Arctic Cat 2005 Snowmobile Service Manual All Models

- -_-.!
TABLE OF CONTENTS
2005 Sno\Nmobile Service Manual
Click on the Green Text to Go! Section Forevvord 1. 2. 3. 4. 5. 6. 7. 8. 9. General Information (Vol. I) Engine (Vol. I) Engine-Related Items (Vol. I) Fuel Systems (Vol. I) Engine Electrical Systems (Vol. I) Chassis Electrical Systems (Vol. Steering and Body (Vol. II) Drive Train and Brake Sy,stilli Track/Rear Suspension (Vol.
FOREWORD
This Arctic O lt Service !'vlanuai Volume One contains service and maintenance informatio n for the Model Year 2005 Arctic 0 1.1 Snow mobiles. The complete two-volume set is designed to aid service pe rsonnel in service-orie nted applications. Thi s volume is divided into sections. The sectio ns cover specific snowmo bile compo nent's o r systems and , in additio n to the standard service procedures, includes assembling. di sassembling. and inspecl'ing instructio ns. When using lhis manual as a guide , the techni cian should usc discretio n as to how much disassembl y is needed to correct any given conditi oll. The service technician should beco me familiar with the ope ratio n and constructio n of the co mpo nents o r systems by carefull y studying the complete two-volume sct. This will assist the service technician in becoming more a ware of and effi cient with sen licing procedures. S uch effi ciency not onl y helps build consume r confide nce but also saves time and labor. All Arctic Cat publicatio ns and snowmo bil e decals di splay the words Warning , Cautio n, and Note to emphasize impo rtant informatio n. T he symbol Lbo WARNING identifies pe rsonal &'l fety -related info nnation. Be sure to fo ll ow the di rective because it deals with the possibility of severe personal injury o r even death. The symbol Lbo CAUTION identifies unsafe practices which may result in snowmobile-related damage. Follow the directi ve because it deals with the possibility of damaging pmt o r parts o f the snowmobile. T he symbol_ NOTE: idelltifies suppl ementary info nnation wOithy of particular attention. At the time o f publication, all info rmation, photographs, and illustrations were technically correct. Some photographs and illustrations used JO this volume are used for clarity purposes onl y and are not designed to de pict actual conditions. Because Arctic Cat Inc. constantl y refines and improves its products, no retroacti ve obli gation is incurred. All mate ri als and specifi cations are subject to change witho ut noti ce_ Keep this manual accessibl e in the sho p area fo r reference. Product Service and Warranty De pa/tment Arctic C'lt Inc.
tel ?nn4 4 r,.ti,.,
r:~t
In,.,
October 2004
SECTION 1 - GENERAL INFORMATION
TABLE OF CONTENTS
Snowmobile Identification ... ..... ......... ..... .... Recommended Gasoline and Oil.. .. ... .. ... ..
Break-In Procedure ...... ............................
... 1-2 .. 1-2

..1-2
Genuine Parts ...................... " ........................... " ... 1-3 High Altitude Operation .......................................... 1-3 Preparation For Storage ......................................... 1-3 Preparation After Storage .................... ... .. ... . 1-4 After Break-In Checkup (100 Miles) ....................... 1-5 After Break-In Checkup Checkli st .............. ......... .. . 1-6 Torque Conversions ............................................... 1-7 Tightening Torque (General Bolts) ........................ 17 Fraction/Decimal Conversion Chart ....................... 18 Drill Bit Sizes (Number) Chart ............ ..... .. .. 18 ... 19 MM/ln. Conversion Chart ...... ............. Servicing Symbols ........ .. ........... ................ .. ......... 1-10
Page: 3
2005 Arctic Cat Service Manual - all models - www.ReadManuals.com
1-1
Snovvmobile Identification
T he A rclic Cat Snow mobile has two impOl1'ant identificati o n numbe rs. The Vehicl e Ide ntification Number (V I N) is stamped into the tuone l near the ri ght-side footrest. The Engine Serial Number (ESN) is stamped
ioto the crankcase of the enginc.
RECOMMENDED GASOLINE (EFI Models)

The recom me nded gasoline to use in th ese snowmobiles is 87 minimum octane regular unleaded. In many areas, oxygenates (either ethanol or MTBE) arc added to the gasoline. Oxygenated gasol ines contain ing up to 10 % ethano l or up to 15 % MfBE are acceptable gasolines. Do not usc gasolines contai ning methanol.
_NOTE : When using the recommended gasoline, the Fuel Designation Connector (the gray wire at the ECU) must be connected. _NOTE: When using oxygenated gasolines, the Fuel Designation Connector (the gray wire at the ECU) must be disconnected.
VIN
&.
CAUTION
00 not use white gas or gasoline containing methanol. Only Arctic Cat approved gasoline additives should be used.
&.
0726-383
CAUTION
These numbers are required to com pl et e warrant y claims properly. No warranty wili be allowed by Arctic Cat Inc , jf the engine seri al number or VIN is removed or mutilated in any way.
If oxygenated gasoline is to be used, it is extremely important that the Fuel Designation Connector at the ECU is disconnected. If not, severe engine damage may occur. NOTE: In order for the ECU to change modes, the engine must be OFF when connecting or disconnecting the Fuel Designation Connector.
Recommended Gasoline and Oil

RECOMMENDED GASOLINE
(Carbureted Models)
RECOMMENDED OIL
The recommended o il to use in the oil- injection system is Arctic Cat 50: I Injectio n O il (fo r standard models) o r A rctic C at Sy nthetic AP V 2-Cycle O il (for A PV mode ls). The o il is s pec iall y formulat ed to be used either as an injection o il or as a pre-mi x o il (for carbureted model break-in) and meets all of the lubri cati on req uire me nts of the Arctic Cat snowmobile e ngine.
The recom mended gasoline to use in these snowmobiles is 87 minimum octane regular unleaded_ In many areas, oxygenates (either ethanol or MTBE) are added to the gasoline. Oxygenated gasolincs containing lip to 10 % ethanol or lip to 15% MTB E are acceptable gasolines; however, whenever using oxygenated gasolines, the carburctor main jet must be one size larger than the main j et required for reg ular unleaded gasoline. For example, if a 400 main jet is recommended for regular unl eaded gasoline, a 4 10 main jet mus t be ins l" all ed if using an oxygena ted gasol ine. W he n using etha no l blended gasoli ne, it is not necessary to add a gasoline antifreeze since et hano l will prevent the accumulatio n o f moisture in the fuel system.
Break-In Procedure
T he A rctic C at 2-stroke e ngine (w he n new o r rebuilt) requires a s hort break-in period before the e ng ine is s ubjected to heavy load conditions. Arctic e,l requires that the first tankful o f fuel be premixed at a 100: I ratio in all o il -injectio n mooels.
&.
CAUTION
00 not use white gas or gasolines containing methanol. Only Arctic Cat approved gasoline additives should be used.
1-2
Page: 4
During the break-in pe riod, a maximum of 1/2 throltle is recommended; however, brief full -throttle accelerati ons and va riati ons in dri ving speeds contribute to gexxl e ngine break-in.
I. Clean the scat cushion with a damp cloth and Arctic C'll Vinyl Protectant (pIn 0638-3 13). 2. Clean the snow mobile thoroughly by hosing dilt , oil , grass, and other foreign matter from the skid 'ln. All ow the frame, tunne l, hexxl, and bell y Ix snowmobile 1 0 dry thoroughl y. DO NOT get water into any p<llt of the engine. 3. Place the rear of the snowmobile up on a shielded safety stand.
NOTE: On M-Series and " Laydown" engine models, the air silencer boot can be pried forward to access the intake bores. Pry the boot forward; then proceed to step 7. NOTE: On some standard models, the air-intake silencer is a one-piece unit, and the silencer boot(s) can be removed to access the intake bore(s). Remove the boots; then proceed to step 7. _ NOTE: On some standard models, the air-intake silencer includes a cover/tool tray assembly and a baffle/resonator, and the silencer boot cannot be removed to access the intake bores. Proceed to step 4.
Lh
CAUTION
00 NOT exceed the one (1) tankful limitation of a 100:1 gaS/oil break-in mixture. Continuous use of a gaS/oil mixture, unless consistently operating in extremely cold conditions (-26C/-15F or colder), could cause spark plug fouling and excessive carbon buildup, A 100:1 gaS/oil mixture must be used in conjunction with the oilinjection system to ensure adequate engine lubrication in extremely cold conditions.
Genuine Parts
When replacement of IXlrts is necessary, usc only genuine Arctic O lt pmts. They are precision-made to ensure high quality and correct fit.
High Altitude Operation

O pe rating a snowmobile at varying altitudes requires changes in pe rformance components. These changes a/Tect dri ve train components (on all model s) and ca rburetion components (on carbureted models). Hi gh altitude information decal(s) are located beneath the hexxl of the snowmobile.
4. O pe n the air-intake silencer cover; then remove the three screws securing the cover/tool tray assembly to the silencer. 5. Close the cover; then tip the cover/tool tray assembly fo rward and out of its slots and remove the assembl y. 6. Using a large tlat-blade screwdriver, re move the baftlelresonator tabs from the air-intake silencer slots and remove the baflle/resonator to access the intake bores.
NOTE: The baffle/resonator can be removed more easily by removing the back tabs first.
Lh
CAUTION
On carbureted models, carefully follow the Main Jet Chart recommendations for proper main jet selection for altitude, temperature, and gasoline being used.
King ellt and M.-Series snowmobiles are initially set up at the fact ory for o peration betwee n 6000-9000 feet. Consult the appropriate specifications for this information.
7. Start the e ngine and allow to idle. With the engine idling. spray Arctic Cat Engine Storage Preserver (pin 0636-1 77) into the intake(s) until the engine ex haust starts to smoke heavil y or until the engine stUlts to drop in RPivl. Turn engine off.
NOTE: On M-Series and " Laydown" engine models, secure the air silencer boots onto the intake bores. _NOTE : On some standard models, install the airintake silencer boot(s) ; on some standard models, install the baffle/resonator and the coverltool tray assembly.
8. PI ug the exhaust system outlet with a clean cloth.
Preparation For Storage

Prior to storing the snow mobile, it must be pro perl y serviced to prevent corrosion and component deterioratio n. An a uthori zed Arctic C at Snow mobil e dea le r should pe rform thi s service: however, the ow ner/o pe rator can pe rform thi s service if des ired. To pre pare the snow mobile for stora ge, Arctic Cat recomme nds the following procedure:
Page: 5
9. With the ignition sw itch in the OFF position: A. Disconnect the high tension lead(s) from the spark plug(s); then remove the plug(s), connect
2005 Arctic Cat Service Manuat - all models - www.ReadManuals.com
1-3
it/them to the lead(s), and ground it/them on the cylinder head(s).
19. Clean and polish the hood, console, and cik"lssis
Lh CAUTION
Never crank the engine over without grounding the spark plug(s). Damage to coils and/or COl unit may result.
with Arctic Cat Hood and Windshield Cleaner/ Poli sh (pIn 0636-174). DO NOT USE SOLVENTS OR SPRAY CLEA NERS. THE PRO- PELLENT WILL DA ivlAGE THE FI NISH. 20. On electric start models, disconncct the battery cables making sure to di sconnect the negati ve cable first; then clean the tx"lttery posts and cables. 2 1. If possible, store the snowmobile indoors. Raise the track off the fl oor by blocking up the back end making sure the snowmobile is secure. Loosen the track adjusting bolts to reduce track tension. Cover the snowmobile with a machine cover or a heavy tarpaulin to protect it from dirt and dust. 22. If the snowmobile must be stored outdoors, position the snowmobile out of di rect sunli ght ; then block the entire snowmobile off the ground making sure the snowmobil e is secure. Loosen the track adjusting bolts to reduce track tension. Cover with a machine cover or a hcavy tarpaulin to protect it from dirt, dust, and rain.
B. Pour 29.5 ml ( 1 fl oz) of SAE #30 petroleumbased oi l into each spark plug hole and pull the recoil stm1er handle slowly about 10 times. C. Install the spark plug(s) and connect the high tension lead(s). 10. On carbureted models, drain the gas from each ca rburetor Iloat chamber. 11. Fill the gas tank to its rated capaci ty; then add Arctic Cat Fuel Stabilizer (pIn 0638- 165) to the gas tank follow ing directions on the container for the stabilizer/gasol ine ratio. Tighten the gas tank ca p securely. 12. Drain the chain-case lubricant by removi ng the chain-case drain plug located on the backside of the chain-case assembly. Remove the chain-case cover and inspect chai n, sprockets, chain tensioner, and rollers for wcar and the chain for proper tension. Install the drain plug, chain-case cover, and seal ; then pour Arctic C'lt Transmission Lube (pin 0636-817) into the filler hole according to appropriate specifications. 13. Drai n the fluid from the gear case. Install the drain plug ; then pour Arctic C'lt ACr Drive Fluid (pin 4639-027) into the gear case accordi ng to appropriate speci fications. 14. Clean and inspect the dri ve clutch and dri ven pulley. 15. Remove the drive belt from the dri ve clutch/driven pulley. Lay the belt on a flat surface or slide it into a cardboard sleeve to prevent warpi ng or distol1ion during storage; then clean and inspect the dri ve cl utch and driven pull ey. 16. Appl y light oi l to the upper steering post bushing, ski spindles and bolts, front and rear pi vot bushings of the skid fra me, and plungers of the shock absorbers. 17. Lubricate all grease fittin gs (front and rear suslx:nsion, spindles, speedometer drive adapter, and the driven sha ft support bearing) with a lowtem lx:rature grease. 18. Tighten all nuts, bolt'), and ca p screws making sure all calibrated nuts, bolts, and cap screws are ti ghtened to slx:eifications. Ma ke sure all ri vets holding the components together are tight. Replace all loose ri vets.
Lh CAUTION
Avoid storing in direct sunlight and using a plastic cover as moisture may collect on the snowmobile causing corrosion.
Preparation After Storage

Tak ing the snowmobile out of storage and correc tl y preparing it for another season will assure many miles and hours of trouble-free snowmobi lin g. Arctic Cat recom mends tJle following procedure:
Lh CAUTION
On carbureted models if the gas in each carburetor float chamber was not drained prior to storage, the carburetor(s) must be cleaned before starting the engine.
I. Clean the snowmobi le thoroughl y. Polish the
exterior of the snowmobile. 2. Clean the engine. Remove the cloth from the exhaust system. Check exhaust system and airintake silencer/air filter for obstructions. 3. Inslx:ct all control wires and cables for signs of wear or fra ying. Replace if necessary. Use cable ti cs or tape to route wi res and cables away from hot or rotating parts. 4. Inspect the dri ve belt for cracks and tears. Check belt slx:cifications. Replace if damaged or worn. Install Ule dri ve belt.
1-4
Page: 6
2005 Arctic Cat Service Manual - all models - www. ReadManuals.com
NOTE: If the old belt is worn but in reasonable condition, retain it with the snowmobile as a spare in case of emergency.
After Break-In Checkup

(100 Miles) The 100 mil e checkup offered by some dealerships reduces problems and warrant y costs. A program of thi s kind sho uld be offered by all deal erships. Many deal erships have added the price of the checkup into the selling price of the snowmobile, and others offer it as a bonus to the customers who purchase snowmobiles from their dealership . There are three areas that require adjustme nt after the break-iO period in order to obtain peak performance. These areas are the following. A. G lrburetor jetting
5. On carbureted mooels, inspect the in-line fuel filter and repl ace if necessary.
6. Inspect all fuel hoses and oil hoses for deterioration or cracks; replace if necessary. Make sure all connections arc tight ; then fill the oilinjection reservOir with the recommended injection oil.
NOTE: After prolonged storage, 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. Inspect the enti re brake system, all controls, headlight , taillight , brakclight , ski wear bars, and headli ght aim ; adjust or replace as necessary. 8. Inspect each spark pI ug. Replace, gap, or clean as necessary. 9. Adjust the track to the proper tension and ali gnment. Lock the jam nul'). 10. Adjust the earburetor(s) and choke cabl e on carbureted mooels and throltle cablc on all mooels.
B. Dri ve belt dell ection/Break-ln

C. Track tension and ali gnment
CARBURETOR JETTING (Carbureted Models) -
Altitude, temperature, and the use of oxygenated gasoline affect the carburetion needed for optimum engine pe rfo rmanc e. The carbureto r main j ets mu st be changed in conjunction with changes in operating altitude, oxygenated gasoline usage, and temperature.
DRIVE BELT DEFL.ECTION - Dri ve belt defl ec tion is very important to the snowmobile. Even if it is checked and is correct when the snow mobile is setup , it docs change (more so during the break-in peri od) Thi s is because the rubber engine mounts and the rubber snubber on the torque link will all take a "set" during the fir st 100 mil es, which all ows the di stanc e between the dri ve clutch and dri ven pulley to sh011en. Whe n thi s happens, the snow mobil e will a ppear to have a too long dri ve belt. To add to this, the dri ve belt itself wears and stretches somew hat. T hi s all leads to a low-e nd performance probl em and, if not corrected , causes premature dri ve belt wear.
,6, WARNING
On VM-style carburetors, 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 piston valve not to return to the full-closed position.
11 . Tighten all nuts , bolts, and cap screws making sure all calibrated nuts, bolts, and cap screws are tightened to specifications. 12. Lubricate all grease fitting s (rear suspension, spindles, speedometer dri\'e adapter, and the dri ven shaft SUPIXll1 bearing) with a lowtemperature grC<lsc. 13. On liquid eooled models. check the coolant level and all coolant hoses and connections for deterioration or cracks. Add properly mixed coolant as necessary. 14. On fan cooled models, clean the engine cooling fins and all vents. 15. On electri c start models. charge the battery; then connect the battery cabl es making sure to connect the positi ve cable first. Test the electric start system.
After the break-in period, dri ve belt defl ection should be checked according to the instructions given in this manual. To correct for too much defle ction, washer(s) fr o m bet ween the dri ven pull ey s hea ves ca n be removed to "tighten the dri ve belt " and allow the belt to return to the proper ratio for dri ve clutch engagement.
DRIVE BELT BREAK-IN - It is critical for maximum dri ve belt life to all ow the belt to break in before subj ectin g it to hard use such as wide-ope n-throul e operation or hill climbing.
The fir st 20 miles on the dri ve belt should be at If2 throttl e o r lower. Thi s will all ow the belt to gain its optimum fl ex ibi lity and will extend belt life. Do not exceed 50 ~vIPI-1 during the first 20 miles. If thi s procedure isn't followed, it is IXlssible to destroy a new dri ve belt in less than 50 miles. T his should be ex plained to customers at the time of drive belt sales.
Page: 7
1-5
To increase the li fe of a dri ve belt , it is very impOitant that the belt be warmed up before subjecting it to any type of use. In co ld te mperature (0 or below), the engine should be allowed to idle fo r a pe riod of 8 to 10 minutes. This will allow heat from the engine compmtment to soft en the dri ve belt . Not only will this procedure increase belt life but wi ll also help prevent e ngine damage from cold seizure. Each operator should be in structed to drive the snowmobil e for several minutes at a low throttle setling to wa rm Ule belt up before using wide-ope n-throttle. T his practi ce should be foll owed on all models fo r maximum belt life. In addition to in structing eac h opera to r about these dri ve belt break-in procedures, Arctic Cat also recommends that the operators be informed that a dri ve belt (like brake pads, wear slrips, etc.) is considered a normal wear item a nd is li sted as an exclusion on the Arclic Cat Limited Warra nty. TRACK TENSION AND ALIGNMENT - There is a cel1ain amount of stretch on all tracks during the first 500 miles. The track must be adjusted after the first 50 to 100 mil es to the specifications given in the Setup and Pre -deli very rvlanual and pe ri od icall y the reafte r. If these adj ustments are n't perfor med, the track ma y "derai l" which leads to track and slide rail damage. Along with these three major areas, there arc also other areas that should be c hecked and adjusted during the "A ft er Break -In C heckup. " A checkli st to assist you with lhis service follows. Not onl y willihe custome r be ha ppi e r, but it also gets the c ustome r back into your dealership, which in many cases will mean additional sales in aecessories, belts, oil, etc.
After Break-In Checkup Checklist

Below is a recommended li st of ite ms to c heck after the brea k-in pe riod. By performing thi s in spection , warranty eost can be reduced and customer sati sfac tion can be increased. Th e reco mm e nded mil eage for thi s in s pec ti on is between 100 and 300 miles. Please e ncourage the Cll Stomers to ha\'e thi s important checkup done.
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Jet carburetor(s) according to average temperature, type of gasoline being used, and altitude Adjust drive belt deflection Adjust track tension and alignment Adjust throttle cable tension Check oil-injection pump adjustment Check engine idle Check coolant level Check chain case lubricant level Check lights (highllow beam, brakelight) Check safety switch operation Check driveshaft area for any rubbing components Check steering hardware for tightness Check skid frame and A-arm mounting hardware for tightness Check brake lever travel and adjustment Grease all lubrication points
1-6
Page: 8
Torque Conversions
ft-Ib
kg-m
ft-Ib
kg-m
ft-Ib
kg-m
ft-Ib
kg-m
ft-Ib
kg-m
11 .2
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
0.1 0.3 0.4 0.6 0.7 0.8 1.0 1.1 1.2 1.4 1.5 1.7 1.8 1.9 2. 1 2.2 2.4 2.5 2.6 2.8
21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
2.9 3.0 3.2 3.3 3.5 3.6 3.7 3.9 4.0 4.2 4.3 4.4 4.6 4.7 4.8 5.0 5.1 5.3 5.4 5.5
41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59
60
5.7 5.8 5.8 6.1 6.2 6. 4 6.5 6.6 6.8 6.9 7. 1 7.2 7.3 7.5 7.6 7.7 7.9 8.0 8.2 8.3
61 62 63
64
65 66 67
68
69 70 71 72 73 74 75 76
77
8.4 8.6 8.7 8.9 9.0 9.1 9.3 9.4 9.5 9.7 9.8 10.0 10.1 10.2 10.4 10.5
10.7
78 79 80
10.8 10.9
11 .1
81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100
11.3 11.5 11.6 11.8 11.9 12.0 12.2 12.3 12.5 12.6 12.8
12.9
13.0 13.1 13.3

13 .4
13.6 13.7 13.8
Tightening Torque
(General Bolts)
Thread
Tightening Torque
kg-m ft-Ib
1.5-3.0 3.0-5.0 7.0-11.5 16.0-25.5 2.0-4.5
6.0-8.5 13.0-20.0 29.0-43.5
Type of Bolt
Diameter A (mm)
Conventional Boll
(Conventional or
4 Marked Bolt)
5
6 8 10 5 6 8 10
(7 Marked Bolt)
0.2-0.4 0.4-0.7 1.0-1.6 2.2-3.5 0.3-0.6

0.8-1.2 1.8-2.8 4 .0-6.0
1t!@l111
(]
4 Marked Bolt
7 Marked Bolt
Page: 9
1-7
Fraction/Decimal Conversion Chart

8th,
16ths 32nds
kg-m x 7.235 = ft-Ib ft-Ib x 0 .1383 = kg-m
64ths
64ths (cont)
118= 114 _ 318 112 518 314 _ 718 -
.1 25 .250 .375 .500 .625 .750 .875
1116 = .0625
3116- .1875 5116 - .3125 7116 - .4375 9116 - .5625 11116 _ .6875 13116 _ .8 125 15116 _ .9375
-
1132 = .03125 3132 - .09375 5132 - .15625 7132 - .21875 9132 - .28125 11132 _ .34375 13132 _ .40625 15132 - .46875 17132 - .53125
19/32 - .59375
1164 = .0 15625
.65625 .71875 .78125 .84375 .90625 31132 - .96875
21132 23132 _ 25132 _ 27132 _ 29132 -
3164 - .046875 5164 - .078125 7164 - .109375 9164 - .140625 11 164 _ .171 875 13164 _ .203125 15164 _ .234370 17164 - .265625 19164 - .296875 21164 - .328125 23164 _ .359375 25164 _ .390625 27164 _ .421875
29/64 - .453125
33164 = 35164 37164 39164 41164 -
43164 _ 45164 _ 47164 _ 49164 51164 55164 57164 59164 61164 63164 -
.515625 .546875 .578125 .609375 .640625 .671875 .703125 .734375 .765625 .796875 .859375 .890625 .921875 .953125 .984375
53/64 - .828125
31164 - .484375
Drill Bit Sizes (NulTlber) Chart

No SIze of Drill In Inches No
SIze of Dnll to Inches
No
SIze of Dnll In Inches
No
SIze of Dnll Inches
In
1 2 3 4 5 6 7 8 9 10
11
12 13 14 15 16 17 18 19 20 1-8
.2280 .2210 .2130 .2090 .2055 .2040 .2010 .1990 .1960 .1935 .1910 .1890 .1850
.1820
.1800 .1770 .1730 .1695 .1660 .1610

Page : 10
21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
.1590 .1570 .1540 .1520 .1495 .1470 .1440 .1405 .1360 .1285 .1200
.11 60
.11 30 .111 0
.1100
.1065 .1040 .1015 .0995 .0980
41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60
.0960 .0935 .0890 .0860 .0820 .08 10 .0785 .0760 .0730 .0700 .0670 .0635 .0595 .0550 .0520 .0465 .0430 .0420 .0410 .0400
61 62
63
64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80
.0390 .0380 .0370 .0360 .0350 .0330 .0320 .0310 .0292 .0280 .0260 .0250 .0240 .0225 .0210 .0200 .Q180 .0160 .0145 .0135
MM/IN. Conversion
Chart
mm .01 .02 .03 .04 .05 .06 .07 .08 .09 .10 .11 .12 .13 .14 .15 .16 .17 .18 .19 .20 .21 .22 .23 .24 .25 .26 .27 .28 .29 .30 .31 .32 .33 .34 .35 .36 .37 .38 .39 .40
on
.00039 .00079 .00 11 8 .00157 .00197 .00236 .00276 .00315 .00354 .00394 .00433
.00472
.00512 .00551 .00591 .00630 .00669 .00709 .00748 .00787 .00827 .00866 .00906 .00945 .00984 .01024 .Q1 063 .01102
.01142
.01181 .01 220 .01 260 .01 299 .01339 .01378 .01417 .01457 .01496 .01 535 .01575
mm .41 .42 .43 .44 .45 .46 .47 .48 .49 .50 .51 .52 .53 .54 .55 .56 .57 .58 .59 .60 .61 .62 .63 .64 .65 .66 .67 .68 .69 .70 .71
.72
on
.0 1614 .0 1654 .01693 .01732

.01772
.01811 .Q1850 .Q1890 .0 1929 .01969 .Q2008 .02047 .02087 .02126 .02165 .02205 .02244 .02283 .02323 .02362 .02402 .02441 .02480 .02520 .02559 .02598 .02638 .02677
.02717
.02756
.73 .74 .75 .76 .77 .78 .79 .80
.02795 .02835 .02874 .02913 .02953 .02992 .03032 .03071 .03110 .03150
mm .81 .82 .83 .84 .85 .86 .87 .88 .89 .90 .91 .92 .93 .94 .95 .96 .97 .98 .99 1.0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
on
.03189 .03228 .03268 .03307 .03346 .03386 .03425 .03465 .03504 .03543 .03583 .03622 .03661 .0370 1 .03740 .03780 .03819 .03858 .03898 .03937 .03937 .07874 .11811 .15748 .19685 .23622 .27559 .31496 .35433 .39370 .43307 .47244 .511 8 1 .5511 8 .59055 .62992 .66929 .70866 .74803 .78740
mm 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60
on
.82677 .86614 .90551 .94488 .98425 1.02362 1.06299 1.1 0236

1.14173
1.1 8 110 1.22047

1.25984
1.29921 1.33858 1.37795 1.41 732 1.45669 1.49606 1.53543 1.57480 1.6141 7 1.65354 1.69291 1.73228 1.77165
1.8 11 02
1.85039 1.88976
1.92913
1.96850 2.00787 2.04724 2.08661 2.12598 2.16535 2.20472 2.24409 2.28346 2.32283 2.36220
mm 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100
on
2.40157 2.44094 2.48031 2.51968 2.55905 2.59842 2.63779 2.67716 2.71653 2.75590 2.79527 2 .83464 2.87401 2.91338 2.95275 2.99212 3.03149 3.07086 3.11023 3.14960 3.18897 3.22834 3.26771
3.30708
3.34645 3.38582 3.42519 3.46456 3.50393 3.54330 3.58267 3.62204 3.66141

3.70078
3.74015 3.77952 3.81889 3.85826 3.89763 3.93700
Page: 11
1-9
Servicing Symbols
Listed in the table below are symbols indi cating special instructions and other importa nt info rmatio n necessary fo r proper servicing. Please note the definition for each sy mbol. These symbols are used lhroughoullhi s Iwovolume set
SYMBOL
Torque control required 242 243 270 271 609 apply apply apply apply apply
DESCRIPTION
blue Loctite #242 (pIn 1639-815) blue Loctite #243 (pIn 1639-413) green Loctite #270 (pin 1639-817) red Loctite #271 (pin 1639-820) green Loctite #609 (pin 1639-821)
Lubricate with Arctic Cat 50:1 Injection Oil (pin 0636-286) Lubricate with Arctic Cat Extreme 50:1 Injection Oil (pin 0639-112)
Lubricate with Arctic Cat Low-Temp Grease (pIn 0636-593)
38 - Three Bond Sealant (pIn 0636-070) HT - High-Temp Sealant (pin 0636-069) AS - Anti-Seize Thread Compound (pin 0678-146)
1-10
Page : 12
SECTION 2 - ENGINE
TABLE OF CONTENTS
Arctic Cat Engine Specifications ............................. 22 Torque Conversions ... ..... ............ .. ..... ....... .. ..... ..... .. 2-3 Piston Replacement Guide .. ....... .. ...... ....... .. ........... 2-4 Assembly Schematics (Table of Contents) ... ....... .. .. 2-4 Engine Piston Travel Versus Crank Angle Chart ." 2-22 Cylinder Head Volume Specifications ................... 223 Crankshaft Runou! Specifications ......................... 223 Engine .. ... ..... ............ .. ..... ............ .. ...... ...... .. ..... .. ... 2-24 Removing Engine (Table of Contents) .. . .. .. .. 2-24 Disassembling Engine (Table of Contents) .. ......... 2-34 Servicing Top-Side Components (500/6001700 cc "Laydown" Engine Models) ..... 262 Cleaning and Inspecting Engine ........................... 266 Measuring Critical Components .. .. ..... ......... ........ .. 270 Assembling Engine (Table of Contents) .. .............. 272 Installing En~jn e (Table of Contents) .. ........ .. .. ..... 2-107 Troubleshooting Engine (Carbureted Models) ..... 2-118 Troubleshooting Engine (EFI Models) ................. 2-121 Engine Information (Table of Contents) ............... 2-125
Page : 13
2-1
..ca .... . 0
()
U)
()
II)
Il.
GI
GI
.-
[(a: a: a:
0000
M(')'I""I"
. ....
(J
C Cl C W
ca
() ()
a. a. a. a.
~:?:8~
::::!~~::::?;
@J@.l@J@J
l@S9
::2::2::2::2 a... a... a... 0.. [(a: er a:

0000
~g8~
,....r-C\lN
!!
C
E
c
@)@)@)@)
eS6@
'"
2-2
Page : 14
2005 A rctic Cat Service Manual - all models - www.ReadManuals.com
Torque Conversions
ft-Ib
1 2 3 4 5 6 7 8 9 10
11
kg-m
0.1 0.3 04 0.6 0.7 0.8 1.0
1.1
ft-Ib
21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37
kg-m
2.9 3.0 3.2 3.3 3.5 3.6 3.7 3.9 4.0 4.2 4.3 44 4.6 4.7 4.8 5.0 5.1 5.3 54 5.5
ft-tb
41 42 43 44 45 46 47 48 49
50
kg-m
5.7 5.8 5.8 6.1 6.2 64 6.5 6.6 6.8 6.9 7.1 7.2 7.3 7.5 7.6 7.7 7.9 8.0 8.2 8.3
ft-Ib
61 62
kg-m
84 8.6 8.7 8.9 9.0 9.1 9.3 94 9.5 9.7 9.8
10.0
10.1
ft-Ib
81 82 83 84 85 86 87 88 89
90
kg-m
11.2 11 .3 11.5 11.6 11.8 11.9
12 13 14 15 16 17 18 19 20
1.2 14 1.5 1.7 1.8 1.9 2.1 2.2 24 2.5 2.6 2.8
38 39 40
51 52 53 54 55 56 57 58 59 60
63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80
12.0 12.2 12.3 12.5 12.6 12.8 12.9
10.2
lOA
10.5 10.7 10.8
10.9
11.1
91 92 92 94 95 96 97 98 99 100
13.0
13.1
13.3
13.4
13.6 13.7 13.8
Page : 15
2-3
Piston Replacement Guide

ENGINE SIZE
370 cc
440~
YEAR
2005 2005
2005
PISTON
RING
3004-825
3006-413
PISTON & RING SET

3005-913 3005-920 3006-427 3006-746 3006-685 3006-528 3005-748 3006-645
3006-393
500 cc w/APV 500 cc wlo APV

550~
570 cc 600cc (8TD)

600 cc ("Laydown ") 900 cc
2005 2005 2005 2005

2005
700 cc
2005 2005
3005-828
3005-828
3003-760 3006-004 3005-714 3006-004 3006-394

3006-500
3006-499
Not a Service Part
Assembly Schematics Table of Contents

370/440 cc _. _, ____ .. ...... _ _ .. _ _ _ .. .....,.... _ _ .. _ _ .... .... __ ... ... ... 26
550 cc ............. ................ ......................... ... .......... 2-8
570 cc ............. ..................................................... 2-10

600 cc (STD) .......................... ............................... 2-1 2
900 cc ................................................................... 2-14 500 cc "Laydown" Engine Model (w/APV) .... _ _ ... ... . 2-16 500 cc " Lay~own " En~ine ~odel (w/o APV) .......... 2-18 6001700 cc Laydown Engine Models .................. 2-20
Listed in the table below are symbols indicating srx~c i a l instructio ns and other importa nt info rmatio n necessary fo r proper servicing. PI ease note the definition for eac h symbol. These symbols are lIsed througho llt thi s twovolume set.
DESCRIPTION
SYMBOL
Torque control required 242 243 270 271 609 - apply - apply - apply - apply - apply
blue Loctite #242 (pIn 1639-815) blue Loctite #243 (pIn 1639-413) green Loctite #270 (pin 1639-817) red Loctite #271 (pIn 1639-820) green Loctite #609 (pin 1639-821)
Lubricate with Arctic Cat 50 :1 Injection Oil (pin 0636-286) Lubricate with Arctic Cat Extreme 50 :1 Injection Oil (pin 0639-112)
Lubricate with Arctic Cat Low-Temp Grease (pIn 0636-593)
3B - Three Bond Sealant (pin 0636-070) HT - High-Temp Sealant (pin 0636-069) AS - Anti-Seize Thread Compound (pin 0678-146)
24
Page : 16
2005 Arctic Cat Service Manual - all models - www. ReadManuals.co m
NOTES
Page : 17
2-5
370/440 cc
1.8-2.8 kg-m
(13-20 11-1b)
0 0
0
~
(;) (;) (;)
lQ
~
2.5-4 kg-m (1829 I1lbl
1.1 kg-m (S IHb)
1.8-2.2 kg-m (1316 ft~b)
0@~.
~
2.8 kgm (ZO fH b)
O .4.(J.7 kg-m (3-5 11-1b)
.~.
2.8 Icg-m (2O ft-ll)
"""'1/iV
.
6.9-7.6 kg-m
(50-55 ft~b)
2.8-3.5 kg.." (20-2511-1b)
0.4-0.7 kg-m (3-SfHb)
3744 ENG
2-6
Page : 18
2005 Arctic Cat Service Manual - all models www.ReadManuals.com
kg-m (SO.S-65IHb)
r!JA
2.6-3.3 r.g..m
(1924 11-1b)
::Jo-a
6 mm 0.8-1.2 kg-m
(6-9ft-lb)
8 mm 1.S-2.8 kg-m (13-20fl-lb)
"
1.82.2 kgm
(13-16 fI lb)
3744 ENG 2
Page : 19
27
550 cc
1.8-2.8kgm (13-20H-lb)
5mm
O _ 8-12 kgm
(6-9 H-Ib)
(j)
-0
5SO ENG
2-8
Page : 20
1.8-2.8 kg-m (13-20 fI-lb)
~
4-6 kg-m
(2943.5 fI-lb)
~
/0.7-1kg-m (5-7f1-lb)
(13-16 -I
, , Q'
'
1 kg-m (7 f1-lb}
0.7-1 kg-m (5-7 n-Ib)
550 ENG2
Page: 21
2005 Arctic Cat Service Manual all models www_ ReadM anuals_ co m
29
570 cc
2.5'2,8 kg-m
(l8-20ft-lb)
9 1 312
11 4 210
6 mm 0.812 kgm (6-9 f1lb) 8 mm 1.8-2.8 kg m(13-20 ft-Ib)
O .8-1 .2kg-m (6-9 H-Ibj
::I~" ,---""7 2,8-3.5 kgm
t",~'1 .-lr A
\ ,/<1 < f! f \~ " --' /-:1"' / .... f4, v.:

'
~.
Jt
~ "'
. "
(20-25 '-Ib)
~Jev"",c:l,1 ~
if?
~-:l:I6.9-7.6 kg-m
2.8 kgm (20 ft, lbl
(50-55 '-Ib)
570EN G
2-10
Page : 22
0a.1 .21rij-m (6-9 n~b)
MJSI De used inCCflp,mcticn "",111 Lccllte Pnmer 17471
1S.22 kgm
(1~16MIb)
071
O~m
1 S.221rGm
(1316n-l
(5-7 n-ll)
570ENG2
Page: 23
2005 Arctic Cat Service Manual all models www.ReadManuals.com
211
600 cc
(STD)
11 i;g-m (8f1lb)
8~
0 0
2 4
0 0
r
"IT
11
10
3 1
o71t;-m
(511lb)
5&6 ENG
2-12
Page : 24
1.8-2.8 kg-m (13-20 fl-lb)
V /
~~:l O.7"-k-g.Dm
4-6 kg-m
..
<I
(29-43.5 h- Ib)
~'ll>~ 1 '. ~/"'~ ~ ;.?

c
~~
-
/~
(5-7 ft-Ib)
1.8-2.2 Iqj-m
:~"
, I
,r
I . ;'
i..../
r-,
1 kg-m
(7 ft-Ib)
(13-16ft-)b)
"lP~
,
~ .
~ ..
, .-~ ~ \
/,
"
i(fJ "j l .. ~@
/, W0/
I
1.1 kg-m
:l
(S h-1bJ
7-9 kg-m (50.5-65 ft-Ib)
~
.
~
./
1f- ~7.1kgm (5-71t-lb)
O.S-I.2 kg-m (6-9 ft-lb)
~''''-';
~-~
1. 1 kg-m
~_:;>
~, ,-,
~~.~~~ , t"D
. .'" .$
_ 0.S-1.2 kg-m
~~
:l'
(6-9 ft-Ib)
. _ -:iJ
(Sft-b)
5&6NG04
Page : 25
2-13
900cc
10 mm 4.2-4.6 kg-m
.5
(30-35 ftlb)
6mm 0.8-1 .2 kg-m
(6-9 fI lb)
(!)
(!)
0)
0)
@@
0)
0
k!cm
(20-25 fI-lb)
'1,
, ..
/A~-<r
k-<
2.4kg-m
(17 ft~b)
/ ~6.9-7.6 kg-m
(50-55 fIlb)
9OO ENG
2-14
Page : 26
2005 A rctic Cat Service Manual - all models - www. ReadManuals.co m
.,
3.2-3.8 kg-m
(2H7.51t1:l)
(35-52 h-Ibj
26-33 kg-m ~;:;;;::-( 1g.24ftlb)
.~ .
2Ik9.m{15ft'lb)~
4.a-.7.2kg-m (35-52 h-Ib)
'\f'@ / 0
0.9-1.3 kg-m
(6.5-9.5 flAb)
1 kg-m
(7 11-1b)
6.5-7.5 kg-m (475411-1)
\ -1.4 kg-m (710ft-lb)
900-ENG 2
Page : 27
2-15
500
CC ( " Laydovvn" vv/APV)
1.802.8 kg-m
( l~20It-l))
4-6.1 kg.m (29-44 n-ll)
1.1 ~9-m (9 11-1:1)
6.5-7.5 kg.m (47-541\-4b)
0.8-1 .2 kg-m (6-9 h-tl)
2.6-3.3 kg-m (19-24 ft-Ib)
@..",.:;::-'
"'\(@~
2.1 kgm (15 ft.lb)./
SOOCC 1
2-16
Page: 28
2005 A rct ic Cat Service Manual - all models - www.ReadManua ls.com
.. ill
ill ill ill ill
. ..
0
ill
0
ill ill
'"
L
'-
(5
>-
2.5-2.81g-m
(1&20"~1J)
5OOCC2
Page: 29
. C at Service . Manual - al 1 m odels- www. Rea dManuals.com 2005 Arctic
2-17
500
CC ( " Laydovvn" VIll a APVI
~. 1 kg-m (29-4411-1:1)
< ,.~-
1.1 kg-m (8 It-b)
k,~
(571t1b)
2.6-3.3 kg-m
(19-24 h-l:l)
~~o
2.1 kg-m (lSft.Ib)"/
2.6-3.311g-m (19-2411-11)
SOOCC1A
2-18
Page: 30
2005 A rct ic Cat Service Manual - all models - www. ReadManuals.com
(l)
(l)
"
(l) (l) (l)
(l)
I[)
(j)
"
(l)
5 9
1 _1
3
10
:12_ 5-2,8 kg-m

(1 820 fj-Ib)
SOOCC2A
Page : 31
e Cat Service Man ual - all models 2005 ArcI I
www. ReadManuals.com
2-19
600/700 cc
(ULaydoW'n
..)
2.5-2.8 kg-m
(1820Itlbj
0.7' kgm
(5071t-lb)
4-6Hgm
(29-4411-1:1)
..
1.1 kg-m (8IHb)
~'8-2.2 kg.m
(13-16IHbj
~J' ,
/'<'~
/'-.-
...........
~-
:)::1_
1.1 kg-m
(81tlb)
--- "'l::l__
0.8-1.2 kg.m
(6-9It-/b)
1.1 kgm
(SIHbl
6.57.s kg-m (47-504 fHb)
, Ie"
::I
0.7' kg-m
(5-71t-lb)
:12.6-3.3 kg-nl
~O
2.1 kg-m (15h-lb)
(19-24 h-lb)
3@
700CC I
2-20
Page: 32
e Cat Service Manual - all models 2005 A rc I I
~ ,..
(j) (j)
12 ,.,
(j)
11
1 lilllll 3
13
I'"~
a:>o@
(j) (j) (j)
0
@
:~
/
,
00
(j)
~,
2.5-2.8 kg-m
(l8-20 ftlb)
6,9-76 kgm (50-55 fI-l b)
700CC2
Page : 33
2-21
Engine Piston Travel Versus Crank Angle Chart
When using any of the charts below, first know the engine stroke and timing in degrees; then select the proper chart and read across from
the degree figure to find timing in either mm or inches.
"
62.7 mm stroke
70 mm stroke 65 mm stroke
63 mm stroke
66 mm stroke
76 mm stroke
~
0.157 0.226
0.308 0.402 0.508
De .p" ee B DC
mmBTDC
in. BlOC
mmBTDC
in. BlOC
mmBTDC
in. BlOC
mmBTOC
in. BlOC
mmBTDC
in. BlOC
mmBTDC
in. BlOC
0.007 0.010 0.014
0.018
" g.
()
5 6 7 8
!;
'" <
g"
, " o
!!.
10 11 12 13 14
l:, 3
"
8.
15 16 17 18
1:'
, " o
" 8 3
-
19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
0.151 0.218 0.296 0.387 0.489 0.603 0.729 0.867 1.017 1.178 1.351 1.535 1.730 1.937 2.155 2.384 2.624 2.875 3.137 3.409 3.692 3.985 4.288 4.602 4.925 5.258 5.601
0.006 0.009 0.012 0.015 0.019 0.024 0.029 0.034 0.040 0.046 0.053 0.060 0.068 0.076 0.085 0.094 0.103 0.113 0.124 0.134 0.145 0.156 0.169 0.181 0.194 0.207 0.220
0 .150 0.216 0.295 0.384 0.486 0.600 0 .725 0.862 1.011 1.171 1.343 1.526 1.720 1.926 2.143 2.371 2.609 2.859 3 .119 3.390 3.671 3.962 4.264 4.576 4.897 5.228
0.006 0.009 0.012 0.015 0.019 0.024 0.029 0.034 0.040 0.046 0.053 0.060 0.068 0.076 0.084 0.093 0.103 0.113 0.123 0.133 0.145 0.156 0.168 0.180 0.193 0.206
0.169 0.243 0.331 0.432 0.546 0.674 0.815 0.969 1.136 1.316 1.509 1.714 1.933 2.164 2.407 2.663 2.931 3.211 3.504 3.808 4.123 4.451 4.790 5.139 5.500 5.872
0.007 0.009 0.013 0.017 0.021 0.026 0.032 0.038 0.045 0.052 0.059 0.067 0.076 0.085 0.095 0.105 0.115 .0126 0.138 0.150 0.162 0.175 0.188 0.202 0.216 0.231
0.627 0.757 0.901 1.056 1.223 1.403 1.594 1.797 2 .012 2.238 2.476 2.725 2 .986 3.257 3.540 3 .834 4 .138 4.453 4.778 5.114 5.459 5.815' 6.181' 6.556'
0.006 0.009 0.012 0.016 0.020 0.025 0.030 0.035 0.042 0.048 0.055 0.063 0.071 0.079 0.088 0.097 0.107 0.118 0.128 0.139 0.151 0.163 0.175 0.188 0.201 0.215 0.229' 0.243' 0.258"
0.160 0.230 0.313 0.409 0.517 0.638 0.772 0.917 1.076 1.246 1.429 1.624 1.830 2.049 2.280 2.522 2.776 3.041 3.318 3.606 3.905 4.215 4.536 4.867 5.209 5.561 5.923 6.295 6.677
0.006 0.009 0.012 0.016 0.020 0.025 0.030 0.036 0.042 0.049 0.056 0.064 0.072 0.081 0.090 0.099 0.109 0.120 0.131 0.142 0.154 0.166 0.179 0.192 0.205 0.219 0.233 0.248 0.263
0.182 0.262 0.356 0.465 0.588 0.726 0.878 1.044 1.224 1.417 1.625 1.847 2.082 2.331 2.594 2.869 3.158 3.460 3.775 4.103 4.443 4.796 5.161 5.538 5.927 6.328
0.023 0.029 0.035 0.041 0.048 0.056 0.064 0.073 0.082 0.089 0.102 0.113 0.124 0.136 0.149 0.162 0.175 0.189 0.203 0.218 0.233 0.249
ENGINE TYPE
Cylinder Head Volume Specifications G"

SQUISH
HEAO INSTALLED " (KOMI;: IcCI
FLAT PLATE I'OLUME Iccl
370<;(:
MO~
~.272
95
19.1 22.0
20.4-26.4
~,
24325.1
~,
"
.089-'16
700 cc r Ulj<jO'Mll
"
"
"
.(155. .074
' .39-' .67
SlOCC
~~ ~oo
'" '"
.1)56..076
1.41-'.94
~,
'"
"
2701
23.5-26.5
22.43
28.8
34.4-35.0
~ .~
in.
~
6:)0 CC (8TC)
600cc
r la)<JO'Mll
"
'"
" ", ,,,

~
27.8
25.0-27.6 34.' -38.0
".
m
=00
"
"
.~
'" ,,, '"
",
NOTE: For accurate reading when using the head installed volume method , subtract 2.44 cc from the total amount of fluid used (if using a BR9EYA spark plug) or 2.20 cc (if using a BASES spark plug).
CAUTION
The above specifications are not intended to be used for engine modification. Reducing the head volume to the smaller specification could cause piston detonation problems which is not a warranty situation.
Crankshaft Runout Specifications

1 --' -1 )1 ' "1
ri- ----.
Engmc
_.,
SI,Ol<C
~
72B-144A
HXh 0.15 (3,937 " 0.(06) 11 9.7 .. 0.1 5 (4712 .. 0.006)
,
55 .. 0.15 (2.165 .. 0.006) 64 .. 0.15 (25 19,0.006)
,
(3,937) lI S .. 0.4 (4 ,645" 0.0 15)
RunOUl 0 E F Po,nt
370cc
MO~
" 00'1
~n. )
'" '"
65 xes
"'"
(0,866)
~
D~
(1 ,377)
~
I
" 00'1
>n
(0.866)
=~
79,7 X70
~n. )
(1 ,1el )
(0,196)
1
(" 0(2) (.. .(02)
>,
(0.196)
""~
~~
73,4 X 65
~
~n. )
112.5 .. 0, 15 (4,4(19 , 0.(06) 71 X 63 114,7 .. 0.15 (4,515 .. 0.(06)
60 .0.1 5 (2 362 .. 0.006) 66,S .. 0.15 (2,618 .. 0.006)
10(hO.4 (4,174) 106.0A (4.465" 0.015)
(1062)
" "
(1181)
~
~n. )
(1 ,062)
(0,196)
(" 0(2)
~
I I I
>,
(0.197)
>,
(0.197)
000 CC (STD) 600 cc (""LaJ<jov.n1
~n . )
78 X 62.7 73S X70
11 4" 0.15 (4,88. 0006) 119.7. 0.15 (4.712.0.006) 119 .. 0.15 (UO" 0 ,(06) 125,5 .0.15 (4,94" 0 ,006)
66,5 ,,0.15 (2.62 .. 0,006) 64.0.15 (2,5 19. 0.006) 62,3. 0.15 (2.45 .. 0 ,(06) 68 .. 0.15 (2.68.0,006)
11;6,8-106 (4,165-4.173) 11 S.0.4 (4,645" 0.015) 100.7 (4320) lZl + 0-0,4 (4,84 + 0-0,015)
(1,2)
~
(1 ,181 )
~
DOO
>,
(0.197)
( .0(2)
~
~n. )
(1.1el )
(0,196)
1
( .0(2)
>,
(0.196)
570CC
73,S X 66
~n. )
(0,945)
~
"
(1 ,181) (1= . 181 )
DOO
1
(" 0(2)
m
(0.590)
=00
85 X76
GrI-)
(1 .2)
m
(0.590)
NOTE: Measure in from the shaft end the specified amount when checking runout at points O-F. When checking runout in the center, place indicator on center of bearing as shown at Point E. Maximum runout at any of the 3 measuring points is O.OS mm (0.002 in.).
Page : 35
2-23
Engine
Thi s engine servicing section has been orga ni zed into
sub-secti ons which show a prog ress ion for the com-
pl ete se rvic ing of the Arctic Cat e ngine. For consistency purposes, thi s secti on shows a complet e and
thorough progression; however, for effi ciency it may be preferable to remove the e ngin e as a comp lete assembl y, to remove and disassemble only those components whi ch need to be addressed , a nd to serv ice onl y those components. Also, some componenl'S may vary from model to modeL T he technician should usc
discretion and sound judgment.
NOTE: Some illustrations and photographs used in this section are used for clarity purposes only and are not designed to depict actual conditions.
Removing Engine Table of Contents

FIG Models ... .. .... .. ................ .. .. ... ...................... ... . 2-24 600 ST01900 cc Models ........................................ 2-26 550 cc Model ... .. ...... ...... .. ..... .. .......... .. ..... ............ .. 2-28 500/600noo cc "Laydown" Engine Models .. ....... .. 2-30
5. Remove the clutch from the engi ne compartment. G. Remove the cap screw and washer securing the dri ven pulley; thcll slide thc pull ey off the dri\'en shafl. Account for and note the position of any alignment washe rs.
NOTE: If the driven pulley will not slide off the driven shaft, use the Driven Pulley Puller (pIn 0744-023) for removal.
Removing Engine
(Fie Models)
NOTE: If equipped with electric start, disconnect the battery.
Turn the gas tank shut-off val ve to the CLOSED position. 2. O pen the belt guard. 3. Re mo\'e the drive belt ; then remove the plug from the bell y pan_
NOTE: Before installing the clutch puller, apply oil to the threads of the puller and a small amount of grease to the tip of the puller,
4. Remove the bolt and lock washers securing the drive clutch to the crankshaft ; then using the Drive Clutch Pull er (pIn 0644-207) and a n impact wre nch or a breakcr bar and Drive Clutch Spanncr Wre nch (pIn 0644-1 36), ti ghten the pull er. If the drive clutch will not rele<lse, sharply strike the head of the puller with a hammer. Repeat this procedure until the clutch releases .
7. Loosen the torque bumper from the engine mount.
2-24
Page : 36
13. Loosen the carhuretor Oange c1ump(s). Remove the carburetor(s) from the intake Oange(s) and carburetor boot(s). Place the carburetor(s) to the side in an upright position.
NOTE: If equipped with electric start, remove the lock nut and washer securing the ground cable to the starter motor and loosen the two Allen-head cap screws (A) securing the flexdrive to the starter motor; then remove the cap screws securing the starter motor to the chassis. Remove the starter motor.
8. Remove the springs securing the expansion chamber to the exhaust manifold and resonator; then remove ex pansion chamber.
9 . Remove the cap screws and lock washers securing
the recoil stmtec then remove the stmter. Leave it in the e ngine compmtmenl.
14. Disconnect the oil -injection ca ble from the oil -
injection pump. Account for the E-cl ip and washer; then disconnect the oil suppl y hose from the pump and plug the hose to prevent leakage.
10. Disconnect the fou r-prong main wiring harness
connector and the CDI ullit wiring harness ,

11. Disconnect the impulse hose from the crankcase.
12. Disconnect the spark plug caps.
15. Re move the cap screws securing the engine to the
chassis. Account for washers, eap screws, and lock nut.<; .

Page : 37 2005 Arctic Cat Service Manual - all models - www. ReadM anuals.com
2-25
2. O pen the belt guard ; then remove the dri ve belt. NOTE : On the ZR to remove the drive belt, see Section 8. 3. Remove the plug from the bell y pml. Using a Y2-in. 12-IXlint socket. remove the ca p screw and lock washer securing the dri ve clutch to the crankshaft . 4. Using Clutch Puller (pin 0644-207) and an impact wre nch or a breaker bar and Spanne r Wrench ( pi n 0644- 1 36), tighten the puller. If the drive clutch will not release, sharpl y strike the head of the puller. Repeat thi s step until the clutch releases. Remove the dri ve clutch. If applicable, account for the two sleeves.
5. Rcmove the cap screw and washer securing the dri ven pulley; then slide the driven pulley off the dri ven shaft. Account for a key, stub shaft , and alignment \\lashe rs.
16. Lift the engine out of the engine compartment.

17. Re move the cap screws, washcrs, and lock
washcrs securing the engine mounting brackets to the engine: then remove the brackets. NOTE : If the driven pulley is tight on the driven shaft, pull the driven pulley off using the Driven Pulley Puller (pin 0744-023). NOTE : On the ZR, remove the cap screw securing the driven pulley; then slide the driven pulley off the gea r case input shaft, Account for alignment washers. 6. Remo\'e the two cap screws servomotor cover. securing the
Removing Engine
(600 (STDI/900 cc Models)
NOTE: If applicable, disconnect the battery cables.

I. Re move all
springs securing the expansion chamber($) and remove the expansion cha mber(s) from the engine compartment.
2-26
Page : 38
7. Using a small screwdri ver, pry 01T the cable reta ining cover.
10. Re move the screw securing the servomotor 0 the air-intake silencer; then pull mounting plate 1 the mounting pl ate fo rward and up to remove it from the silencer. La y the mounting plate aside out orthe way.
8. Rotate the servomotor actuator counte rclockwise 1 0 loosen the cable: then pull the cable housings oul of the holder. 11 . Lift the silencer cover and remove the COl unit ; then lay the unit aside out of the way. 12. Remo\'e the two APV drain hoses and route them out or the way.
9. Pull the cable up and out of the cable housing holder; the n slide each cable drum to the left and oul or the servomotor actuator. 13. If applicable, remove the machine screw and washer securing the mounting plate (for the ignition coil and fuel pump) to the air-intake sil encer. 14. Remove the screws securing the air-intake sil encer; then move the silencer forward and out of the engine comp.1I1mc nL
Page : 39 2005 Arctic Cat Service Manual - all models - www. ReadManuals.com
2-27
15. Di sconnect the oil-injection cable/control rod from
the oil-injection pump; the n di sconnect the oil supply hose from the pump and plug the hose to prevent oil drainage.
16. Loosen the flange clamps securing the throttle
2 1. Re move the recoil stm1er from the engine. Leave it in the e ngine compm1ment.
_NOTE : If applicable, disconnect the solenoid-tostarter motor cable from the starter motor.
body/carburetor to the flange; then remove the throttle body/carburetor. Place them to one side in an upri ght position. 17. O n carbureted models, disconnect the impulse hose from the crankcase.
22. Loosen the cap sc rews/lock nuts securing the engine mounting brackets to the front end. 23, Remove the cap from the coolant drain hose and route the hose into a suitable container. Remove the fill er cap; then once the coolant sto ps draining, install the drain hose cap.
18. Loosen the engine torque bumper and remove the left rear engine nut and washer.
24, Loosen the clamp securing the suppl y hose to the coolant tank and remove the hose. Loosen the clamp securing the hose to the the rmostat cap; then remove the hose from the cap.
_NOTE : Inspect the engine to ensure all wires, hoses, and cables have been removed.
25. Lift the engine with mounting brackets out of the engine compm1ment. 26. Re move the cap screws sec uring the engine mounting brackets to the crankcase; then remove the brackets. 27. Re move the exhaust manifold from the engine. Account for nuts, washe rs, and gaskets. 28. Remove the clamp securing the coolant suppl y hose to the water pump. Then re move the hose from the pump,
Removing Engine
(550 cc Model)
I. Disconnect the battery cabl es making sure to disconnect the negati ve cable first. 19. Secure the hood with a tic-dow n strap; then remove the hood cable. 20, Di sconnect all electrical wires from the e ngine.
2-28
Page : 40
2. Turn the gas tank shut-off val ve to the CLOSED position. 3. Re move the cabl e li e and positi ve banery cabl e from the starte r motor.
4. Remove the springs securing the expansion chamber to the exhaust manifold , front end, and resonator. Remove the ex pansion chamber and grafoil gasket. 5. Attach a long piece of fuel hose to the engine coolant drai n (located on the exha ust side of the engine). Route the hose outside the engine compartment and into a container. Open the drain and remove the fill er cap. Once the coolant stops fl owi ng, remove the hose and ti ghte n the drain valve.
NOTE: If the driven pulley is tight on the driven shaft, pull the driven pulley off using the Driven Pulley Puller (pin 0744-023)_
9. Loosen the flange clamp sec uring each carburetor to its flange; then remove the ca rburetors. Position the carburetors to one side in an upright IXlsition.
10. Di sconnect the impulse hose from the crankcase. II Remove the cable tie sec uring the engi ne and COl wiring harnesses to the engine ; then disconnect the main wi ring harncss from the engi ne and COl wiring harnesses. 12. Remo\'c the spark plug caps and the cable tie securing the temperature-gauge sender wire; then disconnect the sender wi re. 13. Remove the E-clip and washer securing the oil injection cable: then di sconnect the oi l-injection Ct'lble from the pump. Disconnect the oil -supply hose from the pump and plug the hose to prevent oil drainage.
6. Opcn the belt guard: then remove the dri ve belt.

NOTE: Remove the rubber plug from the belly pan.
7. Using a J.1 -in. twelve-poi nt socket, remove the bolt and lock washer securing the drive clutch to the cran kshaft. Using the Cl utch Puller (pin 0644-207) and an impact wrench or a breaker bar and the A ywheel Pulley/Spanner Wrench (pIn 0 144-3 10), tighten the puller. If the drive cl utch will not release, sharply strike the head of the pull er. Repeat this step until the clutch releases. Remove the dri ve cl utch. If applicable, account for the two sleevcs. 8. Remove the cap sc rew and washer securing the dri ven pulley; then slide the driven pulley off the dri ven shaft. Account for a key and alignment washers.
14. Loosen the clamp sec uring the supply hose to the water pump housing: then remove the hose from the water pump. Loosen the clamp sec uring the hose to the thermostat cap: then remove the hose from the cap.
Page : 41
2-29
15. Re move the four cap sc rews and lock washers
securing the recoil stm1e r; then remove the starter from the engine. Lea ve it in the engine compartment,
NOTE: Account for the ground wire.
16. SUppOl1 the hood; then remove the hocxl. cable
from the exlmust manifold.

NOTE: Loosen the set screws and remove the flex-drive shaft from the starter motor.
17. Loosen the torque bumpe r and remove the lock nut
securing the engine mount to the chassis. 19. Lift the engine with mounting brackets out of the engine compm1menL
&
CAUTION
00 not use the starter motor shaft to lift the engine. Damage may occur.
20. Re move the engine mounting brackets.
Removing Engine
(500/600/700 cc "Laydownn Engine Models)
I. Remo\'e all
springs securing the ex pansion chamber and resonator; the n remove these cOllllXlnents from the e ngine compartment .
18. Remove the loc k nut from the front PTO-side mounting bracket; then re move the two remaining ca p screws securing the engine to the chassis.
2-30
Page : 42
2. O pen the bell guard; then remove the drive bell (see Section 8). 3. Re move the plug from the belly pan. Using a Y.o:-in. 12-point socket, remove the cap screw and lock washer securing the dri ve clutch to the crankshaft .
6. Re move the cap screw and washer sec uring the dri ven pulley; then slide the dri ven pulley off the dri\'en shaft. Account for a key, stub shaft , ali gmnent washe rs, and a n inner and outer O-ring.
4. Using Cl utch Compressor (pIn 0644-420), lock the dri ve clutch in the compressed position with the locking clamp.
NOTE: If the driven pulley is tight on the driven shaft, pull the driven pulley off using the Driven Pulley Puller (pin 0744-023) . NOTE: On the Firecat/M-Series, remove the access panel from the belly pan; then remove the cap screw from the driven pulley and slide the driven pulley off the gear case input shaft. Account for alignment washers.
5. Using Cl utch Puller (pIn 0644-207) and an impact wre nch or a breake r bar and Spanne r Wrench (pIn 0644- 136), tighten the puller. If the dri ve clutch will not release, sharpl y strike the head of the pull cr. Repeat thi s step until the clutch releases. Re mo\'e the dri\'e clutch. If applicable, account for the two sleeves.
7. Loosen the two cap screws securlng the sen 'omotor a nd cover; the n re move the cover. Using a small screwdri ver, pry off the cabl e retaining cover.
Page : 43
2-31
10. Remove the cap from the coolant drain hose and route the hose out of the exhallst outlet in Ihe belly pan into a suitable container. Remove the fill er cap; then once the coolant sto ps draining, insta ll the drain hose ca p.
8. Rotate the servomotor actuator counte rclockwise to loosen Ihe cable; then pull the cable housings out of the holder.
II . Loosen the !lange clamps securing Ihe throttle body/ca rburetor assembly to the !lange; then move the throttle body/carburetor assembly forward 10 allow room to disconnect the oil injection cablel control rod from the oil-injection pump. 12. O n the carbureted model s, disconnectlhe impulse hose from the crankcase.
9. Pull the cable up and out of the cable housing holder; then slide C<lCh cable drum back and out of the servomotor actuator.
13. Loosen the clamps securing the coolant hoses connected to the cylinders beneath the ex haust ports; the n remove the vent tube from the top of the cylinder head.
2-32
Page : 44
14. rvlove the throttle body/carburetor assembl y to one
side out of the way to a sec ure position.

NOTE: On the FirecatlSabercat with the throttle body/carburetor assembly out of the way, discon nect the oil hose from the oil pump; then plug the oil hose.
15. Remove the recoil stm1er and ground wire from the engine. Lea ve it in the engine eompm1me nt. 16. Remove the four torx-head screws and the three lock nuts sec uring the side-pl ate brace to the chassis; then remove the hardware securing the lefl-side engine mounting bracket. Re move the bracket.
NOTE: On the MSeries, the cap screw and lock nut securing the steering support to the chassis must be removed to remove the side-plate brace.
17. Loosen the cap screwllock nut securing the rightside engine mounting bracket 1 0 the front end.
Page : 45
2-33
FirecatiM-Series
MS383A
Is' Disconnect all electri cal wires from the e ngine. 19. Disconnect the lower coolant hose; then move the engine toward the left and up to allow enough room to re move the re maining coolant hose.
NOTE: If equipped with electric start, loosen the two set screws securing the flexdrive shaft to the pinion drive. NOTE: Inspect the engine to ensure all wires, hoses, and cables have been removed.
20. Lift the engine Ollt of the engine compmtment. 2 1. Re move the exha ust manifold from the engine. Account for nuts, washe rs, and gaskets. 22. Re move the clamp securing the coolant suppl y hose from the cylinder head to the water pump. Then re move the hose from the e ngine.
Disassembling Engine Table of Contents

370/440 cc Models ....... .......... ... .......... ................ 2-35 550 cc Model ................ .......... ... ................. ......... 2-38 570 cc Models ................. ........ ..... .......... 24 1 600 cc Standard Engine Model ........... .................. 246 900 cc Models ......................................... .............. 25 1 5001600nOO cc "Laydown" Engine Models ........... 257
2-34
Page : 46
Disassembling Engine
(370/440 cc Models)
I. Rcmo\'c the four nuts and lock washers securing
the ex haust manifold; then remove the exhaust manifold. Account fo r two gaskets. 2. Noting the location of the longer cap screws for assembly purposes, remove the 14 cap screws, lock washers, and washers securing the top and
ex haust-side cooling shrouds.
3. Lift the top cooling shroud off the engine and slide the ex haust-side cooling shroud off the ex haustmanifold studs. Account for two ex haust-manirold shroud gaskets.
8. Temporaril y install the stalter pull ey o n the fl yw heel with three cap screws. Using the fl yw heel spanner wre nch to secure the crankshaft , loosen and remove the fl )'w heelnut and washers.
4. Disconnect the two oil-injection hoses from their fillings on the mta ke manifold (si ngle carburetor) o r on the adapter plates (twin carburetor). 5. A. On the 370 ce, remove the nuts securing the intake manifold ; then rclUo\'c the manifold with flange from the engi ne. Account for two Insulato rs. Discard the gaskets.
NOTE: If an impact wrench is being used, use of a flywheel spanner wrench will not be necessary.
9. Remove the cap screws securing the stalter pulley to the fl yw heel and remove the pulley. 10. Remove the !lange nuts securing the fan case to the c rankcase; the n re move the fan case.
NOTE: For further servicing of the axial fan com ponents, see section 3.
B. O n the 440 cc, remove the nuts, lock washers, and washers securing the intake !langes; then remove the !langes from the engi ne. Remove the screws securing the adapter plates; then remove the adapter plates. Discard the gaskets.
6. Remove the intake-manifold cooling shroud fro m the engine. Discard the two gaskets. 7. Using Flywheel Spanner Wrench (pIn 0 144-007) to secure the crankshaft, remove the three cap screws and lock washers securing the stalter pulley to the fl yw heel. Remove the stmter pulley; then carefull y pry the fan belt dri ve pulley from its seated lX)sitioll on the fl ywheel and remove.
II. Install a protecli\'e cap onto the end of the crankshaft.

Page : 47 2005 Arctic Cat Service Manual - all models - www.ReadManuals.com
2-35
NOTE: A suitable protective cap can be made by welding a 3 mm (1/8 in.) plate on one side of a spare flywheel nut.
14. Remove the stator plate from the engine. 15. Remo\'e the screws, lock washers, and washers securing the oi l-injection pump to the crankcase; then remove the pump, retainer, shim, and gear. Account for two gaskets .
Lb. CAUTION
To prevent damage to the crankshaft, thread a protective cap onto the crankshaft. The puller must bottom on the cap and not on the crankshaft. Also, do not thread puller bolts more than 12.7 mm (112 in.) into the flywheel. Damage to the coils may result.
12. Using the Flywheel Puller/Span ner Wrench (pIn 0 144-310) or suita ble eq ui valent, remove the Il ywheel from the crankshaft by tightening the puller bolt, striking the head of the puller bolt with a hammer, and tightening again. Repeat procedure until the Ilyw heel is free. Account for the key in the end of the crankshaft. 16. Remove the spark plugs. 17. Remove the eight nuts, lock washers, and washers securing the cylinder heads to the cylinders. Note the position of the different-sized nuts. Remove the heads and account for two gaskets and four dowel pins.
NOTE: To ensure the cleanliness of the flywheel magnets, place the flywheel (with the magnets fac ing upward) on a clean bench.
13. Scribe a reference line on the stator plate and crankcase to aid in assembly ; then remove the two Alle n-head cap screws, lock washers, and washers sec uring the stator plate.
NOTE: The two stator plate Allen-head cap screws had Loctite applied to the threads during assembly. Before removing them, apply a sharp blow to the head of each screw to break the Loctite loose. If this isn't done, the screws can be very difficult to remove.
2-36
18. Using a rubber hammer, genU y tap the cylinders and re move from the crankcase by lifting them straight up 01T the ir studs. Discard the two gaskets. Account fo r two dowel pins.
22. Lift the pi stons clear of the connecti ng roos and remove the small e nd connecting-rod bea rings; then remove the piston rings. Keep each piston with it.<; rings, piston pin, a nd beari ng together as a set.
NOTE: Place rubber bands over the connecting rods and around the cylinder studs. This will keep the connecting rods from damaging the c rankcase.
CAUTION
When removing a cylinder, make sure to support the pistons so they will not be damaged.
19. Using a felt -tipped marker, mark an M on the t\'IAG-side head, cylinder, and pi ston and a P on the Pf O-side head, cylinder, and piston .
NOTE: For proper assembly, keep all MAG-side components and all PTO-side components separated. Assemble them on their proper sides.
20. Removc the PfO-side piston-pin c irelip from the PTO-side piston; rcmove the MAG-side piston-pin ci rcl ip from the MAG -side piston.
23. Remove the cap screws securing the crankcase halves. Note the position of the di lTe rent-sized cap screws.
2 1 Using the Pi ston-Pin Puller (pin 0644-328), remove the piston pins fro m both pistons.
24. Separate the crankcase ha lves by insta lling two crankcase cap screws in diagonal corners leav ing the heads approximately 6 mm (l i4 in.) out. Using a plastic hammer, ta p on each cap screw head unti l the ha lves sepa rate. Remove the ca p screws.
A A
CAUTION
CAUTION
00 NOT drive any tool between the crankcase halves to separate the c rankcase , Damage to the sealing surfaces will result.
25. Remove the rubber ba nds holdi ng the connecti ng
00 NOT use any type of punch to drive the piston pin free of the piston ; damage may result. Use a piston-pin puller only.
rods; then separate the cran kcase hah'es. Account for the two dowel pins. Lift the crankshaft free fro m the crankcase half and slide the two crankshaft seals off the crankshaft. Account for the C-ring and five bearing reta ini ng pins.
Page: 49
2005 Arctic Cat Service Manu al - all models - www. ReadM anu als.co m
2-37
(550 co Model)
I. Using the spanner wrench to secure the fl yw heel,
NOTE: To ensure the cleanliness of the flywheel magnets, place the flywheel (with the magnets fac~ ing upward) on a clean bench.
remove the fl ywheel nut , lock washer, and fl at washer; the n remove the three slm1cr pulley cap screws and remove the pulley.
4. Scribe a line o n the stator plate and magneto case to aid in assembl y; then remove the two Alle nhead cap screws. lock washers, and washers securing the stator plate. Remove the stator plate from the engine.
2. Install the Crankshaft Protecto r C1.p (pIn 0644234) onto the end of the crankshaft
NOTE: A suitable substitute protective cap can be made by welding a 3 mm (1/8 in.) plate on one side of a spare flywheel nut.
_NOTE : The stator plate screws had Loctite applied to the threads during assembly. Using an impact driver, apply a sharp blow to the head of each screw to break the Loctite loose before removal.
3. Using the Flywheel Pull er/S panner Wre nch (pIn 0 144-3 10) or suitabl e substitute, remove the fl ywheel fro m the crankshaft by tightening the puller bolt, striking the head o f the puller bolt with a hammer, and tightening again. Repe. 'lt this
procedure until the n yw heel is free. Account for the key.
5. Remove the four nuts and lock washers sec uring the exhaust manifold .
6. Re move the manifold and acco unt for the two ex haust gaskets. 7. Re mo \'e the three cap screws securing the thermostat cap ~ then remove the cap, gasket, and thermostat.
NOTE: The thermostat is of the lockopen type. If the thermostat is ever allowed to fully open, it will remain open and replacement will be necessary.
A CAUTION
To prevent damage to the crankshaft, the puller must bottom on the cap and not on the crankshaft. Also, do not thread puller bolts more than 12.7 mm (1/2 in.) into the flywheel. Damage to the coils may result.
8. Re mo \'c the four cap scrcws securing the thermostat manifo ld to the cylinder hC<lds. Re move the manifo ld and discard the gaskets. 9. Re move the slxlrk plugs.
10. Re move the six cap screws and O rings securing
each he.: 1d; then separate from the cylinde r. Account for two large O-rings beneath each head. II. Re move the o il -injection hose from each cylinder and the crankcase nozzle.
2-38
Page : 50
12. Remove the eight OlltS, lock washers, and washers
sec uring the cylindcrs to the crankcase ; then using a rubber hammer, gently tap the cylinders and remove from the crankcase by lifting them straight up ofT their studs. Account for two gaskets.
&. CAUTION
00 NOT use any type of punch to drive the piston pin free of the piston ; damage may result. Use a piston-pin puller only.
15. Li ft the pi stons clear of the connecting rods and
&. CAUTION
When removing a cylinder, be sure to support the piston to prevent damage to the crankcase and piston , NOTE: The metal cylinder base gaskets may be reused. When reusing gaskets, they must be cleaned and sprayed with Copper Coat Gasket Sealant (pin 0636-092) on each side.
remove the small-end connecting-rod beari ngs; then remove the piston rings . Keep each piston with its rings: keep each piston pin and bearing together as a set.
NOTE: Place rubber bands over the connecting rods and around the cylinder studs. This will pre-vent the connecting rods from damaging the crankcase.
16. Remove the two screws, lock washers, and
washers sec uring the oil-injection pump to the crankcase. Remove the pump, retainer, and O-ring.
17. Remove the water pump cover. Account for the 0 -
ring gasket.
18. Remo\'e the ca p screw securing the water pump
impeller; then slide the impell er free of the shaft. 19. Using an impact dri ver. remove the screws securing the PTO-end plate to the crankcase: then remove the plate.
20. Position the crankcase (with its bottom side up) on
NOTE: If servlClOg the intake flanges, remove them at this time.

13. Remo\'e the prO-side piston-pi n circlip from the
two blocks of wood. Remove the fom1ee n cap screws securing the crankcase halves. Note the posi tion of the diffe rent-sized cap sc rews. 21. Separate the crankcase hal ves by installing two crankcase cap screws in opposite corners leav ing the heads approximately 6 mm (1 /4 in.) oul. Using a plastic-tipped hammer, tap on each cap sc rew head until the case hal ves separate. Remove the cap screws.
prO-side pi ston; then remove the rvlAG -side piston-pi n eirclip fro m the ivlAG -side pi ston.
14. Using the Piston Pin Pul ler (pin 0644-328),
remove the piston pins from both pistons.

