operator`s manual

Transcription

operator`s manual

OPERATOR’S MANUAL
ZR 6000 R CROSS COUNTRY
www.arcticcat.com
Limited Warranty
Arctic Cat Inc. (hereinafter referred to as Arctic Cat) extends a limited warranty as described below on each new Arctic Cat Snowmobile it assembles and on each
genuine Arctic Cat Snowmobile part and accessory assembled and sold by an authorized Arctic Cat Snowmobile dealer. The limited warranty on an Arctic Cat
Snowmobile is extended to the original retail purchaser for the time periods described below; however, the balance of the remaining warranty may be transferred to
another party unless the purchase is for commercial use (see below). Warranty coverage is only available in the country in which the original retail purchase occurs
to the original retail purchaser resident in that country or to a transferee resident in that country of the balance of the remaining warranty.
Arctic Cat warrants only the products it assembles and/or sells and does not warrant that other products will function properly when used with an Arctic Cat
Snowmobile or will not damage the Arctic Cat 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), any parts that are found to be warrantable in material or workmanship.
This repair work MUST be done by an authorized Arctic Cat Snowmobile dealer. No transportation charges, rental charges, or inconvenience costs will be paid by Arctic
Cat. The warranty is validated upon examination of said parts by Arctic Cat or an authorized Arctic Cat Snowmobile dealer. Arctic Cat reserves the right to inspect 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 from December 1 of the current year.
—If purchased between December 1 and April 30, ONE (1) YEAR from the date of sale.
2. For snowmobiles used for commercial purposes (including rental operations), ONE (1) YEAR from the date of invoice and/or 5000 MILES whichever comes first
(non-transferable).
3. THIRTY (30) DAYS from date of sale of snowmobile on Arctic Cat supplied batteries.
Exclusions to this warranty include normal wear, abuse (i.e. a track run on marginal snow conditions without proper lubrication or additional idler wheels), and the
following parts:
Fuel Filter
Light Bulbs
Windshield
Drive Belt
Torn or Punctured Upholstery
Wear Bars
Brake Pads
Spark Plugs
Drive Clutch/Driven Clutch Wear Parts
Wear Strips
Shock Absorber(s) - Standard*
Shock Absorber(s) - Rebuildable**
* Limited to one (1) year or 1000 miles of “normal” riding conditions - replace for defective or leaking shock, corroded or pitted shaft, peeling chrome.
** Limited to one (1) year or 1000 miles of “normal” riding conditions - rebuild for leaking shock (warranted) - replace for defective shock, corroded or pitted shaft, peeling
chrome.
The following will VOID Arctic Cat’s warranty:
1. Failure to perform the proper break-in procedure and all related maintenance, storage procedures (if stored for extended periods), and/or 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 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, addition, or removal of parts unless instructed to do so by Arctic Cat.
8. Use of the snowmobile in any way for racing purposes.
9. Removal of the engine for use in another vehicle.
10. Removal or mutilation of the Vehicle Identification Number or Engine Serial Number.
11. Use of parts not sold or approved by Arctic Cat.
12. Track and tunnel damage resulting from either ice stud or hooker plate installation.
13. Damage due to improper transportation.
Arctic Cat shall not be responsible for and this limited warranty excludes recovery of economic, punitive, consequential and incidental damages, lost profits, and loss
of use. Some states or provinces do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation may not apply to you. Arctic
Cat’s aggregate liability may not exceed the price of the product. The law of the State of Minnesota shall apply to all claims or disputes, exclusive of its conflicts of
law provisions.
IMPLIED WARRANTY EXCLUSION AND DISCLAIMER
To the fullest extent permitted by law, Arctic Cat excludes and disclaims all implied warranties of merchantability and fitness for a particular purpose.
If you are not satisfied with warranty service or repairs, you should contact Arctic Cat at (U.S.) 1-218-681-9851 or (Canada) 1-204-982-1656.
FOREWORD
Congratulations! You have chosen a quality Arctic Cat Snowmobile designed and manufactured to give dependable service. Be sure, as the owner/operator of an Arctic Cat Snowmobile, to become thoroughly familiar with its
basic operation, maintenance, and off-season storage procedures. Read this manual and the accompanying Snowmobile Safety Handbook before operating the snowmobile to ensure safe and proper use of your new Arctic Cat
Snowmobile. Always operate the snowmobile within your level of skill and current terrain conditions.
The Operator’s Manual, Snowmobile Safety Handbook, and snowmobile decals display the words Warning, Caution, and Note to emphasize important information. The symbol ! WARNING identifies personal safetyrelated information. Be sure to follow the directive because it deals with the possibility of severe personal injury or
even death. A CAUTION identifies unsafe practices which may result in snowmobile-related damage. Follow
the directive because it deals with the possibility of damaging part or parts of the snowmobile. The symbol
NOTE: identifies supplementary information worthy of particular attention.
This manual covers operator-related maintenance, operating instructions, and off-season storage instructions. If
major repair or service is ever required, contact an authorized Arctic Cat Snowmobile dealer for professional service.
At the time of publication, all information and illustrations were technically correct. Some illustrations used in this
manual are used for clarity purposes only and are not designed to depict actual conditions. Because Arctic Cat Inc.
constantly refines and improves its products, no retroactive obligation is incurred.
This Operator’s Manual should be considered a permanent part of the snowmobile and must remain with the snowmobile at the time of resale. If the snowmobile changes ownership more than once, contact Arctic Cat Inc., Service
Department, P.O. Box 810, Thief River Falls, MN 56701, for proper registration information.
Every Arctic Cat Snowmobile meets or exceeds the standards of the Snowmobile Safety and Certification Committee and displays the SSCC decal. Arctic Cat endorses and encourages the safe use of all snowmobiles. Always wear
a helmet and 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 to improve trails, sponsor events, and generally support the
sport of snowmobiling. As a member of the National Snowmobile Foundation, Arctic Cat Inc. promotes snowmobiling through education, charity, and research programs.
© 2014 Arctic Cat Inc.
Printed in U.S.A. September 2014
! WARNING
This snowmobile is a very high performance snowmobile. Because it does accelerate rapidly and is capable
of very high speeds, it should not be operated by a
novice or an inexperienced operator. Never accelerate
rapidly or drive at high speed beyond the limits of visibility or without being totally familiar with the terrain
and what lies in front of you. Obey speed limits and
never operate at speeds that do not allow adequate
maneuvering and stopping distances. Read and study
the entire Operator’s Manual and Safety Handbook.
Failure to follow this warning could result in personal
injury to yourself or others.
PARTS AND ACCESSORIES
When in need of replacement parts, oil, or accessories for your Arctic Cat Snowmobile, be sure to only
use GENUINE ARCTIC CAT PARTS, OIL, AND
ACCESSORIES. Only genuine Arctic Cat parts, oil,
and accessories are engineered to meet the standards
and requirements of your Arctic Cat Snowmobile.
For a complete list of accessories, refer to the current
Arctic Cat Accessory Catalog.
To aid in service and maintenance procedures on this
snowmobile, an Illustrated Parts Manual is available
through your local Arctic Cat Snowmobile dealer.
If the snowmobile is purchased
through the Team Arctic Race
Department Racing Program, there
is no warranty.
Reference Information
The Arctic Cat Snowmobile has two important identification numbers. The Vehicle Identification Number
(VIN) is stamped on the side of the tunnel. The Engine
Serial Number (ESN) is stamped into the crankcase of
the engine.
These numbers are required by the dealer to complete
warranty claims properly. No warranty will be allowed
by Arctic Cat Inc. if the engine serial number or VIN is
removed or mutilated in any way.
Always provide the snowmobile name, VIN, and ESN
when contacting an authorized Arctic Cat Snowmobile
dealer for parts, service, accessories, or warranty. If
the complete engine must be replaced, ask the dealer to
notify Arctic Cat for correct registration information.
Write the appropriate information for your Arctic Cat
Snowmobile in the spaces below. Always use these
numbers when referring to your snowmobile.
Model: ____________________________________
Date of Purchase: ____________________________
VIN (Vehicle Identification Number):_____________
ESN (Engine Serial Number): ___________________
Your Arctic Cat Dealer: ________________________
Address: ____________________________________
Phone: _____________________________________
TABLE OF CONTENTS
Specifications/Charts/Patterns/Diagrams.............. 2-15
General Specifications ............................................ 2
Engine Specifications ............................................. 2
Torque Specifications.............................................. 2
Torque Conversions (ft-lb/N-m) ............................... 3
Tightening Torque (General Bolts) .......................... 3
Crankshaft Runout/Repair Specifications ............... 3
Crankshaft Runout/Repair Specifications ............... 3
Arctic Power Valve (APV) System Specifications.... 3
Component Voltage/Resistance Chart - Water
Temperature......................................................... 4
Drive System Specifications ................................... 5
Drive Clutch/Driven Clutch Optional Components .. 5
Drive Clutch Cam Arms (w/Set Screw) ................... 5
Chain Case Performance Calibrations.................... 6
Chains and Sprockets............................................. 7
Rear Spring Selection Chart................................... 7
Installed Spring Rate Chart .................................... 7
Front Suspension Sway Bar.................................... 7
Rebuildable Shock Tools Required ......................... 8
Optional Front Arm Shock Springs ......................... 8
Valve Stacks/Specifications .................................... 9
Rebuildable Shock Accessory Part Numbers ....... 10
Fraction/Decimal Conversion Chart ...................... 11
Drill Bit Sizes (Number) Chart............................... 11
MM/IN. Conversion Chart ..................................... 12
Wiring Diagram - Hood Harness........................... 13
Wiring Diagram - Ignition/Main Harness (p/n 1686732) ................................................................... 15
Setup Instructions ............................................... 17-22
Removing Snowmobile From Crate/Handlebar
Assembly ........................................................... 17
Installing Windshield ............................................ 17
Installing Spindle/A-Arm ....................................... 17
Installing Front Shock Absorbers .......................... 17
Installing Skis........................................................ 17
Sway Bar............................................................... 18
Brake System........................................................ 18
Ski Alignment........................................................ 18
Recommended Gasoline ...................................... 20
Preoperation Checks ............................................ 20
Checking Headlight Aim........................................ 20
Track Tension/Track Alignment.............................. 21
Test Ride ............................................................... 22
General Information ............................................ 23-25
Control Locations.................................................. 23
Arctic Power Valve (APV) System ......................... 23
Exhaust Controlled Timing (ECT) System ............ 23
Arctic Power Valve (APV) System ......................... 23
Testing Exhaust Temperature Sensor ................... 24
Handlebar Tilt........................................................ 24
Rear Bumper......................................................... 24
Exhaust System .................................................... 24
Liquid Cooling System .......................................... 24
Drive Clutch And Driven Clutch............................. 25
Drive Clutch/Driven Clutch Alignment ................... 25
Shock Absorbers................................................... 25
Track Studs ........................................................... 25
Towing ................................................................... 25
Operating Instructions ......................................... 26-27
Starting And Stopping Engine............................... 26
Braking .................................................................. 26
Emergency Stopping............................................. 27
Lubrication................................................................ 28
Chain Case ........................................................... 28
Rear Suspension .................................................. 28
Maintenance........................................................ 29-87
Periodic Maintenance Checklist ............................ 29
Pre-Race/Practice Checklist ................................. 30
Engine ................................................................... 30
Track Drive ............................................................ 49
Drive Sprockets ..................................................... 50
Brake System........................................................ 51
Brake Fluid ............................................................ 51
Checking Brake Lever Travel ................................. 52
Bleeding Brake System......................................... 52
Checking/Changing Brake Pads ........................... 53
Drive Belt............................................................... 54
Drive Clutch........................................................... 55
Driven Clutch......................................................... 56
Servicing Float X Evol Shock Absorbers............... 61
Rear Suspension .................................................. 77
Servicing Zero-X Shock Absorbers....................... 78
Adjusting Rear Transfer Adjuster Cams ................ 85
Lights .................................................................... 85
Ski Wear Bar ......................................................... 86
Rail Wear Strip ...................................................... 87
Performance Tips ..................................................... 88
Preparation For Storage ........................................... 89
Preparation After Storage......................................... 90
Genuine Arctic Cat Products .................................... 91
Special Tools ..................................................... 92-101
Declaration of Conformity................ Inside Back Cover
1
General Specifications
Chassis Length
Height
Width
Spindle Center-to-Center Distance
Dry Weight (approx)
Gas Tank Capacity
Chain Case Lubricant Capacity
Gasoline (Recommended)
Engine Oil
Chain Case Lubricant
Suspension Grease
Brake Fluid
Taillight/Brakelight Bulb p/n
Headlight Bulb p/n
Cooling System Capacity
Starting System
307 cm (121 in.)
122 cm (48 in.)
125-128 cm (49.25-50.25 in.)
106-109 cm (41.90-42.90 in.)
225 kg (495 lb)
44.3 l (11.7 U.S. gal.)
355 ml (15 fl oz)
91 Octane (minimum)
Arctic Cat CTec2
Arctic Cat Chain Lube
All-Temperature
High-Temp DOT 4
3303-849
0109-724
3.81 l (4.0 U.S. qt)
Manual Recoil
Engine Specifications
Engine Number
Displacement
Bore x Stroke
Compression Ratio
Cooling System
Ignition Timing (Engine Warm)
Spark Plug (NGK)
Spark Plug Gap
Piston Skirt/Cylinder Clearance
Piston Ring End Gap
Cylinder Trueness Limit
Piston Pin Diameter
Piston Pin Bore Diameter
Connecting Rod Small End Bore
Connecting Rod Radial Play
Crankshaft Runout (t.i.r.)
Crankshaft End Play
Reed Stopper Height
0962-011
599 cc
73.8 x 70 mm
6.62:1
Liquid
16.5° @ 2000 RPM 0.072”
BPR9ES
0.028-0.031”
0.0041-0.0053”
0.012-0.0196”
0.004”
0.8659-0.8661”
0.8661-0.8665”
1.0631-1.0634”
0.0001-0.0008”
0.002”
0.002-0.004”
0.512”
Torque Specifications
NOTE: Torque specifications have the following tolerances:
Torque (ft-lb)
0-15
16-39
40+
Drive Clutch***
Drive Clutch Cover
Cam Arm Pin Lock Nut
Cam Arm Set Screw
Driven Clutch**
Movable Sheave*
Chain Case (Cap Screw)
2
Secured to
Engine
Movable Sheave
Cam Arm Pin
Cam Arm
Driven Shaft
Torque Bracket
Chassis
Item
Chain Case (Torx-Head Screw)
Chain Case Cover
Brake Caliper
Outside Caliper Housing
Brakeline
Brakeline
Brake Caliper
Torque
ft-lb
51
120 in.-lb
11
19 in.-lb
20
27
96 in.-lb
Secured to
Chassis
Chain Case
Chassis
Inside Caliper Housing
Caliper
Master Cylinder
Shield Cover
Torque
ft-lb
12
12
25
25
25
25
96 in.-lb
STEERING/FRONT SUSPENSION/CHASSIS
Item
Secured to
Ski
Spindle
Ski
Wearbar
Ski
Ski Handle
Handlebar Adjuster
Post
Steering Support
Mounting Block
Steering Tie Rod Link
Steering Post
Steering Tie Rod Link
Steering Arm
Steering Post Cap
Riser Block
Steering Post
Chassis
Steering Tie Rod
Steering Arm
Tie Rod
Spindle Arm
Steering Support
Spar
Steering Support
Upper Console
Steering Arm
Chassis
A-Arm (Upper)
Chassis
A-Arm (Lower)
Chassis (Front)
A-Arm (Lower)
Chassis (Rear)
A-Arm
Spindle
Shock Absorber
Spindle
Shock Absorber
Chassis
Sway Bar Link
A-Arm/Sway Bar Link
Sway Bar Mounting Bracket
Chassis
REAR SUSPENSION
Wear Strip
Rail
End Cap
Rail
Mounting Block
Rail
Rear Arm
Rail
Rear Arm
Idler Arm
Spring Slide
Rail
Front Arm
Rail
Coupler Block Axle
Rail
Limiter Strap
Rail Support
Rear Tri Hub Wheel
Rear Tri Hub Wheel
Rear Wheel Axle
Rail
Skid Frame
Tunnel
Front Shock
Rail
Rail Support
Rail
Limiter Strap
Front Arm
* w/Green Loctite #609
** w/Blue Loctite #243
*** w/Oil
Tolerance
±20%
±15%
±10%
DRIVE SYSTEM
Item
DRIVE SYSTEM
Torque
ft-lb
35
8
54 in.-lb
15
8
35
20
15
55
20
32
20
30 in.-lb
8
23
65
45
45
45
45
23
9
50 in.-lb
80 in.-lb
20
45
55
20
52
40
72 in.-lb
50 in.-lb
34
55**
50
20
72 in.-lb
NOTE: The proper location for checking crankshaft
Torque Conversions
(ft-lb/N-m)
ft-lb
N-m
ft-lb
N-m
ft-lb
N-m
ft-lb
N-m
1
1.4
26
35.4
51
69.4
76
103.4
2
2.7
27
36.7
52
70.7
77
104.7
3
4.1
28
38.1
53
72.1
78
106.1
4
5.4
29
39.4
54
73.4
79
107.4
5
6.8
30
40.8
55
74.8
80
108.8
6
8.2
31
42.2
56
76.2
81
110.2
7
9.5
32
43.5
57
77.5
82
111.5
8
10.9
33
44.9
58
78.9
83
112.9
9
12.2
34
46.2
59
80.2
84
114.2
10
13.6
35
47.6
60
81.6
85
115.6
11
15
36
49
61
83
86
117
12
16.3
37
50.3
62
84.3
87
118.3
13
17.7
38
51.7
63
85.7
88
119.7
14
19
39
53
64
87
89
121
15
20.4
40
54.4
65
88.4
90
122.4
16
21.8
41
55.8
66
89.8
91
123.8
17
23.1
42
57.1
67
91.1
92
125.1
18
24.5
43
58.5
68
92.5
93
126.5
19
25.8
44
59.8
69
93.8
94
127.8
20
27.2
45
61.2
70
95.2
95
129.2
21
28.6
46
62.6
71
96.6
96
130.6
22
29.9
47
63.9
72
97.9
97
131.9
23
31.3
48
65.3
73
99.3
98
133.3
24
32.6
49
66.6
74
100.6
99
134.6
25
34
50
68
75
102
100
136
runout is the very edge of the straight portion of the
shaft where the oil seal makes contact. From the illustration, note that three check points are called out: at
either end, out on the taper as shown, and also on the
center bearing race. The crankshaft must be supported
on the inner bearings using V blocks.
0747-810
Arctic Power Valve (APV)
System Specifications
Tightening Torque
(General Bolts)
Type of Bolt
(Grade 8.8)
Thread
Diameter A
(mm)
5
60 in.-lb
6
96 in.-lb
8
20 ft-lb
10
40 ft-lb
12
(Grade 10.9)
Tightening
Torque
65 ft-lb
6
12 ft-lb
8
28 ft-lb
10
50 ft-lb
12
95 ft-lb
VALVE POSITION
Mid-Open
Full-Open
6000
CYCLE RPM
67-7500 (Low/High Alt)
77-8500 (Low/High Alt)
APV CABLE LENGTH
36.5 mm ± 1 mm
Crankshaft Runout/
Repair Specifications
To use the specifications, first refer to the drawing; then
find the letter indicating the specification and refer to the
chart below the illustration.
0735-516
3
Electrical Specifications
Component
Spark Plug Cap
Oil Level Sensor
Ignition Switch
Test Value
+ Test Connections -
4000-6000 ohms cap end
Less than 1 ohm terminal
(float end down)
Less than 1 ohm terminal
(key in OFF
position)
Component Voltage/
Resistance Chart - Water
Temperature
cap end
terminal
terminal
Temperature
230 °F
226 °F
223 °F
219 °F
216 °F
212 °F
208 °F
205 °F
201 °F
198 °F
194 °F
190 °F
187 °F
183 °F
180 °F
176 °F
172 °F
169 °F
165 °F
162 °F
158 °F
154 °F
151 °F
147 °F
144 °F
140 °F
136 °F
133 °F
129 °F
126 °F
122 °F
118 °F
115 °F
111 °F
108 °F
104 °F
100 °F
97 °F
93 °F
90 °F
86 °F
110 °C
108 °C
(Normally Open Ignition)
106 °C
Ignition Coil (Primary) 0.24-0.36 ohm black/white
white/blue
(Secondary) 5040-7560 ohms high tension wire high tension wire 104 °C
Charge Coil (1)
8.8-13.2 ohms black/red
green/red
102 °C
Charge Coil (2)
8.8-13.2 ohms brown/white
green/red
100 °C
Lighting Coil
0.08-0.12 ohm yellow
yellow
98 °C
Ignition Timing Sensor (1) 148-222 ohms green/white
brown/green
96 °C
Ignition Timing Sensor (2) 148-222 ohms green/white
brown/green
Fuel Injector
10-14 ohms
terminal
terminal
94 °C
Injection Coil
15.2-22.8 ohms blue/white
blue/white
92 °C
Fuel Pump Coil
1.52-2.28 ohms orange
orange
90 °C
Servomotor
12 DC Volts
red/black
black/red
(counterclock- (counterclock88 °C
wise)
wise)
86 °C
black/red
red/black
(clockwise)
(clockwise)
84 °C
Voltage Regulator/
9-14.5 DC Volts red/blue
black
82 °C
Rectifier*
80 °C
* Harness plugged in
78 °C
The main harness connectors must be unplugged
76 °C
(except on the primary coil and regulator/rectifier
74 °C
tests), the spark plugs removed and grounded, and by
72 °C
pulling the recoil starter rope briskly.
70 °C
68 °C
NOTE: Lighting coil output is unregulated volt66 °C
age.
64 °C
62 °C
! WARNING
60 °C
Most voltages generated by the ignition system are suf58 °C
ficient to interrupt pacemakers! All technicians, espe56 °C
cially those using pacemakers, must avoid contact with
all electrical connections when pulling the recoil starter
54 °C
rope or after the engine has been started.
