Snowmobile Operator`s Manual

Snowmobile Operator`s Manual
Snowmobile
Operator’s
Manual
p/n 2258-236
LIMITED WARRANTY
Arctic Cat Inc. (hereinafter referred to as Arctic Cat) extends a limited warranty on each new Arctic Cat
Snowmobile it manufactures and on each part and accessory manufactured or sold by Arctic Cat. The
warranty is extended to the original retail purchaser only on parts and accessories sold through an
authorized Arctic Cat Snowmobile dealer. Warranty on snowmobiles is extended to the original retail
purchaser; however, the balance of the unused warranty may be transferred to a second party.
Arctic Cat warrants only the products it manufactures and/or sells and does not warrant that 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 sale and/or 5000 MILES whichever comes first.
3. THIRTY (30) DAYS from date of sale of snowmobile on all batteries.
4. THIRTY (30) DAYS from date of sale for all dealer installed service parts and accessories.
5. UNTIL EXPIRATION OF THE NEW PRODUCT WARRANTY for all eligible replacement
parts.
Exclusions to this warranty include normal wear, abuse (i.e. a track run on marginal snow conditions
without proper lubrication or additional idler wheels), and the following parts:
Fuel Filter
Drive Belt
Fan Belt
Light Bulbs
Wear Bars
Spark Plugs
Windshield
Water Pump Belt
Wear Strips
Torn or Punctured Upholstery
Brake Pads
Drive Clutch/Driven Pulley Wear Parts
The following will VOID Arctic Cat’s warranty:
1. Failure to perform the proper break-in procedure and all operator related maintenance,
storage procedures, and service as recommended in the Operator’s Manual.
2. Repairs and/or adjustments by anyone other than an authorized Arctic Cat Snowmobile
dealer.
3. Use of an improper fuel mixture ratio.
4. Use of improper carburetor main jets.
5. Use of improper gasoline, lubricating oils, or spark plugs.
6. An accident or subjecting the snowmobile to misuse, abuse, or negligent operation.
7. Any modification or removal of parts (i.e. air-intake silencer, muffler, etc.) unless instructed
to do so by Arctic Cat.
8. Use of the snowmobile in any way for racing purposes.
9. Removal of the engine for use in another vehicle.
10. Removal or mutilation of the Vehicle Identification Number or Engine Serial Number.
11. Use of parts not sold or approved by Arctic Cat.
12. Track and tunnel damage resulting from either ice stud or hooker plate installation.
13. Damage due to improper transportation.
In consideration of the foregoing, any implied warranty is limited in duration to the various warranty
periods set forth. This warranty gives you specific legal rights, and you may also have other rights which
vary from state to state and country to country. Some states do not allow limitations on how long an
implied warranty lasts, so the above limitations may not apply to you.
Table of Contents
Limited Warranty ......... Inside Front Cover
Foreword ................................................ 1
Declaration of Conformity....................... 2
Snowmobile Safety Rules ...................... 3
General Information .......................... 4-27
Snowmobile Identification.................. 4
Control Locations............................... 4
Gasoline-Oil....................................... 6
Engine Break-In (2-Stroke Models) ... 7
Engine Break-In (1100 cc Models) .... 8
Speedometer/Tachometer Indicator
Icons (Standard Gauge) ................. 8
Speedometer/Tachometer Indicator
Icons (Premium Gauge) ............... 11
Diagnostic Codes
(Standard/Premium Gauges) ...... 14
Handlebar Tilt
(Bearcat/Crossfire/
M-Series Models) ......................... 15
Handlebar Tilt (F-Series/T-Series STD Models) ................................ 15
Handlebar Tilt (Cam Lever Style) .... 16
Telescopic Handlebar (Crossfire/
M-Series Sno Pro/Sno Pro LE
Models)......................................... 17
Exhaust System............................... 17
Air-Intake Silencer ........................... 17
Battery (Electric Start Models) ........ 17
Cooling System (Liquid) .................. 18
Drive Clutch and Driven Pulley ........ 18
Drive Clutch/Driven Pulley
Alignment ..................................... 18
Fuel Pump ....................................... 18
Shock Absorbers (Standard Gas).... 19
Shock Absorbers
(Rebuildable Gas)......................... 19
Deep-Lug Track ............................... 19
Standard-Lug Track ......................... 20
Track Studs ...................................... 20
Reverse Transmission
(Lever Style Models)..................... 21
Reverse Transmission
(Switch Button Style Models) ....... 22
Towing ............................................. 22
Adjustable/Movable Backrest
(T-Series Models) ......................... 22
Removable Rear Seat
(Bearcat XT Models) .................... 23
Removable Rear Seat
(T-Series Models) ......................... 23
Removable Seat
(Crossfire/M-Series Models)......... 24
Removable/Adjustable Seat
(TZ1 Turbo/LXR Models) .............. 24
Removable/Adjustable Seat
(F-Series/Z1 Models) ....................25
Arctic Power Valve (APV) System ....26
Exhaust Controlled Timing (ECT)
System (600/800/1000 cc
Models) .........................................27
Operating Instructions .....................28-34
Starting and Stopping Engine ..........28
Braking .............................................30
Emergency Stopping........................32
Throttle/Ignition Monitor Switch........32
Varying Altitude Operation ...............34
Lubrication .......................................35-38
ACT Drive Gear Case ......................35
Front Suspension .............................37
Rear Suspension .............................38
Maintenance ....................................39-71
Periodic Maintenance Checklist .......39
Air Cleaner/Filter (1100 cc Turbo) ....40
Fuel System .....................................40
Checking Engine Oil Level
(1100 cc Models) ..........................42
Changing Engine Oil/Filter
(1100 cc Models) ..........................43
Coolant Level ...................................44
Adjusting Carburetors ......................45
Selecting Carburetor Main Jets........48
Spark Plugs (1100 cc Models) .........48
Spark Plugs (2-Stroke Models) ........49
Checking/Adjusting Valve Clearance
(1100 cc Models) .........................50
Battery (Electric Start Models) .........50
Fuses (Electric Start Models)...........52
Hydraulic Brake System...................53
Drive Belt .........................................56
Track Tension ...................................58
Track Alignment................................60
Suspension ......................................61
Lights ...............................................65
Ski Wear Bars ..................................70
Adjusting Ski Stance (M-Series/
Crossfire/Bearcat 570/570 XT/
Bearcat Z1 XT Models) .................70
Rail Wear Strips ...............................71
Performance Tips .................................72
Preparation For Storage ..................73-74
Preparation After Storage ................75-76
U.S. EPA Emission Control
Statement/Warranty Coverage......78
Change of Address, Ownership,
or Warranty Transfer......................79
Warranty Procedure/Owner
Responsibility.......Inside Back Cover
REFERENCE 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: ________________________________________
Vehicle Identification Number: ______________________________
Engine Serial Number: ____________________________________
Your Arctic Cat Dealer: __________________________________
Address: ______________________________________________
Phone: ________________________________________________
! WARNING
A snowmobile is a very high performance vehicle. 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.
PERSONAL INJURY
• To avoid injury to yourself and others, NEVER operate the snowmobile without
first reading and understanding this manual and the Snowmobile Safety Handbook; then follow the instructions and heed the warnings given.
• USE COMMON SENSE.
• DON’T DRINK and DRIVE.
• STAY IN CONTROL at ALL TIMES.
• TELL YOUR FRIENDS. If you see a friend operating a snowmobile recklessly, at
excessive speeds, while intoxicated, or in other unsafe ways, don’t wait until it is
too late to warn of the consequences of snowmobile misuse. Such conduct
endangers everyone. TAKE AN ACTIVE ROLE IN THE SAFETY OF YOURSELF AND OTHERS.
PARTS AND 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 these snowmobiles, an
Illustrated Parts Manual and a Service Manual are available through your local
Arctic Cat Snowmobile dealer.
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 learn 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 safety-related information. Be sure to follow the directive because it deals with the possibility of severe
personal injury or even death. The symbol ! 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. This manual was prepared by the Product Service and Warranty
Department of Arctic Cat Inc.
Every Arctic Cat Snowmobile meets or exceeds the standards of the Snowmobile
Safety and Certification Committee and displays the SSCC decal. Arctic Cat Inc.
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.
© 2008 Arctic Cat Inc.
Printed in U.S.A.
1
DECLARATION OF CONFORMITY
Application of council directives:
Issued by European Commission.
EMC Directive 89/336/EEC
EC Machinery Directive 98/37/EC
Type of Equipment: Snowmobile
Brand Name: Arctic Cat
Model Numbers:
S2009F5DFCUSG
S2009F5DFCOSG
S2009T5CTOUSG
S2009T5CTOOSG
S2009T5DFCUSG
S2009T5DFCOSG
S2009TZNTOUSG
S2009TZNTOOSG
S2009CFD1EUSB
S2009CFH1EUSB
S2009CFHSPUSW
S2009CFHLEUSB
S2009M8HLEOSB
S2009M1L3EUSB
S2009M1LSEUSW
S2009M1LLEUSB
S2009CFHRCUSO
S2009F1LEPOSG
S2009TZNPKUSG
S2009TZNLXUSB
S2009TZNLXOSB
S2009TZNTXUSB
S2009TZNTLUSB
S2009TZNTLOSB
S2009BCDFCUSL
S2009BCDFCOSL
S2009BCDWTUSL
S2009BCDWTOSL
S2009CFHLEOSB
S2009CFL1EUSB
S2009CFLSPUSW
S2009CFLLEUSB
S2009M1LEKUSB
S2009M1LSPUSW
S2009CFLEXUSB
S2009F6DEPOSG
S2009BCNWTUSL
S2009BCNWTOSL
S2009BCNWTUSB
S2009F5CEFUSG
S2009F5CLXUSG
S2009F6DEPUSG
S2009F6DEPUSO
S2009F8HEFUSG
S2009F8HEPUSG
S2009F8HEPUSO
S2009CFLLEOSB
S2009M6D3EUSB
S2009M6D3EOSB
S2009M8H3EUSB
S2009M1LSPOSW
S2009CFHEXUSB
S2009CFLRCUSB
S2009F8HEPOSO
S2009F8HLXUSG
S2009F8HLEUSB
S2009F1LEPUSG
S2009F1LEPUSO
S2009Z1NEFUSG
S2009Z1NLXUSB
S2009Z1NTBUSB
S2009Z1NTSUSB
S2009Z1NTXUSB
S2009CFC1EUSB
S2009M8HEKUSB
S2009M8HSPUSW
S2009M8HSEUSW
S2009M8HLEUSB
S2009M1LSEOSW
S2009CFHRCUSB
S2009CFLRCUSO
S2009Z1NTXOSB
Standards to which conformity is declared:
EMC:
EN 50082-1/ 1992, EN 50081-1
MACHINERY:
EN 292-1, EN 292-2, EN 953, EN 1050, EN 954-1
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.
Fred Bernier
Manager, Product Testing & Certification
2
SNOWMOBILE SAFETY RULES
SNOWMOBILE SAFETY RULES
3
GENERAL INFORMATION
SNOWMOBILE
IDENTIFICATION
 NOTE: The VIN also appears on
a decal beneath the seat (Crossfire/M-Series) or attached to the
The Arctic Cat Snowmobile has two right-side tunnel (remaining modimportant identification numbers. The els). The decal also displays pertiVehicle Identification Number (VIN) is nent production information.
stamped into the tunnel near the rightside footrest. The Engine Serial Num- These numbers are required by the
ber (ESN) is stamped into the crank- dealer to complete warranty claims
properly. No warranty will be allowed
case of the engine.
by Arctic Cat Inc. if the engine serial
number or VIN is removed or mutilated in any way.
0726-383
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.
CONTROL LOCATIONS
Shown are the typical control locations
for Arctic Cat snowmobiles. Location
of a specific control will vary according to model.
Bearcat 570/570 XT/F 570 - T500/T570 Models
742-456A
4
GENERAL INFORMATION
Bearcat Z1 XT/F5/F6/F8/F1000/Z1/TZ1 Models
0743-518
Crossfire 500/600/800/1000/M-Series Models
741-633A
Crossfire 800R/1000R
0743-441
GENERAL INFORMATION
5
GASOLINE-OIL
Recommended
Gasoline (Carbureted
Models)
The recommended gasoline to use in
these snowmobiles is 87 octane regular
unleaded. In many areas, oxygenates
(either ethanol or MTBE) are added to
the gasoline. Oxygenated gasolines
containing up to 10% ethanol or up to
15% MTBE are acceptable gasolines;
however, whenever using oxygenated
gasolines, the carburetor main jet must
be one size larger than the main jet
required for regular unleaded gasoline.
For example, if a 400 main jet is recommended for regular unleaded gasoline, a 410 main jet must be installed if
using an oxygenated gasoline.
When using ethanol blended gasoline,
it is not necessary to add a gasoline
antifreeze since ethanol will prevent
the accumulation of moisture in the
fuel system.
! CAUTION
Do not use white gas or gasolines
containing methanol. Only Arctic
Cat approved gasoline additives
should be used.
Recommended
Gasoline (EFI Models)
The recommended gasoline to use in
these snowmobiles is 87 octane regular
unleaded.
 NOTE: On the 2-stroke EFI
engine models for optimum performance, do not exceed the recommended 87 octane gasoline. Using
a higher octane gasoline will not
increase overall performance.
6
 NOTE: The Z1 Turbo models will
detect lower octane gasoline and
reduced engine performance will
result. It is recommended that 91
octane (minimum) gasoline be
used in these models.
In many areas, oxygenates (either ethanol or MTBE) are added to the gasoline.
Oxygenated gasolines containing up to
10% ethanol or up to 15% MTBE are
acceptable gasoline. Do not use gasolines containing methanol.
! CAUTION
Do not use white gas or gasoline
containing methanol. Only Arctic
Cat approved gasoline additives
should be used.
Recommended
Injection Oil
The recommended oil to use in the oilinjection system is Arctic Cat 50:1
Injection Oil (for standard models) or
Arctic Cat Synthetic APV 2-Cycle Oil
(for APV models). These oils are specially formulated to be used either as
an injection oil or as a pre-mix oil (for
break-in) and meets all of the lubrication requirements of the Arctic Cat
snowmobile engine.
! CAUTION
Any oil used in place of the recommended oil could cause serious
engine damage.
Recommended Engine
Oil (1100 cc Models)
The recommended oil to use is Synthetic Turbo 0W-40 Oil (p/n 5639173).
GENERAL INFORMATION
After the engine break-in period, the
engine oil should be changed every
2500-3000 miles on the 1100 cc STD
models or 1500-2000 miles on the 1100
cc Turbo models and before prolonged
storage.
2. Pour 236 ml (8 fl oz) of the recommended 2-cycle oil into the gasoline container.
Filling Gas Tank
4. Fill the gasoline container with
gasoline; then cap the gasoline
container and shake the mixture
vigorously.
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.
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 wellventilated 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.
Break-In Gas/Oil
Mixing Instructions
(2-Stroke Models)
Before mixing gasoline and oil, make
sure the oil is at room temperature (20°
C/68° F). Use a U.L. approved 22.7 l (6
U.S. gal.) gasoline container for mixing the gasoline and oil. To properly
mix the fuel at a 100:1 ratio, use the
following procedure:
! CAUTION
Never mix oil and gasoline in the
snowmobile gas tank.
3. Install cap on gasoline container
and shake the mixture vigorously.
5. Using a fine-mesh screened funnel, pour the fuel mixture from the
gasoline container into the snowmobile gas tank.
! WARNING
Always fill the gas tank in a wellventilated area. Never add gasoline
to the snowmobile gas tank near
any open flames or with the engine
running. DO NOT SMOKE while
mixing fuel or filling the gas tank.
ENGINE BREAK-IN
(2-Stroke Models)
The Arctic Cat engine (when new or
rebuilt) requires a short break-in period
before the engine is subjected to heavy
load conditions. Arctic Cat requires
that the first tankful of fuel be premixed at a 100:1 ratio in all oil-injection models.
During the break-in period, a maximum of 1/2 throttle is recommended;
however, brief full-throttle accelerations and variations in driving speeds
contribute to good engine break-in.
After one (1) tankful break-in period,
the snowmobile may be taken to an
authorized Arctic Cat Snowmobile
dealer for a checkup. This checkup is at
the discretion and the expense of the
snowmobile owner.
1. Pour gasoline into the gasoline
container until approximately half
full.
GENERAL INFORMATION
7
SPEEDOMETER/
TACHOMETER
DO NOT exceed the one (1) tankful INDICATOR ICONS
limitation of a 100:1 gas/oil break- (Standard Gauge)
! CAUTION
in mixture. Continuous use of a
gas/oil mixture, unless consistently operating in extremely cold
conditions (-26°C/-15°F or colder),
could cause spark plug fouling and
excessive carbon buildup. A 100:1
gas/oil mixture must be used in
conjunction with the oil-injection
system to ensure adequate engine
lubrication in extremely cold conditions.
Certain models are equipped with a
standard gauge combination speedometer/tachometer. Indicator icons are
incorporated within the speedometer/
tachometer. Also incorporated into the
speedometer/tachometer is a digital
readout screen.
ENGINE BREAK-IN
(1100 cc Models)
The Arctic Cat engine (when new or
rebuilt) requires a short break-in period
before the engine is subjected to heavy
load conditions.
This engine does not require any premixed fuel during the break-in period.
FZ003C
A. Oil Pressure/Low Oil
B. Coolant Temperature
! CAUTION
C. Low Fuel
DO NOT use premixed fuel in the
snowmobile gas tank. Engine damage will occur.
D. Fuel Level
To ensure trouble-free operation, careful adherence to the following break-in
guidelines will be beneficial.
E. Service
F. High Beam
G. Charging System (1100 cc)
RPM/MPH (kph)
0-200 miles 1/2 Throttle (45 MPH-max)
200-400 miles
1/2-3/4 Throttle
400-600 miles
1/2-3/4 Throttle *
By pushing the left button once, the
RPM and MPH will be displayed (one
on the readout screen and one with the
needle). By pushing the button once
* With occasional full-throttle operation.
To ensure proper engine break-in, Arc- again, the functions will be reversed.
tic Cat recommends that the engine oil By pushing the left button (with speed
and filter be changed after 500 miles. being displayed) for more than two
This service is at the discretion and seconds, the display will change
expense of the snowmobile owner.
between standard mph or metric kph.
Release the button when desired display appears.
8
GENERAL INFORMATION
With RPM displayed on the readout
screen by pushing and holding the left
button, maximum RPM will be displayed on the readout screen. The maximum RPM readout will reset when the
right button is pushed (while maximum
RPM is displayed).
Service Icon
On electric start models, the icon should
illuminate each time the key is turned to
RUN or START, and it should go out
when the engine starts. If the icon stays
illuminated (on electric start models) or
it illuminates while the engine is running, the system is receiving input that
Odometer/Trip-Meter
is outside of its established parameters.
