terrainconditions.

NOTE: Care should be takento have equal pressure in theshocks before operating thesnowmobile.

80 MAINTENANCE

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

NOTE: When adjusting airpressure, all weight must beremoved from the front suspen-sion, and the shock absorbersmust be fully extended.

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

1. Remove the air valve cap fromthe shock.

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

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

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

NOTE: Pressing the buttonfully down and releasing it willallow only a small amount of airto escape (micro-adjust).

4. To increase air pressure in theshock, pump until desired pres-sure is attained.

5. Remove the pump valve from theshock air valve.

NOTE: As the pump valve isbeing removed from the shock,the sound of air loss is from thepump hose, not from the shock.

6. Install the air valve cap onto theshock.

Skid Frame Front Arm

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

The skid frame front arm shock springand limiter straps are adjustable. How-ever, Arctic Cat recommends that theshock spring be maintained as loose aspossible. Tightening the skid framefront arm shock spring may causeimproper balance and may ruin thehandling features of the snowmobile.

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

When customizing the amount of skipressure, be sure to adjust both strapsequally and do not over-adjust the lim-iter straps to adversely affect steeringand operator control of the snowmo-bile. Some experimentation may berequired until the proper adjustmentfor the operator’s individual style isobtained.

! WARNING

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

MAINTENANCE 81

0730-537

0739-714

Adjusting Rear Spring Pre-Load

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

NOTE: These cam positionsettings are suggestions only.Personal riding style will greatlyinfluence cam position settings.Spend time to determine settingpreferences.

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

741-450A

To rotate an adjusting cam, use thespark plug wrench from the tool kit.Rotate the wrench until the cam is inthe desired position. To stiffen theride, rotate the cam so as to raise thespring end. Make the appropriateadjustment on the other cam.

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

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 mayoccur.

82 MAINTENANCE

Articulating Skid Fame(Bearcat Wide Track Models)

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

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

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

0739-642

Overload Springs

Some models have overload springsbuilt into the rear suspension. Wheneither carrying a heavy load or riding2-up, the overload springs should beengaged by rotating the spring tensionblocks to the UP position. The springtension blocks lock in an over-centerposition when engaged. To eitherengage or disengage the spring tensionblocks, use the Spring Block Tool, aspark plug socket, and a screwdriverto adjust the spring block to thedesired position. Make sure bothspring blocks are in the same position(either engaged or disengaged).

0739-625

LIGHTS

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

Removing and Installing Taillight/Brakelight Bulb

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

0728-239

0739-712

MAINTENANCE 83

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

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

4. Install the lens and secure withthe screws.

Removing and Installing Taillight/Brakelight Bulb (F-Series/Jaguar Z1)

1. Remove the two screws securingthe taillight cover.

2. From inside the rear storage com-partment, remove the self-tap-ping screws and washers securingthe taillight/brakelight housing;then remove the housing.

741-680A

741-331A

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

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

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

6. Push the socket into the housingand rotate it clockwise to lockinto place.

7. Install the housing and securewith the self-tapping screws andwashers.

8. Place the taillight cover into posi-tion and secure with the twoscrews.

Removing Headlight Bulb (3-Bulb Style)

NOTE: The bulb portion of theheadlight is fragile. HANDLEWITH CARE. When replacing theheadlight bulb, the bulb assem-bly must first be removed fromthe housing.

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

0733-178

84 MAINTENANCE

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

Installing Headlight Bulb (3-Bulb Style)

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

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

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

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

NOTE: The bulb portion of theheadlight is fragile. HANDLEWITH CARE. When replacing theheadlight bulb, the bulb assem-bly must first be removed fromthe housing.

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

0740-462

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

1. Plug the wiring harness into theheadlight bulb.

2. Insert the bulb into the headlighthousing.


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

! WARNINGDo not operate the snowmobileunless headlight beam isadjusted properly. An incorrectlyadjusted beam will not providethe operator the optimumamount of light.