NOTE: For proper assembly, keep all MAG-side components and all PTO-side components separated . Assemble them on their proper sides.
&. CAUTION
00 NOT drive any tool between halves to separate the crankcase. Damage to the sealing surfaces will result.
Page: 51
2005 Arctic Cat Service Manual - all models - www. ReadManu als.com
2-39
22. Lift the bottom half of the crankcase 01T the top half. 23 . Lift the crankshaft free from the to p half of the crankcase and slide the crankshaft oil sea ls off the cranks haft. Account for the C-ring. Remove the two dowel pins a nd the four bearing reta ining pins. 24. Remove the oil -injection pump driveshaft from the lower crankcase half. Account for the thrust washer on the outer end of the shaft .
26. Re move the snap ring securing the inner seal in the cmnkcase. 27. Using the hooked e nd of the tool, pull the inner seal free of the crankcase.
28. Using a sharp, pointed tool, pry the seal ring from the backside of the water pump impeller.
NOTE: Do not replace the inner seals unless the water pump shows signs of leaking coolant out of the small bleed hole in the bottom half of the crankcase. If a water pump seal is to be replaced, use the Water Pump Searing and Seal Kit (pIn 0644-084) and see Cleaning and Inspecting Engine in this section.
25. Place the c rankcase on the bench with the water pump side dow n. Using the long seal dri ver, dri ve the water pump seal from the crankcase.
2-40
Page : 52
(570 cc Models)
I . Remove the exhaust manifold. Account for the
gaskets.
2. Rcmo\'c the nuts, lock washers, and washers sec uring the intake flange assembl y. Account for the gaskets, insulators, and the heat deflector. 3. Remove eight cap sc rews securing the main fan
shroud; then remove the shroud w ith the recoi l
stalter assembly.
5. Rcmo\'c the spark plug grommets .
NOTE: Cap screws securing the front and rear shrouds use special washers.
4. Remove the fi ve cap screws securing the front (exhaust-side) shroud to the cyli nder head. Account for the special washers.
6. Using Spanner Wrench (pIn 0 144-(07) to hold the sl'mter pulley, remove the ca p screw securing the fl ywheel to the crankshart.
NOTE: Keep the special mounting hardware with the shrouds for assembling purposes.
7. Using Spanner Wrench (pin 0 144-(07) to ho ld the stm1er pulley, remove the three cap screws sec uring the stm1er pulley and ran to the fl yw heel.
Page : 53
241
L!'. CAUTION
To prevent damage to the crankshaft, install a protective insert into the end of the crankshaft. The puller must bottom on the insert and not on the crankshaft. Also, do not thread puller bolts
more than five threads into the flywheel. Damage to the stator coils may result.
8. Install Flywheel Puller inscI1 (pIn 0644- 179) into the end of the crankshaft. Using Flywheel Pull erl Spmmc r Wre nch (p/n 0 144-310) or suitable substitute, remove the fl ywheeL
10. Remove the rubber insulator gro mmet rrom the crankcase; then remove two Phillips-head cap screws securing the ignition timing sensor and pull the wi res through the ho le in the crankcase,
NOTE: To ensure the cleanliness of the flywheel
magnets, place the flywheel (with the magnets fac illg upward) on a clean bench.
9. Remove the six cap screws securing the rear (intake-side) shroud; then remove the shroud. Account for the special washers.
2-42
Page : 54
12. Remove the four Allen-head cap screws securing the stator plate. Remove the stator plate.
11 . Remo\'e the three All en-head cap screws securing
the stator and remo\'e it along wi lh the stator wifing.
13. Remove the four cap sc rews securing the seal retainer plate on the PTO-side; then remove the plate.
14. Remove the spark plugs.
Page : 55
243
15. Remove the eight cap screws, two nuts, and two washers securing the cylinder head to the cylindcrs; then remove the cylinder head. Discard the cyl inder head gasket.
17. Remove the cylinders making sure to support the pistons so they arc not damaged. Account ror rour dowel pins.
& CAUTION
When removing a cylinder, make sure to support the piston so it will not be damaged.
16. Remove the rour 6 mm Iluts and eight 10 mm nuts sec uring the cylinders to the crankcase.
NOTE: Using a felHip marker, mark the cylinders as to MAGside and PTOside for assembling. Also, mark the pistons at this time.
18. Using an awl, remove the outside piston-pin ci rclip and remove the piston pin using Piston Pin Puller (pIn 0644-328) taki ng care not to drop the piston-pin bearing washers into the crankcase.
2-44
Page : 56
NOTE: The open sides of the piston pin bearing washers face inward.
19. Remove the two All en-head cap screws sec uring thc oi l-injection pump; then removc the pump. Account for an O-ring.
()
o
MOO208
NOTE: If the existing rings will not be replaced with new rings, note the location and top side of each ring for proper installation. When replacing with new rin~s , replace as a complete set only. When replacing rings note notches in ring ends which correspond with locating pins in ring grooves on intake side of the piston. This prevents the rings from turning on the piston when assem bled.
Page : 57
245
20. Remove the oil-injectio n pump drivesha fl retainer. Account fo r an O -ring.
2 J Removc the o il-il~ cction Account for a thrust washer.
pump
driveshaft.
24. Remove the two cap screws; then remove the crankshaft assembly from the upper crankcase half making sure to hold both ends of the crankshafl to keep the bearings and seals from fa lling off. Account for bearings and a C-ring.
&
CAUTION
To prevent damage to the crankshaft, crankshaft bearings, or seals, be sure to always lift the crankshaft from both ends,
22. Place the crankcase (with its bottom side up) on t\\'o blocks of wood. Remove the 12 cap screws securing the crankcase hal ves. Note the position of the dirlerent-sized cap screws. 23. Separate the crankcase hal ves by installing two of the cap screws in opposite corners leaving the heads approximately 6 mm (1 /4 in.) out. Using a plastic mallet, tap on each cap screw until the c~ankca se hal ves separate. Account for four dowel
pillS.
(600 cc Standard Engine Model)
I. Using the spanner wrench to secure the nywheel, remove the fl ywheel nut , lock washer, and flat washer; then remove the three starter pulley cap screws and re move the pulley.
2-46
Page : 58
NOTE: A suitable substitute protective cap can be made by welding a 3 mm (1/8 in.) plate on one side of a spare flywheel nut.
3. Using the Flywheel Puller/Spanner Wre nch ( pin 0 144-3 10) or suitabl e substitute, remove the Il ywhecl from the crankshaft by tightening the pull er boll , striking the head of the pulle r boll with a hamme r, and tightening again. Re peat this procedure until the nyw hecl is free. Account for the key.
&
CAUTION
To prevent damage to the crankshaft, the puller must bottom on the cap and not on the crankshaft. Also, do not thread puller bolts more than 12.7 mm (1/2 in.) into the flywheel. Damage to the coils may result.
2. Install the Crankshaft Protector Cap (pin 0644234) onto the end of the crankshaft.
NOTE: To ensure the cleanliness of the flywheel magnets, place the flywheel (with the magnets fac ing upward) on a clean bench.
4. Re move the Allen-head cap screws securing the stator to the stator plate.
Page : 59
247
5. Remove the Allen-head cap screws securing the stator plate.
6. Remove the stator plate from the engine.
8. Remove the three cap screws securing the thermostat cap ; then remo\'c the cap, gasket, and thermostat. 9. Remove the nuts securing the APV covers to the cylinders; then slide the covers back to expose the val ves .
NOTE: The stator plate screws had Loctite applied to the threads during assembly. Using an impact driver, apply a sharp blow to the head of each screw to break the Loctite loose before removal.
7. Rcmove the ignition timing sensor.
10. Remo\'c the cap screws securing the \'ah'es to the cylinders; then remove the APV assembli es and set them aside.
NOTE: The following two photographs are for clarity purposes only. This model may vary slightly.
2-48
Page : 60
14. Remove the eight nuts (with lock washers and washers) securing the cylinders to the crankcase; then using a rubber hammer, gently tap the cylinders and remove rrom the crankcase by lining them straight up orr thei r studs. Account ror gasket(s) and any alignment bushings.
CAUTION
When removing a cylinder, be sure to support the piston to prevent damage to the crankcase and piston.
15. Remove the PTa -side pi ston-pin circiip rrom the prO-side pi ston; then remove the MAG-side piston-pin circiip rrom the MAG -side pi ston.
II . Rcmovc thc srmrk plugs_ 12. Rcmo\'c thc cap scrcws with a -rings securing the cylindcr head; then scparatc rrom the cylindcrs. Account ror the a -rings. 13. Rcmove the oil-injection hose rrom each cylinder and the crankcase nozzle. 16. Using the Piston Pin Pullcr (pin 0644-328), remove the pi ston pins rrom both pistons.
CAUTION
00 NOT use any type of punch to drive the piston pin free of the piston; damage may result. Use a piston-pin puller only.
17. Lin thc pi stons clear or the connecting rods and remove the small-cnd connecting-rod bearings (account ror two washers); then removc the pi ston rings. Keep each piston with its rings; keep each piston pin and bearing together as a set.
249
24. Separate the crankcase hal ves by installing two crankcase cap screws in opposite corners leaving the heads approximately 6 mm (1 /4 10. ) a lit. Using a plastic-tipped hammer, tap on each cap screw head until the case hal ves separate. Remove the cap screws.
CAUTION
DO NOT drive any tool between halves to separate the crankcase. Damage to the sealing surfaces will result.
NOTE: Place rubber bands over the connecting rods and around the cylinder studs. This will prevent the connecting rods from damaging the crankcase.
18. Remove the intake Oanges and reed valve assemblies.
25. Lift the oottom half of the crankcase off the top half
A CAUTION
Care must be taken to not allow the connecting rods to drop onto the sealing surface of the bottom case half.
19. Remove either lower union cap screw securing the lower check valve assembly; then remove the two screws, lock washers. and washers securing the oi l-injection pump to the crankcase. Remove the pump, retainer, and a -ring. 20. Remove the fi ve screws securing the water pllmp cover to the crankcase and remove the cover. Account for the O-ring gasket. 21. Remo\'e the cap screw securing the water pump impeller; then slide the impeller free of the shaft. 22. Remove the ca p screws sec uring the prO-end plal"e to the crankcase; then remove the plate. 23. Position the crankcase, with its oottom side lip, on two bloc ks of wood. Remove the cap screws securing the crankcase hal ves.
26. Lift the crankshaft free from the lOp half of the cran kcase and slide the crankshaft oi l seals off the crank... haft. Account for the C-ring. Remove the bearing reta ining pins and account for the cran kcase dowel pins. 27. Remove the oil -injection pump/water pump dri veshaft from the lower crankcase half. Account for the Ihrust washer on the ollter end of the shaft.
2-50
Page : 62
NOTE: Do not replace the inner seals unless the water pump shows signs of leaking coolant out of the small bleed hole in the bottom half of the crankcase. If a water pump seal is to be replaced, use the Water Pump Bearing and Seal Kit (pIn 0644084).
(900 cc Models)
I. Using a spanne r wre nch to sec ure the fl yw heel,
28. Place the c rankcase on the bench with the watcr pump side down. Using the long seal dri ver, dri ve the mechanical water pump seal from the crankcase.
remove the fl yw heel cap screw, lock washer, and nat washe r.
29. Using a pilir of snap ring pliers, remo\'e the snap ring securing the inner seal in the crankcase. 30. Using the hooked end of the tool, pull the inner seal free of the crankcase.
2. Using a spanner wrench to secure the crankshaft , remove the three cap screws from the starter pulley. Remove the starter pulley.
3. Install the Ryw hecl Puller Insel1 (pIn 0644- 179) inlo the end of the c rankshaft.
3 1. Using the hookcd end of the 1 001, pry the seal ring
from the backside of the watcr pump impell er.
Page : 63
251
,&, CAUTION
To prevent damage to the crankshaft, place a puller insert into the crankshaft. The puller must bottom on the insert and not on the crankshaft. Also, do not thread puller bolts more then 12.7 mm (112 in.) into the flywheel. Damage to the coils may result.
4. Using Flyw heel Pull er (pin 0144-310), remove the fl ywheel from the crankshaft by tightening the puller bolt, striking the head of the puller bolt with 11 brass hammer, and tightening again. Repeat procedure until the fl yw heel is free. Account for
the key in the crankshaft keyway.
6. Rcmove the cap screws sec uring the stator.
,&, CAUTION
When installing Flywheel Puller (pin 0144310), it must be installed with its welded side facing
outward or the puller will be damaged.
7. Rcmovc the rubber grommet from the stator wiring harness. Slide the stator free o f the crankshaft and remove.
AJ015
,&, CAUTION
Before applying excessive pressure to the center flywheel puller bolt, check to make sure puller bolt is pulling straight. If it is pulling to one side, the crankshaft will be damaged. Square the puller using the three bolts that attach the puller to the flywheel . NOTE: To ensure the cleanliness of the flywheel magnets, place the flywheel (with the magnets fac ing upward) on a clean bench.
5. Rcmo\'e thc two screws securing the timing sensor; then loosen the sc rews securing the wiring harness retainer tab. Remove the liming sensor from the crankcase.
8. Remove the cap screws securing the stator backing plate. Remove the plate from the crankcase.
9. Remove the nuts securing the APV covers to the cylinders; then slide the covers back to expose the valves.
2-52
Page : 64
2005 Arctic Cat Service Manual all models www. ReadManuals.com
10. Remove the cap screws securing the val ves to the cylinders; then remove the APV assemblies and set them aside.
NOTE: The following two photographs are for clarity purposes only. These models may vary slightly.
13. Removc the spark plugs. 14. Remo\'e the cap screws and O-rings securing each head; then sepmHte each head from each cylinder. Account for two O-rings beneath each head .
_NOTE : Mark each cylinder head, cylinder, and piston and keep together as an assembly, Mark the MAG cylinder components #1 and the PTO cylinder components #2
NOTE: If servicing the intake flanges, remove them at this time.
15. Remove the four cylinder base nuts and four nange cap screws securing the cylinders to the crankcase. Account for four nat washers and lock washers. Using a rubber hammer, gentl y tap on the side of each cylinder to free it from the crankcase.
II. Remove the three cap screws securing the thermostat cap; then remove cap, rubber gasket, and thermostat. 12. Remove the cap screws securing the thermostat manifold to the cylinder heads. Remove the manifold and di scard the gaskets.
Page : 65
253
16. Slowly lift each cylinder strai ght lip and free of the studs. Grasp the connecting rocl and pi ston as the cylinder clears the piston to prevent the rocl from dropping against the crankcase. Remove and save the cylinder base gaskets.
A CAUTION
00 NOT use any type of punch to drive the pin free of the piston; damage may result. Use a piston-pin puller only.
19. Lift the pi stons clear of the connecting rocls and account for two washers. Remove the small -end connecting-rocl bearings; then remove the piston rings. Keep each piston with its rings; keep each piston. pin, and bearing together as a set.
APl 38
17. Remove the pr O-side pi ston-pin cirelip from the prO-side piston; remove the MAG -side piston-pin circlip from the MAG-side piston.
20 Remove the four ca p screws securing the PTO-end plate to the crankcase; then remove the plate.
18. Using the Pi ston Pin Puller (pIn 0644-328), remove the pi ston pins from both pistolls.
AP142
2 \. Remove the intake manifold and reed block assemblies. 22. Remo\'e either lower union bolt securing the lower check valve assembl y; then remove the two cap screws securing the oil -injection pump to the crankcase. Remove the pump, retainer, and two 0 nngs .
2-54
Page : 66
25. Separate the crankcase Iml ves by installing two crankcase cap screws in opposite corners leaving the heads approximately 6 mm (1 /4 in.) Ollt. Using a plastic tipped hammer, tap on each cap screw head until the case hal ves separate; then remove the two cap screws. Lift the top half of the crankcase orr the bottom hair. Grasp the connecting rods as the top half or the crankcase is removed. Do not allow them to drop onto the sC<lling surrace of the bottom case hair.
&, CAUTION
23. Remove the six cap screws securing the water pump cover to the crankcase. Remove the cover and O-ring seal. Account ror two dowel pins.
26. Lift the crankshaft rree rrom the crankcase half and slide the crankshaft oil seals off the ends of the crankshafl. Account ror the C-ring. Slide the bearings ofr the crankshafl. Remove and account for the fo ur bearing retaining pins and the two crankcase dowel pins from the crankcase .
NOTE: 00 not remove the water pump impeller or the impeller shaft unless necessary. Only remove impeller and shaft if there are signs of coolant leakage from the small hole located in the bottom of the crankcase directly behind the water pump housing.
KEY
A. 011 Seal
24. I....a y the engi.lle on it s side and remove the cap screws secunng the crankcase halves. Note the position of the different-sizes cap screws for assembling.
B. Bearing C. CoRing
D. Bearing Retaining Pin E. Dowel Pins
AP148A
&, CAUTION
00 NOT remove the water pump impeller or shaft unless necessary. The shaft and impeller should only be removed from the lower crankcase half when there is a coolant leakage problem or a rough inner bearing. To inspect for either condition, follow steps A through O.
A. Remove the O-ring from the oil-injection pump retainer. Slide the retainer into position on the shaft in the lower hair of the crankcase.
B. While holding the retainer ti ght against the
crankcase, rotate the shaft. Bearing rotation must feel smooth.
Page : 67
255
C. If any roughness is feit , remove the retainer and
inspect its bearing by turning it several revolutions. If it is smooth, the shaft must then be re moved and the inner bearing inspected. Turn inner bearing by hand. If any roughness is felt , replace the inner bearing. O. C heck the bottom of the water pump housing for any signs of coolant Ie.:'lkage. The small hole, located on the bottom of the crankcase directly behind the water pump housing, will show coolant stains If the seal has any leakage problems. If stains or any signs of leal-cage are present , remove impe lle r and shaft and re place seals.
28. Remove the oil injection pump/water pump dri veshaft from the lower crankcase half. Account for the thrust washer on the outer end of the shaft.
NOTE: Do not replace the inner seals unless the water pump shows signs of leaking coolant out of the small bleed hole in the bottom half of the crankcase. If a water pump seal is to be replaced, use the Water Pump Bearing and Seal Kit (pIn 0644-084).
29. Place the c rankcase on the bench with the water pump side down. Using the long seal dri ver, dri ve the mechanical water pump seal from the crankcase .
NOTE: For instructions on bearing and seal replacement, see the appropriate Assembling Engine subsection of this manual. Complete steps 2732 only if there is a bad seal or shaft bearing.
27. Remove the ca p screw securing the impeller to the shaft.
30. Using a I)';'li r of snap ring pliers, remove the snap ring securing the inner seal in the crankcase. 3 1. Using the hooked e nd of the tool, pull the inner seal free of the crankcase.
2-56
Page : 68 2005 Arctic Cat Service Manual all models www.ReadManuals.com
32. Using the hooked end of the tool , pry the seal ring f rom the backside o f the water pump impeller.
2. Install Rywheel Pulley Inselt (pIn 0644- 179) onto the end of the crankshaft.
(500/600/700 cc "Laydown" Engine Models)
Using the spanner wrench to secure the Oyw heel, remove the Oyw heel nut , lock washer, and Oat washer; then remove the three starter pulley cap screws and remove the pulley.
3. Using Fl ywheel Puller/Spanner Wrench (pIn 0 1443 10) or suitable substitute, remove the Oywheel from the crankshaft by tightening the pull er bolt, striking the head of the puller bolt with a hammer, and tightening again. Repeat this procedure until the Oyw heel is free. Account for the key.
L1:.
CAUTION
To prevent damage to the crankshaft, the puller must bottom on the insert and not on the crankshaft. Also, do not thread puller bolts more than 12.7 mm (1/2 in.) into the flywheel. Oamage to the coils may result,
NOTE: To ensure the cleanliness of the flywheel magnets, place the flywheel (with the magnets facing upward) on a clean bench.
Page : 69 2005 Arctic Cat Service Manual - all models - www. ReadManuals.com
257
4. Remove the ignition timing sensor.
7. Remove the stator plate from the engine. 5. Remo\'e the Allen -head ca p screws securing the stator to thc stator pl ate. lvlove the stator to the side to access the Phillips-head cap sc rew securing the stator lead wire; then remove the ca p screw.
6. On the 600/700 cc, remove the Allen-head cap screws securing the magneto case to the crankcasc. Account for fo ur ali gnment pins .
NOTE: Note the different-sized cap screws for assembling purposes.
NOTE: The stator plate screws had leetite applied to the threads during assembly. Using an impact driver, apply a sharp blow to the head of each screw to break the Loctite loose before removal.
8. Remove the cap screws securing the APV assemblies to the cylinders; then remove the APV assemblies and set them aside.
NOTE: Note that the APV exhaust valves and gaskets are directional for assembling purposes. NOTE: The following photographs are for clarity purposes only. The models may vary slightly.
2-58
Page : 70
NOTE: When removing the cylinders, place the engine on its intake flanges on a drain tray to allow residual coolant to drain from the cylinder/crankcase water jacket. 12. On the 500 cc , removc the eight nuts securing the
cylinders to the crankcase; thcn using a rubber hammer, gentl y tap the cylinders and rcmove from the crankcase by lifting them straight lip oil their studs. Account for gaskct(s) and any ali gnment pins. 13. On the 6001700 cc, remove the four nuts and four bolts sccuring the cylinders to the crankcase; then using a rubber hammer, gcntl y tap thc cylinders and remove from thc crankcasc by lifting them strai ght up off their studs. Account for gaskct(s) and any ali gnment pins.
FC024
&
CAUTION
When removing a cylinder, be sure to support the piston to prevent damage to the crankcase and piston.
9. Remove the sp,, 1rk plugs.

10. Rcmove the cap screws with O-rings securing the
cylinder hcad: the n scparate from the cylindcrs. Account for the O-rings. II. Rcmove the oil-injcction hosc from cach cylinder and the crankcase nozzle.
Page : 71
259
16. Lift the pi stons clear of the connecting roos and remove the small-e nd connecting-roo bearings (account for two washers); then re move the piston rings. Keep each piston with its rings; keep each piston pin and bearing together as a scI.
14. Remove the PTa-side piston-pin circlip from the PTa -side pi ston; then remove the MAG -side piston-pin circlip from the ~vI AG - s ide pi ston.
NOTE: Place rubber bands over the connecting rods and around the cylinder studs. This will prevent the connecting rods from damaging the crankcase.
17. Re move the int."lke nanges and reed valve assemblies.
15. Using Piston Pin Puller (pin 0644-328), remove the piston pins from both pistons.
FC030
18. Re move the three cap screws securing the thermostat cap: then remove the Ct.'!P, gasket, and thermostat.
,1; CAUTION
00 NOT use any type of punch to drive the piston pin free of the piston; damage may result. Use a piston-pin puller only.
2-60
Page : 72
19. Remove the six screw s sec uring the water pump cover to the crankcase and remove the cover. Account for the O-ring gasket and the alignment pins. 20. Remove the cap screw securing the water pump impell er; then slide the impcller free of the shaft. 2 J. Remove either lower union cap screw securing the lower check vah'c asscmbly; thcn rcmove the two screws securing the oil -injection pump to the crankcase. Remove the pump, retmner, and O-ring.
25. Lift the bottom half of the crankcase off the top half.
L!'. CAUTION
Care must be taken to not allow the connecting rods to drop onto the sealing surface of the bottom case half.
22. Turn the engine upsidc down on support blocks and remove thc water tempcrature sensor switch.
26. Lift the crankshaft free from the top half of the crankcase and slide the crankshaft oil seals off the crankshaft. Account for the Coring. Remove the bearing reta ining pins and account for the crankcase dowel pi ns.
NOTE: On the 6oonoa CC, account for the rubber spacer on the PTO-end of the crankshaft.
27. Remove the oil-injection pump/water pump driveshaft from the lower crankcase half. Account for the thrust washer on the outer end of the shaft.
23. With its bottom side up on two support blocks, remove the cap screws sec uring the crankcase halves .
NOTE: The end bearings are not pressed onto the crankshaft.
24. Separate the crankcase halves by installing two crankcase cap sc rews in OPIXlsile corners leaving the heads approximately 6 mm ( 114 in .) out. Using a plastic-tipped hammer, tap on each ca p screw head unti l the case halves separate. Remove the cap screws.
NOTE: Do not replace the inner seals unless the water pump shows signs of leaking coolant out of the small bleed hole in the bottom half of the crankcase. If a water pump seal is to be replaced, use the Water Pump Beari ng and Seal Kit (pIn 0644-084).
L!'. CAUTION
28. Place thc crankcase on the bench with the water pump side down. Using the long seal dri ver, dri ve thc mechanical water pump seal from the crankcase.
Page : 73
2-61
Servicing Top-Side Components

(500/600/700 cc "Laydown" Engine Models)
Many services can be performed without removing the engine. Some component s ma y vary fro m model 10 model. The technician should lise discretion and sound judgment when remov ing and installing components .
NOTE: Some photographs used in this sub-section are used for clarity purposes only and are not designed to depict actual conditions.
29. Using a pair of snap ring pliers, remove the snap
ring securing the inner seal in the crankcasc.

30. Using the hooked end of the tool , pull the inner
REMOVING TOP.SIDE COMPONENTS

To access top-side components, use the following procedure:
I . Remove the ex pansion chamber and resonator.
2. Using the drain hose, drain the engine coolant out
sea l free of the crankcase.
the exhaust outlet in the belly pan. 3. Rcmove the four torx-head screws and the three cap nuts securing the side-plate brace to the chassis; then remove the exhaust manifold.
3 1. Using the hooked end of the tool, pry the seal ring
from the backside of the water pump impeller.
4. Removc the coolant hose and breather hose
connected to the cylinder hc. .'d.

5. Remove the twelve 10 mm cap screws and two 8
mill
cap screws securing the cylinder head ; then remove lhe cylinder head. Account for lhe 0 nngs.
2-62
Page : 74
FCOS8
6. Remove the APV's from the cylinder.
b. In turn on each fittin g of the crankcase, run the vacuum pump to purge the cylinder/crankcase water jacket of the residual coolant.
7. Di sconnect the two coolant hoses located beneath the exhaust PC)liS on the cylinders.
NOTE: It is critical that all residual coolant is totally removed from the cylinder/crankcase.
9. On the left -side of the engine. loosen the side brace and move it tip out of the way.
NOTE: At this point, remove all loose hardware to avoid any falling down into the chassis.
8. Remove the rcsidu..'l1 coolant from the cylinder! crankcase water jacket.
NOTE: After draining the coolant, approximately 1.75 fluid oz of coolant will remain on both the MAGside and PTOside. To remove the residual coolant, use the following procedure. NOTE: It may be advisable to secure the brace up out of the way with a strap. _NOTE : At this point, remove all loose hardware to avoid any falling down into the chassis.
a. Using Vacuum Pump (pin 0644- 13 1), or a suitable substitute, rig the pump to 3/16 in. outside diameter hose ,
Page : 75
2-63
10. Removc the nuts (.500 cc) or the cap screws and nul" (6001700 cc) securing the cylinders to the crankcase; then using a rubber hammer, gentl y tap the cylinders and rcmovc from the crankcase by lifting them straight up off their studs. Account for gaskct(s) and any alignment pins.
INSTALLING TOP.SIDE COMPONENTS

NOTE: Critical torque specifications are located in the Assembly Schematics sub-section of this section. NOTE: When installing the pistons, make sure to install the MAG-side piston-pin circlips first; then install the pistons and secure with the piston pin and PTO-side piston-pin circlips.
I. Place the cylinders into position on the crankcase accounting for gaskct(s) and any alignment pins.
NOTE: If servicing the MAG-side only, the PTOside cylinder must be removed.
NOTE: When removing the MAG-side piston, the piston must be at top-dead-center.
2. Sec ure thc cylinders with existing hardware I"ightcned to specifications using thc appropriate pattern show n.
~ ~
NOTE: For servicing procedures, see Cleaning and Inspecting Engine and Measuring Critical Components in this section.
0A
0738206
2-64
Page : 76
0738-220
3. O n the left -side of the engine, place the side brace into position and sec ure it with ex isting hardware.
6. Place the cylinder head mto positio n on the

cylinders making sure the O-rings are properly
posit ioned; then o n the 500 cc ill two ste ps, tighten the 6 nlln cap screws to specifi catio ns and o n all model s in two steps, tighten the 8 mm cap screws to specifi cations using the appropriate patte rn
shown.
@
@
@ @
0
<D
<D
<D
0
<D
4. Connect the two coolant hoses on the cylinders
beneath the exhaust p0i1S.
0738-204
o
(j) (j)
o
0738-205
5. Install the APV's on10 the cylinder and secure with existing hardware.
,&, CAUTION
The long side of the exhaust valve must be facing toward the cylinder head or severe engine damage may occur.
7. Install the coolant hose and breather hose onto the cylinde r head. 8. Install the ex haust manifold. Ti ghte n existing hard ware to specifications.
Page : 77
2-65
9. Install the expansion chamber and resonator using exi sting hard\\'are. 10. Install the side-plate brace and secure with ex isting hardware. II . Fill the cooling system with recommended coolant (see Liquid Cooling Syste m in Section 3).
& CAUTION
Water or parts-cleaning solvent must be used in conjunction with the wet-or-dry sandpaper or damage to the sealing surface may result.
CYLINDER HEAD (500/600/700 eel

I. Using a non-metallic carbon removal 1 001, remove any carbon buildup from the combustion chambers being careful not to nick, scrape, or damage the combustion chambers or the sealing surfaces . 2. Inspect the spark-plug holes for any damaged threads. Rqmir damaged threads using a heli-coil insert . 3. Inspect the cylinde r head for Oatness using a straightedge and a feele r ga uge. Acceptable wal"("k1.ge must not exceed 0.05 mm (OJx)2 in.).
NOTE: If the warpage exceeds specification, resurface the cylinder head using procedures identified in step 6 in the Crankcase sub-section of Cleaning and Inspecting Engine.
Cleaning and Inspecting Engine

NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary.
CYLINDER HEADS
I. Usim! a non-metallic carbon re mova l tool, remove any carbon buildup from the combustion chambers being careful not to nick, scrape, or damage the combustion cham bers or the sealing surfaces. 2. Inspect the spark-plug holes for any damaged threads. Repair damaged threads using a heli-coil insert. 3. Place the cylinde r heads on a Surface Plate (pIn 0644-0 16) covered with #400 grit wet-or-dry sandpaper. Using light pressure, move each cylinde r head in a fi gure eight motion. Inspect the scaling surface for any indication of hi gh spots. A hi gh slX)t can be noted by a bri ght metallic fini sh. Correct any hi gh slX)ts before assembly by continuing to move the cylinder head ill a figure eight motion until a uniform bright metallic fini sh is attained.
&
CAUTION
Water or parts-cleaning solvent must be used in conjunction with the wet-or-dry sandpaper or damage to the sealing surface may result.
CYLINDERS
I. Using a non-metallic carbon removal 1 001, remove carbon buildup from the exhaust p0i1S.
2-66
2. Wash the cylinders !O parts-cleaning solvenl.

3 . Inspect the cylinders for pilling, scoring, scuffing,
3. Inspect each pi sto n fo r cracks in the pi sto n pin and skirt areas.
4. Inspect each pi sto n fo r seiZ .ure marks or sc uffing. Re pair with #400 grit wet-or-dry sa ndpaper and
and corrosion. If marks are found, repair the s ~lIface with an appropriate ball ho ne and honing 011 (see ch;:lIl).
water or honing oil.
BALL HONES
Engine Size 370 cc 440/500 cc 550/570/600 cc "Laydown" 600 STDf700 cc 900 cc
pin 0644-290 0644-291 0644-292

0644-293 0644-294
NOTE: To produce the proper 60 crosshatch pattern, use a low RPM drill (600 RPM) at the rate of 30 strokes per minute. If honing oil is not available, use a lightweight, petroleum-based oil. Thoroughly clean the cylinders after honing using detergent soap and hot water and dry with compressed air; then immediately apply oil to the cylinder bores. If a bore is severely damaged or gouged, the cylinder will have to be replaced.
NOTE: If scuffing or seizure marks are too deep to correct with the sandpaper, it will be necessary to replace the piston.
5. Inspect the pe rimeter of each piston fo r signs of excessive " blow by." Excessive " blowby" indicates worn piston rings o r an o ut-of-ro und cylinder.
CRANKCASE
4. Place the head surface of C<lCh cylinder on the surface plate covered with 11400 grit wet-or-dry sandpaper. Using light press ure, move each cylinde r in a fi gure e ight motion. Inspect the surface for any indicatio n of hi gh spo ts. A high spo t can be noted by a bright metallic fini sh. Correct any high spots before assembly by continuing to move the cylinder in a fi gure eight motio n un!'il a unifo rm bri ght mehll1ic fini sh is attained.
i . Wash the crankcase hal ves in palls-cleaning
solvenl.
NOTE: Before washing the crankcase halves, make sure the four bearing dowel pins have been removed and accounted for.
2. Inspect the crankcase halves for scoring. pining, scuffing, o r any imperfections in the casting. 3. Inspect all threaded areas fo r damaged o r stripped threads. 4. Inspect the bearing areas for cracks o r excessive bearing movement. If ev ide nce of excessive bearing move ment is noted, repair by peening the bearing area in a pinking (sawtooth) patle rn .
5. Inspect the bearing dowel pins fo r wear
,&, CAUTION
Water or parts-cleaning solvent must be used in conjunction with the wet-or-dry sandpaper or damage to the sealing surface may result,
PISTON ASSEMBLY
I. Using a non-metalli c carbon removal tool. remove the carbon buildup from the dome of each pi ston. 2. Take an old piston ring and snap it into two pieces: then grind the end of the o ld ring to a 45 angle and to a sharp cdge. Using the sharpc ned ring as a tool, clean carbon fro m the ring-grooves. Be sure to position the ring with its tapered side up.
,&, CAUTION
improper cleaning of the ring-grooves by the use of the wrong type of ring-groove cleaner will result in severe damage to the piston.
6. Inspect the sealing surfaces of the crankcase hal ves for trueness by placing each crankcase half o n the surface plate covered with #400 grit wet-ordry sandpape r, Using light pressure, move each half in a fi gure e ight motion. Inspect the sealing surfaces fo r any indication of hi gh spots. A high SIX'l t can be noted by a bri ght metallic fini sh. Correct any high slX)ts by continuing to move the half in a fi gure e ight motio n until a uniform bright metallic fini sh is attained.
Page : 79
2-67
_NOTE : Care must be taken not to remove an excessive amount of aluminum, or the crankcase will have to be replaced . If excessive aluminum is removed , too much pre-load will be exerted on the crankshaft bearings when assembled.
CRANKSHAFT
I. Wash the crankshaft with bearings in pat1 scl eaning solvent.
&
CAUTION
Water or partscleaning solvent must be used in conjunction with the wet-or-dry sandpaper or damage to the sealing surface may result.
2. Inspect the bearings for wear, scoring, sc uffing, damage, or discoloration. Rotate the bearings. Bearings must rotate freely and must not bind or fee l rough. If any abnormal condition is noted, replace the bearing.
INTAKE MANIFOLD
INSULATORS (Single Carburetor)!
ADAPTER PLATES (Twin

Carburetors) NOTE: For fan cooled models only.
I. Inspect for cracks, scoring, pitting, imperfections,
or warping. 2. Inspect the scaling surfaces for trueness by placing each 0 11 the surface plate covered with #400 grit wet-or-dry sa ndpaper. Using light pressure, move both sides in a fi gure eight motion. Inspect the scaling surface for any indication of hi gh spots or warping. Correct hi gh spots by continuing to move each side in a fi gure eight motion. Warped compo nents must be replaced.
NOTE: On the twin carburetor model in order to inspect adapter plate trueness, it will be necessary to remove the studs.
3. Inspect the connecting-rod bearings by rotating them. The bearings must rotate freely and must not bind or fee l rough. If a connecting-roo bearing must be replaced, the connecting roo and crank pin must also be replaced .
&
CAUTION
Water or parts-cleaning solvent must be used in conjunction with the wet-or-dry sandpaper or damage to the sealing surfaces may result.
4. Inspect the oil-injection pump dri ve gear for any signs of worn or chipped teeth. If either condition exists, re place the gear.
2-68
NOTE: Lubricate bearings thoroughly prior to assembly.
REMOVING OUTER CRANKSHAFT BEARINGS
NOTE: Steps 13 are for removing the MAG-side bearing.
I. Place a bearing support (block of wood, etc .) beneath the MAG -side bearing.
Lb. CAUTION
A bearing support must be positioned beneath the bearing that is being removed to prevent crankshaft damage.
2 . Drive a chisel or bearing splitte r between the
NOTE: On certain models, the end bearings are not pressed onto the crankshaft, The bearings can be removed simply by sliding them off the crank shaft.
5. Inspect the crankshaft bc<lring area for wear. If any wear is noted on either end, replace the crankshaft end.
INSTALLING OUTER CRANKSHAFT BEARINGS
_NOTE : On certain models, steps 13 are for installing the MAG-side bearing.
I. Wra p a thi ck towel around the cranksha ft ; then
bearing race and crankshaft counterweight until the bearing is spread far enough to mstall the ja ws of the crankshaft bearing remover.
3. Place the protective cap on the crankshaft e nd; then using the Crankshaft Bearing Remover (pIn 0 144-302), remove the bearing from the end of the crankshaft. Account for any shim(s). Note the position of the dowel pin hole.
secure the crankshaft vel1icall y in a vise.

2. Heat the bearing e ither by placing the entire
bearing in a pan of oil on a hot plate or by squilting oil into the bearing and using a propane torch to heal Ihe inner race of the beari ng until a slight smoke is noted comi ng from the beari ng.
Lb. CAUTION
DO NOT overheat the bearing.
3. Place any shims re moved during di sassembly onto
the crankshaft : then slide the bearing onto the crankshaft making sure the dowel-pin hole in the oute r race is pro~rl y positioned and will align with its hole and pin in the crankcase.
4. O n cel1ain model s, the I:1fO-side bearing may be 4. O n certain models, slide the prO-side bearing
removed simpl y by sliding the bearing off the pro end.
onto the 1:1f0 end maki ng sure the dowel-pin hol e will ali gn with the hole and pin in the crankcase.
NOTE: On certain models, install the bearings by sliding each bearing onto the crankshaft making sure the dowel pin hole in the outer race is properly positioned and will align with its hole and pin in the crankcase.
Page : 81
2-69
4. Inspect the rced-to-seat clearance. Using a feeler gauge, measure the clearance. Clearance mllst be
less than 0.20 mm (0.008 in.). If clearance is not
within specificatio ns, replace the reed valve.
5. To assemble. place the reed valves 0 11 the cage with its cl ipped corner positioned to the lower ri ght ha nd corner of the cage. Place the reed stoppe r assembl y into lX)sitioll and secure with the Ihree screws coated with red Loctitc #27 \.
REED VALVE ASSEMBLY

L Inspect the reed valves, stoppers. and valve bl ocks for cracks or any dete riorati on.
Measuring Critical Components

AOO46
2. Wash the reed va lves, stopper, and cage assembl y
NOTE: Critical engine component specifications can be found at the beginning of this sub-section.
in pmts-cleaning solvent and blow dry.
CYLINDER TRUENESS
3. Inspect the reed stopper height. Using a calipe r, TnC<lsurc the distance from the scat to the bottom o ul'e r tip edge of the stopper. Measurement must not exceed specifications. If measurement is not within specifications, either bend or replace the reed stoppe r.
\. tvleasure eaeh cylinder in the three locations from front to back and side to side for a lotal of six readings.
2. The trueness (out-of-roundness) is the difference between the highest and lowest reading. Maximum trueness (out-of-roundness) must not exceed speci fi cations.
2-70
Page : 82
0725586
PISTON SKIRT/CYLINDER CLEARANCE

I. Measure each cyli nder front to back about 25 cm ( I in.) fro m the bottom o f each cylinder. 2. i\lleasure the corresponding pi sto n s kirt diametcr at a point I c m (0.394 in.) above the piston skirt at a right angle to the pi ston-pin bore. S ubtract this measurement from the meas urement in step 1. The difference (clearance) must be wi thin specifications.
PISTON PIN AND PISTON.PIN BORE

I. Measure the piston pin diameter at each end and in the center. Acceptable pi sto n pin measurement must be within specificatio ns. If any measurement varies by more than 0.02 mm (0.00 1 Ill.), the piston pin and bearing must be replaced as a scI.
PISTON.RING END GAP

I. Place each pisto n ring in the wear portion above the e.'\haust port of its respective cylinder. Use the pi ston to position each ring squarely in each cylinde r. 2 . Using a feeler ga uge, measure each piston-ring end ga p. Acceptable ring end gap must be within specificatio ns.
2. Insert a snap gauge into each piston-pin bore; then remove the gauge and measure it with a micrometer. The diameter measurement must be within s pecifications. Take two measurements to ensure accuracy.
CONNECTING.ROD SMALL END BORE

I. Insclt a snap gauge into each connecti ng-rod small end bore: thcn rcmove the gauge and measure it with a micro meter.
Page : 83
5. If runout exceeds specifications at any of the checklXlints, the crankshaft mllst be either straightened or replaced.
Assembling Engine Table of Contents

370/440 cc Models ... ......................... ......... ........... 2-72
550 570 600 900 Model ................................................... 2-76 Models ....................................................... 2-82 Standard Engine Model ............................. 289 Models .......................... ......... ..... ............... 2-94 500/6001700 cc "Laydown" Engine Models .. ....... 2- 100 cc cc cc cc
2. The diamete r measurement must be wi thin specifications.

CRANKSHAFT RUNOUT
I Using the V Blocks (pIn 0644-022), Sllpport the cranksha ft on the surface plate .
NOTE: The V blocks should support the crank shaft on the outer bearings.
NOTE: Critical torque specifications are located in the Assembly Schematics sub-section of this section.
Assembling Engine
(370/440 cc Models)
2. Mount a dial indi cator and base on the surface plate. Position the indicator contact point against the crankshaft di stance F (p rO-end) from the crankshaft end. Zero the indi cator a nd rotate the crankshaft slow ly. Note the amount of crankshaft runout (total indicator readi ng) ,
NOTE: For runout distance specifications, see Engine Information sub-section.
NOTE: The use of new gaskets and seals is recommended when assembling the engine, NOTE: When the use of a lubricant is indicated, use Arctic Cat 50 :1 Injection Oil.
I. Install the C-ring and the five bearing retaining
3. Position the indicator contact point against the crankshaft distance D (MAG -end) from the crankshaft end. Zero the indicator a nd rotatc the crankshaft slow ly. Notc the amount of c rankshaft runout (total indicator reading).
pins into the lower crankcase half. 2. Lubricate the inner lips of the crankshaft oil seals with grease; then slide the seals onto the crankshaft maki ng sllre the spring side of each seal faccs the center of the crankshaft.
4, Position the indicator contact point against the cranksha ft at IXlint E (center). Zero the indicator and rotate the crankshaft slowl y. Notc the amount of crankshaft runout (toL.11 indicator reading).
3. Apply oi l to the crankshaft bearings; then install the dowel pins, C-ring, and crankshalt into the lower crankcase half. Be sure the alignment hole in each bearing is lXlsitioned over its respecti ve bearing retaining pin in the crankcase; then seat the crankshaft.
2-72
Page : 84
6, Install the crankcase cap screws making sure the ca p screws are III the correspo nding-sized holes. Tighten in three steps the 8 mm cap screws to specifications and the 6 mm cap screws to specifications lIsing the pattern shown.
13
NOTE: Make sure the crankshaft center seal is properly positioned in the groove of the lower crankcase half.
5
NOTE: To check the bearing for proper position, place the point of a sharp tool into the dimple found in the bearing race. Strike the tool with the palm of the hand in either direction. If the bearing moves, it isn't positioned correctly and must be rotated until it drops onto the dowel pin.
0726-41 2
NOTE: Secure the connecting rods with rubber bands on the cylinder studs.
Lb. CAUTION
If the bearings are not properly seated during
assembly, the crankcase halves will not seal tightly and engine damage will result.
4, Apply a thin coat of Three Bond Scalant (pin 0636-070) to the crankcase sealing surfaces. 5, Assemble the crankcase hal ves making surc the cran kcase dowel pillS arc properly positioned and the end seal tab wi ll not block the oil transfer port in the upper crankcase halr. 7. Install the piston rings on each pi ston so the letter on the top (i nclined surface) of each ring faces the dome of the pi ston.
726-306A
Page : 85
12. Rotate each piston ring until the ring ends are
properly positioned o n each side or the ring keeper; then apply oi l to the piston assemblies and cylinder bores. Remove the rubber bands rrom the connecting rods.
,&, CAUTION
Incorrect installation of the piston rings will result in engine damage.
7263066
8. A ppl y
oil to the connecting-rod small-end bearings; then install the small-end bearings into the connecting rods.
NOTE: Apply a generous amount of oil to the surfaces of the pistons, rings, and cylinder bores. NOTE: Inspect the cylinderbase gasket to ensure proper positioning .
13. For e.:1c h piston , place a piston ho lder (or suitable
_NOTE : Apply oil to the piston pin before install ing.
9. Place each piston over the connecting roo so the

arrow on the pi ston dome points toward the
exhaust P0l1 ; then secure wi th a pi stoll pin.

NOTE: The arrow is found either up inside the piston or on the dome top.
substitute) beneath the piston skil1 and square the piston in rcspectto lhe c rankcase; then using a ring compressor or the ringers, compress the rings and slide the cylinder over the pi ston. Remove the piston ho lde r and seat the cyli nder firml y onto the crankcase.
10. Install the new circlips so the ope n end is directed

either down or up.
14. Place eac h cylinder he.:1d with dowel pillS and
,&, CAUTION
Make sure circlips are firmly seated and the open end is directed either down or up before continuing with assembly.
gasket into position and install the eight nuts. DO NOT TIGHTEN AT THI S T IME.
15. Temporarily install the exhaust maniro ld and secure with four nuts and lock washers to square the cylinde rs. Tighten the manifo ld nuts to specificatio ns.
16. With the exhaust manifold in place, tighten the cylinder head nuts (from step 14) in three steps to
11 . Inslall the cylinder base gaskets o nto the c rankcase making sure each gasket ali gns with crankcase transrer passages_
specifications using the pattern shown.
Page : 86
20. Place the ran case into positio n and secure with rour nuts. Tighten the nuts to specifications.
0
@
0 0
@
0
0
0725-318
17. In order, install the gear, shim , gasket, ret.'line r, gasket, and oil-injection pump. Secure with two screws, lock washers. and washers. Tighten to specifications.
21. O n the 370 cc, apply a thin CO<lt or High-Te mp Sealant (pIn 0636-069) to both sides or the intake gaskets; then In order, install a gasket (one on each p0l1), shroud, gasket (one on each po rt), insulator (one on each POlt), gasket (one o n eac h POlt), and intake manirold with Oange. Secure with nuts (threads coated with red Loctite #27 1). Tighten nuts in three steps to specificalions. l t or High-Temp 22. O n the 440 cc, appl y a thin Co.. Sealant (pIn 0636-069) to both sides or the intake gaskets and the rront side or each adapter plate; then in order, install a gasket (one on each port), shroud , gasket (one o n each port), and adapter plate (one o n each po rt). Secure with screws coated with red Loctite 1127 1.
&
CAUTION
Be sure the gear is properly aligned with the slot of the oil-injection pump shaft. The injection pump will be damaged if these two components are not aligned. NOTE: If removed, secure the ignition coil to the fan case.
23. Place the intake flan ges into position and sec ure with nuts (threads coated with red Loctite #271), lock washers, and washers. Tighte n to specifications. 24. Remove the exhaust manirold. 25. Install slxuk plugs and l; ghlc n to spec;[;caho ns . 26. Att:ach the o il-i njection hoses to their fittings. Secure with clamps.
27. Test the e ngine ror air leaks (see Section 3).
18. Align the reference marks made during di s.:'lssembly; then secure the stato r plate with Iwo Alle n-head cap screws (coated with red Loctile
#27 1), lock washers, and washers.
NOTE: Before installing the flywheel, wipe the crankshaft and flywheel taper clean using a clean cloth.
19. Install the key in the crankshaft and slide the n ywhccl o nlo the cranksha lt making sure the keyways match.
28. Temporarily secure the starter pulley o n the Oywheel with three cap screws. Install the Oywheel washer, lock washer, and nut. Apply red Loctite 1127 1 to the crankshaft threads berore installing the Oywhecl nul. Using a spanner wre nch to secure the crankslmft . tighten the fl ywheel nut to specifications.
Page : 87
29. Remove the stalter pulley. Position the fan belt dri ve pulley into the bell. Align the stalter pulley holes with those in the belt pulley. Stmt one of the cap screws into the Oyw heel, then rotate the belt pulley and starter pull ey in a counterclockwise direction. 30. Whe n the pulley pi vots on the ca p sc rew, rock the pulleys backward or forward until the remaining cap screw holes align. Install the remaining two cap screws and tighten evenl y to specifications.
NOTE: Apply red Loctite #271 to the threads of the cap screws before installing.
32. Apply a thin CUt'lt of High-Temp Sealant ( pIn 0636-069) to the exhaust-manifold gasket; then place a gasket on each ex haust port making sure the metal side of each gasket l~lCes away from the cylinder. Install the ex haust manifold, lock washers, and nuts and tighten to specifications.
Assembling Engine
(550 co Model)
NOTE: The use of new gaskets and seals is recommended when assembling the engine. NOTE: When the use of a lubricant is indicated, use Arctic Cat 50 :1 Injection Oil.
I. Using the water pllmp bearing and seal driver, position the inner water pump shaft seal onto the seal dri ver and gently tap the seal down into position.
NOTE: Apply grease to the lips of the inner seal before installation.
3 1. Place an ex haust manifold gasket on each exhaust pOit making sure the metal side of the gasket faces the cylinder. Slide the exhaust-side cooling shroud onto the exhaust p0i1 studs; then place the upper cooling shroud into position and secure the shrouds with 14 cap sc rews noti ng the location of the longer cap screws from di sassembling . Tighten to specifications. Connect the sj:mrk-plug caps.
NOTE: The seal must be installed with its spring side towards the crankshaft.
2. Using a small screwdriver. apply a thin coat of grease to the inner seal lips. 3. Using a pair of snap ring pliers, install the snap ring securing the ilmer seal in the crankcase.
2-76
4. Using the seal driver, carefull y instal! the outer water pump seal. GenUy tap the seal down into position until it seats itself against its Oange.
NOTE: There is a MAG-side seal and a PTO-side seal.
9. Apply oil to the crankshaft be.:'lI"ings; then insh'll! the crankshaft into the upper crankcase half. Be sure the alignment hole in each bearing is posi tioned o\'er its respecti ve dowel pin in the crankcase; then seat the crankshaft.
NOTE: To check the bearing for proper position, place the point of a sharp tool into the dimple found in the bearing race. Strike the tool with the palm of the hand in either direction. If the bearing moves, it isn 't positioned correctly and must be rotated until it drops onto the retaining pin.
A CAUTION
5. Apply a thin coot of grease to the sca ling surface of the oil-injection pump driveshaft ; then place the Oil Seal Installation Tool (pIn 0644-2 19) at the end of the shaft. Tw ist the dri veshaft clockwise as it is pushed through the oil and water pump seals; then remove the tool. Position the shim on the oil mjection pump end of the driveshaft.
If the bearings are not properly seated during assembly, the crankcase halves will not seal tightly and engine damage will result.
10. Position the two center seal rings with their end gaps ISO apart (up on one and down on the othe r).
A CAUTION
Be very careful not to damage the seals when installing the oil pump driveshaft. Be certain to use the seal installation tool. Twist the driveshaft clockwise as it enters the seal area and while it is being pushed through the seals.
6. Position the uppe r crankcase half upside-down on two woodell blocks; then install the C-ring, the four bc<lri ng retaining pins, and two crankcase dowel pins. 7. Place the PTO-side crankshaft bearing into position making sure the bearing retaining pin hol e is positioned inward.
NOTE: The bearing retaining pin hole is the hole that doesn't go entirely through the bearing case,
II. Apply a thin coat of High-Temp Sealant (pIn 0636-(69) to the entire bottom half of the crankcase sealing surface .
NOTE: Use only High-Temp Sealant (pin 0636069) to seal the crankcase halves.
8. Lubricate the inner lips of the cra nkshaft oi l seal s with grease; then slide the seals onto the crankshaft making sure the spring side of each seal faces the center of the crankshaft.
12. Assemble the crankcase halves making sure that the crankshaft gear and oil -injection pump driveshaft gears mesh. Rotate the crankshaft one full turn to align the crankshaft gear and pump driveshaft . 13. Install the 14 crankcase cap screws securing the crankcase hal ves making sure the cap screws arc in the proper-sized holes. Tighten in three steps the 8 mm cap screws to speci fi cations and the 6 mIU ca p screws to specifications using the pattern shown .
17. Using both thumbs, press the seal into position making sure its marked side is positioned towards the rubber seal cup. 18. Apply a thin coat of grease to the seal outer surface. 19. Place the impell er into IXlsition and secure with a cap sc rew and washer. Be sure the rubber side of the washer is directed toward the impeller. Apply blue Loctite 11242 to the threads of the cap screw and tighten to specifications.
&
o
CAUTION
The rubber side of the washer (which secures the impeller) must be positioned toward the impeller. If installed incorrectly, a coolant leak will result.
0728-' 37
14. Install the oil-i njection pump retai ner O-ring and retainer. 20. Appl y sealant to the crankcase seam ; then install the ali gnment pins into the crankcase.
15. Install the O-ring/gasket and the oil -injection pump maki ng sure the pump shaft and pump ali gn. Secure with two screws and washers. Tighten the two screws to speci fi cations.
&
CAUTION
NOTE: Sealant is only required on the crankcase seam.
Be sure the driveshaft is properly aligned with the slot of the oil-injection pump. The pump will be damaged if these two components are not aligned .
21. Position the O-ring into the water pump cover; then install the cover. Secure with fi ve screws. Tighten securely. 22. Place the cylinder base gaskets into position on the crankcase.
.NOTE: Be sure to spray a thin coat of Copper Coat Gasket Sealant (pin 0636-092) onto the gasket if it is being reused.
16. Position the rubber seal retai ner and seal into the back side of the water pump impeller.
NOTE: The lined or marked side of the porcelain seal must face the rubber retainer_
Page : 90
23. Install the piston rings on each pi ston so the leiter on the top (inclined surface) of each ring fac es the dome of the pi ston.
Lb. CAUTION
726306A
Lb. CAUTION
24. Appl y oil
Make sure the circlips are firmly seated and the open end is directed either up or down before continuing with assembly. 27. Rotate each piston ring until the ring ends are
to the connecting-rod small end bearings: then install the small-end bearings. Install a washer on each side of the connecLing
properl y positioned on either side of the ring keeper; then apply oil to the piston assemblies and cylinder bores. Remove the rubber bands from the connecting rods.
NOTE: If the intake flanges were removed from the cylinders , install them prior to installing the cylinders. Tighten the nuts to specifications. 28. In turn on each cylinder, place a pi ston holder (or
rod.
25. Place each piston over the connecting rod so the arrow on each pi ston will point toward the exhaust port ; then secure with an oiled piston pin.
NOTE: The arrow is found either up inside the piston or on the dome top.
suitable substitute) beneath the pi ston skirt and sqlk'lre the piston in respect to the crankcase: then using a ring compressor or the fingers, compress the rings and slide the cylinder over the piston. Remove the pi ston holder and seat the cylinder firml y onto the crankcase.
NOTE: The cylinders should slide on easily. DO NOT force the cylinders on.
26 . Install the circlips so the ope n end is directed
either up or down.
29. Secure each cylinder by installing the four nuts, washers, and lock washers. 00 NOT TIGIrrEN AT TI-II S T livlE.
30. Apply a thin CO'.lt of Hi gh-Temp Seal ant (pIn
0636069) to each ex haust port ; then install the two exhaust gaskets with the metal sides fa cing out.
3 1. Install the ex haust manifold and secure with fOllr nuts and lock washers. Tighten the four nuts to specifications.
34. Install the two cylinder O-rings on the top of each cylinder making sure they are correctly positioned in the grooves.
32. With the exhaust manifold tightened, sec ure the cylinders by ti ghtening the cylinder base nuts (from step 29) to specifications. Tighten the nuts in three steps using the 1 :k11tern shown.
0 0

725-318e
35. Place new O-rings onto each of the twelve head ca p screws. Place four of these cap screws into one of the cylinder heads. Thread the spark plug in p:1I1 way ; then whil e holding the head above the cylinder, carefull y start all fou r ca p sc rews while observing the cylinder a -rings to make sure they remain in position. Slow ly place the head into position on top of the a -rings. Start the remaining two cap screws being \'ery careful not to move the cylinder head. Repeat the same procedure on the remaining head. ONLY FI NG ER-TIGHTEN AT TI-II S TI ME. 36. Apply a thin coat of sealant to the two thermostat hOllsing gaskets. Place the gaskets and housing into position and sec ure with four cap screws and washers. Tighten the fo ur cap screws ill a cri sscross pattern to specifications.
NOTE: The thermostat housing cap screws must be tightened before tightening the cap screws securing the head. This will allow the gasket surfaces of the head to align with the housing and prevent any coolant leakage.
33. Install the two oi l-injection hoses and secure with the clamps.
2-80
Page : 92
37. Tighten the cap screws securing the head in three steps to specifications using the pattern show n. Pressure test the engine (see Section 3).
NOTE: Before installing the flywheel, be sure to wipe the crankshaft and flywheel tapers clean using a clean towel.
43. Install the key in the crankshaft and slide the tl ywheel onto the c rankshaft making sure the keyways match; then fin ger-tighten the tl ywheel nut with large nat washer and lock washer. Appl y red Loctite #27 1 to the threads of the tl yw hecl nul. 44. Install the stmter pulley; the n secure the starter pulley with three cap screws and lock washers. Secure the pulley while lIsing the spanner wrench and ti ghten the three cap screws evenl y to specifications.
0728-138
38. Place the thermostat , gasket, and cap into position. Secure the cap with three cap screws ti ghte ned to specifications. 39. Place the PrO-end plate into position on the crankcase; then a pply blue Loctite 11242 to the screws and l"i ghten securely. 40. Place the stator plate into position over the crankshaft e nd. 41. Install the lock washe rs and washe rs on the Allenhead cap sc rews; then apply blue LocLite #242 to the threads of the stator plate Allen-head cap screws and install. 00 NOT TIGHTEN AT T I-II S TI ME. 42. Ali gn the stator plale with the ali gmne nt mark made during disassembl y. Tighten both stator plate ca p screws (from step 4 1) securely. 45. Using the spanner wre nch, ti ghte n the tlyw heeJ nut to specifications.
46. Install the spark plugs and li ghten specifications. Connect the spmk plug caps.
to
281
47. Place the engine mounting brackets into position on the crankcase and secure with the cap screws. Tighten 10 specifications.
Assembling Engine
(570 cc Models) NOTE: The use of new gaskets and seals is recommended when assembling the engine, NOTE: When the use of a lubricant is indicated, use Arctic Cat 50 :1 Injection Oil.
I . Place the uPIx:r crankcase hair (with its bottom side lip) on two blocks or wood.
6. Install crankcase lower half. Install eight 8 mm and four G mm cap screws . Tighten in three steps the 8 mm ca p screws to slx:cifications and the 6
mill cap screws to slx:cificalions using the pattern showll.
&
CAUTION
To prevent damage to the crankshaft, crankshaft bearings, or seals, make sure to always lift the crankshaft from both ends.
9 1 312
2. Lightl y grease the inner lips of the crankshaft seals; then slide them onto the crankshaft. 3. Appl y oil to the crankshaft bea rin gs~ then install the cm nkshaft into the upper crankcase hair. Be slire the ali gnment hole in each bearing is positioned over its reslx:ctive dowel pin in the crankcase; then seat the crankshaft.
NOTE: To check the bearing for proper position, place the point of a sharp tool into the dimple found in the bearing race. Strike the tool with the palm of the hand in either direction. If the bearing moves, it isn't positioned correctly and must be rotated until it drops onto the dowel pin. NOTE: Make sure the crankshaft center C-ring (integral with the center seal) is properly positioned in the groove of the upper crankcase half.
8
11 4 210
737027A
&
CAUTION
If the bearings are not properly seated during
assembly, the crankcase halves will not seal tightly and severe engine damage will result.
4. Instalilhe four crankcase dowel pins. 5. Evenly appl y a thin coot or Three Bond Sealant (pin <Xl36-07O) to the e ntire bottom half cmnkcase sealing surrace.
NOTE: Use only Three Bond Sealant (pin 0636 070) to seal the crankcase halves.
NOTE: Check the reed valve on each cylinder for cracking or fraying around the edges. Make sure they are closing completely. NOTE: To inspect a reed valve assembly, remove the two Phillipshead screws securing the reed valve and reed valve stopper to the block ; then remove the reed valve and stopper.
2-82
Page : 94
& CAUTION
Incorrect installation of the piston rings will result in engine damage . NOTE: If the existing rings will not be replaced with new rings, note the location and top side of each ring for proper installation. When replacing with new rings, replace as a complete set only. When replacing rings note notches in ring ends which correspond with locating pins in ring grooves on intake side of the piston. This prevents the rings from turning on the piston when assem bled . NOTE: Apply blue Loctite #242 on the Phillips head screws when assembling . NOTE: Make sure the angled corner on the reed valve align with the angled corner on the reed valve stopper.
o o
&
CAUTION
u u
0
top
o
MOO""
~ /:
00 not overtighten the Phillipshead screws when installing the reed valves and reed valve stoppers. 7. Install the piston rings on each piston so the letter o n the lop (inclined surface) o f each ring face s the dome of the pi sto n.
726-306A
8. Lubricate the piston pin bearings and install them into the connecting rods_ 9. Install a piston pin bearing washer o n each side of the bearings with the o pen sides facing the bearings.
Page : 95
283
NOTE: The open sides of the piston pin bearing washers must face the bearing.
NOTE: Be sure to spray a thin coat of Copper Coat Gasket Sealant (pin 0636-092) onto the gasket if it is being reused.
A CAUTION
Make sure the circlips are firmly seated in their grooves and the open ends are pointed up or down before continuing with assembly.
12. Rotate each piston ring until the ring ends are properl y positioned with the pins in the ring grooves; then appl y oil to the piston assemblies and cylinder bores. Using a ring compressor or the fingers, compress the rings and slide the cylinder over the piston. Seat the cylinder firml y onto the crankcase. 10, Place pistons o\'er the con necting rods with the arrow (or indicator dot) IXlinting towa rd the ex haust IJOI1 ; then secure with an oi led piston pin. Install piston pin circlips with the open e nds up or down.
NOTE: The cylinders should slide on easily. DO NOT force them on.
13. Secure each cylinder by installing the four 6 mm and eight 8 mm nuts. Tighten the 8 mm nuts to specifications and the 6 mm nuts to specifications.
11. Place the cylinder txlse gasket into position on the crankcase maki ng sure the gasket is properl y oriented so the dowel pins will fit through the holes easil y.
2-84
Page : 96
15. Install the spark specifications.
plugs;
then
tighten
to
14. Install a new cylinder head gasket and the cylinder head; then install the eight Ct'lP screws and two nuts with washers. Tighte n in three steps to lltem shown. specificat ions using the p<
16. Position the seal retai ner plate on the PTO-side; then install the four cap screws. Tighte n the cap screws to specifications.
<D
@
@:
@
17. Install the stator plate and secure with four Alle nhead cap screws. Install the stator plate so the ignition wire cut-out is in the upper left position. Lightl y coat the four Allen-head cap screws with red Loctite #27 1; then tighten them to specifications.
073 8291
Page : 97
2-85
18. Place the slator wi nng through the hole in the crankcase; then install the stator. Lightly coat the three A li en-head cap screws with red Loctite #27 1; then ti ghtcn thcm to specifications.
20. Install the rubber insulator grom met into the crankcase.
2 1. Install the key; then install the n ywheel and cap screw. Tighten the cap screw only until snug. 19. Place the igniti on timing sensor wiring through the hole in the crankcase; then position the igni tion timing sensor and install two Phillips-head cap screws (coated with red Locti te #-27 1). Tighten the ca p screws securely.
NOTE: Do not tighten the flywheel cap screw at this point.
2-86
Page : 98
24. Using the six cap screws and the special washe rs. install the rear (intake-side) shroud. Tighten the cap sc rews to specifications.
22. Place the fan and stmte r pulley into position on the n ywheel. Using Spanner Wrench (pIn 0 144-(07) to hold the stalter cup, ti ghten the three ca p screws (emted with green Loctite #609 and Locti te Primer #747 1) to specifications.
Lh
CAUTION
00 not use green loctite #609 without also using loctite Primer #7471.
25. Using the fi ve 6 mm cap screws a nd the special washers, install the front (ex haust-side) cooling shroud and ti ghten to specifications. Install the rubber spark plug grommets; then ti ghten the eap screws securely.
Lh
CAUTION
When installing the fan, make sure that the locating pins on the flywheel align with the indentations in the fan.
MOO269
23. Using Spanner Wrench (pIn 0 144-(07) to hold the stalter cup, l"ighten the OywhecJ cap screw from step 21 (tlueads coated with red Loctite 11271) to specii1cations.
MOO268
26. Install the main fan shroud and recoil st.'lIter assembly. Tighten the eight cap screws to specifications.
Page : 99
287
29. Install the oil injection pump ali gning the slot on the oil pump with the Oat on the end of the oil injection pump dri veshaft . Ti ghten thc Allen-head cap sc rcws to specifications.
27. Lubricate thc oil-injecti on pump dri vcshaft; thcll whil c rotating the dri veshaft, install it and the thrust washer into the lower crankcase half.
NOTE: Make sure the thrust washer is installed on the oil injection pump driveshaft when it is installed.
28. Install thc oil injection pump dri veshart retainer and O-ring.
NOTE: Make sure the Oring is installed on the oil injection pump driveshaft retainer when it is installed.
30. Install the intakc Oallge assembl y using washers, lock washers, and nuts. Notc the pl acement of gaskets, heat deOector, gaskets, insulators, and Oangcs. Tightcn the nuts (threads coated with red Loctite #27 1) to specifications. 3 1. Install the exhaust manifold and gaskets using lock washers and nuts. Tighten the nuts to specifications.
2-88
Page: 100
Assembling Engine
(600 cc Standard Engine Model)
NOTE: The use of new gaskets and seals is recommended when assembling the engine.
NOTE: When the use of a lubricant is indicated, use Arctic Cat Synthetic APV 2-Cycle Oil . I. Apply a thin coat of grease to the inner seal lips of
5. Apply a thin coat of grease to the scaling surface of the o il-injection pump/water pump dri veshaft ; then place the Oil Scallnstallatio n Tool (pin 06 44219) at the end of the shaft. Twist the driveshaft clockwise as it is pushed through the oil and water pump seals; then remove the tool. Position the shim o n the oil-i njection pump end of the driveshaft.
& CAUTION
the water pump seal. 2. Using the seal dri\'cr, positio n the inner water pump shafl seal onto the seal dri ver and gently tap the seal down into position.
NOTE: Grease must be applied to the lips of the inner seal before installation.
6. Position the up~r crankcase half upside -down on two wooden blocks; then install the C-ring, the four bearing retaining pins. and the two crankcase dowel pins.
3. Insta ll the snap ring securing the inner seal in the

crankcase.
7. Place the PTO-side crankshaft bearing into position maki ng sure the bearing fCtaining pin hole is positioned inward.
NOTE: The bearing retaining pin hole is the hole that doesn't go entirely through the bearing case.
4 . Using the seal driver, carefull y install the outer watcr pump seal. Gentl y tap the seal down into posilion until it seal's itself agai nst it') nange.
8. Lubricate the inner lips of the crankshaft oi l seals with grease; then slide the sC<lis onto the crankshaft making sure the spring side of each seal faces the center of the crankshaft.
Page: 101 2005 Arctic Cat Service Manual - all models - www.ReadManuals.com
289
9. Appl y oil to the crankshaft bearings; then install the cmnkshafl into the upper crankcase half. Be sure the alignment hole in each bearing is positioned over its respeclive dowel pin in the crankcase: then seat the crankshaft.
II . Apply a thin coat of Hi gh-Temp Sealant (pIn 0636-069) to the entire bottom half of the crankcase sealing surface.
_NOTE : Use only Arctic Cat High-Temp Sealant (pin 0636069) to seal the crankcase halves. _ NOTE: To check the bearing for proper position, place the point of a sharp tool into the dimple found in the bearing race. Strike the tool with the palm of the hand in either direction. If the bearing moves, it isn 't positioned correctly and must be rotated until it drops onto the dowel pin. 12. Assemble the crankcase hal ves making sure that the cmnkshaft gear and oil injection pump dri veshaft gears mesh. Rotate the crankshaft one full turn to align the crankshaft gear and pump driveshaft. 13. Install the crankcase cap screws (c()';l ted with blue Loctite 11242) securing the crankcase hal ves. 14. Tightenlhc 8 mm cap screws to spec ifications and the 10 mm cap screws to specifications using the pattern shown.
A CAUTION
If the bearings are not properly seated during assembly, the crankcase halves will not seal tightly and severe engine damage will result. 10. Position the two center seal rings with their end gaps ISO apart (up on one and down on the other).
2 4
'--
711
1\
"
10 5
3 1
812
735-670A
_ NOTE: Secure the connecting rods with rubber bands on the cylinder studs . 15. Install the oil-injection pump retainer O-ring and reta iner.
2-90
Page: 102
21. Position the O-ring into the water pump cover; then install the cover. Secure with fi ve screws. Tighten to specifications. 22. Secure the intake nanges, reed valve assem blies, and gaskets with cap screws. Ti ghtcn to specifications. 23. Place the cylinder base gaskct mto position on the crankcase. 16. Install the O-ring and the oil-injection pump making sure the pump shaft slot and pump dri ven gear shaft align. Secure with two screws (coated with blue Loctite 11242) and washers. Tighten the two screws to spec ifi cations. 24. Install the piston rings on each pi ston so the leiter on the top (i nclined surface) of each ring fac es the dome of the pi ston.
&. CAUTION
Be sure the oil-injection pump!water pump driveshaft is properly aligned with the slot of the oil-injection pump. The pump will be damaged if these two components are not aligned.
17. Position the rubber seal reta iner and seal into the back side of the water pump imr~dlc r. 18. Using both thumbs, press the seal into position making sure its marked side is positioned towards the rubber seal cup: then apply a thin coat of grease to the seal outer surface. 19. Place the impeller into position and secure with a ca p screw and washer. Be sure the rubber side of the washer is directed towa rd the impeller. Apply blue Loctite 11242 to the thre."lds of the cap sc rew and ti ghten to specifications.
726-306A
&. CAUTION
25. Apply oil to the connecti ng-rod small end bearings; then install the small-end bearings. Install a washer on each side of the connecting
rod.
&. CAUTION
The rubber side of the washer, which secures the impeller, must be positioned toward the impeller. If installed incorrectly, a coolant leak will result.
20. Appl y high-temperature sealant to the crankcasel water pump co\'er seam ; then install the dowel pins into the crankcase.
Page: 103
2-91
28. Rotate each piston ring until the ring ends are propcrly positioned on either side of thc ring keeper; then apply oi l to the piston assemblies and cylinder bores. Remove the rubber bands from the connecting rods.
29. In turn on each cylindcr, pl ace a pi ston holder (or suitable substitute) beneath the piston skirt and square the piston in respect to the crankcase; thcll usi ng a ring compressor or the fingers, compress the rings and slide the cylinde r over the piston. Remove the piston holder and seat the cylinder firmly onto the crankcase.
26. Place each piston over the connecting rod so the
afrow (or indicator dot) on each piston will point toward the ex haust port ; then secure wi th an oiled piston pin.
_NOTE : The arrow (or indicator dot) is found either up inside the piston or on the dome top.
30. Secure each cyli nder by installing the four nuts. washers, and lock washers. 00 NOT TIGHTEN AT TI-IIS TI ME.
NOTE: The cylinders will be tightened at the same time as the exhaust manifold is installed to assure proper cylinder to exhaust manifold align ment.
27. Install the new cirel ips so the open end is directed either up or down.
3 1. Install the oil-injection hoses and secure with the clamps; then place the lower check-valve assembly into posilion and secure with the gaskets and union cap screw. Tighten securely. 32. Install the two cylinder O-rings on the top of each cylinder making sure they are correctl y positioned in the grooves.
&
CAUTION
Make sure the circlips are firmly seated and the open end is directed either up or down before continuing with assembly.
2-92
Page: 104
33. Place new O-rings onto each of the head cap screws. Place four o f these cap screws mto the cylinde r head. Thread the spark plugs in pmt way; then while holding the head above the cylinder, carefull y St..11t all fo ur cap screws while observing the cylinder O -rings to make sure they remain in positio n. Slowly pl ace the head into positio n on top o f the a -rings. Start the remai ni ng cap screws being very care ful not to move the cylinder head. ONLY FI NGER-TI GHTEN AT THI S TI ME 34. Tighten the cap screws securing the head (from step 33) in three steps to specifications using the patte rn show n.
40. Secure the ignition timing sensor with screws coated with blue Loctite 11242.
41. Place the PrO-end plate into position on the crankcase; then apply blue Loctite 1/242 to the fo ur screws and tighten to specifications.
42. Secure the stator to the stator pl ate with the Alle nhead cap screws cooted with blue Loctite 11242 and tightened to specificatio ns; then install the stator wires with a grommet into the crankcase.
<D@
O \J:--"
43. Install the key in the crankshaft.
0733524
44. Slide the n yw heel o nto the crankshaft making sure
35. Place the thermostat , gasket, and cap into position. 36. Secure the cap with three cap screws tighte ned to specificatio ns.
37. Appl y a thin coat of hi gh-tempe rature silicone sea lant to each ex haust IJOlt; then install the ex haust gaskets with the metal sides facing o ul.
the keyways match. _NOTE : Before installing the flywheel, be sure to wipe the crankshaft and flywheel tapers clean using a clean towel. 45. Appl y red Loctite 1/271 to the threads o f the fl ywheel nut ; then fin ger-tighten with a large nat washer, lock washer, and the nul. DO NOT TIGHTEN AT TIIlS T1 tvlE.
38. Install the ex haust manifold and secure with fo ur nuts and lock washe rs. Tighten the fo ur nuts to specificatio ns. 39. Tighten the spark plugs to specifications; then secure the cylinders by tightening the cylinder base nuts (fro m step 30) to specifications in three ste ps using the pattern show n. Pressure test the engine (see Section 3).
(0
0 (0
CD
0)
CD
725-3186
46. Place the starter pulley in IJOsition; then loosely secure the stm1er pulley with three cap sc rews (coated with red Loctite 1/27 1) and lock washers. Secure the pulley whil e using the spanner wrench and ti ghten the three cap screws evenl y to specifications.
Page: 105
2-93
Assembling Engine
(900 cc Models) NOTE: The use of new gaskets and seals is rec~ ommended when assembling the engine, NOTE: When the use of a lubricant is indicated, use Arctic Cat Synthetic APV 2~Cycle Oil. _NOTE : 00 steps 1~5 only if the water pump has been disassembled.
47. Using the spa nner wrench, ti ghten the Oywheel nut (from step 45) to specifications. 48. Place the engine mounting brackets into IX)sition on the crankcase and secure with the cap screws. Tighten to speci fi cations. 49. Slide the APV assemblies into position In the cylinde rs; then slide the valve keepers into position and secure with cap sc rcws (coated with blue Loctite 8242). Ti ghten to specifications.
NOTE: The following two photographs are for clarity purposes only. This model may vary slightly.
I. Appl y a thin coat of grease to the inner sC<ll lips of the water pump seal. 2. Using the seal dri ver, position the inner water pump shaft seal onto the seal dri ver and gentl y tap the seal dow n into lX)silion.
_NOTE : The seal must be installed with its spring side towards the crankshaft.
3. Install the snap ring securing the inner seal in the crankcase. 4. Using the seal dri ver, carefull y insta ll the outer water pump seal. Gentl y tap the seal down into position until it scats itself against its Oange.
so.
Slide the vahc covers into position and sccure with ex isting nuts. Tighte n to specifications.
2-94
Page: 106
2005 Arctic Cat Service Manual
all models
www.ReadManuals.com
5. Apply a thin COt'l t of grease to the sealing surface of the oil-injection pump/water pump driveshart; then place the Oil Seal Installation Tool (pin 06442 19) at the end of the shaft. Tw ist the dri veshart clockwise as it is pushed through the oi l and water pump seals; then remove the tool. Position the shim on the oi l-injection pump end of the driveshart .
Retaining Pin Hole
,&, CAUTION
AP150B
9. Lubricate the inner lips of the crankshart oil seals with grease; then slide the seals onto the crankshart making sure the spring side of each seal faces the center of the crankcase .
10. Appl y Arctic Cat 50: I Injection Oil to all of the crankshaft bearings; then install the crankshaft into the upper crankcase half. Be sure the retaining pin hole in each bearing is positioned over its respecti ve dowel pin in the crankcase .
NOTE: Check all bearings by trying to rotate them to make sure they are being held in position by the retaining pin. Each bearing must drop onto the retaining pin.
6. Set the top half of the crankcase upside down on the work benc h with a 4 in. block of woOO under each cnd. 7. Install the C-ring in the uppe r crankcase half. Install the four bearing retai ning pins in the crankcase bearing a reas.
,&, CAUTION
If the bearings are not properly seated during assembly, the crankcase halves will not seal tightly and severe engine damage will result.
8. Using Arctic Cat 50: I Injection Oil. lubricate the
crankshart bearings and slide them onto the crankshaft.
11 . Rotate the crankshart center seal rings so the end gaps of the Iwo large rings are 1800 apart . one end gap being positioned dow nward and the other upward; then seat the crankshaft.
,&, CAUTION
The retaining pin holes on both bearings must be positioned toward the center of the crankshaft.
Page: 107
2-95
736-280A
12. Apply a thin caat of High-Te mp Scalant (pIn 0636-(69) to the lower crankcase scaling surface.
15. Inslall the oil-injection pump retainer O-ring and retainer.
,&, CAUTION
Check to make sure the two crankcase half dowel pins are in position at opposite corners of the lower case half.
16. Inslall the D-ring and the oil -injection pump making sure the pump shaft slot and pump driven gear shaft align . Secure with two screws (coated with blue Loclite 11-242) and washers. Tighten the Iwo screws 1 0 specifications.
13. Assemble the crankcase halves. 14. Install the crankcase cap sc rews securing the cran kcase halves making sure the proper-sized cap screws arc in the proper holes. Tighten in three steps the 10 mm cap screws to specifications and the 6 mm ca p screws to specifications using the pattern show n.
,&, CAUTION
Be sure the oil-injection pumplwater pump driveshaft is properly aligned with the slot of the oil-injection pump. The pump will be damaged if these two components are not aligned.
17. Place the lower check vah'e assembly into position and secure with the gaskets and the union bolt . 18. Position Ihe rubber seal retai ner and seal into the back side of the water pump impeller.
2-96
19. Using both thumbs, press the sea l into position making sure its marked side is positioned towards the rubber seal cup; then apply a thin coat of grease to the seal outer surface. 20. Place the impeller into position and secure with a cap screw and washer. Be sure the rubber side of the washer is directed toward the impeller. Appl y blue Loctite #242 to the threads of the cap screw and tighten to specifications.
,&, CAUTION
21 . Place the end plate into position on the crankcase; then apply blue Loctite #242 to the four cap screws and l"i ghten securel y.
24. Place each piston over the connecting rod so the arrow on each piston will point toward the exhaust port and secure with a piston pin; then insta ll the new circlips so the open end is directed either down or up.
AP142
22. Install the piston rings on each piston so the leiter on the top or inclined surface of each ring faces the dome of the piston.
,&, CAUTION
Make sure circlips are firmly seated and the open end is directed either down or up before continuing with assembly.
25. Apply a thill coat of Copper Coat Gasket Sealant (pIn 0636-092) to both sides of each cylinder-base gasket if the gaskets are being reused. If using new gaskets, it isn't necessary to appl y copper co.'!!. Install the gasket with the raised po rtion of the gasket positioned upward.
726-306A
,&, CAUTION
23. Appl y oi l to the connecting-rod small end bearings; then install the small-end bearings and thrust washers.
Page: 109
2-97
26. Rotate each piston ring until the ring ends are properl y positioned on either side of the ring keeper; then apply oi l to the piston assemblies and cylinder bores.
NOTE: If reusing O-rings and they are slightly stretched , shrink the O-rings by cooling them (in a refrigerator for example) for a short period of time,
30. Check sealing surface to make sure the surface is clean; then set the cyli nder heads in position. 3 1. Apply a thin coat of High-Temp Sealant (p/n 0636-069) to the two thermostat housing gaskets. Place the gaskets and housing into position and secure with four cap screws and washers. Tighten the four cap screws in a crisscross pattern to specifications.
NOTE: The thermostat housing cap screws must be tightened before tightening the head cap screws. This will allow the gasket surfaces of the head to align with the housing and prevent any coolant leakage.
726-3068
27. In turn on each cylinder, place a pi ston holder (or
suitable substitute) beneath the pi ston skirt and square the piston in respect to the crankcase; then using a ring compressor or the fin gers, compress the rings and slide the cylinder over the piston. Remove the pi ston holder and scat the cylinder firml y onto the crankcase.
32. Tighten the head cap screws in three steps to specifications lIsing the pattern shown; then insL.'l1l the spark plugs and tighten to specifications.
(!)
@)
(!)
@)
0738-292
AP138
33. If removed in turn for each cylinder, install the gasket, reed va lve assembly, and carburetor Oange to the crankcase; then secure with six cap screws. Tighten to specifications.
28. Secure each cylinder with four nange cap sc rews and four nuts with Oat and lock washers. Using a cri sscross pattern, tighten the nuts and cap scre\\lS to specifications. 29. Place the O-rings into position on the top of eac h cylinde r.
34. Test the engine for air leaks (sec Section 3). 35. Place the thermostat with gasket and cap into position. Secure with three cap screws. Tighten to specifications.
AJl18
2-98
Page: 110
39. Set the timing sensor into position in the magneto housing. Appl y blue Loctite #242 to the thre. .lds of the two screws and sec ure the timing sensor to the housing. 40. Route the stator wiring harness through the rubber grommet; then place the stator into position and secure with three screws coated with blue Loctite 11242. Tighten securely. 4 1. Secure the stator wiring harness 1 0 the magneto housing using the tab plate and screw. 42. Install the key in the crankshaft and slide the Il ywheel onto the crankshaft making sure the keyways ali gn.
36. Appl y a thin coat of si licone sealant to the crankcase water pump housing sealing surfacc.
NOTE: Sealant is required only on the crankcase seam.
AJ128
43. Appl y blue Loctite #242 to the threads of the cap screw; then install the Ilat washer, lock washer, and cap screw sec uring the Ilyw heel. Tighten the cap sc rew fin ger-tight. 37. Apply a thin coat of High-Temp Sealant (pin 0636-069) to the water pump covcr seal and position the O-ring into the cover. Carefull y place the cover over the impe ller and onto the crankcase. Secure with six cap sc rews. Tighten cap sc rews evenly to specifications. 38. Install the stator backing plate and secure with four cap screws. Appl y blue Loctite #242 to the threads of each cap scrcw before installation. Tighten securely. 44. Place the starter puliey into position on the Il ywheel and secure with three cap screws coated with blue Loctite 11-242. Tighten the three cap screws evenly to specifications.
AJ130
45. Using a spanner wrench, ti ghten the Ilywhecl cap screw (from step 43) to specifications.
Page: 111
2-99
so. Position the coolant suppl y hose on the water pump and secure with a clamp.
Assembling Engine
(500/600/700 cc uLaydown" Engine Models)
NOTE: The use of new gaskets and seals is rec~ ommended when assembling the engine.
AJ131
46. Place the exhaust manirold into position on the cylinde rs; then secure with nange nuts. Tighten to specifications. 47. Place the engine mounting brackets into IXlsition on the engine; then secure with cap screws (co..l ted with blue Loctite #242), lock washers, and nat washers. Ti ghten to specificalions. 48. Slide the APV assemblies into position in the cylinde rs making sure the grooved sides are dow n; Ihen slide the val ve keepers inlo position and secure wi th two cap screws (co..ltcd wi th blue Loctite #242). Tighten to specifications.
NOTE: The following two photographs are for clarity purposes only. These models may vary slightly.
NOTE: When the use of a lubricant is indicated, use Arctic Cat Synthetic APV 2-Cycle Oil.
I. Appl y a thin coot of grease to the inncr seal li ps of
the water pump seal. 2. Using Ihe seal driver, position the inner water pump shaft seal onlo the seal dri ver a nd gentl y tap the seal dow n into IXlsition.
3. Install the snap ring sec uring the inner sea l in the crankcase. 4. Using the seal dri ver, carefull y install the outer water pump seal. Gentl y tap the seal down into position until it scats itself against its nange.
49. Slide the APV covers into position and secure wi th ex isiting nuts. Tighten to spec ificalions.
2-100
Page: 112 2005 Arctic Cat Service Manual
~
all models
5. Apply a thin COt'l t or grease to the sealing surrace or the oil-injection pump/water pump driveshart; then place the Oil Seal Installation Tool (pin 06442 19) at the end or the shart. Tw ist the dri veshart clockwise as it is pushed through the oi l and water pump seals; then remove the tool. Position the shim on the oi l-injection pump end of the driveshart .
9. Apply oil to the crankshaft bearings; then install the crankshaft into the upper crankcase hair. Be sure the alignment hole in each bearing is posi tioned o\'er its respecti ve dowel pin in the cran kcase; then seat the crankshaft.
,&, CAUTION
NOTE: To check the bearing for proper position, place the point of a sharp tool into the dimple found in the bearing race. Strike the tool with the palm of the hand in either direction. If the bearing moves, it isn't positioned correctly and must be rotated until it drops onto the dowel pin.
6. Position the upper crankcase hair upside-down on two wooden blocks; then install the C-ring . the rour bearing retaining pins. and the two crankcase dowel pins. 7. Place the prO-side crankshaft bearing into position making sure the bearing retaining pin hole is positioned inward .
NOTE: The bearing retaining pin hole is the hole that doesn't go entirely through the bearing case.
,&, CAUTION
If the bearings are not properly seated during assembly, the crankcase halves will not seal tightly and severe engine damage will result.
10. Position the two center seal rings with their end gaps 180 a pmt (up on one and down on the other).
11 . Apply a thin COt'lt or Hi gh-Temp Sealant (pIn 0636-069) to the entire bottom half or the crankcase scaling surraee. 8. Lubricate the inner lips or the crankshaft oi l seals with grease; the n slide the seals (a nd rubber spacer on the 6001700 ee) onto the crankshaft making sure the spring side or each seal races the center of the crankshaft.
Page: 113
2-101
15. Install the oil-injection pump retainer O-ring and retainer.
NOTE: Use only Arctic Cat High-Temp Sealant (pin 0636-069) to seal the crankcase halves.
12. Assemble the crankcase halves making sure that the crankshaft gear and oil-injection pump dri veshaft gears mesh. ROlal"e the crankshaft one full turn to align the crankshaft gear and pump driveshaft . 13. Install the crankcase cap screws (coated with blue Loctite 11242) securing the crankcase halves. 14. Tighten the three 6 mm cap screws to specifications and the tCIl 10 mm cap screws to specifications using the appropriate paltern shown.
16. Install the O-ring and the oil-injection pump making sure the pump shaft slot and pump dri ven gear shaft align . Secure with two screws (coated with blue Loctite 11242) and washers. Tighten the two screws to speci fi cations.
L1:.
CAUTION
500cc
1 5~f 9
5
Be sure the oil-injection pumplwater pump driveshaft is properly aligned with the slot of the oil-injection pump. The pump will be damaged if these two components are not aligned .
'Irl()te) l~
17. Position the rubber seal retainer and seal into the back side of the water pump impeller. 18. Using both thumbs, press the sea l into IXlsition making sure its marked side is positioned towards the rubber seal cup; then appl y a thin co.at of grease to the seal outer surface.
10
8
IV !I'
4 2
I~, ~
6
0738-201
19. Place the impeller into position and secure with a cap sc rew and washe r. Be sure the rubber side of the washer is directed toward the impeller. Apply blue Loetite 11242 to the threads of the cap screw and tighten to specifications.
600noo cc
12
L1:.
CAUTION
20. Appl y high-temperature sCo:'llant to the crankcase! water pump cover seam ; then install the dowel pins into the crankcase.
4
6
738202A
2-102
Page: 114
FC134
NOTE: It is important to not get sealant into the breather hole in the crankcase. If sealant gets into the hole, carefully remove before proceeding.
22. Noting the alignment dots, install the thermostat housing with thermostat. Tighten the ex isting hardware securely.
23. Secure the intake nanges. reed val ve assemblies, and gaskets with cap screws. Ti ghten to specifications. 24. Place the cylinder base gasket into position on the crankcase. 25. Install the piston rings on each pi ston so the letter on the top (inclined surface) of each ring fac es the dome of the piston.
21 , Position the O-ring into the water pump cover; then install the cover. Secure with six screws. Tightcn to spcc ifications.
Page: 115
2-103
_NOTE : The arrow (or indicator dot) is found either up inside the piston or on the dome top.
726-306A
,1;CAUTION
28. Install the new circlips so lhc open end is dircctcd cilhcr up or down .
26, Appl y oil to the connecting-rod small end bearings; then install the small-end bearings. Install a washer on each side of the connecting
rod.
,1; CAUTION
Make sure the circlips are firmly seated and the open end is directed either up or down before continuing with assembly.
29. Rotate each piston ring until the ring ends are properl y positioned on either side of the ring kcepe r; then apply oil to the piston assembli es and cylindcr bores. Rcmove the rubber bands from the connecting rods, 30. In turn on cach cylinder, placc a pi ston holdcr (or suitablc substitute) beneath the pi ston skilt and square the piston in respect to the crankcase; then using a ring compressor or the fingers, compress the rings and slide the cylinder over the piston. Removc the pi ston holder and seat the cylinder firml y onto the crankcase. 27. Place each pi ston over the connecli ng rod so the arrow (or indicator dot) on cach piston will point toward the intake/exhaust pOlts; then sec ure with an oiled piston pi n.
2-104
Page: 116
36. Fro m step 35 on the 500 cc in two steps, tighten the 6 mm cap screws to specificatio ns and o n all models in two steps, tighten the 8 mm cap screws to specifications using the appropriate patte rn shown.
3 1. O n the .500 cc, secure each cylinder by installing
the fo ur nuts, washers, and lock washers. DO NOT TIGHTEN AT T HIS TI ME.
32. O n the 6001700 cc, secure eac h cylinder by
installing the four nuts and fo ur cap screws. DO NOT TIGHTEN AT T HI S Tll"fE. NOTE: The cylinders will be tightened at the same time as the exhaust manifold is installed to assure proper cylinder to exhaust manifold alignment. 33. Install the o il-injectio n hoses and secure with the clamps; lhen place the lower check-valve assembly into lX)siti oll and sccure with the gaskets and unio n cap screw. Ti ghten securely. 34. Install the two cylinder a -rings on the top o f each cylinde r making sure they arc correctly positio ned in the grooves.
0738-204
@o@
o
@
0738-205
37. Apply a thin coat of hi gh-tempe rature silicone x)11; then install the sealant to each ex haust 1 exhaust gaskets with the metal sides facing o ut. 38. Install the ex haust manifold and secure with fo ur nuts and loc k washers. Tighten the four nuts to specificatio ns.
39. Secure the cylinders (from steps 3 1-32) by
tightening the cylinder b.. 'lse nuts (and cap screws o n the 600/700 cc) to specificatio ns in three steps lIsing the appropriate pattern show n; then ti ghte n the spark plugs to specificatio ns. Pressure test the engine (see Sectio n 3 ). 35. Place new a -rings onto each of the head cap screws. Place fo ur o f these cap screws into the cylinde r head. Thread the spark plugs in pmt way; then while holding the head a bove the cylinder, carefull y stmt all fo ur cap screws while observing the cylinder a -rings to make sure they remain in lX)sitio n. Slowly pl ace the head into IX)sitio n 0 11 top o f the O-rings. Start the remaining cap screws being very care ful not to move the cylinder head. ONLY FINGER-TIGHTEN AT Till S T IME
0738-206
Page: 117
2-105
0738-220
40. Secure the st.'ltor plate to the crankcase with the 'lted with blue Loctite Alle n-head cap screws co.. #242 and ti ghtened to specifications; the n install the stator assembly with wires and a grommet into the crankcase.
43. Install the key in the crankshaft. 44. Thread two puller bolts into the fl yw heel; then slide the fl ywheel onto the crankshaft making sure the keyways match. Remo\'e the pulle r bolts.
_NOTE : Before installing the flywheel, be sure to wipe the crankshaft and flywheel tapers clean using a clean towel.
45. Appl y red Loctite #27 1 to the threads of the fl ywheel cap sc rew ; then fin ger-ti ghten with a large fl at washer and lock washe r. 00 NOT TI GHTEN AT TI-IIS TI ME.
4 1. Sec ure the IgOltlon timing sensor with screws coated with blue Loctite #242. 42. On the 6001700 cc , install the magneto case on the crankcase accounting for the different-si zed cap screws and the ali gnment pins. Tighten cap screws to specifications. 46. Place the starter pulley in position; the n loosely secure the stUiter pulley with three cap screws (coated with red Loctite #27 1) and lock washers . Secure the pulley while using the spanner wrench and ti ghten the three ca p screws evenl y to specifications.
FC081
2-106
Page: 118
47. Using the slu1.nner wrench, tighten the Oyw heel cap screw (from step 45) to specifications. 48. Slide the APV assemblies into position In the cylinde rs; then slide the valve keepers into position and secure wi th cap sc rews (cO<lted with blue Loctite 8242). Tighten to specifications.
Installing Engine
(F/C Models)
I. Place each engine mounting bracket onto the engi ne. Secure with cap screws, washers, and lock washers. Tighten to specifications. 2. Place the engine assembly into position in the engine compartment. Secure the engine to the front end with the cap screws, washe rs, and lock nuts. Tighten to specifications.
&.
CAUTION
The long side of the exhaust valve must be facing toward the cylinder head or severe engine damage may occur.
FC024
Installing Engine Table of Contents

FIG Models ...... ........... .... ..................................... 2- 107 Standard LIe Models .......................................... 2-1 09 500/6001700 cc "Laydown" Engine Models ......... 2-11 2
NOTE: Critical torque specifications are located in the Assembly Schematics sub-section of this section.
3. Connect the oi l-suppl y hose to the oil -injection pump; then bleed the system (see Section 4).
Page: 119
2-107
NOTE: If equipped with electric start, place the starter motor bracket on the crankcase and install the front two and lower rear cap screws, lock washers, and washers. Place the starter motor into position and secure with two washers and lock nuts. 4. Connect the oi l-injection ca ble to the oi l-injection pump control arm and secure the cable mo unting pin with a nylon washer and E-clip. 5. Place the carburetor(s) into position making sure the bootes) are properl y positioned and sec ure with the nange clamp(s). 9. Place the engine mo unt shims into position between the to rque bumpe r and engine mounting bracket ; then tighten the torque bumper jam nut. 10. Place the drive clutch into positio n on the crankshaft ; then ins!"all the lock washer and bolt. Ti ghten the clutc h bolt to specifi cations.
NOTE: At this point, check oil-injection system synchronization (see Section 4). 6. Connect the impul se hose to the crankcase, the main wiring harness, the COl unit wiring harness, and the spark plug caps. 7. Place the recoil starter into position a nd secure with four cap screws and lock washers. Tighten to specificatio ns. NOTE: If equipped with electric start, secure the battery ground cable with the rear cap screw.
NOTE: Apply a coat of Anti-Seize Thread Com~ pound (pIn 0678-146) to the keyway end of the driven shaft. 11 . Install the dri ven pulley and alignment washers. Secure with a cap screw and washer tightened to specificatio ns.
8. Place the expa nsion chamber and grafoi l gasket into position and secure with springs. NOTE: At this point, check drive clutch/driven pulley alignment (see Section 8). 12. Install the drive belt and secure the belt guard. Install the plug in the belly pan. 2-108
NOTE: If equipped with electric start, connect the battery.