(1)/Trip-Meter (2)/
If the icon illuminates indicating an
Hour-Meter/Clock
error, take the snowmobile to an autho NOTE: The clock is available on rized Arctic Cat Snowmobile dealer for
electric start models only.
service. If not under warranty, this service is at the discretion and expense of
By pushing the right button, the read- the snowmobile owner.
out screen will display odometer, tripmeter (1), trip-meter (2), hour-meter, Coolant Temperature
and clock. To reset the trip meter with Warning Icon
the trip meter displayed, push and hold
the right button until the display is If the coolant temperature is at or
cleared. The hour-meter readout will above the maximum running temperature of 80° C (176° F), the coolant temnot reset.
perature warning icon will flash a
warning (alert). If the coolant temperaClock
(Electric Start Models) ture is at or above the maximum running temperature of 93° C (200° F), the
With the clock selected on the readout
coolant temperature warning icon will
screen by pushing and holding the right
cease flashing and will remain conbutton for two seconds, the option of
stantly illuminated.
selecting the 12-hour or 24-hour clock
is available. Push the left button for 12- Steady Flash
Coolant Temperature
hour display; push the right button for (Coolant
Above 80° C (176° F).
24-hour display. At this point, the Temperature Icon)
hours and minutes will begin to flash. Constant On
Coolant Temperature
Above 93° C (200° F).
Push the left button to change the hour (Coolant
display; push the right button to change Temperature Icon)
the minute display (either tap the but! CAUTION
tons for individual number display or
push and hold the buttons for rapid At this point, take precautionary
measures such as changing to
number display).
 NOTE: During clock setting if
neither button (left, right) is
pushed within a 5-second time
period, the clock-setting mode will
be exited with changes saved.
GENERAL INFORMATION
loose snow terrain, shutting the
engine off (allowing the engine to
cool down), and checking coolant
level. If unable to either determine
or remedy the problem, take the
snowmobile to an authorized Arctic Cat Snowmobile dealer for service. If not under warranty, this
service is at the discretion and
expense of the snowmobile owner.
9
Charging System
Warning Icon
(1100 cc Models)
The Charging System Warning Icon is
designed to warn the operator if the
battery charging system is not functioning. The icon should illuminate
each time the key is turned to RUN or
START, and it should go out when the
engine starts. If the icon stays illuminated or it illuminates while the engine
is running, the battery is not being
charged, and the snowmobile is running on battery reserve power only.
Oil Pressure Warning
Icon (1100 cc Models)
The Oil Pressure Warning Icon indicates engine oil pressure, not the oil
level; however, if the oil level is low, it
may affect oil pressure.
The icon should illuminate each time
the ignition switch is turned to RUN or
START, and it should go out when the
engine starts. If the icon illuminates
while the engine is running, oil pressure has been lost and the engine will
automatically shut off.
If the Charging System Warning Icon If oil pressure is lost, use the following
illuminates, you should, as soon as pos- procedure to check the oil level:
sible, take the snowmobile to an autho1. With the engine off, remove the
rized Arctic Cat Snowmobile dealer for
engine oil level stick and wipe it
service. If not under warranty, this serclean. Without screwing it in, set
vice is at the discretion and expense of
the stick back in the oil tank.
the snowmobile owner. The engine
Remove it and observe the oil
WILL NOT RUN without battery
level on the stick. If the oil level is
power.
at or below the ADD mark on the
oil level stick, add only enough
Low Oil Warning Icon
recommended oil to raise the level
(2-Stroke Models)
to the NORMAL range. DO NOT
The Low Oil Warning Icon is designed
overfill the reservoir with oil.
to alert the snowmobile operator when
2. Open the air bleed bolt located on
the oil in the oil injection reservoir gets
the oil pump (beneath the coolant
below a prescribed level; however, it is
tank) to purge air from the oil
highly recommended that a visual verihose.
fication of the oil level in the reservoir
be done prior to operating the snowmobile. Once the Low Oil Warning Icon
illuminates during operation of the
snowmobile, the operator must periodically monitor the level of oil in the reservoir and must fill the reservoir the
next time gasoline is added to the gas
tank. The “alert level” of the Low Oil
Warning Icon is approximately equal to
1 tankful of gasoline under normal
ZJ004A
operating conditions.
 NOTE: When air can no longer
be heard purging from oil pump
bleed, tighten the bleed bolt to 7.5
ft-lb.
3. Start the engine. The warning light
should go out within five seconds.
10
GENERAL INFORMATION
4. If the warning light does not go RPM/MPH (kph)
out, shut the engine off immediately and repeat step 2; then repeat By pushing the increment button once,
the RPM and MPH will be displayed
step 3.
(one on the readout screen and one
If the warning light does not go out or with the needle). By pushing the button
if the engine does not start, take the once again, the functions will be
snowmobile to an authorized Arctic reversed.
Cat Snowmobile dealer. If not under
warranty, this service is at the discre- By pushing the increment button (with
tion and expense of the snowmobile speed being displayed) for more than
two seconds, the display will change
owner.
between standard mph or metric kph.
SPEEDOMETER/
TACHOMETER
INDICATOR ICONS
(Premium Gauge)
With RPM displayed on the readout
screen by pushing and holding the
increment button, maximum RPM will
be displayed on the readout screen. The
Certain models are equipped with a maximum RPM readout will reset
premium gauge combination speedom- when the decrement button is pushed
eter/tachometer. Indicator icons are (while maximum RPM is displayed).
incorporated within the speedometer/
tachometer. Also incorporated into the Odometer/Trip-Meter
speedometer/tachometer is a digital (1)/Trip-Meter (2)/
Hour-Meter
readout screen.
By pushing the decrement button, the
readout screen will display odometer,
trip-meter (1), trip-meter (2), and hourmeter. To reset the trip meter with the
trip meter displayed, push and hold the
decrement button until the display is
cleared. The hour-meter readout will
not reset.
Clock/Altimeter
FZ001A
A. High Beam
B. Oil Pressure/Low Oil
C. Coolant Temperature
D. Increment Button
E. Select Button
F. Decrement Button
G. Service
H. Charging System (1100 cc)
GENERAL INFORMATION
 NOTE: The altimeter is available
on the 800/1000/1100 cc models
only.
By pushing the select button, the readout screen will display clock, altimeter,
and maximum altimeter.
With clock selected on the display by
pushing and holding the select button
for two seconds, the option of selecting
the 12-hour or 24-hour clock mode is
available. Push the increment button to
toggle between the 12-hour display and
the 24-hour display. When desired
mode is displayed, push the select button.
11
At this point, the hours display will
begin to flash. Push the increment button to increase the hours; push the decrement button to decrease the hours.
Pushing and holding a button will
accelerate the number display. When
desired hour number is displayed, push
the select button.
At this point, the minutes display will
begin to flash. Push the increment button to increase the minutes; push the
decrement button to decrease the minutes. Pushing and holding a button will
accelerate the number display. When
desired minute number is displayed,
push the select button.
To reset the maximum altimeter readout with the maximum altimeter displayed, push and hold the select button
for a minimum of two seconds.
Service Icon
On electric start models, the icon
should illuminate each time the key is
turned to RUN or START, and it should
go out when the engine starts. If the
icon stays illuminated (on electric start
models) or it illuminates while the
engine is running, the system is receiving input that is outside of its established parameters. If the system icon
illuminates indicating an error, take the
snowmobile to an authorized Arctic
Cat Snowmobile dealer for service. If
not under warranty, this service is at the
discretion and expense of the snowmobile owner.
 NOTE: During clock setting if no
button (increment, decrement,
select) is pushed within a 5-second time period, the clock-setting
mode will be exited with changes
Coolant Temperature
saved.
Warning Icon
The altimeter readout is based off barometric pressure and may require cali- If the coolant temperature is at or
above the maximum running temperabration as weather conditions change.
ture, the coolant temperature warning
To calibrate the altimeter to an estab- icon will flash a warning (alert). If the
lished altitude with altimeter selected coolant temperature is at or above the
on the display screen by pushing and maximum running temperature, the
holding the select button for a mini- coolant temperature warning icon will
mum of two seconds, the acronym cease flashing and will remain conCAL will be displayed on the readout stantly illuminated.
screen for one second; then the altitude
value will flash. Push the increment
Crossfire/F-Series/M-Series/T500
button to increase the displayed alti- Steady Flash
Coolant Temperatude; push the decrement button to (Coolant
ture Above 80° C
decrease the displayed altitude. Push- Temperature Icon) (176° F).
ing and holding a button will accelerate Constant On
Coolant Tempera(Coolant
ture Above 93° C
the number display.
 NOTE: If MPH has been selected
in the speed readout, the altitude
value will be displayed in feet. If
kph has been selected in the
speed readout, the altitude value
will be displayed in meters.
12
Temperature Icon)
(200° F).
Z1/TZ1
Steady Flash
Coolant Tempera(Coolant
ture Above 110° C
Temperature Icon) (230° F).
Constant On
Coolant Tempera(Coolant
ture Above 115° C
Temperature Icon) (239° F).
GENERAL INFORMATION
 NOTE: On the Z1/TZ1 models if
the coolant temperature icon is
constantly on, the engine will shut
off if vehicle speed is reduced to
1.5 kph (0.9 MPH) or slower.
! CAUTION
At this point, take precautionary
measures such as changing to
loose snow terrain, shutting the
engine off (allowing the engine to
cool down), and checking coolant
level. If unable to either determine
or remedy the problem, take the
snowmobile to an authorized Arctic Cat Snowmobile dealer for service. If not under warranty, this
service is at the discretion and
expense of the snowmobile owner.
Charging System
Warning Icon
(1100 cc Models)
Low Oil Warning Icon
The Low Oil Warning Icon is designed
to alert the snowmobile operator when
the oil in the oil injection reservoir gets
below a prescribed level; however, it is
highly recommended that a visual verification of the oil level in the reservoir
be done prior to operating the snowmobile. Once the Low Oil Warning Icon
illuminates during operation of the
snowmobile, the operator must periodically monitor the level of oil in the reservoir and must fill the reservoir the
next time gasoline is added to the gas
tank. The “alert level” of the Low Oil
Warning Icon is approximately equal to
1 tankful of gasoline under normal
operating conditions.
Oil Pressure Warning
Icon (1100 cc Models)
The Oil Pressure Warning Icon indicates engine oil pressure, not the oil
The Charging System Warning Icon is level; however, if the oil level is low, it
designed to warn the operator if the may affect oil pressure.
battery charging system is not functioning. The icon should illuminate The icon should illuminate each time
each time the key is turned to RUN or the ignition switch is turned to RUN or
START, and it should go out when the START, and it should go out when the
engine starts. If the icon stays illumi- engine starts. If the icon illuminates
nated or it illuminates while the engine while the engine is running, oil presis running, the battery is not being sure has been lost and the engine will
charged, and the snowmobile is run- automatically shut off.
ning on battery reserve power only.
If oil pressure is lost, use the following
If the Charging System Warning Icon procedure to check the oil level:
illuminates, you should, as soon as pos1. With the engine off, remove the
sible, take the snowmobile to an authoengine oil level stick and wipe it
rized Arctic Cat Snowmobile dealer for
clean. Without screwing it in, set
service. If not under warranty, this serthe stick back in the oil tank.
vice is at the discretion and expense of
Remove it and observe the oil
the snowmobile owner. The engine
level on the stick. If the oil level is
WILL NOT RUN without battery
at or below the ADD mark on the
power.
oil level stick, add only enough
recommended oil to raise the level
to the NORMAL range. DO NOT
overfill the reservoir with oil.
GENERAL INFORMATION
13
2. Open the air bleed bolt located on Crossfire/F-Series/Mthe oil pump (beneath the coolant Series/T500 Models
tank) to purge air from the oil
Additional codes are displayed on the
hose.
readout screen. Refer to the following
chart for diagnostic codes.
ZJ004A
 NOTE: When air can no longer
be heard purging from oil pump
bleed, tighten the bleed bolt to 7.5
ft-lb.
3. Start the engine. The warning light
should go out within five seconds.
4. If the warning light does not go
out, shut the engine off immediately and repeat step 2; then repeat
step 3.
If the warning light does not go out or
if the engine does not start, take the
snowmobile to an authorized Arctic
Cat Snowmobile dealer. If not under
warranty, this service is at the discretion and expense of the snowmobile
owner.
DIAGNOSTIC CODES
(Standard/Premium
Gauges)
Diagnostic codes are activated by the
ECU and may be displayed on the
readout screen for a number of reasons.
If a code is displayed while the engine
is running, the ECU is receiving input
that is outside of its established parameters. If a code has been activated, take
the snowmobile to an authorized Arctic
Cat Snowmobile dealer for service. If
not under warranty, this service is at the
discretion and expense of the snowmobile owner.
14
Code
Trouble
2
Failure in injector(s).
4 Open or short circuit in barometric
pressure sensor.
5
Open or short circuit in intake air
temperature sensor.
6 Open or short circuit in water temperature sensor.
7
Open or short circuit in throttle
position sensor.
12
Failure in ignition coil.
16* Incorrect adjustment/failure in APV
cable.
17*
Failure in exhaust temperature
sensor.
18*
Failure in servomotor.
21*
Failure in knock sensor.
23* Fail-safe mode activated in knock
control system.
* On certain models.
Bearcat Z1 XT/Z1/TZ1
Models
These diagnostic codes are displayed
on the readout screen incorporated
within the speedometer/tachometer.
Refer to the following chart for diagnostic codes.
Code
Trouble
1
Failure in the fuel system.
2
Failure in injector (#2).
3
Failure in injector (#1).
Failure in barometric pressure sen4
sor.
5
Open or short circuit in intake
manifold air temperature sensor.
6
Open or short circuit in water
temperature sensor.
7
Open or short circuit in throttle
position sensor.
8
Open or short circuit in manifold
air pressure sensor.
GENERAL INFORMATION
Code
Trouble
9
Failure in crankshaft position sensor.
11
Failure in speed sensor.
12
Failure in coil (#1).
13
Failure in coil (#2).
14
Failure in ISC valve.
15
Failure in oxygen sensor.
19
Failure in camshaft position sensor.
21
Failure in knock sensor.
22*
Failure in coil (#1 secondary).
23*
Failure in coil (#2 secondary).
OCTN*
Low octane gasoline.
* Turbo models
0743-467
2. Adjust the handlebar up or down
to operator’s desired tilt; then
tighten the lock nuts/cap screws
evenly and securely. Check steering for maximum right/left turning
capabilities.
3. Recheck lock nuts/cap screws;
tighten securely.
HANDLEBAR TILT
(Bearcat/Crossfire/
M-Series Models)
 NOTE: Recommended torque
value of lock nuts is 18 ft-lb. RecThe handlebar can be adjusted to the ommended torque value for the
position providing the operator with Allen-head cap screws is 20 ft-lb.
the most comfort. To adjust the handle NOTE: Do not adjust the handlebar, use the following procedure:
bar to a position that allows the
 NOTE: It may be necessary to brake fluid to be below the low
remove the handlebar cover for mark on either side of the master
this procedure.
cylinder.
1. Loosen the four lock nuts (Allenhead cap screws on models with a
telescoping handlebar) securing
the handlebar caps and block to
the steering post.
! WARNING
Tighten lock nuts according to
specifications to prevent unexpected “movement” of the handlebar during operation over rough
terrain and DO NOT position handlebar so steering (maximum right/
left turning capabilities) or throttle
and brake controls are affected.
HANDLEBAR TILT
(F-Series/T-Series STD Models)
0743-442
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.
GENERAL INFORMATION
15
2. Adjust the handlebar up or down
and/or rotate the handlebar to operator’s desired position; then press
down on the cam lever until the
lock pin is properly positioned and
locked. Check steering for maximum right/left turning capabilities.
 NOTE: At this point, gently lift
the cam lever without pressing in
on the lock pin. If the cam lever
2. Adjust the handlebar up or down cannot be lifted, the lock pin is
to operator’s desired tilt, tighten secure.
the cap screws evenly to 25 ft-lb,
and check steering for maximum  NOTE: Do not rotate the handleright/left turning capabilities.
bar to a position that allows air to
enter the brake system.
 NOTE: Do not adjust the handlebar to a position that allows the
3. Test the handlebar to ensure that it
brake fluid to be below the low
does not rotate within the riser
mark on either side of the master
block. If it does not rotate, proceed
cylinder.
to step 4. If it does rotate, release
the cam lever and rotate the cam
! WARNING
lever clockwise; then press down
Tighten cap screws according to
on the cam lever until the lock pin
specifications to prevent unexpected
is properly positioned and locked.
“movement” of the handlebar durRepeat this procedure until the
ing operation over rough terrain. DO
handlebar is properly secured.
741-708A
NOT offset the handlebar so steering
(maximum right/left turning capabilities) are altered or throttle and brake
controls will be affected.
HANDLEBAR TILT
(Cam Lever Style)
4. After the handlebar is “locked” in
position, release the cam lever and
rotate it one turn clockwise; then
press down on the cam lever until it
“locks” in place.
 NOTE: At this point, gently lift
The handlebar can be adjusted to the the cam lever without pressing in
operator’s preference. To adjust the han- on the lock pin. If the cam lever
cannot be lifted, the lock pin is
dlebar, use the following procedure:
secure.
1. Press inward on the lock pin to
release the cam lever and “flip” the
! CAUTION
cam lever up.
If at any time the lock pin will not
engage into the locked position, do
NOT operate the snowmobile. Take
the snowmobile to an authorized
Arctic Cat dealer for service.
0741-427
16
GENERAL INFORMATION
AIR-INTAKE SILENCER
! WARNING
Care must be taken to securely
lock the handlebar cam lever to
prevent unexpected “movement”
of the handlebar during operation
over rough terrain. DO NOT offset
the handlebar so steering (maximum right/left turning capabilities)
are altered or throttle and brake
controls will be affected.
TELESCOPIC
HANDLEBAR
(Crossfire/M-Series
Sno Pro/Sno Pro LE
Models)
1. From each side of the steering
post, compress the locking tabs to
unlock the handlebar.
Used in conjunction with the fuel
intake system is a specially designed
air-intake silencer. The purpose of the
silencer is to quiet the intake of fresh
air. Since the fuel intake system is calibrated with the air-intake silencer in
place, the engine must never be run
with the silencer removed. Performance will not be improved if the airintake silencer is removed. In contrast,
severe engine damage will occur.
! CAUTION
These snowmobiles are not
designed to be operated in dusty
conditions. Operating the snowmobile in dusty conditions will
result in severe engine damage.
BATTERY
(Electric Start Models)
It is extremely important that the battery be maintained at full charge at all
times and that the battery connections
be clean and tight. If charging the battery becomes necessary, refer to Battery sub-section in the Maintenance
section of this manual.
0743-463
2. With the tabs compressed, adjust
the handlebar up or down to the
desired position; then release the
tabs to lock the handlebar in place.
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.