MAINTENANCE 85

Removing Headlight Bulb (Crossfire/M-Series Models)

NOTE: The bulb portion ofheadlight is fragile. HANDLEWITH CARE. When replacing theheadlight bulb, the bulb assem-bly must first be removed fromthe housing. Do not touch theglass portion of the bulb. If theglass is touched, it must becleaned with a dry cloth beforeinstalling.

To access the headlight bulbs, use thefollowing procedure:

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

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

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


0740-462

Installing Headlight Bulb (Crossfire/M-Series Models)



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

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

5. Tighten the headlight adjustmentknobs.




86 MAINTENANCE

Removing Headlight Bulb (F-Series/Jaguar Z1)

NOTE: The bulb portion ofheadlight is fragile. HANDLEWITH CARE. When replacing theheadlight bulb, the bulb assem-bly must first be removed fromthe housing. Do not touch theglass portion of the bulb. If theglass is touched, it must becleaned with a dry cloth beforeinstalling.

To access the headlight bulbs, use thefollowing procedure:

1. On the F-Series LXR and JaguarZ1 models, release the latchessecuring the windshield to thewindshield base; then remove thewindshield.

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

741-505A

3. Remove the cap screw and locknut securing the front of the head-light assembly to the air-intakesilencer.

4. Lift the front of the consoleenough to allow the headlighthousing to be removed; thenremove the housing.


741-329A


MAINTENANCE 87

Installing Headlight Bulb (F-Series/Jaguar Z1)



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

0741-506

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

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

6. On the F-Series LXR and JaguarZ1 models, place the windshieldinto position on the windshieldbase; then secure with the latches.


Adjusting Headlight Aim

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

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

NOTE: There should be an“average” operating load on thesnowmobile when adjustingheadlight aim.

2. Measure the distance from thefloor to midpoint of the headlight.

3. Using the measurement obtainedin step 2, make a horizontal markon the aiming surface.

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

Do not operate the snowmobileunless headlight beam isadjusted properly. An incor-rectly adjusted beam will notprovide the operator the opti-mum amount of light.

88 MAINTENANCE

4. Make a vertical mark which inter-sects the horizontal mark on theaiming surface directly in front ofthe headlight.

5. Engage the brake lever lock andstart the engine. Move the head-light dimmer switch to the HIGHbeam position. DO NOT USELOW BEAM.

6. Observe the headlight beam aim.Proper aim is when the mostintense beam is centered on thevertical mark 5 cm (2 in.) belowthe horizontal mark on the aimingsurface.

0741-448

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

8. On the Bearcat W/T Turbo/F-Series/Jaguar Z1/T660 models,adjust the headlight using theadjustment knobs until correctaim is obtained. Shut the engineoff; then disengage the brakelever lock.

SKI WEAR BARS

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

Removing Ski Wear Bars

NOTE: Determine which typeof wear bar is being replacedand remove and install accord-ingly.

1. Remove ice and snow buildupfrom the ski.

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

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

MAINTENANCE 89

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

737-454A

731-037D

0739-596

0739-016

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

Installing Ski Wear Bars

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

NOTE: If installing a double-offset wear bar, the carbide edgemust be directed to the outsideof the ski; however, on the T660Touring models, the carbideedge must be directed to theinside of the ski.

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

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

1. Place the front of the snowmobileon a support stand.

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

90 MAINTENANCE

2. Remove the cotter pin; thenremove the slotted nut and capscrew securing the ski assemblyto the spindle. Remove the ski.Account for the rubber damper,inserts, and washers.

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

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

5. Position the ski over the saddle.

6. Apply a low-temperature greaseto the non-threaded portion of thecap screw; then slide the capscrew through the ski and saddleaccounting for the rubber damper,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 (45 ft-lb).

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

9. Repeat procedure for the otherski.

RAIL WEAR STRIPS

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

If wear strip measurements are lessthan specified, replacement of bothwear strips is necessary to prevent pre-mature track clip wear and possibletrack damage. Take the snowmobile toan authorized Arctic Cat Snowmobiledealer for this service. This service isat the discretion and expense of thesnowmobile owner.