13. Turn the gas tank shut-off val ve to the OPEN
position. 14. Check the ignition timing. 15. Place the rear of the snowmobile up on a shielded safety stand. Start engine and all ow to warm up. Adjust engi ne idle to 1500 RPM and check all safety switches for proper operation. 16. Test dri ve the snowmobile: then tighten the clutch bolt to specifications. 4. On the 600 cc , sec ure the hO<Xl cable and ground wire to the magneto case with the machine screw I"i ghtened to s l~ci fi ca ti ons . 5. On the 550 cc , attach the hood cable to the exhaust manifold and the ground wires to the magneto case. 6. Secure the rear ground wires to the magneto case with the machine screw ti ghtened to specifications. 7. Place the coolant return hose into position on the thermostat housing and secure with the clamp.
&
CAUTION
8. Place the recoi l starter into position and secure the starter with four cap screws and lock washers. Tighten to specifications. 9. Connect all electrical wires.
NOTE: Use cable ties to secure the wiring harnesses as necessary.
If the engine had a major overhaul or jf any major part was replaced, proper engine break-in procedures must be followed.
Installing Engine
(Standard LIe Models)
I. Place the engine into the engi ne compal1ment;
10. Connect the oi l-injection cablclcontrol rod to the oil-injection pump and secure; then connect the oil -supply hose to the pump and secure with the clamp. Bleed the oil -injection system (see Section 4).
then place the coolant suppl y hose on the water pump (coolant tank on the 900 cc) and secure with the clamp. 2. Secure the right-side front and rear and left-side front engine mounts to the front end making sure the mounts are properl y positioned. Tighten the ca p screws and nut to specifications. 3. Adjust the torque bumper to allow a clearance between the engi ne and the torque bumper of 1.78 mm (0.070 in.) ; then secure the adjustment by tightening the jam nuts.
11 . On carbureted models, connect the impulse hose to the crankcase.
Page: 121
2-109
12. Place the carburctorsfthrottle bodics into position
and secure with the nange clamps. Synchronize the oil-injection system (see Section 4).
NOTE: On the 900 cc, install the air-intake silencer; then place the COl unit into position and close the cover.
13. Place the exp< 1nsion cham ber and grafoil gaskets
NOTE: Apply a coat of Anti-Seize Thread Compound (pIn 0678-146) to the keyway end of the driven shaft,
15. Install the dri ven pulley, key, stub shaft , and ali glUnent washers. Secure with a cap screw and washer. Tighten to specifications.
into position and secure to the ex haust manifold , front end, and rcsonator with the springs.
NOTE: When installing the three exhaust manifold springs, the long hook portion of the spring must be attached to the exhaust manifold or premature spring failure will result. NOTE: Before installing the drive clutch, be sure to wipe both the crankshaft taper and clutch mounting taper clean using a clean towel.
14. Place the dri ve clutch into
position on the cranks haft and secure with the cap screw and lock washer. Tighten to spec ifications.
SC 013D
NOTE: On the ZR, install the alignment washer; then install the driven pulley on the gear case input shaft. Tighten to specifications.
2-110
Page: 122
16. Check dri ve clutchfdri ven pulley ali gnment (see Section 8). 17. Install the dri ve belt. Check belt deflection. Secure the belt guard.
22. Position the tab (on the bottom of the servomotor mounting plate) into the slot in the air-intake sil encer; the n secure the mounting pl ate to the sil encer with a sc rew. 18. Fill the cooling syste m (see Section 3). 19. On models equipped wlelectrie sta rt, connect the positi ve cabl e to the stmle r motor; then sec ure with the washers and nut making sure the cabl e is di rected toward the PTO-side or the engine. Secure the positi ve cable with a long cable tie. 20. On models equipped w/electric stmt, connect the cables to the battery making sure to connect the positi ve cable first.
NOTE: Steps 21 through 25 are for APV equipped engines.
21 . Slide the cabl e drums into the servomotor actuator; then place the cable housings into position in the servomotor. Secure the cable housings with the holder.
23 . Place the sen 'omotor with cover into position on the mounting plate; then secure with two cap screws.
Page: 123
2-111
2-t Check APV cable adjustment. See Arctic Power Valve (A PV) System in Section 3.
25. Connect the two APV drain hoses making sure they me not in contact with hot or movi ng parts.
FirecatiM-Series
MSm,
NOTE: If equipped with electric start, insert the flex-drive shaft into the pinion drive and secure with the two set screws.
26. If applicable, turn the gas tank shut-off val ve to the OPEN position. 27. Start engine and verify ignition timing. 28. Test dri\'e or run the snowmobile and recheck the coolant level after 5-6 minutes. Tighte n the dri ve clutch cap screw to specifications.
2. Place the engi ne into the mounting position; then from the left side, tip the engine forward , raise the left side of the engine, and allow the chassis to support the engine in this position. Connect the coolant tank hose to the bottom left outlet on the engi ne and secure with the hose clamp.
A CAUTION
If the engine had a major overhaul or jf any major component was replaced, proper engine break-in procedures must be followed. If the proper engine break-in procedures are not followed, severe engine damage may result.
Installing Engine
(500/600/700 cc "Laydo"",," Engine Models)
I. Place lhe engine into the engine compartment and posilion it so the magneto case is resting on the right-fronl torque bumper; then attach the water pump coola nt hose to the front he.."lt exchanger. Secure with the hose clamp.
2-112
3. Connect all electrical wiring making sure all wiring and coolant hoses are routed properly; then place the cngine into the mounting position .
NOTE: Use cable ties to secure the wiring har nesses as necessary.
4 . Install the cap screw securing the righi -side engine mounting bracket to the side plale. DO NOT
TIGHTEN AT TI-I1S Tl ME_
6. Tightcn the rour mounting bracketlrei nrorccmcnt plate-to-cngine 8 mill cap scrcws to specifications; thcn ti ghten the two cap screws to specifications. Tightcn the right-side cngine cap SCfCW and nut (rrom step 4) to specifi calions.
5. Install the lcrt-side e ngi ne mounting brackct; then securc the mounting bracket to the rront framc. Tighten bracket hardware to specifications.
Page: 125
2-113
9. Confirm that the two coolant hoses which run beneath each exhaust po rt on the cylinders are accessible to connect and that the fuel line and oil pump linkage (EFt ) or cable (carbureted) and impulse lines are connected; then place the throttle lxxIies/carburetors into position and secure with the Oange clamps. Synchronize the oi l-injection pump (see Section 4).
7. Connect the oil -injection cable/control rod to the oil-injection pump and secure; then route the oil supply hose through the left-side engine mounting bracket, into the reinforcement pl ate, and to the pump and secure with the clamp. Bleed the oi1injecti on system (see Secti on 4) .
8. On carbureted models, connect the impulse hose
to the crankcase. 10. Install the side-plate brace onto the chassis and secure with the three cap nUls and four torx-head screws. Tighten securely,
_NOTE : On the FirecatIM-Series, secure the sideplate brace with the torx-head screws. Tighten securely.
2-114
Page: 126
13. Place the recoil starter with ground wire mto position and secure the starter with four cap screws and lock washers. Tighten to specifications.
NOTE: On the MSeries after securing the brace, secure the steering support to the chassis. Tighten to specifications. _NOTE : Steps engines only. 1416 are for APV-equipped
14. Slide the cable drums into the servomotor actuator; then place the cable housings into posi tion in the servomotor. Secure the cable housings with the cable retaining cover.
11 . Install the ex haust manifold noting that the gaskets are directional (can go on onl y one way) ; the n install the four cap nuts and tighten to specifications.
12. Fill the cooling system (see Liquid Cooling System in Section 3). 15. Place the servomotor cover mto position; then sec ure with two cap screws.
Page: 127
2-115
NOTE: Apply a coat of AntiSeize Thread Com pound (pIn 0678146) to the keyway end of the driven shaft.
16. Check APV cable adjustment. See Arctic Power Val ve (A PV) System in Section 3.
NOTE: Before installing the drive clutch, be sure to wipe both the crankshaft taper and clutch mounting taper clean using a clean towel . NOTE: Before installing the drive clutch, it must be locked in the compressed position.
FC053
17. Plaee the dri ve clutch into position on the crankshaft and secure with the cap screw and lock washer. Ti ghten to specifications.
NOTE: On the FirecatIM-Series, install the alignment washers; then install the driven pulley on the gear case input shaft. Tighten the cap screw to specifications.
18. Using Clutch Compressor ( pi n 0644-420), compress the dri ve clutch and remove lhe locking clamp.
L, WARNING
Never attempt to start the engine without remov ing the locking clamp from the drive clutch. Severe damage and/or injury may occur.
MS378
19. Install the dri ven pulley (with inner and outer 0 rings), key, stub shaft , and ali gnment washe rs. Secure with a cap screw and washer. Tighten to specifications.
20. Check dri ve clutch/dri ven pulley alignment (see Section 8).
2-116
Page: 128
NOTE: When installing the three exhaust mani fold springs, the long hook protio" of the spring must be attached to the exhaust manifold or premature spring failure will result.
23. St.art engine and verify ignition timing. 24. Test drive or run the snowmobile and recheck the coolant level aftcr 5-6 minutes. Ti ghte n the dri ve clutch cap screw to specifications.
L!':. CAUTION
MS390
2 I, Install the drivc belt , Check belt deflection. Sec ure the belt guard. 22. Install the resonator and sccure with three springs; then place the ex pansion chamber and gmfoil gaskets into position and secure 1 0 the ex haust manifold and resonator with thc springs.
If the engine had a major overhaul or if any major component was replaced, proper engine break-in procedures must be followed. If the proper engine break-in procedures are not followed, sever engine damage may result.
Page: 129
2-117
Troubleshooting Engine
(Carbureted Models)
Problem: Engine Does Not Start (No Spark at Spark Plugs)
Condition
1. Ignition switch malfunctioning - not in RUN position 2. Wiring harness shorting
3. Emergency stop switch knob in DOWN
Remedy
1. Replace ignition switch - turn switch to RUN

position 2. Repair - replace wiring harness
3. Move knob to UP position - replace throttle
position - malfunctioning
4. Throlllelignition monitor switch (TM-style)
switch
4. Adjust (tighten) throttle cable - replace
adjusted too loose - malfunctioning

5. Throlllelignition monitor switch (VM-style)
throWe switch
5. Adjust (loosen) throttle cable - replace
adjusted too tight - malfunctioning

6. Carburetor safety switches (VM-style)
throttle switch 6. Adjust - replace carburetor safety switches

7. Clea n - gap - replace spark plugs 8. Replace spark-plug caps 9. Service - replace high tension wires/coil 10. Replace C Ol unit 11 . Replace coil
adjusted inco rrectly - malfunctioning

7. Spark plugs fouled - damaged 8. Spark-plug caps damaged - lea king -
shorting 9. High tension wireS/coil loose - grounded faulty 10. COl unit faulty 11. Charge coil (1) faulty 12. Charge coil (2) faulty
12. Replace coil

13. Replace flywhee l 14. Replace key
13 . Flywheel magnets weak

14. Flywheel key shea red
Problem: Engine Does Not Start (No Fuel at Cylinders) Condition

1. Gas tank empty 2. Shut-off valve (VM-style) closed 3. Fuet hose broken - pinched Remedy 1. Fill tank
4. Gas-tank vent - hose obstructed 5. In-line fuel filter obstructed - damaged

6. Fuel pump malfunctioning - faulty 7. Impulse hose cracked - broken - pinched
2. 3. 4. 5.
Open shut -off valve Replace - service hose Remove obstruction - replace vent - hose Remove obstruction - replace in-line fuel filter
6. Replace - repair - clean fuel pump
7. Replace - connect impulse hose 8. Troubleshoot - clean - replace ca rburetors 9. Repair - replace damaged - worn engine components
- disconnected 8. Carburetors adjusted incorrectly - dirty damaged
9. Primary compression (crankcase) absent
2-118
Page: 130
Problem: Engine Overheats Condition 1. Spark plug heat range 100 hal 2. Coolant low - absenl 3. Carburetors adjusted incorrectly - jetted incorrectly - dirty 4. Carburetor-to-cylinder air leak 5. Heat exchangers no snow for cooling 6. 7. 8. 9. Rings/grooves carboned Exhaust ports obstructed Muffler obslrucled Gas/air mixture incorrect Remedy 1. Install lower heat-range spark plugs 2. Add coolant 3. Troubleshoot - clean carburetors - jet correctly 4. Replace - repair gaskets - intake flanges service intake ports 5. Select new trai l - install ice studs to chew up hard packed snow and ice 6. Clean - replace rings - pistons 7. Remove obstruction 8. Remove obstruction 9. Replace jets - adjust jet needle E-clip position 10. Replace - bleed - adjust oil-injection pump 11 . Repair - replace damaged - worn eng ine components 12. Time ignition 13. Use 87 minimum octane gasoline 14. Replace - rebui ld water pump - replace thermostat
10. Oil-injection pump malfunctioning adjusted incorrectly 11 . Primary compression (crankcase) low absent 12. Ignition timing adj usted incorrectly 13. Gasoline octane too low 14. Water pump - thermostat damaged faulty Problem: Engine Backfires Condition 1. ThrottleJignition monitor switch adjusted incorrectly 2. Spark plugs fouled - damaged 3. Spark plug heat range too hot 4. High tension wires/coil shorting 5. Carburetor-to-cylinder air leak 6. Carburetors adjusted incorrectly - dirty damaged - loose 7. Gas/air mixture incorrect - too lean 8. Oil-injection pump malfunctioning adjusted incorrectly
Remedy 1. Adjust throttle cable free-play - service spring 2. 3. 4. 5. Clean - gap - replace spa rk plugs Install lower heat-range spark plugs Service - replace high tension wires/coil Repair - replace gaskets - intake flanges service intake ports 6. Troubleshoot - tighten ca rburetors
7. Adjust jetting
8. Replace - bleed - adjust oil-injection pump
Problem: Engine Four-Cycles (Floods Excessively) Condition 1. Carburetors adjusted incorrectly - dirty damaged 2. Gas/air mixture incorrect 3. Oil-injection pump malfunctioning adjusted incorrectly 4. Air-intake silencer obstructed Remedy 1. Troubleshoot - clean carburetors 2. Adj ust jetting 3. Rep lace - bleed - adjust oil-injection pump 4. Remove obstruction
Page: 131
2-119
Problem: Engine Stops Gradually Condition

1. In-line fuel filter obstructed - damaged 2. Fuel hose obstructed - broken - pinched 3. Head gasket(s) burned out Remedy
4. 5. 6. 7. 8.
Cylinder head loosening Spark plugs loose Impulse hose cracked High tension wires/coil faulty Float bowl vent hose (TM-style) obstructed - kinked - damaged
1. Remove obstruction - replace in-line fuel filter 2. Remove obstruction - replace - repair fuel hose 3. Replace head gasket(s) - service cylinders - head 4. Tighten cylinder head cap screws 5. Tighten spark plugs 6. Replace impulse hose 7. Service - replace high tension wires/coil 8. Service - replace float bowl vent hose
Problem: Engine Stops Suddenly Condition

1. In-line fuel filter obstructed damaged 2. Fuel hose obstructed - broken - pinched 3. 4. 5. 6. 7. COl unit faulty Ignition coil faulty Charge coil (1) faulty Charge coil (2) faulty Gas-tank vent - hose obstructed damaged 8. Engine seized 9. ThrottleJignition monitor switch faulty throttle cable adjusted incorrectly Remedy
1. Remove obstruction replace in-line fuel filter 2. Remove obstruction - repair - replace fuel hose 3. Replace COl unit 4. Replace ignition coil 5. Replace coil 6. Replace coil 7. Remove obstruction - replace vent - hose
8. Overhaul engine 9. Replace throttle control - adjust throttle cable free-play - adjust - connect - replace ca rburetor safety switches (VM-style)
Remedy 1. Replace COl unit 2. Connect four-prong co nnector
Problem: Engine Fails to Stop (Continues to Run, Even with All SWitches Off) Condition
1. COl unit shorted to ground 2. Main wiring harness four-prong connector disconnected
2-120
Page: 132
Troubleshooting Engine
(EFI Models)
Problem: Engine Does Not Start (No Spark al Spark Plugs)

Condition
Remedy
1. Ground connections dirty
loose
2. Throttlelignition monitor switch malfunctioning - ignition switch not on 3. Wiring harness shorting - disconnected 4. Emergency stop switch in DOWN position malfunctioning 5. Throttlelignition monitor switch malfunctioning 6. Spark plugs louled - damaged 7. Spark-plug caps damaged - leaking shorting 8. High tension leads/coilloose - grounded laulty 9. ECU laully 10. Ignition timing sensor faulty
1. Check all ground connections clean and tight 2. Replace faulty switch - turn switch on
3. Repair - replace - connect wiring harness 4. Move switch to UP position - replace throttle control
5. Adjust throttle cable tension - replace throttle body assembly 6. Clean - replace spark plugs 7. Replace spark-plug caps
8. Service - replace high tension leads/coil

9. Replace ECU 10. Replace sensor Remedy 1. 2. 3. 4. 5. Fill tank Replace dropping resistor Replace regulator - hose Replace gasoline Service - replace fuel pump - connections - wires Replace - service hose Remove obstruction - replace vent - hose Remove obstruction - replace pick-up valve(s) Repair - replace damaged - worn engine components Replace ECU
Problem: Engine Does Not Start (No Fuel at Cylinders)
Condition 1. Gas lank empty 2. Injector dropping resistor faulty 3. Fuel pressure regulator laulty 4. Gasoline contam inated 5. Fuet pump laulty
6. Fuel hose broken - pinched 7. Gas-tank vent - hose obstructed 8. Pick-up vatve(s) obstructed - damaged
6. 7. 8. 9.
10.
9. Primary compression absent

10. ECU faulty
Page: 133
2121
Problem: Engine Does Not Start (Fuel Does Not Ignite) Condition
1. ECU LED trouble code 2. Spark absent Remedy
3. Primary compression low 4. Secondary compression low

5. Engine tlooded 6. Gasoline contaminated
1. Service - replace problem component 2. Check for spa rk - see No Spark at Spark Plugs sub-section 3. Service engine 4. Service engine 5. Clea r engine (hold throttle full-open) 6. Clean tank and entire fuel system
Remedy
Problem: Engme Does Not Idle Condition

1. ECU LED trouble code 2. Throttle position sensor idle adjustment incorrect 3. Injector(s) faulty 4. Fuel pressure regulator faulty 5. Air-intake silencer obstructed
1. Service - replace problem component 2. Adjust idle RPM to specifications

3. Replace injector(s) 4. Replace reg ulator - hose 5. Clean air-intake silencer Remedy 1. Check LED for trouble code - repair replace problem circuit or sensor 2. Replace spark plugs 3. Service - replace coil 4. Service - replace vent hose 5. Service engine 6. Replace reg ulator 7. Replace - relocate pick-up valve(s) 8. Replace - bleed - adjust oi l-injection pump
Problem: Engine Loses Power or Runs on One Cylinder Condition

1. Sensor faulty 2. Spark plug fouled 3. External coil faulty 4. Gas tank vent - hose obstructed 5. Secondary compression low 6. Fuel pressure regulator faulty 7. Pick-up valve(s) obstructed - out of position 8. Oil-injection pump malfunctioning adjusted incorrectly 9. Throttle bodies out of synchronization
9. Replace throttle bodies from a similar engine - if problem is corrected , replace the original
assembly 10. Replace injector 11 . Test resistor - replace as necessary
10. Injector faully 11 . Dropping resistor faulty
2-122
Page: 134
Problem: Engine Overheats Condition Spark plug heat range 100 hal Coolant low - absenl Heat exchanger obstructed Intake flange to cylinder air leak Drive system (drive clutch - driven pulley - track - drive belt) adj usl ed incorrectly worn - damaged 6. Rings/grooves carboned 7. Exhaust ports obstructed 8. Expansion chamber obstructed 9. Oil-injection pump malfunctioning adjusted incorrectly 10. Primary compression low - absent 11 . Gasoline octane too low 12. Water pump - thermostat damaged faully Problem: Engine Backfires Condition 1. LED trouble code 2. Throttlelignition monitor switch adjusted incorrectly 3. Spark plugs fouled - damaged 4. High tension leads/coil shorting 5. ECU faully - damaged 6. Fuel mixture lean 7. Oil-injection pump malfunctioning adjusted incorrectly Remedy 1. Se rvice replace problem component 2. Adjust throttle cable tension - service spring 3. 4. 5. 6. 7. Clean - replace spark plugs Se rvice - replace high tension leads/coi l Replace ECU Repair fuel regulator - injector(s) Replace - bleed - adjust oil-injection pump 1. 2. 3. 4. 5. Remedy 1. 2. 3. 4. 5. Inslalilower heal-range spark plugs Add coolanl Remove obstruction Replace - seal inlake flange(s) Troubleshoot - adjust drive system
6. Clean 7. Remove 8. Remove 9. Replace
replace rings - pistons obstruction obstruction - bleed - adj ust oi l-injection pump
10. Repair - replace damaged - worn engine components 11 . Use 87 minimum octane gasoline 12. Replace water pump - thermostat
Problem: Engine Four-Cycles (Floods Excessively) Condition 1. 2. 3. 4. 5. LED trouble code Fuel pressure too high Injector faulty Throttle position sensor fau lty Air-intake silencer obstructed Remedy 1. 2. 3. 4. 5. Se rvice - replace problem component Replace regulator - hose Replace injector Replace throttle body assembly Remove obstruction
Page: 135
2-123
Problem: Engine Stops Suddenly Condition 1. Gas tank empty 2. Spark absent 3. LED trouble code 4. COl relay faulty 5. Fuel filter(s) obstructed 6. Fuel pressure low 7. Fuel pump faully 8. Fuel pump relay faulty 9. Gas tank vent hose obstructed 10. ECU faulty 11 . Fuel hose obstructed - broken - pinched 12. Ignition coil faulty 13. Engine seized 14. Throttlelignition monitor switch - throttle cable tension faulty - adjusted incorrectly Condition 1. ECU shorted to ground 2. Engine w iring harness connections wet Remedy 1. Fill tank 2. See No Spark at Spark Plugs sub-section 3. Service - replace problem component 4. Rep lace CO l relay 5. Replace filter(s) 6. Replace reg ulator - hose 7. Service - replace fuel pump 8. Replace relay 9. Service vent hose 10. Replace ECU 11. Remove obstruction - repair - replace fuel hose 12. Replace ignition coi l 13. Overhaul engine 14. Replace throttle co ntrol - adjust throttle cable
Problem: Engine Fails to Stop (Continues to Run, Even with All SWitches Off) Remedy 1. Rep lace ECU 2. Clea n - dry connections
2124
Page: 136
2005 Arctic Cat Service Manu al - all models - www. ReadM anu als.com
I. Fill buret with lOW engine oil.
Engine Information Table of Contents

Cylinder Head Volume Tests .. .. ..... .. Crankshaft Repair ............ ...........
2. Remove the s park plugs from the cylinde rs. 3. Run piston up to T DC (Top Dead Cente r).
......... 2-125 ...... .. 2-126
4 . Insert buret into spark plug hole and o pen buret valve. Run o il into the s park plug hole until it reaches the top of the s park plug ho le . T urn o ff the buret valve.
Cylinder Head Volume Tests

CYLINDER HEAD VOLUME
5. C heck the buret scale to see how much oi l has been used to fill the combustio n chamber. From the total amount. s ubtract 2.20 cc or 2.44 cc. Compare the findings with the chmt .
(Squish.Gap Method)
To check the squi sh ga p, a mi cro meter and a hea vy piece of solder will be needed.
I. Remove the s park plugs from the engine . 2. Insert the solder piece down through the spark plug hole and push it up against the inner cylinder bore towards the MAG-side o f the engine .
3. Pull the recoil rope and crank the engine over several times while the solde r is being held firml y in place.
NOTE: The above procedure will work fine on a new engine. Engines with many hours of use, may require a small change in the procedure. In step 3, remove the cylinder head. Wipe a small amount of heavy grease around the outer diameter of the piston to seal space between the piston and cylinder bore. Replace head and tighten to specification; then continue with steps 4 and 5.
CYLINDER HEAD VOLUME
(Flat Plate Method)

The third method of c hecki ng fo r pro pe r combust ion chamber vol ume will require a 118 in . or 3/ 16 in. thi ck piece of plexiglass, some heavy grease, and a buret. T he plexiglass pi ece must be nat and also large e nough to cover the entire gasket s urface of the cylinder hCt'ld. Using a 3 / 16 in. drill bit , drill two holes through the plexiglass piece. Locate the ho les o ne inch apart inside the combustio n chamber area (towards center o f piece) . I. Remo\'e the cylinder head from the e ngi ne . C lean all carbon from the combustion cha mber area. 2 . Position the cylinde r head squarel y in a vise with its gasket surface up. Leave a BR9ES s park plug in place and grip the metal pOition of the spark plug fo r ho lding the cylinder head. 3. Apply a light coat of grease to the gasket s urface o f the head. Squeeze the piece o f plexiglass firml y down o nto the gasket s urface. T he grease will act as a sealant between the two pi eces . 4 . Using a buret filled with light oil , fill the combus tion chamber through either o f the two holes drilled in the plexiglass. Continue to fill the combustio n chamber until the fluid appears at the bottom of the second hole. Sto p fillin g procedure and take a reading o ff the buret as to how much nuid was lIsed. The s pecification found in the chart includes the s p.a rk plug volume, so there won't be any need to subtract from the reading.
4 . Remove the solder fro m the cylinder. Using the micrometer, measure the vcry end of the squeezed solde r pi ece. Record the reading.
NOTE: If the solder hasn't been squeezed by the piston, a larger piece of solder must be used. Repeat procedure.
5. Using the opposite end o f the solder piece, insert it dow n through the s park plug hole towards the PI"O-side of the engine . Pus h on the solder until it contacts the inner cylinder bore. 6. Pull the recoil ro pe and crank the engine over several times. Remove the solder from the cylinde r and measure the squeezed end with a micrometer. Record readi ng and refer to the chmt.
NOTE: Measure from PTO to MAG-side of the piston to accurately measure the squish gap. Never measure across piston, exhaust to carbUrE~ tor side, as the piston will rock and the reading won't be accurate.
Readings may vary fro m side to side. rvlake s ure the s malle r reading is within the s pecifications listed .
CYLINDER HEAD VOLUME (Cylinder Head Installed Method)

To check the cc volume, a measuring tool called a buret will be needed. It is capabl e o f measuring a liquid in cc volumes.
Page: 137
2-125
Crankshaft Repair
For those w ho have crankshaft work sent
O llt
NOTE: We have given the proper location for checking crankshaft runout as the very edge of the
straight portion of the shaft where the oil seal

makes contact. From the drawings on page 23 of this section , note that Arctic Cat has called out three check points: at either end , out on the taper as shown, and also on the center bearing race. The
to another
sho p, it is advisable to provide them with thi s information. To use the spec ifi cati o ns, first re fe r to the draw in g; the n find the Ictter whi c h indi cates the specifi cati o n and refer to the chart below the illustratioll. Be sure to no te the pro pe r e ng ine column . S pecifi cati o ns a rc called o ut in both millimeters and inc hes.
crankshaft is still supported on the outer bearings using V blocks. The maximum runout shouldn't exceed 0.05 mm (0.002 in.).
2-126
Page: 138
SECTION 3 - ENGINE-RELATED ITEMS
TABLE OF CONTENTS
Axial Fan/Belt (370/440 eel ........................ ............ 3-2 Repairing Water Pump (Standard Models) .. ........... 3-4 Repairing Water Pump ("Laydown" Engine Models) .................... ............. 3-8 Pressure Testing Engine ....................................... 3-1 1 Liquid Cooling System ...... .. .. ... .. . ... ............... ..... 3-11 Cooling System Schematics .... .................... ....... .. 3-12 Recoil Starter ........... .. ..... ............ .. ..... ....... .. ..... ..... 3-16 Arctic Power Valve (A,P\!) Sxstem ............. .......... .. 3-18 Exhaust Controlled Timing (Eel) System ............ 3-30
Page: 139
31
4. Remove the fan with shan .
Axial Fan/Beli:
(370/440 ee)
5. Dri ve the bearings from the ran case and account

for the sp..'l cer between the bearings.
REMOVING FAN
I. Re move the four cap screws sec uring the recoil stm1cr to the ran case.
2. Remove the three cap screws securing the recoil slm1er pulley and fan dri ve pulley to the fl ywheel ; then remove the recoil starter pulley and fan dri ve
pulley.
3 . Remove the cap screws and flange nuts securing the ra n case assembly to the engi ne; then remove the ra n case from the engine comp<1 11mcnt.
DISASSEMBLING
I. Remove the ran cover; then remove the belt.
2. Using the Fan Spanner Wrench (pIn 0644- 139),
NOTE: A circlip is positioned between the bearings. The bearings must be driven from the center to the outside of the fan case. 6. Remove the circiip from the fan case.
remove the Ilut , lock washer, and washer securing pulley halves.
3. Slide the outer pulley half, shim(s), ran belt , and inner pulley half o ff the shan and account for the
key and the fan bell.
CLEANING AND INSPECTING

NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. I. Clean all axial fan compo nent'). 2. Inspect the 1~1Il case and shaft threaded areas for damage o r stripped threads; then check the shaft keyway and key ro r excessive wear. 3. Inspect the fan for broken, bent , o r damaged vanes. 4. Inspect the bearings ror smooth rotation. 5. Inspect the pulley hal ves ror cracks, gouges, or othe r damage. 6. Inspect the ran belt ro r cracks, tears, or rraying.
A909
3-2
Page: 140
ASSEMBLING
""
4. 5. 6. 7. 8. 9.
1. Drive Pulley
2. Bell 3. Fan
Key Bearing
Space r Cltcllp
Pulley Hall
Shim
10. Washer 11 . Look Washer
12. Nut 13. Shaft

14. Cap Screw 15. Fall Assy
"
"
0733-277
7. Using the fan spanner wrenc h, secure the pulley with a washer, lock washer, and nul. Tighten the nut to 2.5-4 kg-Ill ( 18-29 ft-lb). INSTALLING FAN I. Place the fan case assembl y o n the engine; the n secure with fl ange nuts and cap screws. Tighten the flange nuts to 1,8-2.2 kg-m ( 13 - 16 ft -Ib). Tighten the cap screws to 0.4-0.7 kg-m (3-5 ft -lb). 2, Place the new fan belt into IXJSition on the upper pull ey. 3. Place the fan dri ve pulley onto the fan belt and align one of its holes WiUl one of the mounting holes in the fl yw heel; then stmt a cap screw into the aligned holes and finger-tighten. 4. Rotate the fan dri ve pulley clockwise while observi ng the other two holes in the pulley. When they align with the two holes in the fl ywheel, sl'mt the re maining two mo unting cap screws.
I. Install the circlip into the groove of the ran casco
2. Press a bearing into the fan case until it is seated against the c irelip. 3. Fro m the opposite side of the ran case, install the spacer and press the fCmaining bearing into the fun case until it is scated.
NOTE: The spacer is positioned between the two fan-case bearings.
5. Tighten the three cap screws o nl y to position the fan drive pulley on the fl yw heel; then remove the three cap screws and inst.'ll! the recoil st.'lrter pulley. Apply red Loctite #27 1 to the threads of the three ca p screws and install them into the fl ywheel. Tighten the three cap screws e venly to 0.8- 1.2 kg-m (6-9 ft -lb). 6. Check the fan belt tension. Adjust as necessary.
4. Insclt the fan with shah through the fa n bearings. 5. Install the key into the shaft 6. Slide the inncr pull ey half. requi red shim(s), ran bell, and outer pulley half onto the shaft. 7. Insta ll the fan cover and secure with six screws. Tighten the screws to 1. 1 kg-m (8 ft -lb). 8. Install the recoil stmter. Secure with fo ur cap screws. Tighten to 1.1 kg-m (8 ft -lb). REPLACING FAN BELT 1. Remove the fan cover and the recoil stmter. 2. Re move the three cap screws securing the recoil starter pulley and the fan dri ve pulley to the Il ywheel. 3. Rel"':love the fan dri ve pulley and fan bell fro m the engine.
Page: 141
33
4. Place the new fan belt into position on the upper pulley.
5. Place the fan drive pulley onto the fan belt and align one of its holes with one of the mounting holes in the Oyw hecJ; then start a cap screw into the aligned hole and fin ger-ti ghten.
2. Squeeze the belt at midspan and observe the belt
deOection. The maximum belt del1ection on either side must not excced 6 mm ( l f4 in.). If the deOection is not within specifications, adjust the belt tension.
6. Rotate the fan drive pulley clockwise while obsen'ing the other two holes in the pull ey. When they align with the two holes in the Oywheel, stm1 the re maining two cap screws.
7 . Tighten the three cap screws only to position the
fan dri ve pulley on the Oyw heel; then remove the three cap screws and install the recoi l sl'artcr pullcy. Appl y red Loctite 1127 1 to the threads of the thrce cap screws and install into the Oywhecl. Ti ghtcn the threc cap screws evcn ly to 0.81.2 kg-Ill (6-9 ft-l b). 3. Install the fan covcr. Tightcn the screws to 1. 1 kgm (8 rt-Jb).
ADJUSTING BELT TENSION

I. Remove the fan covcr. 2. Using the fan spanner wrench. remo\'e the nut, lock washer, a nd washer securing the pulley hal ves. 3. Slide the outer pulley half off the shaft and account for any shim(s). 4. Add or remove shim(s) to attai n correcl belt te nsion.
_NOTE : To increase belt tension, remove shim(s)j to decrease belt tension, install shim(s).
NOTE: With the new belt installed, check fan belt tension (see Checking Belt Tension).
8. Install the fan cover. Tightcn the scrcws to 1. 1 kgIII (8 ft-Ib). Install the recoi l st.arter. Tightcn the ca p screws to 1. I kg-Ill (8 ft -lb),
CHECKING BELT TENSION

I. Remove the fan cover.
5. Insta ll the fa n belt and the outer pulley half on the sh..'lft and, using the fan spanner wrench, sec urc pullcy with a washer, lock washer, and nut. Tighten to 2.5-4 kg-m ( 18-29 ft -Ib). 6. Recheck belt tension; adjust if necessary. 7. Install fan cover. Tighten the screws to 1.1 kg-Ill
(8 ft-Jb) .
Repairing Water Pump

(Standard Models)
NOTE: A bleed hole is located at the bottom of the water pump housing. If there are any signs of coolant leakage from the bleed hole, the water pump seals must be replaced. When servicing the water pump, use Water Pump Bearing and Seal Kit (pin 0644-084).
1. Remove the expansion chamber from the engine coml:k1.rtment.
3-4
AB075
2. Attach a long piece of fuel hose to the engine coolant drain val ve (located on the front lower half of the crankcase). Route the fuel hose outside the engi ne compartment and into a container. Open the drain valve and remove the filler cap. Once the coolant stops !lowi ng, remove the hose and ti ghten thc drain \'alvc. 3. Rcmovc the coolant hose from the watcr pump cover. 4. Remove the screws securing the water pump cover; then remove the cover and account for the O-ring seal.
NOTE: If the impeller won't slide off the shaft, start the cap screw into the shaft and tap on the cap screw driving the shaft back out of the impeller.
10. Remo\'c thc oil-injcction pump rctaincr and shaft
from the opposite side of the crankcase. Account for Ihe thrust washer located between the retainer and shaft ilange.
5. Loosen the throttl e body/carburetor ilange damps; thcn remo\'e the throttlc body/carburetors. 6. Rcmove the mounting hardware securing the engi ne 1 0 the fronl-end assembly. Remove the hose from the thermostat housing and tip the engi ne forward. 7. Rcmovc cither lowcr union cap scrcw sccuring the lower chcck \'ah'e assembl y. Remove the two screws securing the oil-i njection pump and pull thc oil pump from the enginc. Leave thc pump hose and cable attached.
8. Remove the cap screw securing the impeller.
11 . Using the long seal driver, dri ve the water pump
seal from the crankcase.
AN233
12. Using a pair of snap ring pliers, remove the snap ring securing the inner sca l in thc crankcasc.
9. Rcmovc thc impellcr from the shaft.
Page: 143
35
13. Using the hooked cnd of the long seal dri ver, pull the inner seal free of the crankcase.
ASSEMBLING
4. Using a pair of snap ring pliers, install the snap ring securing the inner seal in the crankcase.
I Wipe the seal area clean using a clean rag.
AN249
5. Using the seal driver, carefull y install the outer water pump seal. Gentl y tap the seal dow n into position until it seats itself against its flan ge. 2. Position the inncr seal onto the scal dri\'cr (spring side towards the crankshaft ). Gently lap into position.
3 . Using a small screwdri ver, apply a light coat of grease to the inner seal lips.
6. Appl y a light coat of greasc to the sealing surface of the oil-injectioll pump dri veshaft ; thcn inst.a ll Oil Seal Installation Tool (pIn 0644-2 19) at the end of the shaft. Twist the shaft as it is pushed through the oil and water pump seals; then remove the tool. Position the shim on the oil pump end of the shaft.
36
Page: 144
7. Install the oil -injection pump retainer O-ring and retainer.
11 . Apply sealant to the crankcase scam; then install the ali gnment pins into the crankcase (if removed).
8. Install the O-ring and the oil-injection pump. Make sure the pump shaft and oil pump align. Secure with two screws and washers. Tighten the two screws to 0.7 kg-m (5 ft-Ib).
12. Position the O-ring into the water pump cover; then install the cover. Secure with the screws , Tighten to 1. 1 kg-m (8 ft -Ib),
9. Place the lower check vah'e into position ; then secure with the gasket's and union cap screw. Tighten securel y. 10. Place the Impeller into position and secure with a cap sc rew and washcr. Be sure the rubber side of the washer is directed towards the impeller. Apply blue Loct'itc #242 to the threads of thc cap screw and ti ghtcn toO.8-1 .2 kg-m (6-9 ft-Ib).
13. Set the cngine down into position and sec urc to the front-end assembly. Tighten to specifications (see Section 2). 14. Connect the coolant hose to the water pump cover and secure with the clamp. 15. Install the throttle body/carburetors and secure with clamps. 16. Install the cxpanslon cham ber and sccure with springs,
Page: 145
37
NOTE: When installing the springs, the long hook portion of the spring must be attached to the exhaust manifold or premature spring failure will result.
17. Install the thermostat hose and rill the cooling system with antifreeze. Start and run the engine. Check fo r leaks and recheck the cooling system to make sure it has been properly rilled.
Repairing Water Pump

(n"Laydovvn" Engine Models)
4. Remove the impe ller from the shaft.

NOTE: The engine must be removed for this procedure. NOTE: A bleed hole is located at the bottom of the water pump housing. If there are any signs of coolant leakage from the bleed hole, the water pump seals must be replaced . When servicing the water pump, use Water Pump Bearing and Seal Kit (pin 0644-084).
I. Remove the screws securing the water pump cover; then remove the cover and account for the O-ring seal.
NOTE: If the impeller will not slide off the shaft, start the cap screw into the shaft and tap on the cap screw driving the shaft back out of the impeller.
2. Re move either lower union cap screw securing the lower check val ve assembl y. Remove the two screws securing the oil -injection pump and pull the oil pump from the engine. Leave the pump hose and cable attached. 3. Remo\'e the cap screw securing the impe ll er. Account ror the rubber washer behind the cap screw. 5. Remove the oil-injection pump retainer and shaft from the opposite side of the crankcase. Account for the thrust washer located bet ween the retmner and shaft nange.
3-8
Page: 146
ASSEMBLING
I. Wipe the seal area clean using a clean rag.
6. Using the long seal dri ver, dri ve the water pump mechanical seal from the crankcase. 2. Position the inner seal onto the seal driver (spring side towards the crankshaft). Gentl y tap into position.
7. Using a pair of snap ring pliers, remove the snap ring securing the inner seal in the crankcase.
3. Using a small screwdri ver, apply a li ght coat of grease to the inner seal lips.
.I "
8. Using the hooked end of the long seal dri ver, pull the inner seal free of the cra nkcase.
FC127
4. Using a pair of snap ring pliers, instHIl the snap ring securing the inner sea l in the crankcase.
Page: 147
39
5. Using the seal driver, carefully install the outer water pump mechanical seal. Gently tap the SCt'l1 down into lX)sitioll until it seats itself agai nst its flange.
8. Install the O-ring and the oil-mjection pump.
Ma ke sure the pump shaft and oi l pump align. Secure with two screws, Tighten the two screws to 0.7 kg-m (5 ft-Ib).
6. Apply a li ght coat of grease to the sealing sllliace of the oil -injection pump dri veshaft ; then install Oil Seal Installation Tool (pIn 0644-2 19) at the cnd of the shaft. Twist the shaft as it is pushed through the oi l and water pump seals; then remove the tooL Posi tion the shim Oil the oil pump end of the shaft.
9. Place the lower c heck valve into positi o n~ then secure with the gaskets and union cap screw. Tighten sec urel y. 10. Place the impeller into position and secure with a cap screw and washe r. Be sure the rubber side of the washer is directed towards the impeller. Appl y blue Loctite 11242 to the threads of the cap sc rew and tighten to 0,8- 1.2 kg-m (6-9 ft-lb) ,
7. Install the oil-injection pump retainer O-ring and retainer. 11. Apply sealant to the crankcase seam; then install the ali gnment pins into the crankcase (if removed).
310
Page: 148
a. Install a plug into each intake-manifold port and tighten the Ilange clamps securely. b. Placc a rubber plug and covcr on cach cx haust I)()lt and sccure. c. Connect the tester pump to an impulse finin g on the crankcase; then plug any remaining impulse fittin gs and pressuri ze the crankcase to 8 psi and close the valve.
&
NOTE: It is important to not get sealant into the breather hole in the crankcase. If sealant gets into the hole, carefully remove before proceeding.
CAUTION
00 NOT exceed 8 psi pressure or damage to the seals will result.
d. Monitor the pressure gaugc. Thc pressure must not drop at a rate of more than 1 psi per minute.
12. Position the O-ring into the water pump cover:
then install the cover. Sec ure with the screws. Tighten to 1. 1 kg-m (8 ft -Ib).
c. If the pressure drops faster thun specified, inspect for an air leak with soapy water or by completely submcrging the pressurized cngine in clean fresh water. Rcpair as nccded.
&
CAUTION
When submerging the engine to test for air leaks, all external electrical components must be removed to avoid damage.
Liquid Cooling System

FC134
The liquid cooling systcm consists of heat exchangers, wa terpump, and th ermosta t. The system should be inspected for lea ks or damage whenever an overheating problcm is ex pcricnccd.
FILLING COOLING SYSTEM
Pressure Testing Engine

I . Test the engine for air leaks using the foll ow ing proccdure and Pressure Testing Kit (pin 0 144127).
&
CAUTION
Be sure the cooling system is throughly filled using the following procedure.
I . Elevatc the front of tile snowmobilc 30-60 em ( 1214 in.).
Page: 149
3-11
2. Remove the coolant tank cap and check coolant level. The coolant tank should be fill ed to the coolant level line. 3 . Install the coolant tank cap; the n start the engine. Run the engine at 3000-3500 RPM until the bottom hcat exchangers become hot to thc touch. Stop thc cngine and all ow thc system to cool. 4. Lower the front of the snowmobile and elevatc the rear of the snowmobile 12- 14 in. Repeat the procedures in step 3. 5. Check the coolant level. Add coolant as required to the coolant tank (coolant tank should be fill ed to coolant Icvcllinc). Rcpcat procedurc until coolant lcvcl stabilizcs in the coolant tank. NOTE : If coolant is required, mix coolant for a temperature of 36C (34F). Follow mixing recom mendations of the manufacturer of the coolant.
INSPECTING COOlANT HOSES AND CLAMPS

All coolant hoses and connccti ons should be checked annually for dctcrioration, cracks, and wcar. All coolant hoscs and cl amps should be rcplaced evcry four ycars.
INSPECTING THERMOSTAT
I. Inspect the thcrmostat for corrosion, wcar, or spring damagc. 2. Using thc following procedurc, thermostat for proper opc ration. inspcct the
a. Suspe nd the thermos!. '"!t in a container fill ed with waler. b. Heal the water and monitor the temperature with a thcrmomcter. c. The thcrmostat should opcn at 50C (122F). Once the thermostat starts to open, I!vIMEDl f\TELY remove the thcnnos!.'"!t as it will lock in the open posilion if allowed to open full y. NOTE : The thermostat is of the lockopen type. If the thermostat is ever allowed to fully open, it will remain open and replacement will be necessary.
&
CAUTION
It is extremely important that the Filling Cooling System procedure is followed very closely and the cooling system is properly filled. If the system isn't properly filled, piston damage will occur.
Cooling System Schematics

The follow ing schematics are representati ve of the different styles of 2-stroke cooling systems in the 2005 Arctic Cat snowmobiles. Some compo ncnts may vary from model to model ; therefore, thc tcchnician should use discrcti on and sound judgment whcn servicing a particular cooling system.
Left-Side Heat Exchanger Tube
, C:oolant Tank
Heat Exchanger Tube
Coolant Flow: Thermostat Open ~ - + Thermostat Closed - + - 3-12 Page: 150
Front Heat Exchanger
Pump
0 734 -45 1
Rear - _, Heat Exchanger Right Heat Exchanger
Left Heat Exchanger
)<:';J,"~J------ Front Heat Exchanger

Water Pump Thermostat
738-067A
KEY
". ". ". H. ". ".

". >S.
".. " C.p
,. ,. Hose Clamp ,. ,. ,. ,.
H~.
1. Left Heal Exchanger RighI Heal Exchanger Rear Heat Exc hanger
Loc k Nul Machine Screw Rivet Rivet SeIITapping Serew Coolant Tank
Cable Tie Hose Clamp

H~
Hose Clamp
H~
Lock Nul Hose Clamp

H~. H~ H~.
H~
". ". ". ".

29 . 30.
". Hose Clamp ". 23.

Hose Clamp
HoseC lamp Cable Tie Hose Protector Machine Screw
20.
". N"
32.
,'- FMm FMm

0739756
Page: 151
3-13
KEY
H~ 20. Foil Tape
... ... ". ... ". ... ... ...
D.", S. 6. Rivet ,. Spacer Cablelle 9.

Ho~ H~. H~
1. Coolant Tank 2. Hose 3. Clamp
Heat Exchanger Clamp 13. Hose Guard Cap Screw Rivet
Cop 17. Heat Exchanger

H~
0739-147
KEY
1. Coolant Tank 2. Cap 3. Decal
4. Clamp
5. Machine Sc rew 6. Hose

7. Lock NUl 8. Clamp
9. Hose 10. Heat Exchanger 11 . Rivet

12. Hose
13. Hose
14. Hose 15. Cable Tie
16. T-F inlng (600 eel

17. Hose Clamp(600cc) 18. Hose (600 cc)
19. Conduit (600 eel 20. Hose (600 eel
0738-536
314
Page: 152
KEY
1. Heal e.changer
2. Ri vet 3. Clamp 4. Hose
D Jll(1llol
W .. n. .. ! CI.lOII .... LOOIt.

1 ~~1!.loI l C1 . ~
fClJ. 1/II>.1'
JUOIa"' ICII .IOOII"" . IT1lI .21.
S. Protector
6. Rivet
7. 8. 9. 10. 11. Heal Exchanger Heal Ellc hanger Hose Protector Clamp Hose Clamp Coolant Tank
H~ H~
". IS. ". "'.
". ". D."'

"- C.p
H~
"-
Clamp
". ". 25. Support Pad

H~
Clamp "- Cable Tie 22. Clamp
Hose Protector
COOLING ASSEMBLY
IL 0139514
0739-574
KEY
1. Heal e xc hanger 2. Hose 3. Clamp Heal Elfc hanger Insert Heat e xchanger
,. 7. Rivet Ri vet 9.
H~ H~ H~ H.~
". n 13. ". ". ". ". IS. D."' C.p ". "'. "- Spacer Cap Screw Guide ". lRope ock Nut ".
H~
10. Clamp
Coolant Tank Foil Tape Cable Tie
Clamp
22.
25. Cap Screw 26. Protector
~
0739-568
Page: 153
3-15
Recoil Starter
REMOVING
I. Tic a slip-knot in the start'Cl" rope below the
3. While exelti ng downward pressure on the fricti o n plate, remove the nut and washer o r cap screw.
console and allow the rope to slow ly retract against the stalter casco 2. Remove the knot at the handle, remove t he handle.
and account for the handle cap; then thread the rope through the bushing in the console. 3. Remove the cap screws securing the stmtcr assembly to the magneto case; then remove the
stalter assembl y.
6523
DISASSEMBLING
4. Slowly release the plate and lift the plate with friction spring free o f the recoil roller. 5. Remove the fricti o n spring from the plate.
Always wear safety glasses when servicing the recoil starter.
I. Secure the recoi l stalter in a vise.
& WARNING
During the disassembly procedure, continuous downward pressure must be exerted on the reel so it does not accidentally disengage and cause injury.
2. Rotate the roll er counterclockwi se until the notch of the roller is nca r the rope guide in the casco G uide the ro pe into the notch and slow ly allow the roller to retract until all recoil spring tension is released,
6524
6. Remo\'e the pawl ; then removc the return spring.
6522
6525
& WARNING
Care must be taken when allowing the recoil roller to unwind. Make sure all spring tension is released before continuing.
7. Carcfull y lift the roller free of the case making sure the main spring does not accidentally disengage from the case.
Care must be taken when lifting the roller free of the case.
316
Page: 154
8. Removc the main spring from the casc by lifting the spring end up and oul. Hold the remaindcr of the spring with thumbs and alternatel y release each thumb to allow the spring to gradually release from the case.
NOTE: Do not remove the main spring unless replacement is necessary. It should be visually inspected in place to save time.
I. Hook the end of the main spring around the mounting lug in the case. 2. Insert the main spring into the casc; thcn wind it in a counterclockwi se dircction until the complete spring is installed .
NOTE: The main spring must seat evenly in the recoil case.
9. Unwind the ropc from the roller, untie the slipknot, and remove the rope.
NOTE: Whenever a part is worn excessively, cracked , or damaged in any way, replacement is necessary.
3. hlSClt thc rope through the hole !O the roller and tie a knot !O the end; then wrap the rope counterclockwise around the roller leaving approximately 50 cm (20 in.) of rope free of the roller. 4. Appl y low -temperature grease to the main spring and hub. S. Ali gn the hook in the end of the main spring with the notch in the roller. 6. O lrefull y slide the roller over the hub and engage the spring with the roll er. 7. Install the return spring making sure the end is properl y install ed in the hole in the roller; then install lhe pawl making sure lhe return spring is properl y preloaded.
I. Clean all recoil stmter components. 2. Inspect all springs, washers, and pawl for wear or damage. 3. Inspectlhe roller and case for cracks or damage. 4. Inspect the center hub for wear, cracks, or damage.
S.
Inspect the rope for breaks or fra ying.
6. Inspect the main spring for cracks, crystalli l..ation, or abnormal bends. 7. Inspect the handl e for damage, cracks, or deterioration.
ASSEMBLING
B525
8. Slide the end of the rope through the rope guide of the case; then tic a slip-knot in the rope. 9. Place the fri ction spring into position on the fricti on plate making sure the head of the spring is oPIX)site the flat of the inller hole. Appl y a lowtemperature grease to the plate.
KEY 1. Starter Assy 2 . Starter Roller 3. Main Spring 4 . Ratchet Set 5. Friction Spring 6 . Was her 1. Return Spring 8. Friction Plate 9. Nut 10. Starter Rope 11 . Cap S<: rew 12. Starter Pulley 13. Cap S<: rew 14. Clamp
0739915
Page: 155
3-17
NOTE: Before tightening the cap screws, slowly pull the recoil rope until the pawl engages; then tighten the cap screws. This will center the recoil against the magneto case.
3. ThrC<ld the rope through the bushing in the console; then install the handle and secure with a knot. Seat the cap. 4. Release the slip-knot in the rope.
8524
10. Place the plate into position making sure the nat of the inner hole is correclly positioned in the hub. Appl y blue Loctite #242 to the threads; then sccure the dri ve plate with a washer and nut or with a ca p screw. Tighten the nut to 1 kg-Ill (7 ft-I b) or ti ghte n the cap screw to 0.8-2.1 kg-Ill
(6-9 ft-Ib).
Arctic Povver Valve (APV) System

NOTE: On carbureted models, the servo will cycle once each time the engine is started. If the servo cycles three times and then quits, the cable lengths are incorrect and must be adjusted . NOTE: On EFI models, the servo will cycle once at 7100 RPM. If the servo cycles three times, cable length adjustment or valve inspection is required.
APV VALVE POSITION One Stage RPM Ranges ENGINE MODEL
SOOcc
Acceleration APV Cycle RPM Peak H.P. RPM 83-8400 82-8300 78-8000 78-8000 73-7500 73-7500 73-7500
600 cc STD 600 cc EFt "Laydown' 700 cc EFI "Laydown" 700 cc "Laydown" (Carb) 900 cc (Carb) 900 cc EFI
8 526
7250 7000 (Low Alt) 7170 (High All) 7300 (Low All) 7400 (High All) 7200
6800 (Low All) 6900 (High All)
11 With 50 em (20 in. ) of rope exposed, hook the rope in the notch of the roll er. 12. Rotate the roll er four or fi vc turns counterclockwise; then release the rope frolll the notch and allow the rope to retract. 13. Pull the rope out two or three times to check for correct tension.
NOTE: Increasing the rotations in step 12 will increase spring tension.
6750 6800
INSTALLING
Place the starter assembly into position against the magneto case. 2. Sec ure the starter with cap screws. Tighten to 1 kg-Ill (7 fl-Ib) on the Lie models or to 1.1 kg-Ill (8 ft-I b) on the FIC models.
739-S17A
318
Page: 156
&:::::::::::::::::::::
739-581A
'f
J
0 735-516
APV CABLE LENGTH ( " Laydown")

ENGINE MODEL
:i:
CENTER 1 mm (0.039 In.)

34.5 mm
(1 .35 in.)
500cc 600ce
34.5 mm (1.35 in.) 34.5 mm (1.35 in.)
~::::::::::::::::::::~
I1 -.
0735-516 CENTER :I: 1 mm (0.039 in.)
700cc
The Arctic Power Valve CA PV) System adjusts the size of the exhaust ports to produce maximum horsepower on th e t o p cnd w hile prov idin g exce ll ent l ow end power and increased lo uring fuel economy.
AP V CABLE LENGTH ( STO)

ENGINE MODEL
600ce 900cc
THEORY
Two-cyc le engin es and th eir ex hau st sys te ms are
designed to prod uce max imum ho rsepower in a g iven RPM range. This RPM range will change according to how hi gh (or low) the ex haust p0i1 is in relatio n to the cy linder. E ngines des igned fo r rac ing have a " hi g h po rt " ex haust syste m a nd will pro duce mo re ho rse power at hi gher RP~vl but onl y with the loss of low end power a nd overall fue l econo my. '"Low port" eng ines will produce max imum horsepower in t he low RPM ranges and prov ide good mid-range fuel econo my, but they sacritlce top end perfo rmance. T he APV system does not increase engine ho rsepower, but it does a llow the e ng ine to be designed fo r max imum to p end ho rsepower witho ut the losses associated with a " hi gh port " exhaust system.
7382326
28.2mm(1 .11 in.)
39.5 mm (1 .56 in.)
OIIT... k
Se""""olor
Support Tube Steering Post

} ~-- .""'.. c....
Servomo or - Adju s te r Nut ' -J am Nut Adjuster Nut

0739-7 15
'\ '.
7354766
Page: 157
319
COMPONENTS
The main component s o f th e A P V sys tem are the
roll ow ing.
A.
B.
DC Powe r Coill Li ghting Coil Regulato r/Reclifier
There is one major differe nce between the carbureted and fu el inj ected model s concerning the conde nser's locati on. O n the carbureted models, the condenser is a separate compo nent In the fu el inj ected mode ls, the condenser is located within the ECU and is part o f the
ECU.
CDI Unit or ECU
C
D.
E.
Condenser
C DI Unit or ECU
Servomotor
Power Vah'c O lbJcs

Power Val yes
The computer within the C Ol o r ECU has been programmed to raise and lower the power val ves at a specific engine rpm. Whe n thi s rpm is rc.. "lched , DC current is ro uted to the servomotor by the COl o r the ECU.
Servomotor
G.
DC Power Coil/Lighting Coif

As the engine is turned over on models having a power coil , the DC power coil (located on the stator plate) generates AC current which fl ows to both the regulator/reclifie r and the C Ol unit on carbureted models or the ECU o n the EFI models. The AC current which fl ows to the C DI or ECU signals eithe r of these compo ne nts that the e ng ine is turning ovcr in the pro pe r direction. If the engine sho uld b.lc kfirc and start to run In reverse, the signal from the DC power co il will indicate this reverse rolalio n. The C Ol or ECU co mputer the n shuts down. On several models, AC current fo r the APV syste m is supplied by the li ghting coil. Thi s AC curre nt is regulated to 13.5 volts by the \'o lt"age regulator. T hese model s also may no t have a separate regulatorfrectifie r o r conde nse r. T hese two co mpo ne nt s are the n located within the ECU and perfo rm the same functio n. The AC curre nt gene rated by the DC power coil , o r li ghting co il , whic h n ows to the regulator/rectifie r, is the power source for the APV system.
Regulator/Rectifier
T he servomotor consists of two c ircuits. O ne c ircuit is a DC c ircuit , w hich operates the DC moto r within the servo, and the other is a po tentio meter, which measures the resistance, ampe rage, and servo pulley positio n. The computer within the COl unit and ECU ha ve been programmed to ope rate the sen 'omoto r between a low and hi gh resistance range. If resistance is not within the range, the compute r w ill shut dow n the APV circuit. T he co mpute r will the n ma ke a to ta l o f three mo re attempts to cyc le the power val ves. If the correct resistance, ampe rage, or pulley position isn"t seen, the APV circuit is shut down and no more attempts will be made until the engine is shut dow n and restarted.
Cables
T he ex ha ust va lves are connec ted to the actua tin g cables and , along with the return springs, arc contained inside the APV ho using on the ex ha ust side of each cylinder. The othe r end of the actuating ca bJc is connected to the servo. The re is al so a vent hose o n eac h A PV ho using to re lieve the pressure o f " blow by" gases that may escape fro m the cylinder.
OPERATION
At idle and low speed ope rati on, the ex haust \'al ves are held in the "low po rt" pos iti o n by the re turn sprin g. When e ngine RPivl reaches a predetermined point , the COl/ECU w ill send a sig nal to the servo w hich will cyele and pull the ex haust val ves into the up o r " hi gh po rt" positio n. The RPM at which the valves o pen is different with each model. W hen the engine is first started (2004/2005 model s), the ex hau st val ves will cycl e o nce at low rpm (2500 rpm ) on all model s except the Firecat 700 EFI and carburet ed model s. O n th ese model s, th ey won"t cycl e until 7200 rpm.
If th e se r vo m o t o r cy cl es th e ex hau s t val ves a s ex plained above, the exhaust val ve circuit is o pe rating sati sfa cto ril y. If the servomo tor makes no atte mpt to o pe n the val ves o r if the servo atte mpt s to cycl e the val ves three times (then stops working), the re is a pro blem and it must be corrected.
T he AC current from the power coil first enters the regulato r/rectifie r which is then changed from AC c urrent to pul sating OC current. Since the APV circ uit cannot W ie pulsating DC curre nt , it must be converted (by the conde nser) to straight DC curre nt whi ch is necessary fo r the APV syste m. O n those mode ls us in g the li g htin g co il a s a power source, AC c urre nt e nters the ECU from the li g htin g coil and is changed fro m AC to DC current by a rectifi er located within the ECU.
Condenser
The pulsating DC current from the regulator/rectifier is passed through the condenser. The conde nser filt ers the pulsal"ing DC current and converts it to regular DC curre nt, much like fro m a 12 ~vo lt bauery.
3-20
Page: 158
Servomot:or Cycles Three Times
In thi s situati on the CO l or ECU computer ha s been progra mm ed with a resistance range (low and hi gh) that the servomotor must ope rate within. If the servomotor is put under too much load, its resistance goes up and lTlay exceed the range upper limit. lt will then stop and attempt two more times. If the resist.'lnce sti ll is 100 high, it shuts dow n. The sa me is true if the resistance is too low under a li ght load. The servomotor resistance wiII be low and the se rvomoto r will again cycle t wo more times to attempt to find the correct circuit resistance. If not sensed by the CDI or ECU computer, the servo is shut down. Improper se rvomotor ci rcuit resistance is normall y caused by one or more of the following:
A.
NOTE: When troubleshooting the above components with either a COlor ECU, there are some major differences. With the COl system, the regula tor/rectifier and condenser are located separately outside the COl unit.
On the fuel injected lTlodels, the condenser (and sometimes the rectifi er) arc part of the EC U. In thi s case, first check to make sure the lighting coi l output meets speci fi cations; then check the DC current coming from the ECU to the servomotor. If the current entering the ECU is sa ti sfac tory, but low coming o ut , the ECU would be considered to be bad.
NOTE: For testing individual APV system com ponents, see Section 5.
M
MAINTENANCE
The APV system requires onl y periodic cleaning and cable adjustment. T he cables should be checked every 1000-2000 miles and adjusted as necessary. To ensure ma ximum performance and minimi ze maintenance req uirements. Arctic Cat recommends using A rclic Cat Syn theti c APV 2-Cycl e Oi l. Us in g oi ls other than the reco mme nd ed oi l ma y increa se the frequenc y of requi red cleaning due to increased buildup of carbon deposits.
Incorrect exhaust valve cable le ngth (too long or 100 sh0l1). Exhaust va lve cable(s) sticking, broken, or disconnected at pulley. Exhaust valves st icking. Exhaust valve spring(s) weak or broken.
8.
C.
D.
Check each of the above probable causes in the order given to locate the problem of the servomotor cycling three times in succession; the n shutting down. Check fo r correct exhaust valve cable le ngt h speci fications for model being worked on in this section.
Servomot:or Makes No Attempt To Cycle
CABLE ADJUSTMENT
(St:andard Models)
Proper cable adjustment is criti ca l to the operation of the APV system. Whil e it is recommen ded that the cable adjustment be inspected every 1000-2000 mil es. the cab le should not need adjustment oft en. To check the cable adjustment, use the foll ow ing procedure. I. Remove the lwo cap screws securing the servo cover.
If when running the e ngi ne the servomotor makes no altempt to operate, this is caused by one or more of the foll ow ing: A. Bad connecti on from the wi ring harness and connector from the DC power coil or the lighting coil 10 the regulator/rectificr, to condenser, to CDI or EeU. or from COlor ECU to servomotor. DC coi l output is non-ex istent or too low. Regulatorlrectifier output is too low. Condenser output is too low. COlor ECU output to servomotor is too low.
F.
B.
C.
D.
2. Using a small screwdri ver, remove the cable retai ni ng cover.
Servomotor failure.
Page: 159
3-21
5. While holding the cable housing firml y. pull the cable as far out as it will go; then release. Repeat three to four times. The cable/ex haust valve should move freel y without binding. If the cable! ex haust valve does not move freely. the ex haust val ve assembly will need to be removed for ftu1her inspection.
NOTE: When measuring the cables, they are to be routed and as close to their installed position as possible.
6. While holding the cable housing, lightly pull on one cable end to remove any slack. 3. Rotate the servo actlk'ltor counterclockwise to loosen the cable; then pull the cable housings out of the holde r. 7. tvleasure the amount of exposed cable from the cable housi ng to the end of the cable.
NOTE: The two cable measurements must be equal in length or less than 0.5 mm (0.020 in.) dif ference in length from each other. NOTE: Repeat steps 6 and 7 for each cable; then compare the measurements to the appropriate chart. NOTE: The measurements m..u..s1 be within the specifications from the chart. If the measurements are within specifications, no adjustment is neces sary. If they are not within specifications, proceed to step 8.
4. Pull the cable lip and out of the cable housing holder: then slide each cable drum to the left and out of the servo actuator.
8. Loosen the jam nut on the cable to be adjusted; then using the adjusting nuls, le ngthe n or shorten the housing as needed. 9. Once the proper le ngth has been attained , hold the adjusting nut in place and tighten the jam nut securely.
10. Install the actuating cables IIlto the servo. 11 . Install the servo cover and secure with the two cap
screws.
NOTE: If for any reason the pulley was removed from the servo, make certain to align the space between the two cables with the mark on the shaft of the servo .
NOTE: Before proceeding with the cable adjust ment, ensure that the exhaust valves are free to move.
3-22
Page: 160
CABLE ADJUSTMENT
(~~LaydownH
Engine Models)
Proper cable adjustme nt is c riti cal to the operat ion of the APV system . W hil e it is recommended tha t the cab le adjustment be inspected every 1000-2000 mil es , the cable should not need adjustment oft en. To c heck the cablc adj ustment, usc the following procedure.
I. Remove
the
Iwo cap screws securing
the
servomotor cover.
4. Pull the cable up and out of the cable housing holder ; then slide each cable drum back and o ut of
the actuator.
_NOTE : Before proceeding with the cable adjustment, ensure that the exhaust valves are free to move.
2. Using a small screwdri ver, remove the cable retaining CO\'C I".
5. While holding the cabJc ho using firml y, pull the cable as far out as it will go; then release. Repeat three to four times. The cable/ex haust valve should move freel y without binding. If the cablel ex haust valve does not move freely, the ex haust val ve assembly will need to be removed fo r fUl1her inspection.
NOTE: When measuring the cables, they are to be routed and as close to their installed position as possible.
6. While holding the cable housing, li ghtly pull on o ne cable end to remove any slack. 7. t\'leasure the amount of exposed cable fro m the cable housi ng to the end of the cable.
NOTE: The two cable measurements must be equal in length or less than 0.5 mm (0.020 in.) dif terence in length from each other.
3. Rotate the servomotor actuator counterclock wise
to loosen the cable; then pull the cable housings

out of t he holder.
NOTE: Repeat steps 6 and 7 for each cable; then compare the measurements to the appropriate chart. NOTE: The measurements .m..u..il be within the specifications from the chart. If the measurements are within specifications, no adjustment is necessary. If they are not within specifications, proceed to step 8.
8. Loosen the jam nut o n the cable to be adjusted; then using the adjusting nuts, le ngthe n or shorten the hOllsing as needed. 9. O nce the prope r le nh1.h has been attained , hold the adjusting nut in place and tighten the jam nut securel y.
10. Install the actuating cables into the servomotor.
Page: 161
3-23
11 . Install the servo cover and secure with the two ca p screws,
NOTE: If for any reason the pulley was removed from the servo, make certain to align the space between the two cables with the mark on the shaft of the servo.
3. Remove the retaining pin from the valve stopper.
SERVICING
T hcrc arc two sty les of power val\'cs in usc in the 2005 Arcti c Cat engi ncs. The " fl at stylc" va lve is 011 the 500,600 CL,a ydown") , 700, and 900 cc cngincs, and the " round style" \'alvc is on the 600 cc (STD) engine.
Removing/Disassembling (600 cc STD)
NOTE: To avoid a parts mixup, it is recommended that only one valve assembly at a time be removed from the engine.
I. Rcmovc the va lvc asscmbl y from thc enginc (see
AP163
4. Slidc the valve stopper back on the cable until the c.able end and return spring clear the stopper. Remove the valve stopper and return spring from the cable.
Section 2).
AP164
Cleaning and Inspecting
2. Slidc the ex haust valvc/valvc guidc assembly off the retai ning pin and frec of the valve stopper. Rcpeat with thc second exhaust valve/valve guide assclTl bly.
I. Remove all carbon deposits with solve nt and a soft abrasive such as a Scotch-Brite pad. 2. Inspect all parts for nicks, burrs. or other signs of unusual wear.
3-24
Page: 162
Assembling/Installing (600 cc STD)
G
KEY
A. Exh aust Valves
B. Valve Guides C. Valve Stopper D. Retaining Pin
E. Retaining Plate F. Return Spring G. Cover
4. One at a time, slide eac h or the exha ust vah'el valve guide assembli es through the retaining plate and onto the pin in the valve stopper.
I. Slide the return spring onto the ca ble e nd .

NOTE: Make sure the small cable end spring stays in place at the end of the cable.
2. Place the valve stoppe r on a clean surface with the slotted side up; then place the cable in the slot and pull the cable through the stoppe r until the cable end and return spring are in place in the stoppe r. Secure with the retaining pin.
NOTE: The single center mounting hole on the retaining plate should be up.
5. Slide the val ve assembly into the prope r cylinder.
NOTE: The retaining pin is inserted long end first from the right side of the valve stopper. Ensure that the retaining pin washer is in the recess in the valve stopper.
3. Assemble the ex haust \'al ve and \'aive guide as show n.
6. Secure the valve assembl y to the cylinde r with three Alle n-head cap screws (coated with blue Locti te 11242). Tighte n to 1.1 kg-Ill (8 rt-Ib).
Page: 163
3-25
AP1 23
7. Slide the valve cover onto the studs on the engine. Secure with rour nuts. Ti ghten securel y.
3. Hold the val ve stopper securely and pull the cable back and up until it clears the top or the stopper; then slowly rel ease the cabl e and remove it rrom the vah'e stopper.
8. Perrorm steps 6-10 in the appropriate Cable Adjustment in this sub-sectioll.

Removing/Di sassembling (900 ee)
NOTE: To avoid a parts mixup, it is recom mended that only one valve assembly at a time be removed from the engine.
I. Remove the valve assembl y rrom the engine (sec
I. Remo\'c all carbon deposits with solvent and a sort abrasive such as a Scotch-Brite pad . 2. Inspect all parts ror nicks, burrs. or other signs or unusual wear.
Assembling/Installing (900 ee)
Section 2).
~F
D. Retaining Screw E. Retaining Plme F. El(haust Valve
2. Remove the retaining screw securing the exhaust valve to the \'al\'e stopper.
A. COVel"
B. Return Spring C. Val ve Stopper
I. Slide the return spring over the end or the
actuating cable.
3-26
NOTE: Make sure that the small cable end spring stays in place at the end of the cable.
2. Place the valve stopper on the cable and slide it dow n until the cable end is inside the stoppe r.
6. Place the va lve cover with the gasket into position on the engine. Secure with four cap sc rews. Tighten to 0.9-1.3 kg-m (6.5-9.5 ft-Ib).
3. Slide the ex haust va lve through the retaining plate and insert it into the valve stopper. Sec ure with the retaini ng screw. Tighten to 0.6 kg-m (4 ft -Ib).
7. Perform steps 6-10 in the appropriate Cable Adjustment in this sub-section.

Reanovi ng/Disassernbling ("LaydoW'n" Engine Models)
AP123
4. Slide the \'HI \'C aS$cm bly into thc propcr cylinder.
NOTE: To avoid a parts mix-up, it is recommended that only one valve assembly at a time be removed from the engine.
1. Re move the valve assembly fro m the engine .
NOTE: The flat side of the retaining plate must be down.
5. Secure the valve assembly to the cylinder with two Allc n-hC<ld ca p screws (coatcd wi th blue Loctile 00.9- 1.3 kg-m (6.5-9.5 ft-\b). #242). Tighten 1
2. Remove the retaining sc rew securing the exhaust valve to the valve stopper.
Page: 165
3-27
3. Hold the valve stopper securely and pull the cable back and up lllltil it clears the top of the stopper; then slow ly release the cable and remove it from lhe valve stopper.
Assembling/Installing
c .... ~ @ +-O E .... cCJ!Ia>

H--+
G-.
KE Y
I. Remove all ca rbon deposits with solvent and a soft abrasive such as a Scotch-B rite pad. 2. Inspect all parts for nicks, burrs, or ot her signs of unusual wear.
Replacing Oil Seal
I. O lrefull y pry the seal up from beneath taking care
A. B. c. D. E.
Exhausl Valve Cover Gaskel Valve Plate 0 11 Seal Gaskel
F. Stopper G. Stopper Pin

H. Relum Spring I. Valve Cover
FC111A
I. Slide the return spring over the end of the
actuating cable.
Ilotto damage the valve plate.
NOTE: Make sure that the small cable end spring stays in place at the end of the cable.
2. Install the new seal using an appropriate-sized seal driving tool.