GENERAL INFORMATION
! CAUTION
On the 1100 cc models, always turn
the ignition switch key to the OFF
position when the snowmobile is
not being used. Leaving the ignition
switch in the ON position will result
in discharging the battery and possible damage to the battery.
17
COOLING SYSTEM
(Liquid)
When operating the snowmobile at
high altitudes, it may be necessary to
change certain component parts of the
Some snowmobiles are equipped with a drive clutch and/or the driven pulley.
closed liquid cooling system for engine See an authorized Arctic Cat Snowmocooling. The cooling system should be bile dealer for further information.
inspected daily for leakage and damage.
Also, the coolant level should be
! CAUTION
checked daily. If leakage or damage is
detected, take the snowmobile to an DO NOT attempt to service the
authorized Arctic Cat Snowmobile drive clutch and driven pulley. The
dealer for service. If not under warranty, drive clutch and driven pulley must
this service is at the discretion and be serviced by an authorized Arctic Cat Snowmobile dealer only.
expense of the snowmobile owner.
When filling the cooling system reservoir, use an ethylene glycol-based coolant/water mixture which will satisfy the
coldest anticipated weather conditions
of your area in accordance with the coolant manufacturer’s recommendations.
For checking/filling cooling system,
refer to Coolant Level sub-section in
the Maintenance section of this manual.
DRIVE CLUTCH AND
DRIVEN PULLEY
The drive clutch and driven pulley do
not require lubrication; therefore, no
special maintenance is required by the
snowmobile owner.
However, the drive clutch and driven
pulley should be disassembled,
cleaned, and inspected by an authorized Arctic Cat Snowmobile dealer
after every 800 miles of operation or at
the end of the snowmobiling season
whichever occurs first. This service is
at the discretion and expense of the
snowmobile owner.
18
DRIVE CLUTCH/
DRIVEN PULLEY
ALIGNMENT
The parallelism and the offset between
the drive clutch and driven pulley are
set at the factory. Normally, no adjustment is necessary as long as neither the
drive clutch nor the driven pulley is
removed or disassembled. However, if
premature drive belt wear is experienced or if the drive belt turns over, the
drive clutch/driven pulley alignment
must be checked. Take the snowmobile
to an authorized Arctic Cat Snowmobile
dealer for this service. If not under warranty, this service is at the discretion and
expense of the snowmobile owner.
FUEL PUMP
The fuel pump is designed to provide
adequate amount of gas to the carburetors (on carbureted models) or to the
injectors (on EFI models) at all throttle
settings. If a fuel delivery problem is
suspected, take the snowmobile to an
authorized Arctic Cat Snowmobile
dealer. If not under warranty, this service is at the discretion and expense of
the snowmobile owner.
GENERAL INFORMATION
SHOCK ABSORBERS
(Standard Gas)
Each shock absorber should be visibly
checked weekly for fluid leakage,
cracks or breaks in the lower case, or a
bent plunger. If any one of these conditions is detected, replacement is necessary. Take the snowmobile to an
authorized Arctic Cat Snowmobile
dealer for this service. If not under warranty, this service is at the discretion and
expense of the snowmobile owner.
Servicing rebuildable shock absorbers
is considered normal maintenance and
is the responsibility of the owner. Take
the snowmobile to an authorized Arctic
Cat Snowmobile dealer for this service.
This service is at the discretion and
expense of the snowmobile owner. Kits
are available to either stiffen or soften
gas shock valving. If changes in shock
valving are desired, see an authorized
Arctic Cat Snowmobile dealer. This
service is at the discretion and expense
of the snowmobile owner.
 NOTE: When the snowmobile is
operated in extremely cold weather
(-23° C/-10° F or colder), a small
amount of leakage may be present.
Unless the leakage is excessive,
replacement is not necessary.
Each shock absorber should be visibly
checked weekly for fluid leakage,
cracks or breaks in the lower case, or a
bent plunger. If any one of these conditions is detected, replacement is necessary. Take the snowmobile to an
authorized Arctic Cat Snowmobile
SHOCK ABSORBERS
dealer for this service. If not under war(Rebuildable Gas)
ranty, this service is at the discretion and
 NOTE: The presence of an ACT expense of the snowmobile owner.
identifier (decal or embossed) on a
shock absorber body indicates a  NOTE: When the snowmobile is
operated in extremely cold weather
“rebuildable” shock absorber.
(-23° C/-10° F or colder), a small
 NOTE: The frequency of servicing amount of leakage may be present.
rebuildable shock absorbers will Unless the leakage is excessive,
vary according to the types of con- replacement is not necessary.
ditions and terrain the snowmobile
has been subjected to. If riding DEEP-LUG TRACK
quality deteriorates (or seems to be
deteriorating), take the snowmobile Some models are equipped with a deepto an authorized Arctic Cat Snow- lug track which is specially designed for
mobile dealer for shock absorber use in powder snow riding conditions.
evaluation and/or servicing. This When the deep-lug track is operated in
service is at the discretion and hard-packed snow conditions, it will run
slightly slower than a standard-lug track
expense of the snowmobile owner.
and it will accelerate wear strip wear. To
decrease the amount of wear strip wear,
slower speeds must be maintained when
operating on hard-packed trails. Accelerated wear strip wear caused by operating a deep-lug track on hard-packed
snow conditions is NOT covered under
Arctic Cat Inc. warranty policy.
GENERAL INFORMATION
19
 NOTE: If operating on ice or hardpacked snow conditions with a
Crossfire model (except the Crossfire R) or with an M-Series model, it
is recommended that Ice Scratchers (p/n 4639-958) be installed to
reduce wear strip and engine overheating.
STANDARD-LUG TRACK
Accelerated wear strip wear caused by
operating on hard-packed snow conditions is NOT covered under Arctic Cat
Inc. warranty policy.
TRACK STUDS
 NOTE: Stud or hooker plate
installation will void track and tunnel warranty.
 NOTE: Stud installation can be
performed by the snowmobile
owner if qualified to do so. If the
owner does not feel qualified, take
the snowmobile to an authorized
Arctic Cat Snowmobile dealer for
this service. This service is at the
discretion and expense of the
snowmobile owner.
! CAUTION
If installing studs on the Crossfire
or F-Series Sno Pro models with a
single ply track, studs with a head
diameter of at least 28.6 mm (1.125
in.) must be used.
! WARNING
When installing studs on a single
ply track, it is important to use Arctic Cat-approved studs (proper
head diameter). If approved studs
(proper head diameter) are not
used, studs could tear free of the
track causing possible injury or
even death. Consult an authorized
Arctic Cat Snowmobile dealer for
information.
20
! CAUTION
If installing studs on the F-Series or
Z1 models, a short Snowflap (p/n
4706-462) or on the Crossfire models (p/n 5639-232) must be installed
or component damage will occur.
 NOTE: To prevent tunnel damage
from the studs, Tunnel Protector Kit
(p/n 4639-771) for F 570/T 570 models, (p/n 4639-968) for Crossfire models, or (p/n 5639-143) for the Bearcat
Z1 XT model must be installed.
For proper installation, use the following procedure:
1. Using appropriate stud template
(see chart), mark the desired stud
pattern to be used.
Stud Template Chart
Track Length
p/n
128 in.
4639-443
136 in.
4639-344
141 in.
4639-991
144 in.
5639-160
2. Using the proper-sized stud hole
drill bit, drill out the stud holes.
3. Push the stud through the hole
from inside the track; then place
the domed support plate and lock
nut on the exposed stud.
4. Using a wrench to secure the stud,
tighten the lock nut on the exposed
stud.
It is also recommended that whenever
studs are installed on a track, carbide
wear bars should be installed on the
skis. Carbide wear bars complement
the track studs to balance steering control under these conditions. The length
of the carbide on the wear bars should
be proportionate to the number of track
studs (i.e. small number of track studs
— short length of carbide...many track
studs — long length of carbide). The
proper proportion between the number
of studs and carbide length on the wear
bar will maintain steering balance.
GENERAL INFORMATION
! WARNING
Always balance the snowmobile
with
the
proper
proportion
between the number of studs and
carbide length on the wear bars.
Do not “over drive” conditions;
use common sense in all operating
conditions.
! CAUTION
Do not use studs that are more
than 9.525 mm (0.375 in.) longer
than the track lug height.
! WARNING
Do not operate a snowmobile with
loose studs as they may be thrown
from the track. Always use a
shielded safety stand whenever
performing any maintenance or
adjustments.
Always use minimal speed when operating in reverse and come to a complete
stop before shifting from either forward to reverse or reverse to forward.
Once you have shifted to a new gear,
apply slight throttle until positive
engagement of the shift has been
observed. To shift the reverse transmission, use the following procedure:
1. Come to a complete stop.
2. Pull the shift lever outward and
downward (from the forward position) to lock into the reverse position; then apply slight throttle until
positive engagement of the shift
has been observed.
! WARNING
DO NOT stand behind the snowmobile or near the rotating track.
NEVER run the track at high speed
when the track is suspended.
REVERSE
TRANSMISSION
(Lever Style Models)
The reverse transmission offers the
operator the convenience of being able
to back up the snowmobile rather than
having to turn the snowmobile around
by hand. This feature, under most situations, should not be used to free a
stuck snowmobile as it will tend to dig
the skis deeper into the snow. Before
starting the snowmobile, be sure the
shift lever is in the desired position for
either forward or reverse operation.
0742-499
! WARNING
Use caution and minimal speed
when operating the snowmobile in
reverse. Be sure the shift lever is in
the desired lever position.
No special maintenance is required for
the reverse transmission; however, if
chattering is experienced when the
transmission is shifted into reverse, the
linkage may have to be adjusted. Arctic
Cat recommends taking the snowmobile to an authorized Arctic Cat Snowmobile dealer for this service. If not
under warranty, this service is at the
discretion and expense of the snowmobile owner.
 NOTE: A warning buzzer will
sound when the transmission is in
the reverse position; however,
always check the position of the
shift lever before accelerating.
GENERAL INFORMATION
21
REVERSE
TRANSMISSION
(Switch Button Style
Models)
The reverse transmission offers the
operator the convenience of being able
to back up the snowmobile rather than
having to turn the snowmobile around
by hand. This feature, under most situations, should not be used to free a
stuck snowmobile as it will tend to dig
the skis deeper into the snow. Always
use minimal speed when operating in
reverse and come to a complete stop
before shifting from either forward to
reverse or reverse to forward. To shift
the reverse transmission, use the following procedure:
1. Come to a complete stop.
 NOTE: The snowmobile must be
at a complete stop and the engine
running under 3000 RPM before
the system will allow shifting.
! WARNING
Use caution and minimal speed
when operating the snowmobile in
reverse. Be sure the button is in
the desired position.
 NOTE: A warning buzzer will
sound when the transmission is in
the reverse position.
TOWING
If the 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 spindles.
ADJUSTABLE/
MOVABLE BACKREST
(T-Series Models)
The backrest is designed for maximum
comfort and safety. When riding double, the backrest must be in the rearward position.
2. With the engine at idle (under 3000 When riding single, the backrest can be
RPM), press the reverse switch but- moved to the forward position.
ton; then release the button. The
! WARNING
reverse selection will be complete.
Moving the backrest to the forward
position limits the seating capacity
to one person only.
T-Series Models
741-438A
 NOTE: The system will not shift
until the button is released.
3. To shift into forward, stop the
snowmobile and allow the engine
to idle (under 3000 RPM); then
press the button and release. The
forward selection will be complete.
22
0742-494
To change the height of the backrest,
push the adjuster down, adjust the
backrest up or down, and raise the
adjuster to lock the backrest in place.
GENERAL INFORMATION
To move the backrest, push the adjuster To install the rear seat, use the followdown, pull the backrest up and out of ing procedure:
the slots, slide the backrest into the
1. Place the seat into position on the
desired position, and raise the adjuster
mount making sure the four pin
to lock the backrest in place.
holes are properly aligned with the
mounting location on mount.
! CAUTION
If moving the backrest to the forward position, the rear seat must
be removed.
REMOVABLE REAR
SEAT (Bearcat XT
Models)
2. Install the four pins making sure
they are properly seated.
! WARNING
Make sure the rear seat is securely
locked in place with the four pins
before carrying a passenger or
personal injury may result.
These snowmobiles are equipped with
a removable rear seat to allow for additional cargo space when no passenger REMOVABLE REAR
is being carried.
SEAT (T-Series
 NOTE: If additional cargo is
being added, maximum weight on
the snowmobile (operator/passenger/cargo) should not exceed the
maximum limitation set for each
snowmobile. See the chart in the
Suspension - Overload Springs
sub-section of this manual for
details. Also, the overload springs
should be engaged.
To remove the rear seat, use the following procedure:
Models)
These snowmobiles are equipped with
a removable rear seat to allow for additional cargo space when no passenger
is being carried.
 NOTE: If additional cargo is
being added, maximum weight on
the snowmobile (operator/passenger/cargo) should not exceed the
maximum limitation set for each
snowmobile. See the chart in the
Suspension - Overload Springs
1. Remove the four pins securing the sub-section of this manual for
rear seat to the seat/Speedrack details. Also, the overload springs
should be engaged.
mount.
To remove the rear seat, use the following procedure:
 NOTE: On LXR models, the luggage bag must be removed.
0743-329
1. Rotate the seat latch either clockwise or counterclockwise and hold
it in that position; then lift the seat
and move it rearward far enough to
access the electrical connector.
2. Lift on the back of the seat and
move it rearward to remove it
from the mount.
GENERAL INFORMATION
23
1. Slide the front of the seat into
position on the tunnel; then lower
the rear of the seat onto the locking pins.
0742-593
2. Unplug the electrical connector;
then remove the seat from the tunnel.
To install the seat, use the following
procedure:
2. Press down on the rear of the seat
until the retaining clips snap into
place on the locking pins; then rotate
the latch cover until it snaps into
place on the right-side locking pin.
! WARNING
Make sure the seat is securely
locked in place or personal injury
may result.
REMOVABLE/
1. Place the seat into position on the
tunnel; then plug in the electrical ADJUSTABLE SEAT
(TZ1 Turbo/LXR
connector.
2. Rotate the seat latch either clockwise or counterclockwise and hold
it in that position; then slide the
seat forward, allow it to settle into
position, and release the latch to
lock the seat securely.
! WARNING
Make sure the rear seat is securely
locked in place before carrying a
passenger or personal injury may
result.
REMOVABLE SEAT
(Crossfire/M-Series
Models)
These snowmobiles are equipped with
a removable seat. To remove the seat,
use the following procedure:
Models)
These snowmobiles are equipped with
a removable/adjustable operator seat.
To remove the seat, use the following
procedure:
1. Adjust the seat to the lowest position; then while lifting on the top
forward part of the seat, remove the
self-tapping screw from the right
side of the seat support assembly.
2. Press in on the left-end of the seat
adjuster lever at the rear storage
compartment; then pull out on the
seat adjuster lever.
3. Lift on the back of the seat and
move it forward and upward to
remove it from the chassis.
! CAUTION
1. Inside the rear storage compartment on the bottom of the seat- Do not use the adjuster lever to lift
base, rotate the latch cover away the seat.
from the right-side locking pin.
To install the seat, use the following
2. Lift on the back of the seat and procedure:
move it rearward to remove it
from the tunnel.
To install the seat, use the following
procedure:
24
GENERAL INFORMATION
1. With the seat adjuster lever pulled
out, slide the front of the seat into
position on the chassis; then with
seat position selected, lower the
rear of the seat onto the rear storage compartment.
5. Install the rear seat.
! WARNING
Make sure the seats are securely
locked in place or personal injury
may result.
2. Press down on the rear of the seat;
then secure the seat by releasing REMOVABLE/
ADJUSTABLE SEAT
the seat adjuster lever.
(F-Series/Z1 Models)
3. With the seat adjusted to the lowest position, install the self-tapping These snowmobiles are equipped with
screw into the right side of the seat a removable/adjustable seat. To adjust
the seat, use the following procedure:
support assembly.
1. Press in on the left-end of the seat
! WARNING
adjuster lever at the rear storage
compartment; then pull out on the
Make sure the self-tapping screw
seat adjuster lever at the rear storis securely tightened and the seat
age compartment.
is securely locked in place or personal injury may result.
To adjust the seat, use the following
procedure:
1. Remove the rear seat.
2. Pull up on the operator seat
adjuster.
741-434A
2. Lift up on the back of the seat;
then move the front of the seat up
or down into one of the seven
available positions.
! CAUTION
0742-592
3. Lift up on the back of the seat;
then move the front of the seat up
or down into one of the seven
available positions.
4. Press down on the rear of the seat;
then secure the seat by releasing
the seat adjuster.
Do not use the adjuster lever to lift
the seat.
3. Press down on the rear of the seat;
then secure the seat by releasing
the seat adjuster lever.
! WARNING
Make sure the seat is securely
locked in place or personal injury
may result.
To remove the seat, use the following
procedure:
GENERAL INFORMATION
25
1. Adjust the seat to the lowest position; then while lifting on the top
forward part of the seat, remove the
self-tapping screw from the right
side of the seat support assembly.
! WARNING
Make sure the self-tapping screw
is securely tightened and the seat
is securely locked in place or personal injury may result.
ARCTIC POWER VALVE
(APV) SYSTEM
! CAUTION
741-718A
The correct engine oil to use is
Arctic Cat Synthetic APV 2-Cycle
Oil (p/n 4639-348). Any substitute
may cause an APV malfunction.
2. Press in on the left-end of the seat
This RPM controlled servomotor
adjuster lever at the rear storage
(servo) actuated system adjusts the size
compartment; then pull out on the
of the exhaust ports to provide peak perseat adjuster lever.
formance throughout the RPM range.
3. Lift on the back of the seat and
The system consists of an exhaust
move it forward and upward to
valve assembly mounted to the exhaust
remove it from the chassis.
side of each cylinder and connected by
adjustable cables to an electronic servo
! CAUTION
mounted beneath the hood.
Do not use the adjuster lever to lift
the seat.
 NOTE: The mounting location of
the servo will vary from model to
To install the seat, use the following model.
procedure:
1. With the seat adjuster lever pulled
out, slide the front of the seat into
position on the chassis; then with
seat position selected, lower the
rear of the seat onto the rear storage compartment.
2. Press down on the rear of the seat;
739-152F
then secure the seat by releasing
At
low
RPM,
the
exhaust
valves
are
the seat adjuster lever.
held in the DOWN position by return
3. With the seat adjusted to the low- springs. This gives the engine a “low
est position, install the self-tapping port” exhaust design calibrated to proscrew into the right side of the seat vide maximum low RPM power and
support assembly.
improve fuel economy at trail speeds.
26
GENERAL INFORMATION
EXHAUST
CONTROLLED TIMING
(ECT) SYSTEM (600/
800/1000 cc Models)
This system automatically adjusts the
ignition timing to provide maximum
performance through a variety of operating conditions. The ECU receives
739-152G input on engine RPM (demand) and
At high RPM, the exhaust valves are exhaust pipe temperature (engine conraised. This creates a “high port” dition) and adjusts the ignition timing
exhaust design calibrated to provide accordingly. This system is not adjustable and is maintenance free.
maximum performance at high RPM.