Each time a new set of wear strips areinstalled, they should be tempered.Temper the wear strips by driving thesnowmobile for approximately a mileon a hard pack trail; then immediatelydrive into deep snow and allow thewear strips to cool. Repeat the proce-dure (warming up the wear strips; thencooling them down) two or threetimes.

NOTE: The rail wear strips willwear rapidly if the snowmobileis operated on terrain on whichthe snow cover is minimal.Loose snow is required to cooland lubricate the wear stripsand prevent accelerated wear.

0727-726

AXIAL FAN BELT (370 cc Models)

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

MAINTENANCE 91

1. Be sure ignition key is in the OFFposition.

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

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

726-155A

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

NOTE: If the axial fan belt isdamaged or if the belt deflectionexceeds the specification, takethe snowmobile to an authorizedArctic Cat Snowmobile dealerfor repair or adjustment. Thisservice is at the discretion andexpense of the snowmobileowner.

5. Install the fan cover.

ACCESSORY BELT (660 cc Models)

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

Checking Belt Tension

1. Be sure ignition key is in the OFFposition.

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

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

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

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

0736-564

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

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

92 MAINTENANCE

Adjusting Belt Tension

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

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

0736-553

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

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

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

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

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

MAINTENANCE 93

PERFORMANCE TIPS

Operating 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 (wi th the sheaves fu l lyclosed). If the belt sits below this level,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 in thesame direction. Installing the drive beltso the part number can be read willensure that the drive belt is always runthe same direction.

DRIVE CLUTCH AND DRIVENPULLEY — Keeping the drive clutchand driven pulley clean should be theprimary consideration of the operator.The clutch sheaves can be cleaned ofany drive belt accumulation using aclean cloth and parts-cleaning solvent.All pivot points can be maintainedclean using compressed air.

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

94 PERFORMANCE TIPS

PREPARATION FOR STORAGE

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

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

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

NOTE: On 4-stroke models,change the engine oil and cleanthe air filter; then proceed tostep 9.

3. Place the rear of the snowmobileup on a shielded safety stand.

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 StoragePreserver (p/n 0636-177) into theintakes until the engine exhauststarts to smoke heavily or untilthe engine starts to drop in RPM.Turn engine off.

NOTE: On the “Laydown”engine models after step 4, pro-ceed to step 9.

NOTE: On some standardmodels, the air-intake silencer isa one-piece unit, and thesilencer boot(s) can be removedto access the intake bore(s).Remove the boots; then proceedto step 8.

NOTE: On some standardmodels, the air-intake silencerincludes a cover/tool trayassembly and a baffle/resonator,and the silencer boot cannot beremoved to access the intakebores. Proceed to step 5.

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

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

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

NOTE: The baffle/resonatorcan be removed more easily byremoving the back tabs first.

PREPARATION FOR STORAGE 95

8. Start the engine and allow to idle.With the engine idling, spray Arc-tic Cat Engine Storage Preserver(p/n 0636-177) into the intake(s)until the engine exhaust starts tosmoke heavily or until the enginestarts to drop in RPM. Turnengine off.

NOTE: On some models,install the air-intake silencerboot(s); on some models, installthe baffle/ resonator and thecover/tool tray assembly.

9. Plug the exhaust system outletwith a clean cloth.

10. With the ignition switch in theOFF position:

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

B. Pour 29.5 ml (1 fl oz) of SAE#30 petroleum-based oil intoeach spark plug hole and pullthe recoil starter handle slowlyabout 10 times.

C. Install the spark plugs andconnect the high tension leads.

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

12. Fill the gas tank to its rated capac-ity; then add Arctic Cat Fuel Sta-bilizer (p/n 0638-165) to the gastank following directions on thecontainer for the stabilizer/gaso-line ratio. Tighten the gas tankcap securely.

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

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

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

16. Clean and inspect the drive clutchand driven pulley.

! CAUTIONDo not do step 10 on the 4-strokemodels; severe engine damagecould result.