52 °C
50 °C
48 °C
46 °C
44 °C
42 °C
40 °C
38 °C
36 °C
34 °C
32 °C
30 °C
4
Volts Ohms
129
137
145
153
161
169
180
191
202
213
224
240
256
273
289
305
327
349
371
393
415
445
475
505
535
565
609
653
697
741
785
849
913
977
1041
1105
1214
1323
1432
1541
1650
0.115
0.129
0.143
0.157
0.171
0.185
0.192
0.199
0.206
0.213
0.220
0.235
0.250
0.265
0.280
0.295
0.317
0.339
0.361
0.383
0.405
0.438
0.471
0.504
0.537
0.570
0.598
0.626
0.654
0.682
0.710
0.759
0.808
0.857
0.906
0.955
1.023
1.091
1.159
1.227
1.295
Temperature
82 °F
79 °F
75 °F
72 °F
68 °F
64 °F
61 °F
57 °F
54 °F
50 °F
46 °F
43 °F
39 °F
36 °F
32 °F
28 °F
25 °F
21 °F
18 °F
14 °F
10 °F
7 °F
3 °F
-0.4 °F
-4 °F
-8 °F
-11 °F
-15 °F
-18 °F
-22 °F
-26 °F
-29 °F
-32 °F
-36 °F
-40 °F
-44 °F
-47 °F
-51 °F
-54 °F
-58 °F
28 °C
26 °C
24 °C
22 °C
20 °C
18 °C
16 °C
14 °C
12 °C
10 °C
8 °C
6 °C
4 °C
2 °C
0 °C
-2 °C
-4 °C
-6 °C
-8 °C
-10 °C
-12 °C
-14 °C
-16 °C
-18 °C
-20 °C
-22 °C
-24 °C
-26 °C
-28 °C
-30 °C
-32 °C
-34 °C
-36 °C
-38 °C
-40 °C
-42 °C
-44 °C
-46 °C
-48 °C
-50 °C
Volts Ohms
1800
1950
2100
2250
2400
2670
2940
3210
3480
3750
4170
4590
5010
5430
5850
6510
7170
7830
8490
9150
9422
9694
9966
10238
10510
13688
16866
20044
23222
26400
30520
34640
38760
42880
47000
55100
63200
71300
79400
87500
1.377
1.459
1.541
1.623
1.705
1.806
1.907
2.008
2.109
2.210
2.327
2.444
2.561
2.678
2.795
2.901
3.007
3.113
3.219
3.325
3.421
3.517
3.613
3.709
3.805
3.885
3.965
4.045
4.125
4.205
4.267
4.329
4.391
4.453
4.515
4.553
4.591
4.629
4.667
4.705
Drive System
Specifications
Model
Altitude
ZR 6000R Cross Country
0-5000
Drive
Clutch
Spring
Green
Cam
Arm
64g
Driven
Clutch
Spring
Black/Blue
Torque
Bracket
Drive
Belt
Engagement Peak
RPM
RPM
44°/42° 0627-083
42-4600
81-8200
Top
Gear
23T
Bottom Chain
Gear Pitch
40T
86
Drive Clutch/Driven
Clutch-Related
Specifications
OFFSET P/N
0644-428
ALIGNMENT BAR
CENTER-TO-CENTER
OFFSET
12.10”
1.485”
FLOAT
None
Drive Clutch/Driven
Clutch Optional
Components
ARCTIC CAT DRIVE CLUTCH SPRING CHART
p/n
Rate @ 2 9/16" Rate @ 1 5/16"
Color
LIGHT
HEAVY
0646-439
0646-148
0646-150
0646-149
0646-432
0646-433
0646-376
0646-252
0646-147
0646-373*
0646-155
0646-229
0646-379*
0646-035
50 lb
53 lb
72 lb
74 lb
74 lb
75 lb
75 lb
103 lb
114 lb
114 lb
121 lb
122 lb
122 lb
143 lb
250 lb
224 lb
188 lb
228 lb
228 lb
275 lb
275 lb
315 lb
267 lb
257 lb
240 lb
285 lb
285 lb
286 lb
0646-447
(Titanium)
0646-367
0646-684
0646-410
143 lb
286 lb
Black/White
Blue
Silver
Red
Black/Red
Black/Gold
Gold
Green
Yellow/Green
Yellow/Green
Purple
Yellow/White
Yellow/White
Orange/
Black
Pink
143 lb
158 lb
165 lb
250 lb
285 lb
310 lb
Black
Black
Black/Blue
Spring
Color
Spring
Rate
0648-749
Black/White
160/260
0648-702
Red/Black
140/240
0648-784
Black
155/222
0648-790
Black/Light Blue
180/260
0648-792
Black/Orange
180/280
DRIVEN CLUTCH
Torque
Bracket
Degree
0648-779* 58-46-36/
58-48-36
0648-775* 52-42-46/
52-44-46
0648-773* 70-44-32/
68-48-46
0648-789* 68-48-36/
64-48-41
0648-791* 48-44-36/
48-42-36
Drive Clutch Cam Arms
(w/Set Screw)
ARCTIC CAT DRIVE CLUTCH CAM ARMS
p/n
Grams
p/n
Grams
0746-661
52.0
0746-712
77.0
0746-662
52.0
0746-713
48.0
0746-663
52.0
0746-715
77.0
0746-664
52.0
0746-716
73.0
0746-666
55.0
0746-742
83.5
0746-668
55.0
0746-744
50.0
0746-669
60.0
0746-748
46.0
0746-670
65.0
0746-749
65.0
0746-671
70.0
0746-771
44.0
0746-672
75.0
0746-772
42.0
0746-673
80.0
0746-773
85.0
0746-676
70.0
0746-786
63.0
0746-678
55.0
0746-787
44.0
0746-687
57.0
0746-788
47.5
0746-689
69.0
0746-789
42.0
0746-690
47.0
0746-791
60.0
0746-691
44.0
0746-792
47.0
0746-692
50.0
0746-793
63.0
0746-694
63.0
0746-814
83.0
0746-695
67.0
0746-821
82.0
0746-696
63.0
0746-822
71.5
0746-698
64.0
0746-824
66.0
0746-699
66.0
0746-825
50.0
0746-701
49.0
0746-826
64.0*
0746-702
57.5
0746-830
60.0
0746-703
68.0
0746-704
51.0
0746-708
51.0
0746-710
72.0
* Notched Cam Arm
*Lightweight driven clutch only.
5
Chain Case Performance
Calibrations
NOTE: The following table should be used as a guide only.
NOTE: The above gearing options are combinations which allow acceptable chain tension. Any other
combinations will not allow acceptable chain tension.
6
Chains and Sprockets
Part
Number
2602-582
2602-523
2602-377
2602-335
2602-403
2602-666
2602-212
2602-461
2602-405
2602-406
2602-371
2602-372
2602-522
2602-364
2602-363
2602-548
1702-406
1702-405
Part
Number
2602-369
2062-514
2602-370
2602-365
2602-373
2602-710
2602-733
Sprocket
SPROCKET, REX-19T FWD-(13 WIDE/19 SPLINE)
SPROCKET, 40T TOS-ASSY
SPROCKET, 49T TOS-ASSY
Chain
CHAIN, REXNORD-84P (13 WIDE)
Wire
Number Coil Length Length Degree
Diameter Angle
of
Width (D)
(B)
(E)
(In lb)
(A)
Coils
(C)
1704-382/
.359
90°
5.75
3.00 15.62 4.60
17
383
(Light)
1704-384/
.375
90°
5.75
3.00 15.62 4.60
20
385
(Heavy)
1704-916/
.405
120°
5.90
3.20 15.62 4.70
24
917
2704-224/
.437
105°
6.80
3.75 15.62 4.70
27.3
225
1704-576/
.405
90°
6.75
3.65 18.50 5.50
18.5
577
2704-384/
.405
115°
6.80
3.65 15.62 4.70
18.9
385
2704-380/
.437
92°
6.75
3.75 15.62 4.70
27.4
381*
2704-382/
.405
89°
6.75
3.65 15.62 4.70
18.9
383**
P/N
* Production (Sno Cross) **Production (Cross Country)
NOTE: The wire diameter and length of the spring
have a large influence over the valving of the
shocks.
Installed Spring Rate
Chart
Suspension Fully
Suspension Fully
Extended
Extended
(in.-lb - Adjuster Set 1 & 1) (in.-lb - Adjuster Set 3 & 3)
1704-382/383
1360
1700
1704-384/385
1600
2001
1704-916/917
480
960
2704-224/225
1350
1890
1704-576/577
1480
1850
2704-380/381
2082
2630
2704-382/383
1550
1928
2704-384/385
567
945
Suspension Fully
Suspension Fully
Collapsed
Collapsed
P/N
(in.-lb - Adjuster Set 1 & 1) (in.-lb - Adjuster Set 3 & 3)
1704-382/383
3740
4080
1704-384/385
4411
4812
1704-916/917
3840
4320
2704-224/225
5130
5670
1704-576/577
4070
4440
2704-380/381
5918
6466
2704-382/383
4196
4574
2704-384/385
3213
3591
P/N
Rear Spring Selection
Chart
Below is a list of rear suspension springs and specifications. A longer spring in areas (D) and (E) can be
selected if cut off to match the original spring. The
replacement spring must match the original spring in
areas (C), (D), and (E).
Front Suspension
Sway Bar
0730-218
Sway Bar p/n
Bushing p/n
Description
2703-615
2603-944/945 (inc.)
11.1 mm diameter
2703-793
2603-946/947 (inc.)
12.7 mm diameter
NOTE: Sway Bar Mounting Kit (p/n 6639-001).
7
Rebuildable Shock Tools
Required
P/N
Tool
0744-020 Inflation Needle
0644-486 Gas Shock Retaining Blocks
0644-544 Replacement Needle
0644-169 Piston Location Tool
0644-151 Nitrogen Regulator
0644-268 Bearing Cap Seal Protector
0644-403 Bearing Cap Seal Protector (1/2-in. O.D. x 3/8 in. I.D.)
0644-404 Bearing Cap Seal Protector (5/8-in. O.D. x 3/8 in. I.D.)
0644-542 Bearing Cap Seal Protector (5/8 in. O.D. x 1/2 in. I.D.)
0644-543 Gas Shock Shaft Clamping Tool
0644-350 Floating Piston Location Gauge
0644-539 Inflation Needle Replacement Tip
0744-072 Float Shock Spanner Wrench
0644-584 Air Sleeve Bushing Installation Tool
0644-585 Air Sleeve Bushing Installation Tool
0644-456 Bullet Air Sleeve Bushing Installation Tool
Optional Front Arm
Shock Springs
P/N
LB
2704-755*
100/250
Length (Inches)
7.75
2704-228
100/250
7.75
2704-229
160/260
7.75
1704-819
230
7.50
1704-820
170
7.50
1704-821
190
7.50
1704-822
210
7.50
1704-831
250
7.50
Ice Racing Springs
2704-749
70
6
2704-750
90
6
2704-751
110
6
* Stock Spring
8
Valve Stacks/
Specifications
Part Number
3703-346/347
Extended Length: 18.94 in.
Collapsed Length: 13.29 in.
Stroke: 5.65 in.
Piston Orifice: 0.059 in.
Description
Ski Shock
Rebuild Kit - p/n 2603-929
(Reservoir)
Piston Depth: 2.50 in.
Compression (Piston Side)
Rebound (Piston Side)
1.300 x 0.008 in.
1.300 x 0.008 in.
0.800 x 0.006 in.
1.300 x 0.010 in.
1.250 x 0.010 in.
1.100 x 0.008 in.
0.800 x 0.004 in.
1.125 x 0.080 in.
Ground
0.620 x 0.093 in.
Backup
1.100 x 0.010 in.
1.000 x 0.010 in.
0.900 x 0.010 in.
1.125 x 0.093 in. Top out
Compression (CD Piston)
0.700 x 0.010 in.
0.700 x 0.010 in.
0.600 x 0.010 in.
0.500 x 0.006 in.
0.400 x 0.020 in. (BU)
0.400 x 0.020 in. (BU)
CD Knob @ 12 clicks from full closed; RB Knob @ 12 clicks from full closed.
Eyelets tightened to 3.9 kg-m (28 ft-lb). Piston nut tightened to 3.0 kg-m (22 ft-lb).
Tighten the shaft nut to 3.0 kg-m (22 ft-lb). Shocks charged at 250 psi (nitrogen)/80/200 psi (air).
Green Loctite #620 on shock eyelet threads.
Part Number
2704-635
Stroke: 3.80 in.
Description
Front Arm Shock
(Reservoir)
Compression
(Piston Side)
Rebound
(Piston Side)
1.300 x 0.008 in.
1.300 x 0.008 in.
0.800 x 0.004 in. (Center)
1.300 x 0.10 (Ring)
1.100 x 0.004 in.
1.000 x 0.004 in.
1.100 x 0.008 in.
0.600 x 0.004 in.
0.700 x 0.010 in.
1.125 x 0.080 in.
(Top Out)
0.620 x 0.093 in.
Backup
1.000 x 0.004 in.
0.700 x 0.004 in.
1.250 x 0.093 in. (Top Out)
Piston Orifice: None
Compression @ 12 clicks counterclockwise from full stop.
Eyelets tightened to 3.9 kg-m (28 ft-lb). Piston nut tightened to 3.0 kg-m (22 ft-lb). Tighten shaft nut to 3.9 kg-m (28 ft-lb). Shock
charged at 250 psi. Green Loctite #620 on shock eyelet threads.
Part Number
Description
2704-636
Rear Arm Shock
Stroke: 4.53 in.
(Reservoir)
Piston Orifice: None
Compression
(Piston Side)
Rebound
(Piston Side)
1.600 x 0.004 in. (DB)
1.600 x 0.010 in.
1.600 x 0.010 in.
1.100 x 0.006 in.
1.600 x 0.012 in.
1.600 x 0.012 in.
1.600 x 0.012 in.
1.425 x 0.010 in.
1.350 x 0.010 in.
1.100 x 0.008 in.
1.570 x 0.128 in. (Top Out)
1.425 x 0.015 in.
1.425 x 0.015 in.
1.425 x 0.012 in.
1.350 x 0.012 in.
1.100 x 0.012 in.
0.950 x 0.012 in.
0.800 x 0.020 in.
0.800 x 0.020 in.
0.750 x 0.080 in.
0.750 x 0.100 in. (Backup)
CD Knob @ 12 clicks from full closed; RB Knob @ 5 clicks counterclockwise.
Shock charged at 250 psi. Green Loctite #620 on shock eyelet threads.
Eyelets tightened to 3.9 kg-m (28 ft-lb). Piston nut tightened to 3.0 kg-m (22 ft-lb).
Tighten the shaft nut to 3.9 kg-m (28 ft-lb).
9
Rebuildable Shock
Accessory Part Numbers
NOTE: When rebuilding Fox shocks, use only
Fox valves and/or pistons.
AC PN
10
Description
2603-499
Valve: [0.500 OD X 0.252 ID X 0.006 TH]
2603-500
Valve: [0.600 OD X 0.252 ID X 0.010 TH]
2603-501
Valve: [0.700 OD X 0.252 ID X 0.010 TH]
2603-902
Valve: [0.550 OD X 0.377 ID X 0.020 TH]
3604-171
Valve: [0.600 OD X 0.377 ID X 0.004 TH]
3604-533
Valve: [0.600 OD X 0.377 ID X 0.012 TH]
2603-224
Valve: [0.620 OD X 0.377 ID X 0.015 TH]
0603-731
Valve: [0.700 OD X 0.377 ID X 0.004 TH]
0603-330
Valve: [0.700 OD X 0.377 ID X 0.006 TH]
0603-331
Valve: [0.700 OD X 0.377 ID X 0.008 TH]
0603-332
Valve: [0.700 OD X 0.377 ID X 0.010 TH]
0603-878
Valve: [0.700 OD X 0.377 ID X 0.012 TH]
0603-884
Valve: [0.700 OD X 0.377 ID X 0.015 TH]
0603-895
Valve: [0.800 OD X 0.377 ID X 0.004 TH]
0603-333
Valve: [0.800 OD X 0.377 ID X 0.006 TH]
0603-334
Valve: [0.800 OD X 0.377 ID X 0.008 TH]
0603-335
Valve: [0.800 OD X 0.377 ID X 0.010 TH]
0603-879
Valve: [0.800 OD X 0.377 ID X 0.012 TH]
0603-885
Valve: [0.800 OD X 0.377 ID X 0.015 TH]
0603-894
Valve: [0.900 OD X 0.377 ID X 0.004 TH]
0603-336
Valve: [0.900 OD X 0.377 ID X 0.006 TH]
0603-337
Valve: [0.900 OD X 0.377 ID X 0.008 TH]
0603-338
Valve: [0.900 OD X 0.377 ID X 0.010 TH]
0603-880
Valve: [0.900 OD X 0.377 ID X 0.012 TH]
0603-886
Valve: [0.900 OD X 0.377 ID X 0.015 TH]
0603-893
Valve: [1.000 OD X 0.377 ID X 0.004 TH]
0603-339
Valve: [1.000 OD X 0.377 ID X 0.006 TH]
0603-340
Valve: [1.000 OD X 0.377 ID X 0.008 TH]
0603-341
Valve: [1.000 OD X 0.377 ID X 0.010 TH]
0603-881
Valve: [1.000 OD X 0.377 ID X 0.012 TH]
0603-887
Valve: [1.000 OD X 0.377 ID X 0.015 TH]
0603-892
Valve: [1.100 OD X 0.377 ID X 0.004 TH]
0603-342
Valve: [1.100 OD X 0.377 ID X 0.006 TH]
0603-343
Valve: [1.100 OD X 0.377 ID X 0.008 TH]
0603-344
Valve: [1.100 OD X 0.377 ID X 0.010 TH]
0603-882
Valve: [1.100 OD X 0.377 ID X 0.012 TH]
0603-888
Valve: [1.100 OD X 0.377 ID X 0.015 TH]
0603-345
Valve: [1.250 OD X 0.377 ID X 0.006 TH]
0603-346
Valve: [1.250 OD X 0.377 ID X 0.008 TH]
0603-347
Valve: [1.250 OD X 0.377 ID X 0.010 TH]
0603-883
Valve: [1.250 OD X 0.377 ID X 0.012 TH]
0603-889
Valve: [1.250 OD X 0.377 ID X 0.015 TH]
0603-348
Valve: [1.300 OD X 0.377 ID X 0.006 TH]
0603-349
Valve: [1.300 OD X 0.377 ID X 0.008 TH]
0603-350
Valve: [1.300 OD X 0.377 ID X 0.010 TH]
0603-891
Valve: [1.300 OD X 0.377 ID X 0.012 TH]
0603-890
Valve: [1.300 OD X 0.377 ID X 0.015 TH]
AC PN
Description
2604-647
Valve: [1.425 OD X 0.377 ID X 0.010 TH]
2604-632
Valve: [1.425 OD X 0.377 ID X 0.012 TH]
2604-633
Valve: [1.425 OD X 0.377 ID X 0.015 TH]
3604-577
Valve: [1.600 OD X 0.377 ID X 0.008 TH]
2604-631
Valve: [1.600 OD X 0.377 ID X 0.010 TH]
2604-683
Valve: [0.650 OD X 0.504 ID X 0.020 TH]
2604-469
Valve: [0.700 OD X 0.504 ID X 0.010 TH]
2604-470
Valve: [0.700 OD X 0.504 ID X 0.020 TH]
2604-471
Valve: [0.750 OD X 0.504 ID X 0.020 TH]
2604-472
Valve: [0.800 OD X 0.504 ID X 0.006 TH]
2604-473
Valve: [0.800 OD X 0.504 ID X 0.008 TH]
2604-474
Valve: [0.800 OD X 0.504 ID X 0.010 TH]
2604-475
Valve: [0.800 OD X 0.504 ID X 0.012 TH]
2604-476
Valve: [0.800 OD X 0.504 ID X 0.015 TH]
2604-477
Valve: [0.800 OD X 0.504 ID X 0.020 TH]
2604-478
Valve: [0.950 OD X 0.504 ID X 0.006 TH]
2604-479
Valve: [0.950 OD X 0.504 ID X 0.008 TH]
2604-480
Valve: [0.950 OD X 0.504 ID X 0.010 TH]
2604-481
Valve: [0.950 OD X 0.504 ID X 0.012 TH]
2604-482
Valve: [0.950 OD X 0.504 ID X 0.015 TH]
2604-483
Valve: [1.000 OD X 0.504 ID X 0.020 TH]
3604-149
Valve: [1.100 OD X 0.504 ID X 0.004 TH]
2604-484
Valve: [1.100 OD X 0.504 ID X 0.006 TH]
2604-485
Valve: [1.100 OD X 0.504 ID X 0.008 TH]
2604-486
Valve: [1.100 OD X 0.504 ID X 0.010 TH]
2604-487
Valve: [1.100 OD X 0.504 ID X 0.012 TH]
2604-488
Valve: [1.100 OD X 0.504 ID X 0.015 TH]
2604-489
Valve: [1.100 OD X 0.504 ID X 0.020 TH]
2604-684
Valve: [1.250 OD X 0.504 ID X 0.006 TH]
2604-685
Valve: [1.250 OD X 0.504 ID X 0.008 TH]
2604-686
Valve: [1.250 OD X 0.504 ID X 0.010 TH]
2604-687
Valve: [1.250 OD X 0.504 ID X 0.012 TH]
2604-688
Valve: [1.250 OD X 0.504 ID X 0.015 TH]
2604-490
Valve: [1.350 OD X 0.504 ID X 0.006 TH]
2604-491
Valve: [1.350 OD X 0.504 ID X 0.008 TH]
2604-492
Valve: [1.350 OD X 0.504 ID X 0.010 TH]
2604-493
Valve: [1.350 OD X 0.504 ID X 0.012 TH]
2604-494
Valve: [1.350 OD X 0.504 ID X 0.015 TH]
2604-495
Valve: [1.425 OD X 0.504 ID X 0.006 TH]
2604-496
Valve: [1.425 OD X 0.504 ID X 0.008 TH]
2604-497
Valve: [1.425 OD X 0.504 ID X 0.010 TH]
2604-498
Valve: [1.425 OD X 0.504 ID X 0.012 TH]
2604-499
Valve: [1.425 OD X 0.504 ID X 0.015 TH]
2604-500
Valve: [1.600 OD X 0.504 ID X 0.006 TH]
2604-501
Valve: [1.600 OD X 0.504 ID X 0.008 TH]
2604-502
Valve: [1.600 OD X 0.504 ID X 0.010 TH]
2604-503
Valve: [1.600 OD X 0.504 ID X 0.012 TH]
2604-504
Valve: [1.600 OD X 0.504 ID X 0.015 TH]
NOTE: Shock Oil (p/n 5639-530) is available from
Arctic Cat Service Department.
Double Bleed Shims (DB)
AC PN
Drill Bit Sizes
(Number) Chart
Description
3603-342
Valve: DB 3 PORT (1.30" OD X .375" ID .004" THK.)
3603-343
3603-344
3603-345
3603-346
3603-347
3603-348
No.
Size of
Drill in
Inches
No.
Size of
Drill in
Inches
No.
Size of
Drill in
Inches
No.
Size of
Drill in
Inches
1
.2280
21
.1590
41
.0960
61
.0390
2
.2210
22
.1570
42
.0935
62
.0380
3603-481
3
.2130
23
.1540
43
.0890
63
.0370
3603-482
4
.2090
24
.1520
44
.0860
64
.0360
3603-483
5
.2055
25
.1495
45
.0820
65
.0350
3603-484
6
.2040
26
.1470
46
.0810
66
.0330
3603-485
7
.2010
27
.1440
47
.0785
67
.0320
3603-486
8
.1990
28
.1405
48
.0760
68
.0310
3603-487
9
.1960
29
.1360
49
.0730
69
.0292
10
.1935
30
.1285
50
.0700
70
.0280
11
.1910
31
.1200
51
.0670
71
.0260
12
.1890
32
.1160
52
.0635
72
.0250
Single Bleed Shims (DB)
AC PN
Description
3603-469
Valve: SB 3 PORT (1.30" OD X .375" ID .004" THK.)
13
.1850
33
.1130
53
.0595
73
.0240
3603-470
14
.1820
34
.1110
54
.0550
74
.0225
4604-038
15
.1800
35
.1100
55
.0520
75
.0210
3603-471
16
.1770
36
.1065
56
.0465
76
.0200
3603-472
17
.1730
37
.1040
57
.0430
77
.0180
3603-473
18
.1695
38
.1015
58
.0420
78
.0160
3603-474
19
.1660
39
.0995
59
.0410
79
.0145
3603-475
20
.1610
40
.0980
60
.0400
80
.0135
3603-410
3603-476
3603-477
3603-478
3603-479
3603-480
Fraction/Decimal
Conversion Chart
8ths
16ths
32nds
64ths
1/8 = .125 1/16 = .0625 1/32 = .03125 1/64 = .015625
1/4 = .250 3/16 = .1875 3/32 = .09375 3/64 = .046875
3/8 = .375 5/16 = .3125 5/32 = .15625 5/64 = .078125
1/2 = .500 7/16 = .4375 7/32 = .21875 7/64 = .109375
5/8 = .625 9/16 = .5625 9/32 = .28125 9/64 = .140625
3/4 = .750 11/16 = .6875 11/32 = .34375 11/64 = .171875
7/8 = .875 13/16 = .8125 13/32 = .40625 13/64 = .203125
—
15/16 = .9375 15/32 = .46875 15/64 = .234370
—
—
17/32 = .53125 17/64 = .265625
—
—
19/32 = .59375 19/64 = .296875
—
—
21/32 = .65625 21/64 = .328125
—
—
23/32 = .71875 23/64 = .359375
—
—
25/32 = .78125 25/64 = .390625
—
—
27/32 = .84375 27/64 = .421875
—
—
29/32 = .90625 29/64 = .453125
—
—
31/32 = .96875 31/64 = .484375
64ths (cont)
33/64 = .515625
35/64 = .546875
37/64 = .578125
39/64 = .609375
41/64 = .640625
43/64 = .671875
45/64 = .703125
47/64 = .734375
49/64 = .765625
51/64 = .796875
53/64 = .828125
55/64 = .859375
57/64 = .890625
59/64 = .921875
61/64 = .953125
63/64 = .984375
11
MM/IN. Conversion Chart
mm
in.
mm
in.
mm
in.
mm
in.