If a system fault is suspected, 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.
739-152H
 NOTE: The RPM ranges will vary
from model to model.
 NOTE: If the servomotor cycles
three times and then shuts down,
the exhaust valve cables are not
0737-314
adjusted correctly. The exhaust

NOTE:
A
disabled
ECT
system
valves may also be sticking.
WILL NOT cause engine damage;
 NOTE: APV cleaning may be however, a failed ECT system will
done by the snowmobile owner if have slower throttle response and
qualified to do so. If the owner may produce slightly less top-end
does not feel qualified, take the performance.
snowmobile to an authorized Arctic Cat Snowmobile dealer for this
service. This service is at the discretion and expense of the snowmobile owner.
GENERAL INFORMATION
27
OPERATING INSTRUCTIONS
STARTING AND
STOPPING ENGINE
It is imperative that the 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. Also, on
2. Check the fluid level in the reservoir. The brake fluid level must be
visible in the sight glass. Add Arctic Cat approved brake fluid as
necessary.
carbureted models, be sure the correct carburetor main jets for the
operating temperature, altitude,
and gasoline are being used. After
the engine has been started, check the
headlights (high and low beam), tail741-328A
light, and brakelight to be sure they are
working properly and adjusted cor-  NOTE: If the sight glass appears
rectly. Make sure all lights are clean to dark, there is a sufficient amount
provide maximum illumination. The of fluid in the reservoir.
headlight and taillight must be clean
and must be illuminated whenever the
! WARNING
engine is running.
 NOTE: If equipped with reverse
shift lever, make sure the lever is
in the forward position before
starting the engine.
1. Test the operation of the 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.).
Do not start the engine if the brake
system is not functioning properly.
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
On liquid cooled models, always
check the coolant level before
starting the engine.
4. Move the emergency stop switch
to the UP or RUN position.
741-328C
28
5. Insert key into ignition switch;
then rotate key to the RUN position.
OPERATING INSTRUCTIONS
6. On carbureted models for a cold
engine, move the choke lever to
the full-choke position. If the
engine is warm, choking is normally not necessary.
 NOTE: On large-displacement
engines in extremely cold weather,
pull the recoil handle slowly two to
three times to begin the starting
procedure.
! 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.
 NOTE: On electric start models,
rotate the key to the START posi0725-001
tion; then when the engine starts,
 NOTE: On carbureted models release the key.
when the engine is being started
with aid of the choke, DO NOT
! CAUTION
COMPRESS THE THROTTLE CONDo
not
continuously
run the starter
TROL LEVER. If the throttle control
lever is compressed, the engine for more than 5 seconds at a time.
will not start because the gas/air
8. On carbureted models when the
mixture will be too lean. To start a
engine starts, allow it to warm up
warm engine, however, the throttle
for approximately 30 seconds with
control lever may have to be comthe choke lever in the full-choke
pressed slightly.
position. After the 30-second
 NOTE: On EFI models when a
warm-up, move the choke lever to
cold engine is being started, DO
the middle position. The choke
NOT COMPRESS THE THROTTLE
lever should be moved to the OFF
CONTROL LEVER. If the throttle
position when engine is warm.
control lever is compressed, the
Slight throttle control lever comengine will not start because the
pression may be necessary after
fuel/air mixture will be too lean.
the engine starts and during warmup. Idle the engine several minutes
 NOTE: On 2-stroke EFI models
until the engine has reached norwhen a warm engine is being
mal operating temperature.
started, the throttle control lever
may have to be compressed
9. On EFI models when the engine
slightly.
starts, allow it to warm up properly. Idle the engine several min7. On manual start models, pull the
utes until the engine has reached
recoil handle slowly until resisnormal operating temperature. Do
tance is felt; then give a short
not idle the engine for excessively
quick pull. Repeat until the engine
long periods of time.
starts.
OPERATING INSTRUCTIONS
29
! CAUTION
It is extremely important that the
engine is properly warmed up
before subjecting the engine to
high speed operation or heavy
loads. The engine should be
allowed to idle at least 3-4 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.
10. Flooding — On carbureted models
if the engine does not start when
the choke is being used but seems
ready to start, move the choke
lever to the OFF position. Engage
the brake lever lock; then compress the throttle control lever
fully and try to start the engine.
When the engine starts, release the
throttle control lever immediately.
After the warm-up, release the
brake lever lock.
 NOTE: On the 1100 cc models if
spark plugs must be replaced, take
the snowmobile to an authorized
Arctic Cat Snowmobile dealer for
inspection and service. This service is at the discretion and
expense of the snowmobile owner.
12. To shut off the engine, turn the
ignition key to the OFF position or
push the emergency stop switch to
the DOWN position.
! CAUTION
On the 1100 cc models, always
turn the ignition switch key to the
OFF position when the snowmobile is not being used. Leaving the
ignition switch in the ON position
will result in discharging the battery and possible damage to the
battery.
BRAKING
The following items are items that the
operator must be familiar with when
operating this snowmobile and its
hydraulic brake system. Important
additional information on the proper
maintenance of the brake system is
 NOTE: Continued choking will found in the maintenance section of
cause the engine to flood more.
this manual.
11. Flooding — On EFI models if the
engine does not start but seems
ready to start, engage the brake
lever lock; then compress the throttle control lever fully and try to
start the engine. When the engine
starts, release the throttle control
lever immediately. After the warmup, release the brake lever lock.
 NOTE: On EFI models except the
1100 cc models if the engine fails
to start during the attempt with the
throttle control lever compressed,
remove the spark plugs and clean
and dry them thoroughly or install
a new set of properly gapped, recommended spark plugs.
30
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.
OPERATING INSTRUCTIONS
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.
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; however, if pumping the
brake lever more than twice is necessary to obtain the necessary
stopping power, immediately take
the snowmobile to an authorized
Arctic Cat Snowmobile dealer for
service. If not under warranty, this
service is at the discretion and
expense of the snowmobile owner.
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.
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.
OPERATING INSTRUCTIONS
31
EMERGENCY
STOPPING
If the snowmobile engine stops
abruptly when the throttle control lever
is released and the activation of the
There are several methods of stopping monitor switch is suspected, use the
or slowing the snowmobile under a following procedure:
variety of situations. Identified in the
following chart are the ways a snow- 1. Rotate the ignition key to the OFF
position.
mobile may be brought to a stop and
the effectiveness under normal condi2. Remove ice and snow from the
tions.
throttle system and wait 5-10 minutes for the engine heat to thaw ice
ITEM
FUNCTION CONDITION
from the throttle system.
Emergency
Stop Switch
Throttle/Ignition Monitor
Switch
Ignition
Switch
Brake
interrupts ignition circuit
interrupts ignition circuit
ALL
ALL
interrupts igniALL
tion circuit
slows the ACT
ALL
drive
Choke (carfloods the
1/2 throttle
bureted
engine
or less
models)
THROTTLE/IGNITION
MONITOR SWITCH
The throttle control is equipped with a
monitor switch for safety purposes
which will stop the engine when a loss
of return spring force occurs. If ice
forms in the throttle system or if there
is some other malfunction of the throttle system resulting in a loss of return
spring force, the monitor switch will
stop the engine when the throttle control lever is released.
! WARNING
If any malfunction of the throttle
system occurs (such as freezing in
fluffy snow) and the monitor switch
does not shut off the engine, press
down on the emergency stop
switch IMMEDIATELY to stop the
engine. DO NOT start the engine
until the malfunction in the throttle
system has been located and corrected.
32
3. Test the throttle control lever by
compressing and releasing it several times. The lever MUST return
to the idle position quickly and
completely.
 NOTE: If the throttle control lever
operates properly and the engine
does not start, compress the throttle lever slightly (approximately 1/8
throttle) and try starting the
engine. If the engine now starts
and stops when the throttle lever is
released, take the snowmobile to
an authorized Arctic Cat Snowmobile dealer for service. If not under
warranty, this service is at the discretion and expense of the snowmobile owner.
! WARNING
If the throttle control lever does not
work properly, DO NOT ATTEMPT
TO START THE ENGINE.
4. If the throttle control lever operates properly, rotate the ignition
key to the RUN position and go
through normal starting procedures.
OPERATING INSTRUCTIONS
 NOTE: On fan-cooled models if
the throttle control lever operates
properly and the engine does not
start, either a malfunctioning monitor switch or a misadjusted magnetic carburetor switch may be the
problem. Take the snowmobile to
an authorized Arctic Cat Snowmobile dealer for service. If not under
warranty, this service is at the discretion and expense of the snowmobile owner. However, if a dire
emergency exists wherein the
engine must be started, disconnect the carburetor safety switch
connectors. If disconnection of the
carburetor safety switch connectors is needed to start the engine,
take the snowmobile to an authorized Arctic Cat Snowmobile dealer
for service as soon as possible. If
not under warranty, this service is
at the discretion and expense of
the snowmobile owner.
 NOTE: To access the switch connectors, open the left-side access
panel and remove the belt guard;
then locate the switch on the leftside of the carburetor and trace
the wire to the connector.
0743-448
 NOTE: On liquid-cooled models
if the throttle control lever operates properly and the engine does
not start, a malfunctioning monitor
switch may be the problem. Take
the snowmobile to an authorized
Arctic Cat Snowmobile dealer for
service. If not under warranty, this
service is at the discretion and
expense of the snowmobile owner.
However, if a dire emergency
exists wherein the engine must be
started, disconnect the throttle
monitor switch located in the rightside handlebar control.
 NOTE: On liquid-cooled models
if disconnection of the throttle
monitor switch is needed to start
the engine, take the snowmobile to
an authorized Arctic Cat Snowmobile dealer for service as soon as
possible. If not under warranty,
this service is at the discretion and
expense of the snowmobile owner.
! WARNING
Under no circumstances should
disconnection of the throttle control wiring harness be used as a
substitute for the monitor switch
during normal operation of the
snowmobile. Personal injury and
damage could occur if the throttle
system malfunctions or if the operator is unable to stop the engine in
an emergency. If the snowmobile
must be operated with a disconnected throttle control wiring harness, EXTREME CAUTION MUST
BE TAKEN. NEVER EXCEED 10
MPH WITH THE THROTTLE CONTROL WIRING HARNESS DISCONNECTED.
 NOTE: The monitor switch is
now bypassed. With exception of
the monitor switch and the emergency stop switch, all other ignition/electrical features (ignition
switch, headlight, taillight, and
brakelight) will operate properly.
OPERATING INSTRUCTIONS
33
VARYING ALTITUDE
OPERATION
! CAUTION
Operating a snowmobile at varying On carbureted models, carefully
altitudes requires changes in perfor- follow the Main Jet Chart recommance components. These changes mendations for proper main jet
affect drive train components (on all selection for altitude, temperature,
models) and carburetion components and gasoline being used.
(on carbureted models).
M-Series models are initially set up at
the factory for operation between
The altitude information decal is
6000-9000 feet.
located beneath the hood of the snowmobile. On carbureted models, the  NOTE: Carburetion and drive
information is incorporated into the train changes can be made by the
Carburetor Main Jet Chart decal.
snowmobile owner if qualified to
do so. If the owner does not feel
 NOTE: Just as important as cali- qualified, take the snowmobile to
brating the snowmobile for higher an authorized Arctic Cat Snowmoaltitudes is recalibrating the snow- bile dealer for this service. This
mobile when going to lower alti- service is at the discretion and
tudes. Always consult the altitude expense of the snowmobile owner.
decal beneath the hood of the
snowmobile.
34
OPERATING INSTRUCTIONS
LUBRICATION
ACT DRIVE GEAR
CASE (Each Season
Prior to Storage)
 NOTE: Flushing the gear case
and replacing the lubricant can be
done by the snowmobile owner if
qualified to do so. If the owner
does not feel qualified, take the
snowmobile to an authorized Arctic Cat dealer for this service. This
service is at the discretion and
expense of the snowmobile owner.
It is very important that the gear case
be flushed and the lubricant be
replaced after each season of use. Arctic Cat recommends that the flushing
and replacing be done prior to off-season storage.
 NOTE: It is recommended that
the gas tank be nearly empty (less
than 1/4 full) when tipping the
snowmobile.
4. Remove the drain plug from the
gear case; then install a drain
adapter fitting with hose into the
drain plug hole.
0743-456
To flush the gear case and replace the
lubricant, use the following procedure:
 NOTE: Gear case profiles will
vary from model to model. Determine which style is being serviced
and refer to the appropriate illustration.
1. Open the left-side access panel;
741-636A
then remove the panel and the belt
 NOTE: To aid in draining the
guard.
lubricant, it is advisable to fashion
2. Remove the drive belt (see Drive a drain adapter by acquiring a fitBelt sub-section); then remove the ting - Gear Case Drain Fitting (p/n
0644-508) - and a length of 3/8-in.
driven pulley.
hose.
 NOTE: If excessive oil deposits
are noticed, take the snowmobile
5. Tip the snowmobile back to the
to an authorized Arctic Cat Snowupright position; then place a drain
mobile dealer for service. If not
pan on the floor next to the drain
under warranty, this service is at
hose and tip the snowmobile
the discretion and expense of the
toward its left side far enough to
snowmobile owner.
allow the lubricant to drain from
the gear case into the drain pan.
3. Tip the snowmobile onto its right
side and place a piece of cardboard  NOTE: It is critical that the snowunderneath to protect the finish on mobile is on a level surface to
ensure the lubricant drains propthe hood and belly pan.
erly and completely.
LUBRICATION
35
6. Secure the snowmobile in this
position until the lubricant is completely drained.
! CAUTION
It is critical that all of the old lubricant be drained from the gear case
prior to flushing the gear case.
! WARNING
DO NOT stand behind the snowmobile or near the rotating track.
NEVER run the track at high speed
when the track is suspended.
12. Start the engine and accelerate
slightly. Use only enough throttle
to turn the track several revolu7. When the lubricant has completely
tions. SHUT ENGINE OFF.
drained form the gear case, tip the
snowmobile back to the upright 13. Open the left-side access panel;
then remove the panel and the belt
position, remove the drain adapter,
guard.
and install and securely tighten the
drain plug; then remove the check/ 14. Remove the drive belt (see Drive
fill plug.
Belt sub-section); then remove the
driven pulley.
8. Pour the recommended amount of
Arctic Cat ACT Drive Flush Fluid 15. Tip the snowmobile onto its right
(p/n 4639-333) into the check/fill
side and place a piece of cardboard
hole; then install the plug. Tighten
underneath.
securely.
16. Remove the drain plug from the
gear case; then install the drain
! CAUTION
adapter fitting with hose into the
Do Not add more or less than the
drain plug hole.
recommended amount of flush
fluid to the gear case.
17. Tip the snowmobile back to the
upright position; then place a drain
9. Install the driven pulley; then
pan on the floor next to the drain
install the drive belt (see Drive
hose and tip the snowmobile
Belt sub-section) and the belt
toward its left side far enough to
guard.
allow the flush fluid to drain from
the gear case into the drain pan.
10. Install the left-side access panel;
then close the access panel.
18. Secure the snowmobile in this
position until the flush fluid is
11. Position the tips of the skis against
completely drained.
a wall; then using a shielded safety
stand, raise the rear of the snowmobile off the floor making sure
! CAUTION
the track is free to rotate.
It is critical that all of the flush fluid
! WARNING
be drained from the gear case prior
to filling with new lubricant.
The tips of the skis must be positioned against a wall or similar
object.
36
LUBRICATION
19. When the fluid has completely
drained from the gear case, tip the
snowmobile back to the upright
position, remove the drain adapter,
and install and securely tighten the
drain plug; then remove the check/
fill plug.
! CAUTION
The correct lubricant to use in the
gear case is Arctic Cat Synthetic
ACT Gear Case Fluid (p/n 4639-628).
Any substitute may cause serious
damage to the drive system.
It is very important that the front suspension is greased on a monthly basis
using low-temperature grease. The
front suspension should also be greased
after trailering the snowmobile on an
open trailer. Pump grease into the spindle grease fitting (both sides) until
grease is noted coming out of the top
and bottom of the spindle. Wipe excess
grease from the spindle.
Crossfire/M-Series Models
20. Pour the exact amount (see specification sheet) of Arctic Cat Synthetic ACT Gear Case Fluid into
the check/fill hole; then install the
plug. Tighten securely.
! CAUTION
Do not add more or less than the
recommended amount of lubricant
to the gear case or damage to the
gear case will occur. Oil level
should be at the Oil Fill Level on
the gear case cover.
21. Install the driven pulley; then
install the drive belt (see Drive
Belt sub-section) and the belt
guard.
22. Install the left-side access panel;
then close the access panel.
FRONT SUSPENSION
 NOTE: Arctic Cat recommends
that Arctic Cat Low-Temp Grease
(p/n 4639-365) be used for this procedure.
LUBRICATION
0737-294
Bearcat/F-Series/
Z1/T-Series/TZ1 Models
741-335A
On the Crossfire/M-Series models,
pump grease into the upper steering
shaft grease fitting (located on each
side of the snowmobile directly below
the inner cap screw securing the upper
A-arm to the chassis) until grease is
noted coming out of the bottom of the
shaft. Wipe excess grease from the
shaft.
37
Crossfire/M-Series Models
 NOTE: Illustrated are the general
locations of grease fittings. Actual
locations will vary from model to
model.
1. Shut engine off and wait for all
moving parts to stop.
0743-219
On the Bearcat/F-Series/Z1/T-Series/
TZ1 models, turn the handlebar to the
right; then from the right side, pump
grease into the steering arms until
grease is noted coming out of either
end of the arms. Wipe excess grease
from the arms.
2. With the gas tank nearly empty
(less than 1/4 full), lay the snowmobile on its left side. A piece of
cardboard should be used to protect the finish on the hood and
belly pan.
3. Remove ice and snow buildup
from the skid frame to expose the
grease fittings.
Bearcat/F-Series/Z1/
T-Series/TZ1 Models
0741-440
REAR SUSPENSION
(Every 40 Operating
Hours)
0741-376
4. Lubricate the grease fittings with
low-temperature grease.
 NOTE: Arctic Cat recommends
that Arctic Cat Low-Temp Grease
(p/n 4639-365) be used for this procedure.