3-28
Page: 166
2. Wi th the cover gasket properly positioned, place the va lve stopper on the cable end and slide it down until the cable end is inside the stopper.
Fe024
3. With the valve plate gasket prope rl y positioned, slide the exhaust va lve through the valve plate and insert it into the valve stopper. Secure with the retaining screw. Tighte n to 0.6 kg-Ill (4 ft- lb).
5. Place the val ve cover into position on the engine. Secure with two cap screws. Tighten to 0.9- 1.3 kgm (6.5-9.5 ft- Ib),
NOTE: Note that the exhaust valve gaskets are directional and must be installed correctly.
6. Perform ste ps 6- 10 m appropriate Adjustment in this sub-section. TROUBLESHOOTING

(Carbureted Models)
Cable
4. Slide the valve assembl y into the proper cylinder.
T he APV syste m has a self-cl eanin g a nd self-testi ng mooe bui lt in. Every time that the engine is stal1ed, the servo will cycle once, and thi s wiil wipe-off the carbon that has accumulated on the ex haust valves . The CDI unit also monitors the voltages at the servo during this cycle to assure they are within operational tolerances. If all \'oltages are within tolerance. the system is ready for operation, If the voltages are not wi thin tol erance, the servo wi ll cycle two more tim es. If the voltages remain out of tolerance , the system wi ll not operate.
Problem: Engine loses power; no top end Condition Remedy
1. Remove carbon deposits, burrs. etc.
CAUTION The long side of the exhaust valve must be facing toward the cylinder head or severe engine damage may occur.
&
1. Exhaust valves sticking in down position
2 . Cables adjusted too long
2. Inspect-adjust
Problem: Poor acceleration ; hesitation Condition

1. Exhaust valve sticking in up position 2 . Cables adjusted too short
Remedy
1. Remove carbon deposits, burrs, etc.-inspectl replace return spring 2. Inspect-adjust
Page: 167
3-29
TROUBLESHOOTING (EFI Models)

T he APV syste m lIsed on EFI moocls is very similar to that fo und o n carbureted model s. T he self-cleanin g and self-testing modes are much alike . The main difference between the two is the hi gher total elect rical power required by the EF I a nd A PV systems combin ed . Because of these more de ma ndin g pow er require me nts , the EFI APV system gets power from the stato r li ghting coil. The ECU constantly mOnitors the power o utput o f the lighting coil , and if the lighting coil output gets too high or too low, the ECU will acti vale the fail -safe mode. The fail -sa fe mode is an ECU operated engi ne RPM limiter. Whe n activated , the fail safe mode w ill be seen as an immediate loss of engine
horscpo\ver.
Tro ubl es hootin g EF! e ng ines with the A PV syste m should be do ne with the Arctic Cat EFt Anal yzer (pIn 0644342). To update an existing EFI A nal yzer, o rder Kit (pIn 0644-34 1).
Exhaust Controlled Timing (ECT) System

T he 500 cc models are equipped with the Ex haust Con trolled Tim ing (Eel') system which utilizes an exhaust pipe te mpe rature sensor. Thi s syste m auto ma tica ll y adjusts the ignitio n timing to provide max imum pe rfor mance th ro ug h a ,'ariety of o pe rati ng conditio ns. The CD! unit rece ives input o n engine RPM (demand) a nd exhaust tempe rature (engine condition) and adjusts the ignitio n timi ng accordingly. This system is not adjustable and is maintenance free. If a syste m fault is s uspected , usc a n o hmmeter to chec k cont inuity of the ex haust pipe tempe rature sen SO l' locat ed in the ex pan sio n chambe r. A reading of either 0 ohm or infinity indicates a fa iled sensor.
For example, if the headlight and tailli ght arc di sa bl ed , the ECU wi ll sense a hi gh voltage conditio n and acti \'ate the fai l-safe mode. Adding mo re than 4 amps of accessori es wi ll create a low volla ge co nditi o n and acti vate the fail -safe mode.
NOTE: When running an APV equipped EFI engine on a dynam ometer, first connect a Voltage Regulator (pin 0603-142, 2-wire) or (pin 0630-643, 3wire) between the lighting coil and the ECU. There must also be a minimum 2.5 amp load installed in-line between the voltage regulator and the ECU (a 2.5 amp load is equivalent to one high beam headlight bulb).
Problem: Engine loses power; no top end Condition
1. Exhaust valves sticking in down position
2. Cables adjusted too long 3. Ughting coil output voltage out 01 tolerance
Exhaust Pipe Temperature Sensor
Remedy
1. Remove carbon burrs. etc, 2. Inspect-adjust
depos~s,
3. Inspect-replace stator
Problem: Poor acceleration ; hesitation

0737314
Condition
1. Exhaust valve sticking in up position
Remedy
1. Remove carbon deposits. burrs. etc. -inspectl replace return spring
2. Cables adjusted too short

3. Ughting coil output voltage out 01 tolerance
2. Inspect-adjust 3. Inspect-replace stator
NOTE: A disabled ECT system WILL NOT cause engine damage; however, a failed ECT system will have slower throttle response and may produce slightly less top-end performance.
330
Page: 168
SECTION 4 - FUEL SYSTEMS
TABLE OF CONTENTS
Fuel System (Carbureted) ....................................... 42 Fuel System (Batteryless EFt) ... .... .4-34 Fuel System (Related Items) ...... ... ..... .......... ....... .. 4-58
Page: 169
41
Fuel System
(Carbureted)
Fuel System
(Carbureted)
Table of Contents
Thi s sub-section has been o rgani zed for servicing carbureted fucl systems; however, some components may
vary from model to model. T he technician should usc discreti on and so undjudgmcnl whe n rcmo\'ingl disassembling and assembling/installing components. W henc\'cr all Y mainte nance o r inspect ion is made 011 the fu el system in which fuel Jcakagc may OC ClII', there should be no welding, smoking , or open flames in the
area.
NOTE: Some illustrations and photographs used in this sub-section are used for clarity purposes only and are not designed to depict actual conditions.
Carburetor Specifications .. .. ........ .. ..... ... .. .. .. ..... ..... .. 4-3 Pre-Maintenance Checks ................................... ..... 44 Changing Main Jet(s) (VM-Style) .. ........................ .. 44 Changing Main Jets (Standard TM-Style) ............... 44 Changing Main Jets ("Laydown" Engine TM-Style). 4-5 Carburetor Schematics ....... ...... ............. .................. 4-6 Removing Carburetor (VM-Style) ... .. .... ..... .. .... ...... .. 4-8 Removing Carburetors (Standard TM-Style) .... ..... .. 4-8 Removing Carburetors ("Laydown" Engine TM-Style) ............................................................. 4-9 Disassembling Carburetor (VM-Style) ............ ......... 4-9 Disassembling Carburetors (TM-Style) .. .... .. ......... 4- 11 Cleaning Carburetor ........... ..... .............. ................ 4-13 Inspecting Carburetor ............................................ 4-1 4 Assembling Carburetor (VM-Style)........................ 4-14 Assembling Carburetors (T M-Style) ...................... 4-16 Installing Carburetor (VM-Style) ............. .... .. .. .. .. ... 4-18 Installing Carburetors (Standard TM-Style) .. .. .. ..... 4-19 Installing Carburetors rLaydown" Engine TM-Style) ........................................................... 4-19 Ad justing Carburetor(s) (VMStyle) .. .......... ........... 421 Ad justing Carburetors (TMStyle) .......................... 423 Throttle Cable (VMStyle) .. .. ........ .. ..... ... .. ..... .. .. ..... 4-25 Throttle Cable (TMStyle) ........... . ............. .. ......... 426 Choke Cable (VM-Style) .. .. .. .... .. .. .. .. .. .. ...... .. ........ .. 4-27 Choke Cable (TM-Style) .......... .. ............ ......... 4-28 Mikuni Tuning Components ................................... 430 Major Tuning Components .................................... 4-3 1 Troubleshooting Fuel System .. ................... .. ......... 4-32
4-2
Page: 170
Carburetor Specifications
MODEL
ALTITUDE
TYPE
MAIN
JET
NEEDLE
JET

JET NEEDLE
60F7-3
6DF7-2 6DF7-1 9EH06-3 9EH06-2 9EH06-1 9EJI-4 9EJI-3 9EJI-2
PILOT
JET
40
CtIfAWAV
2.5
PILOT AIR SCREW (TURNS OUT)

1 3/4
FUEL MIXTURE SCREW (TURNS Oun

N/A
0-5000
Bearcat 570
5-9000
VM-34
9-0ver Firecal500
(2)
TM-38
0-5000 5-9000
9-0ver
(2)
TM-40
0-5000
Firecal700
5-9000
9-0ver
(2)
VM-38
Panlera 550
o-SOOO 5-9000
g-Over
(2)
VM-32
0-5000
Panther 370 5-9000
9-0ver
(2)
VM-34
o-SOOO
Panther 570
5-9000
g-Over
(2)
VM-34
o-SOOO
Sabercal500
5-9000
g-Over
(2)
VM-32
0-5000 Z370
5-9000
g-Over
(1)
VM-32
Z440
0-5000 5-9000
g-Over
(2)
VM-34
Z570
0-5000 5-9000
g-Over
(2)
TM-40
ZA900
0-5000 5-9000
9-0ver 0-3000 3-6000 6-9000 9-0ver 0-3000 3-6000 6-9000 9-0ver
(2)
VM-34
M5"
(2)
King Cal 900"
TM-40
(2)
360 470 340 250 250 290 2SO 280 2SO 430 2SO 360
250
P-4 (480)

40

3.0

15/8
Fixed

Fixed

30

3.0

P-2 (480)
P-O (480)
35 40

3.0
1112 1 1112 3/4
2 1 2112 1 1112 1
N/A
90HS-3
P-6 (159)

60H7-3

40 35

2.5

P-4 (480)

60F7-3
6DF7-2 6DF7-1
40

2.5

1 3/4
N/A

P-4 (480)

35

3.0

7/8
N/A
60F7-3
6DF7-2

P-6 (159)
40 40
60H7-3

2.5
1 112 1
N/A

P-4 (480)

60H7-3

35

2.5
N/A

P-4 (480)

60F7-3
6DF7-2 6DF7-1 9DFH9-4 90FH9-3 9DFH9-2 6DF7-3

40

2.5

1 314
N/A

Fb.ed

45

3.0

2
I 3/4
N/A
1112

P-4 (480)
50 35
6DF7-2
40

2.5
7/8
1 112
N/A

Fixed
9DFH9-4
45
9DFH2-3 9DFH2-2
50

3.0

1112

1112
'See Main Jel Chan
"In~ially
sel up allhe factory for operation between 6000-9000 leet
Page: 171
43
Pre-Maintenance Checks
Before troubleshooting the fuel system , several simple checks should be pcrfonn cd , Many ti mes what appears to be a seriolls problem is onl y a mino r o ne.
I. Make sure the gas tank shut-o ff valve was in the OPEN position.
7. C heck each carburetor float chamber drain hose for water o r debris. If seen, clean by re movi ng the plug and draining the drain hose into a small container. 8 . C heck the gas tank \'e nt hose and ruel hose for obstructio ns; remove any o bstructions. 9. Turn the shut-ofr valvc to the OPEN IXlsi tion.
2. Turn the s hut-olT vah 'c to the C LOSED position; thell remove the in-line fuel filt er. If the filter is dirty, replace the filter.
NOTE: Determine which style in-line fuel filter is being replaced and remove and install accordingly.
Changing Main Jet(s)