.01
.00039
.51
.02008
1
.03937
51
2.00787
.02
.00079
.52
.02047
2
.07874
52
2.04724
.03
.00118
.53
.02087
3
.11811
53
2.08661
.04
.00157
.54
.02126
4
.15748
54
2.12598
.05
.00197
.55
.02165
5
.19685
55
2.16535
.06
.00236
.56
.02205
6
.23622
56
2.20472
.07
.00276
.57
.02244
7
.27559
57
2.24409
.08
.00315
.58
.02283
8
.31496
58
2.28346
.09
.00354
.59
.02323
9
.35433
59
2.32283
.10
.00394
.60
.02362
10
.39370
60
2.36220
.11
.00433
.61
.02402
11
.43307
61
2.40157
.12
.00472
.62
.02441
12
.47244
62
2.44094
.13
.00512
.63
.02480
13
.51181
63
2.48031
.14
.00551
.64
.02520
14
.55118
64
2.51968
.15
.00591
.65
.02559
15
.59055
65
2.55905
.16
.00630
.66
.02598
16
.62992
66
2.59842
.17
.00669
.67
.02638
17
.66929
67
2.63779
.18
.00709
.68
.02677
18
.70866
68
2.67716
.19
.00748
.69
.02717
19
.74803
69
2.71653
.20
.00787
.70
.02756
20
.78740
70
2.75590
.21
.00827
.71
.02795
21
.82677
71
2.79527
.22
.00866
.72
.02835
22
.86614
72
2.83464
.23
.00906
.73
.02874
23
.90551
73
2.87401
.24
.00945
.74
.02913
24
.94488
74
2.91338
.25
.00984
.75
.02953
25
.98425
75
2.95275
.26
.01024
.76
.02992
26
1.02362
76
2.99212
.27
.01063
.77
.03032
27
1.06299
77
3.03149
.28
.01102
.78
.03071
28
1.10236
78
3.07086
.29
.01142
.79
.03110
29
1.14173
79
3.11023
.30
.01181
.80
.03150
30
1.18110
80
3.14960
.31
.01220
.81
.03189
31
1.22047
81
3.18897
.32
.01260
.82
.03228
32
1.25984
82
3.22834
.33
.01299
.83
.03268
33
1.29921
83
3.26771
.34
.01339
.84
.03307
34
1.33858
84
3.30708
.35
.01378
.85
.03346
35
1.37795
85
3.34645
.36
.01417
.86
.03386
36
1.41732
86
3.38582
.37
.01457
.87
.03425
37
1.45669
87
3.42519
.38
.01496
.88
.03465
38
1.49606
88
3.46456
.39
.01535
.89
.03504
39
1.53543
89
3.50393
.40
.01575
.90
.03543
40
1.57480
90
3.54330
.41
.01614
.91
.03583
41
1.61417
91
3.58267
.42
.01654
.92
.03622
42
1.65354
92
3.62204
.43
.01693
.93
.03661
43
1.69291
93
3.66141
.44
.01732
.94
.03701
44
1.73228
94
3.70078
.45
.01772
.95
.03740
45
1.77165
95
3.74015
.46
.01811
.96
.03780
46
1.81102
96
3.77952
.47
.01850
.97
.03819
47
1.85039
97
3.81889
.48
.01890
.98
.03858
48
1.88976
98
3.85826
.49
.01929
.99
.03898
49
1.92913
99
3.89763
.50
.01969
1.0
.03937
50
1.96850
100
3.93700
12
Wiring Diagram - Hood
Harness
(p/n 1686-706) - Cross Country
0748-009
13
NOTES
14
Wiring Diagram (Ignition/Main)
(Harness p/n 1686-732)
0747-813
15
16
Installing Spindle/A-Arm
Setup Instructions
This snowmobile has been prepared at the factory to
minimize required setup items; however, there are
some items and inspections that must be done at a
dealership or by the owner/operator. Please pay close
attention to all items on the following pages. Be sure to
read these instructions thoroughly before starting to set
up the snowmobile.
Removing Snowmobile From Crate/
Handlebar Assembly
CAUTION
746-483A
Care should be taken when removing the snowmobile
from the crate. Damage that is not warrantable may
occur.
1. Remove the top and four sides of the crate.
Remove the skis from the crate sides.
1. Install the A-arms onto the spindle and secure
using new lock nuts. Tighten to 45 ft-lb.
2. Install the steering tie rod to the spindle. Tighten
lock nuts to 40 ft-lb.
Installing Front Shock Absorbers
2. Remove the windshield and hardware kit.
3. Remove all mounting hardware securing the
snowmobile to the crate base; then lift the snowmobile free of the crate base.
4. Swing the handlebar up and tighten the cap screws
evenly to 15 ft-lb; then check steering for maximum right/left turning capabilities. Install the handlebar pad assembly.
Installing Windshield
1. Remove the protective film from the windshield.
2. Install the expansion nuts into the speedometer
bracket; then place the windshield into position on
the console and bracket.
746-484B
1. Raise the front of the snowmobile and place it on a
support stand.
2. Apply grease to the O-rings; then install the O-rings
and the spherical spacers to each side of the shock
eyelet spherical bearing. Take care that the O-ring is
between the bearing and spherical spacers.
3. Place the upper shock into position on the frame;
then install the cap screw and flange nut. Tighten
to 45 ft-lb.
4. Install the lower shock eyelet into the lower A-arm
mounting bracket.
SNO-490
3. Secure the windshield using the screws according to
the illustration.
5. Push the cap screw through the shock eyelet and
backside of the A-arm mounting bracket; then
install the nut and tighten to 45 ft-lb.
6. Install the remaining shock absorber.
Installing Skis
1. Slide a washer onto the cap screw used to secure the
ski; then apply all-temperature grease to the shaft
portion of the cap screw and spindle axle.
17
3. Tighten machine screws evenly to 8 ft-lb.
4. Position the sway bar link onto the lower A-arm
and the sway bar. Install the cap screws and lock
nuts. Tighten the lock nuts to 23 ft-lb.
Brake System
Checking Brake Fluid
1. With the brake fluid reservoir in a level position,
check the fluid level. The brake fluid level must be
just below the high mark.
0747-094
2. Install the spindle axle into the spindle; then position the
ski damper into the bottom of the ski making sure the
damper is properly positioned for the desired ski stance.
NOTE: The ski damper must be positioned in the ski
so it is directly under the spindle.
3. With the cap screw hole of the ski centered with the
spindle axle, slide the cap screw with washer through
the outside of the ski and spindle assemblies.
NOTE: Local laws and/or regulations as to maximum width of the ski stance may be applicable.
Always comply with the maximum width laws and/or
regulations when adjusting ski stance.
NOTE: Install the cap screw so the lock nut will be
located to the inside of the ski and the cotter pin slot
in the cap screw will be horizontal with the ski.
SNO-253
2. If the brake fluid level is below the low mark,
remove the reservoir cover and add Arctic Cat
approved brake fluid until the fluid level is just
below the high mark. Install and secure the reservoir cover. Do not allow moisture to contaminate
the brake system.
4. Install the remaining washer and lock nut; then
tighten the lock nut to 35 ft-lb.
NOTE: Assure that the cotter pin slot in the cap
screw is still horizontal with the ski (see illustration);
then proceed to step 7.
5. Install the cotter pin from the back side of the ski cap
screw and spread the pin.
NOTE: Repeat this sub-section on the opposite side.
CAUTION
Brake fluid is highly corrosive. Do not spill brake fluid
on any surface of the snowmobile.
! WARNING
Do not overfill the brake fluid reservoir. Overfilling the
reservoir may cause the brake system to hydraulically
lock. Use only Arctic Cat approved brake fluid.
Checking Brake Lever Operation
Sway Bar
1. Test the operation of the hydraulic brake system
by compressing the brake lever.
2. The brake lever must feel firm when compressed.
Ski Alignment
Checking
Toe-Out Range
0.0 - 12.7 mm (0 - 1/2 in.)
NOTE: Track tension and alignment must be properly
adjusted prior to checking or adjusting ski alignment.
Ski alignment must be performed on a flat, level surface. Ski toe-out must fall within the specified range.
SNO-2232
1. Place the sway bar into position (mounting location) of the chassis.
2. Secure the bar with the two mounting brackets,
four machine screws.
18
1. Raise the front end of snowmobile just high
enough that the ski shocks are fully extended but
the skis are still resting on the floor.
2. From the riding position on the snowmobile,
check that the handlebar is in a straight-forward
direction for driving.
NOTE: Steering can be centered in the chassis by
taking measurements from each side of the drag
link to a location on the chassis which would be of
equal distance from each side of the drag link.
3. Using a very light hold-down strap (bungee cord)
between the ski handles, apply a very light load
approximately 2-4 lb pulling the skis together just
enough to pull the slack.
NOTE: Track tension and alignment must be
properly adjusted prior to placing the straightedge
against the outside edge of the track.
4. Place a long straightedge against the outside edge
of the track so it lies near the inside edge of the
left-side ski.
7. Measure the distance from the straightedge to the
right-side ski edge in two places: 35.5-38.1 cm
(14-15 in.) in front of the spindle and 35.5-38.1 cm
(14-15 in.) behind the spindle. Record the measurements taken for the right side.
! WARNING
The measurement from the front and rear of ski to the
straightedge can be equal (ski parallel to the track),
but the front measurement must never be less (ski
toed-in) or poor handling will be experienced. The
front measurements to the straightedge must not
exceed the rear measurements to the straightedge (ski
toed-out) by more than 12.7 mm (1/2 in.).
8. If ski alignment is not as specified, adjust the alignment of the ski(s) not parallel to the straightedge.
Adjusting
NOTE: The following procedure can be used to
adjust the alignment of either ski.
1. Unlock the steering tie rod by loosening jam nuts (A).
NOTE: The inside jam nuts are left-hand thread. Care
should be taken to rotate them in the proper direction.
729-887E
NOTE: The straightedge should be long enough to
extend from the back of the track to the front of the ski.
5. Measure the distance from the straightedge to the
left-side ski edge in two places: approximately
35.5-38.1 cm (14-15 in.) in front of the spindle and
35.5-38.1 cm (14-15 in.) behind the spindle.
Record the measurements taken for the left side.
SNO-2233A
2. Adjust ski alignment by rotating the tie rod with a
wrench at hex-point (B).
3. When ski alignment is correct, apply blue Loctite
#243 to the jam nut threaded area and tighten to 20
ft-lb. Tighten both jam nuts against the tie rod.
! WARNING
Neglecting to lock the tie rod by tightening the jam
nuts may cause loss of snowmobile control and possible personal injury.
NOTE: To allow equal rotation of the tie rod end
ball joints, secure the tie rod jam nuts with the tie
rod ends positioned 90° from each other.
729-887D
6. Place the straightedge against the outside edge of the
track so it lies near the inside edge of the right-side ski.
19
Also, if the snowmobile is to remain on a trailer after
filling the gas tank, the bed of the trailer must be maintained level to prevent gasoline from draining out
through the gas tank vent hose.
! WARNING
Always fill the gas tank in a well-ventilated area. Never
add gasoline to the snowmobile gas tank near any
open flames or with the engine running. DO NOT
SMOKE while filling the gas tank. Do not sit on the
snowmobile without first installing the gas tank cap.
0743-088
Recommended Gasoline
CAUTION
Do not use white gas or gasolines containing methanol. Only Arctic Cat approved gasoline additives
should be used.
The recommended gasoline to use in this snowmobile
is minimum 91 octane gasoline with a maximum 10%
ethanol content.
NOTE: For optimum performance, use only 91
octane (minimum) gasoline.
CAUTION
If a situation arises wherein 91 octane non ethanol or
91 octane with maximum 10% ethanol gasoline is not
available, 87 octane gasoline can be substituted in an
emergency; however, the prolonged usage of 87
octane gasoline can cause severe engine damage.
Gasolines containing more than 10% ethanol are not
acceptable gasoline for use in this snowmobile. Do not
use gasolines containing methanol.
Recommended Injection Oil
The recommended oil to use in the oil-injection system
is Arctic Cat C-TEC2 Synthetic 2-Cycle Oil (p/n
6639-520 - 48 oz) This oil is specially formulated to be
used and meets all of the lubrication requirements of
the Arctic Cat C-TEC2 snowmobile engine.
CAUTION
Any oil used in place of the recommended oil could
cause serious engine damage.
Filling Gas Tank
Since gasoline expands as its temperature increases,
the gas tank must be filled to its rated capacity only.
Expansion room must be maintained in the tank particularly if the tank is filled with cold gasoline and then
moved to a warm area.
Engine Break-In
The Arctic Cat engine (when new or rebuilt) requires a
short break-in period before the engine is subjected to
heavy load conditions.
During the break-in period (one tank of fuel), a maximum of 1/2 throttle (with varying throttle positions) is
recommended; however, brief full-throttle accelerations and variations in driving speeds contribute to
good engine break-in.
Premixing fuel and oil during the break in period is not
required. With the oil delivery control strategy of the
electronic oil pump, the pump will automatically compensate and deliver a richer fuel-to-oil ratio during the
engine break-in period.
Some may choose to pre-mix the first tank and if this
is the case, a pre-mix ratio of 100:1 is acceptable. A
pre-mix ratio of 100:1 combined with the richer fuel/
oil delivered from the electronic oil pump during
break-in may cause additional smoke at start up and
idle.
Preoperation Checks
1. Visually check all fluid levels. Add fluids as necessary.
2. Visually check the entire snowmobile for any
loose fasteners. Tighten as required.
3. Start and run the engine to operating temperature.
4. Check all switches (tether, dimmer, brakelight,
emergency stop) to make sure all function properly; then visually check the headlight, taillight,
and brake light for proper illumination.
5. Test the operation of the brakes. The brake lever
must feel firm when the lever is compressed.
Inspect the brake fluid level. The brake fluid level
must be just below the high mark on the brake
fluid reservoir. Add Arctic Cat approved brake
fluid as necessary.
Checking Headlight Aim
1. Position the snowmobile on a level floor so the
headlight is approximately 8 m (25 ft) from an
aiming surface (wall or similar surface).
NOTE: There should be an “average” operating
load on the snowmobile when adjusting headlight
aim.
20
2. Measure the distance from the floor to midpoint of
the headlight.
3. Using the measurement obtained in step 2, make a
horizontal mark on the aiming surface.
4. Make a vertical mark which intersects the horizontal mark on the aiming surface directly in front of
the headlight.
5. Engage the brake lever lock and start the engine.
Move the headlight dimmer switch to the HIGH
beam position. DO NOT USE LOW BEAM.
6. Observe the headlight beam aim. Proper aim is
when the most intense beam is centered on the vertical mark 5 cm (2 in.) below the horizontal mark
on the aiming surface.
0744-068
Rear Suspension Style
129 in. Track @ 20 lb
Setup
Tension
After Break-In
Tension
35-41 mm
(1 3/8-1 5/8 in.)
38-44 mm
(1 1/2-1 3/4 in.)
3. Using Axle Nut Spanner Wrench (p/n 0644-558)
from the tool kit, loosen the right-side rear axle nut.
0745-813
7. Adjust the headlight adjustment knobs until correct aim is obtained. Shut the engine off; then disengage the brake lever lock.
Track Tension/Track Alignment
CAUTION
Track tension has been initially adjusted at the factory
for “run-up testing”; however, track tension (and track
alignment) must be adjusted at the dealership according to the following recommendations.
To adjust track tension/track alignment, use the following procedure.
1. Elevate the snowmobile on a shielded safety stand
high enough to use a spring scale.
! WARNING
The tips of the skis must be positioned against a wall
or similar object for safety.
2. At mid-point of the track (on the bottom side),
hook a spring scale around a track clip; then pull
down on the scale to 9 kg (20 lb). Measure the
deflection (distance) between the bottom of the
wear strip and the inside surface of the track clip.
Compare the measurement with the chart.
0744-067
NOTE: Always loosen the right-side rear axle nut
when adjusting track tension/alignment. The leftside rear axle nut is secured with green Loctite
#609 and should not be loosened or removed.
4. If the distance between the bottom of the wear
strip and the inside surface of the track clip
exceeds specifications, tighten the adjusting bolts.
If the distance between the bottom of the wear
strip and inside surface of the track clip is less than
specified, loosen the adjusting bolts.
5. When proper track deflection is attained, loosen
the right-side rear axle nut just enough to apply
blue Loctite #243 to the axle threads; then tighten
the nut to 40-45 ft-lb.
CAUTION
Make certain the right-side rear axle nut is tightened
or component damage will occur.
21
6. Start the engine and accelerate slightly. Use only
enough throttle to turn the track several revolutions. Shut engine off.
! WARNING
DO NOT stand behind the snowmobile or near the
rotating track. NEVER run the track at high speed
when the track is suspended.
NOTE: Allow the track to coast to a stop. Do not
apply the brake because it could produce an inaccurate alignment condition.
7. When the track stops rotating, check the relationship
of the rear idler wheels and the inner track drive lugs.
If the rear idler wheels are centered between the inner
track drive lugs, no adjustment is necessary.
9. Loosen the right-side rear axle nut; then on the
side of the track which has the inner track drive
lugs closer to the rear idler wheel, rotate the
adjusting bolt clockwise 1-1 1/2 turns.
10. Check track alignment and make necessary adjustments until proper alignment is obtained.
NOTE: Make sure correct track tension is maintained after adjusting track alignment.
11. Loosen the right-side rear axle nut just enough to
apply blue Loctite #243 to the axle threads; then
tighten the nut to 40-45 ft-lb.
! WARNING
If the axle nut is not tightened, the adjusting bolts could
loosen causing the track to ratchet, derail, or lock.
Test Ride
Test ride the snowmobile 5 to 10 minutes. During and
after the test ride, do the following:
1. Burnish the brake pads by driving the snowmobile
slowly and compressing the brake lever repeatedly
until the pads just start to heat up; then allow them
to cool down. This process stabilizes the pad material and extends the life of the pads.
2. Allow the engine to cool; then visually check coolant level. Add coolant as necessary.
0740-118
8. If the idler wheels are not centered between the
inner track drive lugs, adjust track alignment.
! WARNING
Make sure the ignition switch is in the OFF position
and the track is not rotating before checking or adjusting the track alignment.
22
3. Recheck track alignment and tension.
4. Check the engine compartment and underneath the
snowmobile for any signs of fluid leaks (gas, coolant).
General Information
2. While holding the cable housing, lightly pull on
one cable end to remove slack.
3. Measure the amount of exposed cable from the
cable housing to the end of the cable.
Control Locations
0746-486
Arctic Power Valve (APV) System
This RPM and exhaust pipe temperature controlled
servomotor (servo) actuation system adjusts the size of
the exhaust ports to provide peak performance
throughout the RPM range.
At low RPM, the exhaust valves are held in the
DOWN position by return springs. This gives the
engine a “low port” exhaust design calibrated to provide maximum low RPM power.
0735-516
4. Repeat steps 2 and 3 on the other cable; then compare the measurements.
NOTE: Measurements must be within a range of
36.5 mm ± 1 mm.
NOTE: The measurements must be equal and
within the specifications. If the measurements are
within specifications, no adjustment is necessary.
If they are not within specifications, proceed to
step 5.
5. Loosen the jam nut on the cable adjuster to be
adjusted; then using the adjusting nuts, lengthen or
shorten the housing as needed.
6. While holding the adjusting nut in place, tighten
the jam nut securely.
7. Install the actuating cables to the servo.
739-152A
At high RPM, the exhaust valves are raised. This creates a “high port” exhaust design calibrated to provide
maximum performance at high RPM.
CAUTION
If excessive adjustment is required to attain synchronization, the entire adjustment procedure should be
repeated.
Exhaust Controlled Timing (ECT)
System
This system automatically adjusts the ignition timing
to provide maximum performance through a variety of
operating conditions. The ECM unit receives input on
engine RPM (demand) and exhaust pipe temperature
(engine condition) and adjusts the ignition timing
accordingly. This system is not adjustable and is maintenance free.
739-152B
To adjust the APV system, use the following procedure:
If a system fault is suspected, disconnect the exhaust
pipe temperature sensor; then use an ohmmeter to
check continuity of the exhaust pipe temperature sensor located in the expansion chamber. A reading of
either 0 ohm or infinity indicates a failed sensor.
1. Remove the actuating cables from the servo.
23
NOTE: A disabled ECT system WILL NOT cause
engine damage; however, a failed ECT system will
have slower throttle response and may produce
slightly less top-end performance.
NOTE: Do not adjust the handlebar to a position
that allows the brake fluid to be below the low
mark on either side of the master cylinder.
! WARNING
Testing Exhaust Temperature
Sensor
1. Disconnect the sensor harness; then remove the
sensor from the exhaust pipe.
2. Suspend the sensor (only up to the threads) in a
container filled with automatic transmission oil;
then slowly heat the oil on a hot plate.
3. Using a fluid thermometer, closely monitor the oil
temperature, and using a digital multimeter with
the leads connected to the sensor leads, observe
the resistance reading.
4. The resistance must be within the temperature
range (see chart).
Exhaust Temperature Sensor
°F
°C
ohms
77
25
219.6
122
50
238.5
212
100
275.9
302
150
312.7
5. If the resistance and temperature are not within
specifications, replace the sensor.
NOTE: Before replacing the sensor, repeat the
test to confirm results.
Handlebar Tilt
The handlebar can be adjusted to the operator’s preference. To adjust the handlebar, use the following procedure:
1. Loosen the eight cap screws securing the handlebar
caps to the riser and the riser to the steering post.
Tighten cap screws according to specifications to prevent unexpected “fold-down” of the handlebar during
operation over rough terrain. DO NOT offset the handlebar so steering capabilities are altered or throttle
and brake controls will be affected.
Rear Bumper
The rear bumper can be removed and replaced. To remove/
install a rear bumper, use the following procedure.
1. On the inside of the tunnel, drill out all rivets and
remove both screws and nuts securing the rear
bumper to both sides of the tunnel.
2. Remove the existing bumper and install the new
one aligning the holes with the holes in the brackets; then rivet the rear bumper to both sides of the
tunnel. Secure the front of the bumper using the
existing machine screws and nuts.
Exhaust System
The exhaust system is designed to reduce noise and to
improve the total performance of the engine. If any
exhaust system component is removed from the engine
and the engine is run, severe engine damage will result.
Liquid Cooling System
The cooling system should be inspected daily for leakage and damage. Also, the coolant level should be
checked daily. If leakage or damage is detected and the
operator does not feel qualified to service the cooling
system, see an authorized Arctic Cat Snowmobile
dealer for this service.
When filling the cooling system, use a coolant/water
mixture which will satisfy the coldest anticipated
weather conditions of your area in accordance with the
coolant manufacturer’s recommendations. While the
cooling system is being filled, air pockets may
develop; therefore, fill the bottle and run the engine for
five to ten minutes after the initial fill (until the thermostat opens); then add more coolant if necessary. Fill
the coolant tank and take the snowmobile for a test
ride. Let the engine cool down; then recheck the coolant level and add if necessary.