38
LUBRICATION
MAINTENANCE
PERIODIC MAINTENANCE CHECKLIST
ITEM
INTERVAL PAGE
REMARKS
Brake System (Hydraulic)
Daily
53 Check for binding, leakage, and proper operation; lever firmness, travel, caliper, disc, and pads
Cooling System - Liquid
Daily
18,44 Check for leakage, damage, obstructions, coolant level
Oil System
Daily
42-44 Check for leakage, damage, and injection/engine
oil level
Engine Oil (1100 cc STD)
2500 miles/ 42 Change oil and filter
Seasonal
Engine Oil (1100 cc Turbo)
2000 miles/ 42 Change oil and filter
seasonal
Battery
Daily
17,50 Check for proper charge and tight connections
Stop Switch
Daily
— Check for proper operation
Hoses
Daily
— Check for damage, leakage, and routing
Headlight & Taillight/Brakelight
Daily
65-69 Check for proper operation and cleanliness
Steering System
Daily
— Check for proper operation, tightness of bolts,
and binding
Throttle Control System
Daily
32 Check for binding, sticking, proper operation,
throttle cable tension, and routing
Drive Belt
Daily
56 Check for wear, cracks, and fraying
Monthly
Check length and width dimensions
Ski Wear Bars
Daily
70 Check for wear and damage
Carburetors - Main Jets Daily
48 Install proper main jets
Adjustment Screws
Weekly 45-47 Adjust according to specifications
Electrical Wiring
Weekly
— Check for wear, damage, tight connections, and
routing
Exhaust System
Weekly
17 Check for damage, leakage, and obstructions
Nuts, Bolts, Fasteners
Weekly
— Check tightness
Recoil Starter
Weekly
— Check rope for wear, fraying, and proper operation
Shock Absorbers
Weekly
19 Check for fluid leakage and damage
Spark Plugs (2-Stroke)
Weekly
49 Check center electrode insulator color, carbon,
and gap
Valve Clearance (1100 cc)
5000 miles/ 50 Check/adjust
Seasonal
Suspension
Weekly
61 Check for damage, loose components, and
proper adjustment
Track Tension/Alignment
Weekly 58,60 Check/adjust as necessary
Wear Strips
Weekly
71 Check for wear and damage
Wires & Cables
Weekly
— Check for wear, damage, and routing
Fuel System - Tank, Pump, In- Weekly
— Check for damage, wear, obstructions, and leakLine Filter, & Vent Hose
age
Fuel Filter (1100 cc)
5000 miles/ — Replace
2 years
Air Cleaner/Filter
Weekly/
40 Check/Replace
(1100 cc Turbo)
Seasonal
APV System
Monthly
26 Check/adjust as necessary
ACT Drive Gear Case
Seasonal
35 Change drive fluid prior to storage
Heat Exchangers
Monthly
— Check for wear, leakage, and damage
Drive Clutch/Driven Pulley
Monthly
18 Check for damage, abnormal noise, vibration,
binding, and sticking and clean off drive belt
deposits
Front & Rear Suspension
Monthly 37,38 Grease
MAINTENANCE
39
The longevity and safety of the snowmobile can be increased by making
periodic checks of the items in the preceding checklist.
If, at any time, abnormal noises, vibrations, or improper working conditions
of any component of this snowmobile
are detected, DO NOT OPERATE
THE SNOWMOBILE. Take the snowmobile to an authorized Arctic Cat
Snowmobile dealer for inspection and
adjustment or repair. If not under warranty, this service is at the discretion
and expense of the snowmobile owner.
The snowmobile should be taken to an
authorized Arctic Cat Snowmobile
dealer at the end of each snowmobiling
season for general inspection and for
off-season storage servicing. This
inspection and servicing is at the
expense of the snowmobile owner.
AIR CLEANER/FILTER
(1100 cc Turbo)
2. Clean the foam filter with warm
soapy water; then allow it to dry
thoroughly.
! CAUTION
Do not use compressed air to dry
the filter. Damage to the filter may
occur.
! CAUTION
A torn air filter can cause damage
to the turbocharger/engine. Contaminants may get inside the turbocharger/engine if the filter is torn.
Carefully examine the filter for
holes or tears before and after
cleaning it. Replace the filter with a
new one if it is torn.
3. Clean any debris from inside the
air intake plenum.
4. Place the filter into the plenum.
5. Secure the air cleaner cover onto
the plenum.
The air filter inside the air cleaner
housing must be kept clean to provide
! CAUTION
good engine power and gas mileage. If
the snowmobile is used under normal Do not run the engine without the
conditions, inspect the filter weekly air filter installed. Severe damage to
and replace the filter at the intervals the turbocharger/engine will occur.
specified. If operated in adverse condi- FUEL SYSTEM
tions, inspect and service the filter
more frequently. Use the following
! WARNING
procedure to remove the filter and to
Whenever any maintenance or
inspect and/or clean/replace it.
! CAUTION
Failure to inspect the air filter frequently if the snowmobile is used
in adverse conditions can damage
the turbocharger/engine.
inspection is made on the fuel system in which there may be fuel
leakage, there should be no welding, smoking, open flames, etc., in
the area.
1. Remove the air cleaner cover; then
remove the air filter.
40
MAINTENANCE
In-Line Fuel Filter
(Carbureted Models)
Arctic Cat recommends that the in-line
fuel filter be checked weekly. The inline fuel filter is located just in front of
the fuel pump inlet fitting. The filter
must be clean to allow the fuel hose to
transmit the amount of gasoline
required.
If the in-line fuel filter is obstructed,
gasoline flow will be restricted; therefore, the filter must be replaced. To
remove and install the in-line fuel filter, use the following procedure:
! WARNING
The fuel hoses must fit tightly on
the fuel filter. If the fuel hose length
doesn’t permit this procedure,
replace the fuel hose. Also, after
installing the fuel hoses on the filter, check to be sure that the fuel
hoses do not contact any hot or
rotating components.
In-Line Fuel Filter
(1100 cc Models)
Arctic Cat recommends that the in-line
fuel filter be checked weekly and
1. Pinch off the fuel hose between the replaced every 5000 miles. The in-line
fuel filter is located just inside the leftgas tank and fuel filter.
side access panel. The filter must be
2. Remove the clamps; then pry the clean to allow the fuel hose to transmit
fuel hoses off the in-line fuel filter the amount of gasoline required.
and remove the filter.
If the in-line fuel filter is obstructed,
 NOTE: The in-line fuel filter must gasoline flow will be restricted; therebe replaced if obstructed. Filters fore, the filter must be replaced. To
are available from an authorized remove and install the in-line fuel filArctic Cat Snowmobile dealer.
ter, use the following procedure:
3. Install the in-line fuel filter in the
fuel hose so the arrow on the filter
points toward the fuel pump. Make
sure the fuel hoses fit tightly on
the filter. If the existing fuel hose
does not fit tightly on the filter, cut
6 mm (1/4 in.) from the end of the
fuel hose; then install on the filter
and secure with the clamps.
! WARNING
Since the fuel supply hose may be
under pressure, always wear
safety glasses when removing the
fuel hoses.
! CAUTION
Since the fuel supply hose may be
under pressure, remove it slowly
to release the pressure. Place an
absorbent towel around the connection to absorb the fuel.
 NOTE: Before removing the fuel
filter, take note of the filter inlet
and outlet for installing purposes.
728-272B
MAINTENANCE
1. Open the left-side access panel;
then remove the fuel filter from
the bracket.
41
2. Remove the hose clamps and dis-  NOTE: The snowmobile must be
card; then slowly remove the fuel on a level surface for this procehoses from the fuel filter. Dispose dure.
of the excess fuel from the filter
2. Shut the engine off; then remove
properly.
the oil level stick from the oil res3. Inspect the fuel hoses thoroughly
ervoir. Wipe the stick clean.
for any signs of cracking, cuts, or
wear points.
4. Place the new hose clamps on the
fuel hoses; then with the fuel
pump inlet and outlet noted, connect the fuel hoses to the fuel filter.
Secure with the hose clamps.
5. Secure the fuel filter to the fuel filter bracket; then start the engine
and inspect the fuel hoses and filter for any signs of leaks.
Gasoline Additives
Fuel de-icer can be used for all models.
Also, periodic use of an injector
cleaner for EFI models is recommended especially in the last tank of
gasoline before storage. Arctic Cat
Fuel Stabilizer (p/n 0436-907) should
also be added to the last tank of gasoline before storage.
ZJ002A
3. Insert the oil level stick into the oil
reservoir without threading it in
and remove. Read the oil level
shown on the stick. The oil level
should be near the middle of or on
the high end of the NORMAL
range on the stick.
Fuel Pickup Valves
All 2-Stroke EFI models are equipped
with fuel pickup valves in the gas tank.
If ever there is a restricted fuel flow
0741-490
and a pickup valve is suspected, take
the snowmobile to an authorized Arctic  NOTE: To attain an accurate oil
Cat Snowmobile dealer for this service. level reading, do not thread the
If not under warranty, this service is at stick into the reservoir.
the discretion and expense of the snow4. If step 1 was followed and the oil
mobile owner.
level is at or below the ADD mark,
add up to 1/2 qt of recommended
CHECKING
engine oil.
ENGINE OIL LEVEL
(1100 cc Models)
 NOTE: Care must be taken not to
1. Park the snowmobile on a level over-fill the reservoir with oil.
surface; then start the engine and
5. Repeat steps 3-4 until the oil level
allow it to warm up for 5-10 minis within the recommended range
utes, or if the snowmobile was
on the oil level stick.
operated, allow the engine to idle
for approximately 30 seconds.
42
MAINTENANCE
CHANGING ENGINE
OIL/FILTER
(1100 cc Models)
 NOTE: Always install a new Oil
Pan Drain Plug Gasket (p/n 3402011) and a new Reservoir Drain
Plug O-Ring (p/n 1670-926) when
changing the oil.
! WARNING
Care must be taken if a hot drain
plug is removed by hand. Burning
could occur.
 NOTE: Recycle or properly dispose of the used engine oil.
1. Using a putty knife, remove the
belly pan plug.
2. Park the snowmobile on a level
surface; then start the engine and
allow it to warm up for 5-10 minutes, or if the snowmobile was
operated, allow the engine to idle
for approximately 30 seconds.
6. Install a new belly pan plug.
7. Using Oil Filter Wrench (p/n
0644-389), loosen (but do not
remove) the oil filter and allow the
oil to drain from the filter; then
remove the filter.
8. Apply a light coat of fresh engine
oil to the seal of the new oil filter.
9. Install the new oil filter by turning
the oil filter by hand until the seal
has contacted the oil filter mounting surface; then tighten the oil filter to 15 ft-lb.
3. Shut the engine off; then place 10. Pour 2.9 l (3 U.S. qt) of the recomdrain pans beneath both engine oil
mended engine oil into the oil resdrain plugs (crankcase and oil reservoir.
ervoir).
11. Open the air bleed bolt located on
the oil pump (beneath the coolant
tank) to purge air from the oil
hose.
ZJ003A
4. Remove the drain plugs and allow
the oil to drain completely.
ZJ004A
 NOTE: At this point, remove the
strainer from the oil reservoir to  NOTE: When air can no longer
allow the oil to drain completely.
be heard purging from oil pump
5. After the oil has drained com- bleed, tighten the bleed bolt to 7.5
ft-lb.
pletely, install the oil strainer,
drain plugs, and washers and 12. Without starting the engine, place
tighten to 15 ft-lb.
the handlebar emergency stop
switch to the RUN position and
the ignition switch to the ON position. The Oil Pressure Warning
Icon should illuminate.
MAINTENANCE
43
 NOTE: If the warning icon does
not illuminate, take the snowmobile to an authorized Arctic Cat
Snowmobile dealer for service. If
not under warranty, this service is
at the discretion and expense of
the snowmobile owner.
1. Remove the two torx-head screws
securing the console to the chassis;
then lift up the rearward end of the
console and disconnect the console
harness plug-in.
13. If the warning icon illuminates
(from step 12), start the engine.
The warning icon should go out
within five seconds. If it does, proceed to step 14.
 NOTE: If the warning icon does
not go out, shut the engine off
immediately and repeat step 11;
then place the ignition switch to the
ON position and repeat step 13. If
the warning icon does not go out,
take the snowmobile to an authorized Arctic Cat Snowmobile dealer
for service. If not under warranty,
this service is at the discretion and
expense of the snowmobile owner.
0743-428
2. Remove the console.
3. Place the console into position on
the headlight support bracket; then
connect the console harness connector.
4. Secure the console to the chassis
with the two torx-head screws.
14. Shut the engine off and pour the
remaining amount (0.9 l or 1 U.S.
qt) of recommended oil into the oil
reservoir; then proceed to the
Checking Engine Oil Level (1100
cc Models) sub-section to verify
and finalize the procedure.
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.
COOLANT LEVEL
1100 cc
! CAUTION
 NOTE: Use a good quality, ethyl-  NOTE: Always check the coolant
ene glycol-based, automotive-type level with the engine cold.
antifreeze.
 NOTE: The hood must be
500/600/800/1000 cc
removed for this procedure.
 NOTE: Always check the coolant Locate the FULL COLD mark on the
level with the engine cold.
coolant reservoir (located in the forLocate the appropriate FULL mark on ward engine compartment below the
the coolant reservoir. If coolant is hood hinge bracket).
below the FULL mark, add antifreeze If the coolant is below the FULL
to the FULL mark.
COLD mark, add antifreeze to the
On the F-Series/T-Series if adding FULL COLD mark.
coolant, the console must be removed.
For Removing/Installing the console,
use the following procedure.
44
MAINTENANCE
! CAUTION
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.
ADJUSTING
CARBURETORS
Adjusting Choke Cable
1. Be sure the ignition switch key is
in the OFF position and the brake
lever lock is set.
2. Loosen the jam nut securing each
choke cable adjuster. Rotate each
choke cable adjuster clockwise
until it bottoms against the brass
plunger cap.
The carburetors have been calibrated at
the factory for average riding conditions; however, altitude, temperature,
and general wear may necessitate certain carburetor adjustments. Be sure
the correct carburetor main jets
for the operating temperature, altitude, and type of gasoline are being
used (see Selecting Carburetor
Main Jets sub-section). Since carbu-
retor adjustments critically affect
engine performance, Arctic Cat recommends that all changes in internal carburetor calibration and piston valve
synchronization be made by an authorized Arctic Cat Snowmobile dealer;
however, four external adjustments can
be made on each carburetor.
These are the choke cable travel, piston
valves, pilot air screws, and idle speed
screws.
 NOTE: Carburetor adjustments
and changing main jets may be
done by the snowmobile owner if
qualified to do so. If the owner
does not feel qualified, take the
snowmobile to an authorized Arctic Cat Snowmobile dealer for this
service. This service is at the discretion and expense of the snowmobile owner.
0727-156
3. Slowly rotate one choke cable
adjuster counterclockwise while
checking the choke lever for freeplay. As soon as all free-play has
been removed from the end of the
lever, stop rotating the adjuster.
4. With free-play removed from the
lever, slowly rotate each choke
cable adjuster once again clockwise while checking the choke
cable lever for free-play. Adjust
until 3 mm (1/8 in.) free-play
between front bottom edge of lever
and housing is attained. Securely
tighten the adjuster jam nut.
! CAUTION
Make sure to perform these adjustment/synchronization procedures
on all carburetors.
MAINTENANCE
732-848B
45
 NOTE: If a carburetor choke
cable is adjusted too tight, the
engine will only operate on one
cylinder at idle.
Synchronizing Piston
Valves
1. Remove the air-intake silencer
boots from the silencer to access
the intake bores.
2. Rotate the idle speed screws counterclockwise until all spring tension is removed.
6. With the piston valves synchronized, tighten the swivel adapter
jam nuts securely. Slide the rubber
throttle cable caps down over the
swivel adapters.
 NOTE: There must be free-play
in the throttle lever on all models.
! WARNING
Be sure to tighten the swivel
adapter jam nuts securely. If a
swivel adapter jam nut is not tightened, the adjuster can rotate out of
the carburetor cap causing the piston valve not to return to the fullclosed position.
7. In turn on each carburetor, place a
finger against the piston valve.
Rotate the idle speed screw clockwise until it contacts the valve.
0727-156
8. Compress the throttle lever to the
full-open position; then rotate each
idle speed screw clockwise 2 complete turns. Release the throttle lever.
3. Loosen the jam nut securing each
throttle cable swivel adapter; then
rotate each swivel adapter clockwise until each piston valve bot-  NOTE: There must be 0.75-1.5
mm (0.030-0.060 in.) free-play
toms in the piston valve bore.
between the throttle lever and the
4. In turn on each carburetor, place a control housing.
finger lightly against the side of
the piston valve; then rotate the 9. At this point, there must be 0.751.5 mm (0.030-0.060 in.) of cable
carburetor swivel adapter counterfree-play gap in the throttle lever.
clockwise until slight upward
If there is no cable free-play in the
movement of the valve is noted.
throttle lever, the throttle safety
switches will not function prop5. Check to make sure the valves
erly, and the engine will cut out in
start to open at the exact same
the idle position.
moment by placing a thumb and
finger against the valves; then
lightly compress the throttle lever.
 NOTE: If an individual piston
valve starts to open before
another, rotate the swivel adapter
on the valve which is lifting first
clockwise, just enough to synchronize the valves. Recheck by repeating steps 2-5.
0741-518
46
MAINTENANCE
 NOTE: If cable free-play gap is
not correct, rotate each swivel
adapter an equal amount until recommended free-play is achieved.
Each piston valve must be resting
against the tip of its idle speed
screw.
 NOTE: If throttle cable free-play
is incorrect, the carburetor safety
switches will be activated prematurely and the engine will not start.
Fine-Tuning Pilot Air
Screws and Idle Speed
Screws
1. While counting the rotations, carefully rotate the pilot air screws
clockwise until lightly seated.
! CAUTION
Do not force a pilot air screw when
rotating it clockwise; damage to
the pilot air screw needle tip will
result.
2. Rotate the pilot air screws counterclockwise the exact number of
rotations ± 1/4 turn from the seated
position as an initial setting.
3. Install the air-intake silencer boots
taking care that the boots are properly positioned and that the boots
are not “folded” in the air-intake
silencer causing a restriction of air
flow.
4. With the snowmobile on a
shielded safety stand, start the
engine, release the brake lever
lock, and thoroughly warm up.
! WARNING
 NOTE: Make engine idle adjustment only after the engine has
reached running temperature.
Since the idle speed screws have
not been fine-tuned, slight throttle
pressure may be necessary to
keep the engine running. Allow
engine to warm up for 2-3 minutes.
5. After the engine has been thoroughly warmed up, fine-tune the
pilot air screws (equally) and the
idle speed screws (equally) until
the engine runs smoothly.
 NOTE: Engine idle RPM should
be approximately 1500.
! WARNING
If a tachometer is not available,
care must be taken not to adjust
engine idle speed too high.
! CAUTION
It is important that the pilot air
screws are adjusted equally and
that the idle speed screws are
adjusted equally.
6. Test the throttle control lever by
compressing and releasing it several times. The lever must return to
the idle position quickly and completely.
! WARNING
DO NOT operate the snowmobile
when any component in the throttle system is damaged, frayed,
kinked, worn, or improperly
adjusted. If the snowmobile is
operated when the throttle system
is not functioning properly, personal injury could result.
DO NOT stand behind the snowmobile or near the rotating track.