(VM- Style)
The carburetor main jet(s) must be changed in conj unctio n with the changes in temperature, altitude, and type of gasoline bei ng used. I. Loosen each carburetor flange clamp and remove each carburetor rrom the intake flan ge and boot. 2. Remove the drain plug and O -ring from each ca rburetor tlO<lt chamber and drain the gas into either a s mall container o r an absorbent towcl. 3 . Using the Main Jet Wrench ( pin 0644-065), thread the main jet o ut of each carbureto r. Account for the bam e ring. Install the new main jet with b..1ftle ring and ti ghte n securely. 4 . Install the drain plug and O-ring; then ti ghte n securel y.
3 . Install a new filter making s ure the arrow on the filter is d irected toward the fuel pump.
In-Line Fuel Filter
728-2726
!~~~
(
~~~~v- Carburetor Float Chamber
~~
In~ne Fuel Filter
Main Jet _
"\
Remove Main Jet
0728-054
726-065A
5. Install and secure each carburetor.
4 . Check the hoses to ensure Ib.:'l! all a re correctly

connected; then c heck fo r cracks. If any cracks are ev ident in the hoses, replace them making s ure none arc against any hot or movi ng pmts. Hoses must fi t tightly. If hoses do not fit lightly, cut 6 mm ( 11 4 in.) rrom the end and install .
Changing Main Jets

(Standard TM-Style)
T he carburetor main jets mus t be c ha nged in conjunction with the changes in temperalure, altitude, and type of gasoline bei ng used. I. Remo\'e the machine screw and washer securing the mo unting plate (for the ignition coil and fuel pump) to the air-intake sile ncer.
S. C heck the impulsc hose for c racks o r any possibl e

air leaks. T he hose must fit lightly at both e nds. If loose o r cracked , replace the hose. 6 . C heck each carburetor vent hose for kinks or obstructions; remove any obstructions. 4-4
Page: 172
Changing Main ,Jets

(ULaydovvn-- Engine TM ..Style)
The carbureto.r main jets must be changed in co.njunctio.n with the changes in temperature, altitude, and type 0.1' gaso.li ne bei ng used. L Tip the sno.wmo.bil e o.nto. its left side; then using a to.rx-bit, remo.ve the sc rews securing the center belly pa n (skid plate) to. the front e nd.
_NOTE : A piece of cardboard should be used to protect the finish on the hood and belly pan.
2. Re mo.ve the screws securing the air-intake silencer; then mo.ve the silencer fo.rward and o.ut o.f the engine co.mpa ltme nL 3. Loosen the carbureto.r fl ange cl amps and slide the carburetors o.ut o.f the intake flan ges. Tilt the carbureto.rs fo.rward to. access the ma in jet'). 4. Re mo.ve the drain plug (with O-ring) from each carbureto.r fl o.at chamber and drain the gas mto. either a small co.ntainer o.r an abso.rbent to.wel. 5. Using the l\1lain Jet Wrench (pIn 0644-065), thread the main jet o.ut o.f each carbureto.r. Acco.unt fo.r the washer. Install the new main jet and washer and ti ghten securel y.
2. Using a sw ivel adapter and a 17 mm socket. remo.ve the drain plugs fro.m the fl o.at chambers. 3. Using the Main Jet Wrench (pin 0644-065), thread the main j et o.ut o.f each carbureto.r. Acco.unt fo.r the washer. Install the new main jet and washer and tighten securel y.
Carburetor Float Chamber
0 734 -280
Main Jet
"'--1="<
Carburetor Float 'i'1]!-- Chamber
4. Install the drain plug with O-ring; then ti ghten securel y, 5. Place the center bell y pan (skid plate) into. po.sitio.n o.n the front end ; then secure with the screws.
Remove Main Jet
~~ ~ ~ Ma~et
Wrench
0734-280
6. Install the drain plug with O-ring; then ti ghten sec urely. 7. Push the carbureto.rs back into. po.sitio.n and into. the intake fl anges; then ti ghten the fl ange clamps. 8. Place the air-inta ke sil encer into. po.sitio.n in the engine co.mpartment making sure the carbureto.rs are pro.perly po.sitio.ned in the boot and secure with the screws. 9. Place the ignitio.n co.il/fuel pump mo.unting plate into. po.sitio.n o.n the air-intake sil encer and secure with the mac hine screw and washer.
NOTE: If the snowmobile has been tipped on its side for an extended period of time, inspect the oilline hose for any signs of air bubbles. If air bubbles are visible, see Related Items sub-section for bleeding procedure.
Page: 173
45
Carburetor Schematics
NOTE: Some components may vary from model to model. The technician should use discretion and sound judgment.
KEY
Mixing Body Assy 2. Float Cilamber Plate Piston Valve s. Jet Needle 6. Main Jet
KEY
MI. lng Body Assy 2. Starte r Plunger
VM-34
YO. Piston Valve
YO.
Sprin g Plate Magnet Block Sc rew wI Washer E-C llp Was her Jet Needle Piston Valve Needle Jet Sell -Tapping
26. Washer 2T. Needle Valve

Assy
,. C'p s.

T.
Starte r Plunge r Spring Starter Plunger S pring 6_ Idle Speed
".
Y7.
YO. YO.
YS.
,,,T op
... ".
". ". 36.
2YI. Float Pin n . Float Arm
C'p
Float
32. Gasket 33. Root Cha mber

Plate Hose Screw wfSprlng Washe r OT. O-Ring 3S. Drain Sc rew
VM-32
,.
T.
". Y7. Idle Speed ,,,_

Spring
YS . Spring
...
"'. ".
Hose Plate S larter Plunger

Screw wJSpring Washer Plate O-Ring
".
Spring Pi lot Air Screw Pilot Jet YO. BaIlie Ring Main Jel Y2. Mbing Body
20.
2Y .
22.
". ''"_
".
". C'p
Top
YO.
Baffle Ring
Needle Jet E-C lip Float
".
".
Y2. Screw wlSpring Washer YO. MI.lng Body YO. Pilot Ai r Screw
YO . Drain Ptug YO. Washer 20. Float Pin 2Y . Needle Valve Assy 22 . Float Arm Piston Valve Spring Pilot Jet 25. Gasket 26. Starter Plunger Spring 2T . Starter Plunger
". ". 33.
Magnetic Switch Plate 25. Sc rew wfSpring Washer
YO. Wa sher (570 cc)
". C'p
Vent Hose
C'p
"
;;~(H' " , 'EO
" '1
~I
, "
" I
"g
, "
, " ,
0739-474
" ~,,
" " "

0 736-506
KEY
VM-38
Mixing Body
YO Mixing Body
Assy
Was he r
Top
,. C'p Spring ,. Screw T. Spring YO. ".
2. Starter Plunger
YS. Piston Va lve
n.
"'.
33.
Was her
Was he r
".
Y7
YO. YO.
Starter Plunger
Id le Speed
20.
2Y .
22.
Spring Pilot Air Screw Pilot Jet Screw Guide Y2. BaHle Ring YO. Main Jet
".
25.
". Screw
Spring Plate Magnet Block Machine Sc rew EC lip E-C llp Washer Jet Needle Piston Valve
". n. ". ". ". ". ".

ST.
30. Needle Valve Assy

Roe! Arm Pin Float Arm
C'p
Roe!
Gasket Float Chamber Air Vent Tube Screw wlSpring
NeedleJel
Ma~oellc
". Plate
Washer
SWitch
26. Machine Sc rew 27. Washer
YO. ORing Drain Plug
0 738-549
4-6
Page: 174
KEY '- Mixing Body

2, Screw wi
Washer
TM-38
,. Gasket
3. Top Cap
". ".
". ". ".
,. ,. ,.
5. Plunger Cap
Guide Holder Starter Plunger Spring Starter Plunger Gasket Funnel Assy Screw Ai r Screw Spring Washer
20. Retaining Plate
". ". ". ".
KEY
TM-40
Mixing Body Sc rew Assy
O-Ring
Throttle Valve
" . Jet Needle Washer
E'(:lip
Screw Retaining Plate E-Clip Washer Plate Clip Bushing lever Assy Float Assy O-Ring
".
".
35.
". 90,_
Cop
30. S<o,~ 3'- Gasket 32. Float Chamber

O-Ring 35. Drain Plug Fuel Mixture S<o'~ 38. Spring 33. Washer Rubber Washer Starter Jet Pilot Jet Main Jet
21 .
22.
". 25.
2<.
". 28.
23.
". ". ".

".
".
".
". ". ". ".
,. 3. 5. ,. ,. ,.
". Starter Jet

Rubber Washer Washer 20. Spring 21. Fuel Mixture Screw
Top Cap
Gasket
". ".
3>. Clip
Plunger Cap
Spring Starter Plunger Gasket
".
". 38. ". ".
32. Bushing 33. Lever Assy

Thronle Valve
35. Float Assy

35. O-Ring
Screw Gasket 33. Float Chamber Screw O-Ring Drain Plug
Funnel Assy
So,~
". 25. ".
22. Cop 23. E-Clip

Washer Jet Needle 2<. Retaining Plate Screw Retaining Ptate 28. E-Clip Washer 30. Plale
O-Ring 12. Washer 13. Spring AirScrew Main Jet PllotJel
".
".
" -~ l5
~ ,-~
" .. " "

0738-091 0738-670
KEY '-
,.
Carburetor Assy
Sensor Assy 3. Screw wI

Washers Idle Speed S<o'~ Spring
". ". ".
,. Bracket 5. ,. 7. Screw ,. Screw

S<o,~
". ". ".

". ".
TM-38
Bracket
s,,~
Throttle Lever Shaft Assy Lever Ring S<o'~
"'. "'. ".
Washer
Starter Lever
KEY
TM-40
Serew ". lever Ring Screw ". ". Hose ". ". ". ,'- Sensor Assy
Lever Ring
27. Clip
". Lever Ring

18. Screw
".
T-Fitting 30. Hose Clip
80"
Hose Clamp
H~
19. Spring 20. Spacer

Spacer
S<o,~
Spring Throttle Stop
". ". 35. Hose Clamp
32. Hoo.
'- Carburetor Assy ,. ,. Bracket 5. ,. ,.
Throttle Slop Screw 3. Spring Idle Speed Screw Spring Screw
H . Hose Clamp
Spacer
22.
Hose Clip
Carburetor Asay
".
23. Startet Lever Spring 25. Shaft
". ".
". Sleeve ". Spring
8. Screw 9. Boll
T-Fitting Carburetor Assy
Spacer
".
22. 23. Screw wlWashers H_ 25. Clip
Throttle Lever Shalt Assy
0738-687
0738-671
Page: 175
4-7
Removing Carburetor
(VM-Style)
NOTE: On twin carburetor models, remove the carburetors using this basic procedure.
I. Turn the gas lank shut-olT valve to the CLOSED positio n. 2. Remove the mixing body top by rotating it counterclockw ise ; thell remove the top with spring, plate, j et needle with E-clip, and piston valve from the carbureto r.
5. If applicable , di sconnect the safety swi tc h wiring harness connector from the main wiring harness. 6. Loosen the carbureto r-nange clamp; then remove the carburetor.
3. Re move the brass cho ke-cable ho using fro m the

ca rburetor. Account for a washer.
NOTE: Slide the carburetor into the air-intake silencer boot until free of the flange; then remove carburetor.
L1:.
CAUTION
carburetors
Keep MAGside and PTOside identified for installing purposes.
Removing Carburetors
4 . Di sconnect the fuel hose f rom the carburetor i nlet
(Standard TM-S1:yle)
I, Re move the machine screw and washer securing the mo unting plate (for the ignition coil and fuel pump) to the airintake sile ncer.
fitting.
4-8
Page: 176
I. Remove the four screws and lock washers securing the fl oat chamber; then remove the fl oat chamber and gasket.
2. Remove the screws securing the air-intake silencer; then move the silencer forward and out of the engine compa ltmenL 3. Disconnect the throttle cabl e and choke ca ble. 4. Remove the fuel supply hose from the fuel inlet Tfitting . 5. Loosen the carburetor flange clamps; then slide lhe Ct'u buretors out of the flan ges and out of the engine compmtment . 6. Remo\'e the fl oat chamber vent hoses.
NOTE: The floats should be removed only if replacement is necessary or the float chamber requires cleaning with carburetor cleaner.
2. Remove the caps from the fl oat towers; then remove the fl oats. Remove the drain plug and 0 ring.
Removing Carburetors
("Laydovvn" Engine TM-Style)
I. Remove the ex pansion cham bel' and resonator. 2. Route the coolant drain hose through the ex haust outlet in the belly pan and drain the coolant
6 344
3. Di sconnect the four coolant hoses from the ca rburetors accounting for four clamps. 4. Di sconnect the throttle cable; then unplug the T PS harness. 5. Loosen the carburetor flange clamps; then move lhe carburetors far enough forward until clearance will allow the carburetor assembly to be removed from the engine compartment.
3. Remove the fl oat arm pin ; then remove the I1mlt arm .
&
CAUTION
Use care when removing the float arm pin or the towers may break. Also, the pin must be removed from its flattened side.
Disassembling Carburetor
(VM-Style)
NOTE: On twin carburetor models unless there is a problem with the safety switches, do not loosen or remove the screws securing the switch to the carburetor.
Page: 177
49
4. Remove the needle val ve retainer; then remove the needle valve. Remove the seat and account for two washers and a plate.
8. Remove the idle speed screw and spring.

6 347
5. Rcmo\'e the main jet and baffl e ring; then remove the main jet ex tender guide from the needl e jet. Push the nccdlc jct out through the top or the carburetor.
9. Rcmovc thc throttle cable rrom thc pi ston valve; then remove the val ve.
6. Rcmove thc pilotjcl.
10. Removc the Phillips-hcad screw securing the throttle cable retainer to the pi ston val ve; thcn remove the retainer. Account for the jet needl e with E-clip and two washers.
6352
7. While counting the rotations for installing purposes, rotate the pilot air sc rew clockwise until li g ~tl y seated; then remove the pilot air screw and spnng.
NOTE: Note the position of the E-clip on the jet needle for assembly purposes.
4-10
Page: 178
AH042
,&, CAUTION
If an engine problem has been experienced due to improper gas/air mixture, verify the carburetor jetting and E~clip position with the Specification Chart and Main Jet Chart on the snowmobile for altitude, temperature, and type of gasoline.
NOTE: Disassemble the carburetors using this basic procedure.
I. Loosen the screws (w ith washers) securing the top cap to the mixing body; then slide the cap off the body. Account for the gasket
II Separate the starter plunger assembly from the choke cable by compressing the spring and remov ing the plunger from the cable; then remove the spring. Thread the plunger cap off the cable.
Disassembling Carburetors
(TM.Style)
,&, CAUTION
00 not loosen the lever assembly from the throttle lever shaft. If the lever assembly is loosened, the carburetors must be synchronized.
2. Loosen the screw securing the jet needle retaining plate: then slide the plate out of the way.
NOTE: The carburetors do not have to be removed to change jet needles or main jets; how~ ever, changing throttle valves requires removing the funnel assemblies. The clearance between the throttle valve, mixing body, and funnel assembly (approximately 0.50 mm or 0.020 in.) is normal and should not be a concern.
3. Using a pair of needl e-nose pliers, remove the jet needle assembl y. Account for the E-clip and washer.
Page: 179
4-11
4. Remove the Phillips-head screw and the drain plug (with a-ring) securing the float chamber to the mixing body. Remove the chamber and account for the a -ring.
7. Remove the fl oat assembly by lifting it up and out of the mixi ng body. Account for the a -ring.
5. Remove the main jet (w ith washer), pilot jet, and stm1er jet.
NOTE: It may be necessary to use a spray lubricant such as WO-40 to aid in removing the float assembly.
A CAUTION
To remove the throttle valve, the jet needle must be removed or damage to the jet needle will result.
8. Remo\'e the Phillips -head screw s securing the funnel assembly to the mixing body.
6. Remove the screws securing the fl oat assembl y.
9. Move the throttl e lever to the full-open position ; then remove the funnel assembly. Account for the gasket.
4-12
Page: 180
NOTE: In the following step, only one Eclip needs to be removed to free the throttle valve from the lever assembly.
12. Remove the E chp securing the plate to the throttle
valve; then slide the throttl e valve to one side and remove. Account for the plate, washer, clip, and bushings.
10. rvlove the throttle lever sli ghtly ope n; then rotate
the throttle val ve out of the mixing b<xly.
II . While counting the rotations for installing purposes, rotate the fuel mixture screw clockwise unti l li ghtly seated: then remove the mixture screw. Account for a rubber washer, washer, spring, and cap.
CAUTION
Do not force a mixture screw when seating. Forcing a mixture screw may result in damage to the screw taper and/or mixing body.
Cleaning Carburetor A
CAUTION
DO NOT place any nonmetallic components in parts-cleaning solvent or carburetor cleaner because damage or deterioration will result.
I. Place all metallic components in a wire basket and
submerge in carburetor clea ner. 2. Soak for approximately 30 minutes; then rinse with fresh pm1scleaning solvent. 3. Wash all non-metallic components with soap and water. Ri nse thoroughl y. 4. Dry all com]:xments with compressed air only making sure all holes, ori fi ces, and channels arc unobstructed.
Page: 181
4-13
5. Blow compressed air through all hoses to remove any obstructions.
Assembling Carburetor
(VM- Style) I. Install the idle speed screw and spring.
air.
CAUTION
00 NOT use wire or small drill bits to clean carburetor orifices, holes, or channels. Distorted or damaged orifices, holes, or channels can result in poor carburetor operation.
Inspecting Carburetor
I. Inspect the mixing body for cracks, nicks, stripped threads, and any other imperfections in the casting. 2. Inspect the piston/throule \'ah'c for cracks, score marks, or lin perfections in the casting. 3 . On the VJ\II-style, inspect the condition of the piston valve spring. 4. Inspect the noat for perforations or damage. 5. Inspect the gaskets, O-rings, and washers for distol1ion, tears, or noti ceable damage, 6. When applicable, inspect the tips of the idle speed screw. jet needle, pilot air screw, needle val ve. and fucl mixture screw for wear, damage, or di stortion.
NOTE: On the VM-style when inspecting the inlet needle, inspect the side guides and tip for wear. If the guides show any sign of wear, replace the inlet needle.
2. Install the pilot air screw and spring. Rotate clockwise until lightl y seated; then turn counterclockwise the same num ber of turns as noted in di sassembling for an initial setting.
CAUTION
00 NOT force the pilot air screw when seating. Forcing the screw will result in damage to the carburetor body.
7. Inspect the pilot jet and main jet for obstructions or damage. 8. Inspect the stm1er plunger and scat for wear or damage. 9. Inspect the carburetor mounting nanges for damage and tightness.
3. Install the pilot jeL.
CAUTION
An air leak between the carburetor and engine will cause a lean condition and severe engine damage will result.
10. On the 'I'M-style, inspect the throttl e shan seal for
damage and signs of leaking.
6 352
4-14
Page: 182
4. Insert the needle jet into position from the top of the carburetor making sure the groove in the needle jet is aligned with the pin in the mi xing b<xly; then place the jet extender, bafne ring, and main jet into position and secure.
AH046
FLOAT ARM HEIGHT

VM3213 4 VM-38 22-24 mm (0.86-0.94 in.) 17-19 mm (0.66-0.74 in.)
5. In orde r, place a washer, plate, washer, and inlet seat into position and secure. Install the inlet needle val ve and secure with the retaine r.
8. Place the O-ring and drain plug into position and secure; then place the fl oats into position making sure the word UP is prope rly lX)sitioned. Press the caps onto the fl oat towers.
6347
6 344
6. Place the float arm into jX)siti on and secure with the pin.
9. Place the gasket and fl mlt chamber into lX)sition and sec ure with the four screws and lock washers making sure the hose plates are properly positioned on the two front screws. Install the vent hoses.
7. Check the fl oat ann height. Using a calipe rs, measure the distance from the gasket surface to the top of the fl oat arm (with the carburetor inveI1ed). If measurement is not within specifications, adjust by bending the actuating ta b.
10. Place the E-clip into position on the jet needle.
From the bottom of the jet needle. slide the E-clip washer up against the E-cJip. Place the jet needl e into the pi ston valve. Place an E-clip washer on the jet needle above the E-clip.
4-15
Page: 183
NOTE: Place the Eclip in the proper position as noted in disassembly.
, ~.
_--Lean _--Standard Eclip Position ---Rich
, ~.
72S266C
II . Place the ca ble retainer into the piston va lve and secure with the Phillips-head screw. Place the spring and plate over the throttle cable and compress the spring. Guide the cable end down into the cable retainer slot and slide the cable end to the center of the piston valve. Release the spring and retainer plate to lock the cable in position.
2. Making sure the cap, spring, washer, and rubber washer are accounted for from disassembl y. install the fuel mi xture screw in the mixing txxly.
NOTE: The round part of the cable end must come through the hole in the plate. If it doesn't, the cable isn't assembled to the piston valve correctly.
12. Thread the plunger cap onto the choke cable. Place the spring over the cable end and compress. Position the cable end into the stmter plunger and release the spring .
Assembling Carburetors
(TM.Style)
Place the throttle val ve IOto the mixi ng txxly making sure the cuta way faces the funnel assembl y side; then slide the bushing assembl yl plate onto the lever assembl y. Secure the assembl y with the remaining bushings with clip, plate. washer, and E-c1ip.
NOTE: When installing the throttle valve, the cut away must face the funnel assembly side.
3. Rotate the fuel mixture sc rew clockwise until li ghtl y seated; then rotate the mi xture screw counterclockwise the same num ber of turns as noted in di sassembling fo r all initial setting.
&
CAUTION
00 not force the mixture screw when seating. Forcing the mixture screw may result in damage to the screw taper andlor mixing body.
4. Move the throttle lever to the full-open position; then secure the funnel assembl y w/gasket to the mi xing txxly.
4-16
Page: 184
6. Install the stm1er jet, pi lot jet, and main jet (w ith washer).
5. Accounting for the O-ring from disassembl y, install the noat assembl y by pressi ng in on the screw mounting holes; then secure the nO<lt assembly with the screws.
_NOTE : It may be necessary to use a spray lubri cant such as WD40 to aid in installing the float assembly.
7. Place the noat chamocr and O-ring mto position on the mi xing b<xly ; then secure with the screw and drai n plug (with O-ring).
8. Place the washer and E-clip (above the washer) onto the jet needle; then install the jet needle assembly into the mixi ng b<xly. Secure with the retaining plate and screw.
Page: 185
4-17
I. Place the carburetor inlo position III the flan ge and air-intake silencer boot; the n tighten the fl ange clamp making sure the carburetor is level. Do not over-tighten the flan ge clamp as it will damage the carburetor Ilange .
NOTE: Slide the carburetor into the air-intake silencer boot; then slide the carburetor into the flange.
2. Connect the fue l hose to the carburetor inlet filling. 3. ThrC<ld the brass c hoke-cable housing into the carburetor making sure the washe r is pro perly positioned and tighten securely.
9. Place the top cap and gasket on the mixing body; then sec ure with the screws (w ilh washers).
NOTE: If the lever assembly was loosened from the throttle lever shaft, the carburetors must be synchronized.
4. Place the pi ston valve IIlto position making sure the full -length groove in the piston val ve is ali gned with the pin in the mixing chamber bore.
Installing Carburetor
(VM.S~le)
NOTE: On twin carburetor models, install the carburetors using this basic procedure.
4-18
Page: 186
5. Sec ure the mixing txxly top by ti ghte ning the screw and lock washer making sure the mixing txxly top plate is properl y positioned. 6. Ir applicable, connect the s<'"lfety switch harness to the main wiring hamess. 7. Turn the gas tank shut-off valve to the OPEN position.
5. At thi s point , there must be free-pla y gap in the throttle lever.
\'
i'"
8. Adjust the carburetors (see appropriate Adjusting Carburetors in this sub-section).
Throttle Control Housing
~J
""-
~
Throttle Lever
733-081C
Installing Carburetors
(Standard TM-Style)
Prior to installing the carburetors, the carburetor throttle vah'es must be checked for syncluonizat ion . A. Wi th the throttle in the idle position , select a small drill bit that wi ll just fit under the c utaway of the fixed throttle valve. B. Using the same drill bit, check the clearance under the adjustable throttle valve cutaway. If clearance is different from the first carburetor checked, adjust the throttle valve by loosening the lever ring locki ng screw; then using an o pen-end wre nch, rotate the synchroni zing nut in either direction until the cl earance is the same as the first carburetor checked .
Gap of 0.75-1.5 mm (0.030-0.060 in.) between the Throttle Switch Body and Throttle Lever when Safety Switch is set properly
NOTE: If throttle cable free-play is incorrect, the throttle safety switch will be activated prematurely and the engine will not start. NOTE: If cable free-play must be corrected, utilize the jam nuts on the throttle cable bracket until no free-play is attained .
6. Place the air-intake silence r into position in the engi ne compartment making sure the carburetors are properl y positioned in the boot and secure wi th screws. 7. Place the ignition coilffuel pump mounting plate into position on the ai r-intake sile ncer and secure with the machine screw and washe r.
Nut
,fS-mL--Locki,ng Screw
0734-445
C. After synchroni1..:'l tion has been attained, hold
8. Adjust the carburetors (sec appropriate Adjusting Ca rburetors in this sub-section) .
the synchronizing nut with the open-end wrench and tighten the lever ring locki ng screw. 2. Place the carburetors (with OO<lt chamber vent hoses) in the engine compm1 ment and into the ca rburetor boot: then tighten the clamps. 3. Connect the fuel suppl y hose to the fuel inlet '1'fitting. 4. Connect the throttle cable and choke cables.
Installing Carburetors
(U"Laydovvn" Engine TM ..Style)
I. Prior to installing the carburetors, the carburetor
throttle valves synchronization.
must
be
checked
for
Page: 187
4-19
A. With the throtlle in the idle positio n, select a
small drill bit Ih.1I wi ll just fit under the CU !<lway of the fi xed throttle valve. B. Using the sa me d rill bit, c heck the clearance under U1C adjustable throttle va lve cutaway. If clcara nce is di ffe re nt fro m the firs t ca rburetor checked, adj ust the throttle va lve by loosening the lever ring locking screw; then usi ng an open-end wrenc h, rotate the sync h ron i zi l~g nut in either direction until the clearance IS the !cked. same as the fi rst carburetor ch{
=.
Throttle l ever Throttle Control Housing Gap of 0.75-1.5 mm (0.030-0.060 in.) between the Throttle Switch Body and Throttle l ever when Safety Switch is set properly
733-081C
Nut
X''0't--l.oct<ing Screw
6. Fi ll the cooling syste m with coolant.

NOTE: Because the coolant fills slowly into the engine it is necessary to wait for 10 minutes after filling the coolant tank to allow the engine to fill with coolant.
7. Recheck the coolant level. If the level is low after 10 minutes, repe.lt step 6.
8. Install the coolant cap to the " first" position.

0734-445
9. Sta rt the engine. Do not exceed 3000 RPM.

.NOTE: After the engine has run for about 3-5 minutes the right-side running board heat exchange'r should feel warm to the touch , This is a sign that the thermostat has opened , to. Shut o n' the engi ne.
11 .
C. Aftc r sync hronizatio n has been att,linoo, hold the synchronizi ng nut with the o pen-e nd wrench and tighten the lever ring locking scrcw.
2. Connect the coolant hoses to the carburetors and secure with the clamps.
3. Pry the air si lencer boot forward far enough to allow the ca rbureto r asse mbl y to be placed into
Ti ghten the coolant cap to the "second" position.
positio n; thcn ti ghten the carburetor nange clamps, conncct the TPS harness, and connect the throttlc cable.
NOTE: Make sure that the coolant drain is tightened and that the drain hose is routed correctly in the front end_ 4 . Install the resonato r and the expansion chamber.
5. At thi s po int, there mllst be free-play gap in the
12. Tip the snow mobile onto the left-ha nd side (PTOside) to allow air 10 move from the rea r heat exchange r to the coolant tank.
13. Recheck thc coolant level. If the coolant leve l is low, repeat step 6.
14 .
Install the coolant cap to the "fi rst" position.
15. Place the snow mo bile onto a sa fely stand.

16. Start tJle e ngi ne .Uld run fo r I to 2 minutes. [)o not
throlli e lever.
NOTE: If throttle cable free-play is incorrect, the throttle safety switch will be activated prematurely and the engine will not start. NOTE : If cable free-play must be corrected , ut!lize the jam nuts on the throttle cable bracket until free-play is attained.
exceed 5000 RPM . 17. i\.lon itor the heat exc hanger tem pe rature by touc h. 18. Shut the engine ofT fo r 5 minutes . 19. Start the engine and run fo r about 3-5 mi nutes; the n re pe;'lt steps 10 - 18 an < Idditional 2-3 times.
4-20
Page: 188
Adjusting Carburetor(s)
(VM-Style)
NOTE: On twin carburetor models if a carburetor choke cable is adjusted too tight, the engine will only operate on 1 cylinder at idle.
ADJUSTING PISTON VALVE(S)

NOTE: On some models, the airintake silencer is a on~piece unit, and the silencer boot(s) can be removed to access the intake bore( s). Remove the boots ; then proceed to step 4. .NOTE: On some models, the airintake silencer includes a cover/tool tray assembly and a baffle! resonator, and the silencer boot cannot be removed to access the intake bores. Proceed to step 1. I. O pen the air intake silence r cover; then remove the 3 Phillips head screws securing the cover/tool tray assembl y to the silencer.
2. Tip the cover/tool tmy assembly forward and out
,&, CAUTION
The air-intake silencer and boots must be in
position whenever the engine is run. If the silencer is removed and the engine is run, a lean condition will result. Therefore, DO NOT run the
engine when the air-intake silencer is removed.
ADJUSTING CHOKE CABLE(S)

I. Be sure the ignitio n switch key is in the OFF position and the brake lever lock is set. 2. Loosen the jam nut securing the choke cable adjuster. Rotate the choke cable adjuster clockwise until it bottoms aga inst the brass plunger cap. 3. Slowly rotate the choke cable adj usI'CI" counterclockw ise while checking the choke lever for free-play. As soon as all free-pl ay has been
removed from the end o f the lever, stop rotating
o f its slots and re move the assembl y.
3. Using a large nat-blade sc rewdriver, re move the resonator tabs from the air-intake silencer slol') and re move the resonator to access the intake bores.
NOTE: The resonator can be removed more eas ily by removing the back tabs first. 4. Rotate each idle speed screw counterclockwise unlil all spring tension is removed. 5. Loosen the jam nul securing each throttle cable sw ivel ada pte r; then rotate the swivel adapter clock wise until the piston valve bolloms III the piston va lve bore.
6. In turn on each carbureto r, place a finger lightly against the side o f the piston valve; then rotate the carburetor sw ivel adapter counlercl ockwise until slight upward movement of the va lve is noted.
the adj uster.

4 . With frce-play removed from the le"er, slow ly
rotate the cho ke cabl e adjuster once again cl ockwise while checking the c hoke cabJc lever for free-pla y. Adjust unlil 3 mm (118 in.) free-play between front bottom edge of lever and ho using is attained. SecurcJy ti ghten the adjuster jam nul.
Choke Lever
Free-Play Movement
7. In turn on each carburetor, pl ace a finger against either piston valve. Rotate the idle speed screw clockwise unti l it contacts the va lve.
Proper choke cable adjustment is with choke lever lifted 3 mm (1 /8 in.)
0732-848
5. O n twin carburetor models, repeat steps 3 and 4 o n each carburetor.
8. Compress the th.-olile lever to the full -o pen pos iti on~ then rotale each idle speed screw clockwise 2 complete turns. Release the th.-olile lever.
NOTE: On single carburetor models, the throtde control is equipped with a 2wire throttle control switch connector. There must be fre~play between the lever and the control housing.
Page: 189
4-21
NOTE: On twin carburetor models, the throttle control is equipped with a 3-prong emergency stop switch connector. There must be free-play between the lever and the control housing.
5. With slight pressure being applied to the throttle lever, the piston valves should start to open at the exact same time. Compress and release the throttle lever several times to assure accurate determination of piston valve opening. 6. If a piston valve stm1s to open before another, rotate the swi vel adapter on the valve which is lifting first elockwise, just enough to synchronize the \'ah'es.
"
Throttle lever
NOTE: Recheck by repeating steps 4-6.
Throttle Control Housing Gap of 0.75-1.5 mm (0.030-0.060 in.) between the Throttle Switch Body and Throttle lever when Safety Switch is set properly
733-081C
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: On twin carburetor models if throttle cable free-play is incorrect, the carburetor safety switches will be activated prematurely and the engine will not start.
9. On some models. install Ihe air-intake silencer OOot(s); on some models, install the tmfllel resonator and the coverftool tray assembl y.
7. Ti ghten the sw ivel adapter jam nuts securely. Slide the rubber throille cable caps down over the swivel adapters.
SYNCHRONIZING PISTON VALVES

NOTE: Arctic Cat recommends using the Carburetor Synchronizer (pfn 0644-069). If the carburetor synchronizer is not available, use the following procedure.
I. Open the air-intake silencer cover; then remove
the 3 Phillips-head screws securing the cover/tool tray assembl y to the silencer. 2. Tip the cover/tool tray assembl y fo rward and out of its slots and remove the assembly. 3 . Using a large nat-blade sc rewdri ver, remove the resonator tabs from the air-intake silencer slots and remove the resonator to access the intake bores.
NOTE: The resonator can be removed more easily by removing the back tabs first. NOTE: There must be free-play in the throttle lever.
& 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 full-closed position.
4 . Check to make sure the piston valves start to open at the exact same moment by placing a thumb and finger againstlhe val ves; then lightl y compress the throttle lever.
8. Aft er synchroni zation has been attained, IIlstall the resonator and cover/tooltray assembly.
4-22
Page: 190
ADJUSTING PILOT AIR SCREW(S)

I. While counting the rotations, carefull y rotate each pilot air screw clockwise until lightl y seated.
&.
CAUTION
Do not force a pilot air screw when rotating it clockwise; damage to the pilot air screw needle tip will result.
4. O n twin carburetor models, rotate the PTO-side carbureto r idle speed screw clockwise until the tacho meter reads sli ghtly above 1500 RPM; then rotate the idle speed sc rew countercloc kwise to achievc exact 1500 RP;vl reading . The piston valves should now be synchroni zed and the enginc should idle without ho lding a ny tinollle pressure.
_NOTE : If the engine has no ignition spark with the throttle in the idle position but has proper spark with the throttle lever slightly compressed , the carburetor safety switches must be reposi tioned.
2. Rotate eac h pilot air screw counterclockwise the sa me num ber of turns as noted in step I fo r an initial selling. 3. Synchroni ze the oil-injecti on pump (sec Related Items in this sectio n).
5. Test the tinollie conlrol1cver by compressing and releasing il sevcraltimes_T he lever must return to the idle position quickly and completely.
ADJUSTING ENGINE IDLE SPEED

I. With the snowmobile o n a shielded safet y stand , stmt the e ngi ne, release the brake lever lock, and thorough ly warm up. Fine-tunc each idle speed screw and each pilot air screw until the engine idles smoothl y at the desired RPM ( 1500 RPr.." is
recommended) .
&.
WARNING
00 NOT operate the snowmobile when any com ponent 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.
NOTE: Make engine idle adjustment only after the engine has reached running temperature. Since the idle speed screw(s) have not been adjusted, apply slight throttle pressure to keep the engine running. Allow engine to warm up for 23 minutes.
Adjusting Carburetors
(TM.Style)
2. O n twin carburetor models after the engine has been allowed to warm up for 23 minutes, adjust engine idle by first rotating the PTOside carbureto r idle speed screw clockwise until the tacho meter reads 1480 RPM _ 3. O n twin carburetor models. rotate the ivlAG-side ca rburetor idl e speed screw clockwise until tacho meter reads 1500 RPM,
&.
CAUTION
The airintake silencer and boots must be in position whenever the engine is run . If the silencer is removed and the engine is run, a lean condition will result. Therefore, 00 NOT run the engine when the airintake silencer is removed.
ADJUSTING CHOKE CABLES

I. Be sllre ignitio n switch key is in the O FF position and thc brake lever lock is set. 2. Looscn the jam nut securing each choke cable adjuster o n the side of the carburetor.
Page: 191
4-23
~-Tt'".''' Cable
Choke Cable
4. With the throttle in the idle position, select a small drill bit that will just fit under the cutaway of the fi xed throttle val ve.
5. Using the same drill bit , check the clearance under each adjustable throttle valve cutaway. If clearance is different from the first carburetor checked, adjust the throttle va lve by loosening the lever ring locking screw; then using an o pe n-end wrenc h, rotate eac h synchroni zing nut in e ither direction until the clearance is the same as the first carburetor checked.
Idle Adjustment Screw
)/ - A;j, Screw
Fuel Mixture Screws

0735-774
3. Slowly rotate o ne cho ke cable adj uster while

checking the choke lever for frec-play. As soon as
<gf":::::~>-~;Y"Ch'O"iZi"g Nut
rt~r-- L,>cki"g
Screw
all free-pl ay has been removed from the end of the choke lever, stop rotating the adjuster. 4. With free-pla y removed from the lever, slowly rotate the adjuster again while checking the choke lever fo r free-play. Adjust uotil 3 mm ( 1/8 in.)
free-play between front bottom edge o f lever and
hOllsing is attained. Securel y tighten the jam oul.

Choke Lever
0134-445
6. Afte r synchronization has been anained, ho ld the synchroni zing nut with the o pen-end wrench and tighten the lever ring locking screw.
7. Install the resonator and cover/tool tray assembl y.

3mm
> <l!8in.)
_NOTE : On F-chassis models, make sure the air silencer boot is properly positioned over the carburetor bores.
Proper choke cable adjustment is with choke lever lifted 3 mm (1/8 in.)
0732-848
ADJUSTING FUEL MIXTURE SCREWS

I. While counting the rotations, carefull y rotate the fuel mixture screws clockwi se until lightly seated.
Choke C.t"'-~
Idle Adjustment Sco'w -!!~
5. Repeat steps 3 and 4 o n the other ca rbureto r.
SYNCHRONIZING THROTTLE VALVES

NOTE: On F-chassis models, pry the air silencer boot forward far enough to access the intake bores; then proceed to step 4.
Cable
I. Open the air-intake si lencer cover; then remove the 3 Phillips-head screws securing the cover/tool tmy assembl y to the silencer. 2. Tip the cover/tool tmy assembl y forward and out of its slots and remove the assembly.
Air Sco"w---/:'h\:
e---- "" Screw

Fuel Mixture Screws
0135-774
3. Using a large Oat-blade sc rewdriver, remove the resonator tabs from the air-intake silencer slots and remove the resonator to access the intake bores.
NOTE: The resonator can be removed more easily by removing the back tabs first.
L!':. CAUTION
00 not force a fuel mixture screw when rotating it clockwise; damage to the mixture screw taper may result.
4-24
Page: 192
2. Rotate each fuel mixture screw counterclockwise the same number of turns as notcd in ste p I for an initial selling. ADJUSTING AIR SCREWS
I. While counting the rotati ons, carefull y rotate the
REMOVING
KEY
1. 2. 3. 4. 5. 6. Retaining Ring Throttle Cable Cable Tie ERlng Washer Nut
air screws clockwise until li ghtl y scated.
&.
CAUTION
Do not force an air screw when rotating it clockwise; damage to the air screw will result.
2. Rotate the air screws counterclockwise the exact number of rotations 1f4 turn from the seated position as an initial setting. ADJUSTING ENGINE IDLE SPEED
_NOTE : Make engine idle adjustment only after the engine has reached running temperature. Since the idle speed screw has not been adjusted, apply slight throttle pressure to keep the engine running. Allow engine to warm up for 23 minutes.
KEY
, . Retaini ng Clip 2. Throttle Cable 3. ERing 4. Washer 5. Cable Tie 6. Jam Nut
734S33A
I. After the engine has been allowed to warm up for 2-3 minutes, fine-tune the idle speed screw until the tachometer rc. .lds 1500 RPM. 2. Test the throttle control lever by compressing and releasing it several times. T he le\'e r must return to the idle IXlsilion qui ckly and completely,
736742A
&.
WARNING
KEY
1. Cable Tie 2. Throttle Cable 3. Jam Nut 4. E-Ring 5. O-Ring 6. Retaining Clip
00 NOT operate the snowmobile when any com ponent 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.
Throttle Cable
(VM.S~le)
737-544 A
I. Loosen the throttle cable adjuster jam nuts.

NOTE: Determine which type of cable is being replaced and remove and install accordingly.
2. Rcmo\'e the mixing body tops. 3. Re mo\'e the throttl e cabl es from the pi ston valves. 4. Rc move the throttle ca blcs from the mixing body tops. 5. Re move the handlebar pad and console. 6. Re move the cable ties securing thc throttle cablc. 7. Rcmovc the th rottle cable end from the throttl e lcver.
Page: 193
4-25
8. Using Throttle C. 1 ble Removal Tool (pIn 1639963), push down o n the throttle cable retaining clip; then remove the cable from the throttle switc h assembly.
Throttle Cable
(TM-Style)
KEY 1. Reta!nlngCllp 2. Throttle Cable 3. ERi ng 4. Washer S. Cable Tie 6. Jam Nul
NOTE: On twin carburetor models, it may be necessary to remove the PTO-side carburetor.
9. Remove the E-ring securing the oi l-injection cabl e to the contro l arm. Account for a washer.
10. Loosen the jam nut securing the adjustment cable; then remove the cable from the oil-injection pump.
,.A
INSTALLING
I. Route the throttle cable from the throttle switch assembly to the carburetors and oi l-i njection pump; avoid any sharp bends o r mov ing pmts.
2 . Insta ll the oil-injection adjustment cable on the
o il-injectio n pump; secure with the jam nuts.
3. Install the oi l-injection cable o n the contro l ann ;

secure wi th a washer and E-ring.
73S869A
NOTE: Install removed .
the
PTO-side
carburetor
if
4. Install the throttle cable into the throttle sw itch
assembly making s ure it snaps IOtO place.

5 . Install the throttle cable end on the throttle lever.
KEY 1. Cable Tie 2. Throttle Cable 3. Jam Nul 4. ERing 5. ORing 6. Retaining Clip
6. Securc thc throllic cablc to the stccring post with ca blc tics. 7. Install the handletmr pad and consolc. 8. Attach the throttle cable to each throttle valve. The valve must scat in the groove o f the throttle cable end; then thread the throttle cable into each mixing bOOy top. 9. Install cach pisto n valve and mixi ng body top on the carburctor(s). T ighte n securely.
10. Adjust the carburetor(s) (see appro priate Adjusting Carbureto rs in this sub-scction).
-.-'
REMOVING
,
737-7S4A
I . Loosen the throttle cable adjuster jam nut at the bracket.
2. Remo\'c thc throttle cable fro m thc pullcy on the ,Iuonle lcvcr shaft. 3 . Removc the handletmr pad and consolc. 4 . Remove the throttle cable from the throttle lever.
Lb. CAUTION
Compress the throttle control lever to ensure free movement. If the throttle cable sticks or binds, correct the problem before starting the eng ine.
11 . Synchronizc the oil -injection pump (see Related Items s ub-section).
5. Using T hrottle Cable Removal Tool ( pi n 1639963), push down o n the throttle cable rctaining clip; then re movc the cable from thc throllie sw itch assembl y. 6. Opcn thc belt guard ; then rcmove the drivc bell. 7. Remove the oi l-injection cable fro m the control arm .
NOTE: Some models are equipped with " control rod " actuated oil pump. The control rod simply snaps off and on at the control arm.
8. Loosen the jam nut securing the adjustment cable; then re move the cable from the oil-injection pump.
4-26
Page: 194
INSTALLING
KEY
Insta ll the oi l-injection adjustment cable on the o il-injectio n pump; secure with the jam nuts_ 2. Install the oi l-injection cable on lhe control ann. 3. Route the throttle cable from the carburetor to the throttle switch assembl y making sure it snaps into place.
1. Choke Cable 2 . Knurled Nut 3. Choke Lever Kit
A CAUTION
Avoid any sharp bends and hot or moving components or damage may occur.
737490A
4. Install the throttle cable on the throttle lever.

5. Install the handlctmr pad and console.
KEY
t . Choke Cebte
2. Knurled Nut
3. Cho ke Lever Kit
6. Install the throttle cable into the throttle lever shaft pulley.
7. Install the throttle cable into the bracket; then adjust the jam nut to attain no free-play between the throttl e lever and the control housing .
NOTE: There must be no free-play between the lever and the control housing.
736S96A
A CAUTION
Compress the throttle control lever to ensure free movement. If the throttle cable sticks or binds, correct the problem before starting the engine.
8. Synchroni ze the oi l-injection pump (see Related
REMOVING
I. Bend down the lock tabs locking eac h brass choke cable housi ng on each carburetor. 2. Using a 12-mm wre nch, remove each brass choke cable hOllsing from each ca rburetor. Account for the lock tab washers.
Items sub-section). 9. Install the drive belt ; the n close and secure the belt guard .
3. Remove each brass plunger and spring from the cable end ; then re move each brass choke cable housing.
4. Remove the screws securing the console.
Choke Cable
(VM-Style)
5. Position the choke lever in the middle-choke position; then re move the knurled nut secllring the choke lever housing to the console .
Knurled Nut
725-001A
6. Slide the choke lever housing from the console.

4-27
7. Cut any cable ties used to secure the choke cable and remove the choke cable from the engine compmtment.
INSTALLING
Choke Cable
(TM-Style)
KEY
1. 2, 3. 4. Choke Cable Jam Nut Knurled Nul Choke Level" Kit
I. Position the choke \c\'er in the middle-choke position; then from the b.'lck side of the console, insert the choke lever housing through the console. Secure with the knurled nut. 2. Route the choke cable from the console to each carburetor; avoid any sharp bends or moving parts. 3. Install each brass choke cable housing onto the cable end ; then inst.a ll each spring and brass plunger. 4. Place the lock tab washer on each brass housing and insert a choke plunger into each carburetor. 5. Thre.ad e.ach brass choke cable housing into each carburetor and tighten. Bend the lock tab up to secure the brass housing. Adjust the choke cable (see appropriate Adjusting Carburetors in this subsection). 6. Place the console into position and secure with the screws,
737-894A
'"
1. Cho ke Cable 2. Cho ke Nul 3. Choke Lever Kit
736811 A
'"
1. Cho ke Cable 2. Cho ke Nul 3. Cho ke Lever Kit
736-796A
REMOVING
I. Loosen the jam nuts securing the choke cable to the bracket. 2. Re move the cable from the stmter plunger lever. 3. Position the choke lever in the middle-choke position; then re move the knurled nut securing the choke housing to the console.
4-28
Page: 196
2. Route the choke cable from the console to the carburetors: a void any sharp bends or moving parts.
3. Install the choke cable into the bracket: then
Knurled Nul: - _ _ ~
Full
secure with jam nut s making sure the choke lever has 3 mm (118 in.) free-pl ay between the edge of the lever and the housing.
Choke lever
725-OO1 A
4. Remove the console. 5. Slide the choke cable from the console.
Free-Play Movement
INSTALLING
I. Position the choke lever in the middle-choke position; then from the back side of the console, insert the choke lever housing through the console. Secure with the knurl ed nut.
732848 B
4. Place the console into position and sec ure.
Page: 197
4-29
Mikuni Tuni ng Components

MAIN JETS AVAILABLE
NEEDLE JETS AVAILABLE (VM Style)
JET
PIN
JET
PM
6505- 125 6505-146 6505-126 8505- 147 6505-127 6505-148 660&- 149 8505- 150 6505-1 51 6506-376
6500-379
650&-170
N EEDL E
'" '" '00 ,ro

, ~ , ~
""'"
--'"
6505-216 6505217 6505-064

~.~
' 00
'" = '" '" '" ,ro ""

,~ ,~
""'"
6505-144 6505-1 45 6505-137 6505-007 6505-079
--reo
.
'" = =."
.~ ,
"' ~
'" '" .ro ., ." =

~
JET
PM
6505-Q31 8505- 181 6505-824 6505-155 6505-007 6505-05 1 6505-598
~.~
NEEDL E
J ET
PM
6505-641 650559& 6505214
,~=
MAIN JET Size indicated in this area
'W;""
"""" ""0'
-,.,
'00
"" =
",
~
-"" --'"
6505-126
-,~
-~
M~
~,
..,
..,
.."
'" ,., '" ,ro

,.,
'00
'"
--'" "",ro
""000
6505-072 6505-077
6505-076 650507 1
'" "'" '" .., '" ..,

..,
'00
6505-53 1 6506-381 6506-382 8505-172 6500-383 6505-21 1 660&-173 6505-532 6505-174
~
-
PILOT JET
Size indicated in this area
6505-535
650&-169
,W;'" ,w;'"
NEEDLE JET Number indicated
0-6 (480) 0-8 (182) 0-8 (480) P-O (159) P-O(I00) P-O (169) P-O (480) P-2 (480) p4 (159) p4 (166) P-4 (480) P-4 (169) P5 (480) P-6 (159) P-8 (166) P-S (480) P-S (251) P-B (159) P-B (100) P-8 (480) 0 -0 (159) 0- 0 (166) 0-0 (480) 02 (166)
6505-22 1 6505-502 6505-540 6505-164 6605-542 6505-247 6505-539 6505-235

~.~
"~-
6505-433 6505-643 6505-260 6505-190 6505-529 6505500
0 -2 (480) 03 (480) 04 (166) 0 -4 (480) 0-5 (159) 05 (166) 0 -5 (480) 0-8 (166) 0-8 (480) R-O( 166) Z-4 (224) Z-5 (224) Z-S (224) Z-B (224) Z-9 (224) MO(224) Ml (:2:24) AA -2 (224) M-3(224) AA4 (224) AA-O (224) AA-8 (224) 88-0 (224) 885 (:2:24)
,,,.'"
,~~
6505-119
6505-506 6506112 6!S05!S05 6505-806 6505-541 6505597

-~,
6505-616 6!S05544
..,..."
6505-545 6505-604
'''''''
","'.,
PM
6506-116 6500-110 6506114 6506118 6500-115
6505-099 6505-571 6505- 182
JET NEEDLES AVAILABLE
.
'"
"
""'"
6505-124 6505212
'" m
6505-536 6505-537 6505-538
'
PISTON VALVES AVAILABLE (VM Slyle)
in this area
J ET NE EDLE (VM-Sl y te)
PIN
6505-519
J ET NEEDL E (TM-Sl y le ) OC FH1-56 9DH2-59 9OH5-61 9OEH 155 9DEH2-57 9EGY0 157 9EH2-57 9EH8-60 9EJI-60 9EH7-82 9DFH2-58 9DFH259 9DFH3-56
OOC~
SLIDe
CA RB. SIZE (mm)
PM
'.0
" '.0 , ..
'" '" '.0 '" '" ,.
' .0
,= '" '"
~~ ~~
"'~
""""
6505-161 6505-510 6505-528
-= -'" _oro -'" ,,- ..,.'" _m ""' '"" =,

,~,
OC"'
,~.
,~,
'''''
,~,
6505-215 6506297
~,
~~
~~ ~
~ ~
~ ~
6505-61.'
8505-507
~,.
-'" _.", -'" "~"'"

6505-877
-~
JET NEEDLE Number indicated
,~.
_00' 6605-814
in this area
""'-=
6506-113 6506201 6506166 6506-182 6506-221
6506-111 6500-117
" " '.0
, ".. , .. '" , ,.. ..

" '"
'.0 ' .0
'"
" " "
6505592'
9 DFHI -56 9DFH959 9EH6-59

OO~M
"'"~
..,.~,
~ ~
~ ~
~
"~~ "~~
6500-272
..,.
"'"'' "''',.
,~'"
8505813"
6505-575'
...
~
\....k..~
9DFH450 QEFH9-60
",.."
-"" ",".,.,
6506-374
INLET NEEDLE ASSEMBUES AVAILABLE (VM Style)
"~~
" '" , ..
'" For
., - _
40-44
" .,."
40-44 40-44
_n, -'"
6505.070
PISTON VALVE Number indicated
"'--
S E AT OIA. 1. 5 1001(8\001) 1.51001('<11011) 1,51001 (81001) 1.5 1001(81001) 1.5 rnm('<I10I1) 1,8mm('<Ilon) 2.0 rnm (Won)
CAR B . S IZE ( mm) 28,30, 32,34 28, 30. 32, 34 28-34GVM 38,38,40, 44 38.38,40,44 38,38,40, 44 38,38,40,44
PIN
..,.,.,
6505-026 6505-245 6505-103 6505-171 6505-175 6505-176
in this area
_000
.OM
modols v.ith carbiJre10r s...tch
6505-813'
INLET NEEDLE ~ ASSEMBLY
.-:.E
-
THROTTLE VALVES AVA ILABLE (TM STYLE)
Size indicated in this area

INLET NEEDLE SEAT
-=-
INLET NEEDLE ASSEMBLIes AVAILABLE (TM Style) S E AT OIA . CA R B . S IZE ( mm) 38 PIN 6500- 121 6500-144
SLI De
CA RB. SIZE, (mm)
PM
6500-"9
- ,~
,..
'"
" " '.0
" " "
" "
'
1.5 mrn(S1001) 1.8 mm (31001)
6606-232 6506-2 10 6506-273
NEEDLE RETAINER
.-e::e;
PILOT JETS AVAILABLE J ET NO. 17. 5

~
INLET NEEDLE
-C
PIN
6506-218
J ET NO.
PIN
n.
~
-'"
65053 10 6505-075
,~=
""
~.
.""'"
'"
'"
""""
-~,
-'"
6505-261
"".,..
4-30
Page: 198
2005 A rc t ic Cat Servic e Manual - all models - www. ReadManuals.co m
Major Tuning Components

To assist you in selecting four major tuning components of the Vlvi-style and T lv l-stylc carburetors, listed below are the jet needles, needle j ets, pilot jets, and pi ston/thronle valves (slides) 011 chart.. according to their size.
NEEDLE JETS
LEAN
TYPE - 159-166-480 VM30-32-34-38

N-4 N-6 N-8 0-0 0-2 0-4 0-5 0-6 0-7 0-8 p-o P-2 P-4 P-5 P-6 P-8 0-0 0-2 0-3 0-4 0-5 0-6 0-8 R-O R-2 R-4 R-5 R-6
TYPE 224 VM40-44
PILOT JETS
LEAN
12.5 15 17.5 20 22.5 25 27.5 30 32.5 35 37.5

40
Zoo Z-5 Z-6 Z-8 AA-O
RICH
45 50 55 60 65 70
PISTONfTHROTTLE VALVE (SUDES)

LEAN 4.0 3.5 3.0 2.5 2.0 1.5 1.0
AA-'
AA-2 AA-3 AA-5 AA-8
88-0
B8-5
RICH
RICH
R-8
NOTE: The above needle jets may come in different types ; for example, (159) - (166) - (480) - (224)_ When selecting a new needle jet, use the correct series or type.
JET NEEDLES (VM STYLE)
LEAN
RICH
60H2 6DH3
6DH4
60H?
6DH8
6DH41
6EGJl
7F7 70H2 7F6 7DH3 7DH5 7H2 7J2
NOTE: The above chart shows the average per forma nee of a given needle between 1/4 and 3/4 throttle. Needles are constructed in such a way that at any given point, the needle could be richer or leaner than the rating it has.
Page: 199
4-31
Troubleshoo1:ing Fuel Sys1:em

Problem: Carburetor Too Rich (0-1/4 Opening) Condition 1. Choke plunger will not seat 2. Pilot air screw (VM-style) too far in 3. Fuel mixture screw (TM-style) too far out 4. Pilot air passage obstructed - damaged 5. Floatlinlet needle obstructed - damaged adjusted incorrectly 6. Pilot jet loose Problem: Carburetor Too Rich (1/4-3/4 Openmg) Remedy 1. Adjust - service - replace choke cable -plunger assembly 2. Adjust pilot air screw 3. Adjust fu el mixture screw 4. Remove obstruction - replace pilot air screw carburetor 5. Remove obstruction - replace inlet needle - fl oat - adjust fl oat tab
6. Tighten pilot jet
Condition
1. Pilot air screw (VM-style) too far in 2. Fuel mixture screw (TM-style) too far out 3. Needle jet - jet needle worn - adjusted incorrectly - incorrect 4. Pilot air passage obstructed - damaged
Remedy 1. Adjust pilot air screw
2. Adjust fuel mixture screw 3. Replace needle jet - replace - adjust jet needle
E-cli p 4. Remove obstruction - replace pilot air screw carburetor 5. Tighten pilot jet 6. Remove obstruction - replace inlet needle - float - adjust float tab
5. Pilot jet loose 6. Floatlinlet needle obstructed - damaged adjusted incorrectly 7. Main jet loose - too large 8. Primary air passage obstructed
Problem: Carburetor Too Rich (3/4-WOT Opemng) Condition
1. Main jet loose too large 2. Floatlinlet needle obstructed - damaged adjusted incorrectly 3. Needle jet - jet needle worn - adjusted incorrectly - incorrect
7. Tighten - replace main jet 8. Remove obstruction

Remedy replace with smaller main jet 2. Remove obstruction - replace inlet need le - float - adjust float tab 3. Replace needle jet - replace - adjust jet needle E-clip
1. Tighten
Problem: Carburetor Too Lean (0-114 Opemng) Condition 1. Choke plunger remains seated 2. Pilot air screw (VM-style) too far out - damaged 3. Fuel mixture screw (TM-style) too far in damaged 4. Throttle valve sticks open - damaged - worn 5. Pilot jet - outlet obstructed 6. Floatlinlet needle obstructed - damaged adjusted incorrectly 7. Float bowl vent hose (TM-style) obstructed kinked - damaged Remedy 1. Ad just service choke cable plunger assembly 2. Ad just - replace pilot air screw 3. Adjust - replace fuel mixture screw 4. Service - replace throttle valve - throttle cable - spring 5. Remove obstruction 6. Remove obstruction - replace inlet needle - float - adjust float tab 7. Service - replace float bowl vent hose
4-32
Page: 200
Problem: Carburetor Too Lean (1/4-314 Opening) Condition 1. Pilot air screw (VM-style) too far out damaged 2. Fuel mixture screw (TM-style) too far in damaged 3. Needle jet obstructed 4. Pilot jet - outlet - main jet obstructed 5. Floatlinlet needle obstructed - damaged adjusted incorrectly 6. Jet needle E-clip position incorrect 7. Float bowl vent hose (TM-style) obstructed kinked - damaged Problem: Carburetor Too Lean (3/4-WOT Opening) Condition 1. Main jet obstructed - too small 2. Floatlinlet needle obstructed - damaged adjusted incorrectly 3. Needle jet - jet needle obstructed 4. Float chamber vent hose (TM-style) obstructed - kinked - damaged Remedy 1. Remove obstruction - replace with larger main jet 2. Remove obstruction - replace inlet needle - float - adjust float tab 3. Remove obstruction 4. Service - replace float chamber vent hose Remedy 1. Adjust replace pilot air screw 2. Adjust - replace fuel mixture screw 3. Remove obstruction 4. Remove obstruction 5. Remove obstruction - replace inlet needle - float - adjust float tab 6. Adjust E-clip 7. Service - replace float bowl vent hose
Problem: General Fuel System (Engine Cuts Out at High RPM) Condition 1. 2. 3. 4. Fuel delivery inadequate In-line fuel filter obstructed - damaged Gasoline contaminated Gas-tank vent - hose obstructed Remedy 1. 2. 3. 4. Repair Remove Replace Remove replace fuel pump impulse hose obstruction - replace inline fuel filter gasoline - de-ice - clean carburetors obstruction - replace vent - hose
Problem: General Fuel System (One Cylinder Runs Lean) Condition 1. Carburetor-to-cylinder air leak 2. Carburetors (VM-style) not aligned vertically 3. Primary compression (crankcase) low 4. Carburetors not synchron ized Remedy 1. Repair replace gaskets flanges intake ports - tighten clamps 2. Align carburetors vertically 3. Troubleshoot engine 4. Synchronize carburetors service
Page: 201
4-33
Fuel System
(Batteryless EFI)
EFI Specifications
Fuel Pressure (600 cc STD) Fuel Pressure (600 cc "Laydown"' 7001900 cc) Temperature Sensor (Closes) Throttle Valve Angle Degrees (6001700 cc "Laydown") Throttle Valve Angle - Degrees (900 ee) Throttle Valve Angle - Volts (6001700 cc "Laydown") Throttle Valve Angle - Volts (900 ee) 35.7-40.1 psi 42.847.3 psi
194206 F (90_97 C)
This sub-sectio n has been orga ni zed fo r servicing EFI

fuel syst em s: however, so me component s may vary
from model to mode l. The technician should use discretion and sound judgment when removingi disassembling and assembling/installing components. All 2005 EFI models are equipped with the batteryless EFl system.
Fuel System
(Batteryless EFI)
5.100-5.600 - Idle 82.50087.200 Full-Open 5.100-5.600 - Idle 82.500-87.200 Full-Open 0.685-0.707 - Idle 3.750-3.937 Full-Open 0.685-0.707 - Idle 3.750-3.937 Full-Open
Table of Contents Diagnostic Codes

EFI Specifications ................................................. 4-34 Diagnostic Codes ....... ...... ............... ...... 4-34 Introduction ........................................................... 4-35 Arctic Cat Batteryless EFI System ........................ 4-35 Individual EFI Components ..... ............... ........... .. 437 Self-Diagnostic EFI System ............. ..................... 440 Diagnostic Codes .................................................. 4-41 ECU ...................................................................... 4-42 Testing Individual Components. . .............. ...... 4-43 EFI Analyzer .......................................................... 4-47 Recommended EFI Troubleshooting Sequence (Kokusan Mode) ................................................ 448 Testing Individual EFI Components ... .......... ...... ... . 4-49 Peak Voltage Tests and Specifications...... .4-51 Throttle Position Sensor ............. ........... 4-51 Throttle Body Assembly ... ........... ............. ... ........ 4-51 Throttle Body Flange ........ ............................. ........ 4-53 .... .... . 4-53 Throttle Cable....... ................ .... ... .... Basic EFI System Information ... ............................ 4-55 EFI Component Voltage/Resistance Chart Air Temperature ............ ............................. ........ 4-56 EFI Component Voltage/Resistance Chart Water Temperature ............................................ 4-57 Troubleshooting Fuel System ................................ 4-58
Number of Flashes
1
Trouble Open or short circuit in throtlle position sensor. Open or short circuit in water temperature sensor. Open or short circuit in intake air temperature sensor. Open or short circuit in barometric pressure sensor. Failure in injector(s). Failure in servomotor. Coolant Temperature Above 80 C (176 F) Coolant Temperature Above 93 C (200 F)
2
3
S 6
Steady Flash (6001700 cc) Constant On (6001700 cc)
4-34
Page: 202
Introduction
The baucrylcss EFI system is lightweight in design and i s m ade tip o f a number o f co mponent s w hich are ex plained in thi s sub-section. The battcrylcss EFI system eliminates the worr y of battery maintenance or
changing main jets to compe nsate for altitude or tempe rature. T hi s EFI system will prov ide quick and easy starting under all conditi ons. T he electrical cont rol unit (ECU) has a self-di agnostic
mode built in . It is a vcry valuabl e fac lor in trouble-
shooting. O nce the problem area has been dete rmined from the trouble code fla shed by the LED (light emittin g di ode) located und e r th e left e nd o f the ECU (check engine li ght in the speedomete r/tac homete r on
" Laydown" engine model s), follo w the troubl eshoot -
ing procedure in this sub-sectio n. When troubleshooting the baueryless EFI system , spe cial tools are required. These special tools arc the following. A. EFI Analyzer (pIn 0644-342) B. Compression/Pressure Tester Kit (pIn 0644366)
C. Fluke Model 73 Muitimcte r (pIn 0644- 19 1)
D. EFI Anal yzer Ulxiate Kit (pIn 0637-243)

NOTE: Troubleshooting EFI engines with the APV system should be done with the Arctic Cat EFI Analyzer (pIn 0644-342). To update your existing EFI Analyzer, order Kit (pin 0644 341).
w
Arctic Cat Batteryless EFI System

The A rctic Cat Batteryless EFi System o pe rates off a seri es of coi ls located on the stator. T he baucryless EFi system is made up of the fo ll ow ing cOlll lxme nts. I. Charge coil s ( I and 2) whic h are located 011 the stator provide AC voltage to o pe rate the CDI unit. The CDI unit is located within the ECU. The AC voltage is converted to DC voltage within the ECU.
Page: 203
4-35
2. A fuel pump coil located on the stator operates the low voltage, high output fuel pump. At cranking speed, the high output fuel pump provides e nough fuel to charge the fuel rail . 3. An injector coil located on the stator provides the injectors with DC voltage for operation through the ECU. 4. A li ghting coi l located on the stator plate provides output to operate accessories and the lighting system. 5. An electrica l control unit (ECU) calculates input from fi ve sensors (i ntake a ir temperature sensor, water temperature sensor, throttle position sensor, ignition ti ming sensor, barometric pressure sensor) to provide the engine with the correct fuel mixture and timing for optimum o peration.
6 CAUTION
Always use resistor-type spark plugs and spark plug caps. Non-resistor components will cause the ECU to malfunction.
OPTIONAL STARTING PROCEDURE (STD Models)

I. To start an engine fo r the first time or after
EFI FEATURES
I. Automatic compens. 'ltion for tempe rature. 2. Automatic compens.'ltion for altitude. 3. O ptimum throttle response through high pressure injection. 4. Q uick stmting in every condition. 5. Improved fuel effi ciency with maximum mileage in every condition. 6. Engine RPiv l more stabl e ill every condition.
pe rforming service work on the fuel system, place the emergency sto p switch and the Ignition sw itc h in the O N position. Disconnect the yellow water te mpe rature sensor lead wire at the ECU. Crank the engine over 68 times with the recoil starter. With the water temperature sensor lead disconnected, the fuel system wi ll call for maximum mi xture and the system will charge faster. Aft er 6-8 bri sk pull s 011 the recoil starter rope. reconnect the yellow sensor lead . The engine should start in 2-3 additional pull s. Aft er charging the fuel system, the e ngine should stmt in 3-4 pulls when cold. 2. Start the e ngi ne without compressing the throttle. When the engine stmts for the first time, do not touc h the throltle. It will idle slowly and may stop. Repeat this procedure until the e ngine starts and builds RPlv, on its own. T his may req uire 3-4 restarts. O nce the engine has been started and run, the next cold start should occur in 2-3 pull s of the recoil staller rope.
FLOODED ENGINE
If the engine s hou ld become fl ooded , set the brake lever lock, compress the throltle lever to the full-ope n pos ition, a nd crank the e ngi ne over until it starts and clears itself. Release the brake lever loc k.
PRECAUTIONS
WARNING
Whenever working on the fuel system if a fuel hose is removed from any component, slowly bleed the pressure from the hose into an absor bent towel before removing the hose from the component.
FUEL SYSTEM
The EFI fuel system consists of the follo wing components.
I. Gas tank
2. Electric hi gh output fuel pump 3. Two pick-up valves with micron screens
Clamp
4. High-pressure fue l hose 5. Fuel rail 6. Fuel pressure regul ator 7. Throttle bOOy assembly 8. Injectors
Leave from hose end
of 37 mm (0.12-0.28 in.)
0729325
9. Fuel return hose (600 cc STD)

10. ECU
* O n the 6001700 cc "L'lydow n"J900 cc, the regulator

is in the fuel pump.
4-36
Page: 204
T hese compo nents are g ro uped into the fu el handling system. They work togcthe r alo ng w ith fi ve el ectri cal scnsors (fo llow ing li s t) and the ECU to prov ide the engine with a precise fuel mixture for combustio n. The fi ve sensors are the follow ing. I. Ignition Timing Scnsor 2. Intake Air Tcmperature Sensor 3 . Wate r Te mpe rature Sensor 4 . Throttle Position Sensor 5. Baro metric Pressure Scnsor T he rue l is firs t draw n into thc e lec tri c fu e l pump through two pick-up val vcs and hoscs. Thc fuel is thcn ro utcd thro ugh a hi gh-pressure rucl hose to the fuel rail. T he fue l pressure is maintained s pecifi ed psi in the fuel ra il by th e fu e l reg ul ato r. If press ure exc eed s thi s amo unt , the regulato r o pens and returns excess fuel to the gas tank through the fuel return hose (6(X) cc ST D). With the rucl pressurc maintaincd at a constant psi, the EC U evaluates the inrormatio n it rcceives fro m the fi vc electri cal sensors and o pe ns thc injectors ro r precisc pe riods of time (pul se widths) to meet cnginc dcmands. If any of the se nsors s ho uld fail while the engine is running, the ECU will sense a problem and go into a " fail sa fc' mod c. Thi s is a n over-ric h co nditi o n and will greatl y reducc pe rro rmance. Howe\'e r, the cng inc will be protcctcd from a possibl e lean conditio n and enginc damage. The ECU is equipped with a li g ht e mittin g di o d e (L ED) o n s tandard 600 cc mo d e ls o r w ith a c hec k engine lig ht in the s peedometer/tacho meter o n Z R and ""L1.ydown" ' engine model s, which will flas h a series o f pulses when a problem ex ists with any o f the sensors. By o bserviOg the code, the tec hnici an can determine the problem scnsor by comparing thc cooc Ilashcd with thc tro ubl e code chart (see Diag nosti c Codes in thi s s ub-sectio n).
NOTE: The entire EFI system depends on all coils functioning properly on the stator.
Individual EFI Components

ECU
The EC U is the brain o f the E FI syste m. It uses fi ve scnsor inputs to detcrmine the correct rucllair ratio for the engi ne gi\'en the existing conditions of altitude and tempc nl1ure.
MS395A
NOTE: There are no repairs that can be made to the ECU.

If the ECU is not receiving current from o ne of the output co il s o n th c s tato r, that circ uit will no t o perate . Co il s on thc stato r are thc calX lcito r charge coil whi ch o pe rates the C Ol within the BCU. th c inj ecto r coil whic h o pe rate thc injectors, thc fuel pump coil which operatc thc fuel pump, and the lighting co il which o pe rates all accessories and thc li ghting systcm" Refer to thc wiring diagram in this SUb-sectio n.
Page: 205
437
The water temperature sensor is located on the bottom of the thermostat manifold on standard models and on the lowe r crankcase on " Laydow n" engine models. T hi s sensor is very sensiti ve to temperature change. The ECU measures the current now through the sensor to ground. From thi s mcasllfement , the ECU can determine the engine coolant tempe rature and calcul ate the correct fuellair mi xture rati o.
NOTE: If the coolant temperature rises above 80 0 C (176 0 F), the temperature sensor starts to rich en the fuel mixture. At this time , the check engine light will flash constantly. Once the engine coolant temperature reaches the specified temperature 93 0 C (200 0 F), the temperature sensor will signal the ECU to go into the rich mode to protect the engine from overheating. At this time , the check engine light will be constantly on.
A01 32D
INTAKE AIR TEMPERATURE SENSOR
THROTTLE POSITION SENSOR
.......
A013SD
The intake air temperature senso r is mounted on the front of the air-intake sile nccr. It s purpose is to sense air temperature entering the air-intake sil e nce r and engine. The ECU se nds current to thi s sensor, and (de pending on the temperature) the sensor will pass a celtain amount of current through the sensor to ground. T he ECU measures how much CUlTent passes through the sensor to ground. From this measurement, the ECU determines the air temperature and calcul ates the fuel! air mixture rati o. This sensor is very sensiti ve to temperature change. Resistance will drop as the temperature ri ses.
T he throttl e position sensor, located at the end of the throttl e shaft , is a potentiometer (a potentiometer is, essentially, a voltage di vider). This sensor transform s the throttl e-val ve pos iti on into output volta ge to the ECU. In additio n, the se nsor detects the ope ning or closing speed of the throttle val ve and feeds that rate of voltage change to the ECU.
NOTE: The input from the throttle position sensor is one of the main inputs for the ECU calculation of fueVair mixture ratio.
WATER TEMPERATURE SENSOR
IGNITION TIMING SENSOR
0729627
4-38
Page: 206
T his sensor is located on the top of the magneto case near the cylinder on some models. O n other models the sensor is located inside the magneto case next to the Oyw hecl, and on these models, the recoil stm1er and the Oyw heel must be removed to access the sensor. T his sensor is triggered by a small metal di sc precisel y mounted to the Oyw heel n ange. E<lc h time the meta l disc rotates past the sensor, a signal is sent to the ECU. From thi s signal , the ECU de te rmines igniti on a nd injection timing a nd RPM.
BAROMETRIC PRESSURE SENSOR

The fuel injector is an electromagnetic injection val ve controlled by a signal from the ECU. The coil used in the inj ec tor is a hi gh-press ure res ista nce type. T he EC U dete rmines the o ptimum fuel injection time and duration mlsed on signals from the fi ve sensors. When \'oltage is sent to the fuel inj ector, it e nergizes the coil and opens the needle valve, there by injecting fu el. Because the fuel pressure (pressure differe nti al betwee n fuel line and manifold) is kept constant , the amount of fuel injected is dete rmined by the duration of time the val ve is ope n. This sensor is located inside the ECU and is part of the ECU unit. Its purpose is to sense atmospheric pressure. From thi s information, the ECU determines the correct fuel/air mixture ratio.
NOTE: This sensor is not replaceable. If it should fail, the ECU must be replaced.
T he injectors arc coded with symbols (.-e-"') and arc color-coded yell ow and green. Whe n replacement of a fuel injector is necessary, the injector must be replaced with an injector of the same code symbol and color.
&
CAUTION
FUEL INJECTORS
00 not replace an injector with one of a different code symbol or color. Severe engine damage may occur.
FS021
FS02SA
T he fuel inj ectors arc positi oned in the top o f eac h throttle body. O-rings seal the to p and bottom of each injector, and they arc held in position by a locking plate secured to the fuel rail.
NOTE: A green-coded injector is for the 600 cc EFI STD model; the yellow-coded injector is for all remaining EFI models.
FUEL PRESSURE REGULATOR

T he fu el pressure regul ator is attac hed to the end of the fuel rail (600 cc STD) and in the fuel pump (6001700 cc " Laydow n" /900 cc) . The fuel pressure regul ator mainta ins the fuel pressure at a const.a nt specified level .
Page: 207
4-39
For thi s circuil to function correctly, fi ve components

must be in good working order.
~- FS023A
Check the followi ng components be fo re considering the fuel pump assembly to be defective.
1\. Fuel pump coil - see coi l test procedure.
B. Emergency stop sw itch and ignitio n switch

must be ON and
In
good worki ng o rder.
C. Fuel pump - see fuel pump lest procedure.
D. Wiring harness and connectors - clean the

connecto rs and test the harness.
O n the 600 cc (STD) when fuel pressure exceeds the specification , the spring-loaded d iaphragm in the regulator opens a ll owing fucl to fl ow through the ret urn hose back to the gas tank.
E. EeU.
FUEL PUMP CIRCUIT

T he fuel pump and its circuit are prov ided wit h current from the fuel pump coil on the stator.
Self-Diagnostic EFI System

INTRODUCTION
T he Electronic Contro l Unit (ECU) contai ns a built-in, self-diagnosti c system which detects trouble within the fi ve-sensor signal network and then fla shes a code on the LED sig nal light, located under the left e nd o f the ECU (check e ngine li ght ill the speedomelerftachometer on "Laydown" engine model s).
A0142D
4-40
Page: 208
The fue l syste m and the igniti on syste m reml.lln two separate syste ms. In a no-stm1 situation, fi rst determine if the proble m is caused by lack of spark or by a fu e l deli ve ry proble m or by an inte rnal e ngine condition (low cylinder compression for example). Us ing the EFI Igniti on Ana lyzer, equipped with the updat e EPROlv l (c hip) and test harness, connect the test harness to the ECU diagnostic connectors. Connect the test harness red external lead to the lX'lsitive terlninal of a 12-voit baUery and connect the bl ack exte rnal test harness lead to the negati ve terminal . If a ny o f the c irc uit s a rc fault y, a code will now be Oashed by the LED/check e ngine li ght. If no code is fl ashed , turn o n the anal yzer Press the iv lENU SELECT buttons until the words KOK USAN appear on the di splay; then press the TEST button. The analyzer is now programmed for testing the Arctic Cat Baneryless EFl System. Using the rvlENU SELEeI' buttons, press the button re pea tedl y until Me mo ry Pro bl e m Diag nos is Test appears on the display; then press the TEST button. If any sensors have intermitte nt probl ems, they will be indicated 0 11 the di spl ay. Proceed to individual components test procedures covered th roughout this section. The code Oashed from the LED/check engine light will first be a numbe r of fla s hes . Co unt th e numbe r of Oa shes and refer to Diagnostic Codes iO thi s sub-sec ti on. The code re peals itself with approx imately a 2second delay between each series of Oashes.
NOTE: When reading the LEO/check engine light flash sequence, have paper and pencil available to write down the codes being flashed. More than one code may be flashed.
Diagnostic Codes
Number of Flashes
1
Trouble Open or short circuit in throttle position sensor. Open or short circuit in water temperature sensor. Open or short circuit in intake air temperature sensor. Open or short circuit in barometric pressure sensor. Failure in injector(s). Failure in servomotor. Coolant Temperature Above 80 C (176 0
3
4
S 6
Steady Rash (6001700 ee) Constant On (6001700 ee)
FI
Coolant Temperature Above 93 C (200
Fl
TROUBLESHOOTING INDIVIDUAL COMPONENTS

NOTE: With the Arctic Cat Batteryless EFI System, it is extremely important that the ECU receives the proper current output from four coils (two charge coils, an injector coil, and a fuel pump coil) to function as designed. If a problem exists, these coils should be checked using the following procedures.
Charge Coil (1 )/Charge Coil (2)
Resistance Test
T he charge coils lX'lwer the COl system and the EC U. To test these coil s, di sconnect the 3-wire connector rrom the ECU to the stator. I. Set the meter selector to the OHI\1IS scale and test between the blacklred and brownJwhite wires (charge coil I). 2. The metcr must show 17 ohms 20%. 3. Test between the grccnlred and brown/white wires (cha rge coil 2). 4, The meIer must show 17 ohms 20%.
NOTE: If either test is not within specifications, the stator must be replaced . Refer to the wiring diagram in this sub-section.
Once the problem area has been determined, c hec k the components involved using the Fluke Model 73 Mulli mete r (p/n 0644- 19 1) or lhe EFI Anal yzer (p/n 0644342) depe nding 0 11 whi ch test is being made.
Injector Coil Resistance Test

The injector coil located on the stator lX'lwers lhe two injectors. I. DiscOlUlect lhe double-wire plug with two bluel white leads from the stator to the ECU. 2, Set the meter selector to the OH!vIS scale.
Page: 209
441
3. Connect a meter lead to each of the blue/white leads. The meter must show 19 ohms 20%.
NOTE: If reading is not within the specification, recheck to confirm test results. If still out of toler ance, replace the stator. NOTE: If the resistance test is good, a peak read ing voltage test should also be made. Refer to Peak Voltage Tests and Specifications in this sub section.
ECU
ACTIVATING ECU MEMORY
NOTE: The ECU memory on the 2005 Arctic Cat Batteryless EFI system (with the APV system) can be activated only by using the EFI Analyzer (pIn 0644-342) which has had the Update Harness Kit (pIn 0644-341) installed. For " Laydown" engine models, use EFI Analyzer Update Kit (pIn 0637 243).
Fuel Pump Coil Resistance Test" The fuel pump coil powers the fuel pump through the ECU.
NOTE: With the engine running, there should 12.312.9 DC volts supplied to the fuel pump for operation. To test fuel pump coil resistance, use the following procedure.
T he ECU has a self-diagnostic mode built into the unit. It is a \'ery \'aluable tool in troubl eshooting . Once the probl em area code has been fl as hed by the li ght emi tting diode (LED) located at the end of the ECU (check enoi ne Ijol1l in the speedometer/tachometer on "Layee . prodown' engine models), foll ow the troubles hootlllg cedure iO thi s sub-section. The ECU also has a memory mode for determining if any of the fi ve sensors have intermittentl y fail ed. To activate the memory system, follow these steps. I. Connect the anal yzer test harness to the ECU diagnostic connector. 2. Connect the analyzer test harness red and black leads to a 12-volt bauery. 3. Turn the anal yzer sw itch ON. 4, Press the anal yzer MENU SELECr buuons repeatedl y until KOKUSAN appears on the display. Once the word KOKUSAN appears on the display, press the TEST button. The anal yzer IS now set up to test the tmUeryless EFI system.
S, Press the analyzer J'v IEi'lU SELECr
I. Di sconnect the double-plug with the two orange wires from the ECU. 2. Set the meter selector to the OHMS scale. Con nect a meter lead to each of the two orange leads. 3 . The meter must show 1.9 ohms 20%.
NOTE: If reading is out of tolerance, recheck to confirm reading. If still out of tolerance, replace the stator. NOTE: If the resistance test is good, a peak read ing voltage test should also be made. Refer to Peak Voltage Tests and Specifications in this sub section.
Ught"ing Coil Resistance Test The li ghting coil located on the stator provides AC power to the lighting system and accessories through a charging system. To test the lighting coil res istance. follow this procedure. I. Di sconnect the 3-wire connector at the engine. 2. Set the meter selector to the OIHvIS scale. 3. Test between the two yell ow leads. 4. The meter must show 0. 10 ohm 20%.
NOTE: If reading is out of tolerance, recheck to confirm reading. If still out of tolerance, replace the stator.
buttons repeatedl y until the words Memory Problem Diagnosis Test appe<."lrs on the display.
Memory Problem Diagnosis Tea
6. Press the analyzer TEST button. If all sensors are oood, SENSORS ALL O. K. will appear on the display. If any of the sensors ha ve intermittentl y fail ed or are fault y, they wi ll appear on the di splay. Proceed then to checking the faulty sensor individuall y as covered in thi s sectioll.
NOTE: Once problem areas have been determined, always check the component(s) for clean and tight connections.
7. To erase the memory of the ECU. press the TEST button once again ; then push the MENU SELECr buttons until Diagnosis Memory Clear appears on the di splay. Turn the analyzer OFF and then back ON again. Reselect KOKUSA N mode ; then proceed to the Memory Problem qiagnosis Test and push the T EST button . The display should indicate SENSORS ALL OX . which indicates the memory has been cleared.
442 Page: 210 2005 Arctic Cat Service Manual - all models - www.ReadManuals.com
REMOVING
NOTE: On standard models, there isn't a test for the ECU. If a problem is suspected in this unit, try another ECU. When using another ECU, it must be a 19972004 or 2005 model with a battery less sys tern. The ECU may be sent to the Arctic Cat Ser vice Department for testing. Please contact the Service Department before sending any units. I. Disconnect the two wiring harness leads (one lead
2. Using TPS Adjustment Tool (pfn 644-299), connect its wiring harness to the TPS. Connect the two R uke mete r leads (red and black) using the two pin jack adapters prov ided with the adjustment tool to the red and black jacks of the TPS adj ustment tool.
NOTE: Before using the TPS adjustment tool, verify its battery condition. The battery used in the tool is a 9-volt battery. To check battery condition, use a digital volt/ohmmeter set on DC volt scale. Test between the adjustment tool black and red jacks. Insert the red lead of the digital voltmeter into the red jack of the adjustment tool and the black lead of the digital voltmeter into the black jack of the adjustment tool. If voltage is found below 4.9 volts, replace the battery.
o n "Laydown" engine models) fro m the front of the ECU. 2. Rcmo\'c the four screws securing the ECU to the air-intake silencer.
3 . Remove the ECU.
NOTE: If there are any questions concerning lead or harness connections, there is an battery less EFI system wiring diagram in the back of this
section.
INSTALLING
I. Sec ure the ECU to the ai r-intake silencer with the screws.
NOTE: Make sure the diagnostic connector plug faces the oil reservoir.
3. Set the multi meter selector to the DC scale; the n SLOWLY depress the throttle lever. The meter reading sho uld show a smooth rise all the way to wide -o pen throttle. Repeat tllis step until it is assured that there arc no open a reas o r " peaks" in the reading.
NOTE: If a reading contains open areas or peaks, the throttle position sensor may be faulty. Refer to the proper Checking/Adjusting TPS procedure in Section 5 - Throttle Position Sensor in this manual.
2. COIUlect the w iring harness to the ECU.

NOTE: Make sure all connectors are clean and tight. Apply dielectric grease to all connectors.
4. DiscOIUlect the adjustment tool harness fro m the TPS. Connect the snowmobile TPS harness to the TPS.
NOTE: Before installing the TPS harness connector, apply dielectric grease to the connector pins.
FUEL INJECTORS
Testing Individual Components

NOTE: For individual resistance testing procedures, see Section 5 in this Volume. NOTE: For the following tests, use the Fluke Model 73 Multimeter(p/n 0644191) or a multimeter of the same quality.
THROTTLE POSITION SENSOR
(All Models)
I Di sconnect the TPS wi ring harness connector.
T es"ti ng Resistance
A0139D
I. Disconnect the fuel injector wiring harness. 2. Set the meter selector to the OHM S scale. 3. Test between the two injecto r termi nals. Test specification is 2.4-3.3 o hms.
Page: 211
443
4. If not within specificatio ns, re place the injecto r.

Removing
Installing
I. Appl y a li ght coat of oil to all O-rings; then inst.all
the upper and lower O- rings onto each injector.
,&, CAUTION
The fuel supply hose may be under pressure. Place an absorbent towel around the connection to absorb fuel; then remove the hose slowly to release the pressure.
I. Loosen the clamp securing the fuel suppl y hose to
2. Install
the assembly.
injectors
into the
throttle
body
3 . Place the injector ho ld-down plate into position on
to p o f the injectors and secure with two screws. 4. Connect the fuel delivery hose to the fuel rai l and secure with a cla mp. _NOTE : When securing the fuel delivery hose, position the clamp as shown.
the fuel rail ; then remove the hose from the fuel rail. 2. Di sconnect the wiring harness from each injector. 3. Remove the two screws sec uring the injector holddown plate to the throttle b<xly assembl y; then remove the plate from the injecto rs.
Clamp
connections as shown, position the hose so that 2030 mm (0.81.2 in .) of the tube is covered leave cle"a~ce of 3-7 mm (0.12-0.28 in.) from hose
5. Connect the wiring harness to the injectors making sure the number 1 harness is connected to the MAG -side injector. 4. Remove the fuel injectors from the throttle body assembly.
4-44
Page: 212
2. Connect the sensor to the ECU wiring harness; then close the rubber boot. 3. Sec ure loose wires with cable lies.
ELECTRIC FUEL PUMP

I. Re move the hardware sec uring the console to the gas tank and fram e; then move the co nsole o ut of the way. 2. Disconnect the fuel pump (w hite two-w ire connector o n standard EFI models or black twowire COlUlector o n "Laydown" e ngine EFI models) fro m the main wiring harness.
0729-627
NOTE: This sensor is located inside the magneto case next to the flywheel, and the recoil starter and the flywheel must be removed to access the sensor.
3 . Connect the positive lead of a 12-voll power supply to the red wire a nd the negati ve lead o f the 12-volt power supply to the black wire. 4. The pump sho uld ope rate (it would be heard running).
Testing Resistance
I. DisCOIlJlcct the two leads from the sensor to the
NOTE: If the fuel pump fails to operate, the pump is defective and must be replaced.
mai n wi ri ng harness.
2. Sct the meter selector to the OI-i1vIS scale.
FUEL PRESSURE REGULATOR (600 cc STD)
3. Test between the grcen/while and brown leads from the scnsor. Test specification is 152-228
ohms.
Renaoving
I. Loosen the clamp securing the fuel return hose to the fuel regulator; then remove the hose.
2. Remove the two screws securing the fuel pressure reg ulator to the fuel rail ; then slow ly remove the reg ulator. Account for the O -ring.
Removing
I. O pen the rubber boot that protects the main wiring harness connections; then disconnect the ignition liming sensor from the ECU wiring harness . 2. Rcmo\'c the two screws securing the sensor to the magneto ho using. 3 . Remove the sensor.
A CAUTION
Since the regulator may be under pressure, remove it slowly to release the pressure. Place an absorbent towel around the connection to absorb fuel.
Installing
L Using two screws cO<llcd with blue Locti te 11242, secure the sensor to the magneto housing (inner mounting ho le).
Testing Fuel Pressure Regulator

I. Using the Fuel Pressure Tester (pin 0644--203), connect the tester to the regulator fuel inlet.
Page: 213
445
WATER TEMPERATURE SENSOR

Testing Resis1:ance
NOTE: The water temperature sensor is very sensitive to temperature change. Before the resis~ tance test is conducted, it is important to know the coolant temperature. If the engine has been oper~ ated recently and the coolant is warm, the resis tance will measure lower than if the coolant was at room temperature or colder. For accurate test results, check the coolant temperature in the filler neck using a thermometer. I . Disconnect the water temperature sensor wiring harness from the main harness. NOTE: A short piece of 318 in. 1.0. hose will be needed to make the above connections.
2. Set the meter selector to the OHMS position and

test the resistance between the two leads from the sensor.
2. Pressurize the regulator to 2.0-2.2 kg/cm2 (28-3 1.3

psi). T urn the pressure tester shut off valve to the OFF position. O bsen'e the gauge for several minutes and note if there is any loss of pressure. If pressure begins to drop, the cause may be a ruptured diaphragm , worn spring, or leaking valve. If the regulator fails to build or maintain pressure, replace the regulator. NOTE: If there is a drop in pressure, check the hose connections to ensure there are no leaks.
3. Comp< lre the resistance reading to the EFI

Component Voltage/Resistance Chm1 - Water Temperature in thi s sub-section. If resistance is not within the specification, replace the sensor. NOTE: A water temperature sensor voltage test can be made using the EFI Analyzer, Please refer to the analyzer test procedures provided on the following pages.
Installing
L Position the O-ring on the fuel pressure regulator; then place the reg ulator into position on the fuel rail. Secure with t wo sc rews.
Removing
I . Drain the cooling system.
2. Remove the throttle lxx::Iy assembly.

3. D isconnect the w iring harness from the water tcmperature sensor. 4. Remove the sensor from the water temperature case.
2. Connect the fuel return hose to the regulator; then

secure with a clamp.
Clamp
Installing
I. A ppl y tenon tape to the threads of the watcr temperature sensor; then install the sensor.
For tube connections as shown, position the hose so that 2030 mm (0.81.2 in.) of the tube is covered
Leave clearance of 37 mm (0.120.28 in .) from hose end

0729325
L. I
2 . Connect the wi ring harness to the sensor.
3. Install the throttle lxx::Iy assembl y. 4. Fill the cooling system.
INTAKE AIR TEMPERATURE SENSOR

Testing Resistance
NOTE: It is very important to know the component temperature before conducting this test. Allow the engine to reach room temperature. I. Disconnect the wi ring harness from the inl.:'lke air temperature sensor.
4-46
Page: 214
Analyzer Nomenclature
A0135D
2. Set the meter selector in the OHMS position and test the two leads located in the sensor connecto r. Compme with the EFI Comlxmcnt Vo ltagc/ Resistance C hart - Air Tempcrature in this s ubsection.
730222A
I. LCD - Liquid Crystal Display. 2 . Power-Light illuminates when the analyzer is properly connected to the snowmobi le EFI analysis test plug .
3 . On/Off Sw itches .
NOTE: The intake air temperature sensor employs a thermistor, which is very sensitive to temperature changes. Resistance will change as temperature varies.
Removing
I. Di scOimect the wi ring harness fro m the intake air temperature sensor.
2. Using a standard screwdriver, pry the sensor end
4. Menu Select ( up/down) - Enables selectio n of a test function quickl y.

5. Test - O nce the test function is selected, plL<;h the button to complete the test. The button also cancels the CUffent test so the next test function can be selected.
to end to remove it from the air- intake silencer. Account fo r two pus h pins.
Analyzer Test Function (Batteryless Systetn)

T here is s pccial informati on which can be re trieved from the 2004 and newer ECU's s llch as total running time o n e ng ine, running times by tempe rature, max imum RPM by te mperatu re, E PROM c hip chang e check, number of fuel changes by wire di sconnect , and la s t fu e l t y pe used. Thi s info rmati on can on ly be retrieved with the EFI analyzer. W he n the ivL E NU SEL OCf buttons arc pressed , thcre will be three modes: First mode, ARCT CO, second mode, KO KUSAN, and third mode , KOKUSAN SPEC IAL, whi ch is used on ly to retrieve s pec ial info rmation (explained earlie r) found on the 2004 and newer battery less EFI system ECU' s . At this point , select KOK USAN S PECIAL on lhe di splay by pus hing the T EST button. The entire syste m can now be tested by movi ng to the next test using the iVIEN U SELEe r buttons. If the analyzer is turned o ff duri ng the test procedure, the test fun ctio n o n the dis pl ay will automaticall y stm1 ove r at the top of the li st whe n turned back o n. Thi s means the selection o f the system being tested must be repeated before continuing. O nce a test has been completed, press the T EST button again to cancel the test, whic h a ll ows the selectio n o f a different test using one of the MENU SELECr buttons.
Installing
Place the sensor into position in the air-intake silencer and secure with push pins.
2 . Connect the wiring harness to the intake air
tempe rature sensor. Secure the sensor leads with cable ti es so they do not rub o n any other compo nents.
EFI Analyzer
NOTE: Troubleshooting EFI engines with the APV system should be done with the Arctic Cat EFI Analyzer (pin 0644-342). To update your existing EFI Analyzer, order Update Harness Kit (pIn 0644-341).
GENERAL INFORMATION
T he EFI Analyzer (p/ n 0644-342) makes it lX)ssi bl e for technicians to easily pe rform EFI system tro ubleshooting ill a s hort pe ri od of time. To use the analyzer on the batterylcss EFI system, a 12volt battery to lX)wer the analyzer is necessary. Follow the ins tructions under Analyzer Setup fo r testing the batteryless EA system .
Page: 215
4-47
Kokusan Special Mode

T he s now mobile can be run with e ithe r regul ar gasolin e or oxyge na te d gaso lin e . S pec ia l in s t ructi o ns located on top o f the tool OOX lid will instJUct to di sconnect two wi res located in fro nt o f the ECU if oxygenated gasoline is used . If regul ar gasolinc is to be used , the gray wire at the ECU must remain connected or the mi xture will be too rich.
2. Attac h the red external lead to the positi ve terminal o f a 12-volt battery; then connect the negati ve exte rnal lead to the negati ve post. 3. Press the ON butto n of the analyzer. At this point , the lX)wer light of the a nalyzer must be illuminated. 4 . To retrieve info rmatio n found under Kokusa n Special lvlode, push MENU SELEC r button until KO KUSAN SPECIAL mode appears on the dis play; the n pus h the T EST butto n. T he analyzer is now ready to test the spec ial areas show n on the menu list under KO KUSAN SPECIAL mode.
Menu List Organi zation (Kokusan Special Mode)

I. Throttle Adjust - givcn in both volts and degree.
2. Fuel C hange Num ber - num ber o f times fucl lcads have been switched between regul ar gasolinc and oxygenated gasoline. 3 . Last Gasoline Type - in case of e ngine fa ilure, what the syste m was last set for - regular gasoline o r oxygenated gasoline. 4 . Other Ro m C heck - (for 200 1 and earlier models except 200 1 600 cc) will ind icate if the EPROM chip has been c hanged. If none appears on the di spl ay, thc EPROM c hip has not been changcd since the ECU was assembled . 5. Maximum Revolutions by Tempe rature - prov ides a range in increments of 10 from _30 C to _10 1 C. Will show engine RPJ\II fo r each temperature range and if the engine has becn operated in the range. 6.
Tot ~ 1 Running Time - will s how total hours on the cngille.
NOTE: When testing the batteryless EFI system, KOKUSAN SPECIAL mode must be on the display. Once the TEST button is pressed with KOKUSAN SPECIAL mode on the display, the analyzer will stay in this mode until it is turned OFF. NOTE: Each time the analyzer is turned OFF, reselection of the KOKUSAN SPECIAL mode is necessary.
EFI Components Not Tested by Analyzer

W he n troubl es hooting the EFI syste m with the EFI Anal yzer, the re are EFI compone nts the analyzer \V iII NOT diagnose. T hese co mpone nt s, (in the fo ll ow ing list) must be tested using a good di gital volliohmmeter o r a fu e l press ure ga uge using recomm e nded procedures in this s ub-sectio n and in Sectio n 5. I. Fucl Pump Coil - Injecti on Coil - Timing Sensor. 2. Ignition Primary Coil.
7. Ba ro metric pressure.
Press ure
prov ides
current
air 3. Ignition Seco ndary Coil. 4 . Fuel Pressure Regul ato r - rvlaintains fuel pressure at specified psi. 5. Electric Fue l Pump - Located in the gas tank. Supplies fuel under pressure to fuel injecto rs. 6. Switches and Stato r Coils - Supplies all systems with electrical current. 7. Servomoto r.
To test a n balle ry less EFI syste m using the EFI Analyzer, follow all instructi ons carefull y a nd completely,
Analyzer Set.up
I. Befo re connecting the anal yzer to the snowmo bil e, always check to make s ure the ana lyzer is OFF; then connect the a nalyzer batte ryless test harness (equipped with red and black ex telllalleads) to thc ECU diagnosis connector.
Recommended EFI Troubleshooting Sequence

(Kokusan Mode)
W he n troubleshooting the battery less EFi system , use the following troubleshooting sequence to locate problems quickl y and effi ciently.
4-48
Page: 216
EXISTING PROBLEM DIAGNOSIS TEST

Th is should be th e fir st test made , Inlhi s mode, th e anal yzer test') the following components all at once. A. Throttle Position Sensor
B . Intake A ir Temperature Sensor C. Water Te mperature Sensor
4. Press the TEST bultoll. If all sensors are good, SENSORS ALL O. K. wi ll a ppear on the di splay. If any of the sensors listed under Ex isting Problem Diagnosis Test are defecti ve, that sensor will be indicated on the di splay. Proceed then to chec k the defective sensor individually as covered in this sectio n.
NOTE: If proceeding to another test, first press the TEST button once again to cancel the present test. To select a different test function, use the MENU SELECT buttons.
D. Barometric Pressure Sensor
E. Fuellnjeclors
After pushing the TEST butlon on the analyzer, the display will indicate either SENSORS ALL O.K. o r which o f the sensors are defecli,'c. C heck these components indi viduall y lIsing the recommended procedures in thi s sub-sectio n.
MEMORY PROBLEM DIAGNOSIS TEST (Engine Off) FUNCTION

NOTE: Select KOKUSAN SPECIAL by pressing the TEST button. This will allow the testing of the batteryless EFI system.
MEMORY PROBLEM DIAGNOSIS TEST

Thi s should be the second test made. In thi s mooe, the anal yzer will reveal any probl ems in the sensor area whic h might have occurred intermittently as the snowm obi le was being operated.
I. With the analyzer OFF, connect its wiring harness to the diagnosis test plug. Connect the external leads of the harness to a good 12-voll bauery. 2. Switch the analyzer O N. 3. With both indicator li ghts illuminated, press the MENU SELEC T buttons repeatedl y until i'vlemo ry Problem Diagnosis Test appears on the display.
Mamory Problem Diagnosis TEST
If the re were any such intermiUent problems, the problem arC<1 will be shown o n the display. Check the indicated area for a w ire connecti on proble m o r loose or corroded connections.
4. Press the analyzer TEST bullo n. If there has been an intermittent pro blem in a sensor, that sensor will be indicated on the display. Ma ke necessary repairs.
NOTE: If proceeding to another test, first press the TEST button once again to cancel the present test. To select a different test function, use the MENU SELECT buttons .
Testing Individual EFI Components

NOTE: For all of the following tests using the EFI Analyzer, the analyzer power light must be illuminated. If not illuminated, the problem must be cor reeted before proceeding. Also the analyzer must be properly connected to a 12~volt battery.
CLEARING MEMORY
I. With the analyzer harness attached to the diagnosis lest plug, press the iv lENU SELEC T buttons until the words Diagnosis Memo ry Clear appear o n the displ ay,
Diagnosis Memory Claar
EXISTING PROBLEM DIAGNOSIS TEST (Engine Off) FUNCTION

I. With the anal yzer OFF. connect its harness to the diagnosis test plug. Connect the external leads of the harness to a good 12-voll battery. 2. Switch the anal yzer ON. 3. With anal yzer power li ght illuminated , press the MENU SELECf bullons repeatedly until the words Ex isting Problem Diagnosis Test appear on the di splay.
Existing Problam Diagnosis TEST
Page: 217
2. Press the anal yzer TEST button and the words Please Key Off should appear o n the LC D; then turn the anal yzer switch to the OFF position. Immediately turn the analyzer sw itch to the ON position and the memory should now be clear.
Plaasa Kay OH
NOTE: To check if the memory is clear, perform Memory Problem Diagnosis Test to see if all sensors test good. If a problem still remains on memory, repeat Clearing Memory procedure.
449
THROTTLE VALVE ANGLE TEST (DegreesNolts) FUNCTION

T he correct throttl e valve angle is ex tremely im portant for pro per e ngine operation. If the throttle va lve angle isn"t corrcct in the idle position , the e ng ine may be vcry difficult to stm1 "cold." If the throttle valve angle isn't correct in any of the olT- idl e pos itions, engine
damage or poor performance TTlay result because of an
6. Ir the " idle" position throttle valve angle test specificatio n remains out of tolerance, adjust the idle speed screw. If the throltle va lve angle cannot be corrected by either an idle speed screw or cable adjustment , replace the throttle txxIy assembly. 7. Compress the throttle lever to the '" full -open" position (engine not running). The test specification must be within the to lerance shown in c hart. Ir the test spec ifi ca tion is out of tolerance, " rasp the throttle cable next to the throttl e shan ~nd pull o n the cabl e. If the test specificatio n is, now within tolerance, adjust the throttle cable. II the throttle valve angle remains o ut o f to lerance, replace the throttle body assembly.
8. Ir
incorrect mixture.
NOTE: Select KOKUSAN by pressing the TEST button. This will allow the testing of the battery less
EFI system.
I. Connect the anal yzer harness to the diagnosis test
plug. Make sure the analyzer is OFF. 2. Switch the anal yzer ON. 3 . With the analyzer power light illuminated, press the MENU SELECT buttons o n the analyzer repeatedly until the words Throttle Valve Angle appear on the display.
Throttle Valva Angle
the specifications listed below A RE DISPLAYED during the test, re place the throttl e txxIyassembly.
Throttle Valve Angle DegreesIVolts Degrees/Volts RPM Range Idle to 3000
2.25/0.570
NOTE: When performing the Throttle Valve Angle Test, test both the idle and full'open throttle posi tions. Specifications are given for both positions in degrees and volts. 4. With the IhrOLile in the '" idle" position (engine not running), press the analyzer TEST button. The throttle valve angle should now appear on the d isplay.
Throttle Valve Angle Degrees Model Idle
3.7154.065 5 .1005.600 5 .100.5.600
NOTE: If the Throttle Position Sensor should fail, the ECU will go into the "fail safe" mode and the above readings in the idle position will be displayed. NOTE: If proceeding to another test, first press the TEST button once again to cancel the present test. To select a different test function, use the MENU SELECT buttons.
INTAKE AIR TEMPERATURE SENSOR (Engine Off) FUNCTION

NOTE: When using an analyzer which has been updated with the new EPROM chip, first ~ele~t Kokusan by pressing the TEST button. ThiS will allow the testlOg of batteryless EFI system. I. With the analyzer OFF, connect its harness to the diagnosis test plug. Connect the external leads of the harness to a good 12voll tx "ltte ry. 2. Switch the analyzer O N. 3. With the anal yzer IXlwer li ght illuminated, press the l'vIENU SELECf buttons repeatedly until Intake Air Temperature appears on the di splay.
Intake Air Temperature
Full-Open
77.265-86 .135 82.50087.200 82.500.87.200
600 cc STO
600nOO cc "Laydown" 900 oc
Throttle Valve Angle - Voltage Model Idle (Volts) Full-Open (Volts)
600 ccSTO 600nOO cc

"Laydown" 900 oc
0.625-0.647 0.685-0.707 0.685-0.707
3.575-3.937 3.750-3.937 3.750-3.937
5. If the '" idl e" posilion throttle val ve angle or voltage isn't within test specificati ons, push down o n the throttle shan to make sure it is full y closed. If lhe lest specifications are now within tolerance, loosen the throttle cable.
4. Press the analyz.er TEST button and the intake air te mpe rature will be indicated o n the display. NOTE: Intake air temperature will be displayed in both C and O F. NOTE: The temperature indicated should be close to room temperature if the snowmobile hasn't recently been run. Consider what temperature the snowmobile is actually at.
4-50
Page: 218
5. If when testing the intake air temperature sensor, an indicated temperature of _ 400 C and of is noted and the actual snow mobile te mperature isn't close to this tempe rature, replace the sensor. The ECU will automatically go to _ 400 C and of when the intake air temperature sensor fail s. NOTE: If proceeding to another test, first press the TEST button once again to cancel the present test. To select a different test function, use the MENU SELECT buttons.
Throttle Position Sensor

It is not possibl e to replace the thranl e position sensor on the balleryless EFI system. Irthe sensor should malfun ction , the complete throttle body assembly must be replaced.
NOTE: It is important to order a throttle body assembly with the same symbol marking on the injectors as the ones being replaced. The symbol is located on the side of the injector top.
BAROMETRIC PRESSURE SENSOR TEST (Engine Off) FUNCTION

I. With the analyzer OFF, auaeh its harness to the diagnosis test plug. 2. SwiLch the anal yzer ON. 3. With the analyzer power light illuminated, press the lv lEN U SELECf buttons repeatedl y until the words Barometric Pressure appear on the display. Barom.tric P .....ur. 4. Press the analyzer TEST button and actual area barometric pressure will be indicated.
NOTE: Actual area barometric pressure can be obtained from a local airport, radio station, etc.
Throttle Body Assembly

_NOTE : Determine which type of assembly is being replaced and remove and install accordingly_
""
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11 . 12.
5. Ir the barometric pressure sensor has failed , the ECU will automaticall y go to the bmometric pressure shown below. If these readi ngs A PPEA R on the display, replace the ECU.
Model 600(700 cc
900
Throttle Body Assem bly Fuel Pressure Regulator Bolt Delivery Pipe Fuel Injector Screw Control Rod Rod End Spring Pin Hose HoseC lamp ()"Rlng set
600
cc STO
Barometric Pressure 880 mm/hg 880 mmlhg
'~
,
co
I I
(34.65 in./hg) (34.65 in.klg)
Peak Voltage Tests and Specifications

NOTE: For peak voltage testing procedures, see Section 5 in this Volume.
073(;-279
Page: 219
451
KEY
1. Throttle Body 2. Delivery Pipe 3. Fuel InJecto r
REMOVING
600 cc "Laydown"1700 cc
_NOTE : On the FirecatiM-Series, the expansion chamber must be removed for this procedure.
4. 5. 6. 7. 9.
Screw Hose Clamp C-R ing Set Conttol Rod
L DisCOIUlcct the wiring harness from each injector and from the throttl e position sensor connector. 2, Remove the coolant hoses from the throttl e bodies and plug them to prevent leakage,
_NOTE : On the FirecatIMSeries, the throttle bodies must be moved forward and out of the air silencer in order to remove the coolant hoses. NOTE: On the 600 cc STD model, remove the fuel return hose and supply hose from the fuel pressure regulator and delivery pipe. Label for assem~ bly.
3. Remove the fuel supply hose from the deli very pipe.
0738-076
A 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 fuel.
KEY
1. Throttle Body Assembly
2. Delivery Pipe
3. Fue!tnjector 4. Screw S. Hose
900cc
4. Loosen the nange clamps.

5. Slide the throttle body assembl y out of the nanges; then loosen the jam nut securing the throttle cable and remo\'c.
6. Hose Clamp 7. aRing Set
~,
0736-975
6. Rcmove the throttle body asscmbly.
INSTALLING
I. Attach the tluol1lc cable to the throttle body.
Secure with jam nul. 2. Place the throttle body assembly into position. Makc sure the Oanges and boots are positioned properl y. Secure with nange clamps.
NOTE: On the FirecatlMSeries, the coolant hoses must be connected first; then the throttle bodies must be installed into the air silencer.
3. Connect the fuel suppl y hose to the deli very pipe.

NOTE: On the 600 cc sro model, secure the fuel supply hose and return hose to the delivery pipe and regulator.
A CAUTION
These hoses must be connected to the correct fittings.
4-52
Page: 220
all models
www.ReadManuals.com
Clamp
2. Install the flan ge clamps on the fl anges ; then place the throttle lxxly assembl y into the fl anges and secure with the clamps. 3. Secure all wires and hoses with cable ties.
'
..
' .'-.-"
Leave clearance of 3-7 mm (0.12-0.28 in.) from hose end

0729325
L I
For tube connections as shown, position the hose so that 20-30 mm (0.8 1.2 in.) of the tube is coveted
Throttle Cable
.NOTE: Determine which type of cable is being replaced and remove and install accordingly.
KEY
1. 2. 3. 4. Throttle Cable E-Ring Washer Cable Tie
4. Secure the coolant hose to throtlle lxxly assembly.
5. Connect the wi ring harness to each injector and throttle lX)Sition sensor.
NOTE: On the FirecatIM-Series, install the expan sion chamber.
S. locking Nut 6. Retaining Clip

7 . RubberPlug
6. Place the rear of the snowmobile on a shielded safety stand and start the engine without touching the throttle. It may idle slow ly and stop. Restart using the same procedure until the engine starts and builds RPM on its ow n.
,
KEY
1. 2. 3. 4.
Check all hose connections for leakage.
as
7. Check the cooling system.
8. Adjust the throttle cable as necessary.
Cable Tie Throttle Cable Jam Nul E-R ing
S. D-Ring 6. Retaining Clip
,
Throttle Body Flange
REMOVING
I. Loosen the clamps securing the throttl e body assembly to the throttle body flanges. 2. Remove the throttl e body assembly from the flanges. 3. In turn on eac h flange, remove the two nuts, lock washers, and flat washers securing the intake flange to the cylinder; then remove the fl ange.
KEY
1. Cable Tie 2. Throttle Cable 3. locking Nul
737-7S4A
('
4. Retaining Clip
INSTALLING
I. Apply a thin eO<.lt of high-temperature silicone to the cylinder side of each flange: then attach each flange to a cylinder and secure each with two flat washers, lock washers, and nuts. Tighten to 1.5\.9 kg-m (1 1- 14 ft -lb).
737-973A
REMOVING
I. Loosen the throttle cable adj uste r at the bracket.
Page: 221
453
2. Re move the throttle cable from the pulley on the throttle body lever shaft .
3 . O n the ZR, remove the E-clip securing the o il injection cable to the oil-injection pump contro l arm. Account fo r a washer. 4 . O n the ZR, loosen the o il-injection ca ble jam nuts.
5. Remove the handl eb..1r pad (A WS V and Sabcrcat) and the console (AWS V).
6. O n the Z R, install the oi l-i njection ca ble o n the contro l arm ; secure with a washer and E-clip.
7. Secure the throttle cable to the handl ebar and steering post with cable ties.
8. Install the handlebar pad (A WS V and Sabcrcat)
and the console (AWS V). 9. Adjust the throttl e cabl e te nsio n by turning the jam nuts in the appropriate direction until there is 0.751.5 mm (0.030-0.060 in .) free-play in the throttle lever and the butlern y completely o pens and closes. Tighten the jam nuts securely.
6. Remove the cable tics securing the throttle cable.
7. Rc move thc throttle cable ends fro m the throttle lever and from the throttle lever,
_NOTE : The EFI models (except the ZR) are equipped with a control rod activated oil pump. If it must be removed, the rod simply snaps off and on at the control arm.
INSTALLING/ADJUSTING
I. Install the throttle cabl e into the throttle sw itch
assembl y making sure the cable snaps into place.

2. Install the throttle cable end on the throttle lever.
3. Route the thrOltle cable from the throttle sw itch
Throttle Control Housing Gap of 0 .75 1.5 mm (0.0300.060 in.) between the Throttle Switch Body and Throttle Lever when Safety Switch is set property
733081C
Throttte lever
assembly to the throttle body assembly and o il injection pump; avoid any sharp bends or moving compo nents.
4. Attach the throttl e ca ble to the pull ey on the
&
CAUTION
throttle body shaft.

5. O n the Z R, install the o il-injectio n ca ble adjuster
Compress the throttle control lever to ensure free movement. If the throttle cable sticks or binds, correct the problem before starting the engine,
o n the o il-injection pump: secure with the jam nulS.
10. Synchroni zc the o il-injcction pump.
4-54
Page: 222
Basic EFI System Information

Item DescrIption
Basic system Airlfuel flow meter
Fuel supply system Ignition system System Component parts
Electronically controlled multi-point injection (CO l system) Digital
O/N (throttle opening/engine revolution) system & atmospheric pressure compensation Throttle opening sensor Atmospheric pressure sensor One time simultaneous injection per revolution (synchronized ignition) Regulated specified pressure Pressure regulated by pressure regulator. There are fuel returns. 1 stage x duplex (1 bore/cylinder) 46 x 2 (Effective area equivalent to 40) Buttertly type See Testing Individual EFI Components in this section R25 (at wire center) Throttle adjusting screw type Fuel injection control Electric Side feed type Di aphragm type Rne screens on pick-up hose Regulated specified pressure 1 bore/cylinder x duplex Revolution scrubbing type potentiometer Semiconductor type Thermistor type Thermistor type Equivalent to current harness Batteryless EFI System
Injection system Fuel system Fuel pressure Fuel return (600 cc STD) System Diameter of the bore
Throttle system
Type of valve
Operating angle Radius of drum Adjusting system for idle revolution Control unit
c
0
:a m
Co
~
~
~
"0
~
~
1;
E
Co
m c
0 Co
Fuel piping Throttle body Throttle sensor Pressure sensor 0 " Water temperature sensor ~ c m Intake air temperature sensor </)
.r
Q;
Fuel pump Injection Pressure regulator (600 cc STD ) Fuel filter
0 ()
Cable harness Other
Page: 223
455
EFI Component Voltage/Resistance Chart Air Temperature

TEMPle TEMP/F
VOLTAGE
OHMS
555 595 635 675 715 755 819 883 947 1011 1075 11 60 1245 1330 141 5 1500 1640 1780 1920 2060 2200 2410 2620 2830 3040 3250 3595 3940 4285 4630 4975 5490 6005 6520 7035 7550
TEMPle
TEMPIF
VOLTAGE
OHMS
100 98 96 94 92 90 88 86 84 82 80 78 76 74 72 70 68 66 64 62 60 58 56 54 52 50 48 46 44 42 40 38 36 34 32 30
212 208 205 201 198 194 190 187 183 180 176 172 169 165 162 158 154 151 147 144 140 136 133 129 126 122 11 8 11 5
111
0.11 3 0.121 0.1 28 0.1 36 0. 143 0.151 0.162 0.173 0.1 84 0.1 95 0.206 0.222 0.238 0.253 0.269 0.285 0.308
0.33 1
108 104 100 97 93 90 86
0.353 0.376 0.399 0.432 0.465 0.498 0.53 1 0.564 0.612 0.659 0.707 0.754 0.802 0.869 0.937 1.004 1.072 1.139
28 26 24 22 20 18 16 14 12 10 8 6 4 2 0 -2 -4 6 -8 -1 0 -1 2 -14 -1 6 -1 8 -20 -22 -24 -26 -28 -30 -32 -34 -36 -38 -40
82 79 75 72 68 64 61 57 54 50 46 43 39 36 32 28 25 21 18 14 10 7 3 -0.4 -4 -8 -11 -1 5 -1 8 -22 -26 -29 -32 -36 -40
1.230 1.322
1.4 13
1.505 1.596
1.716
1.836
1.955
8540 9530 10520 11 510 12500 14020 15540

17060
2.075 2.195 2.323 2.452 2.580 2.709 2.837 2.969 3.101 3.233 3.365 3.497 3.610 3.722 3.835 3.947 4.060
4.142
4.224 4.306 4.388 4.470 4.522 4.574 4.625 4.677 4.729
18580 20100 23060 26020 28980 31940 34900 39940 44980 50020 55060 60100 76080 92060 108040 124020 140000 156000 172000 188000 204000 220000 261000 302000 343000 384000 425000
4~56
Page: 224
EFI Component Voltage/Resistance Chart Water Temperature

TEMPle TEMP/F
VOLTAGE
OHMS
129 137 145 153 161 169 180 191 202 213 224 240 256 273 289 305 327 349 371 393 415 445 475 505 535 565 609 653 697 741 785 849 913 977 1041 1105
1214
TEMPle
TEMPIF
VOLTAGE
OHMS
110 108 106 104 102 100 98 96 94 92 90 88 86 84 82 80 78 76 74 72 70 68 66 64 62 60 58 56 54 52 50 48 46 44 42 40 38 36 34 32 30
230 226 223 219 2 16 212 208 205 201 198 194 190 187 183 180 176 172 169 165 162 158 154 151 147 144 140 136 133 129 126 122 11 8 11 5
111
0.115
0.129 0.143 0.157

0.171
108 104 100 97 93 90 86
0.185 0.192 0.199 0.206 0.213 0.220 0.235 0.250 0.265 0.280 0.295 0.317 0.339 0.361 0.383 0.405 0.438 0.471 0.504 0.537 0.570 0.598 0.626 0.654 0.682 0.710 0.759 0.808 0.857 0.906 0.955 1.023 1.09 1 1.1 59 1.227 1.295
1323 1432 1541 1650
28 26 24 22 20 18 16 14 12 10 8 6 4 2 0 -2 -4 6 -8 -1 0 -1 2 -1 4 -1 6 -18 -20 -22 -24 -26 -28 -30 -32 -34 -36 -38 -40 -42 -44 -46 -48 -50
82 79 75 72 68 64 61 57 54 50 46 43 39 36 32 28 25 21 18 14 10 7 3 -0.4 -4 -8 -11 -1 5 -1 8 -22 -26 -29 -32 -36 -40 -44 -47 -5 1 -54 -58
1.377 1.459 1.541 1.623 1.705 1.806 1.907 2.008 2.109 2.210 2.327 2.444 2.561 2.678 2.795 2.901 3.007
3.11 3
3.219 3.325 3.421 3.5 17 3.613 3.709 3.805 3.885 3.965 4.045 4.125 4.205 4.267 4.329 4.391 4.453 4.515 4.553 4.591 4.629 4.667 4.705
1800 1950 2100 2250 2400 2670 2940 32 10 3480 3750 4 170 4590 5010 5430 5850 6510 7170 7830 8490 9150 9422 9694 9966 10238
10510
13688 16866 20044 23222 26400 30520 34640 38760 42880 47000 55100 63200 71300 79400 87500
Page: 225
2005 Arctic Cat Service Manu al - all models - www. ReadManu als.com
457
Troubleshooting Fuel System

Problem. Too Rich Condition
1. Diagnostic trouble code Remedy
2. Fuel pressure too high 3. Fuel return hose obstructed 4. Injectors leaking Problem: Too Lean
1. 2. 3. 4.
Replace problem se nso r Replace reg ulator Service - replace hose - remove obstruction Replace injectors
Condition 1. Diagnostic trouble code 2. Fuel pressure too low

3. Vent hose obstructed 4. Fuet fitter(s) obstructed
Remedy 1. 2. 3. 4. Rep lace problem senso r Rep lace reg ulatorlfuel pump Remove obstruction Reptace fuel tilter(s)
Fuel System
(Related Itents)
Some components may vary from model to model. The
Oil-Injection Pump
REMOVING
tec hnic ian should lise di scretion and sound judgment when removing and in"laliing compo nents. W henever any mainte nance o r iOspect ion is made on the fuel system in which fucllcakage may occur, there should be no weldi ng, smoking . o r o pen /lames ill the
area.
NOTE: On "Laydown" engine models to service the oil-injection pump , the engine must be removed (see Section 2); then proceed to step 3.
I. Turn the gas tank shut-off valvc to thc CLOSED position.
2. If applicable. rcmo\'c the carburctors .
3. Disconncct the oil-supply hose from the pump and plug to prevent oil drainage. 4. Remove the two oil-delivery hoses from the adapter plates.
Fuel System
(Related Items)
5. Disconncct the oi l-injection ca blc/control rod. 6. Rcmo\'c the two screws. lock washers. and washers securing the oil -lOjection pump and retainer to the crankcase.
Table of Contents
Oil -Injection Pump ........... ......... .. . .... .......... .... .... . 4-58 Synchronizing Oil-Injection Pump .... ..................... 4-59 Bleeding Oil-Injection System (Standard Models). 4-60 Bleeding Oil-Injection System ("Laydown" Engine Models) ........................ .......... .............. ... ........ 4-60 Test!ng O!I-Inject!on Pump .................................... 4-61 Testmg OIHnjectlon Check Valves ........................ 4-62 Fuel Pump (Carbureted Models) ........................... 4-62 Air-Intake Silencer (One-Piece Style) ......... ..... .... . 4-64 Air-Intake Silencer (CoverfTool Tray Style) .... ........ 4-64 Air-Intake Silencer ("Laydown" Engine Style) ........ 4-64 Gas TanklSeat Assembly .............................. ........ 465
AB078
-""'"
458
Page: 226
7. Pull the oil-injection pump away from the engine and account for a gasket.
8. Turn the pump sideways; then remove the lower
Synchronizing OilInjection Pump

CHECKING
NOTE: On " Laydown" engine models to access the oil pump, tip the snowmobile on its left side; then using a torx-bit, remove the screws securing the center belly pan (skid plate) to the front end.
I. With the ignition sw itch key in the OFF position,
union boll. Account for two gaskets. Remove the pump. 9. Remove the remailllng ullion bolts securing the check val ves to the pump. Account for two gaskets. 10. Remove the check valves. Account for two gaskets.
INSTALLING
I. In turn on each front union bolt , install a gasket,
move the throttle lever to the full-open position. 2. Check the alignment of the mark on the pump housing and the mark on the control ann. If the marks align, the oil -injection pump is synchronized with the carburetors and no adjustment is necessary. If the marks do not ali gn, adjust until ali gnment is attained.
check val ve, and gasket; then install on the oilinjection pump. 2. Place the gasket and oil-injection pump near the engine; then install the lower union bolt through a gasket, check valve, and gasket. 3. Position the oil-injection pump on the engine making sure the oil-injection pump gear is correctl y ali gned with the oil-injection pump dri ve gear. 4. Secure the pump with two screws, lock washers, and washers. Tighten screws to 0.7 kg-m (5 ft-Ib). 5. Connect the two oil -deli very hoses to the adapter plates. Secure with clamps. 6. Connect the oil-injection cable/control rod to the pump and secure. 7. Connect the oil -suppl y hose to the oil -injection pump inlet fittin g. Secure with the clamp. 8. Bleed the oil-injection system (see Bleeding Oil Injection System in thi s sub-section).
Pump 80ss Alignment Mark
'-"---", lG
Control Arm Idle Mark
2~ ".1=\~
Full-Open Mark Oil Bleed Plug
727-185C
~-
~ Adjusting Hut
Linkage Roo
' - Jam M ut
9. Check the oil-injection system synchronization (see Synchronizing Oil-Injection Pump in this subsection). Ti ghten the jam nuts securel y.
.NOTE: On "Laydown" engine models to install the engine, see procedure in Section 2.
Idle Ma lt
C ontrol A rm
10. If applicable, install the carburetors.

full Opeo M ark
II . Turn the shut-off valve to the OPEN position.
.NOTE: On some models, the oil pump linkage can be adjusted at the junction in the oil pump! throttle cable.
Page: 227
459
ADJUSTING
I Loosen the jam nuts securing the cable/control roo adjuster. 2. Move the throttle lever to the rull-o pen positio n.
Unkage Roo Adjustin& Hut
3. Rotate the jam nuts/control rod in the proper

direction until the marks align. 4 . Lock the jam nuts to secure the adjustment.
NOTE: On FirecatlSabercat models if the snow mobile has been tipped on its side for an extended period of time, inspect the oil-line hose for any signs of air bubbles. If air bubbles are visible, see the appropriate Bleedi ng Oil-Injection System in this sub-section.
Idle Nark
FullOpen Mark O il Pump Bon A1 i& nment Mark

738-338A
Bleeding Oil-Injection System

(Standard Models)
3. Using a shielded safety stand, raise the rear o f the snowmobile. Engage the brake lever lock: then stal1 the engine and a llow it to idle.
4. Using a stiff wire with a hooked end, pull the

contro l arm upward to the full-o pe n position.
Lb. CAUTION
Whenever bleeding the oil-injection system, use a 100:1 gaS/oil mixture in the gas tank to ensure adequate engine lubrication. Failure to use the 100:1 mixture during oil-injection system bleeding will result in severe engine damage.
I . Fi ll the oi l reservoir with recommended injection oiL
5. Idl e the engine until oi l fl ow ing to the top of the oi l-de li very hoses is free of air bubbles.
6. W hen oil fl ows free of all air bubbles, shut the

engine off and check fo r leakage.
2. Place all absorbent towel below the o il bleed screw ; thell remove the bleed sc rew from the pump. Allow the oi l to fl ow through the oi l-suppl y hose until the hose is fill ed with oil and free o f air bubbles; then install the bleed screw.
NOTE: To aid in bleeding the oil system, blow into the vent hose to force the oil toward the pump. The oil reservoir cap must be on for this proce dure.
7. Release the brake lever lock.
Bleeding Oil-Injection System

(ULaydown" Engine Models)
NOTE: The oil reservoir must be full for this pro-cedure.

I . Tip the snowmobile o nto its left side; then using a to rx-bit , remove the sc rews securing the center belly pan (skid plate) to the front e nd.
~ ,.
""
Idle Mark
J.mN"I'
Pump Boss Alignment Mark
I(; . II v
2. Loosen, but don "t remove, the o il bleed screw ; then finger-tighten the bleed screw.
Control Arm -<1I~V'1-,! T-~'\i(
3. Tip the snowmobile back to the upri ght position;

then raise the rear of the snow mobile o nto a safet y stand so the track is at least 6 1 c m (24 in.) off the gro und.
727-185C
Full.Open Mark
Oil Bleed Plug
4. Place a drain pan beneath the engine compm1ment; then loosen the bleed screw until oil begins to drain o ut.
460
Page: 228
5. Allow the oil to drain out until there are no visible signs of air bubbles in the oil -line hose; then tighten the bleed screw.
6 . Lower the
3. Fill the usage tool with recommended oil to the 0 line.

4. Wipe the tip of the tool to remove excess oil ; then
rear of the snowmobile, tip the snowmobile onto it s left side, ensure the bleed screw is secure, and install the center belly pi lll (skid plate).
attach the tool to the oil -suppl y hose and remove the bulb. 5. Secure the tool to the oil reservoir by twisting the rubber strap one half turn and placing the rubber strap around the tool and the oil reservoir fill er neck.
NOTE: If the snowmobile has been tipped on its side for an extended period of time, inspect the oilline hose for any signs of air bubbles. If air bubbles are visible, repeat the bleeding procedure. NOTE: Prior to operating the snowmobile, make sure the oil reservoir is full of recommended oil.
Testing Oil-Injection Pump
6. Start the engine and run the engine at 3000 RPM for 3 minutes with the control ann in the FULLCLOSED lX)sition. Compare the amount of oil used against the specifications on the chm1 . 7. Using a stiff wire, pull the oil-injection control arm to the FULL-OPEN position. Run the engine at 3000 RPM for 2 minutes. Compare the amount of oil used against the specifications on the clulI1 .
Always wear safety glasses when performing this test.
Oil Consumption @3000 RPM MODEL 370cc 440cc 500cc 550 cc 570cc 600 cc STD 600 cc "Laydown"' 700cc 900cc FULL-CLOSED 3 Minutes
TBA TBA TBA TBA TBA TBA TBA TBA
I. Clamp off the oil-suppl y hose between the oil reservoir and oil pump ; then remove the suppl y hose from the pump. 2. Attach a suitabl e length of oil-suppl y hose to the oil pump; then using Oil Injection Us.1.ge Tool (pIn 0644-007), fill the hose with Arctic Cat 50: 1 Injection Oil.
NOTE: On APV equipped engines, use Arctic Cat Synthetic APV 2-Cycle Oil (pin 2639-512).
FULL-OPEN 2 Minutes
TBA TBA TBA TBA TBA TBA TBA TBA
8, If the oil-injection pump output does not meet the specifications, see Testing Oil-Injection C heck Val vcs in this sub-secti oll. 9. Disconnect the oil usage tool, remove the plug from the reservoir, attach the oil -supply hose to the oil reservoir, and re move the vacuum pump. 10. Bl eed the oil-injection system (sec appropriate Bleeding Oil-Injection System in this sub-section).
NOTE: When filling the oil-supply hose with oil, do not insert the usage tool until it is tight in the hose. There must be enough room around the tip of the tool and the hose to allow air in the hose to escape.
Page: 229
461
PRELIMINARY CHECKS
Testing Oil-Injection Check Valves

In the event there is an eng ine problem due to lack of lubrication, the oi l-injection pump c heck val ves sho uld be tested lIsing a vacuum pump to make sure the chec k valves are operating properly.
When testing the check valves, remove them from the
I. Ivlake sure the gas tank shut-o ff valve is in the OPEN position. 2. Make sure there is adeq uate gasoline in the gas tank. 3. Make sure all hoses are clear and free of kinks and obstructio ns. 4. Ivlake sure the fuel filt er is not plugged or damaged. 5. Make sure fuel and impul se hoses are in good condition. 6. Make sure there is ev idence of good impul se at the crankcase impulse fitting.
pump assembly.
I. Remove the c heck valves from the oi l-injectioll
pump.
KEY 1. Gasket
2. Check Valve 3. Gasket 4. Union
~=~ @) 3
TESTING PRESSURE
I. Connect a pressure ga uge between fuel pump and
carburetor using a pi ece o f fuel hose and a Tfittin g. 2. Place snowmobile o n a safety stand and stm1 the engine. At the follo wing engine speeds. the specified pressures must be indicated.
731-551A
1-4
RPM
1000-2000 3000-4000 SOOO-6000
psi
3.0-3.5 4.S-S.S 6.0-7.0
k9'cm2
0.21-0.25 0.32-0.39 0.42-0.49
2. A ttach the vacuum test pump hose to the check val ve.
3. Squeeze the vacuum pump handle and watch the pump gauge. The check valve should release at 4.5-5 Ib and aga in reset itself at 3.5-4 lb. If "release" and "reset" arc not withi n specifications, replace the chec k valve.
4. Record the " release" and "reset" rerldings for the
3. Remove gauge and hose and connect fuel hose to carburetor.
TESTING VACUUM
NOTE: Make sure adequate fuel is in the carburetor for this test.
I. Turn the gas tank shut-off valve to the CLOSED
valve; then pe rform the test o n the other valve. The " release" and " reset"' readings must fall within specifications and must be wi thin 1.5 lb of each other. If either o r both are not met, replace the check valves. 5. If the check valves arc within specifications but the oi l-injection usage is not, replace the oi linjection pump.
pos ition , then disconnect fuel suppl y hose from the shut-olT valve. 2. Connect a vacuum gauge directly to the fuel pump inlet fittin g. 3. With snowmobil e on a safet y stand, start the engi ne and accelerate to 2000-3000 RPlvl for a period o f 30 seconds. Note maximum reading of gauge. Reading must be withi n the ra nge li sted.
Acceptable Fuel Pump Vacuum (2-3000 RPM)
Fuel Pump
(Carbureted Models)
in.-hg
mm-hg
175-250
NOTE: When servicing a fuel pump, determine which style pump is being serviced and follow the appropriate procedure.
7-10
4. Stop engine. Connect fuel hose. Turn the shut -o ff valve to the OPEN positio n.
4-62
Page: 230
SERVICING
KEY 1. 2. 3. 4. 5. 6.
Case Membrane Diaphragm Gasket Case Screw
2. Remove the screws securing the fuel pump; then fro m the top of the fuel pump, remove the top, packing, diaphragm , packing, valve sectio n, packing, diaphragm , a nd packing.
NOTE: Be sure all fuel pump components are clean and the fittings are tight.
3. Push the gro mmets out of the \'alve sectio n; then remove the val ve from each gro mmet. 4. Place a valve o nto eac h gro mmet; the n push each valve with grommet into the valve section. 5. In sequence on the bottom of the fuel pump, place a 1 l.:1cking, diaphragm , packing, va lve section, packi ng, diaphragm , packing, and top .
0727-830
NOTE: Make sure the scribed line made during disassembly is aligned.
I. Scribe a line across the fuel pump sectio ns. 2. Remove the screws securing the fuel pump; thell
from the top of the fuel pump, remove the top
6. Secure the fuel pump with the screws, Tighten sec urely.
case, gasket, diaphragm , and membrane.

_NOTE : Be sure all fuel pump components are clean and the fittings are tight
SERVICING
3. In sequence on the bottom case of the fuel pump, place the membrane, diaphragm , gasket , and top casco
NOTE: Make sure the scribed line made during disassembly is aligned and the tabs on the two lower packings align with the tabs on the bottom and valve section of the pump.
~
8 --
-u - - J
,j,
4. Secure the fuel pump with the screws. Tighten securely.
SERVICING
I Scribe a line across the fuel pump sections.
KEY
~ - .. . . ~
730-349N
1. Packing 2. Diaphragm 3. Packing

4. Valve Section wlGrommets
0 738-347 0 728-279
I. Scribe a line across the fuel pump sectio ns.
Page: 231
4-63
2. Remove the screws and lock washers securing the fuel pump: then from Ihe top of the fuel pump, remove the cap, thick packing, diaphragm, thin rubber packing, val ve section, thin rubber packing, diaphragm, and thick packing. 3. Push the grommets out of valve section; then remove the valve from each gronunet.
Air-Intake Silencer
(One ..Piece Style) The air-intake silencer is a spec iall y designed component used to silence the incoming fres h air and al so to catch the fuel that "spits back" out of the ca rburetors. T he carbureto rs arc calibrated with the air-int ake silencer in position; therefore. the engine must nevcr be run with the air-intake si lencer removed.
4. Place a valve onlo e. .leh grommet; then push each valve with grommet into the val ve section of the fuel pump. S. In sequence on the bolloll1 of the fuel pump, place a thick packing, diaphragm, thin rubber packing, valve section, thin rubber p< lcking, diaphragm, thick rubber packing, and cap.
NOTE: Make sure the scribed line made during disassembly is aligned and the tabs on the two lower packin9s align with the tabs on the bottom and valve section of the pump.

Check for holes or cracks in the silenccr. 2. Periodically cl ean the silenccr by blow ing fresh air through it.
Air-Intake Silencer
(Cover/Tool Tray Style)
6. Secure the fuel pump with the screws and lock washers. Ti ghten securel y.
SERVICING
I. Scri be a line across the fuel pump sections. 2. Remove the Phillips-head sc rews and lock washers securing the fuel pump sections; thell from the top of the fuel pump, remove the cap, gasket, di aphragm, gasket, valve section, gasket, diaphragm, and gasket.
T he air-intake sil encer is a speciall y designed component used to silence the incoming fres h air and al so to ealch the fuel that "spits back" out of the throttle body/ ca rbureto rs. The throttl e body/carburetors are ca li brated with the air-lOtake sil encer in pos iti on; therefore, the engine must never be nm with the air-intake silencer removed.

I. Check for holes or cracks in the silencer. 2. Periodicall y clean the silencer by removing the cover/tool tray assembl y and vaclluming the interior of the silencer.
3. Push the grommets out of the valve section; then remove the valve from each grommet. 4. Place a valve onto each grommet: then push each valve with grommet into the val ve secti on of the fucl pump.
S.
Air-Intake Silencer
(" Laydown*' Engine Styte)
In sequence on the bottom of the fuel pump, place a gasket, diaphragm, gasket, valve section, gasket, diaphragm, gasket, and cap.
NOTE: Make sure the scribed line made during disassembly is aligned and the tabs on the two upper gaskets align.
T he air-intake sil encer is a spec iall y designed component used to silence the incoming fres h air and also to catch the fuel that "spits back" out of the throttle body/ ca rburetors. The throttl e body/ca rburetors arc ca li brated with the air-intake sil encer in pos iti on; therefore, the engine must never be nm with the air-liltake silencer removed.
6. Secure the fuel pump with the Phillips-head screws and lock washers. Ti ghten securely.
REMOVING
I. Remove the two hood pins securing the hood to
the front end ; then carefull y move the hood back allow ing it to rest against the handlebar.
4-64
Page: 232
2. Using a 1120 to rx-bit , remove the three sc rews securing the air silence r to the front bumper assembl y. Account fo r the position of the hood screen. NOTE: On the 6conoa cc, it is necessary to first remove the two screws securing the ECU to the air silencer.
INSTALLING
I . Positio n the hO<X! screen to the front bumpe r
assembly; then install the air silencer into the front end . 2. Secure the air silencer with the thrce screws. NOTE: On the 6CanOa ce, secure the ECU to the air silencer with the two screws.

I. Check for ho les or cracks in the silence r. 2. Periodicall y clean the silencer by blowing fresh air through il.
Gas Tank/Seat Assembly

NOTE: To service the gas tank/seat assembly, see Section 7 in Volume 2.
Page: 233
465
SECTION 5 - ENGINE ELECTRICAL SYSTEMS

TABLE OF CONTENTS