NOTE: Use a good quality, glycol-based, automotive-type antifreeze.
CAUTION
SNO-2236
2. Adjust the handlebar up or down to operator’s
desired tilt, tighten the cap screws evenly to 15 ftlb, and check steering for maximum right/left turning capabilities.
24
After operating the snowmobile for the initial 5-10 minutes, stop the engine, allow the engine to cool down,
and check the coolant level. Add coolant as necessary.
Drive Clutch And Driven Clutch
Shock Absorbers
The drive clutch and driven clutch do not require lubrication; therefore, no special maintenance is required
by the snowmobile owner. However, the drive clutch
and driven clutch should be disassembled, cleaned,
and inspected before each race.
Each shock absorber should be visibly checked daily for
excessive fluid leakage, cracks or breaks in the lower
case, a bent plunger, and wear or leakage in the hoses. If
any one of these conditions is detected, replacement is
necessary. If the operator does not feel qualified to service or replace shock absorbers, see an authorized Arctic Cat Snowmobile dealer for this service.
NOTE: A small amount of grease should be
applied to the driven shaft before installing the
driven clutch.
When operating the snowmobile at high altitudes, it
may be necessary to change certain component parts
of the drive clutch. If the operator does not feel qualified to change clutch components, see an authorized
Arctic Cat Snowmobile dealer for this service.
CAUTION
Use Clutch Puller (p/n 0744-062). Never substitute a
different puller or drive clutch damage will occur.
Drive Clutch/Driven Clutch
Alignment
The parallelism and the offset between the drive clutch
and driven clutch are set at the factory. Normally, no
adjustment is necessary as long as neither the drive
clutch nor the driven clutch is removed or disassembled. However, if premature drive belt wear is experienced or if the drive belt turns over, the drive clutch/
driven clutch alignment must be checked. If the operator does not feel qualified to align the clutch/clutch,
see an authorized Arctic Cat Snowmobile dealer for
this service.
Track Studs
NOTE: The track on this snowmobile is not
equipped with studs. For additional information,
see the 2015 POGA Reference Guide.
The decision to install studs should be made only after
reviewing the International Snowmobile Racing, Inc.
regulations as they pertain to the type of racing you
participate in. Arctic Cat has a variety of studding
products available from your authorized Arctic Cat
Snowmobile dealer.
Towing
If this snowmobile is to be towed by another snowmobile, do not tow using the loops in the skis. The tow
rope should be attached to the lower A-arms.
25
Operating Instructions
Starting And Stopping Engine
It is imperative that the hydraulic brake system be
checked for wear and proper operation and that all
safety checks found in the accompanying Snowmobile
Safety Handbook be performed before attempting to
start the engine. After the engine has been started,
check the headlights (high and low beam), taillight,
and brakelight to be sure they are working properly
and adjusted correctly. Make sure all lights are clean to
provide maximum illumination. The headlight and
taillight must be clean and must be illuminated whenever the engine is running.
1. Test the operation of the hydraulic brake system
by compressing the brake lever. The brake lever
must feel firm when compressed; then while holding the brake lever in the compressed position,
measure the distance between the brake lever and
the handlebar. The distance must be greater than
2.54 cm (1 in.).
! WARNING
Do not start the engine if the brake system is not functioning properly (if the lever feels spongy, if the brake
lever can be compressed to within 2.54 cm (1 in.) of
the handlebar, or if the brake fluid level is not correct).
Service the brake system or have it properly repaired
prior to operating the snowmobile. Serious personal
injury or even death may occur if the brake system is
not operating properly.
3. Test the throttle control lever by completely compressing and releasing it several times. The lever
MUST return to the idle position quickly and completely.
CAUTION
Always check the coolant level before starting the
engine.
4. Move the emergency stop switch to the RUN position.
5. Assure that the tether switch cap is secured to the
tether switch.
7. Pull the recoil handle slowly until resistance is
felt; then give a short quick pull. Repeat until the
engine starts.
CAUTION
To avoid damaging the recoil starter, DO NOT pull the
recoil rope to its limit or release the recoil handle from
an extended position. Allow the rope to rewind slowly.
CAUTION
0745-816
2. Check the brake fluid level in the master cylinder
reservoir. The brake fluid level must be just below
the high mark on the master cylinder reservoir.
Add Arctic Cat approved brake fluid as necessary.
It is extremely important that the engine is properly
warmed up before subjecting the engine to high speed
operation or heavy loads. Do not idle the engine for
excessively long periods of time. The engine should
be allowed to idle at least 1-2 minutes before it is operated at more than 1/2 throttle. In extremely cold conditions, the warm-up time will be longer. Cold seizure
and piston scuffing caused by insufficient warm-up
will not be covered by warranty. Also, do not idle the
engine for excessively long periods of time.
8. To shut off the engine, either depress the emergency stop switch to the OFF position or pull the
tether switch cap off the tether switch.
Braking
Operating a snowmobile with hydraulic brakes is different from operating a snowmobile with mechanical
brakes. The following items are items that the operator
must be familiar with when operating this snowmobile
and its hydraulic brake system.
SNO-253
26
NOTE: Important additional information on the
proper maintenance of the brake system is found
in the maintenance section of this manual.
1. Use the brakes wisely. Each time the brakes are
applied in all hydraulic brake systems (including
automotive applications), heat is transferred to the
brake fluid. The amount of heat transferred during
high speed stops and/or repetitive use may be high
enough to boil the brake fluid and cause the brakes
to either fade or may cause an unexpected loss of
brakes. If this occurs, the brake fluid requires a cool
down period before the brakes will again function
properly. This cool down period will vary depending
upon the ambient air temperature and the temperature of the brake fluid. If loss of brakes has occurred
because of high fluid temperatures, do not operate
the snowmobile until the cool down period has
expired and brake lever firmness has returned.
! WARNING
Excessive repetitive use of the hydraulic brake for
high speed stops will cause overheating of the brake
fluid and premature brake pad wear which will result
in an unexpected loss of brakes.
2. Be sure to maintain the brake fluid at the proper
level and take care not to get any moisture in the system as moisture in the brake fluid lowers the boiling
point. If the brake fluid is ever boiled (by high speed
stops or repetitive use) or if moisture is allowed to
enter the system, it must be changed. Never substitute or mix different types or grades of brake fluid.
! WARNING
Use only Arctic Cat approved brake fluid. Never substitute or mix different types or grades of brake fluid.
Brake loss can result. Check brake fluid level and pad
wear before each use. Brake loss can result in severe
injury or even death.
3. Never ride the brake. Even maintaining minimal
pressure on the brake lever will cause the brake
pads to drag on the disc and may overheat the
brake fluid.
4. The brake lever lock is not a parking brake and
should not be applied for periods exceeding 5 minutes. NEVER OPERATE THE SNOWMOBILE
WITH THE BRAKE LEVER LOCK ENGAGED.
! WARNING
The brake lever lock is not a parking brake and should
not be applied for periods exceeding 5 minutes. The
brake lever lock maintains the brake lever in the compressed position and maintains pressure against the
brake disc; however, after a period of time, the pressure applied to the brake disc may relax below the
amount required to hold the snowmobile stationary.
5. Pumping the brake lever is permissible but not acceptable on a snowmobile designed for racing; therefore,
if pumping the brake lever more than twice is necessary to obtain the necessary stopping power, the system must be serviced. If the operator does not feel
qualified to service the brake system, see an authorized Arctic Cat Snowmobile dealer for this service.
6. When new brake pads are installed, a “burnishing”
process is required. Drive the snowmobile slowly
and compress the brake lever several times until
the pads just start to heat up; then allow them to
thoroughly cool down. This process stabilizes the
pad material and extends the life of the pads.
Emergency Stopping
There are several methods of stopping or slowing the
snowmobile under a variety of situations. Identified in
the following chart are the ways a snowmobile may be
brought to a stop and the effectiveness under normal
conditions.
ITEM
FUNCTION
CONDITION
Emergency Stop Switch
interrupts ignition circuit
ALL
Tether Switch
interrupts ignition circuit
ALL
slows the driveshaft
ALL
Brake
! WARNING
If any malfunction of the throttle system occurs (such
as freezing in fluffy snow) and the engine does not idle
down, use the emergency stop switch or disconnect
the tether switch IMMEDIATELY to stop the engine. DO
NOT start the engine until the malfunction in the throttle system has been located and corrected.
! WARNING
If the throttle control lever does not work properly, DO
NOT ATTEMPT TO START THE ENGINE.
27
NOTE: If excessive oil deposits are observed, the
chain case must be serviced. Also, when the oil level
is at the add mark, approximately 2 fl oz of transmission lube must be added to the chain case.
Lubrication
Chain Case
The recommended amount of synthetic chain lube in
the chain case is 15 fl oz. Adding more transmission
lube to the chain case (above the recommended
amount) may result in leakage. To check the transmission lube level, use the following procedure:
NOTE: The snowmobile must be on a level surface
for this procedure.
Check chain case lube level using the chain case sight
glass at the right-side footrest. If the lube is at least
halfway up the sight glass, the level is correct.
CAUTION
The correct lubricant to use in the chain case is Arctic
Cat Synthetic Chain Lube (p/n 5639-038). Any substitute may cause premature chain failure or serious
damage to the chain drive system.
Rear Suspension
1. With the gas tank nearly empty (less than 1/4 full),
lay the snowmobile on its side. A piece of cardboard should be used to protect the finish on the
hood and belly pan.
NOTE: Prior to tipping the snowmobile on its
side, apply the brake and set the brake lever lock.
2. Lubricate the grease fittings with an all-temperature grease.
0746-115
3. If the lubricant level is above the add mark, the
lubricant level is satisfactory. If the lubricant level
is below the add mark, proceed to step 4.
4. If oil is low, add transmission lube by removing the
oil fill plug.
0746-474
0746-475
0746-471
28
Maintenance
The longevity and safety of the snowmobile can be increased by making periodic checks of the items in the following checklist. Perform maintenance checks more often if the snowmobile is used under severe conditions.
Periodic Maintenance Checklist
EVERY
RACE
EVERY
1 ½ - 2 HRS
EVERY
3 RACES
EVERY
4 ¼ - 6 HRS
EVERY
5 RACES
EVERY
7 ½ - 10 HRS
Spark Plugs
Spark Plug End Caps
Drive Belt
Cooling System
Chain Case Lubricant
Drive Chain/Sprockets
Chain Tensioner
I
I
I
I
I
I
I
R*
I
I
I
R
I
I
I
R
R
I
I
I
I
Brake Fluid
Brake Pads
Throttle Cable/Lever
Fuel Hoses
APV Cables
I
I
I
I
I
R
I
I
I
I
I
I
I
I
I
Exhaust Valves
Exhaust System
Pistons/Rings
Reed Valves
Front Suspension
Steering
—
I
—
I
I
—
I
I
I
I
—
I
R
I
I
I
Rear Suspension
I
I
I
Shock Oil
—
—
—
Track
Wear Strips
Drive Clutch
Driven Clutch
Recoil Rope/Handle
Skis and Wear Bars
Cap Screws/Nuts
I
I
I
I
I
I
T
I
I
I
I
I
I
T
I
I
I
I
I
I
T
INTERVAL
SERVICE ITEM HRS
REMARKS
Check for condition and heat range.
Check for secure connection.
Check for proper deflection, burn spots/wear.
Replace coolant and engine coolant hoses every year.
Change after break-in period.
Inspect for broken/stretched links.
Inspect for worn or damaged components. Check and retighten
sprocket cap screws.
Replace brake hose every year.
Inspect for wear.
Inspect for proper adjustment and wear.
Inspect for wear and pinching. Replace yearly.
Readjust after break-in period. Check for proper adjustment,
wear, routing.
Check for cracks and missing springs.
Replace yearly.
Apply grease to bellcrank fittings. Inspect for damaged parts.
Inspect ski alignment. Check for damaged or worn
components. Apply grease to bell crank fittings and steering
bearing.
Inspect for damaged or worn components. Apply grease to
fittings.
Change oil at end of normal race season (10-12 races). If a
long race season is planned, change oil mid-season and at end
of season.
Inspect for proper tension/alignment.
Inspect for wear/damage.
Inspect surfaces for belt build-up and glazing.
Inspect for glazing.
Inspect rope for fraying/handle for cracks.
Check condition and alignment.
Tighten to torque specifications (if applicable).
R= Replace, T=Tighten, I = Inspect and clean, adjust, or replace if necessary
* For optimum performance
29
Pre-Race/Practice Checklist
PRE-RACE/PRACTICE CHECKLIST
WHAT TO
CHECK
Spark Plugs
1.
2.
Coolant
1.
Chain Case Oil 1.
Drive Chain
1.
Drive Clutch/
1.
Driven Clutch
2.
Drive Belt
1.
2.
3.
4.
Brake
1.
2.
3.
Brake Pads
1.
Throttle
1.
2.
APV System
1.
2.
Exhaust
1.
2.
Steering
1.
2.
Track
1.
2.
Suspension
1.
2.
3.
Shock
1.
Absorbers
2.
3.
4.
Gas Tank
1.
2.
3.
Fuel Lines
1.
2.
Cap Screws
1.
Nuts
Lights and
1.
Tether
Snowflap
1.
Skid Plate
1.
CHECK FOR
Tightness and loose end caps
High tension wires
Proper level
Proper level
Adjusted to proper tension
Clean sheaves
Smooth operation
Wear
Delamination
Within specifications
Proper deflection
Brake lever condition and movement
Fluid level
Operation of system
Wear
Proper cable routing and adjustment
Smooth operation
Proper cable routing and adjustment
Proper operation
Properly secured
Missing springs
Smoothness
Proper ski alignment
Tension
Alignment
Smooth operation
Loose or damaged components
Spring pre-load adjustment
Leakage
Component damage
Proper calibration/air pressure
Properly routed and secured hose
Secured properly
Leakage
Proper fuel level
Contact wear
Pinching
Tighten to torque specifications
(if applicable)
This engine sub-section has been organized to show a
progression for the removing/installing of the Arctic Cat
6000 engine. For consistency purposes, this sub-section
shows a complete and thorough progression; however,
for efficiency it may be preferable to remove only those
components needing to be addressed. Also, some components may vary from model to model. The technician
should use discretion and sound judgment.
SPECIAL TOOLS
A number of special tools must be available to the technician
when performing service procedures in this engine section.
Description
Drive Clutch Bolt Tool
Drive Clutch Puller
Drive Clutch Spanner Wrench
Hood Harness Extension
p/n
0644-281
0744-062
0644-136
1686-659
NOTE: Special tools are available from the Arctic
Cat Service Parts Department.
CAUTION
Never attempt to substitute any other drive clutch puller
for the recommended puller or severe clutch or crankshaft damage will occur.
Removing
NOTE: For assembling purposes, note cable tie locations securing the harness and cables to the chassis.
NOTE: Prior to removing the engine, disconnect the
hood harness and remove the side access panels; then
remove the screws securing the hood to the chassis.
Proper operation (including brakelight)
Restraints
Lower belly pan for holes or tears
If, at any time, abnormal noises, vibrations, or
improper working conditions of any component of this
snowmobile are detected, DO NOT OPERATE THE
SNOWMOBILE. Immediately diagnose and repair
any component. If the operator does not feel qualified
to service the suspension, see an authorized Arctic Cat
Snowmobile dealer for this service.
30
Engine
0746-793A
1. Carefully remove the exhaust temperature sensor
from the expansion chamber.
2. Remove all springs securing the expansion chamber
and resonator; then remove the expansion chamber
and resonator.
3. Remove the torx screw from the driven clutch and
slide the driven clutch (along with the drive belt) off
the driven shaft. Account for alignment washers.
4. Using Drive Clutch Bolt Tool, remove the torx-head
screw and high-collar washer securing the drive
clutch to the crankshaft.
5. Using Drive Clutch Puller and Drive Clutch Spanner
Wrench, tighten the puller. Remove the drive clutch.
NOTE: If the drive clutch will not release, sharply
strike the head of the puller. Repeat this step until the
clutch releases.
6. Remove the two screws (A) securing the heat shield
to the chassis; then remove the heat shield from the
two front locating pins (B) and remove the heat
shield.
EL-004A
10. Slide each cable end out of the slot of the clutch; then
disconnect the harness from the servomotor.
11. Remove the cap screws and lock nuts securing the
shock mount bracket support to the shock mount
brackets; then remove the shock mount bracket support.
EL-001A
7. Disconnect the ECM; then remove the screws securing the right- and left-side fascia panels to the chassis. Remove the panels and ECM as an assembly.
EL-003A
12. Remove idle speed control (ISC) hoses (A) from the
top of the throttle bodies; then disconnect the ISC
from the main harness (B). Remove the screws (C)
securing the ISC; then remove the ISC.
EL-002A
8. Remove the cap screws securing the PTO-side front
spar to the steering support and shock mount bracket;
then remove the spar.
NOTE: Take care to not drop the spar inserts and
nuts when removing the spar.
9. Using a small needle-nose pliers, remove the servomotor cable holder; then pull the cable housings
down and out of the servomotor.
EL-006A
13. Loosen the four clamps securing the throttle body;
then lift up the throttle body and disconnect the coolant hoses. Set the throttle body up and out of the way.
14. Remove the intake boot from the chassis.
15. Remove all three oil hoses from the front of the
engine.
31
16. Loosen the clamp securing the gasline hose to the
throttle body and remove the hose; then close-off the
hose and secure the hose up and out of the way.
! WARNING
The hose may be under pressure; remove it slowly to
release the pressure. Place an absorbent towel around
the connection to absorb gas.
17. Remove the main harness wrap and disconnect the
six harness connectors. Secure the harness up and
out of the way.
18. Remove the recoil starter from the engine. Secure it
out of the way.
19. Remove the cap screws securing the MAG-side
engine mount to the engine.
20. Remove the spark plug caps from the spark plugs;
then disconnect the knock sensor and coolant temperature sensor connectors. Remove the cylinder
head vent hose.
PC178A
22. Remove the four screws securing the PTO-side
engine mounting plate to the engine.
NOTE: Before removing the cap screws, apply a
sufficient amount of heat to the cap screws to soften
the Loctite.
23. Remove the cap screw and two lock nuts securing
the engine support plate to the chassis; then lift the
engine out of the engine compartment.
NOTE: If replacing the engine, make sure to remove
the engine support plate, exhaust manifold, and three
coolant hoses for installation on the new engine.
CWI-092
21. Disconnect the lower coolant hose from the front
heat exchanger; then remove the coolant hose from
the heat exchanger at the rear of the engine.
This engine sub-section has been organized to show a
progression for servicing of the Arctic Cat 6000 engine.
For consistency purposes, this sub-section shows a complete and thorough progression; however, for efficiency it
may be preferable to disassemble only those components
needing to be addressed. Also, some components may
vary from model to model. The technician should use
discretion and sound judgment.
SPECIAL TOOLS
when performing service procedures in this engine section.
Description
PC141A
Ball Hone
Flywheel Spanner Wrench
Flywheel Puller
Flywheel Puller Insert
Extractor Nut (Medium)
Oil Seal Protector Tool
Piston Pin Puller
Surface Plate
Water Pump Bearing and Seal Tool Kit
V Blocks
Vacuum Test Pump
p/n
0644-294
0144-007
0744-040
0644-568
0643-074
0644-219
0644-328
0644-016
0644-557
0644-535
0644-131
Disassembling
NOTE: When disassembling top-side components,
mark MAG-side and PTO-side components for assembling purposes.
32
1. Using the Flywheel Spanner Wrench to secure the
flywheel, remove the flywheel cap screw and
washer; then remove the cap screws securing the
recoil cup.
CWI-074A
6. Remove the screws securing the stator to the stator
plate. Route the stator lead wire out of the crankcase;
then remove the stator assembly.
CWI-070
2. Install the Flywheel Puller Insert onto the end of the
crankshaft.
CWI-072
3. Using Flywheel Puller or suitable substitute, remove
the flywheel from the crankshaft by tightening the
puller bolt using an pneumatic gun. Account for the
key.
7. Remove the screws securing the stator plate to the
engine; then remove the plate.
CWI-005A
NOTE: For assembling purposes, note the indentation (A) of the stator plate is aligned with the harness
opening (B) in the crankcase.
CAUTION
To prevent damage to the crankshaft, do not thread
puller bolts more than 1/2 in. into the flywheel. Damage
to the stator may result.
NOTE: To ensure the cleanliness of the flywheel
magnets, place the flywheel (with the magnets facing
upward) on a clean bench.
4. Remove the cap screw securing the ground wire to
the crankcase.
5. Remove the screw (A) securing the stator lead wire
plate to the crankcase; then remove the screws (B)
securing the timing sensors and bracket, remove the
sensors, and account for the harness grommets.
CWI-005B
NOTE: The stator plate screws have Loctite applied
to the threads during assembly. Using an impact
driver, apply a sharp blow to the head of each screw
to break the Loctite loose before removal.
8. Remove the cap screws securing the APV assemblies
to the cylinders; then remove the APV assemblies
and set them aside. Account for all four dowel pins
and make sure the pins do not fall into the engine.
33
CWI-006A
CWI-011A
9. Disconnect the coolant hose from the back of the cylinder head.
12. Remove the eight nuts securing the cylinders to the
crankcase; then using a soft hammer, gently tap the
cylinders and remove from the crankcase by lifting
them straight up off their studs. Account for a gasket
and alignment pins.
10. Remove the cap screws with O-rings securing the
cylinder head (in the order shown); then separate the
head from the cylinders. Account for the O-rings on
top of the cylinders.
CAUTION
When removing a cylinder, be sure to support the piston
to prevent damage to the crankcase and piston.
CWI-009
CWI-012
13. Remove the PTO-side piston-pin circlip from the
PTO-side piston; then remove the MAG-side pistonpin circlip from the MAG-side piston.
CWI-010
11. Remove the four nuts securing the fuel rail to the
back of the cylinders; then remove the fuel rail and
injectors as an assembly. Account for all gaskets.
CWI-013A
14. Using Piston Pin Puller and medium Extractor Nut,
remove the piston pins from both pistons.
NOTE: For proper assembly, keep all MAG-side
components and all PTO-side components separated. Assemble them on their proper sides.
34
CWI-081
CWI-014
CAUTION
DO NOT use any type of punch to drive the piston pin
free of the piston; damage may result. Use a piston-pin
puller only.
17. Remove the four screws securing the thermostat cap;
then remove the cap, gasket, and thermostat.
15. Lift the pistons clear of the connecting rods and
remove the small-end connecting-rod bearings; then
remove the piston rings. Keep each piston with its
rings; keep each piston pin and bearing together as a
set.
CWI-017
NOTE: For assembling purposes, note that the
bypass/check valve is directed up.
CWI-015
16. Remove the screws securing the intake flanges.
Remove the intake manifolds and reed valve assemblies.
CWI-018A
18. Remove the seven screws securing the water pump
cover to the crankcase and remove the cover.
Account for the O-ring gasket and the alignment
pins.
CWI-020
35
CWI-016A
CWI-023A
19. Remove the cap screw securing the impeller. Account
for the rubber washer and gasket behind the cap screw.
Remove the impeller from the shaft.
21. Tip the crankcase assembly up onto the water pump
side; then remove the black torx-screw from the bottom of the crankcase and tip down and drain the
injection oil from the center cavity into a container.
CWI-082
20. Prior to turning the engine upside down, remove the
two crankcase torx screws (A) from the water pump
side of the engine; then remove the two cap screws
(B) from the magneto housing.
CWI-023A
22. With the bottom side up on two support blocks,
remove the cap screws securing the crankcase
halves.
NOTE: Remove the cap screws in order from #10 to
#1. The numbers are embossed next to each cap
screw.