NEVER run the track at high speed
when the track is suspended.
MAINTENANCE
47
SELECTING
CARBURETOR MAIN
JETS
Altitude, temperature, and the use of
oxygenated gasoline affect the carburetion needed for optimum engine performance. The carburetor main jets must
be changed in conjunction with changes
in operating altitude, oxygenated gasoline usage, and temperature. As the
ambient temperature rises or as the
snowmobile is operated at a higher altitude, the main jets must be replaced
with leaner main jets. The original
equipment (production) main jets may
need to be changed (depending on the
type of gasoline you are using, your
operating altitude, and temperature). A
Main Jet Chart decal is located beneath
the hood of the snowmobile. It should
be noted that when selecting the proper
main jets, it is better to be too rich rather
than too lean. To change carburetor
main jets, use the following procedure:
! WARNING
Whenever any maintenance is performed on the fuel system, there
should be no welding, smoking,
open flames, etc., in the area.
1. Loosen each carburetor flange
clamp and remove each carburetor
from the intake flange and boot.
2. Remove each drain plug and Oring from the carburetor float
chamber and drain the gas into a
small container or shop towels.
3. Using the main jet wrench (from
the tool kit), thread the main jet
out of each carburetor. Account for
the baffle ring/washer. Install the
new main jet and the existing baffle ring/washer. Tighten the main
jet securely.
! CAUTION
Use only GENUINE Mikuni brass
main jets. Also, if using an oxygenated gasoline (up to 10% ethanol
or up to 15% MTBE), the carburetor
main jet must be one size larger
than the main jet required for regular unleaded gasoline.
 NOTE: Carburetor main jets may
be changed by the snowmobile
owner if qualified to do so. If the
owner does not feel qualified, take
the snowmobile to an authorized
Arctic Cat Snowmobile dealer for
this service. This service is at the
discretion and expense of the
snowmobile owner.
! CAUTION
0728-054
4. Install each drain plug and O-ring;
then tighten securely.
5. Install and secure the carburetors.
SPARK PLUGS
(1100 cc Models)
 NOTE: If spark plugs must be
replaced, take the snowmobile to
an authorized Arctic Cat Snowmobile dealer for inspection and service. This service is at the
discretion and expense of the
snowmobile owner.
A main jet which is too small will
cause severe engine damage.
Engine damage caused by lean jetting WILL NOT BE covered by Arctic Cat warranty policy.
48
MAINTENANCE
SPARK PLUGS
(2-Stroke Models)
 NOTE: Always use the recommended spark plugs in the engine.
See the appropriate specifications
chart for correct spark plug gap.
Varying terrain conditions and operating usage may require spark plugs of a
different heat range. For example, sustained cross-country riding will usually
require colder heat-range spark plugs
while trail riding or other continual
slow speed operation will usually
require hotter heat-range spark plugs.
Removing/Installing
Spark Plugs (Crossfire/
M-Series Models)
1. Remove the springs securing the
expansion chamber to the exhaust
manifold and resonator; then move
the expansion chamber out of the
way to access the spark plugs.
2. Remove the spark plug caps from
the plugs.
3. Using a spark plug
remove the plugs.
wrench,
4. Install the plugs and finger-tighten.
5. Tighten the spark plugs to 19 ft-lb;
then install the spark plug caps.
0743-428
2. Lift the rearward end of the console and disconnect the main/hood
harness connector; then remove
the console.
3. Remove the spark plug caps from
the plugs.
4. Using a spark plug
remove the plugs.
wrench,
5. Install the plugs and finger-tighten.
6. Tighten the spark plugs to 19 ft-lb;
then install the spark plug caps.
7. Place the console into position on
the headlight support bracket
keeping the rearward end slightly
elevated; then connect the main/
hood harness connector.
8. Lower the rearward end of the
console into position; then install
the two torx-head screws. Tighten
securely.
6. Place the expansion chamber into Checking Spark Plugs
position and secure to the exhaust (2-Stroke Models)
manifold and resonator with the
To see if the spark plugs being used are
springs.
of the proper heat range (after the
snowmobile has been operated under
Removing/Installing
normal driving conditions), remove the
Spark Plugs (Bearcat
570/570 XT - F-Series/ spark plugs and examine the condition
of the center electrode insulator of each
T-Series Models)
spark plug.
1. Remove the two torx-head screws
securing the console to the headlight support bracket.
MAINTENANCE
49
! CAUTION
AO352A
If a spark plug is light gray, white,
or black and another is tan or light
brown, take the snowmobile to an
authorized Arctic Cat Snowmobile
dealer for inspection and service. If
not under warranty, this service is
at the discretion and expense of
the snowmobile owner.
A. TAN or LIGHT BROWN insulator indicates correct spark CHECKING/
ADJUSTING VALVE
plugs (heat range).
B. LIGHT GRAY or WHITE
insulator indicates over-heating
of the engine. This condition is
caused by a too lean condition
or incorrect spark plugs (heat
range too hot).
C. BLACK insulator indicates
fuel in the combustion chamber
is not burning completely. This
condition is caused by a too
rich condition, too much oil, or
incorrect spark plugs (heat
range too cold).
 NOTE: If the center electrode
insulators are light gray, white, or
black and if the carburetor adjustments (on carbureted models), oilinjection pump synchronization,
and ignition timing are correct, different heat-range spark plugs may
be necessary. Authorized Arctic Cat
Snowmobile dealers have detailed
spark plug information. Consult a
dealer before changing spark plugs,
as incorrect heat-range spark plugs
could cause poor engine performance or engine damage.
50
CLEARANCE
(1100 cc Models)
After 5000 miles or prior to seasonal
storage, valve clearance should be
checked and adjusted as necessary.
 NOTE: Take the snowmobile to
an authorized Arctic Cat Snowmobile dealer for inspection and service. This service is at the
discretion and expense of the
snowmobile owner.
! CAUTION
It is critical that the checking/
adjusting valve clearance be done
at the recommended intervals or
severe engine damage may occur.
BATTERY (Electric
Start Models)
These standard and sealed batteries
after being in service require regular
cleaning and recharging in order to
deliver peak performance and maximum service life. The following procedures are recommended for cleaning
and maintaining standard and sealed
batteries. Always read and follow
instructions provided with battery chargers and battery products.
MAINTENANCE
 NOTE: Battery maintenance may
be done by the snowmobile owner
if qualified to do so. If the owner
does not feel qualified, take the
snowmobile to an authorized Arctic Cat Snowmobile dealer for this
service. This service is at the discretion and expense of the snowmobile owner.
To remove and charge the battery, use
the following procedure:
! WARNING
Any time service is performed on a
battery, the following must be
observed: Keep sparks, open
flame, cigarettes, or any other
flame away. Always wear safety
glasses. Protect skin and clothing
when handling batteries. When
servicing battery in enclosed
space, keep the area well-ventilated. Make sure battery venting is
not obstructed.
! WARNING
Battery posts, terminals, and
related accessories contain lead
and lead compounds, chemicals
known to the state of California to
cause cancer and reproductive
harm. Wash hands after handling.
2. Thoroughly wash the battery with
soap and water.
 NOTE: If battery posts or cable
ends have a build-up of white/
green powder residue, apply water
and baking soda to neutralize acid;
then flush off with warm soapy
water.
3. Using a wire brush, clean the battery posts and cable ends removing
all corrosive buildup. Replace
damaged cables or cable ends.
4. On a standard battery, add clean
distilled water to bring fluid level
to the UPPER level line.
! CAUTION
Do not remove seal strip on a
sealed battery.
! WARNING
Battery acid is harmful if it contacts eyes, skin, or clothing. Care
must be taken whenever handling
a battery.
! CAUTION
Never use electrolyte (sulfuric
acid) to “top off” the battery. Use
only distilled water or severe battery damage may occur.
1. Remove the negative battery
5. Using a multimeter, test the battery
cable; then remove the positive
voltage. The meter must read no
cable and on the standard battery,
less than 12.5 DC Volts for a fully
the battery vent tube. Remove the
charged battery.
battery from the snowmobile. Care
should be taken not to damage the  NOTE: At this point if the meter
vent tube.
reads as specified, the battery may
be returned to service (see step 9).
! WARNING
Avoid spillage and contact with
skin, eyes, and clothing.
! CAUTION
Do not charge the battery while it
is in the snowmobile with the battery terminals connected.
MAINTENANCE
6. If the meter reads less than specified voltage, charge the battery
using the following guidelines.
A. When using an automatic battery charger, always follow the
charger manufacturer’s instructions.
51
B. When using a constant-current
battery charger, use the following Battery Charging Chart.
! CAUTION
Never exceed the standard charging rate.
! WARNING
An overheated battery could
explode causing severe injury or
death. Always monitor charging
times and charge rates carefully.
Stop charging if the battery
becomes very warm to the touch.
Allow it to cool before resuming
charging.
Battery Charging Chart
(Constant-Current Charger)
Battery
Voltage
(DC)
Charge
State
Charge Time
Required
(at 1.5-2.0
Amps)
12.5
(minimum)
100%
None
12.2-12.4 75%-99%
3-6 hours
12.0-12.2 50%-74%
5-11 hours
11.0-11.9 25%-49%
13 hours
(minimum)
11.5 or less
0-24%
20 hours
(minimum)
 NOTE: If the battery voltage is
11.5 DC Volts or less, some chargers may “cut off” and fail to
charge. If this occurs, connect a
fully charged booster battery in
parallel (positive to positive and
negative to negative) for a short
period of time with the charger
connected. After 10-15 minutes,
disconnect the booster battery
leaving the charger connected and
the charger should continue to
charge. If the charger “cuts off,”
replace the battery.
52
7. After charging the battery for the
specified time, remove the battery
charger and allow the battery to sit
for 1-2 hours.
8. Connect the multimeter and test
the battery voltage. The meter
should read no less than 12.5 DC
Volts. If the voltage is as specified,
the battery is ready for service.
 NOTE: If voltage in step 8 is
below specifications, charge the
battery an additional 1-5 hours;
then retest. Recheck electrolyte
level (standard battery) and the
battery is ready for service.
9. Place the battery into position in
the snowmobile; then coat the battery posts and cable ends with a
light coat of multi-purpose grease.
! CAUTION
Before installing the battery, make
sure the ignition switch is in the
OFF position.
10. Connect the battery cables (positive cable first).
! CAUTION
Connecting cables in reverse (positive to negative and negative to
positive) can cause serious damage to the electrical system.
FUSES
(Electric Start Models)
Fuses protect the snowmobile electrical
system from overloading. If electrical
parts in the snowmobile are not working, the system may have been overloaded and caused a blown fuse.
Before repairing or replacing any electrical part, check the appropriate fuses.
If a fuse blows (opens a circuit), all the
parts of the snowmobile that use that
circuit will not work.
MAINTENANCE
4. Install the fuse panel cover.
Once which fuse to check has been
determined, perform the following
Even after replacing a fuse, it may consteps:
tinue to blow if the cause of the over1. Open the right-side access panel; load is not determined. If the fuse
then on 4-stroke models, remove continues to blow, take the snowmobile
the fuse panel cover (the fuse to an authorized Arctic Cat Snowmopanel is located behind the bat- bile dealer for service. If not under
tery). On 2-stroke models, discon- warranty, this service is at the discretion and expense of the snowmobile
nect the fuse connector harness.
owner.
HYDRAULIC BRAKE
SYSTEM
ZJ005A
Arctic Cat recommends that the brake
system (brake lever, fluid 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 visible
in the sight glass.
! WARNING
ZJ306A
 NOTE: On 4-stroke models, there
are spare fuses inside the fuse
panel.
2. Remove the suspected fuse.
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.
Checking/Adding
3. Look through the clear side of the Brake Fluid
fuse to see if the metal wire inside
1. With sight glass reservoir in a
is separated. If it is, the fuse is
level position, check the fluid
blown and should be replaced with
level. The brake fluid level must
a fuse of the correct amperage ratbe visible in the sight glass.
ing.
 NOTE: If the sight glass appears
! WARNING
dark, there is a sufficient amount
Always replace a fuse with one of fluid in the reservoir.
having the same specified amperage rating. Using a fuse with a
higher rating can cause severe
wire damage and could start a fire.
MAINTENANCE
53
Checking Brake Lever
Travel
Before each use, check the brake lever
travel using the following procedure:
1. Compress the brake lever fully.
741-328A
2. If the brake fluid is not visible in
the sight glass, remove the reservoir cover and add Arctic Cat
approved brake fluid until the fluid
is at the recommended level.
Install and secure the reservoir
cover. Do not allow moisture to
contaminate the brake system.
 NOTE: Do not pump the brake
lever as it will produce an inaccurate reading.
2. Measure the distance between the
brake lever and the handlebar. The
distance must be greater than 2.54
cm (1 in.).
! 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. 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 Brake Fluid
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. Take the snowmobile
to an authorized Arctic Cat Snowmobile dealer for this service. This service
is at the discretion and expense of the
snowmobile owner.
54
741-328B
3. If the resultant distance is less than
specified, take the snowmobile to
an authorized Arctic Cat Snowmobile dealer for service. If not under
warranty, this service is at the discretion and expense of the snowmobile owner.
! WARNING
Do not operate the snowmobile if
the compressed distance between
the brake lever and the 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:
MAINTENANCE
 NOTE: The brake system may be
5. When the brake fluid is free of all
bled by the snowmobile owner if
air and the brake lever feels firm
qualified to do so. If the owner
when compressed, fill the reserdoes not feel qualified, take the
voir; then install and secure the
snowmobile to an authorized Arccover. Remove the tube from the
tic Cat Snowmobile dealer for this
bleeder valve.
service. This service is at the discretion and expense of the snow- Checking/Changing
mobile owner.
Brake Pads
1. Remove the reservoir cover and The condition of the brake pads must
fill the reservoir with Arctic Cat be checked daily and changed if worn
or damaged. To check and change the
approved brake fluid.
brake pads, use the following procedure:
! CAUTION
Brake fluid is highly corrosive. Do
not spill brake fluid on any surface
of the snowmobile.
! WARNING
Use only Arctic Cat approved
brake fluid. Any substitute may
result in a loss of brakes.
 NOTE: The brake pads may be
changed by the snowmobile owner
if qualified to do so. If the owner
does not feel qualified, take the
snowmobile to an authorized Arctic Cat Snowmobile dealer for this
service. This service is at the discretion and expense of the snowmobile owner.
2. Slide a piece of flexible tubing
over the ball of the bleeder valve  NOTE: When installing new
and direct the other end into a con- brake pads, always install them as
a set. Never install just one pad or
tainer.
use brake pads which have been
used in another snowmobile.
1. Measure the thickness of both
brake pads. The brake pad thickness must be greater than 5.0 mm
(0.20 in.). If the brake pad thickness is less than specified, replacement of both pads is necessary.
739-269B
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.
4. Repeat step 3 until the brake fluid
flows free of air bubbles.
 NOTE: It may be necessary to
refill the reservoir during the
bleeding process.
MAINTENANCE
0739-269
2. Remove the pin/hairpin clip securing the brake pads to the caliper
assembly.
55
3. Remove the brake fluid reservoir DRIVE BELT
cover; then remove most of the
brake fluid from the reservoir. The drive belt transfers power from the
drive clutch to the driven pulley. If the
Install the cover.
belt is worn, cracked, or stretched,
 NOTE: The above procedure will maximum power will not be transmitallow room for the fluid from the ted and the belt could also fail and
caliper when the pistons are therefore must be replaced. Periodic
pushed into the caliper for install- checks (at least once a month under
ing new brake pads. Replacing the normal usage) of two drive belt specificover will prevent fluid spillage.
cations are essential.
4. Using a pair of pliers, pull one
brake pad out of the caliper assembly.
 NOTE: Changing one pad at a
time will prevent one piston from
pushing out the other piston from
the caliper.
5. Using a flat-blade tool, slowly and
carefully push the piston into the
caliper.
1. Measure the outside circumference
of the drive belt. The belt should
be within the recommended range
in circumference.
2. Measure the outside width of the
drive belt. The belt should be within
the recommended range in width.
3. Check the belt for cracking, fraying, etc.
If any of the specifications or condi6. Position the new brake pads into tions are unsatisfactory, replace the
the caliper.
drive belt.
7. Repeat steps 4-6 for the other pad;  NOTE: Drive belts should be purthen secure the pads with the pin/ chased from an authorized Arctic
hairpin clip.
Cat Snowmobile dealer, as Arctic
Cat drive belts are made to exact
8. Remove the reservoir cover and specifications and of quality materemove the remaining fluid; then rial. Belts made by other manufacfill the reservoir with fresh fluid turers may not be of the same
and install the cover.
specifications or quality and,
therefore, usage could result in
9. Pump the brake lever to ensure poor performance and premature
correct positioning of the brake belt failure.
pads; then release.
10. Remove the reservoir cover and
fill the reservoir to the proper level
with fresh brake fluid; then install
the cover.
 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.
56
! 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.
MAINTENANCE
Also, drive belts have a break-in period
of approximately 20 miles. After
installing a new drive belt, drive the
snowmobile for 20 miles at 1/2 throttle
or less. This will allow the drive belt to
gain its optimum flexibility and will
extend drive belt life.
Checking/Adjusting
Drive Belt Deflection
 NOTE: Adding shim washers will
decrease belt deflection and removing shim washers will increase belt
deflection. Available shim washers
from Arctic Cat are p/n 0648-714
(0.090 in.) - one included in the tool
kit, p/n 0648-715 (0.030 in.), and p/n
0648-716 (0.060 in.).
 NOTE: Removing/adding shim
washers may be done by the snowmobile owner if qualified to do so.
If the owner does not feel qualified,
take the snowmobile to an authorized Arctic Cat Snowmobile dealer
for this service. This service is at
the discretion and expense of the
snowmobile owner.
Removing Drive Belt
 NOTE: Changing a drive belt can
be done by the snowmobile owner
if qualified to do so. If the owner
does not feel qualified, take the
snowmobile to an authorized Arctic Cat Snowmobile dealer for this
1. Place a straightedge on the top of service. This service is at the disthe drive belt. The straightedge cretion and expense of the snowshould reach from the drive clutch mobile owner.
to the top of the driven pulley.
1. Turn ignition key to the OFF position and wait for all moving parts
 NOTE: Make sure the drive belt
is all the way out in the driven pulto stop.
ley before checking drive belt fit.
2. Set the brake lever lock.
2. Using a stiff ruler centered
between the drive clutch and 3. Open the left-side access panel;
then remove the belt guard.
driven pulley, push down on the
drive belt just enough to remove
4. Remove the cap screw, lock
all slack and note the amount of
washer, washer, and sheave
deflection. The deflection should
adjuster from the end of the driven
be within the range of 28.5-31.8
pulley.
mm (1 1/8-1 1/4 in.).
 NOTE: Assure that the shims
3. To correct drive belt deflection, and O-ring are not removed from
remove the sheave adjuster from the adjuster.
the pulley, remove or add shim
washers to the adjuster, and install
the adjuster.