Electrical Specifications Chart ........ .. ..... ... ...... ..... .. 5-2 Resistance Tests Chart ... ............ .. .. .. ..... ... .. ......... .. . 5-2 Electrical Specifications (Individual) ..... .. ................. 5-3 Testing Electrical Components ................ .............. 5-10 TroubleshootingfTesting Ignition System EFI Models .......... .. ... .. ... .. ........ ... .. ... .. ... . 5-10 Fan Cooled Models ... .. ........ .. .. .. ... ...... ... .. .......... 5- 11 UC Models ..... ..... .. ... .. ....... .. .. .. ... .. ....... .. ... .. ... .. 5-15 Throttle Position Sensor (5001 60017001 8001900 cc Models) ..................... 5-17 Testing Electrical Resistances EFI Models ... ..... .... .............. .. .. .. ... ...... ... .. .......... 5-20 370/440 cc Models .... .. ............ .. ..... ....... .. ..... ..... 5-22 500 cc w/APV .. .. ....... .............. ... ..... .......... .. .. ..... 5-24 550 cc Model .......... ............................. .............. 5-25 900 cc Carbureted Models .............. .................. 5-27 500 w/o APV/570 cc Models .. .... ...................... . 5-28 700 cc "Laydown" Carbureted Models ... .. ..... ..... 5-30 Voltage Regulator Test .. .. ............ .. ..... .......... .. .. ..... 5-31 Voltage Regulator Test (EFI Models) .. ... .. .. .. ..... ..... 5-31 Voltage Regulator (APV) Test (EFI Models) .. .. .. .. .. 5-32 Regulator/Rectifier Test (Carbureted APV Models) ................................. 5-32 Condenser Test (Carbureted APV Models) .5-32 Servomotor Test ....... .. ..... .. .. ........ .. ..... ..... ..... .. .. ... .. 5-32 Potentiometer Test ... .. .. .............. ... ..... .......... .. .. ... .. 5-33 Peak Voltage Tests {Fan Cooled Models) ............. . 5-33 Peak Voltage Tests (700/900 cc Carbureted Models) ....................... 5-34 Peak Voltage Tests (550 cc Model) .. ................ ..... 5-34 Peak Voltage Tests (500 cc w/APV Models) ........ .. 5-35 Peak Voltage Tests (500 cc w /o APV Models) .. ... .. 5-36 Peak Voltage Tests (EFI Models) .. ..... ....... .......... .. 5-36 Testing Low-Qil Ught Sensor................................. 5-37 Testing High Temperature Sensor. . ..... ..... 5-38 Testing High Temperature Warning Ught .............. 5-38 Testing Fuel Gauge .. .. ..... .. .. ... .. .. .. ..... .. .5-38 Testing Fuel Gauge Sender ..... .. . .. .......... .. .. ..... 5-38 Testing Electric Fuel Pump .. ..... ....... .. ........ .. ..... ..... 5-39 Electric Start Components Solenoid .......................................... .................. 539 Charging Diode ...... ............................. .............. 5-39 Fuse .... ...... ...... ...... .. .......... ... ... ..... ....... .. .. .. ..... 5-39 Ignition Switch - Electric Start Function ... ........ .. 5-40 Starter Motor .. ....... .... .. ............ .. ... ...... ... .. .......... 5-40 Troubleshooting Electric Start .......... .. ............... 546 Ignition Timing ......................................... .............. 5-46 Ignition Timing Specifications (Table of Contents) .. .. .. ....... .. .. .. ..... ....... .. ..... ..... 5-47 Ignition Timing Specifications ...... .. ... ...... .... .. ......... 5-48 Wiring Diagram Index (Ignition) ... .. ..... ....... .. ..... ..... 5-55 Wiring Diagrams ......... ............................. .............. 5-56
Page: 234
5-1
Electrical Specifications Chart
SOOcc wfAPV 500 cc w/o A P V
AVSOL4
AWSOL4
Kokusan Oenki
"30 (!)
5.258
0.207
Kokusan Denkl
"25 <:>
3.692
0.145
. ,,. .
,,.
WA
BR9EVA
0.7-0.8
0.028-0.031
OPEN OPEN
12V/156W
BR9EYA
0.7-0.8
0.028-0.031
12V1156W
570c c
600cc "laydown"
(EFI)
AJ60L2
Kokusan Oenkl
',5 0
1.509
0.059
BR9EYA
0.7-0.8
0.028-0.031
OPEN
12V1190W
900 c c (EFI) 1I>@ 1400 RPM O@ 18oo RPM a>@2000RPM
AB86L4
Kokusan Oenki
"23
3.775
0.149
,,.
BR9EYA
0.7-0.8
0.028-0.031
OPEN
12V/,90W
0 @2500RPM <!l @3200 RPM <iJ @3500RPM
0>@ 4ooo RP M
-e ngine Warm
"'@ 435O RPM
Resistance Tests Chart
Ignilion Coli - Secondary
Lighting Coil
Stator Coil (C harge)
(DC Power) (C harge 1)
WA NfA NfA NfA NfA 0.89<020% NfA NfA 15 t. 20% NfA
160 :1:.20%
NfA
RNI- SIR
RN - YIR
172O% SIR - BRfW
17:1:20% BRIW - GIR
0.65 20% R/ V - YIR

NfA NfA
NfA NfA NfA
0.89
AN
20%
VIR
160 :1: 20%

RIW- 81W
17 20% Bil'l-RIW
NfA NfA
NfA NfA
B.fI - GIR
15:1:20% BRIW - GIR
(C harge 2)
Ignition Timing Sensor Injector Coil
NfA
NfA
NfA
NfA
NfA
NfA
Fuel Pomp Coil

Sp ar1\ Plug Cap
;00"
ABBREVIATI ON KEY B Blac k BL Blue W Whi te Y Yellow
;000 ,
5000~20%
;000 ,
R Rw BR B~ "
GRND Ground NtA Not Appl icable
POS
Orange Pos iti ve HT High Tension N EG Negative

OR
NOTE: All Models must use both resi stor type spark plug s and spark plug caps.
52
Page: 235
Electrical Specifications
(370/ 440 ee)
NOTE: The ignition system is a Normally Open Ignition (NOI).

DescriptIon
Ignition Coil Primary (External) Secondary
Resistance Test Test Value

0.26-0.35 ohm 6800-10,200 ohms
128-192 ohms
+ Test Connections
orange high tension wire black high tension wire black/red yellow cap end
Stator Coil (Charge)

Lighting Coil Spark-Plug Cap
redlwhite
yellow
0 .17-0.26 ohm 4000-6000 ohms
cap end
Description Voltage Regulator

Low Oil-light Sending Unit Ignition Switch
Test Value
11-14 AC volts
+ Test Connections yellow

terminal terminal
Less than 1 ohm

(float end down)
brown terminal terminal
Less than 1 ohm

(key in OFF position)
Description
Primary Coil (External)
Stator Coil (Charge) Lighting Coil
Peak Voltage Test

17Q-187V 200-220V
9.0-9.9V
orange
+ Test Connections black blacklred yellow redlwhite yellow
Peak Voltage Tests were made w ith the Fluke Modc173 Multi meter (pIn 0644-191) set to the DC Volt scale and the Peak Voltage Readi ng Adapter (pIn 0644-307) with the connectors plugged in. spark plugs re moved and gro unded. and by pull ing the recoi l starte r rope briskly.
NOTE: Lighting coil output is unregulated voltage_
Page: 236
53
(550 ee)
DescriptIon
Ignition Coil Primary (External) Secondary

0 .26-0.35 ohm 6800-10,200 ohms
128-192 ohms
+ Test Connections"
orange high tension wire black high tension wire
Charge Coil (1)

Charge Coil (2) Lighting Coil Spark-Plug Cap
redtwhite
blacklWhite
redlWhile yellow
13.6-20.4 ohms 0 .17-0.26 ohm 4000-6000 ohms
blackked
yellow
cap end
cap end
Description
Voltage Regulator
Low Oil-Light Sending Unit
Test Value
11-14 AC volts
Less than 1 ohm (float end down)

terminal
brown
terminal
High Temperature Sensor
Open (water temperature lower than 190F) Up
terminal terminal
ground ground
High Temperature Warning Light Ignition Switch Description Primary Coil (External) Charge Coil (1) Charge Coil (2) Lighting Coil
(water temperature higher than 230 F) Less than 10 ohms

Q
to 20 ohms
terminal terminal
terminal terminal
Less than 1 ohm (key in OFF position) Peak Voltage Test 177-195V 9.0-9.9V 9.0-9.9V 10-11 V
+ Test Connections orange redtwhite black/red yellow black black/white redtwhite yellow
Peak Voltage Tests were made w ith the Fluke Model 73 M ultimeter (pin 0644- 19 1) set to the OC Volt scale and the Peak Voltage Re.. ' lding A dapter (pin 0644-307) with the connectors plugged in , spark plugs removed and grounded, and by pulling the recoil starter rope bri skly.
NOTE : Lighting coil output is unregulated voltage.
54
Page: 237
(500 cc vv/ APV) NOTE: The ignition system is a Normally Open Ignition (NOI).
DescriptIon
Ignition Coil Primary Secondary

0.27-0.41 ohm 6800-10,200 ohms
+ Test Connections orangelblack high tension wire blacklorange high tension wire
DC Power Coil
Ignition Timing Sensor Lighting Coil Spark-Plug Cap
0 .71-1.07 ohms
148-222 ohms 0.12-0.18 ohm 4000-6000 ohms
red/yellow
greenlwhite yellow
yellow/red
brown/green yellow
cap end
cap end
Description
Voltage Regulator
RegulatorlRectifier
Test Value
11-14 AC Volts

redlblue
brown
brown/yellow
11.2-16.8 DC Volts
(@2000RPM)
Condenser
Low Oil-Light Sending Unit
11.6-17.4 DC Volts
red
brown
terminal terminal
(@2000RPM)
Less than 1 ohm
terminal terminal
Ignition Switch Description Primary Coil (External) DC Power Coil Ignition Timing Sensor Lighting Coil DC Power Coil
(float end down) Less than 1 ohm (key in OFF position) Peak Voltage Test
150V
+ Test Connections orangeiblack red/yellow greenlwhite yellow yellowlred black/orange yellowlred brown/green yellow redlyellow
tOV (Static) lA-l .6V 4V 12.6-18AV (@2000RPM)
Peak Voltage Tests were made with Max iC li ps (pfn 0644-455), the Fluke Modc173 M ultimeter (pin 0644- 19 1) set to the DC Volt scale, and the Peak Voltage Read ing Ada pter (pIn 0644-307) with the engine running at 2000 RPM or with the connectors plugged in, spark plugs removed and grounded, and by pulling the recoil stm1er rope briskly.
NOTE : Lighting coil output is unregulated voltage. NOTE : On APV-equipped carbureted models, the traditional charge coil(s) have been replaced by a single DC power coil on the stator.
Page: 238
55
(500 vv/o APV/570 ee)

Description
Ignition Coil Primary (External)

0.26-0.35 ohm 6800-10,200 ohms 12-18 ohms 12-18 ohms
orange
+ Test Connections
black
Secondary
Charge Coil (1)
Charge Coil (2)
Ignition Timing Sensor

Lighting Coil Spark-Plug Cap
148-222 ohms
0.12-0.18 ohm 4000-6000 ohms
high tension wire blacklred brownlwhite greenmhite
high tension wire
yellow cap end

yellow terminal terminal
greenlred greenlred brown yellow cap end

brown terminal
DescriptIon
Voltage Regulator Low Oil-Light Sending Unit
Test Value
11-14 AC volts
Less than 1 ohm (float end down)
+ Test Connections
Ignition Switch
Less than 1 ohm

(key in OFF position)
terminal
Description
Primary Coil (External) Charge Coil (1) Charge Coil (2) Ignition Timing Sensor Lighting Coil
Peak Voltage Test

185-204V 69-76V 79-87V 1.4-1.6V 7 .0-7.7V
+ Test Connectionsorange blacklred brownlwhite greenlwhite yellow black greenlred greenlred brown yellow
Peak Vollage Tests were made w ith the Fluke ivlodel 73 Mullimeter (prn 0644- 19 1) set to the DC Volt scale and the Peak Voltage Reading Adapter (pin 0644-307) with the connectors plugged in , spark plugs re moved and grounded, and by pulling the recoil starte r rope briskl y.
NOTE: Lighting coil output is unregulated voltage.
56
Page: 239
Electrical Specific ations

(EFI Models)
NOTE: The ignition system is a Normally Open Ign ition (NOI).
Description
Ignition Coil Primary

0.24-0.36 ohm 6800-10,200 ohms 13.6-20.4 ohms 13.6-20.4 ohms 0 .08-0.12 ohm 152-228 ohms 15.2-22.8 ohms 1.52-2.28 ohms 4000-6000 ohms
+ Test Connectionsblack/orange high tension wire blacklred brown/white orangeiblack high tension wire brownlWhite
Secondary
Charge Coil (1) Charge Coil (2) Lighting Coil
yellow
greeniWhite bluefwhite orangelWhite
Ignition Timing Sensor

Injection Coil Fuel Pump Coil Spark-Plug Cap
greenlred yellow brown

bluelwhite
cap end
yellow yellow
rediblue terminal terminal terminal terminal terminal
orangelwhite cap end

brown brown
Description
Voltage Regulator Voltage Regulator
Test Value
11-14 AC Volts 10-15 AC Volts (@2000RPM) 10.7-16.1 DC Volts (@2000RPM) Less than I ohm (float end down) Open (water temperature lower than 190F) Up to 20 ohms (water temperature higher than 230F) Less than 10 ohms
+ Test Connections -
Voltage Regulator (APV) Low Oil-Light Sending Unit High Temperature Sensor
brown terminal ground ground terminal terminal
High Temperature Warning Light Ignition Switch Description Primary Coil Charge Coil (1) Charge Coil (2) Lighting Coil Ignition Timing Sensor Injection Coil Fuel Pump Coil Lighting Coil
' Pantera Model
Less than 1 ohm (key in OFF position) Peak Voltage Test t51-176V 100-t1OV 85-94V 5.4-S.8V (Static) 4.4V 12V 12.3V 14.8-22.2V ( @2000RPM)
+ Test Connections
black/orange black/red brownlwhite yellow greeniWhite blueiWhite orangeiWhite yellow yellow' orangelblack brownlwhite greenlred yellow brown blueiWhite orangelwhite brown yellow'
Peak Voltage Test') were made with the lvlax iClips (pin 0644-455), Fluke lvlodc173 1 Vlultimeter (pIn 0644-1 9 1) set to the DC Volt scale, and the Peak Voltage Reading Adapter (pIn 0644-307) with the engine running at 2000 RPtvl or with the connectors plugged in, spark plugs removed and grounded, and by pulling the recoil stm1er rope briskly.
N OTE : Lig h ti n g coil outpu t i s u n reg u la ted voltage.
Page: 240
57
(700 cc I#LaydownU Carbureted Models)

Description
Ignition Coil Primary (External) Secondary DC Power Coil Lighting Coil Ignition Timing Sensor Spark-Plug Cap

0.24-0.36 ohm 6800-10,200 ohms 0.71- 1.07 ohms 0.08-0.12 ohm 148-222 ohms 4000-6000 ohms
+ Test Connectionsorange high tension wire redlyellow yellow greenlwhite cap end black high tension wire yellowked yellow brown/green cap end
Description
Voltage Regulator RegulatorlRectifier Condenser Low Oil-Light Sending Unit High Temperature Sensor
Test Value
11-14 AC Volts 11.216.8 DC Volts (@2000RPM) 11.6-17.4 DC Volts
+ Test Connections yellow rediblue brown brown/yellow brown terminal ground ground
ced
terminal terminal terminal
(@2000RPM)
Less than I ohm (float end down) Open (water temperature lower than 190F) Up to 20 ohms (water temperature higher than 230F) Less than 10 ohms Less than I ohm (key in OFF position)
High Temperature Warning Light Ignition Switch
terminal terminal
terminal terminal
Description
Primary Coil (External) DC Power Coil Lighting Coil Ignition Timing Sensor DC Power Coil
Peak Voltage Test

229V 10V (Static) 4V 1.4-1 .6V 12.6-18.4V (@ 2000 RPM)
+ Test Connections orange red/yellow yellow greenlwhite yellowlred black yellowlred yellow brown/green red/yellow
Pea k Voltage Tests were made with MaxiC lips (pin 0644-455), the Fluke Model 73 M ultimeter (pin 0644- 19 1) set to the DC Volt scale, and the Peak Voltage Reading Ada pter (pIn 0644-307) with the engine running at 2000 RPM or with the connecto rs plugged in, spark plugs removed and grounded, and by pulling the recoil sta rter rope bri skly.
NOTE: Lighting coil output is unregulated voltage. NOTE: On APV-equipped carbureted models, the traditional charge coil(s) have been replaced by a single DC power coil on the stator.
58
Page: 241
(900 cc .. Carbureted Models)
Description
Ignition Coil Primary (External)

0.24-0.36 ohm 6800-10,200 ohms 0.52-0.78 ohm
orange high tension wire
+ Test Connectionsblack high tension wire yellowlred

brown
Secondary DC Power Coil

Ignition Timing Sensor Lighting Coil Spark-Plug Cap
148-222 ohms
0.08-0. 12 ohm 4000-6000 ohms
red/yellow greeniWhite yellow cap end

yellow cad
yellow cap end
Description
Voltage Regulator RegulatorlRectifier
Test Value
11-14 AC Volts 11.6-17.4 DC Volts (@2000RPM) 11.6-17.4 DC Volts (@2000RPM)
+ Test Connectionsbrown brown
Condenser
Low Oil-Light Sending Unit Ignition Switch
cad
brown
terminal terminal
Less than 1 ohm

(float end down) Less than 1 ohm (key in OFF position)
terminal
terminal
Description
Primary Coil (External) DC Power Coil Ignition Timing Sensor Lighting Coil DC Power Coil
Peak Voltage Test

185-204V 14.0-15.5V (Static) 1.4-1.6V 7.0-7.7V 12.6-18.4V (@2000RPM) orange red/yellow greeniWhite yellow yellowlred
+ Test Connections"
black yellowlred brown yellow red/yellow
Peak Vollage Tests were made with MaxiC li ps (pin 0644-455) , the Fluke lvlode173 Multimeter (pin 0644- 19 1) set to the DC Voll scale, and the Peak Vollage Reading Adapter (pin 0644-307) with the engine runni ng at 2000 RPM or with the connecto rs plugged in, spark plugs removed and grounded, and by pulling the recoil stm1er rope bri skly.
NOTE: Lighting coil output is unregulated voltage. NOTE: On APV-equipped carbureted models, the traditional charge coil(s) have been replaced by a single DC power coil on the stator.
Page: 242
2005 Arctic Cat Servic e Manual - all models - www. ReadManuals.co m
59
A. Defective emergency stop switch
Testing Electrical Components

All tcst's of the engine electrical components should be made using the digital Fluke Model 73 M ullimeter (pI n 0644- 191 ). Replace any compone nl that does not have a test value within specifications.
NOTE: Whenever using a digital-style tester, "open (infinite resistance)" denotes an overload and the meter reading will be Ol since the meter is not calibrated to register resistance values of that magnitude.
NOTE: Whenever testing switches, less than 1 ohm is desirable with the switch in the activated position.
B. Defecti ve safety switch in throttle-control housing

C. Corroded or loose wire con nection at the throttle-control ho using or main wiring harness D. Dcfecti\'e ignitio n switch NOTE : To check these possible causes, proceed to Testing Ignition System.
Testing Ignition System

(EFI Models)
NOTE : There must be free-play between the throttle lever and the control housing.
Troubleshooting Ignition System

(EFI Models)
W hen troubl es hoot ing the standard " normall y open" ignitio n system , use the following procedure.
MAIN WIRING AND SAFETY SWITCHES

I. C heck the wiring connectio ns coming from the Ignitio n key and e me rgency stop sw itches. The throttle control sw itch connector is located on the front side of the steering post. If any of the connections appear dirty or corroded, clean them with fine sandpaper and compressed ai r; then connect all wi res and squeeze the connectio ns with a pliers for additional ti ghtness.
2, Disconnect the main wi ring harness connector coming fro m the engine stator assembl y. Disconnecting this connector will bypass the main wiring harness and all switches which will not allow the engi ne to be shut o ff without first installing an additional auxiliary ground wire.
I. Remove the spark plugs and visuall y check their condil'ioll. Replace any foul ed pJug. Attach the spark plugs to the high tension leads and ground them on the cylinder heads.
&
CAUTION
Before checking for spark, place all the engine switches in the deactivated position. In the event the engine could be flooded, pull the starter rope (slowly at first) several times to clear the engine of excess fuel.
&
CAUTION
Never crank the engine over without grounding the spark plugs. Damage to coils andlor COl unit may result. NOTE: Make sure the ignition switch and the emergency stop switch are in the ON position. 2. C rank the engine over and check for s park. If no spark is present , check to make sure the throttle cable is properl y te nsioned. Compress the throttle contro l and while holding the throttle control in this position, crank the e ngine over and check for spark. If s park is now present, adjust the throttle cable tension. 3 . If no s park is present , disconnect the main wiring harness from the e ngi ne. C rank the engine over. If spark is present , the problem is either o ne or more o f the followin g:
3. Insert an auxiliary ground wi re into the black wire o f the four-wire main harness connector o n the engi ne side. To stop the engine once it has been s(".'lIled , touc h the aux iliary ground wire to the engine. 4 . SUppOil the rear of the s now mobile up on a shielded safety stand ; then set the brake lever loc k. Inspect the complete throttle mechanis m to assure that it's working prope rly. 5. Attempt to stml the engine. To stop the engine (if the engine starts), to uch the auxiliary gro und wire installed into the four-wire con nector to a ground o n the engine. If the engine fail s to stml, the problem is with the coi ls mo unted on the engine , high tension coil assembl y, or the ECU. If the engine starts, the problem is with the switches, main wiring harness, o r throttle cable free-play.
510
Page: 243
IGNITION KEY SWITCH

Di sconnect the ignition key switch connectors; then connect the ohmmeter leads to each of the ignition key switch terminals. 2. With the switch in the OFF position, the meter must read less than I ohm of resistance.
3 . With the switch in the ON position, the meter must

(Fan Cooled Models)
Whe n tro ubl eshooting the standard " normall y open" Ignition system, lISe the rollowing procedure.
I. Re move the spark plugs and visuall y check their
read OL (infinite resistance).
THROTTLE CONTROL SWITCH

I. Verify that the throttle cable has free-play bet ween the throttle lever a nd contro l ho using.
condition. Re place any rouled plug. Attach the slx lrk plugs to the hi gh tension leads and ground them on the cylinder heads.
&, CAUTION
Before checking for spark, place all the engine switches in the deactivated position , In the event the engine could be flooded, pull the starter rope (slowly at first) several times to clear the engine of excess fuel.
2. Di sconnect the throttle control sw itch connector;

then co nnect one o hmmeter lead 1 0 the brow n w ire
and the other ie.: 1d to the blackJwhite wire o f the emergency sto p switch.
3. With the throttle lever in the idl e IXlsilio n and the emergency stop knob in the up (RUN) position. the meier must read no resistance (ope n). If the meter reads resistance (closed), replace the sw itch.
&, CAUTION
Never crank the engine over without grounding the spark plugs. Oamage to coils and/or COl unit may result. _NOTE : Make sure the ignition switch and the emergency stop switch are in the ON position.
4 . With the throttle lever in the idle position and the eme rgency stop knob in the dow n (STOP) position, the meter must read resistance (closed). Ir the meter reads no resistance (open), re place the sw itc h. With the eme rgency stop knob still in the dow n (STOP) position, move the throttle lever to the wide ope n position. T he meter must read no resistance (ope n). Ir the meter reads resistance (closed), replace the switch. 5. Connect one ohmmeter lead to the brown wire and the other lead to the violet wire. With the eme rgency stop knob in the dow n (STOP) position, the meter must read resistance (closed). Ir the meter reads no resistance (ope n), re place the sw itch. With the emergency stop knob in the up (RUN) position, the meter must read no resista nce (ope n). Ir the meter reads resista nce (cl osed), replace the switch.
2. Crank the engine over a nd check fo r spark. Ir no slx lrk is present , check to make sure the throttl e cable is prope rl y te nsioned. Compress the throttle control and while holding the throUle control in thi s position, crank the engine over and check ror slx lrk. Ir spark is now present , adjust the throttle cable tension.
_NOTE : On all models, there must be 0.751.5 mm (0.0300.060 in.) freeplay between the throttle lever and the control housing.
,,
,
, -I' ,
\
Ie
--
-~
Throttle Control;' Housing
:J
"-
~
lever
733-081C
~ Throttle
Gap of 0.75-1.5 mm (0.030-0.060 in.) between the Throttle Switch Body and Throttle lever when Safety Switch is set properly
3 . If no spark is present, disconnect the main wiring harness from the engine. Crank the engine over. If slx lrk is present, the problem is either one or more or the rollowing. A. Derecti ve emergency stop switch
Page: 244
5-11
8. Defecti ve safety switch in throttle-control housing

C. Grounded or sh0l1ed wire connection at the
MAIN HARNESS
throttle-control housing or main wi ring harness D. Defecti ve ignition switch

NOTE: To check these possible causes, proceed to Testing Ignition System. If no spark is present, proceed to Arctic Cat Ignition Analyzer in this section.
I. Disconnect the main wiring harness four-wire connector cOllllng from the engllle stator assembly. COimect one olunmeter lead to the violet wire and the other lead to the brown wire 0 11 the chassis side of the main wiring harness fourwire connector. With all sw itches in the RUN position, the rnet"Cr must read no resistance (open). 2. If the meter reads resistance (closed) , test the Ignition Key Switch and Throttle Control Switch independently of each other.
IGNITION KEY SWITCH

(Single Carburetor FIe Models)
NOTE: The throttle control is equipped with a two-wire throttle control switch connector. There must be 0.75-1.5 mm (0.030-0.060 in.) throttle cable free-play between the throttle lever and the control housing.
I. Disconnect the ignition key switch connectors; then connect the ohmmeter leads to each of the ignition key switch terminals . 2. With the key switch in the OFF position, the meter must read resistance (closed). If the meter reads no resistance (open), the sw itch must be replaced.
NOTE: The throttle control has a two-wire wiring harness connector located on the front side of the steering post. Whenever working with a two-wire throttle control switch, the throttle cable must be adjusted so there is 0.75-1.5 mm (0.030-D.OGO in.) free-play between the throttle lever and control housing.

I. Check the wiring connccti ons coming from the
igniti on key and throttle control sw itches. The two-wire throttl c control switch COlUlector is located 0 11 the front side of thc steering post. If any of the connections appear dil1y or corroded, clean them with fine sandpaper and compressed air: then connect all wires and squeeze the connections with a pliers for additional ti ghtness. 2. Disconnect the main wiring harness four-wire connector coming from the engine stator assembly. Disconnecting the connector will bypass the main wiring harness and all switches which will not allow the engine to be shut off without fi rst installing an additional a u:.. iliary ground wire. 3. Insel1 an auxiliary ground wire into the black wire of the four-wire main harness connector on the engine side. To stop the engine once it has been stal1ed, touch the auxiliary ground wire to the cngllle. 4. SU ppOl1 the rear of the snowmobil e up on a shielded safety stand ; then set the brake lever lock. Inspect the complete throttle mechanism to assure that it's working properly. 5. Attempt to start the engine. To stop the engine (if the engine stm1s), tOllch the auxiliary ground wire IOstalled into the four-wire connector to a ground on the engine. If the engine fails to start, the probl em is with the coils mounted on the engine, hi gh tension coil assembly, or the CDI unit. If the engi ne starts, the problem is with the sw itches , main wiring harness, or throttle cable free-play.
I. Verify that the throttle cable has the specified amount of free-play between the throttle lever and control housing. 2. Disconnect the two-wire throttle control sw itch connector; then connect the ohmmeter leads to each of the switch wires. 3. With the throttle lever in the idle position and the emergency stop knob in the dow n (STOP) position, the meter must read resistance (closed). If the metcr reads no resistance (open), re place the sw itch. 4. Depress the tluoltie lever with the emcrgency stop knob in the up (RUN) position. Thc meter must read no resistance (open). If the metcr reads resistance (closed), replace the switch. 5. With the throttle lever de pressed and the emergency stop knob in the dow n (STOP) position, the meter must read resistance (closed). If the metcr reads no resistance (open), re place the sw itch.
512
Page: 245

(Twoin Carburetor FIC Models)
_NOTE : There must be 0.75-1.5 mm (0.030-0.060 in.) free-play between the throttle lever and the control housing (see Section 4 Adjusting Carburetors).
6. The meter mllst read no resistance (ope n) when the throttle lever is released and the emergency stop knob is in eithe r the UP or the DOWN positio n. 7. If the meter reads resistance (closed), replace the throttle sw itch. 8. Connect one meter lead to the blacklred wire and the other meter lead to the black/white wire. 9. With the throttle lever released (idle position) and the emergency stop knob in the DOWN position, the meter mllst read no resistance (ope n). 10. If above tests were good, proceed to testing Ca rburetor Safety Sw itches and Igni tion Key Switch.

I. Check the wire connections at the ignition key sw itch and at the e me rgency SlOp switch. Thi s
connector is located on the front side of the
steering post If any of the connections appear

dirty or corroded, clean wi th fine sandp<lpcr and
compressed ai r; then connect all wires and squeeze connections with a pli ers for added tightness. 2. Di sconnect the main wiring harness connector coming from the engine. Using an o hmmeter, connect onc lead to the black wi re in the connector of the main harness. Connect the remaining o hmmeter lead to the brown wire in the connector of the ma in harness. 3. With all switches in the RUN positio n. the meter must read resistance (closed). If the meter reads no resistance (ope n), proceed to testi ng Emergency Stop/Throttl e Switch, Carbureto r Safety Switc hes, and Ignition Key Switch .
CARBURETOR SAFETY SWITCHES

I. If the meter read no resistance (open)
iO the previous test, di sconnect the carbureto r safety sw itches one at time and test fo r a closed circuit.
2. Attach the two oh mmeter leads to the two leads comi ng from each carburetor sw itch. T he meter must read resistance (closed). 3. If the meter reads no resist..'lnce (open), the switch mllst either be adjusted or re placed (see Synchronizing Carbureto r Safety Sw itches in this sub-section) . If the meter reads resistance (closed), proceed to testing Ignitio n Key Sw itch.
EMERGENCY STOPI THROTTLE SWITCH

I. If the meter read no resistance (open) in the
IGNITION KEY SWITCH

I. If the meter read resistance (closed) in the previolls test, disconnect the ignitio n key sw itch connecto rs and connect the o hmmete r leads to each of the leads from the sw itch. 2. With the key switch in the OFF IXlsition, the meter must read resistance (closed). If the meter reads no resistance (ope n), replace the switch.
previous test, locate the wiring harness coming from the emergency stop/throttle sw itc h assem bl y. 2. Di sconnect the three-wire connector. Using an o hmmeter, connect one meter lead to the black wire and the other meter lead to the black/red wire in the conncctor. 3. With the emergency sto p knob, located on top of the throttle contro l, in the ON (pulled up) pos ition and the throttle lever compressed, the meter must read resistance (closed). 4. If the metcr reads no resistance (open) and the lever/control ho using free-play is correct , replace the throttle switch. 5. If the meter reads resistance (closed) but the engine will not start , wi th the o hmmeter leads still connected, alternatel y release and compress the throttle lever; then move the e me rgency stop knob down and up.
SYNCHRONIZING CARBURETOR SAFETY SWITCHES

Befo re sync hro ni zing the carbureto r safety switches, check to make certain the carburetor idle speed screws are adjusted equall y and the piston \'ah'es are synchroni zed. The carburetor sa fet y sw itches affect ig niti o n s park at idl e on ly. If ig nition spark problems are observed at partia l o r full-throttl e pos iti ons, the problem is not with the carburetor safety switches.
_NOTE: There must be 0.75-1.5 mm (0.030-0.060 in.) free-play between the throttle lever and the control housing.
Page: 246
5-13
I. Inspect the cable free-play gap bet ween the
throttle lever and the control housi ng at idle. Adjust the throttle cable sw ivel adapter at the top of each carburetor for 0.75- 1.5 mm (0.030-0.060 in. ) cable free-play gap between the throttle lever "nibs" and the control housing . While observing if there is any cable free-play gap, appl y slight pressure to the thronle lever to take up any cable slack that may be prescnt. Howevcr, do not appl y enough pressure to actually raise the carburetor slides during thi s adjustment. Aftcr ca ble free-play is properly adjusted, ti ghten the jam nut on each carburetor securely.
4. If an adjustment is necessary. loosen the switch bracket sc rews, move the sw itch up, ti ghten the screws, and then reset using ste p 3.
NOTE: After completion of any adjustments, throttle lever "side pressure" should not cause an ignition miss at idle. Carburetor switches set too low or an excessively tight throttle cable makes the shutdown system very sensitive to throttle lever " side pressure" near Idle. To test carburetor safety switch synchronization, follow steps 5-9.
\'
, ,
O =~ ~dJ
5. Reconnect the carburctor safcly sw itch conncctors. Place the rc.l r of the snowmobile on a shi clded safety stand; thcn start the cngine and allow it to warm up for 3-4 minutes .
6,
Hold both the top and bottom of the throttle lever pin so thaI depression of the throttle lever does not move the lever pin in its control slot.
Throttle Control Housing
:j~
"
Throttle lever
Gap of 0.75-1.5 mm (0.0300.060 in.) between the Throttle Switch Body and Throttle lever when Safety Switch is set properly
133-081C
2. To determine which switch needs adjusting, discOimect both carburetor sa fety switches from the main wiring harness conncctor.
.... ppl1 OUIW.td _ _ ure to Tntotllo L.".,

~ nd
. ~y
forward
Pin .. ~n tn"mb
~nd ~~~,
mo _ ~t
will "
<_ __Ing
to pn ..... nt
3. COIUlCCt a digital ohmmetcr to one carburetor safety sw itch connector; then compress the throttl e lever while observing the meter reading and measure the gap between the throttle lever and control housing at the moment the meter reading changes from open to closed. Repeat this step for the other carburetor sa fety switch.
NOTE: The correct throttle lever/housing gap should be in a range of 9.5 - 12.7 mm (0.375-0.500 in.) the moment the meter reading changes from open to closed. A switch that changes from open to closed before the other one is the switch that must be raised to attain safety switch synchronization.
Tnroltlo levtI, with tnumb on oU- nond.
0728916
7. Slowly dcpress the throule levcr to increase cnginc R.PM. NOTE: It is very important that engine RPM be allowed to increase slowly, since most engines have a "rich area" at approximately 2500 RPM .
8. Obscrve the tachometcr and the drive clutch to dctermine the momcnt the carburetor safcty switches shut dow n the ignition. Since retaining thc thronle lever pin prevcnts the switch in thc throttle control housing from closing, thc carburctor safcty switches should shut dow n the ignition at or slightl y after clutch engagement. 9. Repeal ste ps 6-8 several times. If ignition shutdow n al ways occ urs at or slightl y after clutch engagemenl, the carburetor safety switches arc synchroni zed,
Gap of 9.512.1 mm (O.375.(}.500 In.) between the Thrott le Switch Body and Throttle Lever when the Safety Switches open and close. 733-082A
514
Page: 247
10. Again, inspect the gap between the throttle lever
A. Defecti ve emergency stop switch

B. Defecti ve safety switch in throttle-control handle
C. Corroded or loose wire con nection at the
and the control housing at idle. Adjust the throttle cable swivel adapter at the top of each carburetor for 0.75- 1.5 mm (0.030-0.060 in.) cable free-play gap between the throttle lever "nibs" and the control housing. While observing if there is any cable free-pl ay gap, appl y sli ght pressure to the throttle lever to take up any cable slack that may be prcscnt. However, do not apply enough pressurc to actually rai se the carburetor slides during this adjustment. Aft er cable frce-pla y is propcrly adjusted , tighten the jam nut on cach carburetor securely.
_ NOTE: After completion of any adjustments, throttle lever "side pressure" should not cause an ignition miss at idle, Carburetor safety switches set too low or an excessively tight throttle cable makes the shutdown system very sensitive to throttle lever "side pressure" near idle.
throttle-control housing or main wiring harness D. Derecti\'e ignition switch

_NOTE : To check these possible causes, proceed to Testing Ignition System, If no spark is present, proceed to Peak Voltage Tests,

(LIC Models)
_NOTE : There must be 0.75-1,5 mm (0.030-0.060 in.) throttle cable free-play between the throttle lever and the control housing.

(LIC Models)

I. Check the wiring connections coming from the ignition key, emergency stop, and carburetor sw itches (on Vlvl-style). The throUle control switch connector is located on the front side of the steeri ng pOSl. Ir any or the connections appear dirty or corroded, clean them with fin e sandlxlper and comprcssed air; then connect all wires and squeeze the connections with a pliers for additional tightness. 2. Disconnect the main wiring harness connector coming from the engine stator assembl y. DiscOimecting thi s connector will bypass the main wiring harness and all switches which will not allow the engi ne to be shut orr without first installing an additional auxili ary ground wirc. 3. h}Selt an auxiliary ground wire into the black wire of the main harness connector on the engine side. To stop the engine once it has been started, touch the auxiliary ground wire to the engine. 4. SUpp0l1 the rear or the snowmobil e up on a shi elded safet y stand ; then set thc brake lever lock. Inspect the complete throttle mechanism to assure that it's working properly. 5. Attempt to start the engine. To stop the engine (if the engine starts), tOllch the auxiliary ground wire installed into the connector to a ground on the engine. If the engine fail s to start, the problem is with the coils mounted on the engine. high tension coil assembl y, or the CDI unit. If the engine st.'uts, the probl cm is with the sw itches, main wiring harness, or throttle cable rrce-play.
When troubleshooting the standa rd " normally open" ignition system, usc the following procedure.
I. Remove the spark plugs and visuall y check their
condition. Replace any fo uled plug. Attach the spark plugs to the high tension leads and ground thcm on thc cylinder heads.
&
CAUTION
Before checking for spark, place all the engine switches in the deactivated position, In the event the engine could be flooded , pull the starter rope (slowly at first) several times to clear the engine of excess fuel.
&
CAUTION
Never crank the engine over without grounding the spark plugs. Damage to coils andlor COl unit may result. _ NOTE: Make sure the ignition switch and the emergency stop switch are in the ON position.
2. Crank the cngine over and check for spark. Ir no spark is present , check to make sure the carburetor throttlc cables are propcrl y tensioned. Compress thc throttle control and wh ile holding the throttle control in this position, crank the enginc o\'cr and check ror spark. If slxlrk is now prescnt , adjust the carburetor throttle cable te nsion. 3. If no spark is present, disconnect the main wiring harness from the e ngine. Crank the engine over. If spark is present, the problem is either one or more or the followin g:
Page: 248
5-15
MAIN HARNESS
Di sconnect the main wiring harness connector coming from the engine stator assembl y. Connect o ne o lunmctcr lead to the vio let wire and the other lead to the browil wire 0 11 the chassis side of the main wiring harness fo ur-wire connector. With all sw itc hes in the RUN lX)siti on, the mete r must read
no resistance (open) ,
CARBURETOR SAFETY SWITCHES (VM.Style)

I. DiscOlUlect both carburetor safety sw itches at the carbureto rs from the main wiring harness. 2. Connect the o hmmeter leads to one of the carbureto r safety sw itches. With the throttle lever in the idle IXlsition, the o hmmeter must read no resistance (open). If the meter reads resistance (closed), adjust the switch (see Synchro nizing OU 'bureto r Safety Switches in this sub-sectio n). Test the remaining sw itch.
2. If the metc r reads resistance (closed), lest the

Ignition Key Sw itch , Throttle Control Sw itch, and C arbureto r Safety Switches independentl y o f each other.
IGNITION KEY SWITCH

I. Di sconnect the ignition key switch connectors;
then connect the ohmmeter leads to each of the
SYNCHRONIZING CARBURETOR SAFETY SWITCHES (VM.Style)

Befo re synchroni zing the carbureto r safety sw itches, check to make certain the carburetor idle speed screws are adjusted equall y and the thrott le va lves a rc sy nchroni zed. The carbureto r sa fety switc hes affect igni tio n spa rk at idl e o ill y. If igniti on spark probl e ms are observed at partial o r full-th rottl e pos iti ons, the problem is not with the carburetor safety switches.
_NOTE : There must be 0.75-1.5 mm (0.030-0.060 in.) free-play between the throttle lever and the control housing.
I. Inspect the cable free-play gap bet ween the
Ignition key switch terminals.
2. With the switch in the OFF positio n, the meter must read less than I ohm resistance. 3. With the switch ill the ON Ix>siti on, the meter must read OL (infinite resistance).

I. Verify that the throttle cable has 0.75- 1.5 mm
(0.030-0.060 in.) free-play between the throttl e lever and control housing. 2. Di sconnect the throttle control sw itch connecto r; then connect one o hmmete r lead to the brow n wire and the other lead to the black/white wire of the emergency sto p switch. 3. With the throttle lever in the idle position and the emergency sto p knob in the up ( RUN) positio n, the meter must read no resistance (ope n). If the meter reads resistance (closed ), replace the switch. 4. With the throttle lever in the idle IXlsition and the eme rgency sto p knob in the dow n (STOP) positio n, the meter must read resistance (closed). If the meter reads no resistance (ope n), re place the sw itch . With the eme rgency sto p knob still in the dow n (STOP) positio n, move the throttle lever to the wide ope n positio n. The meter must read no resistance (open). If the meter reads resistance (closed), replace the switch. 5. Connect o ne o hmmeter lead to the brown wire and the other lead to the vio let wire. With the eme rgency sto p knob in the dow n (STO P) positio n, the meter must read resistance (closed). If the meter reads no resistance (open), re place the sw itch. With the emergency stop kno b in the up (RUN) IXlsition, the meter must read no resistance (ope n). If the meter reads resistance (closed), replace the switch.
throttle lever and the contro l ho using at idle. Adjust the throttle cable swivel acL'lpter at the top of each carburetor for 0.75- 1.5 mm (0.030-0.060 in.) cabl e free-pl ay gap between the throttle lever " nibs"' and the contro l ho using. Whil e observing if there is any cable free-play gap, appl y sli ght pressure to the throttle lever to take up any cabl e slack that may be present. However, do not apply eno ugh press ure to actually rai se the carburetor slides during thi s adjustment. After cable free- play is prope rly adjusted, tighten the jam nut o n each carbureto r secure! y.
\' , ,
;
Ie
_.
1 (0
-.
.
~
Throttle Control I' Housing
"
:, "
..j~
- "'-
~
Lever
733091 C
~ ThroHte
Gap of 0.751.5 mm (0,0300,060 in,) between the Throttle Switch Body and Throttle Lever when Safety Switch is set properly
2. To determine which switch needs adjusting, disconnect both carburetor safety switches from the main wiring harness connecto r.
516
Page: 249
3. Connect a digital ohmmeter to one carburetor safety sw itch connector; the n compress the throttle lever while observi ng the meter reading and measure the gap between the throttle lever and control housing at the moment the meter reading changes from open to closed. Repeat this step for the other carburetor safety switch.
NOTE: The correct throttle lever/housing gap should be in a range of 9.512.7 mm (0.3750.500 in.) the moment the meter reading changes from open to closed. A switch that changes from open to closed before the other one is the switch that must be raised to attain safety switch synchronization.
7. Slowly depress the throttle lever to increase engine R..Pivl.

.NOTE: It is very important that engine RPM be allowed to increase slowly, since most engines have a "rich area" at approximately 2500 RPM.
8. Observe the tachometer and the drive clutch to determine the moment the carburetor safet y switches shut down the ignition. Since retaining the throttle lever pin prevents the sw itch in the throttle control housing from closing, the carburetor safety switches should shut down the ignition at or slightl y after clutch engagement. 9. Repea' ste ps 6-8 seve",1 times. II 'gnlt,on shutdown always occurs at or slightl y after clutch engagement , the carburetor safety sw itches arc synchronized.
10. Again, inspect the gap between the throttle lever
o- - ~
Throttle Sw itch
Boo,
~9.S.12.7
Throttle Lever
mm (.375 . 500 in.)
Gap of 9.512.7 mm (0.375..0.500 in.) between the Throttle Switch Body and Throttle Lever when the safety Switches open and close. 733082A
4. If an adjustment is necessary, loosen (he switch bracket sc rews, move the switch up, ti ghten the screws, and then reset using ste p 3.
NOTE: After completion of any adjustments, throttle lever "side pressure" should not cause an ignition miss at idle. Carburetor switches set too low or an excessively tight throttle cable makes the shutdown system very sensitive to throttle lever "side pressure" near idle. To test carburetor safety switch synchronization, follow steps 5-9.
and the control hOllsing at idle. Adjust the throttle cable swivel adapter at the top of each carburetor for 0.75 1.5 mm (0.030-0.060 in.) cable free. play gap bet ween the throttle lever "nibs" and the control hOllsing. While observing if there is any cable free-pla y gap, apply sli ght pressure to the throttle lever to take up any cable slack that may be present . However, do not appl y enough pressure to actually rai se the carburetor slides during this adjustment. Aft er cable free-play is properl y adjusted, tighten the jam nut on each carburetor secure! y.
NOTE: After completion of any adjustments, throttle lever "side pressure" should not cause an ignition miss at idle. Carburetor safety switches set too low or an excessively tight throttle cable makes the shutdown system very sensitive to throttle lever "side pressure" near idle.
5. Reconnec( the carburetor safety switch connectors. Place the rear of the snowmobile on a shielded safety stand; then slm1 the engine and allow it to warm up for 3-4 minutes. 6. Hold both the top and bottom of the throttle lever pin so that depression of the throltle leve r does not move the lever pin in its control slot.
Thro1:1:le Posi1:ion Sensor

(500/600/700/800/900 cc Models)
NOTE: If a TPS must be replaced on an EFI model, order pIn 3006-939 for "Laydown" engine models or pin 3006-940 for standard engine mod els. NOTE: Ignition timing and fail-safe timing speci fications are located on the Electrical Specifications Chart in this section.
KaOOleb. . Grip
Apply ""tword pMSSu.. 1o Throm.. L.... r 000 Pin ",lito Ift"",b .nd IInge, to p ..... r>t lOY lo ..... rd movem9nt",hlle comt><KIl"ll Throttio Love, voIth thumb on 01lI0, "'00.
0728-916
Page: 250
5-17
DIGITAL 3.0 IGNITION (Carbureted Models)

The advantage o f a 3 -D igniti o n syste m is it actuall y has up to twelve sli ghtl y diffefCnt liming curves which a rc contro ll ed by both throttl e positio n and e ng in e RPM. Thi s system allows the COl to select the timing curve best suited to the o perati ng conditions provi ding both max imum pe rformance and in c reased e ng in e
durability.
I. Remove the carbureto r assembly from the engine compm1ment (see Section 4). 2. Loosen the idle adjustme nt screw until it is not in contact w ith the throttle lever.
W hen checking the ig nitio n timing, a couple points must be remembered. First, since the ignition timing is affected by the throttl e position, the throttle position sensor (TPS) must be in good operati ng conditi oll and adjusted correctly. Second, the ignition timing must be checked according to the Ignition Ti ming S pecificatio ns in thi s section.
&CAUTION
Never remove the drive belt to make the timing check. Always place the rear of the snowmobile on a shielded safety stand and allow the track to rotate freely.
When checking ignitio n timing, it is impol1allt that the timing li ght be connected to the number I spark plug wi re, which is the MAG -side cylinder. If the number 2 cylinder spark plug wire is used, the timing li ght may show a 2 0 erro r in ignition timing when ignition timing is actually correct. For example, the correct ignition timing o n the 500 cc wlAPV is30 2 0 BTOC at 2000 RP~vI . To quickl y c heck T PS o peration , measure the timing according to the c hm1; then di sconnect the TPS wiring and rec heck the timing. A system with a functioning TPS will show a change in the timing. T his is knowll as " Fail-Safe Ignition Timing" and is built into the system to protect the engine should the TPS fail. If this change is no t see n, the TPS ma y have fail ed and must be checked. If the igni ti on timing isn't 300 2 0 at 2000 RPM , the TPS sho uld be checked fo r proper adjustment using the TPS Adjustme nt Tool (pIn 0644-299) and a di g ital voltmeter.
3. De press the throttle lever to raise the throttle val ves (slides); then insert Pin Gauge (pIn 0644345) into the TPS-side carburetor (hro.'lt beneath the val ve. Slow ly release the throule lever allowing the val ve to rest o n the gauge.
NOTE: The pin gauge MUST be installed on the engine side of the carburetor, NOTE: Before using the TPS adjustment tool, verify its battery condition, The battery used in the tool is a 9-volt battery. To check battery condition, use a digital volt/ohmmeter set on DC volt scale, Test between the adjustment tool black and red jacks. Insert the red lead of the digital voltmeter into the red I'ack of the adjustment tool and the black lead 0 the digital voltmeter into the black jack of the adjustment tool, If voltage is found below 4,9 volts, replace the battery.
TESTING TPS (All Models)

For procedures for testing the TPS, see Testing Indi vidual Components in the Bnue ryless EFI sub-sectio n of Section 4.
NOTE: Procedure for testing the TPS is the same on carbureted models and EFI models.
CHECKING TPS (Carbureted Models)

NOTE: On " Laydown" engine models to check the TPS, Test Harness (pIn 0686-959) must be used.
4. Using TPS Adjustment Tool (pIn 0644-299), connect it') wi ring harness to the TPS . Counect the two digital \'o!tmeter leads (red and black) using the two pin jack adapters provided with the adjustment tool to the white and black jacks of the TPS adjustment tool.
518
Page: 251
5. With the throttle in the elosed position (valve resting on the pin gauge), compare the reading on the voltmeter to the chalt. If the reading is at the prescri bed specification, proceed to step 6. If the reading is not at the prescri bed specification, proceed to Adjusting TPS (OHbureted Models) in this sub-section,
Engine 500 cc 700 cc (' Laydown") 900 Idle Position
1.7V 0.SO-0.53V 0.S6V
CHECKING/ADJUSTING TPS (EFI Models)

NOTE: Before using the TPS adjustment tool, verify its battery condition. The battery used in the tool is a 9-volt battery; also, the Test Harness (pin 0686-999) must be plugged into the analyzer for testing voltage.
Wide-Open Position
3.BV+
3.9V+ 3.941-4.370V
cc
6. Hold the throttle in the wide-open position; then compare the reading on the voltmeter to the chmt. If the reading is not within the specification range, recheck the closed position reading. If the closed posilion reading is correct and the wide-ope n position reading is not, the TPS is faulty and must be replaced. 7. If both voltmeter readings are correct , remove the test harness and pin gauge, install the carburetor assembl y (see Section 4), and connect the snow mobile T PS harness to the T PS .
NOTE: Before installing the TPS harness connector, apply dielectric grease to the connector pins.
Using a di gital volt/ohmmeter, set the me te r selector knob on the IX volt scale. Connect the mete r red lead to the red jack of the analyzer. Connect the meter black lead to the anal yzer blac k jack. Connect the T PS test ha rness to the top of the analyzer. The green power li ght on the anaylzer should now be illuminated. Read the batte ry power on the meter. If less tha n 4 ,9 volts, replace the ba ttery.
I. Using Throttle Position Sensor er pS) Adjustment
Tool Kit (pin 3639-89 1), connect its wiring harness to the TPS. Connect the two di gital voltmeter leads (red and black) using the two pin jack adapters prov ided with the adjustme nt tool to the white and black jacks of the TPS adjustment tool. 2. Ensure that the throttle cabl e has the amount of free-play. proper
ADJUSTING TPS
(Carbureted Model s)
3. With the throttle in the idle position, compare the reading on the voltmete r to the ehmt. If the reading is at the prescri bed specification, proceed to step 6. If the re.: 'lding is not at the prescribed speci fi c.ation, proceed to step 4.
Engine
600 cc (STD) 6001700 cc (' Laydown")
I. Using TPS Screwdri ver (pIn 0644-344), loosen the two retaining screws securing the T PS to the carburetor. 2. Adjust the TPS to obtain the correct closed position reading on the voltmete r. 3. Tighten the two retaining screws sec urely. 4 . To verify TPS position is correct, proceed to steps 6 and 7 of Checking TPS (Carbureted Models) in this sub-section,
Idle Position
0.64V 0.69-0.71V 0.69-0.7 1V
Wide-Open Position
3.S7S-3.937V 3 .S7S-3.937V 3.S7S-3.937V
900
NOTE: If the snowmobile is in warranty, breaking the seal on the idle screw jam nut or the Phillips~ head screws on the TPS will void warranty. If the snowmobile is out of warranty, proceed to Step 4.
REPLACING TPS
(Carbureted Model s)
4. Loosen the jam nut securing the idle sc rew. Rotate the idle screw cloc kwise or countercloc kwise to achieve the correct idle position voltage.
Di sconnect the throttle cable from the throttle shaft. 2. Turn the idl e adjustment sc rew counte rclockwise until it is not in contact with the throttl e lever. 3. Di sCOllllcCt the TPS wiring harness connector. Using TPS Screwdriver (pin 0644-344), remove the two retaining screws securing the TPS to the carburetorlthrottle body. 4. Install the new TPS and secure with two retaining screws, nat washers, and lock washers. 5. Adjust the TPS using the appropriate procedures in this sub-secti on.
Page: 252
5. With the idle voltage corrected, hold the idle sc rew in positi on and ti ghte n the idl e screw jam nut ; then compress lever to the wide-ope n position and allow to snap closed several times to verify correct idle voltage.
6. De press the throttle lever slow ly to the wide-open position. T he meter reading should show a smooth ri se in voltage all the way to the wide-ope n throttle position. If you see the voltage to Ix! erratic or doesn't meet the prescribed specification a bove, repeat thi s procedure several times to confirm resul ts.
2005 Arctic Cat Servic e Manual - all models - www.ReadManuals.com
5-19
7. If the wide-open throttle voltage remains erratic or out of specification, replace the thrOllle body assembly.
8. Di sconnect the adjustment tool harness from the
TPS. Connect the snow mobile TPS harness to the newly installed or adj usted TPS. NOTE : Before installing the TPS harness connector, apply dielectric grease to the connector pins,
REPLACING TPS (EFI Models)

NOTE: If the snowmobile is in warranty, the TPS is not a service part; if the snowmobile is out of warranty, proceed to step 1. NOTE: It is important that the throttle shaft is in the completely closed position for this procedure.
I. Di sconnect the throttle cable from the throttle
6. Install the two screws, flat washers, and loc k washers securing the sensor to the throttle body. Do not tighten at thi s time. 7. DiscOIUlect the adjustment tool harness from the TPS . COl1nectthe snowmobile TPS harness to the newl y installed or adj usted TPS . NOTE : Before installing the TPS harness connector, apply dielectric grease to the connector pins , NOTE : To adjust the TPS, proceed to Checking! Adjusting TPS (EFI Models), Step 4.
shaft. 2. Rotate the idle screw countercl ockwise until it no longer conl"acts the throttle shaft stop. T he throttle shaft should now be completely closed. Open the throttle shaft by hand and release it , all owing the shaft to snap closed several times. 3. Disconnect the TPS wi ring harness from the main harness; then noting the position of the TPS, remove the two screws securing the TPS to the throttle body hOllsing and remove the sensor. Accollnt for the O-ring which fit s into groove of throttle body. 4. Apply a light coa t of silicone grease to the area around the outside of the TPS fl ange and into the O-ring groove. Install the O-ring into the groove .
FAlL.SAFE IGNITION TIMING

Engines equipped with throttle position sensor ha ve a prolecLI ve feature called "fa il -sa fe" igniti on liming which prevents engine damage should the T PS fail. If the T PS docs fa il , the engine will run normall y at low RPlvl but wi ll run poorl y at high RPM . Th is wi ll all ow the operator to get the snow mobil e to safet y with littl e or no engi ne damage. NOTE : The engine will continue to operate this way until the TPS is replaced.
Testing Electrical Resistances

(EFI Models)
NOTE : Resistance tests of the engine electrical components should be made using the Fluke Mul timeter only. Analog-style multitesters may not be accurate enough to use in these critical tests. Replace any component that does not have a test value within specifications.
MS399
5. Install the new TPS onto the throttle shaft by aligning the " fl ats" on the throttle shaft cam with the "flat s" on the sensor.
IGNITION COIL (Prin>ary)

I. Disconnect the double wire plug from the ECU to
the ignition coil 2. Set the selector in the X I position.
520
Page: 253
3. Connect the red meter lead to the black/orange lead ; then conncct the black meter lead 10 the orange/black lead.
3. Connect the red meter lead to the black/red wire in the plug ; then connect the black meter lead to the brown/white wire in the plug.
4. Ignition coil primary resistance must be betwecn
0.24-0.36 oh m.
IGNITION COIL (Secondary)
4. Charge coi l ( 1) resistance must be betwcen \3.620.4 oh ms.
CHARGE COIL (2)

I. Disconnect the triple-wire plug from the ECU to
I. R?movc thc spark-plug caps from thc high tension wires. 2. Set the selector in the X 1K position. 3. Connect the red mctcr lead to one high tension wire; then connect the black meter lead to the other high tension wire.
the magneto. 2. Set the selector in the X I position. 3. Connect the rcd meter lead to the brown/white wire In the plug; then connect the black meter lead to the green/red wirc in the plug.
AKOSOD
4. Ignition coil secondary resistance must be betwecn 6800- 10,200 ohms.

CHARGE COIL (1)
I. Di sconnect the triple-wi re plug from the ECU to
4. Charge coil (2) resistance must be between \3.62004 oh ms.

LIGHTING COIL
I. Disconnect the main wi ring harness from the
the magneto. 2. Set the selector in the X I position.
engine. 2. Set the selector in the X I IXlsition. 3. Connect the two meter leads to each of the yellow leads in the connector from the engine.
Page: 254
5-21
2. Rotate the key to the OFF position.

3 . The meter must read less than I o hm resistance between the ignitio n switch terminals.
4. Rotate the key to the RUN positio n.

5. The meter must read O L (infinite resistance).

4. Lighting coi l resistance must be between 0.080.12 ohm.
(370/440 cc Models)

Di sconnect the two timing sensor leads (greenl white and brown) from the ECU.
2 . Set the selector in the XlOO pos iti on~ then connect
NOTE: Resistance tests of the engine electrical components should be made using the Fluke Multimeter only. Analog-style multitesters may not be accurate enough to use in these critical tests. Replace any component that does not have a test value within specifications.
the meter leads to the sensor leads.
IGNITION COIL (Prin>ary)

I. DiscOimect the two con nectors from the COl unit to the ignition coil.
2. Set the selector in the X I positio n.
3. Connect the red meter lead to the orange lead: then
3. Ignition timing sensor resistance mus t be between

152-228 o hms.
SPARK.PLUG CAP
I
R~mo\'e
the spark-plug caps from the high tension
wires.
connect the black meter lead to the black lead.
2. Set the selector in the X 1K position.
3. In turn
011 each cap, touch a tester 1 C<ld to each end o f the sl)';lrk-pl ug cap.
4. Ignition coil primary resistance mllst be between 0.26-0.35 ohm.

4 . Spmk-plug cap resistance must be between 6OClO oh ms.
4(XX)-
I. R?mo\'e the spark-plug caps from the high tension wires.
IGNITION SWITCH
Remove the main wiring harness connecto rs from the ignition switch.
2. Set the selector in the X I K positio n. 3 . Connect the red meter lead to o ne high tensio n wire: the n connect the black meter lead to the other high tension wire.
5-22
Page: 255
AK050D
4. Ignition coil secondary resistance mllst be between 6800- 10,200 ohms.

STATOR COIL (Charge)
4. Lighting coil resistance must be between 0. 170.26 ohm.

SPARK.PLUG CAP
Di sconnect the triple-wire plug from the COl unit to the magneto. 2. Set the selector in the X 100 position. 3. Conncctthc red mete r Icad to the red/white wirc in the plug ; then connect the black meter lead to the black/red wire in the plug.
I. Remove the spark-plug caps from the high tension wi res. 2. Set the selector in the X I K position. 3. In turn on each cap, touch a tester lead to cac h end of thc spark-plug cap.
4. Stator (charge) coil resistance mllst be between 128- 192 ohms.

LIGHTING COIL
4. Spark-plug cap resistance mllst be between 40006000 ohms.

IGNITION SWITCH
Di sconnect the main wi ring harncss from the engme. 2. Setlhe selector in the X 1 position. 3. Conncct thc two meter leads to each of the ycllow lcads in thc conncctor from the enginc.
I. Remove the main wiring harness connectors from the ignition switch. 2. Rotate the key to the OFF position. 3. The meter mllst read less than I ohm resist.'lnce betwccllthc ignition switch terminal s. 4. Rot.'ltc the kcy to the RUN posi tion. 5. The meter must read OL (i nfinite resistance) .
Page: 256
5-23

(500 cc vv/APV)
NOTE: Resistance tests of the engine electrical components should be made using the Fluke Multimeter only. Analog-style multitesters may not be accurate enough to use in these critical tests . Replace any component that does not have a test value within specifications.
IGNITION COIL (Primary)

Disconnect the double wire plug from the COl unit to the ignition coil. 2. Sellhe selector in the X I position. 3. Conncct the red meter lead to the orange/black lead; then con nect the black metcr lead to the black/o range lead .
AK050D
4. Ignition coi l second'lry resistance mllst be between 6800- I 0,2CXJ o hms.
DC POWER COIL
_NOTE : On APV-equipped carbureted models, the traditional charge coil(s) have been replaced by a single DC power coil on the stator.
Disconnect the two plugs (red/yellow and yellowl red) rrom the CDI unit to thc DC lX'lwcr coi l.
2. Set the selcctor in thc X 1 lX'lsition.

3. Connect the red mete r lcad to one wirc; thcn connect the black metcr Icad to the othcr wi rc.
4. IX lX'lwer coil resistance mllst be between 0.7 11.07 ohms.
LIGHTING COIL
I . Disconnect the main W iring harness rrom the
engme. 4. Ignition coil primary resistance must be between 0.27-0.4 1 oh m.

2. Set the selector in the X I lX'lsitio n.

Remove the spark- plug caps from the high tension wires.
3. Connect the two meter leads to each or the yellow lcads in thc connector rrom thc enginc.
2. Set the selector in the X 1K position.
3. Connect the red metcr lead to onc high tcnsion wire; then con nect thc black meter Icad to the other high tension wire.
4. Lighting coil resistance must be between 0. 12-
O. 180hm .

I. Disconnect the two timing sensor leads (green! while and brown/green) rrom the COl unit.
524
2. Set the sclector in the X loo position; then connect the meter leads to the scnsor leads. 3. Ignition timing sensor resistance must be between 148-222 ohms.
2. Set the selector in the X I position. 3 . Connect the red mete r lead to the orange wire in the plug; then connect the black meter lead to the black wire in the plug.
SPARK.PLUG CAP
I. Re move the spark-plug caps from the high tension
wires. 2. Set the selector in the X I K position. 3. In turn 0 11 each cap, touch a tester lead to each end of the spark-plug cap.
4. Ignition coi l primary resistance mllst be between 0.26-0.35 ohm.

I. R?movc the spa rk-plug caps from the high tension
wires. 2. Set the selector in lhe X I K position. 4 . Spark-plug C. .lp resistance must be between 40006000 ohms. 3. Connect the red meter lead to one high tension wire: the n connect the black mete r lead to the othe r high tension wire.
IGNITION SWITCH
I. Re move the main wiring harness connectors from the ignition switch. 2. Rotate the key to the OFF position. 3. The meter must read less than I ohm resistance between the ignit ion switch terminals. 4. Rotate the key to the RUN l:osition. 5. The meter must read OL (infin ite resistance).
- -'A'KOSOD

(550 cc Model) NOTE: Resistance tests of the engine electrical components should be made using the Fluke Multimeter only. Analog-style multitesters may not be accurate enough to use in these critical tests. Replace any component that does not have a test value within specifications.
4. Ignition coil second'lry resistance must be between 6800- 10,200 ohms.
CHARGE COIL (1)

I. Disconnect the triple-wi re plug from the CDI unit
to the magneto. 2. Set the selector in the X 100 position. 3. Connect the red meter lead to the red/white wire in the plug; then connect the black meter lead to the black/white wire in the plug.

I. Disconnect the double wire plug from the COl unit to the ignition coil.
Page: 258
5-25
4. Charge coil ( I) resistance must be between 128192 ohms.

CHARGE COIL (2)
4. Lighting coil resistance must be between 0. 170.26 ohm.

SPARK.PLUG CAP
Di sconnect the triple-wire plug from the COl unit to the magneto. 2. Set the selector in the X 1 position. 3. Conncctthc rcd meter lcad to the black/red wi re in the plug; then connect the black meter lead to the red/whi tc wire in the plug.
1. Remove the spark-plug caps from the high tension wires. 2. Set the selector in the X I K position. 3. In turn on each ca p, touch a tester lead to eac h cnd of thc spark-plug cap.
4. Charge coil (2) resistance must be between 13.620.4 ohms.

LIGHTING COIL
4. Spark-plug cap resistance must be between 40006000 ohms.

IGNITION SWITCH
Di sconnect the main wi ring harness from the engme. 2. Set the selector in the X 1 position. 3. Conncct thc two meter leads to each of the yellow lcads in the conncctor from the enginc.
1. Remove the main wiring harness connectors from the ignition switch. 2. Rotate the key to the OFF position. 3. The mete r must read less than 1 ohm of resist.'lnce betwecn thc ignition switch tcrminals. 4. Rot.'ltc the kcy to the RUN posi tion. 5. The meter must indicate 0 1... (infinite resistance).
526
Page: 259

(900 co Carbureted Models)
4 , Ignition coil second 'try resistance must be between 6800- 10,200 o hms.
DC POWER COIL
NOTE: On APV-equipped carbureted models, the traditional charge coil(s) have been replaced by a single DC power coil on the stator.
I . Disconnect the two plugs (red/yellow and yellowl red) from the C Dlunit to the DC power coil .
NOTE: Resistance tests of the engine electrical components should be made using the Fluke Multimeter only. Analog-style multitesters may not be accurate enough to use in these critical tests . Replace any component that does not have a test value within specifications.
2. Set the selector in the X 1 positio n.

Di sconnect the double wire plug from the C Ol unit to the ignition coil. 2. Sellhe selector in the X I position. 3 . Conncct the red metcr lead to the orange lead; then connect the black meter lead to the black lead.
3. Connect the red meter lead to one wire; thell

connect the black meter lead to the other wi re.
4. DC power coil resistance must be between 0.520 .78 oh m.
LIGHTING COIL
I. Disconnect the main wi ring harness from the engIne.
2. Set the selector in the X I IXlsition. 3. Connect the two meter leads to each of the yellow leads in the connector from the engine.
4 . Ignition coil primary resistance must be between

0.24-0.36 ohm.

I. Remove the spark- plug caps from the high tension w ires.
2 . Sellhe selector in the X 1K position. 3 . Connect the red meter lead to one high tension wire; then connect the black meter lead to the other high tension wire_
4 . Lighting coil resistance must be between 0.080.12 ohm .

I. Disconnect the two timing sensor leads (greenl white and brown) from the CDI unit. 2 . Set the selecto r in the X 100 position; then connect the meter leads to the sensor leads. 3. Ignition timing sensor resistance must be between 148-222 o hms.
SPARK.PLUG CAP
I. Remove the spark-plug caps from the high tension wires.
2. Set the selector in the X 1K position,

AKOSOD
Page: 260
5-27
3. In turn on each cap, touch a tester lead to each end of the spark-plug cap.
4. Ignition coil primary resistance must be between 0. 26-0.35 ohm. 4. Spmk-plug cap resistance must be between 4(XX)6OClO ohms.

I. Re move the spark-plug caps from the high tension wires. 2. Set the selector in the X I K position. 3. Connect the red meter lead to one hi gh tension wire; the n connect the black mete r lead to the othe r high tension wire.
IGNITION SWITCH
Re move the main wiring harness connectors from the ignition switch. 2. Rotate the key to the OFF position. 3. The meter must read less than I ohm resista nce between the ignition switch terminals. 4. Rotate the key to the RUN position. 5. The meter must read OL (infinite resistance).

(500 wlo APV/570 cc Models)
AK050D
4. Ignition coil second. .try resistance must be between 6800- 10,200 ohms.
CHARGE COIL (1)

L Disconnect the three-wire plug from the CDI unit to the magneto. 2. Set the selector in the X I position. 3. Connect the red meter lead to the bl acklred wire in the plug; then connect the black meter lead to the green/red wire in the plug.

I. Di scOllllect the double wire plug from the COl unit to the ignition coil. 2. Set the selector in the X I position. 3. Connect the red mete r lead to the orange wire in the plug; the n connect the black meter lead to the black wire in the plug.
528
Page: 261
2. Set the selector in the X 10 positio n.

3 . Connect the red tester lead to the green/white wire; then connect the black tester lead to the brown wi re. 4. Ignition timing sensor resistancc mus t be betwecn 148-222 o hms.
LIGHTING COIL
1. Disconnect the main wiring harness fro m the cnglnc.
2. Sct thc sclector in the X I position.

4. C harge coil ( 1) resistance must be between 12- 18 o hms.
3. Conncct thc two mctcr lcads to each of the ye11o\\'

lcads in the connector from the engine.
CHARGE COIL (2)

Di sconnect the three-wire plug from the COl unit to the magncto.
2. Set the selector in the X 1 position.
3. Conncct thc rcd mctcr Icad to thc brown/w hitc

wire inlhe plug; thcn conncct thc black mctcr lead to thc grccnlrcd wi rc in the plug.
4. Lighling coil rcsistance must be between 0. 120.180h m.
SPARK.PLUG CAP
1. Remove the spark-plug caps from the high tension wi res.
2. Sct thc selector in thc X I K positio n.

4. C harge coil (2) resistance must be between 12- 18 o hms.
3. In turn on each ca p, touch a tester lead to c."lch cnd

o f thc spark-plug cap.

Di sconnect thc green/w hite and brown wires from the timing sensor to the main harness.
4 . Spark-plug cap resistance mus t be betwccn 40006000 oluns.
Page: 262
5-29
IGNITION SWITCH
Remove the main wi ring harness connectors from the ignitio n switch. 2. Rotate the key to the OFF positio n. 3. The meter must read less than I o hm resistance between the ignition switch terminal s. 4. Rotale the key to the RUN position. 5. The metcr must read OL (infinite resistance).
AK050D

(700 "Laydo,.,n"
Carbureted Models)
4. Ignition coi l second'lry resistance must be between 6800- I0,2CXJ o hms.
DC POWER COIL
_NOTE : On APV-equipped carbureted models, the traditional charge coil(s) have been replaced by a single DC power coil on the stator.
Disconnect the two plugs (red/yellow and yellowl red) from the CDI unit to the DC IXlwer coi l.
2. Set the selector in the X 1 IXlsition.

3. Connect the red mete r lead to one wire~ then connect the black meter lead to the other wi re.
4. DC IXlwer coil resistance must be between 0.7 11.07 ohms.

Di sconnect the double wire plug from the COl unit to the ignition coil. 2. Set the selector ill the X I position. 3. Connect the red meter lead to the o range lead; then connect the black meter lead to the black lead.
LIGHTING COIL
I. Disconnect the main wiring harness from the engme. 2. Set the selector in the X I IXlsitio n. 3. Connect the two meter leads to each of the yellow leads in the connector from the engine.
4. Ign ition coil primary resistance must be between 0.24-0.36 ohm.

Remove the spark- plug caps from the high tension wires. 2. Set the selector in the X I K position. 3. Connect the red meter lead to one high tension wire ~ then connect the black mete r lead to the othe r high tension wire.
530
Page: 263
4. Lighting coil resistance must be between 0 ,080. 12 ohm .

I. Disconnect the two timing sensor leads (green! white and brown/green) from the COL
2. Set the selector in the X IOO position; then connect the meter leads to the sensor leads. 3. Ignition timing sensor resistance mllst be bet wee n 148-222 ohms.
SPARK.PLUG CAP
I. Re move the spark-plug caps from the high tension
NOTE: Test specifications are on the Electrical Specifications (Individual) pages in this section.
This test should be made at the accessory connector of the hood harness.
& WARNING
Most voltages generated by the ignition system are sufficient to interrupt pacemakers! All technicians, especially those using pacemakers, must avoid contact with all electrIcal connections after the engine has been started .
wires. 2. Set the selector in the X I K position. 3. In turn on each cap, touch a tester lead to each end of the spark-plug cap.
I. Connect the red maxiclip and meter lead to the yellow wire in the connector; then connect the black maxiclip and meter lead to the brown wire in the connector. 2. Start the engine and allow it to idle. Mcte r rcading must be within spec ification.
Voltage Regulator Test

(EFI Models)
NOTE: The following test should be made using MaxiClips (pIn 0644-455) and the Fluke Model 73 Multimeter (pin 0644-191) set to the AC Volt scale. .NOTE: Test specifications are on the Electrical Specifications (individual) pages in this section.
4. Spark-plug C. .lp resistance mllst be between 40006000 ohms.
IGNITION SWITCH
I. Re move the main wiring harness connectors from the ignition switch. 2. Rotate the key to the OFF position. 3. The meter mllst read less than I ohm resistance between the ignition switch terminals. 4. Rotate the key to the RUN l:osition. 5. The meter must read OL (infinite resistance) .
& WARNING
Most voltages generated by the ignition system are sufficient to interrupt pacemakers! All technicians, especially those using pacemakers, must avoid contact with all electrical connections after the engine has been started . NOTE: Locate the 2-wire connector at the voltage regulator (Pantera model) or the 3-wire connector at the voltage regulator (other models).
I. Connect the red max iclip and meter lead to the
Voltage Regulator Test

NOTE: The following test should be made using MaxiClips (pin 0644-455) and the Fluke Model 73 Multimeter (pin 0644-191) set to the AC Volt scale.
yellow lead of the connector; then connect the black maxiclip and meter lead to the brown lead of the connector. 2. With the rear of the snowmobile on a shielded safcty stand, run the engine at 2(xx) RPlvl. 3. Metcr reading must be within specifical"ion.
Repeat test three times to confirm results.
Page: 264
5-31
Volt:age Regulat:or (APV) Test:

(EFI Models) NOTE: The following test should be made using
MaxiClips (pin 0644-455) and the Fluke Model 73 Multimeter (pin 0644-191) set to the DC Volt scale. NOTE: Test specifications are on the Electrical Specifications (individual) pages in this section. NOTE: Locate the redlblue and brown leads at
Condenser Test:
(Carbureted APV Models)
NOTE: The following test should be made using MaxiClips (p/n 0644455) and the Fluke Model 73 Multimeter (pin 0644191) set to the DC Volt scale. NOTE: Test specifications are on the Electrical Specifications (individual) pages in this section. NOTE: Locate the leads at the condenser.
the voltage regulator.

L COIUlcct the rcd mux icJip and meter 1 C<ld to the
I. Conncctthe red max iclip and metcr lead to thc red lead ; then conncct the black maxiclip and meter lead to the brown lead. 2. With the rear of the snowmo bile on a shielded safety stand, run the engine at 2cxx) RPM . 3. Metcr reading must be within specifi cal"ion.
NOTE: Repeat test three times to confirm results.
red/ bluc lead; then connect the black maxiclip and meter lead to the brown lead, 2. With the rear of the snowmobile on a shielded safety stand , run engine at 2000 RPM. 3. Meter rcading must be within specification.
NOTE: Repeat this test three times to confirm results.
Servomotor Test: Regulat:or/Rect:ifier Test:

(Carbureted APV Models)
NOTE: A 12volt battery and test leads will be needed for this test. I. Re mo \'c thc scn 'omotor from the snow mobilc.
NOTE: The following test should be made using

MaxiClips (pin 0644455) and the Fluke Model 73 Multimeter (pin 0644191) set to the DC Volt scale. NOTE: Test specifications are on the Electrical Specifications (individual) pages in this section. NOTE: Locate the 4wire connector at the regula tor/rectifier (50onOO cc) or the 2wire connector at the regulator (900 cc).
A CAUTION
Care must be taken not to contact the servo yellow, orange, or blacklwhite terminals, or damage to the potentiometer circuit wilt result.
2. Contact the blacklred servo terminal with the battery positive lead; then co ntact the red/black servo terminal with the battery negati ve lead. 3. The servo sho uld rotate when the negati ve lead contacts the red/black te rminal Note the direction of rotatio n. 4. Re \'crsc thc connections o n the servo terminal s; positi ve lead to red/bl ack a nd negati ve lead to black/red. The servomotor sho uld rol"ate in the o pposite direction. 5. Install the servomoto r.
NOTE: If the servo operates correctly in the above test but fails to operate when connected to the ECUlCDI at the designated RPM, proceed to Potentiometer Test.
Connect the red maxiclip and meter lead to the red/blue lead in the connector (5001700 cc) or to the red lead In the co nnecto r (900 cc); then co nnect the black maxiclip and meter lead to the brown/yellow lead (5001700 cc) or to the brown lead (900 cc). 2. With thc rear of thc snowmobil c on a shieldcd safcty stand, run thc enginc at 2cxx) RPM. 3. Metcr reading mllst be within specification.
NOTE: Repeat test three times to confirm results.
532
Page: 265
Potentiometer Test
_NOTE : The following test should be made using MaxiClips (pin 0644-455) and the Fluke Model 73 Multimeter (pin 0644-191) set to the ohms scale.
I . Remove the servomotor from the snowmobile.
NOTE: Peak Voltage Tests were made with connectors plugged in, spark plugs removed and grounded, and by pulling the recoil starter rope briskly.
& WARNING
Most voltages generated by the ignition system are sufficient to interrupt pacemakers! All technicians, especially those using pacemakers, must avoid contact with all electrical connections when making these tests.
2. Connect the red maxiclip and meter Icad to the black/white servo terminal ; thell connect the black maxiclip and meter Icad to the yell ow servo tcnninai.
3 . Rotate the servo pulley clockwise. The ohms
STATOR (Charge) COIL OUTPUT (370/440 ee) I. Connect the red meter lead to the red/whi te wire from the stato r; then connect the black meter lead to the blac k/red wire from the stator. 2. Pull the recoil stmter rope briskly. Metcr reading must be within spec ification. LIGHTING COIL OUTPUT I. Connect the red mcter lead to o ne yellow wi re; then connect the black mcter lead to the othcr yellow wire. 2. Pull the recoil stmtcr rope briskly. Meter reading must be within specification. CHARGE COIL (1) OUTPUT (570 ee) I. Connect the red metcr lead to thc black/red wirc; then connect the black metcr lead to the green/red wire.
should increase as the pulley is rolated until it

reaches 4700-5000 o hms.
4. Continue the pulley rotation , and there wi ll be a small area in the rotation at which the o hm reading will disappear; then it will return agai n. 5. Continue the pulley rotation , and the ohms sho uld appear at a very low value but will again increase to 4700 o hms. Thi s is no rmal o peration. 6. Install the servomotor.
NOTE: If the servo operates correctly and the potentiometer test is correct but fails to operate when connected to the ECUlCDI at the designated RPM, replace the ECUlCDI.
Peak Voltage Tests

(Fan Cooled Models) NOTE: The following tests should be made using the Fluke Model 73 Multimeter (pin 0644191) set to the DC Volt scale with Peak Voltage Reading
Adapter (pin 0644-307)_
2. Pull the recoil starter rope briskly. Meter reading must be within spcci fication. CHARGE COIL (2) OUTPUT (570 ee) I. Connect thc rcd mcter lead to the brown/white wi re; the n conncct the black mcter lead to the green/red wire. 2. Pull the recoil startcr rope briskly. Meter reading must be within spcc ifi cation. PRIMARY COIL OUTPUT I. Connect the rcd mcter lead to the orange wi re; then connect the black metcr lead to the black wire. 2. Pull the recoil starter rope briskly. Meter reading must be within specification.
NOTE: Peak voltage test specifications are on the Electrical Specifications (Individual) pages in this section.
The Fluke Multimeter wi Adapter can perform the fol lowing tests. A. StatorlCharge Coil(s) Output 8. Lighting Coil O utput
C. Primary Coil O utput
Page: 266
5-33
Peak Voltage Tests

(700/900 cc Carbureted Models)
NOTE: The following tests should be made using the Fluke Model 73 Multimeter (pin 0644-191) set to
I. Attach the red maxiclip to the yellow/red lead ; then attach the black maxiclip to the red/yellow lead. 2. Connect the red mete r lead to the red maxiclip; then connect the black mete r lead to the black maxiclip. 3. With the rear of the snowmobi le on a shie lded safety stand. run the engine at 2000 RPM , 4. ivleter reading must be within specification. PRIMARY COIL OUTPUT
I. Connect the red meter lead to the orange wi re;
the DC Volt scale with Peak Voltage Reading Adapter (pin 0644-307). For " engine running" test, use Maxielips (pin 0644-455). NOTE: Peak voltage test specifications are on
the Electrical Specifications (Individual) pages in
this section.
The Fluke M ultimeter wi A dapter can perform the following tests.
then connect the black meter lead to the black wire. 2. Pull the recoil stmter rope briskly. Ivleter reading must be within spec ification. IGNITION TIMING SENSOR I. Connect the red meter lead to the green/white wire; the n connect the black meter lead to the brown/green wire (700 cc) or brown wire (900 cc), 2. Pull the recoil starter rope briskly. Meter reading must be within specification. LIGHTING COIL OUTPUT
A. DC Power Coil O utput B. Primary Co il O utput
C. Ignition Timing Sensor

D. Lighting Coil O utput
NOTE: Peak Voltage Tests (unless otherwise
indicated) were made with connectors plugged in, spark plugs removed and grounded, and by pulling the recoil starter rope briskly.
WARNING
Most voltages generated by the ignition system are sufficient to interrupt pacemakers! All techni cians, especially those using pacemakers, must avoid contact with all electrical connections after the engine has been started.
I. Connect the red meter lead to o ne yellow wife; then connect the black meter lead to the other yellow wire. 2, Pull the recoil stmter rope briskly. Meter reading must be within specification.
DC POWER COIL OUTPUT (Static) I. Connect the red meter lead to the red/yellow wire from the stato r; then connect the black meter lead to the yellow/red wire from the stato r. 2. Pull the recoil starter rope bri skl y, Meter reading must be within specifi catio n. DC POWER COIL OUTPUT ( @ 2000 RPM)
NOTE: Locate the 4wire connector attached to the regulator/rectifier.
Peak Voltage Tests

(550 cc Modell
NOTE: The following tests should be made using the Fluke Model 73 Multimeter (pin 0644191) set to the DC Volt scale with Peak Voltage Reading
Adapter (pin 0644-307)_

NOTE: Peak voltage test specifications are on the Electrical Specifications (Individual) pages in this section .
534
Page: 267
The Fluke M ultimeter wi Adapter ca n perform the fol lowing tests. A. C harge Coil (I ) O utput B. C harge Coil (2) O utput
Peak Voltage Tests

(500 co vv/APV Models) NOTE: The following tests should be made using the Fluke Model 73 Multimeter (pin 0644-191) set to the DC Volts scale with Peak Voltage Reading Adapter (pin 0644-307). For "engine running" test, use MaxiClips (pin 0644-455) . NOTE: Peak voltage test specifications are on the Electrical Specifications (Individual) pages in this section .
The Fluke M ultimeter wI Adapter can perform the fol low ing tests. A. DC Power Coil O utput B. Primary Coil O utput
C. Lighling Coil O utput

D. Primary Coil O utput
NOTE: Peak Voltage Tests were made with connectors plugged in, spark plugs removed and grounded, and by pulling the recoil starter rope briskly.
WARNING
Most voltages generated by the ignition system are sufficient to interrupt pacemakers] All technicians, especially those using pacemakers, must avoid contact with all electrical connections after the engine has been started.
C. Ignition Timing Sensor

D. Lighting Coil O utput
CHARGE COIL (1) OUTPUT

Connect the red meter lead to the red/white wire; then connect the black meie r lead to the blaclJ white wi re . 2. Pull the recoil starte r rope bris kly. Meter reading must be within specificatio n.
NOTE: Peak Voltage Tests (unless otherwise indicated) were made with connectors plugged in, spark plugs removed and grounded , and by pulling the recoil starter rope briskly.

Connect the red mete r lead to the blackJ red wi re; then connect the black meter lead to the red/while wire. 2. Pull the recoil starter rope bris kly. Meter reading must be within specificalio n.
WARNING
Most voltages generated by the ignition system are sufficient to interrupt pacemakers! All technicians, especially those using pacemakers, must avoid contact with all electrical connections after the engine has been started.
DC POWER COIL OUTPUT (Static)

I. Connect the red meter lead to the red/yellow wire from the stato r; then connect the black meter 1 C<ld to the yellow/red wi re from the stator. 2. Pull the recoil starter rope bris kly. Meter rcading must be within s pec ifi cation.
LIGHTING COIL OUTPUT

I. Connect the red meter lead to one yellow wa c; then connect the black meter lead to the other yellow wire. 2. Pull the recoil starter rope bris kly. wleter reading must be within speci ficati o n.
DC POWER COIL OUTPUT ( @ 2000RPM)

NOTE: Locate the 4~wire connector attached to the regulator/rectifier.
I. Attach the red max icli p to the yell owlred lead ; thell attach the black maxicli p to the red/yellow lead.
PRIMARY COIL OUTPUT

I. Connect the red meter lead to the orange wIre; then connect the black meter lead to the black wIre.
2. Pull the recoil starter rope bri s kl y. Meter reading must be within speci fi catio n.
2 . Connect the red meter lead to the red maxiclip; then connect the black mete r lead to the black maxiclip. 3 . With the rear o f the snowmobi le 011 a shielded safety stand, rUll the engi ne at 2000 RPM . 4 . Meter reading must be within s peci fi cation.
5-35
PRIMARY COIL OUTPUT

Connect the red meie r lead to the orange/black wire; then COimect the black meter lead to the black/o range wire. 2. Pull the recoil starte r ro pe briskly. Meter reading must be within spe cificatio n.

I. Connect the red meter 1 e.: 1d to the black/red wire: then connect the black mctcr lead to the grcenlred wire. 2. Pull the recoil starter rope briskl y. Meter reading must be within spec ifi cation.

I. Connect the red meter lead to the grecn/white wire; then connect the black mete r lead to the brown/green wire. 2. Pull the recoil starte r rope briskly. wlele r reading must be within specificatio n.

I. Connect the red mcter lead to the brown/white wire; thc n connect the black metc r lead to the grecnlred wire. 2. Pull the recoil startcr rope briskly. Mctcr reading must be within specification.

I. Connect the red meter lead to olle yellow WIfe; thell connect the black meter lead to the other yellow wire. 2. Pull the recoil stmte r rope briskly. Mete r rcading must be within spe cificatio n.

I. Connect thc red meter lead to o nc yell ow wire;
then connect the black meter lead to thc othcr yellow wire. 2. Pull the recoil stmter rope briskly. Ivleter reading mllst be within specification.
PRIMARY COIL OUTPUT
Peak Voltage Tests

(500 cc vv/a APV Models)
NOTE: The following tests should be made using the Fluke Model 73 Multimeter (pin 0644-191) set to the DC Volt scale with Peak Voltage Reading Adapter (pin 0644-307). NOTE: Peak voltage test specifications are on the Electrical Specifications (Individual) pages in this section.
I. Connect the red meter lead to the orange wire;
then connect the black mete r lead to the black wire. 2. Pull the reco il starter rope briskly. Meter reading mllst be within specification.

I. Connect the red meter lead to thc grecn/white wire; thc n connect thc bl ack mete r lead to the brown wire. 2. Pull the reco il stmter rope briskly. Meter reading must be within specification.
The Fluke Multimete r wi Adapter can pe rfo rm the fo llowing tests.

A. C harge Coil (I ) O utput
B. C harge Coil (2) O utput

C. Li ghting Coil O utput
Peak Voltage Tests

(EFI Models)
NOTE: The following tests should be made using the Fluke Model 73 Multimeter (pin 0644-191) set to the DC Volt scale with Peak Voltage Reading Adapter (pin 0644307). For " engine running" test, use Maxielips (pin 0644455). NOTE: Peak voltage test specifications are on the Electrical Specifications (Individual) pages in this section .
D. Primary Coil O utput E. Ignition Timing Sensor

NOTE: Peak Voltage Tests (unless otherwise indicated) were made with connectors plugged in, spark plugs removed and grounded, and by pulling the recoil starter rope briskly.
WARNING
Most voltages generated by the ignition system are sufficient to interrupt pacemakers! All technicians, especially those using pacemakers, must avoid contact with all electrical connections after the engine has been started. 5-36 Page: 269
T he Fluke tv lultim e te r w/Adapte r ca n pe rfo rm th e fo llowing output tcsts. A. Fucl Pump Coil B. Injector Coil
2005 Arctic Cat Service Manuat - all modets - www.ReadManuats.com
C. Charge Coil ( I) Output
2. Pull the recoil starter rope briskl y. Meter reading must be within specification.
LIGHTING COIL OUTPUT (Static)
O. C harge Coil (2) Output E. Ignition Timing Sensor

F. Primary Coil Output
G. Lighting Coil Outp ut NOTE: Peak Voltage Tests (unless otherwise indicated) were made with connectors plugged in, spark plugs removed and grounded , and by pulling the recoil starter rope briskly.
I. Connect the red meter lead to one yellow wI re;
then connect the black meter \cad to the other yellow wire. 2. Pull the recoil stmter rope briskly. Meter reading must be within spec ification.
LIGHTING COIL OUTPUT ( @ 2000RPM)
NOTE: On the Pantera model, locate the two yellow leads in the 3-wire connector from the engine; on the other models, locate the yellow and brown leads from the stator.
I. Attach the red maxiclip 1 0 the yell ow 1 C<ld; the n
it WARNING
Most voltages generated by the ignition system are sufficient to interrupt pacemakers! All technicians, especially those using pacemakers, must avoid contact with all electrical connections after the eng ine has been started.
FUEL PUMP COIL

I. Test between the two
oralH~e/w hit e
attach the black maxiclip to the other yellow lead (Panle ra model) or to the brown lead (other model s). 2. Connect the red mete r lead to the red maxicli p; then connect the black mete r lead to the black max iclip. 3. With the rear of the snowmobile on a shielded safety stand, run the engine at 2000 RPM . 4. Meter reading must be wi thin specification.
wi res in the
four- prong con nector from the stator. 2. Pull the recoil stmte r rope briskly. Mcter rcading must be within specification.
INJECTOR COIL
I. Test between the two blue/white leads in the connector harness from the slator plate. 2. Pull the recoil stmte r rope briskly. Mete r reading must be within speci fi cation.
Testing Lovv-Oil Light Sensor

T he low-oil light scnsor is a magnctic switch. Its operation is ba sed on a magne t located a ro und the in side di ameter of a 11 2 in. hole in a plastic fl oat. The sw itch located in the ste m of the sending unit is positioned through the hole in the fl oat. Whe n the fl oat drops to the lower part of the ste m, the magnet closes the el ectrica l contacts (located in the stem) allow ing the c urrent to pass on to the warning li ght. If the sensor should fail, it must be replaced. To test the sensor, use the follow ing proccdure.
I. Remove the sensor from the oil reservoir by
I. Test between the brown/white and blacklred wires in the triple-plug con nector from the stator. 2. Pull the recoil starter rope briskly. Mcter reading must be within specificat ion.
I. Test between the grcenlred and brown/white wires in the triple-plug connector from the stator. 2. Pull the recoil stmter rope briskly. Ivlete r reading must be within specification.
I. Test between the green/while and brow n wires in
twisting and pulling upwards. Wipe excess oil fro m the sensor. 2, Unplug the sensor from the wiring harness. 3. Using an ohmmeter, set the selector on the X I K position. 4. Touc h each of the meter leads to one of the two wires comi ng from the sensor. With the sensor in its normal IXlsition (fl oat end dow n) , the meter should read resistance.
5-37
the connector from the sensor. 2. Pull the recoil stmte r rope briskly. Mcte r rcading must be within specification.
PRIMARY COIL OUTPUT
Connect the red meter lead to the black/orange wire; then connect the black mcter lead to the orange/black wirc.
Page: 270
5. If the meter reads no resistance, check to make sure good contact has been made with each of the wires coming from the sensor. If the meter still reads no resistance. replace the sensor. 6. While maintaining contact between the meter leads and the sensor, raise the fl oat. The meter must rC<ld no resistance. If the meter reads resistance, re place the sensor. 7. If the sensor tested out satisfactory but the light doesn't illuminate with onl y a small amount of oil in the reservoir, check the bulb.
8. If the bulb is in good condition, check for voltage
3. If the hi gh temJX:rature warning li ght is illuminated with the engine running (and harness terminal grounded), test the li ght bulb. ohmmeter must read less than 10 ohms across bulb filament.
not the An the
4. If the bulb docs not illuminate even when tested good, usc the ohmmeter to test the bul b harness. Also test the red/white wire conti nuity from the temperature sensor connector to the bulb connector.
at the connection where the sensor plugs into the accessory wiring harness. Using a multimeter set on the 50 ACV sca le, stm1 the engine and all ow it to idl e. Touch the red lead of the voltmeter to the red wire in the two-prong connector. Touch the black lead to the black wire in the wiri ng harness. At idle, the meter should read 5 to 6 volts (AC). If no voltage is present but the lights on the snow mobile operate normall y, either chec k the wiri ng harness for a broken wire or replace the harness.
Testing Fuel Gauge

I. Disconnect the fuel ga uge from the hood wiring harness. 2. Connect the posili ve lead of a 12-volt power supply to the yellow wire and the negati ve lead of the 12-volt power suppl y to the brown wire. 3. The fuel gauge needle should peg in the negati ve (empty) direction, 4. With the fuel gauge sti ll connected to the 12-volt power supply (from ste p 2), install a JumJX:r wire (such as a pape r clip) between the brown wire and the gray wire. 5. The fuel ga uge needle should peg in the positi ve (full ) direction.
NOTE: A fuel gauge failing these testing procedures is defective and must be replaced.
Testing High Temperature Sensor

Di sconnect the main wiring harness connector from the temperature sensor. 2. Connect an ohmmeter between the sensor terminal and any convenient chassis ground (or any brown wire). T he ohmmeter must read less than 20 olmls of resistance with the water temperature more than +230o E The ohmmeter must read no resistance with the water temperature less than + 1900 E
NOTE: It may be easier to remove the sensor from the water manifold for testing purposes. Immerse the sensor body (only up to the threads) in automatic transmission fluid and slowly heat the fluid. The ohmmeter must indicate the above resistances when connected between the sensor terminal and the sensor body/chassis.
Testing Fuel Gauge Sender

I. Remo\'e the hardware securing the console to the fuel tank and fram e; then mo\'e the console out of the way. 2. Disconnect the fuel gauge sender unit (black twowire connector) from the main wiring harness. 3. Connect the ohmmeter leads to the two sender wires. 4. Compare the reading to the chart followi ng.
Fuel Gauge Sender Position
Ohms
Testing High Temperature Warning Light

I. Disconnect the main wiring harness connector
from the temperature sensor. 2. Temporaril y place a jumper wire fro m the main wiring harness sensor connector to any convenient chassis ground (or any brown wire).
538
Page: 271
Full
4-6
37.6-56.4 76-1 t4
112
Empty
Testing Electric Fuel Pump

I. Rcmo\'c the hardware securing the console to the
gas tank and fram e; then move the console out of the way.
4. A loud , audible " click" should be heard as the soleno id internal contacts release.
_NOTE : An in-line ammeter would measure between 2 and 4 amps of solenoid coil current flow with the battery connected.
& CAUTION
NEVER connect an in-line ammeter with the large starter cables because the 200 amps of current flow will instantly damage most ammeters.
2. Disconnect the
fuel pump (w hite two-wire
connector on standard EFI models or the black
two-wire connector on the F-chassis EFI models) from the main wi ring halllcss. 3. Connect the positi ve lead of a Il-volt power suppl y to the red wi re and the negati ve lead of the 12-voll power supply to the black wire.
4. The pllmp should operate (it would be heard funning).
Charging Diode
(Electric Start Models)
TESTING I. Disconnect the electric stal1 harness from the main wiring harness.
NOTE: If the fuel pump fails to operate, the pump is defective and must be replaced.
& CAUTION
Solenoid
TESTING
NOTE: The electric start solenoid may be tested
To prevent ohmmeter damage when testing circuits on snowmobiles equipped with an electric start, be sure to disconnect the battery before testing.
using either one of the following methods.
2. Connect the o hmmeter positive lead (red) to the diode yellow wi re a nd the oh mmeter negative lead (bl ack) to the diode red wire. The ohmmeter must read between 300 and 700 o hms. 3. Connect the o hmmeter positi ve lead (red) to the diode red wire and the o hmmeter negative lead (black) to the diode yellow wire. The ohmmeter must read OPEN (infinite resist..nce).
Method #1
I. DiscOllllcct the electric slm1 harness from the main wiring harness. 2. Place the ohmmeter leads across the soleno id coi l terminals (brown wire and red/white wire). 3. The o hmmeter must read bet ween 3 and 5 ohms.
Fuse
TESTING I. Remove the fuse from the fuse holder. 2. Connect the ohmmeter across the fuse end-caps. 3. The ohmmeter must read less than I ohm of resistance.
Method #2
I. Connect the battcry to the sole noid coil terminals (brow n wi re and red/white wire). 2. A lo ud , audible " click" should be heard as the solenoid internal contacts make connection. 3. Disconnect the battery fro m the solenoid.
Page: 272
5-39
2. Remove the expansion chamocr.
Ignition Svvitch Electric Start Function

3 . Remove the nut and washer(s) securing the positi ve cable; then remove cable from the starter motor. 4. Remo\'e the dri ve clutch.
TESTING
& CAUTION
To prevent ohmmeter damage when testing circuits on snowmobiles equipped with an electric start, be sure to disconnect the battery before testing.
5. Remo\'e the hardware securing the stm1er motor and end plate/drive cap assembly to the bracket; then remove the starter motor assembl y.
REMOVING (570 cc/Pantera Models)

I. DiscOimect the tmltery.
NOTE: On certain models, it may be necessary to remove the expansion chamber.
I. Disconnect the wifing harness fro m the ignition switch; then remove the sw itch from the console.
2. Using the ohmmeter, test the connections
indicated in the following chart. If the meter does not read as specified or has morc than o ne ohm of resistance. the switch must be replaced.
Position
OFF ON ON
START
2. Remove the nut and washer(s) securing the positi ve cable; then remove cable from the starter motor. 3. Loosen the two Allen-head screws securing the flex-dri ve shaft to the pinio n dri\'e; then remove the hardware securing the starter motor to the bracket. Remo\'c the starter motor assembly.
Lead to
Lead to
Terminal
Terminal
Meter Reading
-M -M
B
+M +M
A
CLOSED OPEN
REMOVING lAWS VI Models)

I. DiscOimect the baltery. 2. Remove the nut and washer(s) sec uring the positi\'e cable; then remove cable from the starter motor. 3 . Remove the lock nut securing the upper mounting bracket to the steering suppo rt ; then remove the two lock nuts securing the starter motor to the lower bracket and remove the starter motor assembly. 4. Loosen the two Allen-head screws securing the fl ex -drivc shaft to the pinio n dri\'e; then remove the lock nuts securing the lower mounting bracket and removc the bracket.
CLOSED
OPEN
-M
B
+M
S
START
CLOSED
Electric Start Key Switch

B
-M
o
+M
0000-126
DISASSEMBLING
NOTE: For assembly purposes, scribe a reference line on the end plate/drive cap, commutator cap, and the case.
NOTE: Some ignition-switch terminals may not

be labeled (-M, +M, A, e, or $). Refer to the wiring
harness diagram of the ignition switch when connecting the ohmmeter.
I. If applicable, remove the snap ring securing the primary gear to the stm1er motor; then re move the gear and account for the spring washer.
Starter Motor
REMOVING 1370/440 cc Models)
I Di sconnect the battery.
2. Remove the two long through-bolts. As the bolts are being removed, hold pressure against the commutator cap.
5-40
Page: 273
AI028
3. Slowly remove the cap and account for the four brush holder springs.
6. Lift all brushes from the brush holder and account for the fou r brush springs. 7. Using a 5116-iu. socket, remove the two cap screws securing the ground brushes to the commutator ca p. Remove the brushes and brush holder from the ca p.
AI026
4. Using a plastic hammer, tap the end plate/drive cap free of the stm1er case and slide the cap free from the armature shaft. Account for any washers. 8. Using a 7/ 16-in. wrench , remove the nut securing the cable stud to the cap. Account for the number of and the position of washers.
AI027
5. Slide the armature free of the starter case.
AI037
9. While holding the brush wires, pull the stud from the end cap. Account for the plastic insulator.
Page: 274
541
I . Thoroughly clean all components except the armature and brus hes in parL,> -cleaning sol vent ; then dry wi th compressed air.
5. Inspect the commutator cap bushing for wear. Using a calipe rs, measure inne r diameter at the cap bus hing. If found to be 8.6 mm (0.338 in.) or larger, replace the cap.
AI031
AI029
6. Inspect the end plate/drive cap bus hing for wear. Using a calipers, measure the inner diameter o f the ca p bushing. If fo und to be 13. 2 mm (0.523 in.) or larger, replace the cap.
,&, CAUTION
00 not wash the armature and brushes in any kind of solvent. Use only compressed air and clean dry cloth in cleaning these components .
2. Inspect all threaded areas fo r damaged o r stripped threads.
3. Inspect the brus h ho lde r assembly and brushes for

damage or wear. Using a ca lipe rs, measure the length o f the brushes. If brus h meas urement is less than 7.5 mm (0.30 in.), replace brushes as a set along with new brus h s prings. 7. Inspect the brass comm utator end o f the armature for any burned spoL'> o r damage. If the commutator is slightly burned or damaged, the armature must be replaced. This is a molded commutator and no allemptto turn it down in a lathe sho uld be tried.
,&, CAUTION
00 not use emery cloth to clean the commutator as emery particles will become imbedded in the brass commutator resulting in a short circuit. Use only HOO grit sandpaper.
8. Inspect the commutator for buildup in the grooves. Buildup in the grooves must be re moved to prevent any chance of arcing between indi vidua l sections of the commutator. Carefull y remove any buildup lIsing a thinly ground hacksa w blade. Do not cut any deeper than the o riginal groove which ca n be seen by looking at the commuta tor from the side.
4. Inspect brush leads for cracks, wear, o r fra ying. If
any o f these conditions exist, re place the brushes as a set al ong wit h new brush springs.
542
Page: 275
NOTE: After cleaning any buildup from the commutator, use compressed air to clean.
0725-653
9. Inspect the armature for shorting. Use the multitester and the foll owing procedure:
A. Set the selector on the X I K positi on; then touch
11 . Inspect the ground brushes to make sure they are properl y grounded. Use the multi tester and the following procedure:
A. Set the selector on the X 1K position; then touch
the leads and zero the meter. B. Touch the black teste r lead to the armature shaft.
C. Using the red tester lead, probe the commutator
the leads and zero the meter.
B. Touch the black tester lead to a ground brush.

C. Touch the red teste r lead to the commutator
e nd of the armature. The meter indicator should not move. If the indicator needl e moves, the a rmature must be re placed.
ca p. The meter needle should move to the ri ght. If the needle docs not move to the ri ght, check that the ground connection is ti ght and clean. Recheck for prope r ground. If there still isn't any meter needle moveme nt, replace the brushes as a set along with new brush springs.
AI034
10. Inspect the armature for shorting. Use a " O"rowler" and the followin g procedure: e A. Place the armature in the "grow ler. " B. While holding a metal strip over the armature, rotate the armature an entire revolution. If the metal strip vibrates at any point on the armature, the armature is sh0l1ed and must be replaced.
ASSEMBLING
1. Install the stud with the positi ve brush set attached in the commutator cap. Make sure the insulator is in position over the stud and the 1 0nO"est brush lead is positioned to the right of the stud 1101 e.
Page: 276
543
AI040
,&, CAUTION
Check the stud to make sure insulator is between stud and cap on backside.
2. In order fro m disassembling, place the washers 011 the stud. Appl y a small amo unt o f red Loctite /1-271 to the stud threads and secure with the nul. Tighten to 0.7 kg-m (5 rt-Ib).
6. Place the four brush springs into the brus h holder and place each brus h (flat side dow n) on top o f the springs. NOTE: Apply a small amount of low-temperature grease to the cap bushings. 7, Place a wave washer and a thrust washer o n the armature shaft : then slide the front cap iOto position.
8. Apply a thin CUt 'lt of grease to the armature shaft and slide the dri ve gear and s pring washer onto the shaft. Secure with a snap ring.
9. Start the commutator end of the a rmature assembly into the starter case at the end with the field s nearest the end of the housing. Ali gn the marks on the front cap and case.
AI039
3 . Place the brush ho lde r into IXlsitioll ill the

commutator cap.
NOTE: Position the longest positive brush lead beneath the ground wire on rig ht side.
4. Place a cap screw through the left ground brush

lead eyelet and position the eyelet flat against the
brush holder. Sec ure w ith a cap screw.
S. Place the right gro und brus h eyelet flat against the brus h ho lder and secure with a cap screw, The eyelet stem must be positioned to the top of the threaded hole boss in the com mutator cap.
10 . Compress the four brushes ( fl at side dow n) into the brush ho lde r. Hold the brushes in lXlsition using the Sl'arter Assembl y 'IOaI (pin 0644-052).
544
Page: 277
CLEANING AND INSPECTING PINION

_NOTE : Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary.
I. Using parts-cleaning solvent , wash grease from the pinion gear. Dry with compressed air.
11. Carefull y place the stmter case and armature assembly into the commutator cap. Again , check to make sure the scri bed marks of these two components are ali gned. With the case nat on the assembly tool, slow ly pull the tool from the starter motor. The case should then drop into place.
2. Inspect the pinion gear for wear. If the gear is worn or chipped, replace the pinion assembl y. 3.
In s l~ct the inner gear and housing. If the gear shows any signs of wea r, repl ace the pinion assembly. In s l~ct the inner housing for tightness and cracks. If the housing shows any signs of being loose or cracked, re place the pinion assembl y.
4.
5. Inspect the pinion return spring for wear. If the spring shows any worn areas, re place the spring.
ASSEMBLING/INSTALLING PINION
I. Slide the pinion gear, spring retainer, pinion spring , and snap-ring retainer (note end-for-end orientation) onto the shaft in their original positions.
AI044
12. Appl y red Loctite #27 1 to the threads of the two through-bollS: then IOstall and secure the bolts. Tighten to 1-1.4 kg-m (7-10 ft -Jb).
NOTE: The starter shouldn 't be picked up until the two throughbolts have been secured. Spring pressure from the brush springs will push the commutator cap off the case.
2. Place new Snap Ring (pin 0645-384) over the end of the pinion shaft ; then slide the snap ring over the shaft. Using a 11 mm or 7116 in. socket and a hammer, gently tap the snap ring into the groove on the shaft. 3. Apply Pinion Grease (pIn 10.56-072) over the pinion spring area. 4. Slide the dust cover over the pillion assembl y being careful not to dislodge the grease. Firmly push the dust cover until it snaps into its retaining groove.
DISASSEMBLING PINION
I. Remove the dust cap from the end of the pinion drive by fi rst pulling straight out and then twisting the dust cap to the side. 2. Place a II mm or a 7116 in . soc ket over the end of the pinion shaft and t.'lp the socket gently with a hammer.
NOTE: This procedure will dislodge the snapring retainer and expose the snap ring.
TESTING STARTER MOTOR

_NOTE : Before installing the starter motor, per form test to ensure proper operation using the following procedure.
1. Attach a black jumper cable to a good ground on the starter. 2. Attach the opposite end of the black juml~ r cable to the negative post of a good 12V battery. 3 . Attach the red jumper cable to the positive post of the baltery. 4. Holding the starter firml y down 011 a work bench, touch the red juml~ r cable to the positi ve cable stud of the starter.
545
3. Using a side culler, diagonal cutter, or suitable pliers, remove and discard the snap ring. 4. Remove the snap-ring retainer (note end-for-end ori entation), pinion spring, spring retainer, and pinion gear. Retain all components.
Page: 278
WARNING
INSTALLING (AWS VI Models)

I. Place the lower mounting bracket into position and secure with the loc k nuts. 2. Install the Oex-drive shan onto the starter motor and secure with the two Alle n-head screws . 3. Place the starter motor into the uppe r bracket; then secure with existing ha rdwa re. Tighte n securely. 4. Attach the red positi ve cabe to the positi ve stud te rminal a nd secure with a nut and washers. While tightening the Ollst, hold the cable in position so it is parallel with the stalter.
Be sure to keep clear of the pinion gear area as it will spin at a high RPM when the red cable is touched to the positive stud. Personal injury may result if contact is made with a spinning pinion.
NOTE: Starter motor must instantly spin at a high RPM. The pinion must snap out against the stopper. If the motor does not spin, remove the red cable immediately. Check the battery condition and all connections. If everything checks out satisfactorily and the starter does not spin , disassemble the motor and check for pinched or broken wires.
INSTALLING (370/440 cc Models)

Place the starter molor into the bracket ; then
CAUTION
secure with existing hardware. Tighten to 1.7-2. 1

kg-m (12- 15 ft-Ib).
Check the cable installation to make sure it isn 't near any moving parts or against any sharp edges.
2. Attach the red posili ve ca ble to the positi ve stud terminal and secure with a nut and washers. Whil e tighten ing the nut, hold the cabl e in posi tion so it is parallel with the starter.
Troubleshooting Electric Start

Problem: Hot or Smoking Wires Condition 1. System wired incorrectly Condition
1. 2. 3. 4.
CAUTION
Check the cable installation to make sure it isn 't near any moving parts or against any sharp edges.
3. Secure the positi ve ca ble to the starter motor with a long cabl e tie. 4. Connect the ca ble to the positi\'e post or the battery; then connect the negative cable to the negati ve post. 5. Install the dri ve clutch. 6. Install the expansion c ha mber.
Remedy 1. Check wiring against wiring diagram Remedy

1. Check/charge the
Problem: Starter Does Not Turn Over BaHery discharged Connection loose Grounding improper Fuse blown not installed
battery
2. Check tightness of all
connections
3. Check round
connections
4. Check - replace fuse
INSTALLING
(570 cc/Pantera Models)

I Install the Ocx-dri ve shan onto the starte r motor and secure with the two Allen-head screws. 2. Place the starter motor into the bracket assembly; then secure with ex isti ng hardware. Ti ghten to 2.4 kg-m ( 17 ft -Ib). 3 . Attach the red positi ve ca ble to the positi ve stud terminal and secure with a nut and washers. While tightening the nut , hold the cable in position so it is parallel with the starter.
Ignition Timing
_NOTE : Ignition timing can be checked andlor verified on all snowmobile engines ; however, ignition timing can be adjusted only on certain models. Refer to the following Ignition Timing Specifications sub-section for information on models which are adjustable and on models for which no timing adjustment is required .
CAUTION
CHECKING
I. Connect a timing li ght to the ivlAG-side spark plug lead.
Check the cable installation to make sure it isn't near any moving parts or against any sharp edges.
5-46
Page: 279
2. Using a shielded safety stand, raise the rear of the snowmobile off the noar and start the engine. G raduall y Increase the engine speed to the specified RPM ; the pointer should align with the proper timing mark on the n ywheel. 3. If timing is not correct , adjust the ignitio n timing.
4. Insta ll the n yw heel. startcr pulley. and recoil stm1er. 5. Recheck timing for accuracy and adjust if necessary.
ADJUSTING
Rcmove the recoil starter, starter pulley, and n ywheel. 2. Loosen the two screws securing the stator plate and rolate the stator plate in the proper direction to attain correct timing.
NOTE: Rotate the stator plate clockwise to retard the timing or counterclockwise to advance the tim ing. The stamped marks on the stator plate at the upper sockethead cap screw mounting hole can be used for timing.
Ignition Timing Specifications

(Table of Contents)
370 cc .................................................................... 548 440 cc .................................................................... 548 500 cc w/o APV ......... ............................. ............... 549 500 cc w/APV . ......... ............... .. ................ .. ......... 549 550 cc .................................................................... 5-50 570 cc .................................................................... 550 600 cc "Laydown " EFI ........................................... 551 600 cc STD .. ............................. . ................. ..... 551 700 cc Carbureted .. .. .................. ................ .. ......... 552 700 cc EFI ............................................. ................ 552 900 cc Carbureted ...................... .................. ......... 5-53 900 cc EFI ............................................................. 553
3. Tighten the screws securing the stator pl ate.
Page: 280
5-47
370cc
NOTE: For 6000 RPM timing purposes on the 370 CC, use a dial indicator and scribe a mark on the flywheel for 13 BTDC.
Ignition Timing - Engine Warm BlOC -18 /2000 RPM - 2.012 mm (0.079 in.) BlOC -13 /6000 RPM -1.056 mm (0.042 in.)
Magneto Case
Rotating Direction
BlOC ISO
738950A
440cc
Ignition Timing - Engine Warm BlOC -18/2000 RPM - 2.012 mm (0.079 in.) BTOC - 13 /6000 RPM - 1.056 mm (0.042 in.)
Magneto Case
Rotating Direction
B lOC 18~
738950A
548
Page: 281
500 cc
w/o APV
Ignition Timing - Engine Warm BlOC - 25/1800 RPM - 3.692 mm (0.145 in.)
NOTE: For timing verification on the 500 cc w/o APV, use a dial indicator and scribe a mark on the flywheel for 25 BTDC.
StatOl'/ Coil Assembly (no timina adjustment lequiredl
[8rDC"j~' BlOC IS
BlOC 16 BlOC 14 BlOC 10 BlOC 12
; .
Rotating Direction
7389S9A
500 ccw/ APV
NOTE: For timing verification on the 500 cc wI APV, use a dial indicator and scribe a mark on the flywheel for 30 BTDC.
(/ll;'~- IBTOC 3er l Rotation Direction
-r \1:'---':: ~
Magnetic Rotor I Housing Assembly

BTOC 22' BTDC 24
BTOC 26'
BTOC 10' BTOC l 2 ~'
'---1------'
BTOC 30 BTOC 28'
Stator/ Coil Assembly (no timing adjustment requi red)

738-207A
Page: 282
5-49
550cc
Ignition Timing - Engine Warm BlOC - 33"/2000 RPM - 6.556 mm (0.258 in.) BlOC - 24"/6000 RPM - 3.540 mm (0.139 in.)
o
BTDC
o
, ,. BTDC -,..
BTDC
~=
IBTDC33'~
BTDC 28 BTDC 26 BTDC 24 BTDC 300 BTDC 32"
,....::~
BlOC 34 BlOC 36
0
Rotating Direction
738-9SSA
570cc
Ignition Timing - Engine Warm BlOC -18"/2000 RPM - 2.049 mm (0.081 in.)
Stator/ Coil ~$f!mbly
(no liming adjustment required)
Rotating Direction
738-963A
550
Page: 283
600 cc HLaydown .... EFI
Ignition Timin BlDC _
15"11880 ~~gi Warm Mne - 1.509 mm (0 .059 In.) .
ROTA TING OIRECTION
0740 -130
600 cc STD
Ignition TimBlDC _ 24.~~80 ~ngine Warm PM - 3.390 mm (0.133 in.)
1r;.124
11
21" BlDC 0 B lDC] H BTOC
Rotating Direction
..
(no timing adjus tment Assembly required)
Stator/CoIl
Mill!. ROtOf/HOllsil11l Ass embly
738-982A
Page: 284
2005 Arctic Cat 5 ervlce . Manu al - all models
www. ReadM anu al s.com
551
700 cc Carburet:ed
NOTE: For timing verfication on the 700 cc Carb, use a dial indicator and scribe a mark on the flywheel for 12 BTDC.
BTDe 16'" B lOC 14"
BTtIC 18"
IBlDC
,,.1
BTOC 20" BlOC 22" BlOC 24" BlOC 25"
Stator/Coil Assembly (no timing adjustment required)
I ROTATING DIRECTION
740-131A
700 cc EFI
NOTE: For timing verfication on the 700 cc EFI, use a dial indicator and scribe a mark on the flywheel for 12 BTDC.
Stalor/Coil Assembly (no timing adjustment required)
ROTATING DIRECTION
740-132A
5-52
Page: 285
2005 Arctic Cat Service Manual - all models - www_ ReadManuals_com
900 cc Carburet:ed
NOTE: For timing verification on the 900 cc Carb, use a dial indicator and scribe a mark on the flywheel for 1]0 BTDC.
Rotel)ng Dire<:tlon
o
StI!orlColt Assembly (no liming adjustment rtqllired) Mag. RotOf/HOUIIns Assembly
738-983A
900 cc EFI
NOTE: For timing verification on the 900 cc EFI, use a dial indicator and scribe a mark on the flywheel for 23 BTDC.
I
20" 81OC ~'! IS' SlOC

16' 81OC .
:~:;~ ~ y!-,.."r<
\!3V ,
Rotating Oireetion
22 Broc I WIloc l
o
StlitOflColl Assembly (nQ liming adiu5!m1!n! required)
Mag . RO!OflHoullng AsRfl1b1y

738-984A
Page: 286
553
NOTES
554
Page: 287
Wiring Diagram Index

(Ignition)
Thi s chart is designed to direct the tec hnician to the appropriate Igniti on Harness Wiring Diagram. Se lect
the snowmobile model f rom the chm110 determine the
correct diagram.
Snowmobile Models
Ignition Harness
Snowmobile Models
Pantera 600 EF I
'gnltlon Harness
G
Bearcat 570
Firecal 500/500 Sno Pro Firecat 600 EFI r
Firecat 600 EFI1600 EFI Sno Pro
A B L
M E
Panther 370 Panther 570 Sabercat 500/500 LX

Sabercat 600 EFI EXT Sabercal 600 EFI1600 EFI LX
0 A
elH
J K/J K/J J
Firecat lODf7GO Sno Pro Firecat 700 EFI r Firecat 700 EFlflOO EFI Sno Pro
King Cat 900 King Cat 900 EFI MS M6 M7
L
M
Sabercat 700 EFlflOO EF I LX

Sabercat 700 EFI EXT Z 3701370 LX Z 440 LX Z 5701570 LX ZR 9001900 Soo Pro ZR 900 EFIi900 EFI Soo Pro
TBA F
N N
Pantera 550
0 0 A I TBA
Page: 288
555
Harness A
(pi n 0686-845)
CD
Z 570/570 LX
Bearcat 570 Panther 570
COl
CCI~
IGNmDfj
PLU~
SPIIIA
STATORIFlYWHEH, ENGINE
SlNSOR, TIMING
CONNECTOR, MAIN HARNESS
I
~
<0
"
<0
0 0
l>
". n
()
!<
'" <
- - ':.' , _ I
n'
BRN
~
ci
CYLI ND ER NO . 1
;: , c
l CD
CYl.IN DER
"-
ENGINE
g:,
CHASSIS
;;;
NO. 2
8.
;0
l CD
NOTES, 1. CONNECTORS SHOWN FROM IltATlNG SURFACE.
, c
;:
..
;;;
n 0
iO! 511
2 MAU PIHltRMINAI.. 1 1 : o fEMAU PIN TERMINAL 3. NORMAllY OPEN IGNmON, COl UNIT ILT WIRE MUST BE OPEN TO RUN. GROUNDED TO STOf' IGNmON. 4. 5000 OHM HIGH VOLTAGE RESISTOR IN EAGH SPARK PLUG & EACH SPARK PLUG W. TO REDUCE RFl EMISSIONS.
~I '" '"
0737-378
'"
5-56
Harness B
(pin 1686-0T0) Fireca t 500/Sno Pro
CD
SlATOa,tFLYWHElL ASSY., ENGINE
CD
m
SENSOft, CRANKANGl
COILS, STATOR
MOTOR, APY SERVO
SElISot!, l1lROITLE .osmON IT'S)
CD
CDI
REGULlTOfl, AC
TAiLUGHT
GROUND, CHASSIS
10
SWITCH, WATER TIMP.
11
SWITCH, TlIUMBWARMER
SWITCH, HAHDWARMER
ELEMENT, THUMBWARMER
<0
"
12 13 14
lliMENT. R . KAJlDWARMEII
<0 0
15
ELEMENT. L HANDWAJlMER
0 0
16
CONNECTOR, ACCESSORI/TETHER
11 SENSOR, Oil
l>
", n
: : : ;, , : ' III
CONNECTOR, HOOD HARNESS
()
18 19
SWITCH, DIMMEJVBRAKl
@ ~:i
!<
~-.
20 SElISot!, Sl'EEOO
\lCD ~
'" <
@
21
SWITCH, E -STOP
-i
SWITCH. KEY
n' ;: , c
22 23
swncH,AIU (R'S)
",
24
COIl. HY IGNmaH
e A!~ -.-.
::.\~
g:,
25
SENSOR, EXHAUST TEMP.
@
A'~
;;;
8.
26 CONDNSOR, DC
2J REGULATOR, DC

1'2111101!
~
;0
~ @
HOTIS: I. COHNECTORS SHOWII FROM MATING SURFAc[ SlOt 2. eMALE PIN TERMINAl OFEMALE RECEPTACLE TERMINAL 1 KEY SWJTtH CONTACT CLOSURES AS FOLlOWS:
E <ff
~
a:,~
G4:; ~
@
CD
, c
;:
;;;
n 0
QJIIJ. ..... .
Ir=o-:@
8RNlWHT
0739979
BUllE GRNITIE
OFF 1+1 ON NONE 4. WARMER SWITCHES CONTACT ClOSURE AS FOLLOWS: POSITlOH HW COKTACT TW CONTACT HIGH BRN+GRN+BlI BRN+GRMlWHT+BlIIWHT MED BRH+GRN BRN+GRNJWHT lOW BRN+BlI BRN+BlJI,IWHT OFF NONE NONE
1 1i. @
5-57
Harness C
CD
m
(pi n 1686-00 1) Sabe rc at 500
STATOR/FlYWHEEl ASSY., ENGINE

.~ .
CD
stNSOR. CWK-IliGLI
COILS, STAtOR
MOTOR, APV SfRVO
" ~-~-" 1>!!~
, r-..:..-- ----=;::;=_ - - - .:..:.-.:....:..:.-fiI
SENSOR, THROrnI POSITION (TPS)
CD
)-----'TI!
CIlI
REGULATOR, At
TAlWGHT
GROUND, CHASSIS
SWITCH, WATIRTEMP.
SWITCH, THUMBWARMER
SWJTCH, HANDWAIIMER
~
@
"
13 lliMENT. THUM,WARMER
14
ELIMENT. R . HANDWARMER
ili -
~ l>
6
1IlU:="m
.
1
.Ill.
g , n
:::~,~
;.:;== ~L ? !W~ ~ ..........

~
l ~ ~ m ----. -.. 1111
()
!<
-~
-. ~
-I
II:'
.:::.\~
..
jlj
< g'
g>
~!~
-_.
@
;:
, c
@
-.FROM MAnNG SURFACE SIDE.
'1 '1 '
"-
g:,
TIjiJ@ U
A\~
;;;
8.
--
BRN+GAN+BLX
HRNHRM
il'
M
=,~
, c
;:
;;;
BRN+BLK
N~E
@ i
il 3
II n:: ..z@
@
8RH/WHT
BUllE GRH/lIE
@ ~i.ii @
0739969
5-58
Harness D
(pin 0686-61 3) Panther 370 Z 370/LX
1 CD!
CD
Nom,
1_ C(}NNECTORS SHOWN FROM MATING SURFACE SIOl 2_ MALE PIN TERMINAL FEMALE RECEPTAClE TERMINAL
Z 440 LX
c(}IL, IGNITION
PLUG,SPARK 3_NORMALLY OPEN IGNITION, CD UNITVLT WIRE MUST BE OPEN TO RUN, GROUNDED TO STOP IGNITION_ 4, 5000 OHM HIGH VOLTAGE RESISTOR IN EACH SPARK PLUG & EACH SPARK PLUG CAP, TO REDUCE RFI EMISSIONS,
2 3 4
STATORJfLYWHEEl. ENGINE
CONNECTOR, MAIN HARNESS
<0
"
BUVWIfT
'"
=
0 0
"
l>
g , n
()
!<
iii
..
."
(0
i "
'" <
(/) 1
.J
"-
.m,
n' ;: , c
"-
..
> .
iii
(!)
g:,
(SEE NOTE 4)
8.
T
CD
OO ~
"
II
N N
J:
f'
jW tll
ci
(!)
;;;
;;!
"
w .J
/ BLKiWHT
CYLINDER NO.1
;0
-( ~
DOG
~
0
~ ~i ~
CD
(SEE !,!OTE 4 )
CD
, c " n
;:
~ : 4 -.-
, 'tift'
g ::T=:-
In
NO. 2
C Y LINDER
BUf/RE GRNJRE
CD
BRHllYHT
'1
In
07374"
5-59
Harness E
(pin 1686-047) Fireca t 700/Sno Pro
1 STATOMlYWHEEL, [MGINE ASSY.
MOTOR S[RV() APV
SENSOR, THROntE POsmON (TPS)
CD
COl
CD
REGULATOR, At
TAlWGHT
GROUND, CHASSIS
SWITCH, THUMBWARMER
SWITCH, IIAHOWARMER
CD
CD
11 ElEMUlT, R . IlAHOWARMER
12 EWIENT, L IIANDWIRMER
~
@
.w .~
"
13
OONNECTOfI, ACCESSORY,trrnlER
SWITCH, DIMMER/BRA~
l>
~
@
=:~,.:::
g , n
S ' ,
()
!<
< g'
g>
@ ' 1':".:'01,
@
, ,
1111111111111 LmIlill I IIl1J'
, c
;:
" g:,
~ ~ @ -.-.- ....
@
= 1:"
;;;
8.
~
HOTES: 1. CONNECTORS SHOWN FROM NAmtG SURfAa SIDE. t MALt PIN TERMINAL o FEMALE RECEPTAClE TERMINAL 3. lEY SWITCH CONTACT CLOstJRES AS FOLLOWS:
POSITIOH COftTACT
il'
~T IT _ e".,'
OFF X+Y
-.-
, c
ON N ONE
~
;:
;;;
~
o.
il 3
MED
CD
SRN+GRHJWIfT
4. WARMER SWITCHES CONTACT CLOSURE AS fOUOWS:
IfIGH
HW COHIACt BRtHGRN+BlI BRN+GRN
lW COIfTACI BRN+GRN/WKT+BIJIWHT
I ~CD
BAH+Bl1JW1fT MaNE
lOW Off
BRH+SI.K KOHE
@
0739994
5-60
Harness F
(pi n 1686-024)
M5
1 STATOfI/FlYWHEL. (HGINE ASSl
CD CD
I
I
COILS, STATOR
SERSCH, CRAMI( AHGU
lil.I~ ;!" ~!I " / I"'"
SWITCH, CARS. MAGNETS
SWITCH, KEf
COl
SWITCH, E~STOP
REGUlATOfl, At
r
.. ,,'" (5)
&\~
CD CD
TAIWGHT
EI.MENT, R . KANDWARMER
~v.
_
11 ELEMENT. L. HAHDWARMER
=-- '1
.,....", ~-.r.
.--
... "" (5) CD ~ ' . 1~if5 1 ~

f4~~e "mll'"
12
EUMEHT, R , HlHDWARMER
. .-
"
14 SWITCH, THUMBWARMER 15 SWlTCH, DIMMERJBW1 1&1roNNECU)'. HOOD "'''ESS
17 SENSOR. LOW oil
~ l>
fOS1IL()f4
18 SWITCH, TEMP.
r!n ~ "'I!:=::~--;'~'-;'-" ->=I
J; -:'-.1,.,11 -,
CD
HOllS, 1. CONNECTORS SHOWN FROM MATING SURFACE SlDl
2. MAlE PIN TUMINAl
g , n
I
ell
m
II SEHSOI!. Sl'EIOO
3. m SWITCH cotITACT CLOSURES AS FOUOWS,
o ruuu RECEPTACLE TERNIMAL
()
!<
~
II
HIGH lOW Off
NONE
20 GROUND, CHASSIS
ij@
CD
E:Cl ~
9~ ON NONE
g>
4. WARMER SWITCHES CONTACT CLOSURE AS FOLLDWS,

HW CONTACT TW COftTACT UN+GRN,IWHT BRN+GRNJRED BaN+GRM/BLI BRN+YElJGRN
< g'
@ ta
@:F1l 00
.
m
, c
;:
I~ @ . ~ . --""
.&liMI'-'=
@I! . l iE
NONE
" g:,
ill:='~ ~ '
CUIIOe'pu'" ,
_e'ftIJ.'
;;;
8.
~
,-) ~
... ;
co~,
I
-.o
--
,.------
@:F1l 00
il'
, c
;:
;;;
il 3
I I
I. un II
~O
I I
IJ nel2 f
' ~O
~O
II un
l ___
.u___ L ____ __ ~
07 40013
5-61
Harness G
(pi n 0686-7 3 31
CD
Pantera 600 EFI
MAGHEIO APV, AC POWER
3 MOTOR, SERVO-MOTOR ASST_
.. l!J
CD
MOTOR, 12 VDC
SENSOR, POSIION
o o
ECU
CONNECTOR, DIAGNOSTICS
5 6 7 8
LIGHT, LED
or.<rT.n'T~.,,,,o:r.-n.
>-<
10
-<
COI~ IGNiTION PLUGS, SPAR!
~'~II[fill'i''v~I "O{'Jj,.
11 SENSOR, TtMP
SENSOR, WATER TEMP.
CD
I",
~
<0
"
13 SENSOR, T1tROITLE
<0
14
SELECT, ETHANOL FlJEl
15 INJECTOR, FUEl #2 (PTOI
~!
0 0
INIECTOR, FUEl #1 (MAGI
rb
.
'"
0 , 1 00
n o .3 D
n
IGN ITION
l>
PUMP, FUEL
". n
I P'
SWITCH, MANUAL IFf
8 ,
CD
c
...-~\ ::7 '

!
:0:
"'
()
!<
SW~CII, STOP/THROmE
( SEE N OTE 1 )
20
11lli!!~ " --=~ -~"''-m

~ I
1
I ~ II
8600n
'"
;: , c
~.
21
! SENSOR, liMING ! CONNEClOfI, MAIN HARNESS ~
"-
.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .,
W ~.- ,:
I~ IiU ================ ~ . .
I
~
c
o
o
g:,
..
"
8.
:In
ENGINE
~,
:~
CD
NOTES:
POSITION
(])
1. KEY SWITC H CONTACT C LO SURES AS FO LLOWS :
;:
'"
, c
;;;
99
o
~
OFF ON
x+v
CONTACT
NONE
2. CONNECTORS SHOWN FROM MATING SURFACE SIDE.
n 0
@ @
milO
@
3 . MALE PIN TERMINAL O FEMALE REC EPTACLE TERMINAL

4. GAS/ETHAN O L FUEL S ELECT O N 1999 MODELS, ANO NEWER. CONNECT WIRES FOR GAS.
DISCONNECT FOR ETHANOL F U EL.
0737416
5-62
Harness H
i
_~
1 STAlOR/ftYWllEEl ASSY., ENGINE
CD
__ _
(pin 1686-014) Sabercat 500 LX
GJHlUND. EMGINE
SEN~R,
CRAIIHNGLE
. " ~r
(lO,,$OU---. IIm,.tl.I) ....- EUCTIIC
~
"I
COIlS. HV
SWITCH, CARB. ,MAGNUS
COl
CD
SWITCH, illCTRIC SlART KfJ
REGULATOR, At
AWM, REYRSE
10 TAlWGHTS
11 SWIICII, REVE RSE-UN11ACE
=:.:r..-@ .J . . . .~8;::
~
I
!~ , r~
CD
tRIVMIlI S
...
13 EUMENT, THUMBWARMER
o
o
(JI.M Il.ll - t l _ I$IHTIOM
m.n+lI---"
nt M Olt ~
"
14 ruMEH1I, R _HANDWARMER 15 EUMENT, L HAIODWARMER
~ l>
o o
g , n
OPO@"IIr MUD@"IOI"
J::.@ "-@ @ OKII @'fULl' """@....,,.

Wrr&REDfinlIIII
()
!<
g>
< g'
, c
lU.j.lftI'T@ ftL+1I.I
;:
W
~
~
110 ",1.:@"$1lH'I'EJ'
' 1IlS(!IiI" .antill'
CD
" g:,
@~:::
~
26 SWITCH, [STOP
'" ~ II I
on
~
@
;;;
~'41LI J
8.
OII1I1U~ ,
1 ~ I JrJl
'"
"'i~~
5
I.""' ~
a.ost:D@'ft'fWl"
oPO~"AI D'
@
~
il'
If1\
If1\
, c
;:
;;;
il
HOTES: 1. CONNECTORS SHOWN FROM MATIMG SURFACE SID. Z. MALE PIN TERMIItAL o FMALE RECEPTACLE TERMINAL 3. KEY SWITCH CONTACT CLOSURES AS FOUOWS: POSITION CONTACT --o;rHONE OFF +M+ -M START (MOMENTARY) B+S 4. WARMER SWITCHES CONTACT CLOSURE AS FOu.oWS: POSITION KW CONTACT TW CONTACT HIGH BRN+GRH +BlX BRNHRH/WHT+BlJIWHl NED IIJIH+GRN -_.. - _.......-
LOW OFF
BRN+ Bll
N OHE
0739967
5-63
Harness t
CD
ZR 900/Sno Pro
NOm,
(pin 0666-734) King Cat 900
1 em
t. CONNECTORS SHOWN FROM MAllNG SURFACE SlOE.
2 MAl.E P1f11 TERMINAl. FEMAlE RECEPTAa.E TERMiNAl
SWITCH, STOP/IlKlTTtI
J . NORMAllY OPEN IGNITION; co UNIT 'Ill WIRE MUST
MOTOR, SRYO.MOTOR ASSY.
.,
a
5. AI.1.COIl WlNDIMI RrSlS1AN(IVALUES ARE t
SO<SOR, POSmON
MOTOR. 12 DC
CD
m
AlU.E _
TCH
BE OPEN TO RU N, GROUNDED TO STOP IGNITION. 4. 5000 OHM HIGH VOlTAGe RESISTOR IN EACH SPARK PlUG & EACH SPARK PLUG CAP, TO R(DOCE Rfl EMISSIONS.
COI~
HV IGHmON
TOIlIIAHCE.
PLUG, SPARK
SEJISOR, THROTTLE POSITJOfII
COfrtDEHSOR, lP.V .
CD II 0
. VOlTAGE i O REGULATOR, A.P,V

GIS ..
QD
(91010 NOH, .)
~n
11
STAIOR/fLYWHEE~
ENGINE

U SENSOR. TIMING
..,
13) CONNECTOR, MAIN HARNESS
~ ~
f11 11 ~
rt--------l = ~R ~n
(SEe NOTe.)
~n
~n
.li
=~
~, '
(!)
lCD
~H?
1 H
"' <
" a 0' !? "
~.
?"11) 19J
(!)
, " c
1:-._ ._ _ .-
"
8.
"
:0
~
-m.m E:0
~
~ IO,otiD
L !"' . t
, " c
.....
::J .
10
:w:w
.. 8
m ~
~ == _ __:-::___ _ ._ .............
.Imd . . . . ... . .', . .'. . . . . . -mJm-
101
0737417
5,64
Harness J
(pi n 1686018)
Saberc at 600 EFI/EXT/L X Sabercat 700 EFI/EXT/L X
NOTES:
1. CONNECTORS SflOWN FROM MATING SURFACE: SIO. 2 MALI PIN TEIIMIIIAl. o fEMALE RCf.PTACLE TERMIIW.
r.oTOR, N'V SERVO
IIUECTOR, run #2 (PTO)

-~
IIUEtroff, fUEL #1 (PTO)
PUMP, fUEl
SDIS0R, MlOmI POSfTIOII

Off
(j)
START (MOMEHTART) ON
3. KE'I' SWITCH COHTACT CLOSURES AS FOUOWS; ~ COHTACT

+11 + 11
REGlILJTOfI, APV Eltc. START
,eu
8+5 8+A 4. WARMER SWITCHES cotO"ACT CLOSUR[AS FOLLOWS:
SWITCII, E STOP
REMOfUTAIIT
SWITCII, IIOOD
TWCOHTACT BRM+GRtf/IIfHT + BUVWIIT BRH+GRJVNHT 8RM+8LWHT
SWfTCII, ELfC. START KEY
fA/WOO
I [ tj; I ., ~(~f . , ....., .. '

,-
SWITCII, REmISf UNWiE
~[
Off
""
?t::.
"""
o
AWN, REYDSl
SWlTaI, TIIUIIBWDMER
<0
"
,,=*,ar:
10 11 12 13 14 15 II
SWfTCII, IWIDWAflIIER
<0
17
EWDT, TlIUIIBWAIIMER
.,~
. :,.
0 0
1. EWIDIT, LIWIOWARMEII 19 ELDDT, L IWIDWAflIIER
l>
20
:il::1ll"""'''
~(
", n
21 WISOR, LOW Oil
()
SWlTal, DlMlllEllJBR.W
~k
~@
!<
22 23
GROONO, CHASSIS
'" <
lII:::1'~
24 BAnm,lZV
n'
FUSEHOUJER
@ I
,
25 21
GROONO, CHWiIS
~ I~ I
;: , c
27 SOlDlOiO
"-
' !~
11_ _ " "
_ _ .."
g:,
$TDfU
iI
GROtJNO, CliASSIS
;;;
8.
=,~
~
.
K~
@ _1110~ -
W:~:,u l!
21 21 30
COIL If IGllmOll
31 SUlSOtt.AIRlEIIP.
SUlS011. WATER TtIlP.

+
II
;0
32 a3
SWTTCII, AXlE IRf'SJ
.@
~
@ ,-~ ~
;:
34 ""''''' 35 SEIISOR, CWl-AHGLE 31 STATOR
-~,
' 15
, c
;;;
31
FUD.5WCT
n 0
31
SUlSOf1. SPEEOO
f{j~ @ .11 __
0739986
565
Harness K
(pin 1686-053)
CD
-~
Sabercat 600 EFI Sabercat 700 EFI
1 MOTOR, smo IP'I
INIECTOR, FUEl #2 (PTO)
INJECTOR, FUEL #1 (PIO)
PUMP, FUEL
SfljSOR, IliROTTU PosmON (ll'S)
Eeu
7 SWIICH, E -SIOP 8 REGULAIOR,VOlTAGE
~0 (Ii
!. 'j
11 SWIICI!, THUMBWARMER
CD
o
/
.0
' '110,
~
j.
"
14 ElEMm, R, HARDWARMER
15 ElEMfljl, L HAROWARMER
..w .",::=:
~
',=,=
~ l>
.f!:"I.
g , n
18 SENSOR, lOW Oil 18 SWITCH, DlMMER/BRAXE
CD ~. ~
()
!<
g>
< g'
o'Il:.\ 'lt-
7I i
~~I=I
r .. _.~ 10.............
@
L ,_--b;j
:- ~
l;I.a--J
, c
;:
"-
g:,
;;;
8.
28 FUEL SElECT
il'
-.- ~, IT
.:a,~
CONTACT
, c
...
;:
NOllS, 1. CONNECTORS SJfOWN FROM MATING SURFAtl SIaL 2. MALE PI/t TtRMIIW. o FEMALE RECEPTACU TERMINAL
;;;
HW CONTACT IW CONTACT
3. Kft SWITCH CONTACT CLOSURES AS FOlLOWS:
il 3
!HK+i!K+BlK
POSITION
ON HONE 4. WARMER SWITCHES CONTACT CLOSURE AS FOUOWS:
OfF
POSITION
!BH+iHM./J!!+BlI!iWHT
@ @
0740003
OFF
5-66
Harness L
_ w
Fireca t 600 EFI r Firecat 700 EFI r
(pi n 1686 11 1)
MOTOf!. SERVO APV
INJECTOR. fUR #2
JNJECTOR. fUEL #1
PUMP, FUEL
CD
SENSOR. TNROTILE POSmON UPS)
ECU
SWITCH. ESTOP
REGUl.\TOf!. VOlTAGE
SWITCH. lEY
T~WGHT
SWITCH. RMRSEUNKAGE
CD
SWITCH. THUMBWARMER
13
SWITCH. HANDWARMER
ELIMENT. ntUMBWARMER
I i.~
~
<0
"
14 15
EltMEHT. R . HAHDWARMER
0 0
17 CON NECTOR. ACCSSORU/TETNER
0 0
Sl:NSOR. LOW Oil
l>
18 19
CONNECTOR. HOOD HARNESS
'"-,
". n
Rt;IN'~ JII!'
20 AlARM. REVERS!
()
Q' ~
!<
21
SENSOf!. SPE!OO
'" <
I
I
22 SWITCH. DlMMERI1IRAKE
dIM'IF
23
GROUNO. CHASSIS
~!, ~ U _ @Jil --@ lfH!Oll

@
24
COIl, HV ~NITION
n' ;: , c
"-
SENSOR, AIR TEMP.
g:,
25 28
SENSOf!. WATtR TEMO
27 SWnTCH. AXlE (RPS)
;;;
8.
MAGNETO
28 29 3G
SENSOR. CRANI ANGLE
;0
31
STATOf! fUEL SELECT
NOTIS,
1. CONNECTORS SHOWN fROM MAnNG SURfACE SIDE.
W ....
.ll:t m @ ~ ~@
+-'"""~ ~
2. MALE PIN TIRMINAL
, c
;:
3. lEY SWITCH CONTACT CLOSURES AS fOllOWS, POSITION ~
o FlMAlE RECEPTACU TERMINAL
-......-
;;;
n 0
OFF ON
XH NONE
m_.
L=ou @
0739997
4. WARMER SWITCHES CONTACT ClOSURE AS fOllOWS, POSiTION HW COIITACT TW COIITACT BRN+CRN+BLk BRN+GRHJWHT+BtJiWHT BRN+GRN BRN+GRIt/WHT BRN+BLK BRN+BlI/WHT NONE NONE
567
CD
Harness M
-~
(pin 1686008) Fireca t 600 EFl/Sno Pro Fireca t 700 EFl/Sno Pro
o .0
~,,~
CD CD
0
P~
m--
c'iii!
CDI,
0
I
~
I II
.-
Jt
-~
C!)
II
.!I.
II 6
--. Jt:~W ~------lJ @
=-\~
-! .~ --~" ';;:;l
@
Ir l ---::t;::, ,:::
~
@
ZiT
i!E ~ ~
~ @- ~
=-\~
Nom, 1. CONNECTORS SHOWN F1!OM MATING SURfACE SlOt 2 MAll PIN TERMiNAl fEMALE REClPTACLl TERM IMAL 3. KfY SWITCH comCT CLOSURES AS fOLLOWS, PosmON comCT
It!!
OFF X+Y O. NONE 4. WARMER SWITCHES CONTACT CLOSURE AS fOLLOWS, POSITION HW CONIAC! TW CONTACT HIGK BRH+liKIf+tlL~ BRN+GRI(IWHT +BLNlWHT MED BRN+GRN BRN+GRN/WHT LOW BRN+BlK BRH+BlIVWHT Off NONE NONE
~@
--.
@~~@
mJn
0739993
568
Harness N
CD
-~
(pi n 0686988) M6 M7
1)
MOTOR, APV SERVO
21 INJECTOR, FUEL #2 (PlO)
3 INJECTOfI, FUEL #1IPlO)
PUMP, FUEL
SEHSOR, TIIROTTLE PQSIT10N (IPS)
ECU
SW~CH ,
E-STDP/AXU
SENSOR, SPWJO
9 REGULATOfI, VOLTAGE
CD
"
CD CD
.W. ~
12
"'''''~
CONNECTOR, HOOO HARNESS
~ ~.-1b
"
15
ELEMENT, R . HAIIOWARMER
ttl I
;01.-
~ CD
u:-:'''=
1lI\\ '='
l>
~
L'
g , n
()
!n r@
~
-.
IIl IN'1
!<
.. II
g>
' _ _ e ll" r
~ @ r II 1 1
< g'
21
COIL. HY IGNInOfl
;
I
~~~ m ~~ @ , _ 'W
1 1 ::::" 0 -
, c
;:
~~
@
; ::;, =:
11 _ _ _
"-
g:,
5
~
-
------,
;;;
@
8.
27 FUEL SELECT
"
r----T
:z.\~
il'
@ ~F1l
, c
;:
~~
00
;;;
MOTIS: 1. CONNECTORS SIfOWN FROM MATING SURfACl: SID. 2 MAlEPINTERMIIW. o FEMAlE RECEPlACl TtRMINAl 1 lIlY SWITCH CONTACT CLOSURES AS FOlLOWS:
il 3
OM MONE 4. WAllNER SWncttES CONTACT ClOSUR AS fOllOWS:
- off
POSITION
.comer
X +Y
POsmON
HIGH lOW
OfF
11 _..L_ I unen , 15 L_ @ -@ ______ .J
I , ' ij
Lo n
~O
10
' .
un
0739990
569
Harness 0
(pi n 0686-55 1)
Pantera 550
1 COl
CD
2 COIl, IGNITION
3 PLU~ SPARN
4 STAIOfIIFlYWHEtl, ENGINE
5 CONNECTOR. MAIN IW!NESS
"
l>
~
.' "
.
(2)
( S Ee NOTe 4)
g, n
?l
()
!<
8
c: M
g>
< g'
"
;:
I IO a.
'
c:
-----'l/1lI#,-CYLINDER
~ o
, c
z " ~ J " w
" g:,
.'
SEe NOTE 3
__ .!" r __ .'
NO. 1
;;;
- - """ .
8.
.. .
j o
(SEE NOTE 4)
(3)
o::::::::;:::
In
CYLINDER NO. 2
il'
, c
;:
(3)
;;;
NOTES: 2. MALE PIN TERMINAL
il 3
In
1. CONNECTORS SHOWN FROM MATING SURFACE SIDE . 3 . NORMALLY OPEN IGNITION ; CO UNIT VLT WIRE MUST BE OPEN TO RUN, GROUNDED TO STOP IGNITION . 4 . 5000 OHM HIGH VOLTAGE RESISTOR IN EACH SPARK PLUG & EACH SPARK PLUG CAP, TO REDUCE RFI EMISSIONS.
073741 9
o FEMALE RECEPTACLE TERMINAL
5-70
Page; 304
..
. . . . . . . . . ... . . . . .
:8
LJ
i l
t
I
I :
'- l :
, ~ .
,:
, . ,
"
~
Page; 305
.,...__ .. _... _4_. __ _. __ . ' .
LJ
.,
~
" !
Page; 306 2005 Arctic Cat Service Manual - all models - www.ReadManuals.com
o
0 .3 0
. ooon
Page; 307
....
_--_._--_ ....... .
@ ,
@~~
Page: 308