CWI-075A
CWI-024
23. With all screws removed, carefully separate the
crankcase halves in locations shown below only.
36
CWI-076
FC036
CAUTION
28. Using a pair of snap ring pliers, remove the snap ring
securing the inner seal in the crankcase.
DO NOT drive any tool between halves (sealing surface)
to separate the crankcase. Damage to the sealing surfaces will result.
29. Using the hooked end of the tool, pull the inner seal
free of the crankcase.
24. Lift the bottom half of the crankcase off the top half.
30. Using the hooked end of the tool, pry the seal ring
from the backside of the water pump impeller.
CAUTION
Care must be taken to not allow the connecting rods to
drop onto the sealing surface of the bottom case half.
25. Lift the crankshaft free from the top half of the
crankcase and slide the crankshaft bearings and oil
seals off the crankshaft. Account for the C-ring (A).
Remove the bearing retaining pins (B) and account
for the crankcase dowel pins (C).
AN327D
Cleaning and Inspecting
CYLINDER HEAD
CWI-027A
1. Using a non-metallic carbon removal tool, remove
any carbon buildup from the combustion chambers
being careful not to nick, scrape, or damage the combustion chambers or the sealing surfaces.
26. Remove the water pump driveshaft from the lower
crankcase half. Account for the thrust washer on the
outer end of the shaft.
2. Inspect the spark-plug holes for any damaged
threads.
NOTE: When replacing the inner water pump seals,
NOTE: If warpage is suspected, have a qualified
use the recommended Water Pump Bearing and Seal
Tool Kit only.
machine shop inspect and repair if necessary.
27. Place the lower crankcase on the bench with the
water pump side down. Using the long seal driver,
drive the mechanical water pump seal from the
crankcase.
3. Place the cylinder head on a Surface Plate covered with
#400 grit wet-or-dry sandpaper. Using light pressure,
move each cylinder head in a figure eight motion.
Inspect the sealing surface for any indication of high
spots. A high spot can be noted by a bright metallic finish. Correct any high spots before assembly by continuing to move the cylinder head in a figure eight motion
until a uniform bright metallic finish is attained.
CAUTION
Water or parts-cleaning solvent must be used in conjunction with the wet-or-dry sandpaper or damage to
the sealing surface may result.
37
CYLINDERS
3. Inspect the cylinders for pitting, scoring, scuffing,
and corrosion. If marks are found, repair the surface
with the Ball Hone and honing oil.
6. Inspect the sealing surfaces of the crankcase halves
for trueness by placing each crankcase half on the
surface plate covered with #400 grit wet-or-dry sandpaper. Using light pressure, move each half in a figure eight motion. Inspect the sealing surfaces for any
indication of high spots. A high spot can be noted by
a bright metallic finish. Correct any high spots by
continuing to move the half in a figure eight motion
until a uniform bright metallic finish is attained.
NOTE: To produce the proper 45° crosshatch pat-
NOTE: Care must be taken not to remove an exces-
tern, maintain a low drill RPM. If honing oil is not
available, use a lightweight, petroleum-based oil.
Thoroughly clean the cylinders after honing using
detergent soap and hot water and dry with compressed air; then immediately apply oil to the cylinder
bores. If a bore is severely damaged or gouged, the
cylinder must be replaced or replated.
sive amount of aluminum, or the crankcase must be
replaced. If excessive aluminum is removed, too
much pre-load will be exerted on the crankshaft bearings when assembled.
carbon buildup from the exhaust ports.
2. Wash the cylinders in parts-cleaning solvent.
4. Place the head surface of each cylinder on the surface plate covered with #400 grit wet-or-dry sandpaper. Using light pressure, move each cylinder in a
figure eight motion. Inspect the surface for any indication of high spots. A high spot can be noted by a
bright metallic finish. Correct any high spots before
assembly by continuing to move the cylinder in a figure eight motion until a uniform bright metallic finish is attained.
CAUTION
PISTON
CAUTION
CRANKSHAFT
NOTE: If any servicing of the connecting rods, center bearings, or water pump drive gear is necessary,
Arctic Cat recommends the crankshaft be taken to a
qualified crankshaft rebuild shop for that service.
1. Wash the crankshaft with bearings in parts-cleaning
solvent.
2. Inspect the bearings for wear, scoring, scuffing, damage, or discoloration. Rotate the bearings. Bearings
must rotate freely and must not bind or feel rough. If
any abnormal condition is noted, replace the bearing.
the carbon buildup from the dome of each piston.
CRANKCASE
1. Scrape of any residual silicone from both the top and
bottom crankcase halves making sure not to damage
the sealing surface; then wash the crankcase halves
in parts-cleaning solvent.
NOTE: Before washing the crankcase halves, make
sure the four bearing dowel pins have been removed
and accounted for.
2. Inspect the crankcase halves for scoring, pitting,
scuffing, or any imperfections in the casting.
3. Inspect all threaded areas for damaged or stripped
threads.
4. Inspect the bearing areas for cracks or excessive
bearing movement. If evidence of excessive bearing
movement is noted, the crankcase must be replaced.
5. Inspect the bearing dowel pins for wear.
38
CWI-060
3. Inspect the connecting-rod bearings by rotating
them. The bearings must rotate freely and must not
bind or feel rough. If a connecting-rod bearing must
be replaced, the connecting rod and crank pin must
also be replaced.
CWI-058
4. Visually inspect the springs to make sure they are in
proper location on the seals.
IO019B
REED VALVE ASSEMBLY
1. Carefully pry the reed assemblies from the intake
manifold and inspect the reed valves for cracks or
any deterioration; then remove the screws securing
the reeds.
CWI-083A
5. Inspect the water pump drive gear for any signs of
worn or chipped teeth. If either condition exists,
replace the gear.
NOTE: Lubricate bearings thoroughly prior to
assembly.
REMOVING/INSTALLING OUTER
CRANKSHAFT BEARINGS
NOTE: The end bearings are not pressed onto the
crankshaft. The bearings can be removed simply by
sliding them off the crankshaft.
CWI-084
2. To assemble, place the reed retaining plate (with the lip
facing outward) into position and secure with the screws
tightened to 8.5 in.-lb.
NOTE: When installing the outer reed valves, be
sure the clipped edge matches the clipped edge of
the reed retaining plate.
Inspect the crankshaft bearing area for wear. If any wear
is noted on either end, replace the crankshaft end.
NOTE: Install the bearings by sliding each bearing
onto the crankshaft making sure the retaining pin
hole (A) in the outer race of the bearing is properly
positioned and will align with the retaining pin (B) in
the crankcase.
CWI-110
3. Install the reed valve assemblies into the intake manifold by installing the top and bottom sides of the reeds
first; then press down making sure the reeds are
installed flush with the intake manifold.
39
CWI-055
CWI-080
2. Position a bore gauge between the micrometer points
and move it from top to bottom and side to side to
find zero; then adjust the gauge to zero.
CWI-056
Measuring Critical
Components
CWI-090
CYLINDER TRUENESS
1. Measure each cylinder in locations from front to back
and side to side top and bottom of the cylinder for a
total of four readings.
CWI-089
3. Place the bore gauge in the cylinder and measure
each cylinder in locations from front to back and side
to side top and bottom of the cylinder for a total of
four readings. The difference (clearance) must be
within 0.0031-0.0041 in.
CWI-077
2. The trueness (out-of-roundness) is the difference
between the highest and lowest reading. Maximum
trueness (out-of-roundness) must not exceed 0.004 in.
PISTON SKIRT/CYLINDER
CLEARANCE
1. Measure the piston skirt diameter 10 mm from the
bottom of the piston (just below the slot). Once the
measurement is final, lock the micrometer.
CWI-087
40
CWI-086
PISTON PIN
Measure the piston pin diameter at each end and in the
center. Acceptable piston pin measurement must be
within 0.8659-0.8661 in. If any measurement varies by
more than 0.001 in., the piston pin and bearing must be
replaced as a set.
0747-810
3. If runout exceeds 0.002 in. at any of the checkpoints,
the crankshaft must be either straightened or
replaced.
Assembling
NOTE: The use of new gaskets and seals is recomCWI-079
CRANKSHAFT RUNOUT
1. Using the V Blocks, support the crankshaft on the
surface plate.
NOTE: The V blocks should support the crankshaft
on the middle bearings.
2. Mount a dial indicator and base on the surface plate.
Position the indicator contact point against the crankshaft location points C and D. Zero the indicator and
rotate the crankshaft slowly. Note the amount of
crankshaft runout (total indicator reading).
mended when assembling the engine.
NOTE: Prior to assembling the engine, use parts
cleaning solvent and compressed air and thoroughly
clean the threaded holes of the crankcase and cylinders to properly tighten.
! WARNING
Always wear safety glasses when drying components
with compressed air.
NOTE: When the use of a lubricant is indicated, use
Arctic Cat C-Tec2 engine oil.
1. Apply a thin coat of grease to the inner seal lips of
the water pump seal.
2. Using the seal driver, position the inner water pump
shaft seal onto the seal driver and gently tap the seal
down into position.
NOTE: Grease must be applied to the lips of the
inner seal before installation.
41
CWI-030A
MS986A
NOTE: The seal must be installed with its spring
side towards the crankshaft.
8. Install the crankshaft into the upper crankcase half.
Be sure the alignment hole in each bearing is positioned over its respective retaining pin in the crankcase; then seat the crankshaft.
3. Install the snap ring securing the inner seal in the
crankcase.
4. Using the seal driver, carefully install the outer water
pump seal. Gently tap the seal down into position
until it seats itself against its flange.
5. Secure the upper crankcase half upside-down on a
suitable support; then install the C-ring (A), the four
bearing retaining pins (B), and the two crankcase
dowel pins (C).
IO019A
NOTE: To check the bearing for proper position,
place the point of a sharp tool into the dimple found
in the bearing race. Strike the tool with the palm of
the hand in either direction. If the bearing moves, it
isn’t positioned correctly and must be rotated until it
drops onto the retaining pin.
CAUTION
CWI-027A
6. Apply a thin coat of Loctite 5900 Sealant to the
entire bottom half of the crankcase sealing surface.
If the bearings are not properly seated during assembly,
the crankcase halves will not seal tightly and severe
engine damage will result.
9. Assemble the crankcase halves; then install the
crankcase cap screws securing the crankcase halves.
10. Tighten cap screws (1-10) in two steps using the pattern shown. First tighten to 15 ft-lb; then tighten to
33 ft-lb.
CWI-067
7. Place the crankshaft end bearings into position making sure the bearing retaining pin holes are positioned inward.
42
15. Apply a thin film of low-temp grease to the water
pump cover O-ring; then position the O-ring into the
water pump cover. With the alignment pins in place,
install the cover. Secure with the screws using a
crisscross pattern. Tighten to 102 in.-lb.
742-198A
11. Tighten screw 11 to 20 ft-lb; then turn the engine
right-side up and tighten screws 12-15 in two steps to
102 in.-lb.
12. Apply a thin coat of grease to the sealing surface of
the water pump shaft; then place the Oil Seal Protector Tool at the end of the shaft.
CWI-016A
16. Tip the crankcase assembly up on the water pump
side; then pour Arctic Cat C-Tec2 engine oil into the
center cavity of the crankshaft until the oil is level
with the shoulder of the shaft (A).
CAUTION
Be very careful not to damage the seals when installing
the oil pump driveshaft. Twist the driveshaft clockwise
as it enters the seal area and while pushing it through
the seals.
13. Rotate the water pump shaft while carefully pushing
it through the oil and water pump seals until the
driveshaft and crankshaft gears engage; then remove
the oil seal protector tool (A) from the end of the
shaft.
CWI-016A
CAUTION
Failure to fill the center cavity of the crankcase assembly will result in center gear damage and engine failure.
NOTE: After the center cavity is filled with engine
oil, be sure to install the hose with loom onto the
upper crankcase half or engine oil will leak from that
area.
IO025A
14. Place the impeller into position and secure with the
cap screw (threads coated with blue Loctite #243)
and washers. Be sure the rubber side of the washer is
lubricated with a light coat of grease and directed
toward the impeller. Tighten to 102 in.-lb.
17. Position the shim on the retainer end of the pump
shaft; then install the retainer with a new O-ring.
Tighten screws to 102 in.-lb.
18. Secure the reed valve assemblies and intake manifolds to the engine case using the existing screws.
Tighten in two steps to 115 in.-lb in order from the
letter A to the letter F (embossed on the manifold).
CAUTION
The rubber side of the washer securing the impeller
must be positioned toward the impeller. If installed
incorrectly, a coolant leak will result and engine damage
may occur.
43
CWI-020
19. With the bypass/check valve of the thermostat
directed to the 12 o’clock position, install the thermostat and housing; then in a crisscross pattern,
tighten the screws to 102 in.-lb.
CWI-078A
CAUTION
Incorrect installation of the piston rings will result in
engine damage.
22. Apply oil to the connecting-rod small end bearings;
then install the small-end bearings.
23. Place each piston over the connecting rod so the indicator arrow on each piston will point toward the
exhaust ports; then secure with an oiled piston pin.
NOTE: The indicator arrow is found on the piston
dome.
24. Install the new circlips so the open end is directed
either up or down.
CAUTION
CWI-018A
Make sure the circlips are firmly seated before continuing with assembly.
25. Rotate each piston ring until the ring ends are properly positioned on either side of the ring keeper; then
apply oil to the piston assemblies and cylinder bores.
CWI-064
20. Install the dowel pins into the crankcase; then place
the cylinder base gasket into position on the crankcase.
21. Install the piston rings on each piston so the letters
KDN5 on the top (inclined surface) of each ring
faces the dome of the piston.
CWI-063
26. In turn on each cylinder, place a piston holder (or
suitable substitute) beneath the piston skirt and
square the piston in respect to the crankcase; then
using a ring compressor or fingers, compress the
rings and slide the cylinder over the piston. Remove
the piston holder and seat the cylinder firmly onto
the crankcase.
NOTE: The cylinders should slide on easily. DO NOT
force the pistons into the cylinders.
44
27. Install each cylinder with the eight existing nuts;
then secure the cylinders by tightening the cylinder
base nuts to 15 ft-lb then to 38 ft-lb in a crisscross
pattern.
28. Install the cylinder O-rings (lightly coated with oil)
on the top of each cylinder making sure they are correctly positioned in the grooves.
CWI-008
NOTE: At this time if the coolant temperature sensor was removed, install the sensor (threads coated
with blue Loctite #243) and tighten to 18 ft-lb.
NOTE: At this point, pressure test the engine (see
the Engine-Related Items section).
CWI-010
29. Place new O-rings (lightly coated with oil) onto each
of the head cap screws. Place four of these cap
screws (from opposite end of each other) into the
cylinder head. Thread the spark plugs in part way;
then while holding the head above the cylinder, carefully start and finger-tighten all four cap screws
while observing the cylinder O-rings to make sure
they remain in position. Slowly place the head into
position on top of the O-rings.
33. With the raised edge of the valve aligned with the
channel of the cylinder, slide the APV assemblies
into position in the cylinders; then secure with cap
screws. Tighten to 102 in.-lb.
NOTE: The APV gaskets will align with the contour
of the cylinder and APV assemblies when installed
correctly. Be sure valves move freely after installing
by pulling on the valve cable.
NOTE: To install the remaining cap screws, the
spark plugs must be removed.
30. Start and finger-tighten the cap screws being very
careful not to move the cylinder head; then tighten
the cap screws in two steps to 13 ft-lb then 28 ft-lb
using the pattern shown.
CWI-073
0747-890
NOTE: At this point, install the spark plugs; then
install the knock sensor. Tighten the sensor to 18 ftlb.
31. Install the coolant inlet hose to the cylinder head and
water pump; then secure using the clamp.
32. Install the fuel rail assembly into the back of the cylinders making sure the gaskets are in place; then
secure the rail using new nylon nuts. Tighten to 102
in.-lb.
CWI-068
34. Secure the stator plate to the crankcase with the
screws (coated with blue Loctite #243) and tightened
to 102 in.-lb.
45
35. Route the stator harness through the opening in the
crankcase; then secure the stator to the stator plate
with the screws (coated with blue Loctite #243).
Tighten to 10 ft-lb.
36. Secure the upper ignition timing sensor with cap
screws (coated with blue Loctite #243). Tighten to
80 in.-lb; then install the wiring grommet into the
notch of the crankcase.
37. Secure the lower ignition timing sensor and bracket
with two screws (coated with blue Loctite #243).
Tighten to 80 in.-lb; then install the grommet. With
the stator harness properly positioned, install the
plate and cap screw (coated with blue Loctite #243).
Tighten to 80 in.-lb.
CWI-070
43. Install the exhaust manifold with new gaskets and
secure with the eight nuts. Tighten the nuts in a crisscross pattern to 12 ft-lb.
44. If the knock sensor was removed, secure it to the cylinder head using the existing cap screw. Tighten to
18 ft-lb.
45. After installing the engine, bleed the oil lines using
the Oil Bleeding Procedure included with the CATT
II Tool.
Installing
CWI-074
38. Install the key in the crankshaft (if removed).
NOTE: Before installing the flywheel, be sure to
wipe the crankshaft and flywheel tapers clean using a
clean, lint-free towel.
39. Place the recoil cup in position on the flywheel and
visually center; then secure the cup with three cap
screws and tighten only until snug. While holding
the cup, slide the flywheel onto the crankshaft making sure the keyways match.
40. Apply red Loctite #271 to the threads of the flywheel
cap screw with the large flat washer; then fingertighten only at this time into the crankshaft.
NOTE: If the engine was replaced, make sure to
install the existing engine support plate and the
exhaust manifold on the new engine. Tighten the
exhaust manifold nuts to 12 ft-lb, the M6 engine support plate cap screws to 25 ft-lb, and the M8 engine
cap screws to 35 ft-lb. Install the three coolant hoses.
NOTE: On electric start models, install the starter
motor to the engine.
NOTE: If the engine is brand new, tip the crankcase
assembly up on the water pump side; then pour Arctic Cat C-Tec2 engine oil into the center cavity of the
crankshaft until the oil is level with the shoulder of
the shaft (A).
41. Secure the recoil cup while using the spanner wrench
and tighten the three cap screws (from step 39)
evenly to 18 ft-lb.
42. Using the spanner wrench, tighten the flywheel cap
screw (from step 40) to 50 ft-lb.
CWI-085A
CAUTION
Failure to fill the center cavity of the crankcase assembly will result in center gear damage and engine failure.
46
1. Carefully lower the engine into the engine compartment.
2. Install the coolant hose to the heat exchanger at the
rear of the engine; then connect the lower coolant
hose to the front heat exchanger.
12. Before connecting the wiring harness plug-ins, clean
the connectors and apply Dielectric Grease to the
seal; then connect all harness connectors making
sure all wiring and coolant hoses are routed properly
as noted in removing. Install the main harness wrap.
NOTE: Use cable ties to secure the wiring harnesses as necessary.
13. Connect all three oil hoses from the front of the
engine. Secure using the existing clamps.
PC141A
EL-005A
14. Connect the MAG-side throttle body coolant hose;
then secure with a clamp.
15. Connect the TPS; then lower the throttle body
assembly into the engine compartment.
PC178A
3. Install new MAG-side engine mount “patch-lock”
cap screws. Finger-tighten only at this time.
16. Place the throttle body assembly into position and
secure with the flange clamps; then connect the
gasline hose to the throttle body assembly and
tighten the clamp securely.
CAUTION
4. Install a new “patch-lock” cap screw and new lock
nuts to secure the engine support plate to the chassis.
Finger-tighten only at this time.
When installing the throttle bodies, make sure the
gasline hose is properly routed to avoid premature wear
and/or contact with exhaust components.
5. Install four new “patch-lock” screws to secure the
PTO-side engine mounting plate. Tighten to 30 ft-lb
using a crisscross pattern.
17. Connect the PTO-side throttle body coolant hose;
then secure with a clamp.
6. Tighten the cap screw and lock nuts (from step 4) to
25 ft-lb.
7. Install the access panel to the center belly panel and
chassis and secure using the torx-head screws. Tighten
securely.
8. Tighten the cap screws (from step 3) to 25 ft-lb.
9. Connect the knock sensor and coolant temperature
sensor connectors; then install the spark plug caps.
Secure the coolant temperature sensor connector
with a cable tie.
18. Fill the cooling system (see Liquid Cooling System
in the Engine-Related Items section).
19. Using the existing clamps, secure the intake flanges
to the throttle bodies.
20. With the air intake boot properly positioned on the
throttle bodies, secure with the existing clamps.
21. Install the shock mount bracket support; then using
new lock nuts, secure the support to the shock mount
brackets and tighten to 20 ft-lb.
10. Install the cylinder head vent hose.
11. Place the recoil starter into position and secure with the
cap screws. Tighten in a crisscross pattern to 96 in.-lb.
47
EL-003A
EL-002A
22. Insert the servomotor cable ends into the slot in the
clutch; then connect the servomotor connector.
Secure the cables with the holder.
NOTE: At this point, secure the PDM harness to the
shock mount bracket support using a cable tie.
27. Position the heat shield onto the two front locating
pins (B); then secure it to the chassis with the two
screws (A). Tighten securely.
PC187A
23. Rotate the servomotor clockwise to remove any
slack from the cables; then install the servomotor
retaining clip. Check APV cable adjustment (see
Arctic Power Valve (APV) System in the EngineRelated Items section).
24. Install the PTO-side front spar and secure to the steering post and shock mount bracket using the existing
cap screws. Tighten the cap screws to 25 ft-lb.
25. Secure the idle speed control (ISC) hoses (A) to the
top of the throttle bodies using the existing clamps;
then connect the ISC to the main harness (B). Secure
the ISC to the intake boot using the existing screws
(C). Tighten securely.
EL-001A
28. Install the resonator and secure with the springs; then
place the expansion chamber and gaskets into position and secure to the exhaust manifold and resonator
with the springs.
NOTE: When installing the manifold springs, the long
hook portion of the spring must be attached to the
exhaust manifold or premature spring failure will result.
29. Install the exhaust temperature sensor into the expansion chamber. Tighten to 34 ft-lb.
30. Place the drive clutch with drive belt into position on the
crankshaft and secure with the cap screw (threads coated
with oil) and high-collar washer. Tighten to 51 ft-lb.
CAUTION
When installing the drive clutch, do not tighten the
clutch cap screw with any kind of impact tool. Tighten
cap screw using a hand torque wrench only. Failure to
do so could result in stationary sheave damage.
NOTE: Before installing the drive clutch, be sure to
wipe both the crankshaft and clutch mounting tapers
clean using a clean towel.
EL-006A
26. Install the fascia panels (with ECM) and secure to
the chassis using the existing screws. Tighten
securely. Connect the ECM.
48
31. Install the driven clutch on the driven shaft; then
install the drive belt (see the Drive Train/Track/
Brake Systems section).
32. Check drive belt deflection.
33. Place the hood into position on the front end and
secure with the screws; then install the hood harness.
Install the side access panels.
CAUTION
Never run the engine with the hood harness disconnected or damage to the electrical system will result.
34. Start the engine and warm up to operating temperature; then verify that all components are functioning
properly and that coolant is circulating through the
cooling system properly.
RA032A
35. After running the engine to the proper operating temperature, shut the engine off; then open the access
panels and inspect for any signs of coolant, gasoline,
or oil leakage.
36. Allow the engine to cool; then check the coolant
level and add coolant as necessary. Verify the tightening torque of the drive clutch.
CAUTION
If the engine had a major overhaul or if any major component was replaced, proper engine break-in procedures must be followed (see the General Information
section) or severe engine damage may result.
Track Drive
RA030A
5. Remove the cap screws securing the slide rail
assembly.
Removing
1. Remove the right and left side panels and set
aside; then remove the resonator.