0743-319
The drive belt must have the proper fit
in the drive clutch and driven pulley.
To check for proper drive belt fit, use
the following procedure.
MAINTENANCE
57
2. Remove the sheave adjuster and
install it in its original position
(beveled side out); then install the
cap screw, lock washer, washer,
and sheave adjuster back into the
driven pulley. Tighten the cap
screw to 32 ft-lb.
! CAUTION
0743-395
5. Remove the cap screw (w/lock
washer and washer) from the
adjuster, turn the adjuster around
(reverse it), and insert the cap
screw (w/lock washer and washer)
into the adjuster.
Do not apply Loctite to the driven
pulley cap screw or component
damage may occur.
3. Install the belt guard; then close the
left-side access panel.
! WARNING
Never operate the snowmobile
without the belt guard/access
panel secured in place.
4. Release the brake lever lock.
TRACK TENSION
0743-396
6. Install the sheave adjuster and cap
screw (w/lock washer and washer)
onto the driven pulley; then
tighten the cap screw until the
movable sheave opens far enough
to allow the belt to be removed.
 NOTE: Before installing the drive
belt, use a suitable cleaning solvent to thoroughly clean the
sheaves.
7. Remove the drive belt from the
driven pulley first; then from the
drive clutch.
Installing Drive Belt
1. Place the drive belt (so the part
number can be read) between the
sheaves of the drive clutch first;
then between the sheaves of the
driven pulley.
58
Track tension is directly related to the
overall performance of the snowmobile.
If the track is too loose, it may slap
against the tunnel causing wear or it
may “ratchet” on the track drive sprockets. If extremely loose, the idler wheels
may climb over the track lugs forcing
the track against the tunnel causing the
track to “lock.” Arctic Cat recommends
that the track tension be checked daily
during the first 300 miles of operation
and once a week thereafter and adjusted
according to need. The track will stretch
and take a “set” during break-in. Track
deflection must be maintained within
the recommended range.
! WARNING
Track tension must be properly
maintained. Personal injury could
result if a track is allowed to
become excessively loose.
MAINTENANCE
Checking Track
Tension
Model
! WARNING
DO NOT attempt to check or adjust
track tension with engine running.
Turn ignition key to the OFF position. Personal injury could result
from contact with a rotating track.
1. Remove excess ice and snow
buildup from the track, track drive
sprockets, and the inside of the
skid frame.
2. Place the snowmobile up on a
shielded safety stand. Check to
make sure the track is 5-8 cm (2-3
in.) off the floor.
3. 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 the recommended
pressure. 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.
Setup
Tension
After
Break-In
Tension
Bearcat 570/
44-51 mm 51-57 mm
T-Series/TZ1
(1 3/4-2 in.) (2-2 1/4 in.)
Models @ 20 lb
Bearcat XT
38-44 mm 38-44
Models @ 20 lb (1 1/2-1 3/4 (1 1/2-1 3/4
in.)
in.)
F-Series
44-51 mm 51-57 mm
Models @ 20 lb (1 3/4-2 in.) (2-2 1/4 in.)
Z1
44-51 mm 51-57 mm
Models @ 20 lb (1 3/4-2 in.) (2-2 1/4 in.)
Crossfire
44-51 mm 51-57 mm
Models @ 20 lb (1 3/4-2 in.) (2-2 1/4 in.)
M-Series
51-64 mm 51-64 mm
Models @ 10 lb (2-2 1/2 in.) (2-2 1/2 in.)
 NOTE: On the M-Series, measurement is from the bottom of the
wear strip at the point of the shock
pad on the slide rail.
Adjusting Track
Tension
1. Loosen the rear idler wheel adjusting bolt jam nuts.
739-636B
0743-188
0743-191
MAINTENANCE
 NOTE: To ensure proper track
tension adjustment, perform all
adjustments on both sides of the
snowmobile.
2. If the deflection (distance between
the bottom of the wear strip and
the inside of the track) exceeds
specifications, tighten the adjusting bolts to take up excessive slack
in the track.
59
3. If the distance between the bottom Checking Track
of the wear strip and the inside sur- Alignment
face of the track is less than specified, loosen the adjusting bolts to
! WARNING
increase the slack in the track.
4. Check track alignment (see Track
Alignment sub-section).
5. When proper track tension is
obtained, tighten the adjusting bolt
jam nuts against the axle housings.
 NOTE: Since track tension and
track alignment are interrelated,
always check both even if only one
adjustment seems necessary.
! WARNING
If jam nuts are not tightened properly, the adjusting bolts could
loosen causing the track to
become extremely loose and,
under some operating conditions,
allow the idler wheels to climb over
the track lugs forcing the track
against the tunnel causing the
track to “lock.” If a track “locks”
during operation, severe personal
injury could result.
TRACK ALIGNMENT
Make sure the ignition key is in the
OFF position and the track is not
rotating before checking or adjusting track alignment. Personal
injury could result if contact is
made with a rotating track.
1. Remove excess ice and snow
buildup from the track, track drive
sprockets, and the inside of the
skid frame.
2. Position the tips of the skis against
a wall; then using a shielded safety
stand, raise the rear of the snowmobile off the floor making sure
the track is free to rotate.
! WARNING
The tips of the skis must be positioned against a wall or similar
object.
! WARNING
DO NOT stand behind the snowmobile or near the rotating track.
NEVER run the track at high speed
when the track is suspended.
Proper track alignment is obtained
when the rear idler wheels are equal 3. Start the engine and accelerate
distance from the inner track drive
slightly. Use only enough throttle
lugs. Excessive wear to the idler
to turn the track several revoluwheels, drive lugs, and track will occur
tions. SHUT ENGINE OFF.
if the track is improperly aligned. Arctic Cat recommends that the track  NOTE: Allow the track to coast to
alignment be checked once a week or a stop. DO NOT apply the brake
whenever the track tension is adjusted. because it could produce an inaccurate alignment condition.
4. 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.
60
MAINTENANCE
3. After proper track alignment is
obtained, tighten the adjusting bolt
jam nut against the axle housing.
! WARNING
0727-729
If a jam nut is not tightened properly, the adjusting bolt could
loosen causing the track to
become dangerously loose.
4. Field test the track under actual
conditions.
5. After the field test, check the
alignment of the track. If additional adjustment is necessary,
repeat Adjusting Track Alignment
procedure.
0739-637
SUSPENSION
5. If the idler wheels are not centered The suspension should be adjusted for
between the inner track drive lugs, the operational needs and riding preference of the operator.
an adjustment is necessary.
The front shock springs determine the
amount of ski pressure and the reaction
of the front suspension to rough terrain.
1. On the side of the track which has The amount of ski pressure can also be
the inner track drive lugs closer to changed by adjusting the length of the
the rear idler wheel, loosen the skid frame front arm limiter straps.
adjusting bolt jam nut; then rotate
the adjusting bolt clockwise 1 to 1 The rear springs influence the load carrying capability of the snowmobile and
1/2 turns.
should be adjusted for the weight and
riding preference of the operator.
Adjusting Track
Alignment
Adjusting Front Shock
Springs (STD)
 NOTE: On some models, the front
shock springs are not adjustable.
739-636B
2. Check track alignment and continue adjustment until proper
alignment is obtained.
 NOTE: Make sure correct track
tension is maintained after adjusting track alignment (see Track Tension sub-section).
MAINTENANCE
61
The front shock springs are individually adjustable for the terrain conditions and driving style of the operator.
The spring adjuster has been set at the
factory so the correct amount of
threads are exposed between the spring
adjuster and the shock housing as an
initial setting. Additional ski pressure
can be obtained by tightening the
spring tension; ski pressure can be
decreased by relaxing spring tension.
Adjusting Shocks
(Fox Air Shocks)
 NOTE: It is recommended to
monitor the air pressure in the air
shocks once every month.
 NOTE: Adjusting air shocks may
be done by the snowmobile owner
if qualified to do so. If the owner
does not feel qualified, take the
snowmobile to an authorized Arctic Cat Snowmobile dealer for this
 NOTE:
Equal
adjustments service. This service is at the disshould be maintained on both cretion and expense of the snowsides of the snowmobile.
mobile owner.
To adjust spring tension, rotate the The air shocks are individually adjustentire spring in whichever direction is able for the terrain conditions and drivdesired. If after adjusting spring ten- ing style of the operator. The shocks
sion you note the snowmobile front end are preset at the factory (see chart) as
wants to pitch, relax the spring tension an initial setting; however, it is possible
on the side that is pitching. If both to “fine tune” the shocks to match the
sides are pitching, relax the spring ten- operator’s weight, riding style, and tersion on both sides.
rain conditions.
 NOTE: The spring adjuster will Checking and adjusting air pressure
normally rotate with the spring.
must be done at riding temperature
(outside). Also, it is advisable to check
air pressure when the outside temperature varies more than 25°.
Initial Setting Chart
Model
734-501B
Crossfire
Sno Pro
Front
Shock
(Ski)
Rear Arm
Shock
4.6 kg/cm2 9.5-10.2 kg/cm2
(65 psi)
(135-145 psi)
F-Series
3.9 kg/cm2
Sno Pro/
(55 psi)
Z1 Sno Pro
M-Series
734-500B
N/A
4.2 kg/cm2 9.5-10.2 kg/cm2
(60 psi)
(135-145 psi)
 NOTE: Care should be taken to
have equal pressure in the front
(ski) shocks before operating the
snowmobile.
To increase or decrease air pressure,
use the following procedure.
62
MAINTENANCE
 NOTE: When adjusting air pressure, all weight must be removed
from the suspension, and the
shock absorbers must be fully
extended.
Skid Frame Front Arm
 NOTE: Adding air pressure will
increase the air spring force;
reducing
air
pressure
will
decrease air spring force.
The skid frame front arm shock spring
and limiter straps are adjustable. However, Arctic Cat recommends that the
shock spring be maintained at the factory preset of 1/8-1/4 in. preload.
Tightening the skid frame front arm
shock spring may cause improper balance and may ruin the handling features of the snowmobile.
! WARNING
Do not exceed 10.5 kg/cm2 (150
psi) in the shock.
 NOTE: On some models, the
front arm limiter straps are not
adjustable.
1. Remove the air valve cap from the The length adjustment of the front arm
limiter straps determines the weight
shock.
distribution between the front of the
2. Thread the valve of Shock skid frame and the skis. Tightening the
Absorber Air Pump (p/n 2603- limiter strap (shortening the strap) will
614) onto the shock air valve pull up on the front of the skid frame
approximately six rotations.
and will increase ski pressure. Loosening the limiter strap (lengthening the
 NOTE: As the pump is being strap) lowers the front of the skid frame
attached to the shock, the hose and decreases ski pressure.
will fill with air. This will result in a
lower gauge pressure 0.14-3.52 kg/ When customizing the amount of ski
cm2 (2-5 psi).
pressure, be sure to adjust both straps
equally and do not over-adjust the lim3. To decrease air pressure in the iter straps to adversely affect steering
shock, press the black bleed valve and operator control of the snowmobile.
button half way down and hold Some experimentation may be required
until desired pressure is attained.
until the proper adjustment for the oper NOTE: Pressing the button fully ator’s individual style is obtained.
down and releasing it will allow  NOTE: If the limiter straps are
only a small amount of air to adjusted, it is highly recomescape (micro-adjust).
mended that at least a minimum of
4. To increase air pressure in the 1/8 in. preload on the shock spring
shock, pump until desired pressure be maintained.
is attained.
5. Remove the pump valve from the
shock air valve.
 NOTE: As the pump valve is
being removed from the shock, the
sound of air loss is from the pump
hose, not from the shock.
! WARNING
Do not adjust the front arm limiter
straps to a point at which steering
and operator control of the snowmobile are adversely affected.
6. Install the air valve cap onto the
shock.
MAINTENANCE
63
Adjusting Rear Spring
Pre-Load
To rotate an adjusting cam, use the
spark plug wrench from the tool kit.
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 appropriate adjustment
on the other cam.
Proper adjustment of rear spring preload is necessary to get the most comfortable ride. The chart is designed to
help in setting up rear spring pre-load;
however, riding style is the single
greatest factor in determining rear Articulating Skid
spring requirements.
Frame (Bearcat XT
Rider Weight (lb)
Cam Position
Up to 180
1
180-240
2
Over 240
3
 NOTE: These cam position settings are suggestions only. Personal riding style will greatly
influence cam position settings.
Spend time to determine setting
preferences.
Models)
The rear articulating portion of the skid
frame has two adjusters which control
the amount of travel in the rear suspension.
These two adjusters have been pre-set
at the factory and should require no
further adjustment.
If adjustment is ever required, rotate
the two adjusters equally to permit
12.5-25 mm (1/2-1 in.) travel of the
Rear spring pre-load adjustment is articulating portion of the suspension.
accomplished by rotating the adjusting
cams. Position 3 provides the stiffest
ride, and position 1 is for the light
driver or slow-speed trail riding. Position 2 is for the average operator under
normal conditions. Always rotate the
cam from the lighter position to the
heavier position.
! CAUTION
Never force the adjustment cams
from the low position to the high
position. Cam damage may occur.
741-450A
64
0743-323
Overload Springs
Some models have overload springs
built into the rear suspension. When
either carrying a heavy load or riding
2-up, the overload springs should be
engaged by rotating the spring tension
blocks to the UP position. The spring
tension blocks lock in an over-center
position when engaged.
 NOTE: Arctic Cat recommends
that the overload springs be
engaged whenever a load on the
snowmobile (operator/passenger/
cargo) exceeds 136 kg (300 lb).
MAINTENANCE
Removing and
Installing Taillight/
There are weight limitations for Brakelight (Bearcat XT
these snowmobiles. If additional Models)
! CAUTION
cargo is being added, maximum
weight on the snowmobile (operator/passenger/cargo) should not
exceed the maximum limitation set
for each snowmobile. See chart for
details. Also, the overload springs
should be engaged.
Maximum Weight Limitations
Bearcat 570
170 kg
375 lb
Bearcat 570 XT
272 kg
600 lb
Bearcat Z1 XT
272 kg
600 lb
T-Series
170 kg
375 lb
To either engage or disengage the
spring tension blocks, use the Spring
Block Tool, a spark plug socket, and a
screwdriver to adjust the spring block
to the desired position. Make sure both
spring blocks are in the same position
(either engaged or disengaged).
These models are equipped with an
LED taillight/brakelight. If the LED
fails, it must be replaced. To remove
and install the LED, use the following
procedure.
1. Remove the four pins securing the
rear seat to the seat/Speedrack
mount; then remove the seat.
0743-329
2. Compress the latch on the right
side of the front seat and lift the
front seat away; then disconnect
the taillight harness connector.
0739-625
LIGHTS
For the correct headlight bulb and/or
taillight/brakelight bulb/LED, see the
appropriate specifications sheet.
0743-444
3. Loosen (but do not remove) the
three right-side seat/Speedrack
mount cap screws.
4. Carefully route the harness connector through the hole in the storage compartment panel; then
remove the harness from beneath
the seat/Speedrack mount.
MAINTENANCE
65
5. Remove the two self-tapping
screws securing the taillight to the
bumper; then route the harness out
of the bumper and remove the taillight.
6. Route the taillight harness through
the bumper; then secure the taillight to the bumper with the two
self-tapping screws.
7. Carefully route the harness
beneath the Speedrack mount and
through the hole in the storage
compartment panel; then connect
the harness connector.
8. Tighten the three right-side mount
cap screws; then lower the front
seat.
0743-320
2. Disconnect the taillight harness
connector.
3. Remove the two self-tapping
screws securing the taillight to the
snowflap.
4. Secure the taillight to the snowflap
with the two self-tapping screws;
then connect the taillight connector.
9. Place the rear seat into position on
5. Secure the snowflap to the tunnel
the mount making sure the four
end cap with rivets.
pin holes are properly aligned with
the mounting location on the Removing and
mount.
Installing Taillight/
10. Install the four pins making sure Brakelight Bulb
(Bearcat 570/F-Series/
they are properly seated.
! WARNING
Make sure the rear seat is securely
locked in place with the four pins
before carrying a passenger or
personal injury may result.
Removing and
Installing Taillight/
Brakelight (Crossfire/
M-Series Models)
Z1/T-Series/TZ1
Models)
1. On the F-Series/Z1 models from
inside the rear storage compartment, remove the self-tapping
screws and washers securing the
taillight/brakelight housing.
These models are equipped with an
LED taillight/brakelight. If the LED
fails, it must be replaced. To remove
and install the LED, use the following
procedure.
1. Drill out the rivets securing the
snowflap to the tunnel end cap.
66
741-680A
2. On the Bearcat 570/T-Series/TZ1
models, remove the torx-head cap
screws securing the taillight access
panel.
MAINTENANCE
To access the headlight bulbs, use the
following procedure:
1. With the hood closed, loosen the
headlight adjustment knobs.
2. Carefully push the headlight lenses
rearward far enough to remove the
torx-head screws securing the air
silencer plenum to the hood.
742-467A
3. Disconnect the harness connector
and remove housing.
4. Push in on the socket and rotate it
counterclockwise to remove it
from the housing.
5. Remove the old bulb by pulling it
straight out of the socket.
3. Open the hood; then remove the
O-rings securing the air silencer
plenum to the hood and remove
the air silencer plenum to access
the bulbs.
4. Remove the bulb from the headlight housing and disconnect the
wiring harness from the bulb.
6. Install the new bulb in the socket
by pushing it straight in.
7. Push the socket into the housing
and rotate it clockwise to lock into
place.
8. Connect the harness connector.
9. On the F-Series/Z1 models, place
the housing into position; then
0740-462
from inside the rear storage compartment, secure with the self-tap- Installing Headlight
ping screws and washers.
Bulb (Crossfire/M10. On the Bearcat 570/T-Series/TZ1
models, secure the access panel
with the torx-head cap screws.
Removing Headlight
Bulb (Crossfire/MSeries Models)
 NOTE: The bulb portion of 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.
MAINTENANCE
Series Models)
! CAUTION
Do not touch the glass portion of
the bulb. If the glass portion is
touched, it must be cleaned with a
dry cloth before installing.
1. Plug the wiring harness into the
headlight bulb.
2. Insert the bulb into the headlight
housing.
3. Press the air silencer plenum into
place on the hood and secure with
the O-rings; then close the hood.
67
4. Carefully push the headlight lenses
rearward far enough to install the
torx-head screws. Tighten the
screws securely.
2. Remove the cap screw and lock
nut securing the front of the headlight assembly to the air-intake
silencer.
5. Tighten the headlight adjustment
knobs.
3. Lift the front of the console
enough to allow the headlight
housing to be removed; then
remove the housing.
6. 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.
4. Remove the bulb from the headlight housing and disconnect the
wiring harness from the bulb.
Removing Headlight
Bulb (Bearcat/F-Series/
Z1/T-Series/TZ1
Models)
 NOTE: The bulb portion of 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.