,
;-------- 1-- -------1
' ,
,-----------------;.+,;,. ., ~]e
Page; 309
Page; 310
..
@
" e! l ~'\ II
Ii!
@:
I"
jI
hI!! iJ LiJ
I ! Ii
8
Page: 311
p: _ _ _ :_______ =_ _
I_____ I
f ;: ,::J'"
I. I.
--""
:~"~"="="="="="=";";";";";";"~
~
"I
"
Page: 312
2005 Arctic Cat Service Manual - all models - www.ReadManuals .com
J ..
.. ,
!:>
Page; 313
Page; 314
~
@~
@ iIDe
@ ![fGl
~--.? II
I!fl-.;.:-i
~~=I
Page; 315
e
a
.,
!
~
Page; 316
@/"iic-,... .
-~e
. ~
, , , , L _______________ J
_ _ _ __
~~ fi e
I
~- ~
t!
.,
!
~
i"l ~ IH~""- "

L
~ @
I
.1'8
e
I
!3 i ~ ~
!%
Page; 317 2005 Arctic Cat Service Manual - all models - www.ReadManu als.com
.' ..:
' "
.. POLE LIGHTIN G COILS
::j
u":,,,:,,,:,u
. Il0.0
-~111Jmjb
CHNJIlIPl
un
1.:_
f'f I
:_
:__ .____ : ._ '____ ,
O.3f'l
Page: 318
SECTION 6 - CHASSIS ELECTRICAL SYSTEMS
TABLE OF CONTENTS
Brakelighl Switch (Hydraulic System) ..................... 6 2 Brakelighl Switch (Mechanical System) .................. 6-2 Headlight Dimmer Switch ........................................ 6-3 Testing Handlebar Warmer Elements (HI/OFF/LO Function Standard Models ) ........... 6 4 Testing Hand lebar Warmer Elements (AWS VI/MSeries Models) .................................. 64 Testing Thumb Warmer Element (HI/OFFILO Function - Standard Models) ............ 6-4 Testing Thumb Warmer Element (AWS VI/MSeries Models) .................................. 6 4 Testing Handlebar Warmer Switch (H I/OFF/LO Function Standard Models) ........... 65 Testing Handlebar Warmer Switch (AWS VI/M-Series Models) .................................. 6-5 Testing Thumb Warmer Switch (HI/OFF/La Functio n - Standard Models) ........... 6-5 Testing Thumb Warmer Switch (AWS VI/M-Series Models) .................................. 6-5 Testing Passenger Handwarmer Switch .................. 6-6 Testing Passenger Handwarmer Elements ............. 6-6 Wiring Diagram Index (Main and Hood) .................. 6-8 Wiring Diagrams ...................................................... 6-9
Page; 319
2005 A rctic Cat Service Manual - all models - www.ReadManu als.com
61
INSTALLING
Brakelight Svvitch
(Hydraulic Systetn)
TESTING/REMOVING
NOTE: On AWS VI models, the servomotor must
be removed from the mounting bracket to access the brakelight switch harness connector. I. Di sCOIUlcct the wiring harness from the brake control.
I. O n standard models, slide the brakelight switch into the brake control assembly until the selflocking tabs snap into position , Gi\'e the switch body a li ght pull to make sure the switch is properl y secured . 2, O n AWS VI model s, place the sw itch into position beneath the master cylinder assembly making sllre the alignment pins arc properly positioned; the n secure the switch with the Allen-head screw. 3. Connect the switch harness to the main wiring harness. Posi tion the wires so they wi ll not be eithe r pinched or come in contact with any moving components. Start the engine and check the switch for proper operation.
2. To test the brakelighl sw itch, connect one lester

lead to the II I (yellow) terminal , then connect the other lead to the 114 (rcd) terminal .
Terminal #2
I Wire
Brakelight Svvitch
(Mechanical System)
~
_ _ Terminal # 1 2 Yellow Wires
TESTING/REMOVING
I. Disconnect the wiring harness from the brake
Terminal #4 Red Wire
control.
7276SOA
Tetminal
1
Corresponding Wire Color

Yellow Blue White Red
Wire Usage
Power Supply HeadlightHigh Beam Headlight Low Beam Brakelight
3. W ith the brake lever compressed, the meier Ollist
read resistance. With the brake lever relCt'lscd, the metcr must read no resistance. If the meter does nol read as specified, the brakclight switch is defective and must be replaced.
2 3
4
4. O n standard models to remove the switch , usc a slllall sc rewdri ver to compress the plastic locking tabs by pushing ill on the t.abs; then slide the sw itc h rree or the brake controL
2. Connect one tester lead to the II I terminal ; then connect the other lead to the 114 terminal.
Termlnat #2 Blue Wire
_____ Terminal # 1
2 Yellow Wires
Terminal #4 Red Wire Terminal #3 White Wire

727-650A
5. O n AWS VI models to remove the sw itch, remove the All en-head cap screw rrom beneath the master cylinde r and free the switc h from the master cylinde r assembly.
3 . With the brake lever compressed, the meter mllst read less than 1 o hm of resistance. With the brake lever released, the meter must read no resistance. tr the mete r docs not read as specified, the brakclight switch is defecti ve and must be replaced.
62
Page: 320
4. Use a small screwdri ver to compress the plastic locking tabs by pushing in on the tabs; the n slide the switch free of the brake control.
REMOVING (StandardlM.Series Models)

I. Re move the handlebar pad. 2. Remo\'e the screws from the cover plate sec uring the dimmer sw itch.
INSTALLING
I. Slide the brakel ight sw itch IOto the brake control assembly until the self-locking tabs snap into position. Give the switch bOOy a light pull to make sure the switch is properly secured. 2. Connect the sw itch harness to the malll wiring harness. Position the wires so they will not be eithe r pinched or come in contact with any mov ing compo nents. Start the engine and check the sw itch for prope r operati on.
3. Re move the plate and lift the sw itch free of the control .
Headlight Dimmer Svvitch

TESTING
Di sconnect the headlight dimme r sw itch plug (located next to the air-intake silencer on stand.ud mooels or behind the servomotor on AWS VI models). 2. Use the tester connecti ons indi cated in the following chart . If the mete r does not read as specified, the headli ght dimmer sw itc h is defecti ve and must be replaced.
Position High Beam High Beam Low Beam Low Beam Lead to Lead to Terminal Terminal (Wire Color) (Wire Color) 1 (Yellow) t (Yellow) 1 (Yellow) t (Yellow) 2 (Blue) 3 (White) 2 (Blue) 3 (White)
Met", Reading
INSTALLING (StandardlM.Series Models)

I. Place the dimmer switch into the control and
secure with the cover plate and screws. 2. Connect the four-prong plug; then install and secure the handlebar pad.
REMOVING lAWS VI Models}

I. Re mo\'e the Allen-head cap screw from beneath the master cylinder. 2. Free the switch from the master cylinder assembly.
Less than 1 ohm DL DL Less than 1 ohm
INSTALLING lAWS VI Models}

I. Place the switch into position beneath the master cylinder assembly making sure the ali gnme nt pins arc properly positioned; then secure the sw itc h with the Alle n-head screw. 2. Connect the four-prong plug.
Page: 321
63
Testing Handlebar Warmer Elements

(HI/OFF/LO Function Standard Models)
Remove the ik'lndleb..'lr pad ; then di sconnect the handlebar warmer three-w ire connector. 2. In the element connector, connect onc ohmmeter
Testing Thumb Warmer Element

(HI/OFF/LO Function Standard Models)
Remove the handl ebar pad; then disconnect the Ihumb warme r three-wire connector. 2. In the element connector, co nnecl o ne ohmmeter lead to the green/white lead; the n connect the other l d. o hmmeter lead to the yellow Ic. 3. The meter must read between 3.6 and 4.4 o hms. 4. In the element connector, connect o ne ohmmeter lead to the green/black lead ; then connect the other o hmmeter Ic. l d to the yellow lead.
S. The meter must read between 10.8 and 13.2 o hms.
lead to the green/white lead; then conncct the other o hmmeter lead to the yellow lead. 3. The meter must read between 7.2 and 8.8 o hms.
4. In the element connector, connect the ohmmeter
between the greenlblack and yellow lead wires.

5. The metcr must read bet ween 12.6 and 15.4 o hms.
6. Re place any element measuring less than or more than the specified amo unt.
NOTE: Repeat test for the other element.
NOTE: If either test is not within specification, replace the thumb warmer element .
7. Connect the leads; then install and secure the

handlebar pad,
6. Connect the leads; then install and secure the handlebar pad .
Testing Handlebar Warmer Elements

(AWS VI/M-Series Models) Di sco nnect the handl ebar warmer three-prong connecto r fro m the six-prong main harness co nnecto r. 2. In the element connector, connect o ne o hmmeter lead to the green terminal ; the n connect the othe r o hmmeter lead to the bl ack terminal. 3. The meter must read between 16.8-25.2 o hm s. 4. In the clement co nnecto r, connect the ohmmeter between the green and yellow terminals.
S. The meter must read between 8 and 12 ohms.
Testing Thumb Warmer Element

lAWS VI/M.Series Models)
I. Disconnect the thumb wanner three-prong connector fro m the six-prong main harness co nnecto r. 2. In the e lement connector, connect o ne ohmmeter lead to the green terminal ; then connect the other o hmmeter lead to the yellow terminal. 3. The meter must read between 3.2 and 4.8 o hms. 4. In the clement connector, connect o ne ohmmeter lead to the black terminal ; then co nnect the other o hmmeter lead to the yellow terminal.
S. The meter must read bet ween 9.6 and 14.4 o hms.
6. Re place any clement measuring less than or more than the specified amo unt .
NOTE: Repeat test for the other element.
NOTE: If either test is not within specification, replace the thumb warmer element.
6. Connect the three-pro ng connecto r to the sixpro ng main harness co nnector.

SIX-
7. Connect the three-pro ng connector 10 the pro ng main harness connecto r.
64
Page: 322
Testing Handlebar Warmer Svvitch

(HI/OFF/LO Function .. Standard Models)
R em ove the handlcb.. 'lr pad.
8 . Connect the three-pro ng connector to the main harness.
Testing Thumb Warmer Svvitch

three-w ire
2, Di sconnect connecto r.
the handlebar
warmer
(HI/OFF/LO Function .. Standard Models)

I. Re mo \'e the handleb..'lr l:k 'ld. 2. Disconnect co nnecto r. the thumb wanne r thrce-wire
3. In the sw itch COimector, connect the o lunmetcr leads to the green/white and yellow lead wires , 4. With the switc h in the OFF (middle) positio n, the
metcr must read an open circuit. With the switch in
the HI position, the meter Ollist read I o hm o r less resistance.

5. In the sw itch connector, connect the ohmmeter
3 . In the switch connecto r, connect o ne o hmmeter lead to the grecn/white lead ; then connect the other o hmmeter lead to the brow n lead. 4. With the switch in the OFF (middl e) positio n, the meter must read an ope n circuit. With the switch in the HI IX)sition, the meter must read 1 ohm or less resistancc. 5. In the sw itch connecto r, connect o ne o hmmeter lead to the green/red lead ; the n connect the other o hmmeter lead to the yellow lead. 6. With the switch in the OFF (middle) positio n, the meter must read an ope n circuit. With the switch in the LO positio n, the meter must read 1 ohm or less. 7. Connect the leads; then install and secllre the handlebar pad.
leads to the green/black and yell ow leads. 6. With the switc h in the OFF (middle) positio n, the meter must read an o pe n circ uit. With the switch in the LO IXlsition, the meter must read 1 ohm o r less resistance. 7. Connect the leads ; then install and secure the
handlebar pad.
Testing Handlebar Warmer Svvitch

(AWS VI/M ..Series Models)
Di sconnect the handleb.. 'lr wanne r switch threepro ng connector (located behind the servomoto r) fro m the main harness. 2. In the switch cOimecto r, connect the o hmmeter leads to the black a nd brown wi res. 3. With the switch in the OFF (lower) position, the meter must read an o pe n circ uit. With the switch in .o position, the meter must read I o hm o r less the L resistance. 4. In the sw itch connecto r, connect the o hmmeter leads to the green and browll wires. 5. With the switch in the OFF (lower) position, the meter must read an o pe n circ uit. With the switch in the ivIED positi on, the meter must read 1 o hm or less resistance. 6. In the sw itch COlmecto r, connect the o hmmeter leads to the black and green wires. 7. With the switch in the OFF (lower) IX)sition, the meter must read an o pe n circ uit. With the switch in the HI positi on, the meter must read I o hm o r less resistance.
Page: 323
Testing Thumb Warmer Svvitch

(AWS VI/M.Series Models)
1. Disconnect the thumb \~' armer switch three-prong co nnecto r (located behilld the servomotor) from the main harness. 2. In the sw itch connector, connect o ne ohmmeter lead to the black/w hite wire; thell connect the othe r ohmmeter lead to the brow n wire. 3. With the sw itch in the OFF (lower) lX)sition, the mete r must read an ope n circuit. With the sw itch in the LO lX)sition, the meter must read 1 o hm or less resistance . 4. In the sw itch connector, connect o ne ohmmeter \cad to the green/white wire; the n cOllnect the othe r ohmmeter lead to the brow n wire.
65
5. With the switch in the OFF (lower) position, the meter must read an open circuit. With the switch in the ME)) position, the meter must read 1 ohm or less resistance. 6. In the switch connector, connect one ohmmeter lead to the black/white wi re; then connect the other oh mmeter lead to the green/white wire. 7. With the switch in the OFF (lower) position, the meter must read an open circuit. With the switch in the HI position, the meter must read I ohm or less resistance.
8. Connect the three-prong connector to the main
3. With the switch in one position, the meter must read OL (infinite resistance).
4. When the sw itch is moved to the other position,
the meter must read less than 1 ohm of resist<'lOee.
Testing Passenger Handvvarmer Elements

NOTE: During this test, resistance will vary due to temperature; therefore, this test should be made at room temperature of 20 0 C (68 0 F).
harness,
Testing Passenger Handvvarmer Svvitch

I. Di sconnect the lead wires from the switch.
2 . Connect the ohmmeter leads to each of the lead
I . Disconnect the lead wi res from the main wiring
harness.
2. Connect the lead wires from the grecn/white wire from the element; then connect the other ohmmeter lead to the yellow wire fron the element.
3. The meter must read between 7.6-9.2 ohms.
wires.
66
Page: 324
NOTES
Page: 325
67
Wiring Diagram Index

(Main and Hood)
T hi s chart is designed to direct the tec hnician to the appropriate tvlain Ha rness Wiri ng Diagra m and Hood I-hlrness Wiri ng Diagra m. Select the snowmobi le rrom
the chart to determine the correct diagram.
Snowmobile Models
Mam Harness
R
Hood Harness
Bearcat 570
Firecat 5001500 Sno Pro
Snowmobile Models
Main
Hood
Harness
Harness
Pantera 550 Pantera 600 EFI Panther 370 Panther 570

Sabercat 500/500 LX Sabercat 600 EF I EXT Sabercat 600 EFI!600 EFI LX
G
K
Firecat 600 EFt EXT Firecat 600 EFI1600 EFt Sno Pro
Firecat 600 EFt r/700 EFt r Firecat 700f700 Sno Pro
Firecat 700 EFt EXT

Firecat 700 EFI1700 EFt Sno Pro King Cal 900 King Cat 900 EFI
B C C L P C C
"' "' "' "' '" "'

V V V, V, V,
II II
M N
, ,
SIT
,V
III/IV III/IV
"'
J
Q Q
"'
Sabercat 700 EFlflOO EFI LX

Sabercat 700 EFI EXT
UN UN
V AIH
Z 370/370 LX Z 440 LX Z 570 1570 LX
M5 M6 M7
'V
E E
D'"
, , ,
68
Page: 326
2005 Arctic Cat Service Manu al - all models - www. ReadManu als.co m
Harness A
(pi n 16B6-077) Z 370
/tOrn: 1. COttNECTORS SItOWH FROM MATING SURFACE SID.
!) SWITCH. DI MMEIl/BRAJ([
2. MAlE PIN TERMIIW. FEMAlERECEPTACLTEIIMtIlAL
2J CONNECTtIR. HOOD KARNESS

t3' @ 'IDU' \.V "",. ClOSED @ 'HIGH-SPEED"
e-
1 MAIIIW.IEY SWITCH (N.OJ COHTACT ClOSURES AS FOllOWS:
COHTACT
SWITCI!, SIOP/lllRomE
POSITIOM Off Ott
I+Y NOHE
BUTTON, EMERGEIICY STOP PUSH
CONNECTOR, DelNE
REGULIIOR
CD
m
SWITCH, MAHUAl KEY
m +WHY @'I.DWBWr'
Yn+ BLU @ 'HIGHBEAM'
UEMENT. THUMBWARMER
CD
~
HIGH
'6
8O'
"WI I
em
,IN.,
CD
ELEMENT. R.IWDWARMER
10
ELEMENT. l. HANOWAJIMER
DIMMER
...-'e e'
.fD
BL,
YU
io U
CLOSED@'tDL"
_'PEl! @"RUN " ClOSED @'ST1lfI'

onll @'HIGH-SPEED"
11 SWITCH, L HAHDWARMER
12 SWITCI!, R, THUMBWARMER
CLOSED@'STOP"
OPEII @'RUIf"
, rg
@
ru
m m
~ w
"
@
B""
Offll @"FUll' CLOSED @'EMPTY"
CD
!:l
15 SENSDfI, OIL
l>
g . n
@
OPEX @'OFP CLOSU @'ON'
@~~
~ ~m I
()
!<
< g'
g>
, - -------------------- -- - ----,
, c
RIGKT KAHD CONTROl
;:
OPOI @'Ofr CLOSED@"Ofi'
"-
g:,
;;;
8.
LEFT HAND CONTROL
M
" ~~I !i
91 .
il'
ru
,J
IGlIlTION
!ii I "
CD
, c
I
;:
;;;
"
I n~) ,
40HNS @72 F I
il
I
(SEE NOTE 1 , 3)
g
I gl
CD
0739-878
' _______________ CD CD J' L __________ --'69
I@
I !rc~~r~~~~~~~!'~~f~~~1
I Htttitttrttttttiii
1 1 1IIF~~~i'
..
8:
Page: 328
Harness C
(pi n 1686-008/1686055 EXT) Firecat 600 EFI EXT Firecat 600 EFI/600 EFI Sno Pro Firecat 700 EFI EXT Firecat 700 EFI1700 EFI Sno Pro
CD
IJ"V SERYONOTOR
-O~ ~
0"0
INJECTOR, FUEL #2
INJECTOR, FUEL #1
PUMP, FUEL
salSOR, THROlTlI POSITION ITPS)
Eeu
APV I VOLTA&( REGULATOR
SENSOR, MOT~PEEDO
11 ,A/WOO
(I)
ff I i il I..i ----------->----------erg
r:.t:o.:
"12
cottNECTOR, 11000 HARNESS
~ w
"
ill
15 ElEMENT. TIIUMBWARNER
CD
l' ElENEIIT, R . IWIDWARMER
c&
==-CD
@ -_.
17 El.EMOO, L IWtDWARNER
~ l>
11 CONHECTOfI:. ACCESSOtrY{l'[fHER
g , n
""
()
!<
< g'
1::7'=
g>
~ ~! Q,\~ ill ~@' -( f f' I~I @

~
'='\"!Ior
y'W .
, c
;:
" g:,
@
!it
;;;
8.
21 SEIlSOft, CRANIIJIGlI
U
~@
.:::.\~
21 STATOR
IIOTIS.
1 . CONNECTORS SHOWN FROM MATING SURFACf SIDE.
'ff'
C!!!
il'
X +Y
l MAl! PtN TERM JIW. FEMALE RECEPTAClITERMIIlAL 3. m SWITCH COMTACT ClOSliRESAS FDU.OWS: POSITIOI CONTACT
r:::s>4"
'=
Off
, c
NOME
;:
;;;
il 3
ON HOME 4. WARMER SWITCHES cotI'TACT ClOSURE AS FOllOWS: lOi!I!O.I! !IW COHlACJ HIGH BRN+ GRII + 811 NED BRH+GRN LOW BRN+8U
-_.
Off
0739-993
611
Harness D
(pi n 1686-083) Z 570
CD
MAGNET
1 REGULATOR
DI~~P
CD
MAGNET
SWllCH, STOP/THOTTU
0I'lII @'RUN"
OI'ElI @'IDLF'
SWJTCH. CARB. MAGNETS

ClOS[D@'aul!"
a.os1l @ "Sl~~
OPEl! @"IDl"
(5)
~~=]I
(5) ClOSUl@"R~tr'
TAlWGHT
SWllCH, MAJOUIL KEY
CD
L
~
6 ELEMElIT, THUMBWIIIMER
~===:'J
lliMElIT, HAJj'WIIINER
8 ELEMENT, HANDWARMER
o
rc::;
9 SWITCH, HANOWARMERS
~
.---~ '" I
m
RED
ft
~ ..' m
e ~
,.
RD
12 SWllCH,OIMM!I!,1I11A11
13
m
' - ''''-
CONNECTOR,ACCESSORY
li
i!
m
II.
"
14 COHHECIOI!, HODO HARNESS
YR+ II.U @"IIIGIIBtUiI' Tn + WH1 @"lOW 1WI"
~ ~
~ w
15 COfINECTOR. ENGINE
Dl ...R ~
~ l>
g , n
;::::::t+.--~~~ ~
m@
tFi::J W
e su IIOTE 1&3)
()
!<
!I$'/:
< g'
g>
---1
CD
, c
1 - - --,
;:
@ I . 1mo'I.1JIin.
ee
iJ
-NOTES,
"-
[1 -
g:,
-0 - - - -1- - - -- - !fll..'t'l,ll,:
RIGHT IWID
I aJmOL
;;;
8.
mo'~'9j\:
un !WID
M
~
Pi e e)
~
1
il'
m QJdJ
COIITRUI.
1. CONNECTORS SttQWN fROM MATING SURFACE SID.
;:
LCJ~VLL_~5 " "';e~ :"'~~-Jl!
, c
~~
2 MALE PIN TERMINAL a ffMALE REClPIACl.E TERMINAL 3. KEY swaCH 1'.0.1 COHTACl CLOSURES AS fOUOWS, POsmON ~
Off
;;;
O'
I I
NONE
x+y
il 3
~
I I
I lSI
CD
[5)
I tIM~ 1
'
o L ________
I L ___________
I ~
0739902
6-12
Harness E
CD
-~
(pi n 0686-988) M6 M7
1 APV SERVOMOTOR
INIECTOfI, FUEL #2 (PTO)
INJECTOR, FUEl#l (PTO)
PUMP, FUEL
SEJISOR, THROTTlE POSmON UPS}
ECU
SWITCH, E -STOP/AX1.
SENSOR, SPfEDO
REGULAIOR,VOLTAGE
10 SWlTCI!, KEY
Ii
II
IIII!II
--. ---- .w...,..:
CD CD CD
~ w
~.-rb
::>IiI Q~
L'
"
~G)
~I I
~ .:::.\~
~.t:' :\~
_ ii I
ElEMEIIT, THUMBWIRMEII
~ l>
11 ElEMEJIT, L IWIDWARMEII
g , n
In r.=.lli)
()
!<
~ @ r
I'
< g'
,
:::'I =m
g>
, c
o
!..
;:
!k~ .._..,., -_.,

@ @
~~ ~
1 1 := 0-
~~@'- ~
-~~.~
,
,.....
" g:,
--@
:\~
;;;
@
8.
21 FUEL SELECT
- - --
------1
il'
HOTES:
;:
, c
HOKE TW COHTACT BRN+GRII/RED
1. CONNECTORS SHOWN FROM MATING SURfACE SIDE. 2.eMAUPIN TlRMHW.
i~ '
,
@:~
;;;
x+y
o mw.E RECEPTACLI Tt:RMtlW.
3. KEY SWITCH CONTACT a.OSLlRESAS FOllOWS: POsmON ~
il 3
8RH+YEl/GRII
NONE
OFF
ON
4. WAIIMER SWITCHES COHTACT ClOSUIIf AS FOllOWS,
POSITION HIGH
lOW
KW COffTACT BlII +GRM/WHT
BRN+GRII/BUI
~~o
I
Off
HOME
o ; ij
J.<n
I I
IOn
L _
11 @
I ~
__ @un.... '
___@ 15 __
0739-990
613
Harness F
CD
~
CD
(pi n 1686-085) Z 570 LX MAGN!
,PO
@ ..... CLOSED @'AUM'
1 ) RGULATOR, LCT1I~ STIRI
:Jt4-1
,
!f!lm\~
~~
CD
OPOI @,III'
...........
r"'\\ r<\\ OPal @"\IIl!' \...y CLOSED @"IIIIff' \.jJ
I
...L
MAGNET
CD
.--+
DIDO, BATrnIY CHARGING
o
:;;,;q
~!r ~
SWITCH, RVRS-UNKAG
0 --./
L....
-t
CD
-4
i \
ALARM, REVUlSE
SWITCH, STOP/THROTTlE.
SWITCH, CARB. MAGNTS
il~.R
iQ]j)'" ,..~~ ...
TAJWGHT
0
W
~
r-
~~
8 SWITCH, LcrRIC START kEY
I II ~~ _______
9 STARTR
SOUNOID
@
m lo
ml~~ -
!
u.
(ItIIIIl.I). _ _ _
P!
""""" ----.J
(YLn +_-----.
(SElII(ITU)
BATrnIY, l2V
I'UtILU @ "IIIGIIIWII' m.+WIIT@ 1.DW1UII"
FUSEHOtDER
r----,
ttl
13 LEMNT, TlIUMBWARMR
o "'
~ - ...... ----. _It

CIllO _. _ _ IGRITIOII
<0
"
w w
. tWlOWARMR 14 LMNT, R
15 EUMENT, L HAHDWARMER
00 ...
~
ID\
'-~ @ ...r & w e. ~l
0 0
11 SWITCH. HAHDWARMER 17 SWITCH, THUMBWARMER
l>
". n
18 SENSOR, Oil
()
19 SWITCH,DIMMER/BRAKE
!<
'".' @ 8 I . "" @
ClOSED @ 'DI'Tf"
'" <
CONNECTOR, HOOO HARNESS
0 & m~. ~~~M' ~~~~~~o:m::::~ ::::i===~~__t-______~ ~

.....

ii
'"
n'
22 CONNECTOR, ENGINE
II: rt -- @ ---;-- --- --,
;: , c
23 GROUND, ENGINE CHASSIS
~\~
=D\~
",
g:,
;;;
8.
un IWII
IIIGIIT MAID
~ ~ ~i. ' __~m !
II
....... -
NOTS, 1. CONNECTORS SHOWN FROM MATlMG SURFACE SlOE. 2. MAll PIN TtRMINAL o FtMALE RECEPlACU TERMINAL 3. KI1' SWITCH {N.oJ COffTACT CLOSURES AS FOllOWS: POSIlIOI< CONI!CJ Off +M+ -M ON BH START (MOMENTARY) B+S
Itt
;m

[Q]
;0
;:
, c
IAI : I g
23 eo. @
;;;
n 0
__ @. _ _..l __ _____ @_ ~
4_ 0 1:" r I
la O):
n l
!5J
0= IOl
CD
1-
0739-898
6-14
Harness G
(pin 1686'()89) Pantera 550
. . . @ ..... . . . . @ ....
"" .......CD . Ol
V
a.osm o ,ur
r
"' (0)
I
.p..;fJ - I
..
r--.J
---------.
--/
~ u o ...
I I
CD CD
CD
0l'OI 0 "OFr
Q.OS(II @ ....
~ w
"
l>
g , n
()
@
(IlUu;J A------. lIItMU111 ___
!<
< g'
g>
, c
;:
"-
g:,
;
;;;
8.
~
m
Xi-,
; F===F=~ .
C
0)
il'
~
:
, c
;:
" . .:. : . .p " , ~ 'L _" 'm @
-aW--
~
@
;;;
~
:
~I
~ ~
il
Qh;~ . iV Ij-~ ~ _@ : ;;: II :':'1 :1 ~~

I !
__ ~
17
..
@
I
HI! [
__ L_ \!V _______ @
@~
0739-892
6-15
Harness H
CD
_~:-,-:: ",,~' ~ . ~ EO
~ QfU ..,.'
...... "'" .......