NOTE: At this time, it is recommended to have
the snowmobile tipped on the left-side.
2. Place a suitable safety stand beneath the rear bumper taking the weight of the snowmobile off the
rear suspension.
6. Remove all torx-head screws securing the chain
case cover. Remove cover.
3. Remove all torx-head screws and cap screws
securing the brake disc shield to the chassis.
7. Remove the chain and sprockets. Remove chain
lube oil.
RA013
RA031A
4. Remove the pin and allen-head screws securing
the brake caliper halves together; then remove the
retaining ring securing the brake disc. Remove the
brake disc.
8. Remove the cap screws securing the inner caliper to
the tunnel; then remove the inner caliper and bearings.
NOTE: It may be necessary to use Puller Tool (p/n
0744-067) to remove the caliper/bearing assembly.
49
PC148A
RA027A
9. Pull the driveshaft out to the left; then drop out of
tunnel right side first.
1. For installing purposes, scribe a line on the driveshaft (A) next to the drive sprocket for proper alignment; then scribe a line on the driveshaft directly in
line with the timing arrows (B) on the drive sprockets for proper sprocket timing.
NOTE: At this point, inspect the bearings for
wear or roughness. Replace as necessary.
Installing
1. Place the track drive assembly into position; then
install existing chain and sprockets and secure
using the existing retaining ring (bottom sprocket),
cap screw and washer (top sprocket). Tighten top
cap screw to 25 ft-lb.
2. Tighten chain tensioner; then install chain lube.
3. Install chain case cover using existing torx-head
cap screws. Tighten to 12 ft-lb.
4. Place the slide rail assembly into position and
secure with existing cap screws. Tighten to 34 ft-lb.
5. Secure the left side of the track drive assembly to
the inner brake caliper using the existing cap
screws. Tighten to 25 ft-lb.
6. Install the brake disc and secure using the existing
retaining ring.
7. Secure the brake caliper halves using the existing
two allen-head screws. Tighten to 25 ft-lb.
RA026A
2. Using a suitable press positioned against the tensioncollar of the drive sprocket (located on the chain
case) and of the driveshaft, press the drive sprockets
off the driveshaft.
CAUTION
Always press against the tension-collar of the drive
sprockets or damage to the components will occur.
8. Secure the brake disc guard using the existing
torx-head screws and cap screws.
9. Install the resonator, side panels, and hood.
Drive Sprockets
Removing
NOTE: The drive sprockets must be removed from
the brake side of the track drive.
RA025A
Cleaning And Inspecting
1. Thoroughly wash all metallic components in partscleaning solvent. Dry using compressed air.
2. Wash all non-metallic components with soap and
water.
50
3. Inspect the driveshaft for damaged splines or
stripped threads.
4. Inspect the seals for any breaks or damage.
NOTE: When pressing new sprockets on the driveshaft, align the sprocket alignment marks or the
sprockets won’t be timed correctly.
5. Inspect the track for cuts, gouges, or wear.
6. Inspect the brake disc for wear or cracks.
7. Inspect the track drive sprockets for wear or damage.
Installing
NOTE: The drive sprockets must be installed on the
brake side of the track drive.
0747-018
4. Press sprockets to proper location (shown in the following illustration). Sprockets are to be pressed and
measured from dropcase end of shaft.
RA027B
NOTE: Prior to installing the sprockets onto the
driveshaft, lightly chamfer the inside edge of the
sprocket to avoid binding.
0747-025
Brake System
Arctic Cat recommends that the brake system (brake
lever, reservoir, hose, caliper, pads, and brake disc) be
checked daily for fluid leakage, wear, or damage and
for proper operation. Also, the brake fluid level must
be checked every time before starting the engine. The
brake fluid must be maintained at a level just below
the high mark on the reservoir.
MS362
1. Properly align the scribed line on the driveshaft
(from removing) with the timing arrow on the drive
sprocket; then slide the sprocket onto the driveshaft
as far as it will go.
2. Using a suitable press and fixture, press the driveshaft into the sprocket until it aligns with the line
scribed in removing.
3. Slide the remaining sprocket onto the driveshaft
making sure the timing arrow/lines (from removing)
are aligned; then using the press/fixture, press the
sprocket to the remaining alignment line.
CAUTION
! WARNING
DO NOT operate the snowmobile when the brake lever
lock is engaged or when any component in the brake system is damaged, worn, or adjusted improperly. If the
snowmobile is operated and the brake system is not functioning properly, severe personal injury could result.
Brake Fluid
Checking/Adding
1. With the brake fluid reservoir in a level position and
the cover removed, check the fluid level. The brake
fluid level must be at the high brake fluid mark in the
reservoir.
Always press against the tension-collar of the drive
sprockets or damage to the components will occur.
51
SNO-253
0745-816
2. If the brake fluid level is below the low mark,
remove the reservoir cover and add Arctic Cat
approved brake fluid until the fluid level is just
below the high mark. Install and secure the reservoir cover. Do not allow moisture to contaminate
the brake system.
5. If the distance is less than specified, check the brake
fluid level (see Checking Brake Fluid in this sub-section), inspect for leakage, and check the brake pads.
CAUTION
! WARNING
Do not overfill the reservoir. Overfilling the reservoir may
cause the brake system to hydraulically lock. Use only
Arctic Cat approved brake fluid. Never substitute or mix
different types or grades of brake fluid. Brake loss can
result. Brake loss can result in severe injury or even death.
Changing
The brake fluid must be changed on a regular basis and
whenever the brake fluid has been overheated or contaminated. The brake fluid should be changed every
1000 miles or at the end of the snowmobiling season,
whichever occurs first.
Checking Brake Lever Travel
1. Test the operation of the hydraulic brake system by
compressing the brake lever.
! WARNING
Do not operate the snowmobile if the distance between
the compressed brake lever and handlebar is less than
2.54 cm (1 in.). Brake loss may occur. Brake loss can
result in severe personal injury.
Bleeding Brake System
If the brake lever feels spongy when applied, the brake
system may need to be bled. To bleed the brake, use
the following procedure:
1. Remove the reservoir cover and fill the reservoir to
the high mark with Arctic Cat approved brake fluid.
CAUTION
! WARNING
Use only Arctic Cat approved brake fluid. Any substitute may result in a loss of brakes.
2. Slide a piece of flexible tubing over the ball of the
bleeder valve and direct the other end into a container.
2. The brake lever must feel firm when compressed.
3. To verify lever travel, compress and hold the brake
lever to its maximum resistance.
NOTE: Do not pump the brake lever as it will produce an inaccurate reading.
4. Measure the distance between the brake lever and the
handlebar. The distance must be greater than 1 in.
RA032B
3. Slowly compress the brake lever and hold. Open
the bleeder valve to release the fluid and air. When
the fluid stops, close the bleeder valve; then
release the brake lever.
52
4. Repeat step 3 until the brake fluid flows free of air
bubbles.
4. Using a pair of pliers, pull one brake pad out of the
caliper assembly.
NOTE: It may be necessary to refill the reservoir
during the bleeding process.
NOTE: Changing one pad at a time will prevent
one piston from pushing out the other piston from
the caliper.
5. When the brake fluid is free of all air and the brake
lever feels firm when compressed, fill the reservoir to a level just below the high mark; then
install and secure the cover. Remove the tube from
the bleeder valve.
Checking/Changing Brake Pads
The condition of the brake pads must be checked daily
and changed if worn or damaged. To check and change
the brake pads, use the following procedure.
1. Measure the width of both brake pads. The brake
pad width must be greater than 3.2 mm (0.125 in.).
If the brake pad width is less than specified,
replacement of both pads is necessary. Follow
steps 2-6 to replace brake pads.
2. Remove the pin securing the brake pads to the caliper assembly.
3. Remove the brake fluid reservoir cover; then
remove most of the brake fluid from the reservoir.
Replace the cover.
NOTE: The above procedure will allow room for the
fluid from the caliper when the pistons are pushed
into the caliper for installing new brake pads.
Replacing the cover will prevent fluid spillage.
5. Using a flat-blade tool, slowly and carefully push
the piston into the caliper.
NOTE: The brake pads are labeled (Inner and
Outer) for installation purposes.
6. Position the new brake pad into the caliper.
7. Repeat steps 4-6 for the other pad; then secure the
pads with the pin.
8. Remove the reservoir cover and remove the
remaining fluid; then fill the reservoir with fresh
fluid.
9. Pump the brake lever to ensure correct positioning
of the brake pads; then release.
10. Fill the reservoir to the proper level with fresh
brake fluid.
NOTE: When new brake pads are installed, a
“burnishing” process is required. Drive the snowmobile slowly and compress the brake lever several times until the pads just start to warm up; then
allow them to cool down. This procedure stabilizes
the pad material and extends the life of the pads.
53
Drive Train/Track/Brake
Systems
This section has been organized into sub-sections for servicing drive train, track, and brake systems; however,
some components may vary from model to model. The
technician should use discretion and sound judgment
when removing and installing components.
NOTE: Whenever a part is worn excessively, cracked,
or damaged in any way, replacement is necessary.
SPECIAL TOOLS
when servicing the drive train, track, and brake systems.
Description
Drive Clutch Bolt Tool
Bearing Removal and Installation Tool
Movable Sheave Bearing Tool
Clutch Alignment Bar
Drive Clutch Puller
Driven Clutch Compressor Tool
Rear Suspension Spring Tool
Brake Caliper Bearing Puller
p/n
0644-281
0644-167
0644-594
0644-428
0744-062
0644-136
0644-444
0144-311
0744-067
CAUTION
Never attempt to substitute any other drive clutch puller for
the recommended puller or severe clutch damage will occur.
Drive Belt
The drive belt transfers power from the drive clutch to
the driven clutch. If the belt is worn, cracked, or
stretched, maximum power will not be transmitted and
the belt could also fail and therefore must be replaced.
Periodic checks (at least once a week under normal
usage) of two drive belt specifications are essential.
1. Measure the outside circumference of the drive
belt. The belt should be within specifications in
circumference.
NOTE: Drive belts should be purchased from an.
authorized Arctic Cat Snowmobile dealer, as Arctic
Cat drive belts are made to exact specifications
and of quality material. Belts made by other manufacturers may not be of the same specifications or
quality and, therefore, usage could result in poor
performance and premature belt failure.
CAUTION
Never run the engine with the drive belt removed.
Excessive revving of the engine could result in serious engine damage and drive clutch failure.
Before starting the snowmobile in extremely cold temperatures, the drive belt should be removed and
warmed up to room temperature. Once the drive belt is
at room temperature, install the drive belt.
Also, drive belts have a break-in period of approximately 10 minutes. After installing a new drive belt,
drive the snowmobile for 10 minutes at 1/2 throttle or
less. This will allow the drive belt to gain its optimum
flexibility and will extend drive belt life.
Breaking-In
Drive belts require a break-in period of approximately
25 miles. Drive the snowmobile for 25 miles at 3/4
throttle or less. By revving the engine up and down
(but not exceeding 60 mph), the exposed cord on the
side of a new belt will be worn down. This will allow
the drive belt to gain its optimum flexibility and will
extend drive belt life.
Removing
1. Remove the tether switch cap and wait for all
moving parts to stop.
2. Set the brake lever lock.
3. Remove the left-side access panel.
4. Using Drive Belt Deflection Tool (p/n 0644-424),
thread the tool clockwise into the driven clutch
until the movable sheave opens far enough to
remove the drive belt.
2. Measure the outside width of the drive belt. The
belt should be within specifications in width.
3. Check the belt for cracking, fraying, etc.
If any of the specifications or conditions are unsatisfactory, replace the drive belt.
743-067B
5. When the sheaves are fully apart, pull up on drive
belt and roll belt over stationary sheave until it is
free of the driven clutch.
54
6. When the belt is free of driven clutch, remove the
belt from the drive clutch.
Installing
1. Place the belt (so the part number can be read)
between the sheaves of the drive clutch.
2. With the sheaves fully apart, roll the belt over the
stationary sheave.
3. With the drive belt properly positioned in the drive
clutch and driven clutch, turn the belt tool counterclockwise and roll the belt back and forth to allow
the driven clutch sheaves to fully close.
4. After the belt is installed properly, install the leftside access panel and the hood.
FC055
3. Remove the cam arm pin lock nuts; then using a
small torch, apply heat to the cam arm set screws to
loosen the Loctite used in assembly.
! WARNING
Never operate the snowmobile without the access
panel in place.
5. Release the brake lever lock.
Drive Clutch
Changing Cam Arms/springs
Removing
1. Using Drive Clutch Bolt Tool, remove the cap screw
and lock washer securing the drive clutch to the
crankshaft.
NOTE: Before installing the clutch puller, apply oil
FS001
to the threads of the puller and a small amount of
grease to the tip of the puller.
NOTE: Heat must be applied to the cam arms in
2. Using the Drive Clutch Puller and the Drive Clutch
Spanner Wrench, tighten the puller. If the drive
clutch will not release, sharply strike the head of the
puller. Repeat this step until the clutch releases.
4. After the lock nuts and set screws have been
removed, remove the cam arm pins one at a time noting the position of the alignment notches in the cap
screws for assembly purposes. Account for the Orings.
order to remove the set screws.
3. Remove the drive clutch and drive belt from the
engine compartment.
Disassembling
NOTE: Note the timing marks on the cover, spider,
and movable sheave. These must be aligned when
assembling the drive clutch for balance purposes.
1. Loosen the machine screws securing the cover.
Remove every other cap screw and lock washer from
the cover; then while firmly holding the cover,
remove the three remaining screws and lock washers
equally.
2. Remove the cover and spring.
0739-038
1. Using parts-cleaning solvent, wash grease, dirt, and
foreign matter off all components; dry with compressed air.
! WARNING
Always wear safety glasses when using compressed
air to dry components.
55
2. Remove any drive belt dust accumulation from the
stationary sheave, movable sheave, and bushings
using parts-cleaning solvent only.
3. Inspect stationary sheave, movable sheave, spider,
and cover for cracks or imperfections in the casting.
4. Inspect the cam arm pins for wear or bends.
5. Inspect the spring for distortion, cracks, or wear.
6. Inspect rollers for damage or wear.
Assembling
1. With the head of each cam arm pin positioned
towards the direction of the drive clutch rotation,
install the cam arms.
NOTE: The drive clutch rotates counterclockwise.
2. With the cam arm pins properly positioned, apply
green Loctite #620 to the set screw holes in the cam
arms, install the new set screws (pre-coated with
Loctite), and tighten to 19 in.-lb.
XM009A
CAUTION
Care must be taken when installing the cover not to
damage the bushing.
If equipped and if removed, install the drive clutch fan
and secure with the three cap screws. Tighten to 60 in.-lb.
Installing
NOTE: Before installing the drive clutch, be sure to
wipe both the crankshaft taper and clutch mounting
taper clean using a clean towel.
1. Place the drive clutch into position on the crankshaft;
then apply a few drops of oil to the threads of the cap
screw. Secure with the cap screw and lock washer.
Tighten to 51 ft-lb.
CAUTION
739-040B
CAUTION
Green Loctite #620 must be applied to the set screw
holes in the cam arms or component damage may occur.
3. Secure the cam arm pins with new lock nuts and
tighten to 11 ft-lb.
CAUTION
When installing cam arms, always use new lock nuts
and cam arm set screws.
4. Place the spring and cover into position making sure
the timing mark on the cover is properly aligned; then
compress the spring and install the machine screws
coated with blue Loctite #243 and lock washers. In a
crisscross pattern, tighten evenly to 120 in.-lb.
When installing the drive clutch, do not tighten the cap
screw with any kind of impact tool. Tighten cap screw
using a hand torque wrench only. Failure to do so
could result in stationary sheave damage.
2. Check alignment between the drive clutch and driven
clutch (see Drive Clutch/Driven Clutch in this section).
3. Install the drive belt. Check drive belt deflection (see
Drive Clutch/Driven Clutch in this section). Secure
the belt guard and close the left-side access panel.
NOTE: For installing drive belt, see Drive Belt in this
section.
! WARNING
Never operate the engine without the belt guard/
access panel secured.
4. Either test drive the snowmobile or run the engine
for five minutes; then verify the drive clutch cap
screw torque specification.
Driven Clutch
Disassembling
1. Prior to disassembling, mark the driven clutch
sheaves and cam.
56
4. Remove the movable sheave from the driven
clutch shaft and account for one spacer.
NOTE: Whenever a part is worn excessively,
cracked, or damaged in any way, replacement is
necessary.
1. Using a parts-cleaning solvent, wash grease, dirt,
and foreign matter off all components; dry with
compressed air.
RA020
2. Remove the four torx-head screws securing the
cam to the movable sheave; then grasp the cam
and by working the movable sheave back and
forth, lift it up and off the shaft.
2. Remove any drive belt dust accumulation from the
stationary sheave, movable sheave, and bushings
using parts-cleaning solvent only.
CAUTION
Do not use steel wool or a wire brush to clean components having a bushing; damage to the bushing
will result.
3. Inspect the roller assembly for wear or damage.
NOTE: Flat spots or diameter cannot be less than
23 mm (0.925 in.).
4. Inspect shaft for nicks or burrs.
NOTE: If a spring rate measures less than 10% of
specified load height, it must be replaced.
RA021
NOTE: If only changing cam angles, move the
cam 90° to its optional position and secure the
cam with the four torx head cap screws. Tighten to
6 ft-lb.
2. Using Driven Clutch Compression Tool (p/n 0644444), position the tool over the roller assembly;
then compress the assembly enough to allow the
snap ring to be removed from the end of the shaft.
Remove the snap ring.
5. Measure the inside diameter of the movable
sheave bushing. Bushing to shaft clearance must
not exceed 0.25 mm (0.010 in.).
NOTE: If clearance exceeds the limit, the bushing
must be replaced.
Assembling
1. Install the spacer and the movable sheave onto the
driven clutch shaft.
2. Place the retaining ring and spring into the driven
clutch; then place the roller assembly and snap
ring over the spring.
3. Position the roller assembly so the “X” mark is
directly in line with the “X” on the movable
sheave.
RA022A
3. Remove the compression tool and account for the
snap ring, spider assembly, spring, and a retaining
ring.
RA023A
57
4. With Driven Clutch Compressor (p/n 0644-444),
compress the roller assembly enough to allow the
snap ring to be properly secured to the shaft.
4. Remove the resonator; then remove the right-side
footrest.
5. Remove the torx-head screw securing the belly pan
to the right-side footrest support.
6. Disconnect the speed sensor connector and the oil
level connector.
7. Place a drain pan under the chain case; then loosen
the eleven screws securing the chain case cover/oil
tank assembly to the chain case housing starting with
the bottom screws first.
8. Remove the chain case cover/oil tank and set out of
the way leaving the oil hose(s) connected.
9. Release tension on the chain tensioner; then remove
the ratchet block and the tensioner.
CM090
NOTE: While compressing the roller assembly, it
may be necessary to work the spider assembly
back and forth to properly mate the splines.
5. Place the cam with the desired angle into position;
then secure the cam to the movable sheave with
the four torx head cap screws. Tighten to 6 ft-lb.
Installing
1. Slide the alignment washers onto the end of the
driven shaft.
2. Place the stub shaft into the driven clutch. Place
the driven clutch on the shaft.
NOTE: A small amount of Loctite Anti-Seize
Thread Compound (p/n 0678-146) applied to the
driven shaft will aid in future driven clutch
removal.
XM259
10. Remove the snap ring securing the upper sprocket to
the driven shaft.
3. Secure the driven clutch by installing washers, and
cap screw. Tighten the cap screw to 2.6-3.3 kg-m
(19-24 ft-lb).
NOTE: Make sure the keyways match when
installing the driven clutch. Arrange washers to
allow the least amount of “float” on the driven
shaft. A maximum of 1-2 mm (0.040-0.080 in.) of
float is acceptable.
XM262
Drive Train
REMOVING CHAIN CASE/DRIVEN
SHAFT/DRIVESHAFT/TRACK
1. Remove the left- and right-side panels, hood; then
loosen the quarter turns securing the lower console to
the skid panels and secure out of the way.
2. Remove the drive and driven clutches.
3. Remove the screws securing the PTO engine mount
plate to the engine and the chassis.
58
NOTE: Spread the snap rings only enough to
remove them from the drive and drive shafts.
11. Remove the snap ring securing the lower sprocket.
Remove the sprockets and chain.
14. Remove the skid frame assembly.
15. Remove the brake shield and the left-side footrest.
NOTE: DO NOT split the brake caliper unless necessary service work is required.
16. Remove the cap screws securing the inner caliper to
the tunnel; then remove the caliper and the driveshaft
assembly.
XM261
PC148A
NOTE: If the caliper will not slide off the driveshaft
easily, proceed to step 17.
XM263
12. Remove the inner black snap ring; then remove the
snap ring and washer securing the driven shaft.
17. Remove the retaining pin and the brake disc pads;
then pump the brake lever 3 or 4 times then pull back
and secure the lever to the handlebar using a cable
tie. This will keep the fluid from leaking.
NOTE: Place an absorbent towel under the caliper
to absorb slight amount of brake fluid. Do not compress the brake lever.
18. Remove the retaining ring securing the brake disc to
the driveshaft and remove the brake disc.
NOTE: It may be necessary to use Brake Caliper
Bearing Puller to remove the caliper/bearing assembly.
NOTE: If the chain case needs to be removed,
remove all machine screws with lock nuts.
XM264
CLEANING AND INSPECTING
CHAIN CASE
1. Inspect sprockets and chain for excessive wear or
stretching.
2. Inspect bearings and sprockets for roughness or chipping.
NOTE: If bearing replacement is necessary, the
chain case must be removed from the tunnel and an
appropriate press utilized to remove and install bearings.
XM265
13. Once the snap ring and washers have been removed
from the driven shaft, the shaft and PTO engine
mount plate may be removed from the chassis. Make
sure to keep the shaft 90° to the plate.
59
3. Clean all interior chain case surfaces and components in cleaning solvent and dry using compressed
air.
6. Install the skid frame (see the Suspension section).
! WARNING
NOTE: Remove the cable tie securing the brake
Always wear safety glasses when using compressed
air.
lever; then pump the break lever until the brake lever
feels firm when compressed. To verify lever travel,
compress and hold the brake lever to its maximum
resistance; then measure the distance between the
brake lever and the handlebar. The distance must be
greater than 1 in.
ASSEMBLING/INSTALLING CHAIN
CASE/DRIVEN SHAFT/DRIVESHAFT/
TRACK
If the driveshaft and driven shaft were not removed, proceed to step 12.
7. Install the brake shield and left-side footrest. Tighten
the cover cap screws to 8 ft-lb.
1. Install chain case assembly onto the chassis and
secure with the machine screws and four lock nuts.
Tighten all screws to 12 ft-lb.
8. Install the driven shaft w/mount plate from the leftside; then secure the PTO-side engine mounting
plate to the crankcase and the chassis with the existing cap screws (coated with blue Loctite #243) and
one washer. Tighten to 30 ft-lb.
2. Place the driveshaft/drive sprocket assembly into the
tunnel brake-end first; then into the chain case driveshaft bearing.
9. Install the drive clutch and tighten the clutch cap
screw w/washer to 51 ft-lb; then install the driven
clutch and drive belt. Tighten to 20 ft-lb.
3. Install the inner brake caliper assembly and secure
with three cap screws and the retaining ring. Tightened cap screws (threads coated with blue Loctite
#243) securely.
10. Install the existing washers; then press in on the
driven shaft and secure the shaft using the existing
washers and snap ring.
XM265
PC148A
NOTE: If the brake caliper was split, proceed to step
11. Install the black snap ring onto the inner snap ring
groove in the driven shaft.
4. If not, proceed to step 6.
4. Install the brake disc and secure with the retaining
ring.