To access the headlight bulbs, use the
following procedure:
1. Remove the two torx-head screws
located to the outside of the headlight adjustment knobs; then
remove the single torx-head screw
from beneath the console (located
between the headlights).
741-329A
Installing Headlight
Bulb (Bearcat/F-Series/
Z1/T-Series/TZ1
Models)
! CAUTION
Do not touch the glass portion of
the bulb. If the glass portion is
touched, it must be cleaned with a
dry cloth before installing.
1. Plug the wiring harness into the
headlight bulb.
2. Insert the bulb into the headlight
housing.
3. Lift the front of the console
enough to allow the headlight
housing to be installed; then install
the housing making sure the forks
of the housing go into the grommets on top of the air-intake
silencer. Secure with the cap screw
and lock nut.
743-439A
68
MAINTENANCE
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.
743-439A
4. Position the console onto the airintake silencer; then secure with the
single torx-head screw beneath the
console (located between the headlights).
5. Install the two torx-head screws
located to the outside of the headlight adjustment knobs; then
tighten securely.
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.
6. 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.
Adjusting Headlight
Aim
The headlight can be adjusted for vertical aim of the HIGH/LOW beam. The
geometric center of HIGH beam zone
is to be used for vertical aiming.
0741-448
7. Adjust the headlight using the
adjustment knobs until correct aim
is obtained. Shut the engine off;
then disengage the brake lever
lock.
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.
2. Measure the distance from the
floor to midpoint of the headlight.
MAINTENANCE
69
SKI WEAR BARS
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.
! WARNING
Operating the snowmobile with
excessively worn ski wear bars
may result in a loss of steering
control.
0743-185
4. Remove the wear bar from the ski.
Installing Ski Wear
Bars
1. Move the wear bar into position on
the bottom of the ski.
 NOTE: If installing a double-offset wear bar, the carbide edge
must be directed to the outside of
the ski.
2. Align the wear bar studs with the
holes in the ski; then install the
lock nuts. Tighten to 11-15 ft-lb.
ADJUSTING SKI
STANCE (M-Series/
Crossfire/Bearcat 570/
570 XT/Bearcat Z1 XT
 NOTE: Determine which type of Models)
Removing Ski Wear
Bars
wear bar is being replaced and
 NOTE: Ski stance can be
remove and install accordingly.
increased/decreased by 6.3 cm
1. Remove ice and snow buildup (2.5 in.) on Bearcat models or by
2.5 cm (1.0 in.) on M-Series/Crossfrom the ski.
fire models.
2. Using a suitable safety stand or
lift, elevate the front of the snowmobile.
3. Remove the lock nuts securing the
wear bar to the ski.
1. Place the front of the snowmobile
on a support stand.
2. Remove the cotter pin; then
remove the slotted nut and cap
screw securing the ski assembly to
the spindle. Remove the ski.
Account for the rubber damper,
inserts, and washers.
3. To increase ski stance, place both
ski stance spacers to the outside of
the spindle.
70
MAINTENANCE
4. To decrease ski stance, place both If wear strip measurements are less
ski stance spacers to the inside of than specified, replacement of both
wear strips is necessary to prevent prethe spindle.
mature track clip wear and possible
5. Apply a low-temperature grease to track damage. Take the snowmobile to
the non-threaded portion of the cap an authorized Arctic Cat Snowmobile
screw; then slide the cap screw dealer for this service. This service is at
through the ski accounting for the the discretion and expense of the snowrubber damper, inserts, and wash- mobile owner.
ers.
Each time a new set of wear strips are
 NOTE: Install the cap screw so installed, they should be tempered.
the slotted nut will be located to Temper the wear strips by driving the
the inside of the ski.
snowmobile for approximately a mile
6. Apply red Loctite #271 to the on a hard pack trail; then immediately
threads of the cap screw; then drive into deep snow and allow the
wear strips to cool. Repeat the procetighten the nut to 45 ft-lb.
dure (warming up the wear strips; then
7. Place the cotter pin into the ski cap cooling them down) two or three times.
screw and spread the pin.
 NOTE: The rail wear strips will
8. Repeat procedure for the other ski. wear rapidly if the snowmobile is
operated on terrain on which the
RAIL WEAR STRIPS
snow cover is minimal. Loose
Arctic Cat recommends that the wear snow is required to cool and lubricate the wear strips and prevent
strips be checked weekly and replaced accelerated wear.
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.
0743-189
MAINTENANCE
71
PERFORMANCE TIPS
Operating a high performance snowmobile requires a special attention that
is not required by a low performance
snowmobile. 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.
Finally, 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.
DRIVE CLUTCH AND DRIVEN
PULLEY — Keeping the drive clutch
and driven pulley 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
DRIVE BELT — This link between the clean using compressed air.
engine and drive train is often the most
neglected component. The drive belt CARBURETOR MAIN JETS (Carmust have the proper fit in the drive bureted Models) — Proper carburetion
clutch and driven pulley. Proper fit is is absolutely necessary to obtain peak
when the top surface of the drive belt is performance. Since ambient temperaflush with the top or up to 1/16 in. ture and operating altitude both affect
higher than the driven pulley sheaves the main jet size needed for optimum
(with the sheaves fully closed). If the engine performance, the main jets
belt sits below this level, the snowmo- MUST be changed whenever the tembile will bog at slow speeds and will perature changes 20° F or whenever
have a slower maximum speed. To cor- operating altitude varies by more than
rect this condition, first determine if the 1000 feet. The Main Jet Chart beneath
drive belt is within specifications (see the hood of the snowmobile identifies
Drive Belt sub-section) and replace if the proper main jets to use under all
worn or too long. Secondly, it may be operating temperatures and altitudes.
necessary to remove a shim washer from Follow the Main Jet Chart carefully to
between the driven pulley sheaves to obtain peak engine performance and
allow the driven pulley to close tighter. avoid engine damage.
Adding shim washers will decrease belt
GASOLINE (EFI Models) — On the
deflection and removing shim washers
2-stroke EFI engine models for optiwill increase belt deflection. Available
mum performance, do not exceed the
shim washers from Arctic Cat are p/n
recommended 87 octane gasoline.
0648-714 (0.090 in.) - one included in
Using a higher octane gasoline will not
the tool kit, p/n 0648-715 (0.030 in.),
increase overall performance; however,
and p/n 0648-716 (0.060 in.).
the Z1 Turbo models will detect lower
 NOTE: Removing/adding shim octane gasoline and reduced engine
washers may be done by the snow- performance will result. It is recommobile owner if qualified to do so. mended that 91 octane (minimum) gasIf the owner does not feel qualified, oline be used in these models.
take the snowmobile to an authorized Arctic Cat Snowmobile dealer
for this service. This service is at
the discretion and expense of the
snowmobile owner.
72
PERFORMANCE TIPS
PREPARATION FOR STORAGE
Prior to storing the snowmobile, it
must be properly serviced to prevent
corrosion and component deterioration.
An authorized Arctic Cat Snowmobile
dealer should perform this service;
however, the owner/ operator can perform this service if desired. This service is at the discretion and expense of
the snowmobile owner. To prepare the
snowmobile for storage, Arctic Cat
recommends the following procedure:
1. Clean the seat cushion with a
damp cloth and a 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.
 NOTE: On 4-stroke models,
change the engine oil and clean
the air filter; then proceed to step
6.
3. Place the rear of the snowmobile
up on a shielded safety stand.
4. On the 500/600/800/1000 cc
engine models, start the engine
and allow to idle. With the engine
idling, pry the intake boot forward;
then spray an Engine Storage Preserver into the intakes until the
engine exhaust starts to smoke
heavily or until the engine starts to
drop in RPM. Turn engine off.
Install the intake boot.
5. On the 570 cc engine models,
carefully pry the intake boots partially over the carburetor inlets;
then start the engine and allow to
idle. With the engine idling, spray
an Engine Storage Preserver into
the intakes until the engine exhaust
starts to smoke heavily or until the
engine starts to drop in RPM. Turn
engine off. Install the intake boots.
! CAUTION
Do not run the engine without the
belt guard in place and secured.
6. Plug the exhaust system outlet
with a clean cloth.
! CAUTION
Do not do step 7 on the 4-stroke
models; severe engine damage
could result.
7. With the ignition switch in the
OFF position:
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/ECU
unit may result.
B. Pour 29.5 ml (1 fl oz) of SAE
#30 petroleum-based 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.
PREPARATION FOR STORAGE
73
8. On carbureted models, drain the 17. On electric start models, disconnect the battery cables making sure
gas from each carburetor float
to disconnect the negative cable
chamber.
first; then clean the battery posts
9. Fill the gas tank to its rated capacand cables. Charge the battery.
ity; then add Arctic Cat Fuel Stabilizer (p/n 0436-907) to the gas
! CAUTION
tank following directions on the
container for the stabilizer/gaso- Sealed batteries require charging if
line ratio. Tighten the gas tank cap left for extended non-start perisecurely.
ods. Arctic Cat recommends trickle
10. Flush the gear case and replace the
lubricant (see Lubrication section).
charging once a month. Follow the
manufacturer’s instructions and
cautions.
11. Remove the drive belt from the 18. If possible, store the snowmobile
drive clutch/driven pulley. Lay the
indoors. Raise the track off the
belt on a flat surface or slide it into
floor by blocking up the back end
a cardboard sleeve to prevent
making sure the snowmobile is
warping or distortion during storsecure. Loosen the track adjusting
age.
bolts to reduce track tension.
Cover the snowmobile with a
12. Clean and inspect the drive clutch
machine cover or a heavy tarpaulin
and driven pulley.
to protect it from dirt and dust.
13. Apply light oil to the upper steering post bushing, ski spindles and 19. If the snowmobile must be stored
outdoors, position the snowmobolts, front and rear pivot bushings
bile out of direct sunlight; then
of the skid frame, and plungers of
block the entire snowmobile off
the shock absorbers.
the ground making sure the snow14. Lubricate the rear suspension,
mobile is secure. Loosen the track
spindles,
speedometer
drive
adjusting bolts to reduce track tenadapter, and driven shaft support
sion. Cover with a machine cover
bearing with a low-temperature
or a heavy tarpaulin to protect it
grease.
from dirt, dust, and rain.
15. Tighten all nuts, bolts, and cap
screws making sure all nuts, bolts,
and cap screws are tightened
securely. Make sure all rivets holding the components together are
tight. Replace all loose rivets.
! CAUTION
Avoid storing in direct sunlight and
using a plastic cover as moisture
may collect on the snowmobile
causing corrosion.
16. Clean and polish the hood, console, and chassis with Arctic Cat
Hood and Windshield Cleaner/
Polish (p/n 4639-559). DO NOT
USE SOLVENTS OR SPRAY
CLEANERS. THE PROPELLANT WILL DAMAGE THE
FINISH.
74
PREPARATION FOR STORAGE
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
On carbureted models if the gas in
each carburetor float chamber 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.
 NOTE: After prolonged storage
of 2-stroke models, Arctic Cat recommends one tankful of 100:1 gas/
oil mixture be used in conjunction
with the oil-injection system to
ensure proper lubrication.
7. On 2-stroke models, inspect the
spark plugs. Replace, gap, or clean
as necessary.
8. Verify the condition of and the
adjustment of the carburetors and
choke cable on carbureted models
and throttle cable on all models.
! 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 valve not
to return to the full-closed position.
9. Tighten all nuts, bolts, and cap
screws making sure all nuts, bolts,
and cap screws are tightened
securely.
4. Inspect the drive belt for cracks
and tears. Check belt specifica- 10. Lubricate the rear suspension,
spindles,
speedometer
drive
tions. Replace if damaged or worn.
adapter, and driven shaft support
Install the drive belt.
bearing with a low-temperature
 NOTE: If the old belt is worn but
grease.
in reasonable condition, retain it
with the snowmobile as a spare in 11. On liquid cooled models, check
the coolant level and all coolant
case of emergency.
hoses and connections for deterio5. On carbureted models, inspect the
ration or cracks. Add properly
in-line fuel filter and replace if
mixed coolant as necessary.
necessary.
12. On air cooled models, clean the
6. Inspect all fuel hoses and oil hoses
engine cooling fins and vents.
for deterioration or cracks; replace
if necessary. Make sure all connections are tight; then on 2-stroke
models, fill the oil-injection reservoir with the recommended 2cycle oil (see Gasoline-Oil subsection).
PREPARATION AFTER STORAGE
75
13. On electric start models, charge 14. Inspect the entire brake system, all
controls,
headlight,
taillight,
the battery until fully charged (see
brakelight, ski wear bars, and
Battery sub-section in the Mainteheadlight aim; adjust or replace as
nance section); then connect the
necessary.
battery cables making sure to connect the positive cable first. Test
15. Adjust the track to the proper tenthe electric start system.
sion and alignment. Lock the jam
nuts.
76
PREPARATION AFTER STORAGE
NOTES
77
U.S. EPA EMISSION CONTROL STATEMENT/
WARRANTY COVERAGE
(U.S. Only)
STATEMENT/WARRANTY
Arctic Cat warrants to the original retail purchaser, and each subsequent purchaser, that all U.S. EPAcertified Arctic Cat snowmobiles are designed, built, and equipped to conform to all U.S. EPA Emission
Control Regulations. Please read the following information completely.
Your authorized Arctic Cat snowmobile dealer will repair or replace any defective emission-related
component at no cost to you during the warranty period. You may have non-warranty service performed
by any repair establishment that uses equivalent components. The regulations provide significant civil
penalties for tampering that causes your snowmobile to no longer meet U.S. EPA emission standards.
Arctic Cat further warrants that the engine and its emission-related components are free from defects in
materials or workmanship that could cause the engine to fail to comply with applicable regulations
during the warranty period.
If you have any questions about this information, or the emission warranty coverage statement, contact
your local authorized Arctic Cat snowmobile dealer.
WARRANTY PERIOD
The emission warranty period for this snowmobile begins on the same date as the standard warranty
coverage and continues for 30 months or 2500 miles, whichever comes first.
COMPONENTS COVERED
The emissions warranty covers major emissions control components and emission-related components
listed as follows:
Engine Management and Sensors
Barometric Pressure Sensor
Camshaft Position Sensor
Engine Control Unit (ECU)
Engine Coolant Temperature Sensor
Intake Air Temperature Sensor
Manifold Absolute Pressure Sensor
Oxygen Sensor
Throttle Position Sensor
Ignition System
Ignition Coil
Knock Sensor System
Spark Plugs
Capacitive Discharge Ignition (CDI) Module
Magneto Pick-Up
Fuel/Air System
Fuel Injectors
Fuel Pressure Regulator
Fuel Pump
Carburetor(s)
Turbocharger Assembly
Air Bypass Valve
Turbo Waste Gate Control Valve
Crankcase Ventilation System
ISC Valve
Miscellaneous Items Used
in Aforementioned Systems
Connectors
Switches
Grommets
Clamps
Hoses
Ties
Gaskets
Wiring
OWNER'S RESPONSIBILITIES
The owner of any snowmobile warranted under this Arctic Cat Emission Control Statement is
responsible for the proper maintenance and use of the snowmobile as stated in the Operator's Manual.
Proper maintenance generally includes replacement and service, at the owner's choosing, such items
as air filter, oil and oil filter, or any other part, item, or device related to emissions control as specified in
the Operator's Manual. It is the owner's responsibility to ensure that the snowmobile is used in a manner
for which it was designed.
78
CHANGE OF ADDRESS, OWNERSHIP,
OR WARRANTY TRANSFER
Arctic Cat Inc. keeps on file the current name and address of the
owner of this snowmobile. This will allow Arctic Cat to reach the
current owner with any important safety information which may
be necessary to protect customers from personal injury or
property damage. Please make sure a copy of this form is
completed and returned to Arctic Cat Inc. if you move or if the
snowmobile is sold to another party.
This form may also be used to transfer the unused portion of the
original warranty to a second party. In order to transfer warranty,
fill out this form completely; then return a copy of this form to
Arctic Cat Inc. Arctic Cat will then process the application and
issue warranty for the balance of the time remaining of the
original warranty.
❏
❏
❏
Address Change
Ownership Change
Warranty Transfer
CHANGE OF ADDRESS/OWNERSHIP/
WARRANTY TRANSFER TO:
Name ________________________________________
Address ______________________________________
City/State (Province)/Zip Code (Postal Code) __________
Phone # ( )____________________________________
Year and Model Snowmobile ______________________
Vehicle Identification Number (VIN) _________________
79
Fold Back Once
Place
Stamp
Here
CHANGE OF ADDRESS/OWNERSHIP
ARCTIC CAT INC.
PRODUCT SERVICE AND
WARRANTY DEPT.
P.O. BOX 810
THIEF RIVER FALLS, MN 56701
NOTES
81
NOTES
82
WARRANTY PROCEDURE/OWNER
RESPONSIBILITY
At the time of sale, an Owner Registration form is to be completed by the selling dealer and consumer. The receipt of the registration form by Arctic Cat is a
condition precedent to warranty coverage. It is the selling dealer’s responsibility to retain and/or submit the appropriate copies of the form to the appropriate
place(s) to initiate warranty coverage.
The dealer will furnish to the consumer a signed copy of the form which must
be presented to the dealer when requesting warranty service. The registration
form is the consumer’s proof of ownership and warranty eligibility. The
form is used by the dealer to validate the warranty claim. Retain your copy
of the form and keep it in a safe place.
When warranty repair is suspected, the snowmobile should be taken to the selling dealer, who has the primary responsibility to perform warranty repairs. In
the event the selling dealer has ceased to do business, you have moved, or you
are in a location away from your selling dealer, warranty may be performed by
any authorized Arctic Cat Snowmobile dealer.
The authorized Arctic Cat Snowmobile dealer will examine the snowmobile or
part to determine if, in his opinion, a warrantable condition exists. If a warrantable condition appears to exist, the dealer will repair or replace, at Arctic Cat’s
option, free of charge, including any related labor costs, all parts that are found
to be warrantable and any other parts which the warrantable part caused to be
damaged. You, the consumer, will then be asked to sign a warranty form to
ensure Arctic Cat that the warranty work was actually performed.
It is the consumer’s responsibility to maintain and service the snowmobile in
accordance with Arctic Cat’s recommendations in the Operator’s Manual. To
protect yourself and your snowmobile, follow all safety and service tips. Arctic
Cat will NOT warrant repairs required as a result of not performing standard operator maintenance, storage procedures, and service as outlined in
the Operator’s Manual.
Should you have any questions concerning the warranty, contact an authorized
Arctic Cat Snowmobile dealer.
Arctic Cat Inc., P.O. Box 810, Thief River Falls, MN 56701 (218) 681-8558
ARCTIC CAT
®
Printed in U.S.A. ®TM Trademarks of Arctic Cat Inc. Thief River Falls, MN 56701 p/n 2258-236
Phone: (218) 681-9851 - U.S./(204) 982-1772 - Canada
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