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

96 PREPARATION FOR STORAGE

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

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

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

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

21. On electric start models, discon-nect the battery cables makingsure to disconnect the negativecable first; then clean the batteryposts and cables. On models witha sealed battery, use Arctic CatBattery Charger (p/n 0436-634)when charging the battery.

22. If possible, store the snowmobileindoors. Raise the track off thefloor by blocking up the back endmaking sure the snowmobile issecure. Loosen the track adjustingbolts to reduce track tension.Cover the snowmobile with amachine cover or a heavy tarpau-lin to protect it from dirt and dust.

23. If the snowmobile must be storedoutdoors, position the snowmo-bile out of direct sunlight; thenblock the entire snowmobile offthe ground making sure the snow-mobile is secure. Loosen the trackadjusting bolts to reduce tracktension. Cover with a machinecover or a heavy tarpaulin to pro-tect it from dirt, dust, and rain.

! CAUTIONSealed batteries require chargingif left for extended non-start peri-ods. Arctic Cat recommends notservicing the battery until thesnowmobile is to be used ortrickle charging once a month.Follow the manufaturer’s instruc-tions and cautions.

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

PREPARATION FOR STORAGE 97

PREPARATION AFTER STORAGETaking the snowmobile out of storageand correctly preparing it for anotherseason will assure many miles andhours of trouble-free snowmobiling.Arctic Cat recommends the followingprocedure:

1. Clean the snowmobile thor-oughly. Polish the exterior of thesnowmobile.

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

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

4. Inspect the drive belt for cracksand tears. Check belt specifica-tions. Replace if damaged orworn. Install the drive belt.

NOTE: If the old belt is wornbut in reasonable condition,retain it with the snowmobile asa spare in case of emergency.

5. On carbureted models, inspect thein-line fuel filter and replace ifnecessary.

6. Inspect all fuel hoses and oilhoses for deterioration or cracks;replace if necessary. Make sure allconnections are tight; then on 2-stroke models, fill the oil-injec-tion reservoir with the recom-mended 2-cycle oil (see Gasoline-Oil sub-section).

NOTE: After prolonged stor-age of 2-stroke models, ArcticCat recommends one tankful of100:1 gas/oil mixture be used inconjunction with the oil-injec-tion system to ensure properlubrication.

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

8. Adjust the carburetor(s) andchoke cable on carbureted modelsand throttle cable on all models.

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

! CAUTIONOn carbureted models if the gasin each carburetor float chamberwas not drained prior to storage,the carburetor(s) must becleaned before starting theengine.

! WARNINGBe sure to tighten the swiveladapter jam nuts securely. If ajam nut isn’t tightened, theadjuster can rotate out of the car-buretor cap causing the throttleslide not to return to the full-closed position.

98 PREPARATION AFTER STORAGE

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

11. On liquid cooled models, checkthe coolant level and all coolanthoses and connections for deterio-ration or cracks. Add properlymixed coolant as necessary.

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

13. 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 to thewide-open position until theengine starts to smoke heavily.Release the control arm and turnoff the engine.

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

15. Inspect the entire brake system,all controls, headlight, taillight,brakelight, ski wear bars, andheadlight aim; adjust or replace asnecessary.

16. Adjust the track to the proper ten-sion and alignment. Lock the jamnuts.

PREPARATION AFTER STORAGE 99

U.S. EPA EMISSION CONTROL STATEMENT/ WARRANTY COVERAGE(U.S. Only)

STATEMENT/WARRANTYArctic Cat warrants to the original retail purchaser, and each subsequent purchaser, that all U.S. EPA-certified Arctic Cat snowmobiles are designed, built, and equipped to conform to all U.S. EPA EmissionControl Regulations. Please read the following information completely.

Your authorized Arctic Cat snowmobile dealer will repair or replace any defective emission-relatedcomponent at no cost to you during the warranty period. You may have non-warranty 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, contactyour local authorized Arctic Cat snowmobile dealer.