5. Making sure the seal is correctly installed in the
outer brake caliper, install on the inner caliper and
secure with two cap screws. Tighten to 25 ft-lb.
XM264
12. Install the sprockets and chain onto the driveshaft
and driven shaft and secure using the existing snap
rings.
PC173A
60
Servicing Float X Evol Shock
Absorbers
Disassembling Shock Absorber
! WARNING
Before starting, read through all of these instructions
first to become familiar with the procedure. Make
sure the work area is clean and all of the necessary
tools are available. These shocks contain high pressure nitrogen gas. Always use proper safety equipment such as latex gloves and safety glasses when
working on shock absorbers.
XM261
NOTE: Some illustrations and photographs used
in the following sub-sections are used for clarity
purposes and are not designed to depict actual
conditions.
1. Rotate both adjuster screws counterclockwise to
the full-open position.
2. Securely clamp the EVOL chamber eyelet (bottom) of the shock in a soft-jawed vise; then
remove the green valve caps and set them aside.
XM262
13. Install the ratchet block and tensioner; then set the
tensioner in the fifth notch in the block as it is self
tightening.
XM202
14. Install the chain case cover/oil tank assembly and
secure with the existing screws (threads coated with
blue Loctite #243). Tighten in a crisscross pattern to
12 ft-lb. Fill the chain case with 15 oz. of Arctic Cat
Chain Lube.
15. Connect the speed and oil sensor connector.
16. Install the right-side footrest support and secure to
the belly pan using the existing screws.
A
3. Depressurize the main chamber first; then depressurize the EVOL chamber next.
NOTE: When depressurizing the chambers, a
“hissing” should be noticed as air is released.
Also, the shock normally contracts slightly due to
the internal negative spring.
4. Using a strap wrench at the very end of the sleeve,
loosen, but do not remove, the air sleeve.
17. Install the resonator.
18. Secure the lower console to the skid panels; then
install the hood and both access panels.
61
B
5. Remove the shock from the vise, invert it, and
clamp it in the vise by the reservoir eyelet.
6. Unthread the air sleeve from the EVOL chamber
by hand and slide it down the body.
D
7. Using a 5/64-in. hex key, remove the button screw
from the nitrogen pellet valve.
C
NOTE: Look for oil in the air chamber which may
be at the top of the bearing head assembly. There
should be a small amount of assembly lube (blue)
present, but any indication of shock oil (red) indicates worn shaft seals.
E
8. Using a FOX nitrogen safety needle, press it
through the rubber pellet to depressurize the nitrogen charge. When the shock is fully discharged,
pull the needle away in a straight, smooth motion.
NOTE: At this point, inspect the nitrogen valve
for signs of wear such as holes on the face of the
pellet. Replace if necessary.
62
10. Using a 5/64-in. hex key, carefully loosen the
bleed set screw; then remove the ball bearing and
set it aside.
I
F
9. Press down on the reservoir end cap; then using a
scribe or a pick tool, remove the reservoir snap
ring. Pull the end cap out of the reservoir.
NOTE: It is advisable to use a small magnet to
remove the ball bearing from the hole.
J
G
11. Using an appropriate bearing head removing tool,
unscrew the bearing head assembly from the shock.
K
H
12. Grasp the EVOL chamber end (bottom) of the
shock; then gently pull the piston/shaft/bearing/
EVOL free from the shock body. Set this entire
assembly aside.
63
14. Using a scribe or pick tool, remove the “samurai”
and back-up seals from the air sleeve.
CAUTION
Care must be taken not to score or damage any of the
aluminum sealing surfaces.
L
O
M
13. Remove the air sleeve from the reservoir end of
the shock.
P
15. Pour the shock oil out of the shock body; then
clamp the “piggy-back” body assembly in the vise.
N
Q
64
17. Remove the IFP bleed screw and set aside.
T
18. Using the new seals from the appropriate seal
rebuild kit, replace all IFP seals.
R
16. Using an appropriate IFP removing tool, remove
the IFP from the “piggy-back” body.
U
V
19. Pour the shock oil out of the “piggy-back” body
assembly.
S
65
Z
W
20. Using a 5/8-in. wrench, remove the LSC assembly
from the eyelet, thoroughly clean the assembly,
replace the O-rings, and install the assembly into
the eyelet. Tighten to 14 ft-lb.
1. Using an appropriately-sized IFP removing tool,
insert the tool with a “delrin rod” (or a suitable
substitute) into the air sleeve and strike the rod
with a hammer freeing the bushing.
AA
X
Y
Replacing Air Sleeve DU Bushing
NOTE: The DU bushing must be replaced if it is
significantly worn or damaged.
66
BB
FF
CC
GG
DD
NOTE: To install a new DU bushing, an appropriate bushing installer (A), sizer (B), and machine
press must be available.
3. At this point, the inside diameter of the new bushing must be re-sized.
A. Insert the sizer into the air sleeve.
B. Place the installer tool on top of the sizer.
EE
2. Place the new DU bushing partially into the air
sleeve and place the installer on top of it; then
using the machine press, press the bushing into the
air sleeve.
HH
67
C. Using the machine press, press the stack until
the sizer falls free within the air sleeve. Remove
the installer and the sizer.
LL
Disassembling Shaft Assembly
1. Using a 9/16-in. wrench, remove the shaft lock nut.
II
4. Apply an ample amount of petroleum grease to the
“samurai” and backup seals; then place them into
the air sleeve.
MM
2. Using a scribe or pick tool, lift the piston and
valve assembly collectively off the shaft.
JJ
NN
KK
NOTE: At this point, apply an ample amount of
petroleum grease around the inside lip of the air
sleeve; then set the sleeve aside.
OO
68
NOTE: It is advisable to use cable ties to preserve the upper and lower shim stack/piston order.
4. Remove the O-ring from the piston.
SS
PP
5. Install a new piston O-ring; then using an appropriate piston band installation tool, install a new
band.
QQ
3. Using a sharp blade, cut the piston band; then
remove the band and discard.
TT
6. Remove the spring from the assembly; then
remove the bearing assembly.
RR
NOTE: Care should be taken not to scratch the
piston when cutting the band.
UU
69
VV
7. Remove and replace all O-rings and seals.
ZZ
 NOTE: When installing the main seal, assure that it
is oriented correctly.
WW
AAA
Rebuilding EVOL Reservoir
1. Install a new O-ring in the rebound eyelet assembly.
XX
YY
BBB
 NOTE: It may be advisable to use a cable tie to aid
in removing the main seal.
70
2. Remove the EVOL reservoir from the rebound eyelet
assembly; then install a new reservoir O-ring.
FFF
CCC
5. Replace the IFP seal; then amply lubricate the IFP and
place it into the reservoir.
GGG
DDD
3. Using a shock absorber hand air pump, apply light pressure to the reservoir to extract the IFP.
6. Thread the EVOL reservoir onto the rebound eyelet; then
tighten to 12 ft-lb.
Assembling Shaft Assembly
1. With the shaft assembly clamped in the vise, install the
bottom-out bumper.
HHH
EEE
4. Pour approximately 2 cc of float fluid into the reservoir (down its side) to provide lubrication for
installing the IFP.
2. Place the Bearing Cap Seal Protector (p/n 0644268) onto the shaft, amply lubricate the protector,
and install the bearing assembly onto the shaft.
71
KKK
Assembling Shock Absorber
1. Securely clamp the “piggy-back” body assembly in the
vise; then using an appropriate air sleeve protector tool,
slide the air sleeve over the body.
III
3. Install the lower and upper shim stack/piston assembly.
LLL
JJJ
 NOTE: Care must be taken that the preserved shim
stack/piston assembly be installed correctly.
4. Thread the lock nut onto the shaft; then tighten to 18 ft-lb.
Set the shaft assembly aside.
MMM
72
 NOTE: At this point, pour 3-5 cc of float fluid
between the air sleeve and shock body.
QQQ
NNN
2. Assuring that the LCS adjuster screw is rotated fully open
(counterclockwise), fill the “piggy-back” reservoir with
Fox High V1 Race Oil almost to the rim.
RRR
4. Using an appropriate IFP installing tool, slowly press the
IFP down into the oil purging the trapped air out through
the bleed hole. Do not press the IFP to the bottom of the
reservoir at this time.
OOO
! WARNING
Cover the top of the tool to prevent oil from squirting
upwards.
PPP
 NOTE: It is normal for oil to seep through the CD
into the shock body; continue “topping-off” the reservoir until the oil settles evenly between the reservoir and shock body.
3. Rotate the LCS adjuster screw fully closed (clockwise);
then remove the IFP bleed screw and insert the well-lubricated IFP into the reservoir.
SSS
73
WWW
TTT
5. Install the IFP bleed screw.
7. Assuring that the LCS adjuster screw is rotated fully open
(counterclockwise), fill the shock body with Fox High V1
Race Oil; then rotate the LCS adjuster screw fully closed
(clockwise).
UUU
 NOTE: It is allowable to leave some oil trapped in
the reservoir above the piston.
XXX
6. Using the IFP installing tool, press the IFP to the bottom
of the reservoir; then pull the IFP back 2 in. from the top
of the reservoir.
 NOTE: Repeat this procedure several times to
assure a full bleed; then position the IFP approximately 1 in. from the bottom of the reservoir.
VVV
74
8. Back out the rebound adjuster on the shaft assembly; then by inserting the long end of an Allen
wrench into the shaft post, depress the metering
rod lightly until the metering rod moves away
from the jet.
9. While holding the negative spring and spacer at
the top of the shaft with one hand, insert the shaft
and bearing assembly into the shock lower taking
care not to spill oil into the air sleeve. Very slowly
push the shaft down into the oil while rotating and
“wiggling” the shaft until there are no bubbles rising in the oil.
11. Gently lower the negative spring and spacer into the oil
taking care not to let the oil overflow into the air sleeve.
CAUTION
Make sure the piston assembly and the rebound hole
in the shaft DO NOT come out of the oil bath. If the
rebound adjust hole in the shaft comes out of the oil
bath, air can transfer to the underside of the piston
aerating the shock. Add oil to the shock as required to
keep the hole covered. Pull the shaft assembly out of
the oil until the top of the negative spring is even with
the end of the body.
12. Carefully lower the bearing assembly into the
damping body and thread into the shock; then
using an appropriate bearing head tool, tighten the
bearing assembly to 50 ft-lb.
YYY
10. Using a rubber mallet, gently tap the shaft to allow trapped
air to escape from between the piston and valve shims.
AAAA
BBBB
13. Slide the air sleeve up to be flush with the bearing head
assembly to prevent oil from spilling into the air sleeve.
Gently compress the IFP to purge the last air bubbles from
the body out the bleed screw. Make sure the shaft is fully
extended to the point of it contacting the negative spring.
ZZZ
75
15. Slide the air sleeve down far enough to liberally lubricate
the bearing head assembly.
CCCC
GGGG
16. To set the IFP depth, remove the bleed screw; then using
Floating Piston Location Gauge (p/n 0644-350), adjust the
depth to 2.5 in. Install the bleed screw.
DDDD
14. Install the bleed set screw; then using a 5/64 in. hex key,
tighten the set screw.
HHHH
17. Pour the excess oil from the IFP reservoir, install
the reservoir end cap pressing it down firmly, and
install the snap ring.
EEEE
IIII
FFFF
76
MMMM
JJJJ
NNNN
KKKK
18. Using an appropriate inflation needle, charge the
reservoir to 250 psi (p/n 3703-064/065).
19. Using an appropriate strap wrench, tighten the air
sleeve into the rebound eyelet assembly.
Rear Suspension
The Sno Pro 600 is equipped with a compression adjustable remote reservoir shock in the rear suspension system. This system utilizes front arm limiter straps.
The suspension should be adjusted for the operational
needs and riding preference of the operator.
The rear springs influence the load carrying capability
of the snowmobile and should be adjusted for the
weight and riding preference of the operator.
Rear Arm Shock Rebound
The rear arm shock can be adjusted for rebound qualities. To adjust, use the following procedure.
1. Turn the adjuster clockwise until it stops (hard
position).
2. Turn the adjuster counterclockwise to the initial
setting (see appropriate Valve Stacks/Specifications page in this manual) or turn the adjuster
counterclockwise the desired number of “clicks.”
NOTE: On the rear arm shock, the rebound
adjuster has a total range of 18 “clicks” or 4 1/2 full
turns (4 “clicks”= 1 turn).
LLLL
20. Using a high-pressure hand air pump, pressurize
the shocks to 200 psi EVOL and 80 psi Main.
77
Front/Rear Arm Shock Compression
1. Turn the adjuster clockwise until it stops (hard
position).
2. Turn the adjuster counterclockwise to the initial setting
(see page 9 in this manual) or turn the adjuster counterclockwise the desired number of “clicks.”
NOTE: On the rear arm shock, the compression
adjuster has a total range of 18 “clicks” or 3 full
turns (6 “clicks” = 1 turn).
Front Arm Shock Spring
The skid frame front arm shock spring is adjustable.
However, Arctic Cat recommends that the shock
spring be adjusted to a maximum of 6.4 mm (1/4 in.)
up or down from the standard pre-load setting.
NOTE: The standard pre-load spring length (installed)
is 7.64 in.
CAUTION
Do not exceed the maximum 6.4 mm (1/4 in.) up or
down from the standard pre-load setting.
When customizing the amount of ski pressure, be sure to
not over-adjust the front arm shock spring to adversely
affect steering and operator control of the snowmobile.
Some experimentation may be required until the proper
adjustment for the operator’s individual style is obtained.
! WARNING
Do not adjust the front arm shock to a point at which
steering and operator control of the snowmobile are
adversely affected.
NOTE: Each driver’s style is different and some
experimentation will be required to become familiar with the above adjustment procedure.
! WARNING
DO NOT make adjustments while operating the snowmobile. Keep both hands on the handlebar while the
snowmobile is moving.
Adjusting Rear Spring Tension
Rear spring tension adjustment is accomplished by rotating the adjusting cams. Position 3 provides the stiffest ride,
and position 1 provides the softest ride. Always rotate the
cam from the lighter position to the heavier position.
Servicing Zero-X Shock Absorbers
This procedure shows the proper method for servicing
the front arm shock absorber w/“piggy-back” reservoir.
! WARNING
Before starting, read through all of these instructions
first to become familiar with the procedure. Make sure
the work area is clean and all of the necessary tools
are available. These shocks contain high pressure
nitrogen gas. Always use proper safety equipment
such as latex gloves and safety glasses when working
on shock absorbers.
NOTE: Some illustrations and photographs used
in the following sub-sections are used for clarity
purposes and are not designed to depict actual
conditions.
Disassembling
1. Remove the bearings and retaining rings from the
eyelets.
2. Clean the entire shock assembly with soapy water.
Dry the shock assembly with compressed air.
CAUTION
Use a soft-bristle brush to remove as much dirt and
debris as possible. Do not pressure wash the shock
as this can force water and debris inside causing damage to the seals.
! WARNING
When using compressed air to dry components,
always wear safety glasses.
NOTE: If compressed air is not available, use
clean towel to dry the shock assembly.
3. Clamp the shock body eyelet securely in a softjawed vise and remove the ball from the end cap;
then using a 3/16-in. hex key, slowly loosen the set
screw (FAV3 valve) on the shock reservoir.
! WARNING
Always place a rag or towel over the valve and hex key
for protection when releasing the nitrogen from the
reservoir.
CAUTION
Never force the adjustment cams from the low position to the high position. Cam damage may occur.
To rotate an adjusting cam, use a six-point box-end
wrench. Rotate the wrench until the cam is in the
desired position. To stiffen the ride, rotate the cam so
as to raise the spring end. Make the adjustment on the
other cam and be sure both cams are adjusted equally.
FS383
78
NOTE: At this point, remove the set screw and
discard the valve plug. Always install a new plug
when servicing the shock absorber.
4. Depress the reservoir end cap and remove the end
cap retaining ring.
FS334
8. Remove the shock from the vise and pour shock
oil into a proper disposal container. DO NOT
REUSE OLD SHOCK OIL.
FS331
5. Using a 3/8-24 cap screw, remove the reservoir
end cap from the reservoir; then discard the end
cap O-ring.
FS335
9. Secure the shock body eyelet in the vise with the
open end of the reservoir directed up. Turn the
damping adjuster to the fully open position (counterclockwise).
FS378
6. Loosen and unscrew the bearing assembly from
the shock body.
FS384A
10. Using Piston Location Tool (p/n 0644-169),
remove the IFP from the shock body. Place the IFP
on a clean, lint-free rag or towel. Discard excess
reservoir oil.
FS333
7. Slowly remove the shaft assembly from the shock
body and place it on a clean, lint-free rag or towel.
79
13. Using a 5/8-in. socket, remove the damping
adjuster cartridge; then clean and inspect the
inboard and outboard O-rings.
FS337
FS292A
CAUTION
Care must be taken not to scratch the cartridge when
removing O-rings.
NOTE: At this point, inspect the re-flow check
valve for smooth operation and for not being bent
or deformed.
FS339
11. Remove the relief screw from the IFP. Discard the
relief screw O-ring, IFP O-ring, and the IFP strap.
FS380A
14. Install the cartridge; then tighten to 20 ft-lb.
FS338
12. Clean and dry the IFP; then secure the shock body
eyelet in the vise. Do not over-tighten the vise.
FS381
15. Clamp the shaft eyelet securely in vise with the
piston end up.
FS340
80
FS343
FS348
16. Using a 9/16-in. wrench, remove the piston nut
from the end of the shaft.
2. Slide the bearing assembly over the protector tool
onto the shaft.
FS344
FS349
17. Slide the piston assembly onto a T-handle wrench
to preserve the shim stack/piston order. Remove
and discard the step-cut piston strap and O-ring.
3. Install a new piston O-ring and step-cut piston
strap.
18. Remove the piston, bearing assembly, and spacer.
Inspect and/or replace the bottom out bumper if
necessary.
4. Place the preserved shim stack/piston assembly
onto the shaft; then using a 9/16-in. socket, install
the piston nut and tighten to 18 ft-lb.
FS350
FS346
Assembling
1. Place Bearing Cap Seal Protector (p/n 0644-268)
onto the end of the shaft; then apply grease to both
the tool and the shaft.
81
FS351
FS354
5. Place the shock body and eyelet in the vise with
the open end directed up.
9. Install Floating Piston Location Gauge (p/n 0644350) and cover the top of the tool with a towel; then
slowly press the IFP into the oil until fully covered.
6. Fill the reservoir with Shock Oil (p/n 5639-240)
until approximately 3/4 full.
NOTE: Allow a few minutes for oil to overflow
into the shock body.
FS355
FS352
7. Turn the damping adjuster to the fully closed position (clockwise); then refill the reservoir until
approximately 3/4 full.
FS356
10. Install the IFP relief screw making sure to seat the
relief screw O-ring. Do not tighten.
FS353
8. Lightly grease the IFP; then slowly insert the IFP
into the reservoir and press until the IFP is level
along the flat end of the reservoir.
FS357
82
11. Turn the damping adjuster to the fully open position (counterclockwise).
FS361
FS358
12. Using the IFP location gauge, slowly stroke the
IFP in the reservoir several times to purge air from
between the reservoir and shock body. Repeat this
process until no air bubbles rise through the oil in
the body. Do not expose the IFP above the oil surface.
16. Install new O-rings and piston strap on the piston
shaft assembly and lightly grease the piston strap;
then insert the piston shaft assembly into the shock
body holding the bearing up by the shaft eyelet.
FS362
FS359
13. Depress the IFP to its lowest position; then pull the
IFP to approximately 1 1/2 in. from the top of the
reservoir.
NOTE: Slowly in a circular motion, stroke the piston in the shock body tapping the shaft downward
with a rubber hammer on the down stroke. Repeat
this process several times until the air is purged
from the shim stack/piston assembly.
FS363
FS360
14. Turn the damping adjuster to the fully closed position (clockwise).
17. Fully extend the shaft without exposing the piston
to air; then refill with recommended oil until
approximately 1 in. from the top or to where the
threads for the bearing end.
15. Fill the shock body to approximately 1 in. from the
top with recommended shock oil.
83
FS364
FS368
18. While holding the shaft fully extended, slide the
assembly into the shock body.
NOTE: At this point, oil should overflow. If not,
add recommended oil.
FS369
21. While holding the IFP with the location gauge,
install and tighten the relief screw.
FS365
19. Using a torque wrench with a 1-in. crow-foot,
tighten the bearing assembly to 35 ft-lb.
FS370
22. Discard the excess oil remaining above the IFP.
FS367
20. Remove the IFP relief screw; then set the IFP location gauge to 1.9 in. measured from the top end of
the reservoir.
FS371
23. Lubricate and install the IFP reservoir end cap Oring. Install the reservoir end cap and retaining
ring. Ensure proper seating.
84
FS373
FS376
24. Install the set screw (FAV3 valve assembly) and
tighten only until snug; then loosen two turns.
27. Install the bearings and retaining rings into the eyelets.
25. Insert the needle squarely into the center of the
nitrogen valve set screw and plug (taking care that
the valve is directed away from face and body) and
pressurize the reservoir to 250 psi.
NOTE: Ensure proper shock function prior to
installing on the snowmobile.
Adjusting Rear Transfer Adjuster
Cams
The transfer system has seven positions. To make cam
adjustment, use the following procedure.
0741-231A
FS374
! WARNING
Charge the shock using nitrogen gas only. DO NOT
CHARGE WITH ANY OTHER TYPE OF GAS. Doing so
will compromise the performance of the shock and
may be EXTREMELY DANGEROUS.
26. Using a 3/16-in. hex key, tighten the set screw
(FAV3 valve) on the shock reservoir; then install a
new ball.
1. Loosen the Cap Screw (p/n 8020-040) and Lock
Nut (p/n 8047-366) securing the cams to the slide
rail. Remove the cap screw.
2. Using a 1/4-in. drive ratchet and extension, rotate
the cams to the desired position.
NOTE: Position 1 allows for the most weight transfer, and position 7 allows for the least weight transfer.
NOTE: When setting the cams, the chosen position must be directed toward the rear arm.
NOTE: Standard cam position is position 1.
3. Install the cap screw and lock nut to secure the
cam position; then tighten securely.
Lights
Removing Headlight Assembly
1. Remove the four screws securing the windshield to
the console; then remove the windshield.
FS329
2. Remove the four screws securing the windshield
brace to the console. Disconnect the gauge; then
remove the windshield brace assembly.
3. Disconnect the electrical accessory wires and ignition switch.
85
4. Remove the two screws securing the rear of the console to the hood.
3. Install the bulb and retainer; then rotate the retainer
clockwise until it properly locks in place.
5. Lift the front of the console from the headlight
assembly; then disengage the side console tabs and
remove the console.
4. Install the rubber grommet; then connect the headlight harness connector to the bulb.
5. Check headlight aim (see Adjusting Headlight Aim
in this sub-section).
! WARNING
Do not operate the snowmobile unless headlight beam
is adjusted properly. An incorrectly adjusted beam will
not provide the operator the optimum amount of light.
Installing Headlight Assembly
1. With the headlight assembly in position, install the
front headlight assembly screws. Engage the side
headlight screws in the slots and tighten until snug.
PC108
6. Loosen the two side headlight assembly screws (A);
then remove the two front headlight assembly screws
(B).
2. Engage the side console tabs on the headlight assembly; then place the front of the console over the headlight assembly. and press down until it snaps in place.
3. Install the two screws securing the rear of the console to the hood. Tighten only until snug.
4. Place the windshield brace assembly into position
and secure to the console with the four screws.
Tighten until snug.
5. Connect the gauge; then connect the electrical
accessory wires.
6. With the windshield in position, secure the windshield
to the frame using the four screws. Tighten securely.
PC107A
7. Remove the headlight assembly.
Removing/Installing Headlight Bulb
NOTE: The bulb portion of the headlight is fragile.
HANDLE WITH CARE. When replacing the headlight
bulb, the bulb assembly must first be removed from
the housing. Do not touch the glass portion of the
bulb. If the glass is touched, it must be cleaned with a
dry cloth before installing.
1. Disconnect the headlight harness connector from the
bulb; then remove the rubber grommet from the
headlight housing.
Ski Wear Bar
The ski wear bar is a replaceable bar attached to the
underside of the ski. The purpose of the wear bar is to
assist in turning the snowmobile, to minimize ski wear,
and to maintain good steering control. If the snowmobile is operated primarily in deep snow, ski wear bar
wear will be minimal; however, if the snowmobile is
operated on terrain where the snow cover is minimal,
the ski wear bar will wear faster. To maintain positive
steering characteristics, Arctic Cat recommends that
the ski wear bars be checked before each use and
replaced if worn beyond 1/2 of the original diameter.
Ski wear bars are available from an authorized Arctic
Cat Snowmobile dealer.
2. Rotate the bulb retainer counterclockwise until it
unlocks from the housing; then remove the bulb.
! WARNING
Operating the snowmobile with excessively worn or
missing wear bars may result in a loss of steering control.
NOTE: Always check the official rules for the
appropriate wear bars for the event being participated in.
Removing
1. Raise the front of the snowmobile and place it on a
support stand.
0746-096
86
2. Remove the lock nuts (and washers on the Sno
Cross model) securing the wear bar to the ski.
Rail Wear Strip
Arctic Cat recommends that the wear strips be checked
weekly and replaced as necessary. Measure the wear
strips at 25.4 cm (10 in.) intervals. Wear strips must be
10.7 mm (0.42 in.) thick or thicker. If wear strip measurements are less than specified, replacement of both
wear strips is necessary to prevent premature track clip
wear and possible track damage.
NOTE: The rail wear strips will wear rapidly if the
snowmobile is operated on terrain on which the
snow cover is minimal. Loose snow is required to
cool and lubricate the wear strips and prevent
accelerated wear.
0743-185
3. Remove the wear bar from the ski.
Installing
1. Move the wear bar into position on the bottom of
the ski.
2. Align the wear bar studs with the holes in the ski;
then install the lock nuts with washers (Sno Cross
model only). Tighten to 15 ft-lb.
0744-875
87
Performance Tips
Operating a high performance snowmobile requires a
special attention. Often, a minor adjustment will result in
a large increase in performance. This section is intended
to highlight minor conditions that adversely affect performance and the adjustments needed to correct them. Be
sure, however, to thoroughly read and understand this
entire manual especially the section on spark plugs, track
tension and alignment, and suspension.
DRIVE BELT — This link between the engine and
drive train is often the most neglected component. The
drive belt must have the proper fit in the drive clutch
and driven clutch. Proper fit is when the top surface of
the drive belt is flush with the top or up to 1/16 in.
higher than the driven clutch sheaves (with the sheaves
fully closed). If the belt sits below this level, the snowmobile will bog at slow speeds and will have a slower
maximum speed. To correct this condition, first determine if the drive belt is within specifications (see
Drive Belt section) and replace if worn or too long.
Secondly, always run the drive belt in the same direction. Installing the drive belt so the part number can be
read will ensure that the drive belt is always run the
same direction.
88
DRIVE CLUTCH AND DRIVEN CLUTCH —
Keeping the drive clutch and driven clutch clean
should be the primary consideration of the operator.
The clutch sheaves can be cleaned of any drive belt
accumulation using a clean cloth and parts-cleaning
solvent. All pivot points can be maintained clean using
compressed air.
CAUTION
Use Clutch Puller (p/n 0744-062). Never substitute a
different puller or drive clutch damage will occur.
CARBURETOR MAIN JETS — Proper carburetion,
specifically proper main jets, is absolutely necessary to
obtain peak performance. Since ambient temperature
and operating altitude both affect the main jet size
needed for optimum engine performance, the main jets
will often need to be changed whenever the temperature changes 20° F (11° C) or whenever operating altitude varies by more than 1000 feet.
Preparation For Storage
Prior to storing the snowmobile, it must be properly
serviced to prevent corrosion and component deterioration. To prepare the snowmobile for storage, Arctic
Cat recommends the following procedure.
1. Clean the seat cushion with a damp cloth and Arctic Cat Vinyl Protectant.
2. Clean the snowmobile thoroughly by hosing dirt,
oil, grass, and other foreign matter from the skid
frame, tunnel, hood, and belly pan. Allow the
snowmobile to dry thoroughly. DO NOT get water
into any part of the engine.
8. Drain the chain-case lubricant. Remove the chaincase cover and inspect chain, sprockets, and chain
tensioner for wear and the chain for proper tension. Install the chain-case cover and seal; then
pour Arctic Cat Synthetic Chain Lube (p/n 5639038) into the oil level stick filler hole according to
specifications.
9. Remove the drive belt from the drive clutch/driven
clutch. Lay the belt on a flat surface or slide it into
a cardboard sleeve to prevent warping or distortion
during storage.
10. Clean and inspect the drive clutch and driven
clutch.
11. Apply light oil to the upper steering post bushing
and shafts of the shock absorbers.
3. Place the rear of the snowmobile up on a shielded
safety stand. Remove the air-intake silencer boots
from the carburetors.
12. Lubricate the rear suspension and bellcranks with
a all-temperature grease.
4. Start the engine and allow to idle. With the engine
idling, spray an Engine Storage Preserver into the
carburetors until the engine exhaust starts to
smoke heavily or until the engine starts to drop in
RPM. Turn engine off.
13. Tighten all nuts, bolts, and cap screws making sure
all calibrated nuts, bolts, and cap screws are tightened to specifications. Make sure all rivets holding
the components together are tight. Replace all
loose rivets.
5. Plug the exhaust system outlet with a clean cloth.
14. Clean and polish the hood, console, and chassis
with Cat Cleaner (p/n 4639-371). DO NOT USE
SOLVENTS. THE PROPELLANT WILL DAMAGE THE FINISH.
6. With the tether switch cap removed:
A. Disconnect the high tension leads from the
spark plugs; then remove the plugs, connect
them to the leads, and ground them on the cylinder heads.
CAUTION
Never crank the engine over without grounding the
spark plugs. Damage to coils and/or CDI unit may
result.
B. Pour 29.5 ml (1 fl oz) of SAE #30 petroleumbased oil into each spark plug hole and pull the
recoil starter handle slowly about 10 times.
C. Install the spark plugs and connect the high tension leads.
7. Drain the gas from the carburetor float bowls. Fill
the gas tank to its rated capacity; then add Arctic
Cat Fuel Stabilizer (p/n 0436-907) to the gas tank
following directions on the container for the stabilizer/gasoline ratio. Tighten the gas tank cap
securely.
15. If possible, store the snowmobile indoors. Raise
the track off the floor by blocking up the back end
making sure the snowmobile is secure. Loosen the
track adjusting bolts to reduce track tension. Cover
the snowmobile with a machine cover or a heavy
tarpaulin to protect it from dirt and dust.
16. If the snowmobile must be stored outdoors, position the snowmobile out of direct sunlight; then
block the entire snowmobile off the ground making sure the snowmobile is secure. Loosen the
track adjusting bolts to reduce track tension. Cover
with a machine cover or a heavy tarpaulin to protect it from dirt, dust, and rain.
CAUTION
Avoid storing in direct sunlight and using a plastic
cover as moisture may collect on the snowmobile
causing corrosion.
89
Preparation After
Storage
Taking the snowmobile out of storage and correctly
preparing it for another season will assure many miles
and hours of trouble-free snowmobiling. Arctic Cat
recommends the following procedure.
CAUTION
If the gas in the carburetor float chambers was not
drained prior to storage, the carburetors must be
cleaned before starting the engine.
1. Clean the snowmobile thoroughly. Polish the exterior of the snowmobile.
2. Clean the engine. Remove the cloth from the
exhaust system. Check exhaust system and airintake silencer for obstructions.
3. Inspect all control wires and cables for signs of
wear or fraying. Replace if necessary. Use cable
ties or tape to route wires and cables away from
hot or rotating parts.
4. Inspect the drive belt for cracks and tears. Check
belt specifications. Replace if damaged or worn.
Install the drive belt.
NOTE: If the old belt is worn but in reasonable
condition, keep it in the tool box as a spare in case
of emergency.
90
5. Inspect the in-line fuel filter and replace if necessary. Inspect all fuel hoses for deterioration or
cracks; replace if necessary. Make sure all connections are tight.
6. Inspect the entire brake system (fluid level, pads,
etc.), all controls, headlight, taillight, brakelight,
ski alignment, ski wear bars, and headlight aim;
adjust or replace as necessary.
7. Inspect the spark plugs. Replace, gap, or clean as
necessary.
8. Adjust the track to the proper tension and alignment.
NOTE: Prior to tipping the snowmobile on its
side, apply the brake and set the brake lever lock.
9. Check air pressure in the front ski shocks.
10. Adjust the carburetors, throttle cable, and choke
cable.
! WARNING
Be sure to tighten the swivel adapter jam nuts
securely. If a jam nut isn’t tightened, the adjuster can
rotate out of the carburetor cap causing the throttle
slide not to return to the full-closed position.
11. Tighten all nuts, bolts, and cap screws making sure
all calibrated nuts, bolts, and cap screws are tightened to specifications.
12. If not done during preparation for storage, lubricate the front and rear suspension and spindles
with an all-temperature grease.
Genuine Arctic Cat
Products
Arctic Cat Oil - Developed, tested, and proven especially for Arctic Cat Snowmobile engines. Arctic Cat
Oil is the only oil authorized by Suzuki and Arctic Cat
engineers for use in Arctic Cat Snowmobile engines.
Arctic Cat Oil ensures warranty coverage for lubricating related incidents. Arctic Cat Oil comes in strong,
handy, recloseable containers.
Transmission Lube - A special formula that reduces
friction and fights corrosion. Arctic Cat Transmission
Lube comes in easy-pour, recloseable containers.
Synthetic Chain Lube - A special formula reduces
friction and fights chain case corrosion.
Fuel Stabilizer - Fuel treatment for storage longer
than 60 days. Slows oxidation to prevent gum and varnish buildup. Engines start easily even after storage
periods exceeding one year. Ideal for use in snowmobile gas tanks.
Antifreeze - Pre-mixed ready for use without adding
any water. Comes in 1 gallon container.
Hi-Temp Brake Fluid - Recommended for Arctic Cat
hydraulic brake system.
Product
Container
Part
Size
Number
Pkg/Qty
Synthetic APV 2-Cycle Oil
55 gal.
2639-509
1
1 gal.
2639-511
6/1 gal.
16 gal.
2639-510
1
2-1/2 gal.
2639-975
2—2-1/2 gal.
12/1 qt.
1 qt
2639-512
Synthetic Chain Lube
8 oz
5639-038
–
Transmission Lube
12 oz
0636-817
12/12 oz
Engine Storage Preserver
12 oz
0436-888
12/12 oz
All-Temp Grease (Lithium)
14-1/2 oz
4639-365
10/14-1/2 oz
12/10 oz
Silicone Spray
10 oz
0636-594
Shock Oil - Light (Fox Racing)
1 qt
4639-345
1 qt
Fuel Stabilizer
8 oz
0436-907
12/8 oz
Hi-Temp Brake Fluid
12 oz
0436-908
6/12 oz
Antifreeze
1 gal.
0436-909
6/1 gal.
Fuel System Cleaner
12 oz
3639-619
1
Race Fuel (116-Leaded)
16 gal.
3639-620
1
55 gal.
3639-621
1
16 gal.
2639-098
1
55 gal.
2639-097
1
16 gal.
2639-098
1
55 gal.
2639-097
1
16 gal.
3639-620
1
55 gal.
3639-621
1
1 qt
5639-240
1 qt
Shock Oil
91
Flywheel Puller Insert
Special Tools
To order any special tools, call the Service Department
at Arctic Cat Inc. 1-800-279-2281.
p/n: 0644-179
Usage: Protect the crankshaft end during flywheel
removal.
Ball Hone
p/n: 0644-290 (60-64 mm)
p/n: 0644-291 (65-70 mm)
p/n: 0644-292 (72-74 mm)
p/n: 0644-293 (76-83 mm)
p/n: 0644-294 (83-88 mm)
p/n: 0644-531 (90-95 mm)
p/n: 0644-532 (96-101 mm)
p/n: 0644-533 (102-108 mm)
Usage: Deglaze Nicosil plated cylinders. All are 320 grit
and are recommended for reconditioning Arctic Cat snowmobile engine cylinders.
0644-179
Flywheel Puller
p/n: 0744-040 (Complete Set)
p/n: 0643-086 (Body)
p/n: 0643-087 (Bolt)
p/n: 0423-482 (6 mm Cap Screw)
p/n: 0423-483 (8 mm Cap Screw)
Usage: Pull flywheel off crankshaft on all Arctic Cat 2stroke models.
0644-291
Flywheel Spanner Wrench
p/n: 0144-007
Usage: Hold starter cup while removing/installing flywheel nut.
0744-040
Crankshaft Bearing Remover
p/n: 0144-302
Usage: Remove crankshaft bearings.
0144-007
0144-302
92
Oil Seal Protector Tool
Spring Tool
p/n: 0644-219
Usage: Protect the oil seal when installing the water
p/n: 0644-072
Usage: Remove/install exhaust springs.
pump driveshaft on liquid cooled 2-stroke Arctic Cat
engines.
0644-072
0644-219
Stud Runner
p/n: 0644-018 (6 mm)
p/n: 0644-019 (8 mm)
p/n: 0644-020 (10 mm)
Usage: Install studs on cylinders and crankcase.
Piston Pin Puller
p/n: 0643-073 (Extractor Nut Only-Small)
p/n: 0643-074 (Extractor Nut Only-Medium)
p/n: 0643-075 (Extractor Nut Only-Large)
p/n: 0643-072 (Threaded T-Handle)
Usage: Remove piston pins.
0644-020
Surface Plate
0644-328
p/n: 0644-016
Usage: True sealing surfaces.
Spring Tool
p/n: 0644-554
Usage: Remove/install exhaust springs.
0644-016
0644-554
93
V Blocks
Compression Tester Kit
p/n: 0644-535
Usage: Check crankshaft runout.
p/n: 0444-213 (Complete Kit)
p/n: 0444-207 (10 mm Adapter)
p/n: 0444-093 (12 mm Adapter)
Usage: Test cylinder compression on all Arctic Cat
engines.
0644-535
Water Pump Bearing and Seal Tool Kit
p/n: 0644-557
Usage: Remove/install crankcase water pump bearings
0444-213
Engine Timing Gauge
p/n: 0144-009
Usage: Static time engines without CDI ignition.
and seals.
0644-557
0144-009
Vacuum Test Pump
Timing Light
p/n: 0644-131
Usage: Check components for air leaks.
p/n: 0644-296
Usage: Check ignition timing.
0644-131
0644-296
94
90° Hex Driver (1/4-in.)
Drive Clutch Puller (Arctic)
p/n: 0644-550
p/n: 0744-062
Usage: Make carburetor adjustments on all twin and triple cylinder engines. Also, for any hard-to-get-at hex nuts.
(A. 6 mm Hex)
(B. 0.157-in. D-Head)
(C. 1/4-in. Drive)
(D. Straight Blade)
(E. Phillips-Head)
Usage: Remove drive clutch from the crankshaft on
2010-2012 models.
0644-207
Drive Belt Deflection Tool
p/n: 0644-424
0644-550
Bearing Cap Seal Protector
Usage: Adjust driven clutch for proper drive belt deflection and aid in drive belt removal on Sno Pro 600 model
with Team Industries driven clutch.
p/n: 0644-268
p/n: 0644-403 (1/2 in. O.D. x 3/8 in. I.D.)
p/n: 0644-404 (5/8 in. O.D. x 3/8 in. I.D.)
p/n: 0644-542 (5/8 in. O.D. x 1/2 in. I.D.)
Usage: Protect cap seal on rebuildable shock absorbers.
0644-424
p/n: 0644-136
0644-404
Usage: Hold Comet and Arctic round-shaft drive clutch in
place during removal and installation.
Clutch Compressor
p/n: 0644-420
Usage: Compress and hold drive clutch in the compressed position for changing cam arms and removing/
installing six-post drive clutch.
0644-136
0644-420
95
Drive Clutch Bolt Tool (Torx #60)
Track Clip Installation Tool
p/n: 0644-281
p/n: 0644-194
Usage: Install track clips on Camoplast and Yokohama
Usage: Remove/install drive clutch bolt.
rubber tracks.
0644-281
0644-194
Driven Clutch Compressor Tool
p/n: 0644-444
p/n: 0643-095 (A. Disc Only)
Track Stud Hole Drill (7 mm)
Usage: Disassemble/assemble Arctic ACT and Team
Industries roller driven clutches.
Usage: Drill 7 mm hole through rubber tracks for installing studs.
0644-444
1639-629
p/n: 1639-629
Spider Removal Kit
p/n: 0744-037 (Handle)
p/n: 0744-036 (Removal Tool)
p/n: 0644-380 (Clutch Holder - 33 mm)
p/n: 0744-035 (Clutch Holder - 30 mm)
p/n: 0644-138 (Thin Wall Deep Socket - 1 7/16 in.)
Usage: Disassemble/assemble/remove spider on Arctic
drive clutches.
0644-449
96
Throttle Position Sensor (TPS) Adjustment
Tool Kit
p/n: 1686-436 (Harness Only)
p/n: 0644-359 (Torx-Head Screwdriver - #25 Only)
p/n: 0644-344 (Torx-Head Screwdriver - #30 Only)
p/n: 0644-345 (Pin Gauge Only)
Usage: Precisely adjust the throttle position sensor on
carbureted and EFI models.
3639-891
Idler Wheel Puller Kit
Gas Shock Retaining Blocks (Zero Pro)
p/n: 0644-401 (A. Handle)
p/n: 0644-111 (B. Insertion Tool - 1.000 in.)
p/n: 0644-569 (B. Insertion Tool - 1.560 in.)
p/n: 0644-120 (C. Pivot Plate)
p/n: 0644-118 (D. Adapter Plate - 1 in.)
p/n: 0644-538 (D. Adapter Plate - 1 1/4 in.)
p/n: 0623-310 (E. Cap Screw)
p/n: 0644-432 (F. Puller Bolt)
p/n: 0644-486
Usage: Hold shock secure during disassembly and
assembly.
Usage: Remove/install skid frame idler wheels.
0644-334
Gas Shock Shaft Clamping Tool
p/n: 0644-543
Usage: Hold shock secure during disassembly and
assembly on 2008 Sno Pro 600.
0644-570
Floating Piston Location Gauge
p/n: 0644-350
Usage: Precisely locate and measure floating piston
depth without use of a calipers.
0644-543
Inflation Needle
p/n: 0744-020
Usage: Pressurize rebuildable gas shock absorbers with
nitrogen.
0644-350
0744-020
97
Inflation Needle Replacement
Piston Location Tool
p/n: 0644-544
Usage: Replacement needle assembly for Inflation Nee-
p/n: 0644-169
dle (p/n 0744-020).
Usage: Precisely locate the floating piston in the rebuildable gas shock absorber.
0644-169
0644-544
Inflation Needle Replacement Tip
Piston Location (IFP) Tool
p/n: 0644-539
p/n: 0644-575
Usage: Update earlier inflation needles for Fox Float
shock absorbers. Also, for earlier Fox and ACT shock
absorbers.
Usage: Precisely locate the floating piston (IFP) in the
rebuildable gas shock absorber.
0644-575
0644-539
Axle Nut Spanner Wrench
Nitrogen Regulator
p/n: 0644-454
p/n: 0644-151
Usage: Recharge rebuildable gas shock absorbers.
Usage: Adjust track alignment/tension (2005 440 Sno
Pro).
0644-151
98
0644-454
Axle Nut Spanner Wrench
Insert Holder (5/16 in.)
p/n: 0644-558
p/n: 0644-315
Usage: With Torx Bit Insert (p/n 0644-314), remove and
Usage: Adjust track alignment/tension (2010-2012 Sno
Pro 500 and Sno Pro 600).
install torx-head screws.
0644-558
0644-315
Rear Suspension Spring Tool
Phillips-Head Bits (1/4 in. Hex Drive)
p/n: 0144-311
Usage: Install/remove rear suspension springs.
p/n: 0644-319 (#2)
p/n: 0644-318 (#3)
Usage: With Quick-Disconnect Coupler (p/n 0644-308),
remove and install Phillips-head screws.
0144-311
Hex Bits (1/4 in. Hex Drive)
0644-318
p/n: 0644-317 (5 mm)
p/n: 0644-316 (6 mm)
remove and install bolts and screws.
Quick-Disconnect Coupler
p/n: 0644-308
Usage: Hold 1/4 in. hex drive Torx Bits (page 101), Hex
Bits (page 99), and Phillips-Head Bits (page 99).
0644-316
0644-308
99
Replacement Rivnuts
Rivnut Tool Insert Bit
p/n: 0623-557 (1/4 x 20)
p/n: 0623-582/627 (1/4 x 20)
p/n: 0623-581 (5/16 x 18)
p/n: 0623-699 (3/8 x 16)
p/n: 0623-874 (8-32)
p/n: 0623-529/779 (10-32)
Usage: With Rivnut Tool (p/n 0644-232), replace rivnuts.
p/n: 0644-233 (1/4 x 20)
p/n: 0644-405 (10-32)
p/n: 0644-430 (5/16 x 18)
p/n: 0644-431 (3/8 x 16)
Usage: With Rivnut Tool (p/n 0644-232) and Replacement Rivnuts, replace rivnuts.
0644-233
0623-557
T-Handle Wrench
p/n: 0644-257 (8 mm)
p/n: 0644-024 (10 mm)
p/n: 0644-025 (12 mm)
p/n: 0644-026 (14 mm)
Usage: Remove and install nuts and bolts.
Rivnut Tool
p/n: 0644-232
Usage: Collapse and install rivnuts.
0644-232
Toggle-Switch Wrench
0644-257
p/n: 0644-566
Usage: Remove/install a toggle switch on 2010-2012 Sno
Pro 600.
Jackshaft Bearing Wrench
p/n: 0644-516
Usage: To retain the jackshaft bearing.
0644-566
0644-516
100
T Wrench
Torx Bits (1/4 in. Hex Drive)
p/n: 0644-021
Usage: Drive 3/8 in. square-drive sockets.
p/n: 0644-312 (#25)
p/n: 0644-393 (#27)
p/n: 0644-215 (#30)
p/n: 0644-313 (#40)
remove and install torx-head screws.
0644-021
Torx Bit Insert (5/16 in. Hex Drive)
p/n: 0644-314
Usage: With Insert Holder (p/n 0644-315), remove and
install torx-head screws.
0644-314
0644-312
NOTES
102
Declaration of Conformity
Application of council directives:
Issued by European Commission.
EMC Directive 2004/108/EC
EC Machinery Directive 2006/42/EC
Type of Equipment: Snowmobile
Brand Name: Arctic Cat
Model Numbers:
S2015ACDCCUSG
Standards to which conformity is declared:
EMC:
EN 55012, EN 61000-6-2
MACHINERY:
EN 12100:2010
Manufacturer (if not issuing agent):
Arctic Cat Inc.
601 Brooks Ave. S.
Thief River Falls, MN
56701 USA
I, the undersigned, hereby declare that the equipment specified above conforms to the directive(s) and standard(s) as specified.
Brad Darling
Vice President/General Manager - Snowmobile Division
103
Printed in U.S.A.
®TMTrademarks
of Arctic Cat Inc. Thief River Falls, MN 56701 p/n 2260-495
Phone: (218) 681-9851 - U.S. (204) 982-1656 - Canada

operator`s manual

Transcription

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