WARRANTY PERIODThe emission warranty period for this snowmobile begins on the same date as the standard warrantycoverage and continues for 30 months or 2500 miles, whichever comes first.

COMPONENTS 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's Manual.Proper maintenance generally includes replacement and service, at the owner's choosing, such itemsas air filer, oil and oil filter, or any other part, item, or device related to emissions control as specified inthe Operator's Manual. It is the owner's responsibility to ensure that the snowmobile is used in amanner for which it was designed.

100

101

CHANGE OF ADDRESS, OWNERSHIP, OR WARRANTY TRANSFER

Arctic Cat Inc. keeps on file the current name and address of theowner of this snowmobile. This will allow Arctic Cat to reach thecurrent owner with any important safety information which may benecessary to protect customers from personal injury or propertydamage. Please make sure a copy of this form is completed andreturned to Arctic Cat Inc. if you move or if the snowmobile is soldto another party.

This form may also be used to transfer the unused portion of theoriginal warranty to a second party. In order to transfer warranty,fill out this form completely; then return a copy of this form toArctic Cat Inc. Arctic Cat will then process the application andissue warranty for the balance of the time remaining of theoriginal warranty.

❏ Address Change

❏ Ownership Change

❏ Warranty Transfer

CHANGE OF ADDRESS/OWNERSHIP/WARRANTY TRANSFER TO:

Name _________________________________________

Address _______________________________________

City/State (Province)/Zip Code (Postal Code) __________

Phone # ( ) ____________________________________

Year and Model Snowmobile _______________________

Vehicle Identification Number (VIN) __________________

Fold Back Once

PlaceStampHere

CHANGE OF ADDRESS/OWNERSHIP

ARCTIC CAT INC.PRODUCT SERVICE AND

WARRANTY DEPT.P.O. BOX 810

THIEF RIVER FALLS, MN 56701

WARRANTY PROCEDURE/OWNER RESPONSIBILITYAt the time of sale, an Owner Registration form (included with eachnew snowmobile) is to be completed by the selling dealer andconsumer. The receipt of the registration form by Arctic Cat is acondition precedent to warranty coverage. It is the selling dealer’sresponsibility to retain and/or submit the appropriate copies of theform to the appropriate place(s) to initiate warranty coverage.

The dealer will furnish to the consumer a signed copy of the formwhich must be presented to the dealer when requesting warrantyservice. The registration form is the consumer’s proof ofownership and warranty eligibility. The form is used by thedealer to validate the warranty claim. Retain your copy of the formand keep it in a safe place.

When warranty repair is suspected, the snowmobile should be takento the selling dealer, who has the primary responsibility to performwarranty repairs. In the event the selling dealer has ceased to dobusiness, you have moved, or you are in a location away from yourselling dealer, warranty may be performed by any authorized ArcticCat Snowmobile dealer.

The authorized Arctic Cat Snowmobile dealer will examine thesnowmobile or part to determine if, in his opinion, a warrantablecondition exists. If a warrantable condition appears to exist, thedealer will repair or replace, at Arctic Cat’s option, free of charge,including any related labor costs, all parts that are found to bewarrantable and any other parts which the warrantable part causedto be damaged. You, the consumer, will then be asked to sign awarranty form to ensure Arctic Cat that the warranty work wasactually performed.

It is the consumer’s responsibility to maintain and service thesnowmobile in accordance with Arctic Cat’s recommendations in theOperator’s Manual. To protect yourself and your snowmobile, followall safety and service tips. Arctic Cat will NOT warrant repairsrequired as a result of not performing standard operatormaintenance, storage procedures, and service as outlined inthe Operator’s Manual.

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

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

104

MAINTENANCE RECORD

DATE MILEAGE SERVICE PERFORMED/NOTES

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MAINTENANCE RECORD


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MAINTENANCE RECORD


Printed in U.S.A. Trademarks of Arctic Cat Inc. Thief River Falls, MN 56701 p/n 2257-617®TM

ARCTIC CAT®

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