CD "SlU1"
CD
~\~
OI'U @ 'IIGI-srar
(pi n lSBS'()79) Z 370 LX
RECUlATOR. ELECTRIC START

CII'O 'fGrwMlI"
NOTES: 1. CONNECTORS SHOWN FROM MAnNG SURfAC SID.
SWITCH, RmRStLlNI\AGE
2 MALE PIN TERMINAL o FEMALE RECEPTACl1 TERMINAL
CD
o
~
AWlM, REVERSE
3. KEY SWITCH (H .D .l GOHTACT CLOSlJRES AS FOllOWS,
I'IlSlllllll
CDIIl!CT
SWITCH, SJOP/THlHlnu
,_ _ ILIi
\'-'1 -..
+M+ M
~
r.YJ.
.,..
........
"""@ -
TAIWGHT
DFf OH STARl(MOMOOARn
B+A B+S
iI
~ ..
r .
""" ,
CD
SWJTCH, ELECTRIC START KEY
STARTER
a
"" (01 . )''''
OlGA
I.Il.I
~
W
..
..
"' 0
1IlD.'ftfl
(ft.O
ft
SOUNOID
BATmIY, \2Y
1lI.
~
,
r
!l
I
I
.~
FUSEHOLEDElI
lB.+RlS '1I\gj WAr "Ill.-+ 1IIff U'l1WI'
ELEMENT, THUMBWAIIMERS
~ w
@
"
ELEMElII, HAHOWARMER
~
~ CD
(SEUOTEIl
:EMUlI -- r
t---.J
1lU.,. ----.
13 lliMEHT. HANDWARMER
m.
l::
-~
~L.
~ l>
15 SWITCH, THUMBWARMER
;lK T =
...
.... /-\ ~ . . . ~ :~J~

~ / ~
+ .------.
II*llOII
I11III - -
g , n
11) GOHNECTOR, ACCESSORY
()
@
0
T n
[
a
@ .. .. o J]
. jl'
0 "'
!<
18) GOHHECTQR, HOOO HARNESS
@ "'"
g>
1....: ... K
@
"
---1
CI.OSU @ "EWfr .
A;
" ...
< g'
m
~ ......
DIODE, BATTElIY CHARGI HG
;:
2.2) GROUND, ENGINE CKlSSIS
~ ~ ~ ~ l ~ ~ @- ~ ~-
, c
"-
........ .
CftlI @"Off'
. . . . @ ....
" " @ ....
g:,
;;;
8.
"""" ""'"
....
1 1 1
:I
I:
a
iI
1 1
lJbl
~
1 I.om..i: '
:1
1 1 1 1 1 1 1
.~
il'
T
loa
I '" @
.'
...
"'"
;
;:
, c
UIIII$@11" f I
;;;
J
Ig i
1 1 1 1
I g,
1 51):
:0:
~
~ .~
... !l CD
1m
il 3
. ~ ~ @ ~ ~ ~I~ ~ @~ ~ ~ ~ ~@~
R5l
R5l
CD CD
(ffi n'n @
~
jm
0739-904
6-16
Harness I
CD
~
"""""'
MAGNET MAGNET
(3)
!!!!,,'!;~
... ...
(5) &'l!o\"'" (5) !!!!m1.1\\0.
'0

.~
(pi n 1686-081 ) Z440 LX
REGULATOR
DIODE, BAmRY CHARG ING
SWITCH, REYIRSE-UNKAGE
NOTES: 1. CONNECT ORS SMOWN FJWM MAnNG SURFACE SID. 2 MAlt PIN ltRMINAl . a FEMALE RECEPTACLE tERMINAL 3. KY SWITCH IN.O J CONTACT ctOSURES AS FOLLOWS ,
CD
g
~
JJ I I
II
CD
ALlRM. REVERSE
illIIIlI.II
CD
"" CUI5BI/I,' I EmIS["
i ;1
l
...
1!l a~ a
SWfTCH, STOP/T1lROnu
comcJ Off +111 + -M ON 8+A SIARI (_ENTARYI 8+S
SWITCH, CARB. MAGNETS
W
ft
I
(1EMlJ}1 ___ w.ir1C
IUtfIHI
al. l
rQIj)'"
,;
I
TAlWGHT
SWITCH, ruCTRICSTART
0 1'1
STARtER
"~ n~
" ~
m .... @'llG11WI'
SOLENOID
m +"IMT @'\OWwr
,
!
IIMLU
~ ~:;
BAmRY. I2Y
I
./ '::.
..
FUSEHOLDER
, --I .. ~
-- --
~~ ~ lU
rrl fu 0 .."- - .
CD
, ,,"
ELEMEHT. THUMBWARMER
m
<0
"
~[
m.,\'1'... ,.s,) II i
.
I
--"'.
@
"..J
-,-"
... . -""" ~
'.....",-----1
w w
ELEMENT. R . IWOWARMER
::iii: bJJ
I'll} + M ------.
ELEMENT. L. HANDWARMER
::.m:
@
aa a"
II
II
.... ---- .....
0 0
13 14 15 16
SWITCH, KANDWARMER
k~ ...11
...
l>
17
swrrCH, THUMBWARMER
". n
18
SE.NSOR, OIL
()
!,,; &'l!o\Wor ~
~~
I I
!<
'" <
- --1
.
~~
a
. @~~==============*=~~-+----~
~ .
22
SWITCH, DIMMER/BRAItE
ri -- @ ---'-- @ --
n' ;: , c
23
GROUND, ENGINE CHASSIS
",
:\;w,. .........
01"11
I I
........
a
,;
.... /1,....
g:,
;;;
8.
un ...
M
.'
,
, ~
""'"
, ,
"'v~r

( CIIIlIS @JT f
;0
g m.
;-:.-@
, c
;:
..
0-
;;;
:l ei
a
laO):
@fri4
CD
@
n 0
L __
@ ___ ~ __@ _____@ _ ~
.. A
10
"" +
@
@~
t
0739-907
6-17
Harness J
(pi n 1686-105) King Cat 900
SWtICtt IHMMR/8RAKI
CONNECTOR, HOOD HARNESS
COHHECTOR, TEMP. SWITCII
'f'El+ 81U @"H1GHBWr" YEl+WHT @ 'lOWBEAM'
CD CD
C!J
Q.OSD @ "Har
CONNECTOR. EHGlKE
~ o ...,
OP{, @-"'
SWITCH, FLOAT SENSOR
REGULATOR
'"
ClOSED @ "EMPTI"
II
OPEN @"fULL'
ltgg;~L ------_ t -~TCD o!
*
.~
SWfTCH. MAHUAllEY
EUMOO, THUMBWARMEJI
8 EUMOO, R . KAHOWARMEJI
10 ELIMENT, L HANDWARMER
m
11 SWfTCH. HANDWUMER
..
0.
.
o!
U!L.(c5
~~~
iii
;;
:I
--
12
SWlIett. THUMBWARMER
~ @ ~~
0 '" .0 RED
r
~
13 TAILLIGi!t
~ w
- 1- - - - - - - -r- -,
"
BlltH GRNJWHT @'HI'
14
CONNECTOR, ACCESSORY
@
~
@
BRN+ GRM/RED @ 'HI'
~ l>
g , n
Hl f=..]]
LOfi@
l!FT HAND
BRM+GRNJBtK @ "l.O"
BRN +YWGRN @'lO"
Hl f=..]]
iii
} 'rl[GR!
CRNJR(O
iii
;!
()
!<
RIGHTIWID COWlROl
LOfi@
BR.
_ IQ
;;
< g'
COH1ROl
g>
, c
;:
iiil "
"-
g:,
NOru:
;;;
;;!
8.
1. CONNCTORS SHOWN fROM MAnNG SURFACE SIDE.
2..
MAlI PIN TERMINAL fEMALE RECEPTACLE TERMINAL
DI~ 0 I:
LH-----GRfC/WHT OR",",
PI .
, ,
3. MAJjUAlIEY SWITCH (H.O .) CONTACT CLOSURES AS FOLLOWS:
COHTACT
=
~
'"
,J
40HMS @12 '
IGIIITlOtf
il'
HOHE
1+'
, c
OHMS
;:
;;;
e
'HI
ISlE lion: ll3)
il 3
LO
~
LO
11 OHMS
LO
12 OHMS @J2'
________________
CD
CD CD
~
IIOttMS
L __________
0739-885
6-18
]l
e~
e ~l ~
~
~
o
0
~
~
- .;,
'" ~
~~I~~~~ U~ii
e ~--f t:
~ :oll
0
11 ~ ~
+:I!i
7.
in ~;
~......
1\J c.....
1II:1IIi'"
n 1J
a: e
0e
I J.w
I i
If{
~ll
eO
...
,
...
!,
!
I'" ,,,
@
o i @ q~~
c c
~
.. ijt~
:::
...
.! ~
,
W
:=
()
Page: 337
Harness L
_w
(pi n 1686111) Firecat 600 EFI r Firecat 700 EFI r
APV SERVOMOTOR
INJECTOR. FUEl#2
IMJECTOR, FUEL #1
PUMP, f\JEL
CD
SENSOR, THROnlf POSITION (WS)
EctJ
SWlTCII, SlOP
REGULATOR, VOlTACE
~(3)
,
9 SWlTCII, KEY
10 11 SWITCH, REYERSEUNKAGE 12 SWITCH. THUMBWARMER 13 SWITCH, HIlIOWARMR
TAIlliGHT
CD
o/~
~~
H CD
<0
"
14 ElEMENT, THUMBWARMER
w w
15 ruMENI, R . HAROWARMER 16 EtEMENT. l twlOWARMER
I '-~ -~-.
0 0
11 COftNECTOR, ACCESSORU/TETHER
l>
18 SENSOR, lOW Oil
~@
". n
U_ _ en"f
()
C)
:e:::J.':C
!<
_ _ e l2 "f
'" <
n'
22 SWlTCII. ~MMEJIIIIIlW
<IlIL\Ye
7I
~~
23
GROUND. CHASSIS
;: , c
24
C~l,
HV IGNmO!<
IJJ
",
~ SENSOR, AIR TENP.
@ @
~
@
g:,
SENSOR. WATIR lEMO
;;;
8.
swmCH, IXlE (RPSI
MACNETO
2t 21 2t 2t
SENSOR, CRANK AlfGLE
W
m
;0
~
X+Y
STATOR
13 11"'@l ~
1jI.~
30 31
FUEl SELECT
NOlES. 1. CONNECTORS SMQWN f1KlM MATING SURFACE SID.
, c
;:
2. Mlli PINTERMINAl o FEMALE RECEPTACLE TERMINAL 3. KlY SWITCH CONTACT CLOSURES AS FOLLOWS:
-.-
-.~
;;;
n 0
.l.!... ru<e. @
NONE . WARMER SWITCHES CONTACT CLOSURE AS FOllOWS; POSITION HW CONTACT JW COHIACI BRN +GRN/WHT+ BUlWHT BRN+GRH/WlfT LOW BRN + 8lI BRH+BLK/WHT OFF HONE NOHE
a_.
mm @ ~~ @
0739997
620
Harness M
CD
Of'EJj @"f(lI'I'.IID'
a.GWI @'MISE"
(pin 1686-118) Panther 370
CD CD
1 REGULATOR
2 swrrtIl, REVERSE-UNIAGE
......M,REVERSE
TAIlliGHT
SWITCH, STOP/THROnu
SWITCH, MANUAL KEY
7 ELEMEIfT, THUMBWASIMER
,
i!!
I
;;;~ P~ ~
8 ElEMENT, R. HlNOWARMER 9 ElIMENT, L IlAHDWARMER

iii ..
i
~
10 swnCl!, HAHDWARMER
IElI
In ..
if
t 5 'e. 1'ItL
11 SWITCH. THUMBWARMER
12 SENSOR, OIL
m.+ W!IJ @ '\OWIUoIII'
m.+1W @'11G111U1r@4
~ w
"
I, :
"' 10 F-i.i
1
OJ 'n
110
OI.Et
:;:
13 CONNECTOR, ACCESSORY 14 SWITCH, DIMMER/BRME 15 CONNECTOR, HOOD HARNESS 16 CONNECTOR, EOGINE
,i' "" ClOWI~"mIl"

@
'n !! ...u~---.II~sTii)! o e !!-JV'\!!
....
'"
@
eo
L~~~=""l O 0 00 "
~ e
'" e e
~ l>
g , n
01'01 @'tIISH-Sf'UO"
CI.O$!l) ijiI "O!.1"
()
!<
g>
I .
ee
00
ftC
OPEl @'fUU' a.GWI @'DI'Tf'
Of'ElI @'IIr CLOSED@'rrOf"'
< g'
..... "'"
o e ...
I I
i
;:
""'"
-,
O ,n
_ -I-...
tC\ \.!;
1--+-1 0"
GPO @'IIIU" Cl.IlSOI @"IIIIiH.SI'UD'
EllUlGElICY STOP
....
, c
I
I
,J
NOTES,
(SIU(IlUU}
"-
g:,
0I'lI @'Off" CUlSElI@"OII"
--------r---------
;;;
HlI{l'IWID
8.
a.osED @ "D1f'
OPE.
@'Off"
il'
~
""'"
IDle e)
~
M .....
~
"m...
.....
, c
, "' (00)
;:
!:DCero] 6 re x ..
;;;
LQg '"
~
_I 100) , i
40111S @I! ' r
8 CD
il 3
' ~ r~
1. CONNECTORS SffOWN fROM MATING SURFACE SID. 2 MAll PIN TERMINAL
o FEMAlf RECEPTACLE TERMiNAl
3.
m SWITCH (M.OJ CONTACT CLOSURES AS fOLLOWS;

~mllll
J:IlIlL!l:l
OFF
~
I
ON
X+Y NOlIE
(j) J' L _________ ,___________
CD
'
CD
0739972
6-21
Harness N
CD CD
(!)
~
o
CD CD
(pi n 0686-765) Panther 570
RGUl.IIOR, lIClRIC STARI
~
OJ
~ n~ ~
o
0 fj
BRN
SWITCH, RmRSf LINKAGE
~
.'"
ORG
ALARM, RMJlSf
SWnCII, SIOt'/lHROm
SWITCH, CARB.
. ,=
ltl
TAlWGHT SWITCH, ELECTRIC START KEY
STARTER
~ .
I
e
YEL
RED
SOLENOID
BATTERY, l2V
FUSE HOLDER
ruSE UAMP
YEL
VEL
HANDWARMER, LH.
D[~ . . . .
VEL
~
@
RED WHT VEL VEL
"
!2
~
THUMBWARMER
H .. OWARMR, R .H .
I II
~.
RED
* ~
1 0 0 """
I
BLU
SWIlCH,IHUMBWARMR SWIICII, H"OWARMJI-LH.
""'"
BLU
WHT
p: l!: t'II
_ -
e
II
@ @
o,
~
(StAHlQ A -----,
l>
HARNESS, HOOD
(e 01)
(RED/WKT) s~ START
{RED/BlUIB- '.,.! ELECTRIC
g , n
CONNECTOR, ENGINE
~~
()
!<
SENSOR, LOW OIL
"YEl
g>
SWlTCH, DIMMEIl/BRAKI
RED
o
CD
t MAU PIN lJtMlNAl
tvLn
+M ~
(BRN) -M- .,! IGNITION
< g '
Z2
0100~ CHARGING
;:
"-
g:,
;;;
8.
l!!
frKlTES; 1. CONNECTORS SHOWl( fROM MATING StlRfAt( SIDE.
Jl
(W
~1
a FEMALE RECEPTACU TERMIIW.

3. KY SWITCH (N.O..) COfrflACT CLOSURES AS FOUOWS POSITION
~
il'
, c
;:
OFF ON SlARl {MOMNTARY!
B+A
+M +M
B+S
;;;
il 3
'" '"
~~
~EI
~
CHASSIS
0)
3 0iiz-".
A
ENGINE CHASS I S
A @
ENG INE
-,.:m
0737-339
6-22
Harness 0
(pi n
M5
1686~24 )
1 STATORJFLOOm, JrtGINE ASSY.
COILS, STATOR
ru
CD
lQ;t[D
SEHSOR, CRANK AMGlI

~
SWlleH. CARl MAGNETS
SWITCH, kEY
lir:===:==
... on
MAG'"
COl
7 SWITCH, E STOP
CD
8 REGULATOR, At
(5)
~.
A'~ (j)
(5)
~
f1~~
MOTU: 1. CONNECTORS SMOWH FROM MATING SURFACE SID.
TAIWGKl
9 10
ELENOO, R. HANDWARMER
[~iF5[
oIlII.'L"\\I""""' oIlII.'L","
WMEHT, L. HAHDWARMER
ELEMENT, R . HAHDWARMER
~
~
"
13 SWITCH, HANDWARMER
r=~~")~ In ..-
14 SWITCH, THUMBW,RMER
15 SWITCH, D1MMElIJ1RAKE
"
11) COfjNECTOR, HOOD HARNESS
~ l>
7 SENSOR, LOW OIL
g , n
SWITCH, TEMP.
Jn ~ I!::::;''' ''' ~i
@'= -
CD
SENSOR, SPEEoo
o fEMALE RECPTACLE TERMINAL 3. lEY SWITCH CONTACT CLOSURES AS FOu.oW~
2 MALE PIN TERMINAL
()
!<
< g'
~
~
g>
18 19 20
GROOND, CHASSIS
v@
.
ru
IIO~~
ON NONE 4. WARMER SWITCHES CONTACT ClOSURE AS FOLLOWS: fO.SJIlQtl trW COHTACT JW COtffACT
LOW
~~
;:
HIGH
, c
OFF
HONE
BRN+GRN/BlK
BRN+GRNJWIfT BRN+GRNlREO
BRN+m.tGRN
NONE
"-
g:,
@( r l
.mi."'!&)"
- 1 - - - - - - - - - -+1
IE
;;;
8.
CD
.... m:~nW::J}i .
ru
, ~~-'
..
@:F1l
tiID) tiID)
r- - - - - -
eJJ ~
il'
. -.@:F1l
~ ~Ol!
ru
I
OI'UI @' "
, c
;:
;;;
il 3
I
I eGo :
~ OO
eGo
I II
I
14 n
1 4n
I L ___
( l2 o.n, @ 12 ___ ...L _ ____10. __ .J

0740-013
623
Harness P
(pin 1686-047) Firecat 7001700 Sno Pro
1 STAtOR/FLYWHEEl. [HGINE WY.
St:RVOMOTDR APV
SENSOR, TIIROmE POSITION (lPS)
CD
COl
o
CD
REGUlATOR, At
TAILLIGHT
GROUND, CHASSIS SWnCH, THUMSWARMER SWITCH, HAHOWARMR
10 ruMEHT, THUMSWARMER
11 nUIENT, R . IWIDWARMER
12 EU:MENT, L IWIDWARMER
"
13 COIINECTOR, ACCESSORY/TrnlER
!!II'
l>
~
@
::-:,,:::
eu . -
16 cotINECTOI, HOOD HARNESS
,:
III&B
g , n
()
!<
< g'
g>
I'
@ - .@
@ '1 ':'::'"1,

iIni
, c
;:
~ -.~
.=.s::;..
" g:,
NOlES<
1. CONNECTORS SHOWJII FROM MATIMG SURFACE SIDE. 2. MALE PIHTIRMINAl
25 SENSOR, CRANl-AHGLE
;;;
8.
il'
~
o FEMAIl RECEPTACLE ltRMINAl
3. KY SWITCH CONTACT ClOSURES AS FOllOWS: POSITION CONTACT ----ofF ~ OM HONE
4. WAIIMER SWITCHES COHTACT CLOSURE AS FOUOWS:
lOSI.II.QIt .HI COHTACT
JW COHIACI
EJj -.--. -.@
, c
;:
;;;
HIGH OED
@ i.tJ w
+8l1lWHT
BRN+GRNJWHT BRN+BWMlT NONE
il 3
LOW OFF
o
I
0
0739994
6-24
Harness Q
(pi n 1686-107) King Cat 900 EFI
1 SWaCH, DIMMElIJ1IRAKE
CONNECTOR,HOODHARKESS
m.+ 8LU @"H 1 GHawr VEL +WHT @"lOWBEAM"
CD ,,, CD
'e e'
III
CD
BRH SPLICE
CONNECTOR, Eeu HARNESS
CONNECTOR, ENGINE
DIM MER
REGUlATOR, APV
.-.
. [9
OPEII @"ruu'
CLOSED @"EMPTY"
6
'> iT
ElEMENT, THUMBWARMEfI
7 ELEMEHT, R. HIIIDWARMER
CD
Tn
OPEN @ "RUN" a.OSED @ "STOP"
8 ELEMENT, L HAIIOWARMER
8R.IIIE
swaCH, HAHDWARMER
~~
CD
BRII+ GRNJRf:D @ "H I"
~
@
,,,
III
l:)::: :I@
~
8lI11 +GR/VIVIff @ "tI1" BRII+ GRHi1ILK @"LO"
BRII+ Yt.lJGRH @"lO"
"
~ l>
NOTIS:
g , n
UFTIWID COHlROl
1. CONNECTORS SHOWN fIOM MATING SURFACE SIDE.
HI r==tJ
mJGRH
()
!<
RIGHTIWIO
COlITRIIl
2 MAlE PIN TERMINAl
g>
Q FEMAl RECEPTACLE TERMINAL
Hl r==tJ W ci:ID
W W
Tn
3, MAHUAl KEY SWITCH (H ,D .' CDHTACT CLOSURES AS FDUDWS,
< g'
12mJ2f!
, c
;:
OFF
ON
ClOOill X+Y
NONE
CD
APYDIOOE
"-
g:,
;;;
j;! j;!
8.
(o, e e '
'
il'
~
'')j e ioo
I I
')j
I
\!!!!J
_1 00
I
~
')j e ,o
I
, c
itt
W
;:
0I
SOHMS 4QHMS @12"
0
W W
;;;
1& OHM S
I____________ L I
il 3
16 OHMS
12 OHMS @ 12
CD
________________ _
CD
CD
0739-882
6-25
Harness R
CD
~!m\'or"
CD
"'on
CI.OSllI @ ....,. a.DSm @ '1U1'
(pi n 1686-087) Bearcat 570
CD
OI'EI @'IDl1"
1 REGULAtOR
0I'ElI @ ' 1DI.l"
or~
SWITCH, REVERSELlNKAGE
. . . . @ """
@ "fOtWMO"
CD CD
~9~.
---,
...........
C5l C5l
OPEl @"H'"
.....
AlARM, RfYERS[
!~ ~
SWITCH, STOP/lHROTTLI
SW1TCI!, CARB. MAGNETS
TAIWGHT
.
(
SW1TCI!, MIIIUIUEY ELEMENT, THUMBWARMER
:.
W
ft
(j)
EUMENT, R. KAHDWARMER
ElEMENT, L HAIIDWARMER
11
SWITCH, HANDWARMER
...
.~
12 SWlTCI!, llIUMBWIJIMER
~
@
"
...
...
CONNECTOR, HOOD IWINESS
l>
17 CONNECTOR, ENGINE
::J ~
($UIIOTtl U )
g , n
--1
()
!<
g>
IE
@
..I+GAIJ1IllI @ .... lI . . ftt,.,;III @ 'tO"
0PflI @ 'fULl"
CLOSED @ "DIPn"
< g'
r - - - - - - T - - - - - - - - - - -
, c
;:
" g:,
'\t=::iJ LOW
;;;
8.
~l ~
........
..,.~
NOTES: 1. CONNECTOfiS SHOWN FROM MATING SURfACE SIDE. t MAl! PIN TEIIMIMll o FlMAlE REClPTACU TERMINAL
"''',
..,.~
3. MANUAL KEY SW1TCI! (N.O .) CONTACT Cl.OSURES AS FOLLOWS,
il'
Off
ON
posmON
COIIIACT
----x+Y
HONE
, c
. IOOd
;:
;;;
",PI' -.)
I I
I 11 OHMS
il 3
oo ; ~ oo
. ...
- - - _ - ..I. __ ______ _
0739-897
II~
6-26
Harness S
(pi n 1686-001) Sabercat 500
1 GROUND, ENGINE
STATOR/ftlWHlli ENGINE ASSl.
COILS, STATOR
C!)
SENSOR, CRAMIANGLE
COI~
HY IGNrnON
GROUNO, CHASSIS
7 SWITCH, CAR MAGNEtS
CD
COl
SWITCH, kEY
~.~
;1 ~
o ...
-.
o
. a ir
"
14
dIM" lIf..
ELEMEHT, THUMBWIRMER
15 ELEMEHT, R . HANOWARMER
~ @~:;",==::::!.. ' --~

@
* ~
17 CONNECTOR, ACCESSORY/TiTHER
-----
. " 'O 'mPftll'
PIlJE GP " _
l>
g , n
()
!<
< g'
g>
JDJ/&TII>r!
J------------L----~---J~!; t t :; o
IE'H'
A\'M.r
1111 1'1'B'1fa'
m m
, c
~@
;:
23
SWtTCH, r...sTOP
"-
g:,
;;;
8.
J&
il'
HOlES, 1. CONNECTORS SttOWN FIWM MATING SURFACE SIDE. 2. eMALE PIN TERMINAL O fUIA.LE RECfPTAClE TERMINAL 3. lEY SWITCH CONTACT CLOSURES AS FOllOWS: .osmON CONTACT
-----.--;y
, c
;:
OFF ON
.@~
~
;;;
NONE 4. WARMER SWrrCHES CONTACT ClOSURE AS FOUQWS: POsmOH HW CONTACT 1W CONfACT HIGH BRN+GRN+BLX BRN+GRM/WKJ+BLIVWHT MED BRN+GRN BRN+GRNJWHT
r-=-"
....
@CEl!iiJ @
a_ II _ elf,
il 3
lOW
OFF
NONE
BRN+BLK
HONE
BRN+BLKJWHT
mrm
0739969
6-27
Harness T
(pin 1686-014) Sabercat 500 LX
mTOR/FlYWHEElASSY.. ENGINE
GROUND, EMG1NE
'rr.-- Z------ Z- - Z- Z--------- "$ BiIi!!'9 $ ~ I . -10

-
SENSOR, CIIAIU{'uGL
r\
(l[lf1l$tD) l---.
~.
o!
~~~i . ~ 't:"~
COIlS, HV
5 SwtTCtl, CARB. ,MAGNflS
B COl
7 SWITCH. ElfCTR)C START ID
-ft:. .. CD
::I~@
__ ntCTIIC
~. - ~ .
REGULATOR, At
AlARM, REVERSE
11 SWITCH, REVERS.lIIlIWlE
~!~~WWl!tI
lIWIlUl .I --- " I /IltII
"
13 ELfMEMT, TtlUMBWARMER
14 ruMENT, R , IWfDWARMER
(j)
o
CD
* ~
D IT~
I
.... @ ...
15 ELEMENT, L HANDWARMER
l>
17 SWITCH, DlMMER/BRAXE
g , n
.... e ....
o o
1Il ",l..Sl @ "SlOI'1'ED'
PUUE & '1I10JlllP'
()
!<
< g'
g>
@ @
a.oso o '(II""
iiiSGi
I'tL +WIIT @1.O-......
Ill+IUI @ "II-IUIII'
ClPElI @ 'fUll'
, c
1.n:L
;:
;
@
----I II.'
~"""" -
" g:,
n
1 ~ I .wJl
J
OUIIEI...-
W
Ia,"!!-,
m
;;;
8.
21 swtTC H , [-STOP
~
,
@
W~
ru
@j>'!!....l
~
@ @
lSunrUJ
~ I!! OPY~OIWARr
MOTES:
a.D$lD @ ' 1It'fEISl"
il'
- -
1.
3.
CONNECTD~
SHDWM FROM MATING SURFACE SIDE.
, c
;:
2, MAlE PINTERMIHAl
;;;
o FEMAlE RECEPTAClE TERMIIW. m SWITaI CONTACT ClOSURES AS rouows:

POSITION
~
il 3
START{MOMOOARY) 8+S 4. WARMER SWITCHES CONTACT ClOSURE AS
Off
+ 111 +-"
'""NONE
COHTACT
rouows:
POSITION HIGH MED
LO.
Off
0739967
6-28
!I @ ~ ;i
I,
'I
lrl+FttJi
iI
"
5~
(l{jJi . I m{ii
,l
4~~:: -- ~
Ij
c
~
~
i "
;:it:
*
0
~
oj
w
~
~
" ~,{"
u
~a @
t!
Ui
= .. ~~~O
w -*~ g:A:~ t;~i1 wl!w
~e~
, if I '"
Ii!
~
.~
~ .!: ~
..
~!!I +++~
.:
'" 5i....
!g~
d ~~!!il< *'8
~* ~
5al:t~!z
Ei
~ ~ iii ~I~l!; ;~
*~ ~ iIi=~
::.:
zzzz +++w
.. ..
'" ~
-""
!!j
'"
0
~
0 0
~ e eo
~
w
~
*
0
W
~
~
!! !! " ii! is
'" - '" '" d

0
~
9 9
.:
- - - -- ---- --- -c
:;j
~
~
!i< .. "
'I
0
. ,. .. .~ " '" i! ,.
e; e; e;
w
~ ~ w
E!
*
0
~
!l
'" i !i '" '" '" '" ~ a ~ ~ i "

~ ~
'" '5
Ei
Ii;
* C ;!
~
~ ~ z~
~
* ;!
-' ;! .: .: is is
'" a ,. " ~ ,. " .. .'" " . " ~ '" '" ~

0
lO! ::!
~ ~
~ ~ * * w w 8
::;
'" '" (
w
~
~ 0
;J
.: ~ * I" e;
~ ~ ~
,.
.:
!!
~
~
9
0
is
0
:;j
is
w *
~ ~
-' :;j :;j 8 is is
iii
I:s a:l
'd" '" '" '" '" '" ~ i is 8 0
G
w
~
:;j
;!!;
til iii I:i !II
Page: 347
2005 Arctic Cat Service Manu al - all models - www.ReadManuals.com
Harness V
(pin 1686-018) Sabercat 600 EFI Sabercat 600 EFI Sabercat 700 EFI Sabercat 700 EFI
EXT LX EXT LX
1. CONNECTORS SKOWN fROM MATlItG SlJRfACE SIDE..

-~
.....
APV srRYOMOToti
IIUEctOR, FUEL #2 (PTO)
IItIECTOIt FUEl #1 (PTO)
PUMP, FUEL
CD
mDQ!!. I!W COIfTACT
NIGH NED lOW Off BllII+GRII+ BlI 8RII+ GIHt BRII+ Bll ItOIIE
SEHSOR, THROm! POSmOIl
2..MALE PUI mlilllW. o FEMALE RC[PtACLE TtRMtlW. 3. aT SWlTCtI COlfTACT CLOSURES AS fOUDWS: POSmDIl COIfl'ACT OfT + M+ M START (MOMEIITAR'f) B+S 011 B+A 4. WARMER SWtTCIIES CONTACT ClOSURE AS fOWlW$;
Rf.GULAT~, IP
me.
".
CD
1W co!f11CT BRII+GR N.IWHJ+BI.JIWIIT -_ .. -_ .. ..
SWlTCII, STOfI
REMOTE START
swm:"",
~
_..I:'
"
+. rfrf==fl======~=Jrj~ , '
~
. :.,
l>
17
EIlMOIT, THUIlIWoVtMER
g , n
l..,..JL-1J @
()
!<
g>
< fl'
22
SWITCH, DINMElVSWE
, c
;:
II I I
=:I'l' _
, I'
" g:,
1,1 ,
;;;
@
r:.\-;:;..
I
8.
~ II I ~
I Iii I I
=.,;
~ ~, ~ t!J
;t..
",L;&;'&
-':&;.,
i:'
...
E~
~ III
_' IIi.
1 11~Mjll' .:..
~ ~
-.~~
~-@
, c
;:
;;;
bd
--. @
--
il 3
31
SEII$OfI, SPDO
@
0739986
6-30
Harness I
(pi n 0686-515)
... '"
z
~
!:!
HEADLIGHT
SPEEDOMETER
~
3 TACHOMETtR
4 OONNECTOR. OPTION ACCESSORY
is
5 CONNECTOR. M~N HARNESS
=FF
~ ~~ m~
:a)
,
. 1-
~~ ~
/'
::5 '"' ...
r-
e>
l-
IlU
.to
~
!:!
z
n
... '"
i-I
000
L
I~
""-'"
l@E II
jh((3Ej II
~~]
~~ .~--~-----~ ~::~~l
o
BRN
r=
il'
n-n ,
CD
, c
;:
BRN
II
I
VEL
---~ ' i ~~
;;
BlU
il 3
BlU
CD ...
RED
VEL
~=== WH= T =====I~~ ~ I ~__~~ RE ~ Dffl ~ HT~

~ R5i BRN
0737-324
6-31
Harness II
(pi n 0686-588)
BRN
VEL
VEL BRN
YEL
1 HEADLIGHT 2 SPEEDOMETER 3 At FUEL GAUGE
4 DIODE REClinER
FUSE,olAMP
TlCHMrnR
@
o
PNK
z
CONNECTQfI, Of'TIONAL ACCESSORY
5 6 1 8
CONNECTOfI, MAlN HARNESS
= '"
BRN BRN VEL
VEL
VEL
BRH
YEL
II
NOTES: 1. CONNECTORS SHOWN FROM MATING SURFACE SIDE. 2
o FEMALE RECEPTACLE TERMINAL

HOOD HARNESS
0737-327
MALE PIN TERMINAL
6-32
Harness III
(pi n 1686-115)
1 HEADUGKTS
2 SPEEDIIACH
3 COHH(CIOR. MAtH H<RHESS
4 CONNECTOR, ACCESSORY
NOTES, 1. CONNECTORS SHOWN FROM MATING SURFACE SIDE. 2 MALE PIN TERMINAL FEMALE RECEPTACLE TERMINAL
o
11+1--
MAJORMODSWlTCH
CD
f
'\
;
A
~
~
CD
i;,
"
~
!
;,
~==================~~~========~~E
.. , '>L'"
0739-998
6-33
Harness IV
Ipln 1686065)
HEADLlGKlS
SPEEDITACH
CDflNECTDR, MAIN IWINUS
CDNNECTDR, ACCUSDRY
NOTES, I. CONNECTORS SHOWN FROM MATING SURFACE SIDE. 2. MALE PIN TERMINAL FEMALE RECEPTACLE TERMiNAl
(j)1 (f)1I
+-- MUOR MODE SWITCH
+- MINOR MODE SWITCH
CD
~~~
CD
r--------~--------\
"""
'"
....
SPUCE
..,
0740-006
634
Harness V
(pi n 0686-856)
CD
Q Q
ij ~
CD
ij ~
::i
HfADUGHT
SPElllOMETER
:J
..
~
>-
TACIIOMETER
\/
"' I
~ ~
CONNECTOR, OPTION ACCESSORY
CONNECTOR. MNN HAIINESS
CD
g~ ~~ ~~
@ I @ ) \ ~ c:~ ~~ ~~ W
!;;
.. >- ..
~ . '"
"
N
~ w
~
:E
.. ,.
~
..
'"
'i'
~
:I~~~
::i l ~ ~
~ ~
~ l>
'"
'i'
~~
:
:::
g , n
rf9
~
"' i~
(')
!<
--
g>
fl' ;: , c
z
<
"-
g:, ::i
NOTES.
;;;
~
8.
::i
:l
. ..
CD
..
<D
YEL
VEL
1. CONNECTORS SHOWN FROM MATING SURFACE SIDE.
i:'
2 MALE PIN TERMINAL o FEMAlE RECEPTACLE TERMINAL
, c
;:
;;;
il 3
0738-170
6-35
... ...
8
(I
l # ImII-01
I]~ ~
l:!
e. 8 8 ~
~
'" ~ I ~
~
~
."
z
~
!Ii
Ii
r:l
u
Z
~
~
~ ~
t;
~
~ ~
Page: 354
=$:;;:==; ............. _ ... -
r------------------------~
, , ,
~~ ~~ ~~~ ~~
B I 1011. 1 I r lF'1
i!
:8 ~
~
o0
IL dv --:l
I
II
Ill o l(l
Ie. 't \
I
I L
, , I i
.'--'!'iiiiMO
, I
~ ~ ]
'
I
______ -. _________________ J I
. ... 1
~
Page; 355
... . . . ... . ... . . .
~
~
Page; 356
I I
I
@ [!;oj:8 ~, --i!
@ 1 [JtD @ 1 [JtD G :=jIbl 31~::~]~1'

@
Page; 357
::::.;:::;::;t::; _ _ ...........
w ......
@ ~ ~ n . \~ ~ ! , , T ' .. : ~ . , , r--- - -- - 1 - - - - - - - - - , !I I : 10 :8 ~ fjl. 1. I! , , iii , ' , ,
r-------- - ---------, , ,
' "II!
...
...
I
18..&iJ @
Page; 358
@ 1 l[ftD u;:;;;;..:....: @ \[fG Itfb @3f~::~]~
r--------------- ~
.,. ..
I
I , ' 1i~~~-:_IIh ,
, - - - - - - - - - - - - - - - " L-_ __
!
o
e
e l
Page; 359
r-------, ,
:@~ , ,
: @h ,
, ,
~i
~~ )~
"----,
l_ : __ _. .
, . I''''' I!''; l:jj..o'li" >ej .~ , ,

--------1
II
-.
"!l@ III~
I
1]]e
..
el
;.J L,J
I
~
QB i! . '1 e
;l
~e
Page; 360
r--------------------, ,
I
-------1
.
,
~I
."
I
u
i:i
:, : li ~
,
, , ,
~~ .
L ___________ _
______ J
, ,
" ~ 8
01
.
II
I~
@ @
@
r---------,
, L_
o!
II
I'
I .._,J
& ~
~
I
: rt
I I I
~ , ,r "
1' 8 '
11-~.
I
~~~_J
8 "I: ~_ ~_~_~
Page; 361
, ,
~---------------
@J[I~ , , , 1------
, f[i l:) ,
:"i ~
~!I
, 1
~
I ___ ..: L
. _ __ ________ 1
~G
ii
II
Ltt---~=FI==_t__J: 1] G
Page; 362
, , @~ , , , ....
,
,...-~--
r~~~---~----~----
~\
" :J'
+ o>=-.....~~!!.':
Page; 363
r-------------------------------, , , ,
, , , ,
U
U
B
: "" 1 .~ - 0 . :-;;' I
0
I
Ii.
r~~~~~~~~ ~-
,
II
I
: e i~Q t..=j~!! II~t:'j"I U@ i ~
~ ~I@ , T
I
,
B
__________ J
Page; 364
;;
, , >f!
:I
.. .
II ., " :Ii Ir ilii

r I
I.
}
:
.I
! . i s
.I
Page : 365
2005 Arctic Cat Service Manu al - all models - www.ReadManuals .com
d
o ,
Page; 366
==~;::;:;=;
.. - ................. -
:8 , [it:l
, 1----- --
, ,
r - -------------------~
1111.
I"
@ ;
II
e it
o
" li
@
!!
, :e ~ , ~
,
0 0
o !
B
.~
~----- ---------------~
Page; 367
gl s
Page; 368
, ,
r------ - ---------~
'
'
e
! N g _
w "
Page; 369
_. . . . . . . . . . . . . . . . . . .
o
@
o
I
W .
Page; 370
~::;I::::;-
...... - ......
... -
1----------------------------------' , ,
@ 1i
~.~
I ..
I~
..
.d
(3
IE! tt .0
~.
" " , 'i 1~ I !i e: o

1
'" 1&
.; "
-----------{
8i i
'm ,
_________________ J
m_ a
I
5
....
d .
"
.1111 r-----------------------, , , II "" , ""

, , &1'
, ,
.
~1
,..~
.II
!I
II!
. '" r=:"-1.
'12. II 1!.
' I
l ____________ _
;=:::;-'c.Jj.
1~~8
!k)1 .~ e
!!Q! .~
U
d .
,
Page; 373
d .
,
Page; 375
Page; 376
~
~
m
~
~ 1II' h
...
e I~ ~~l: ,~e
I:
I
~
Iii m
liii>I
I .
-.- .- .--- ---
'0 - ----- ---.~
>0
E
...
o@
e~
.,
ro.
.n
.,
m
e
~
D"l
C@@
- %
~ .
"
Page; 377 2005 Arctic Cat Service Manual - all models - www.ReadManu als.com
.," ii." ."
.~ ~
n l~
~
.,
e
~
!
. .. 1
~
f~81JI
I
:
g
I ~ I 1.:. - . -. ,. : .
= 9 .. ...... '--,- ~
!-
...
a
__ z
, ' Q
O . !Iii! ~ ~ Oi ::!~ z - iii ~

~ ~
,. ;
10
o@
El])@
aID=@
~sITD
Page; 379
Page; 380
...
~. _ ._ I _ -___ IRtO .. -
! ~ ...,.,., :t"~~ "

I
.
..,
...
.,
o@
&:.
lUI <l=.3l
'"- ~@
.i . ". ,
Page; 382
SECTION 7 - STEERING AND BODY
TABLE OF CONTENTS
Steering and Body .. .. .. ... .. .. ... .. ... .. .. ... .. ... .. .. .. ... .. ... .. .. 7-2 Steering Post (AWS V) ............................................ 7-2 Steering Post (AWS VI/M-Series) ... ................. .. ...... 7-7 Ski ........................................................................... 7-9 Ski Wear Bar .. ... .. ... .. .. .. ... .. ... . .... .... .. ... .. ... ... .. ... .... 7-11 Drag Link (AWS V) ... .. ... .. .. ... .. ... .. .. ... .. .. ... .. .. ... .. ... .. 7-1 1 Front Tie Rods (AWS V) .... .. ... .... ... ... .... ... .. .. ... .. ... .. 7- 13 Front Tie Rods (AWS VI/M-Series) ................. .. ... . 7-14 Spindle (AWS Vi ................................................... 7-16 Spindle (AWS VIIM -Series) ................................... 7-18 Steering Tie Rod (AWS V) ... .. ... .. ... .. ... .. .. ... .. .. ... .... 7-20 Steering Tie Rod (AWS VI/M-Series) ... ... .. ... .. ... .. .. 7-2 1
~~~I~~~~~~ionArms(Aw~3"V):::::::::::::::: :::::::::: ~:~~

Front Suspension Arms (AWS VlfM Series) ......... 7-28 Front Suspension (Ski ) Shock Absorber .. .... ... .. ... . 7-32 Sw ay Bar .... .. .. ... .. ..... .. ... .. ... .. ... .. .. ... .. ..... .. ... .. .. ... .. .. 7-33 Console (Standard EFI Models) .. .. ... .. .. ... .. .. ... .. ... .. 7-33 Console (AWS VIIM-Series Models) ....... .. ... .. .. .. ... 7-34 Console (Standard Carbureted Models )................ 7-36 Belly Pan (AWS Vi ...... .... .......... .. .... ....... .... ... .. ... . 7-37 Belly Pan (AWS VlfM Series) ............... .. .. ............. 7-43 Gas Tank/Seat Assembly (AWS V) ... ... .. ... .. ... .. ... .. 7-46 Gas Tan k/Seat Assembly (AWS VI/M-Series) .. .. .. . 7-46 Seat Cushion .. ... ......... ... .. .. ... .. ... .. .. .. ... .. ... .. ... .. ... .. .. 7-48 Tai llight Housing ... ............ . ... ............ .. ... . 7-49 Windshield ........................................... .................. 7-50 BackrestlRackfTaillight Assem bly ............ .............. 7-50 Tunnel/Rear Bum per/Snowfl ap (AWS V) ... ... .. .. .. ... 7-52 Tunnel/Rear Bum per/Snowfl ap (AWS VI/M-Series) ... .. ... ...... .... .. .. .. ..... ... .. ... ....... 7-56 Heat Exchanger (AWS VI/M Series) ... .................. 7-60 Air Silencer Assembly (AWS VI/M Series) ............ 7-63 Headlight Assembly (AWS V) ................. .............. 7-65 Headlight Assembly (AWS VIIM-Series) .. ... .. .. .. ... . 7-65 Ad justing He.a.dli9.ht Aim ... ........ .. .. ... ... ... .... .. .. ....... 7-67 Torque Specifications (AWS V) ... .. .. ... .. ... .. .. ... .. ..... 7-67 Torque Specifications (AWS VI/MSeries) ............. 7-68 Torque Specifications (General Bolts) ..... .............. 7-68
Page: 383
7-1
Steering and Body

Thi s secti on has been organi zed into s ub-sections for
servicing steerin g and body co mpo nents; howeve r, some components may vary from modcllo model. The
3. Re move the Iwo cap screws and lock nuts sec uring the lower steering post bracket to the fro nt end assembl y. Account fo r the backing plate, two washers, bearing caps, bearing hal ves, and washers.
technician should use di scretio n and sOllnd judgme nt when remov ing and installing compo nents.
NOTE: Some illustrations and photographs used in this section are used for clarity purposes only and are not designed to depict actual conditions .
NOTE: Critical torque specifications are located on pages 67-68 of this section.
Steering Post
(AWSV)
4 Tip the snowmobile handlebar pad. upri ght. Removc the
REMOVING
I. Tip the snowmobile 0 11 its side. Remove the screws securing Ihe skid platc.
5. Rc mo \'c the fo ur lock nuts and cap scrcws sccuring the adjustcr caps to the adjuster block; then rcmove the caps. Place thc handlebar asscmbly to thc sidc. Remove thc adjustcr block.
2. Re move the collcr pin, cap SCfcW, and lock nut securing the tie rod to the steering post.
6. Re movc the Phillips -head screws securing the console to thc gas tank.
7-2
Page: 384
7. Remove the two cap screws and lock nuts securing the steering post 1 0 the steering supp0l1. Account for the Iwo washers, bearing caps, bearing halves, washe rs, and backing plale.
10. Re move the cap screws securing the steering
SUppOl1 to the footresl (both sides).
8. Re move Ihe sheet metal screws securing the recoil stm1er rope cup.
II . Re move the cap sc rews securing the oil reservoir 1 0 the steering SUPPC )J1. Accounl for the lock nul and a nal washer.
9. Re move the cap screws securing Ihe recoil starter rope wire form . Account for the lock nut.
12. Re mo\'e the cap screws securing the air-intake sil encer to the steering support. Account for the washers, lock washers, and spacers.
Page: 385
7-3
INSTA LLING
,.. , i
IO''"'e~~~'
13. ivlove the air-Intake silencer forward.
KEY
2. Cap s<:rew
Sleeting Post
Bearing Hall 9. Bearing
Adjuster Block ,. Lock Nut Cap S<:rew 7. Ho using Cap
3. Adjuster Cap
". ".
". ".
Housing Look Nut Look Nut Washer Backing Plate
... ... " ...

".
Cap SCrew 15. Ball Joi nt (Left) Hex Nut (Left) Tie Rod Tube . Hex Nut (Right) Ball Joint (Right) 0738352
14. Carefull y slide the steeri ng post out of the chassis. Be carefu l not to hook any wires or hoses.
INSPEC T ING
NOTE: Whenever a part is worn excessively, cracked, or damaged i n any way, rep lacement is necessary.
I. Inspect
a ll welded deterioration.
areas
for
cracks
or
2. Inspect the steering post and steering-post brackets for cracks, bends, or wear. 3. Inspect the bearing halves, bearing caps, and bearing housings fo r cracks or wear.
KEY
I. 2. 3. 4. 5. 6. 7. B. Steering Post Cap Screw Adjuster Cap Adjuster Block Loo k Nut Cap Screw Housing Cap Bearing Half
". ". ".
'"
9. Bearing Housing Hood Switch Mounting Bracket Lock Nut Lock Nut Washer
14. I S. 16. 17. lB. 19. 20.
Backing Plate Cap Screw Ball Joint (Left) Hex Nut (Left) Tie Rod Tube Hex Nut (Right) Ball Jo int (Right) 0738507
7-4
Page: 386
,
.. ,..-- 12
i3 0~ f " ) ~.-4" ~ ~~\~U ' 12 \ ~ 70 ~ la

' - 21
1I-
i fl 6
4. Secure the steering Slipp0l1 to the footrest (both sides) with the cap screws.
19
'"
1. 2. 3. 4. S. 6. 7.
Steetlng Post Riser Adjuster Cap Adjuster Cap CapScrew CapSc rew Ho using Cap
,. Bearing ". ". ".
Housing
Lock Nut Washer Lock Nut 13. Plate
8. Beating Hall
14. Cap Screw 15. Lock Nut
Ball Joint ". (Righi)
20. He_ Nut (Righi)
". H. ". ".
Washer
Ball Joint (Left) Hex Nul (le ft) TleRod Tobe
I. Clrcfull y slide the steering post into position in
the chassis. Be careful not to hook any wires or hoses . 2. Secure the air-intake silencer to the steering support with the washers, lock washers, spacers, and cap screws. 5. Secure the recoil stalter rope wire form with the cap screws and lock nul.
3. Secure the oil reservoir 1 0 the steering support

w ith the washer and loc k nut.
6. Secure the recoil starter rope cup with the shect metal scrcws.
Page: 387
7-5
7. On the upper end of the steering post , apply a light oil to the bearing halves and place into position around the steering post; then place the beari ng cap between the steering SUpp0l1 and the steering post. Place the bearing housing into position and sec ure with the backing plate, two cap screws, washers, and lock nuts. Tighten to specifications.
10. Secure the handlebar pad.
1I. Tip the snowmobile on its side; thell place the ti c roo into position. Secure with a ca p sc rew (coated with green Loctite N6fJ9) and lock nut. Tighten to specifications. Install the cotter pin and spread the pin.
8. Secure the console with the Phillips-head screws.
9. Place the adjuster block, handlebar assembly, and adjuster caps into position; then secure with four ca p screws and lock nuts. Tighten lock nub evenl y to specifications.
12, On the lower end of the steering post, apply a li ght oil to the bearing hal ves and place into ,Xlsition around the steering post; then place the bearing cap and bearing housing into position. Install the backing plate and secure with two cap screws, washers, and lock nuts. Tighten to specifications.
7-6
Page: 388
3. Tip the snowmobile handlebar pad.
upri ght.
Remove
the
4. Cut the cable ties securing the wiring and brakeline hose to the steering post. 5. Remo\'c the rour lower Allen-head cap sc rcws securing the handlebar riser to the steering post; then lay the handlebar riser assembly aside. Account for the lower adjustcr caps.
13. Install the skid plate. Sec ure with screws.
NOTE: On the MSeries, remove four lock nuts and cap screws secu ring the handlebar to the adjuster block.
G. Remove the ri ve tOl'x- head screws securing the console to the gas tank ; then lay the console asidc .
NOTE: Turn the handlebar to the fullleft and full right to ensure free movement.
Steering Post
(AWS VI/M.Series) REMOVING
I. Using a piece or cardboard to protect the hood and belly pan, lip the snowmobile on its p rO-side. 2. From beneath the rront end, remove the lock nut and washer securing the stecring post to the steering post stop.
NOTE: On the MSeries, remove the ignition switch and the 11 torxhead cap screws securing the console to the gas tank ; then lay the console aside.
7. Remove the cap screw and loc k nut securing the steering tic rod to the steering post.
Page: 389
7-7
INSTALLING
8. Remove the two lock nuts and two torx-head cap
screws with nuts securing the steering post mounting block. Account ror the plastic steering post mounting block and the retaining plate.
KEY
1. Steering Post 2. Riser 3. Adjuster Cap (Upper) 4. Adjuster Cap (Lower) 5. Cap Screw 6. Retai ning Plme
7. Mounting Block
8. Machine Screw
9. lock Nut 10. lock Nut

11. Cap Sc rew
12. lock Nut
13. Ball Joint (Right) 14. He. Nul 15. Tie Rod Tube 16. He. Nut 17. Ball Joint (Left) 18. Washer
0738645
I. Carefull y slide the steering post into IXlsition in
the chassis. Be careful not to hook any wires or hoses .

NOTE: On the MSeries, remove the two lock nuts from the steering post mounting block; then remove the two cap screws securing the steering support to the chassis. NOTE: On the MSeries after the steering post is in position on the chassis, install the steering support and secure to the chassis with two cap screws. Tighten to specifications.
9. Remove the steering post.
2. Place the steering post mounting block and retai ning plate into position taking care not to pinch any wiring.
INSPECTING
I. Inspect
all welded deterioration.
areas
ror
cracks
or
2. Inspect the steering post and steering-IXlst retaining plate ror cracks, bends, or wear. 3 . Inspect the adjuster caps and mounting block for cracks or wear.
NOTE: The brakeline hose should be positioned behind the retaining plate.
7-8
Page: 390
3. Tighten the nuts to specifications. 4. Place the steering tie rod into position on the steering post. Secure with the cap screw (threads coaled with green Loctite #609) and lock nut. Ti ghten the lock nut to specifications.
NOTE: On the M-Series, secure the adjuster block to the steering post with four cap sc rews and lock nuts. Tighten to specifications.
7. Secure the wiring and brakelinc hose to the stcering post with cabl e tics; then install the handlebar pad. 8. Using a piece of cardboard to protect the hood and belly pan, tip the snowmobile on its PTO-side. 9. From beneath the front end, secure the steering post to the steering post stop with the washer and lock nut (threads coated with green Loctite #6(j) . Tighten the lock nut to speci fi cations.
5. Secure the console to the gas tank with the five t or,~- hcad screws. Do not over-tighten the screws .
NOTE: On the M-Series, secure the console to the gas tank with the 11 torx ~ head cap screws. Tighten securely ; then install the ignition switch.
Ski
REMOVING
L Place the front of the snowmobile on a suppo rt stand. 2. Removc the collcr pin; then rcmo\'e the slotted nut and cap screw sec uring the ski assembly to thc spindle, Remove the ski . Account for the rubber damper and washers.
6. Place the handlcbmfriser assembly onto the steering post; thell secure to the steering post with thc lower adjuster cap and four Allen-head cap screws, Ti ghten cap screws to specifications.
Page: 391
7-9
INSPECTING
NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. InspeCllhc ski for cracks or deterioration .
2. Inspect the ski for abnormal bends or cracks.
KEY
3 . Inspect the wear bar for wear. 4. Inspect all hardware and the spindle bushings for wear and damage.
5. Inspect the rubber damper for dt'lmage or wear.
,. Lock NUl ,. Piastlc Handie 6. Lock Nut ,. Machine Screw Machine Screw S. Cap Sc rew
Wear Bar
1. Ski 2. Ski Insert
...
...
10. Cotter Pin Washer "- Lock Nut 13. Damper 14. Spindle A_ Ie 15. Spindle 16. Spindle Insert 11. Grease Fitting Bearing
". ".
".
Bearing
". D.", ,..
". ,..
Thrust Washer Cap Screw 22. Steering Arm Retaining Ring Spindle Cap Spacer
0740-020
INSTALLING
m
KEY
1. Spindle 2. Grease Fitting 3. Bearing
4. Spindle Insert
5. Bearing 6. S pindle Axle

7. Spacer 8. Damper
9. Ski
... ... ". ". ... ". ... ". ...
Ski Sadd le
S ki Saddle Insert Cap Screw
Washer Lock Nut
Cotter Pin
Wear Bat Was her
19. 20. 21. 22. 23. 24. 25.
Plastic Handle Lock Nut Washer Cap Screw Cap Screw Lock Nut Machine Sc rew
1. 2. 3. 4. 5. 6. 1.
Spindle Grease Fitting Spindle Insert Bearing Damper Ski Saddle Ski
...
". ". ,..
Ski Insert Bar ... Wear Washer
Cotter Pin Cap Screw Loc k Nut Washer
15. 16. 11. 19. 19.
Lock Nut Was her Spindle Cap Decal A_Ie
0731-454
26. Deca l
27. Spindle Cap
737-380A
I. Position the ski over the saddle . 2. Appl y a low-temperature grease to the no nthreaded lX)rl"i on o f the cap screw ; then slide the ca p screw (w ith washer as required) through the ski and saddle accounting fo r the rubber damper.
l ock Nut
7-10
Page: 392
NOTE: Install the cap screw so the lock nut will be located to the inside of the ski ,
3. Appl y red Loetite #-271 to the threads of the cap screw ; then tighte n the lock nut (w ith washer as required) to specifications. 4. Place the cotter pin into the ski cap screw and spread the pin.
Ski Wear Bar

The ski wear bar is a re pl aceable bar attached to the underside of the ski. T he purpose of the wea r bar is to assist in turning the snowmobi le, to minimi ze ski wear, and to maintain goocl steering control. If the snowmobile is o perated primaril y in deep snow, ski wea r bar wea r will be minimal ; however, if the snowmobi le is o perated on terrain whe re the snow cover is minimal. the s ki wear bar wi ll wear fa ster. Arctic Cat recom mends that the ski wea r bars be checked once a week and replaced if worn to 1/2 of original diameter.
731-0370
4. Pry the rear of the wear bar down until the wear bar studs are clear of the ski ; the n slide the wear bar rearward until the front of the wear bar is free from the ski . 5. Remove the wear h..l r.
INSTALLING
I. Place spacers (if applicable) on the wear bar studs; then insert the front of the wear bar into the hole at the front of the ski and sw ing the wear bar upward.
REMOVING
Remove ice and snow buildup from the ski. 2. With the gas tank nearl y e mpty (less than 11 4 full ), lay the snowmobile on its side.
& WARNING
DO NOT bend the ski wear bar excessively when installing. Excessive bending of the ski wear bar may cause premature wear, breakage, and possible injury.
&
CAUTION
A piece of cardboard should be used to protect the finish on the belly pan ,
2. Insert the wear Ixlr studs into the holes in the ski. 3. Cente r the wear bar studs in the holes and install the washers and lock nuts. 4. Tighten lock nuts securely.
3. Remove the lock nuts and washers securing the wear bar to the ski. Account for any spacers.
lock Hili
Drag Link
(AWSV) REMOVING
I. Remove the ex pansion chamber if necessary. 2. Re move the lock nuts securing the t"le rods to the spi ndles on both sides of the snowmobile. Account for O-rings and washers.
NOTE: Note whether the tie rod is installed on the top side or on the bottom side of the spindle arm for installing purposes.
0739-016
Page: 393
7-11
NOTE: Applying soapy water to the steering boot will aid in pulling the boot over the tie rod end.
7. Place the dra!! link in a vise and re move the tie roo ends from the drag link.
INSPECTING
I. Inspect the e ntire drag link (especiall y in the areas where the ball joints attach) fo r any signs of cracks, wear, or damage. 2. Inspect the bearings. inserts, and axles fo r Wc.l r or damage.
INSTALLING
3 . O n the side from which the drag link will be removed , rcmove the self-tapping screws sec uring the steering boot to the front cnd. 4. Remove the ca p screws and lock nuts securing the steering tie roo to the steering arm. Account for washers.
KEY
1. Drag Link
2. Bearing
3. Stee ring Arm
4. In sert
5. Idler Arm 6. Cap Screw 7. Lock Nut
8. 9. 10. 11. 12. 13. 14.
CapScrew
A. le Washer l ock Nut
Cap Screw
Washer l ock Nut
15. Washer 16. a-Ring 17. Ball Jo int (Right) 18. He. Nut (Right) 19. Tie Rod Tube 20. He. Nut (left) 21. Ball Joint (left) 0738-354
I. Place the drag link in a vise; then secure the ti e rod to the drag link wi th cap screws, washers. and lock nuts (threads co.ated with green Loctite #6fJ9) . Tighten 10 s pec ifications. 2. Slide the drag link in from the side o f the snowmobi le from which the steering boot was removed; then carefull y slide the boot over the tic rod end.
5. MO\'c the drag link from si de to side to gain access to the lock nuts and cap screws securing the steering arms to the drag link ; then remove the cap screws and lock nuts. Account for washe rs and drag link bearing axles. 6 . From the opposite side from which the boot was removed , care full y pull the stcering boot over the tic roo end ; lhcn remove the drag link.
NOTE: Applying soapy water to the steering boot will aid in sliding the boot over the tie rod end.
3. Secure the drag link to the steering and id ler a rms with cap screws (coated with green Loclite #609). washers, bearing axles, and lock nuts. Tighten to specificatio ns.
7-12
Page: 394
7. Install and secure the exp.a nsion chamber (if removed). 8. Chcck and adjust ski alignment (see appropriate Ski Alignment in this section).
Front Tie Rods

lAWS VI REMOVING AND DISASSEMBLING
4. Secure the steering tie rod to the steering ann with a cap screw (coated with green Loctite #609), washer, and a lock nul. Tighten to spec ifications, 5. Place the stcering boot into position on the front end (bulk head). Secure with self-tapping screws. 6. Install the tic rods (threaded area coated with green Loctite #609) on the spindle arms as noted during remov ing. Secure with O-rings, washers, and lock nuts. Tighten to specifications. I. Remove the lock nut securing the ti c rod to the spindle. Account for a washer and O-ring.
NOTE: Note that the tie rod is installed on the bottom side of the spindle arm for installing purposes.
2. Remove the self-tapping screws or rivets securing the steering boot and retainer to the front end. 3 . Tum the handlebar in the appropriate direction; then remove the cap screw and lock nut sccuring the stcering ann to the drag link. Account for washers. 4. Loosen the jam nut securing each ball joint to the tic rod; thcn remove the ball joi nts from the tic roo. Slide the rod from the steering boot. Remove the jam nuts from the ball joi nts.

I. Inspect the ball joints and tic roos for damaged threads or wear.
NOTE: Check all drag link and ball joint fasteners to ensure they are tight. Turn the handlebars fullleft and full-right several times to ensure free movement
2. Inspect the ball joints and tie rods for cracks or unusual bends.
Page: 395
7-13
3. Wash the ball joints in pmts-cleaning solvent. Dry with compressed air. Inspect the b..'lll joint pi vot area for wear. Appl y a low-temperature grease to the ball joints.
Front Tie Rods

lAWS VI/M.Series) REMOVING
wear safety glasses when air.
I. Remove the lock nut securing the steering tic rod
to the uppe r ann of the stee ring shaft. Account for the washer.
NOTE: Note that the tie rod is installed on the top side of the upper arm for installing purposes.
ASSEMBLING AND INSTALLING

I. Slide the tie rocl through the steering boot and relainer; then install the jam nuts on Ihe ball joints and thread the ball joints onlo the lie rod .
NOTE: Each jam nut and ball joint is either a right-hand or left-hand thread ; therefore, each can only be installed on one end of the tie rod. The right-hand thread is the inside ball joint and jam nut.
2. Secure the tie rod to the ball joint on the forked end of the drag link with a cap screw, washers, and lock nul. Tighten to speci fi cati ons. 3. Secure the steering ann to the drag link with a cap screw, lock nut , and washers. Tighten to speci fi cations. 4. Position an O-ring and washe r on the ball joint assembly (threads coated with green Loctite #609). Install the ball joint on the spindle arm as noted in remov ing; then secure with a lock nut. Tighten to spec ifications. 2. From the right-side. remove the Allen- head ca p screw (A) securing the two tic rod e nds to the lower arm of the steering shaft.
3 . Remove the Allen-head cap screw securing the tie rod to the right -side spindle arm. 5. Place the steering boot and relaine r into position and secure with self-tapping screws or ri vets. 6. Adjust ski alignment (see Alignment in thi s section). appropriate Ski 4. From the left-side, remove the Allen-head cap screw (8) securing the two tie rod ends to the lower arm of the idler shaft.
7. Appl y blue Loctite #243 to the jam nut threaded area and tighten the jam nuts against the ti e rod to specifications.
"'" WARNING
Neglecting to lock the jam nuts against the tie rod may cause loss of snowmobile control and possible personal injury.
7-14
Page: 396
INSTALLING
5. Remove the Allen-head cap screw securing the tie rod end to the left -side steering arm.
KEY 'Steering Shaft
,. Idler Shaft
Shaft Lower Am 5. Snap Ring ,. Cap SCrew
2. Thru st Washer 3. Thrust Washer
". ". ".
".
8. Ball Jo int 9. Cap SCrew Tie Rod Tube Hex Nut Hex Nut Ball Jo int
". ".
".
". P'.,
Cap Screw Ball Join! Tie Rod Tube H. Ball Joint
737862A

I. Inspect the ball joints and tie rods for damaged
threads or wear. 2. Inspect the ball joints and tie rods for cracks or unuslk1.l bends. 3. Wash the ball joints in parts-cleaning solvent. Dry with compressed air. Inspect the ball joint pi vot area for wear. Apply a low-temperature grease to the ba ll joints.
KEY
1. Steering Shaft 2 . Thrust Wesher 3. Thrus t Washer 4 . Shaft Arm 5. Snap Ring 6. Cap Screw 7. Idter Shaft 8. Ball Joint 9. Cap Screw 10. Tie Rod Tube 11. Hex Nut 12. Hex Nut
13. Ball Joint 14. Cap Screw 15. Ball Joint 16. Tie Rod Tube 17. Ball Joint 1B. Plug
0 739BOB
I. Place the two tie rod ends into positi on on the lower afm of thc idler shaft Secure with the AI1enhead cap screw (B) coated with green Loctite 1/6f.'F.J. Tightcn to spec ifications.
Page: 397
7-15
5. Place the steering tie rod into position on the upper arm of the steering shaft . Secure with the washer 'lted with green Loctite and lock nut (threads cCl.: #(1)9). Tighten lock nut to speci fi cations.
2. Place the tie rod into position on the left -side steering arm. Sec ure with the Alle n-head cap screw coated with green Locti te #6(f). Tighten to speci fi cations.
Spindle
(AWSV)
REMOVING
I. Position the front of the snowmobi le up on a safety stand. 2. Remove the ski . 3. Remove the lock nut a nd eap screw securing the shock absorber to the spindl e. Account for all mounting hardware.
3 . Place the two tie rod ends into position on the lower arm of the steering shaft. Secure with the Allen-head cap screw (A) cGt'lted with green Loctite #609. Tighten 10 speci fi cations.
4 . Place the lie rod into position on the right-side spindle arm. Secure with the Allen-head cap screw 0 coated with green Loctite 1I6(f). Tighte n 1 specifications.
4. Remove the lock nut securing the tie-rod ball joint to the spindle (account for the washer and the 0 ring); then relllo\'c the ball joint from the spindl e.
NOTE: Note that the tie rod is installed on the bottom side of the spindle arm for installing purposes.
7-16
Page: 398
2,
In s rx~et
all welds for cracking.
3 . Inspect the suspension arm bushings and axle area for we-'lr. 4. Secure the spindle in a vise. Rotate the spindl e cl ockwise and counterclockwise. The movement should be smooth and free. If the spindle movement is rough or binding, grease the spindl e with a good low-temperature grease. Rotate the spindle. If the movement remains rough, replace the spindle .
NOTE: When greasing the spindle, use enough grease so that it can be seen coming out at both the top and bottom of the spindle.
5. Remove the two cap screws and lock nuts securing the spindle to the suspe nsion arms. Account fo r all mounting hardware.
5. Inspect the spindl e ax le and bemings for wear, damage, or loose fll. Replace the bearings as a set.
NOTE: Replacing the ski bolt bushings is difficult. The existing bushings will be damaged during removal, Be careful, however, not to damage the spindle when removing the bearing, Press the new bushings into the spindle.
INSTALLING
I. Place the upper and lower suspension arm ends with bushings in position into the spindle. Secure with cap screws (Uueads co.ated with green Loctite I/fIJ9) and lock nuts. Ti ghten to specifications. 2. Place the steering tic-rod ball joint inlo IXlsition (Ihre':lds coated with green Loctite 1/6fY9) on the spindle ann as noted during removing (w ith washer and O-ring) and secure with a lock nut. Tighten to specifications.
AL160D
6. Inspect the lie-roo ball joint in place. If damage, wear, or unusual bends are noted, loosen the jam nut ; the n remove the ball joint from the tie roo.
INSPECTING
NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary,
3. Install the ski . 4 Ali gn the lower shock eyelet with the mounting hole in the spindle; then secure with the cap screw, optional washers, and lock nut. Ti ghten to specifications. 5. Remove the safety stand from beneath the front end.
I. Inspect the spindle for excessive wem, cracks, bends, or imperfections.
Page: 399
7-17
Spindle
I. Position the front of the snowmobile up on a safety sta nd. 2. Remove the ski .
3. Remove the lock nut and cap screw securing the shock absorber to the spindle. Account for all mounting hardwa re.
6. Remove the Allen-head cap screw securing the steering arm to the spindle.
4. Remove the Allen-head cap screw securing the tic

rod to the spindl e arm.
7. Remove the cap from the spindl e; then using a plastic mailel, tap the spindle shaft Ollt the bottom
o f the spindle. A ccount for the Iwo washers from
between the steering arm and the spindle.
5. Remove the snap ring securing the steering ann to the spindl e.
&
CAUTION
Care must be taken to not over-extend the snap ring. If the snap ring is over-extended, it must be replaced.
8. Remove the two cap screws and lock nuts sec uring the spindle to the arms. Account for all mounting hardware.
7-18
Page: 400
INSTALLING
I. hlselt the spindle shaft into the spindle making sure the two washers are correctly positioned. 2. Place the upper and lower suspe nsion arm ends with bushings in position into the spi ndle. Secure with cap screws (threads coated with green Loctite #609) and lock nuts. Tighten the lower lock nut to specificatio ns.
3. Tighten the upper lock nut to specifications.
9. Remove the spindl e.
INSPECTING
1. Inspect the spindle for excessive wear, cracks, bends, o r imperfections.
2. Inspect all welds fo r cracking. 3 . Inspect the suspensio n arm bushings and axle area for wear. 4. Secure the spindle in a vise. Rotate the spindl e clockwise and counterclockwise. The movement should be smooth and free. If the spindle movement is rough o r binding, grease the spindle with a good low-temperature grease. Rotate the spindle. If the movement remains ro ugh, replace the spindle. NOTE: When greasing the spindle, use enough grease so that it can be seen coming out at both the top and bottom of the spindle. 5. Inspect the spindl e ax le a nd bearings for wear, damage, or loose fit. Replace the bearings as a set. NOTE: Replacing the ski bolt bushings is diffi cult. The existing bushings will be damaged during removal. Be careful, however, not to damage the spindle when removing the bearing. Press the new bushings into the spindle.
Page: 401
4. Install the cap onto the spindle; then place the steering arm tie rod into position o n Ihe spindle. Secure with the Allen-head cap screw coaled wilh green Loclile #609. Tighlen 10 specificalions.
5. Insta ll the snap ring noting the correct direction of the snap ring. 7-19
NOTE: The sharp side of the snap ring should be directed away from the spindle arm.
6. Place the tic rod into lX)Sition on the spindle ann. Secure with the All en-hcad cap screw cO<.lted with grecn Loctite #609. Tightc n to specifications.
2. Remove the cotter pins, cap screws, and slotted nuts securing the steering tie rod to the steering post and steering ann; then remove the ti e-rod asscmbly.
3 . Loosen the jam nuts securing the ball joints to the
steering tie rod; the n re move the ball joints.

7. Place the shock absorber into position on the
spindle. Secure with the cap sc rew and lock nul. Tighten to specifications.
INSPECTING
I . Inspect the ball joints fo r damaged threads or
8. Install the ski .

9. Rcmo\'e thc safety stand from beneath the front cnd .
wear.
2 . Inspect the tie rod for damage, unusual bends, or
Steering Tie Rod

(AWSV) REMOVING
I. Rcmove thc sc rcws securing the skid plate; then remove thc skid platc.
NOTE: The front machine screw on some models is secured with a washer and lock nut
wear.
INSTALLING
I. Positio n the handlebar in the straight-ahead position; then position the ski s straight ahead. 2. ThrC<ld the jam nuts onto the ball joints; then equall y lhread the mill joints onto the steering tie rod .
NOTE: There must be an approximate equal number of threads exposed on each ball joint.
3. Place the tie-rod assembly into positio n; then rotate the steering tie rod until the holes in the ball joints align with the holes III the steering post and stcering ann . 7-20
4. Ensure correct handlebarlski alignment (adj ust steering tie rod as necessary); the n appl y blue 0 the jam nut threaded area and Loctite 0243 1 tighten to specifications. 5. Secure the ti e-rod assembly with the two cap SCfCWS (coated with green Loctite #609), washe rs, and sloned nuts. Tighten to specifications; then install the colter pins a nd spre..ld the cotler pins.
2. Remove the cap screw and loc k nut securing the steering lie rod 10 the upper arm of the steering shaft. Account for the washer,
WARNING
Neglecting to lock the jam nuts against the tie rod may cause loss of snowmobile control and possible personal injury.
6. Install the skid plate; thell secure wit h screws.

NOTE: The front machine screw on some models is secured with a washer and lock nut.
INSPECTING
I. Inspect the b..ll1 joints for damaged thrc.lds or
wear. 2. Inspect the tie rod for damage. unusua l bends, or wear.
INSTALLING
NOTE: There must be an approximate equal number of threads exposed on each ball joint.
Steering Tie Rod

lAWS VIIM.Series) REMOVING
I. Remove the ca p screw and lock nut securing the
I. Place the steering tie roo into position on the upper arm of the steering shaft. Secure with the cap screw (coated with green Loctite 11609), washer, and loc k nul. Tighten the lock nut to specifications.
steering tic rod to the steering post.
Page: 403
7-21
0 734 -407
2. Place the steering tie roo into position on the steering post. Secure with the ca p screw coated with green Loctite #609 and lock nut. Tighten lock nut to specifications.
NOTE: On AWS V models if the handlebar is not in the straight- ahead position when the hole in the middle of the drag link aligns with the notch in the chassis, the steering tie rod must be adjusted. When handlebar alignment is correct, apply blue Loctite #242 to the jam nut threaded area and tighten to 1.7-2.1 kgm (12-15 ft-Ib). Tighten both jam nuts against the steering tie rod.
3. With the handlebar in the straight-ahead position, secure the handlebar to prevent the aligmTIent from becoming di sturbed during the remainder of the ali gnment procedure .
NOTE: Track tension and alignment must be properly adjusted prior to placing the straightedge against the outside edge of the track.
4. Place a long strai ghtedge against the outside edge of the track so it lies near the inside edge of the len-side ski .
Ski Alignment
CHECKING
Toe-Out Range
1.6-6.4 mm (1/16-1/4 in.)
CDO ""'9 O<>"""OO 0 ""c"c o~
""" COO,,""" "

" D "
"
"
"
"
"
NOTE : Track tension and alignment must be

properly adjusted prior to checking or adjusting ski alignment. Ski alignment must be performed on a flat, level surface. Ski toe-out must fall within the range of 1.S 6.4 mm (1/16-1/4 in.).
Straightedge
729 887B
I. Raise the front end of snowmobil e just hi gh enough to keep the ski s from contacting the tloor. 2. Turn the handle bar to the straight-ahead position. Visually inspect the handlebar for being centered and in the straight-ahead position. NOTE : At this point on AWS V models, the hole in the middle of the drag link should be aligned with the notch (half moon shaped) in the chassis.
_NOTE : The straightedge should be long enough to extend from the back of the track to the front of the ski.
5. Measure the distance from the strai ghtedge to the left- side ski wear bar bolts in two places: approx imalely 18-20 cm (7-8 in.) in front of the spindle and 18-20 em (7-8 in. ) behind the spindle . Record the measurements taken ror the left side.
722
Page: 404
.>
ifii
9
c " o ~
NOTE: The outside jam nuts are left-hand thread. Care should be taken to rotate them in the proper direction.
.. o o ....
c"n~CCOD"
"
0
0 0
Dec
" "
"
" u
n ..
"
..
"
"
c "
....
o o
"
0 0
Upper Suspension Arm
~I ~ -I0( -~!-~!:;:3l
"
"
CD
""
StL9htedge
I
729887A
11 200"' (7"in.) l B2Gcm 7.$ln.)
Steering -----Tie Rod Steering Post
Ski Spindle Adjustment Tie Rod Steering Drag Link

0729-883
..
nnn.n o onnn.
"
..
"OD
DOO
Ski SpiOdIt
Lowe, ....... ""
"''"'......
SlHnng
"'Ie, ...""
0(
0734-408
Spindle TIe Rod
"''"'''' Rod
SlHring POOl
S_ring TIe Rod
.......
6. Place the strai ghtedge against the o utside edge of the track so it lies ncar the inside edge of the rightside ski. 7. Measure the distance fro m the straightedge to the right-side ski wear bar bolls in Iwo places: 18-20
em (7-8 in.) in fronl o f the spindle and 18-20 em (7-8 in.) behind the spindle. Record the
M '1
738-167A
2. Adjust ski a li gnment by rotating the adjustment! steeri ng tie rod. 3. When ski alignment is correct, apply blue Loetite #243 to the jam nut threaded area and tighten to specifications. Tighten both jam nuts against the ti e rod.
measurements taken for the right side.
t:" WARNING
The measurement from the front and rear wear bar bolts to the straightedge can be equal (ski parallel to the track), but the front measurement must never be less (ski toedin) or poor handling will be experienced. The front wear bar bolt measurement to the straightedge must not exceed the measurement from the rear wear bar bolt to the straightedge (ski toed-out) by more than 3.9 mm (5/32 in.).
t:" WARNING
Neglecting to lock the tie rod by tightening the jam nuts may cause loss of snowmobile control and possible personal injury.
VERIFYING
I. With the handlebar in the straight-ahead posi tio n,
8. If ski alignment is not as specified, adjust the ali gnment of the ski(s) not para llel to the straightedge.
ADJUSTING
NOTE : The following procedure can be used to adjust the alignment of either ski.
verify ski ali gnment by measuring across from the o utside edge of the left-side wCt "lr bar bolts to the o utside edge of the right-side wear bar bolts (without usi ng the straightedge) in two places: approximate ly 18-20 cm (7-8 in.) in front of the spindle and 18-20 cm (7-8 in .) behind the spindle. 0 2. The measure ment from in front of the spindle 1 the o ute r edge of the wear bar bolls (witho ut using the strai ghtedge) must not exceed the rear measure ment by mo re than \.6 -6.4 mm ( 11 16- 114 ill.) toe-oul.
Unlock the appro priate adjustment tie rocl(s) o n AWS V mooels or from beneath the hood, the steering tie roo on AWS Vm"I-Series moclels by loosening the jam nuts.
Page: 405
7-23
,12<'10", (7 .tio.)
lI ~Qo ",
(7 _tln .)
4. Remove the cap sc rews and lock nuts sec uring the spindle to the front suspension arms. Account for all mounting hardware.
OOO
"
DDD
"
ODCOD
DDC
073 4 408
WARNING
5. O n models wi th a sway bar. remove the cap screw and lock nut securing the sway bar link to the front suspension ann. 6. Remove the screws and loc k nut securing the skid plate: then remove the skid plate.
The measurement taken in front of the spindle must never be less than the measurement taken behind the spindle or poor handling will be experienced. Neglecting to lock the tie rod by tightening the jam nuts may cause loss of snowmobile control and possible personal injury.
Front Suspension Arms

(AWSV)
REMOVING
I. Remove the expansion chamber if necessary. 2. Position the front of the snowmobile up onto a safety sl'and. 3. Remove the lock nuts and cap screws securing the shock absorber; then remove the shock absorber. Account for all mounting hardware.
7. If applicable. remove the self-tapping sc rews securing the steering boot to the front end, 8. Remove the cap screws and lock nuts securing the suspe nsion arms to the front e nd; then remove the arms.
7-24
Page: 406
INSPECTING
I, Inspect the arm welded areas for cracks or any signs of deterioration . 2. Inspect the beari ngs and ax les for wear or damage. 3. Inspect the ann tubing for signs of twi sting or bending.
INSTALLING
KEY 1. Lower Arm 2. Bearing

3. Upper Arm
9
)
4. Bearing 5. Cap SCrew 6. Washer ,.
e.
". ". ". ". ". ".
".
Axle Ax le Tllbe 9. Look Nut Cap Screw Washer Ax le Ax le TlIbe Lock Nul Axle
Cap Screw
0738-350
KEV '-
Lower Arm Upper Arm Bearing Ax le
,. 5.
2. Bearing
3"",
6. Tube
7. Washer S. CapScrew 9. Lock Nut
10. Tube
11 . 12. 13. 14. Tube Axle Washer CapScrew
15. Lock Nul

16. Lock Nul
17. CapScrew
18. Ax le 19. Cap Screw
0739-121
Page: 407
7-25
'"
1. Lower Arm
2. Bearing
3. Upper Arm
4. Bearing 5. Axle 6. Tube
7. CapScrew
B. Washer
9. Lock Nul
10. 11 . 12. 13. 14. 15. 16. Tube Ax le Tube CapScrew Washer Lock Nut CapScrew
17. Cap Serew lB. Tube
~~ ~11
~
\
'-21
" -12
" -14 13
0738-551
KEY
1. Lower Arm
2. Bearing 3. Upper Arm 4. Beating

5. Cap Screw
6. Washer 7. Ax le (U pperArm - lnnet) 9. Look Nul

9. 10. 11 . 12. 13. 14. 15. Tube CapScraw Ax le (lower Arm - Inner) Brace CapScraw CapScrew Loc k Nut
17. CapScrew
lB. Decal
0739-769
7-26
Page: 408
KEY
1. Lower Arm
2. Beating
3. Upper Arm
4. Bearing 5. Cap Serew 6. Washer

7. Axle (Upper Ann - loner) 8. Lock Nut 9. Tube
10. Cap Screw 11. Btace

12. Axle (Lower Arm - Inner) 13. Cap Screw
14. Cap Screw

15. AxleTube
16. Axle
~ '-- 13
~ 1~
0739803
I. Place the suspension arms into position on the
front end and secure with the cap screws (coated with green Loclile #609) a nd lock nuts. Ti ghten
the upper arm cap sc rew and lock nut to
specifications. Tighten the lower arm cap sc rew and lock nullo specifications.
2. tr applicable, place the steering boot into position on the front end. Secure with the sel f-tapping
SCfcWS,
3. Install the skid plate and secure with the screws,

washer, and loc k nut.
6. Place the shock absorber into position and secure with two cap screws, washers, ax les, spacers, sleeves, and loc k nuts. Tighten to spec ifications.
4. If applicable, pl ace the sway bar link into position on the suspension ann and secure with cap screw and lock nul. Tighten securely. 5. Accounting ror mounti ng hardware, install the spindle onto the suspe nsion arm with the cap screws and lock washers.
_ 0
AL157D
Page: 409
7-27
7. Install and sccure the expansion chamber if removed.
Front Suspension Arms

I. Position the front of the snowmobil e up onlo a safety stand. 2. Remove the ski . 3 . Rcmove the Allen-hcad cap screw securing the tie roo to the steering arm. 4. Rcmove the lock Illils and cap scrcws securing the shock absorber; then removc the shock absorber. Account for all mounting hardware. 6. Remove the cap scrcw and lock nut securing the 0 the fronl suspe nsion arm. sway bar link 1
7. Removc the thrce lorx-head screws securing the air silencer to the fronl bumper.
5. Rcmovc the cap screws and lock nuts securing the spindle to the front suspension arms. Accounl for all mounting hardwarc.
7-28
Page: 410
8. Re move the two tOD. -head cap screws securing the front bumpe r to the side bell y pans.
10. Remove the re maimng eight ton.: -head screws
securi ng the fro nt bumpe r. Account fo r the center belly p,,1n screen.
9. Remove the two hai rpin clips and hood pins securi ng the hood to the fro nt bumper.
II Remove the ca p sc rew and lock nut securing the upper arm. Account for the washer.
&
CAUTION
To avoid damage to the hood, carefully close it and rest it on the handlebar.
12. Remo\'e the 10 torx-head screws securing the
center belly pan to the frame. Note the locatio n of the different-l ength screws for install ing pUfJXlses,
Page: 411
7-29
3. Inspect the arm tubing for signs of twisting or bending.

INSTALLING
I. Place the suspe nsion arms into lX)sition on the front end and sec ure with the cap screws and lock nut s. Tighten ea ch cap screw (threads co.. 1ted with green Loctile 1/609) and lock nut to specificalions.
13. Remove the rear belly p,,1n.
,
14. Re mo\'c the two cap screws and lock nuts securing
2. Place the rear bell y pan into lX)sit ion; then secure with the 10 torx-head screws.
the lower arm ; then re move the arm. Account for all mounting hardware.
\
=--0
l:'" --
:~ "
.~
~:-~
- I
l./
\
-'.
-.
3. Place the front bumper into position; the n secure with the eight torx-head screws. Place the center bell y p. .10 screen into lX)silion.
INSPECTING
NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, rep lacement is necessary.
I. Inspect the arm welded areas for cracks or any signs of deterioration. 2. Inspect the bearings and axles for wear or damage.
7-30
Page: 412
4. Place the hood into position on the front bumpe r; then install the two hood pins and hairpin clips.
7. Secure the swa y bar link to the front arm with the cap screw and lock nut. Tighten the lock nut securel y.
5. Place the side belly pans into position on the front bumper; then secure with the two torx-head cap screws.
8. Secure the arms to the spindle with ex isting hardware. Coat the threads with green Locti te 1/6Cf): then ti ghten the upper arm lock nut to specifications and the lower arm lock nut to specifications.
6. Place thc ai r silencer into position on the front bumper; then secure with the three torx- head screws.
Page: 413
7-31
Front Suspension (Ski) Shock Absorber

REMOVING
I. Position the front of the snowmobil e up onto a safety stand taking all press ure off the skis. 2. Remove the cap sc rews securing the shock absorber to the front end assembly and spindle; then remove the shock absorber. Account for all mounting hardware. 9. Secure the tie roo to the steering arm with the Alle n-head cap screw (coated with green Loctite U6f). Tighten to speci fications.
NOTE: On models with a remote reservoir, remove the clamp securing the reservoir to the belly pan. _NOTE : Note the number of threads exposed between the spring adjuster and shock housing for installing purposes.
3. Using the Shock Spring Removal Tool (pIn 0644057), remove the spring from the shock body by compressing the spring; then remove the spring retainer from the top of the spring. Inspect the shock absorber by quickl y compressing and extending the shock plunger wrule firml y holding the shock body. Resistance mllst be felt in both directions.

10. Place the front shock absorber into position; then secure with existing hardware. Tighten to specifications.
I. Inspect the shock absorber seal area for signs of excessive oil leakage. 2. Inspect the shock absorber mouIlting eyclet, bushings, and slecve for wear or damage. 3. Inspect the threadcd shock slecve for damage or wear. Clean the slec\'e and appl y a light coat of grease to the threads before installing.
INSTALLING
I. Using the shock spring tool, placc the spring on
the shock absorber and sccure with the retainer. II . Install the ski with existing hardware. 12. Remove the snowmobil e from the safety stand . 2. Adjust the retainer nul (spring adjuster) until the specified amount of threads are exposed between the spring adjuster and the shoc k housing (noted in remov ing) as an initial selting. 3. Install thc bushings, sleevcs, and spacers into each shock end ; then place the shock absorber into position. Install both ca p screws from the front. Tighten the lock nuts to specificati ons.
7-32
Page: 414
Svvay Bar
REMOVING
I. Remove the lock nul's and cap screws securing the sway b.'u arm to the links and remove. 2. Remove the lock nuts and cap screws securing the
sway bar arms to the sway bar; then remove the
3. Place the links mto position on the sway bar arms; then sccure with cap scrcws and lock nuts.
Console
(Standard EFI Models) NOTE: Determine which style console is being removed and installed and refer to the appropriate illustration for component details; then remove and install accordingly.
KEY
1. Console
arms. Pull the sway bar out and account for two bearings.
INSPECTING
Inspect the sway bar fo r any signs o f tw isting, fatigue, o r wear.
2. Inspect the sway bar arms for cracks or damage.
2. Door
Ignitio n Sw itch Key Spacer Lock Washer De(:al B. Retaining Nut 9. Sell-Tapping Screw 3. 4. 5. 6. 7.
3. Inspect the links, bushings, bushing retaine rs, and hardware for damage o r wear.
1 ,
INSTALLING
K.y 1. 2. 3. 4. 5. 6. 7. B.
Washer Washe r Look Not Cap Sc rew CapSc rew Look Nut Link CapSc rew
0738-577
9. Lock Nul
10. Sway Bar '1 , Beating 12. Arm
KEY
1. Console 2. Door 3. Ignition Switch
4. Key
5. Spacer 6. Lock Washer 7. Decal - Right
8. Retaining Nut 9. $elf-Tapping s<:rew 10. Decal - Left 11. Outlet wlNut
"/
, . .,,
'
'<~
736-034A
I. Place the sway bar into positio n; thell install a bearing on each end of the sway tmr.
2. Slide the sway txl r arms o nto the sway bar until the holes in the arms align with the notches in the sway bar. Install the cap screws and loc k nuts. Tighten securel y. NOTE: Make sure the arms are positioned on the same flat on both ends of the sway bar.
Page: 415
7-33
REMOVING
I. Remove the self-tapping screws securing the console; then raise the console.
NOTE: If applicable, remove the cap screws and washers securing the remote adjuster clamp to the console; then lay the adjuster on the air-intake silencer.
INSTALLING
I. Place the console into position. 2. Connect the wi ring harness to the ignitio n switch . 3. Secure the console with the self-tapping screws.
2. Di scOimect the wiring harness fro m the ignit ioll sw itc h.

3. Remove the console.
Console
(AWS VI/M ..Series Models)
NOTE: Determine which style console is being removed and installed and refer to the appropriate illustration for component details; then remove and install accordingly.
KEY
1. Console
c
Sell-Tapping Screw Choke Cable Choke NUl Choke Lever Kit Ignition Switch Spacer tgnltlon Switch
2. 3. 4. 5. 6. 7.
10
:--)0 1 ...
.;tW -'
-.,.=<~
9. Retaining Nut 10. Ignitio n Switch Washer 11 . Molded Bumper
K.,
0739750
KEY
1. 2. 3. 4.
5. 6. 7. 8.
Console sell-Tapping SCrew Ignilion Switch Key Retaining Nut Ignilion Switch Washer Ignilion Switch Spacer Molded Bumper
0739-835
7-34
Page: 416
KEY
1. 2. 3. 4. Console Machine Screw Machine Screw Ignition Switch
S. Key
6. Retaining Nut 7. Ignition Switch Washer 8. Ignition Switch Spacer
9. Decal
0739-795
REMOVING
Pull the recoil starter rope out ward ; then tie a slipknot in the recoil rope near the case. Slow ly allow the rope to retmclto the knot. 2. Unti e the knot in the e nd of the recoil stm1er rope; lhen remove the handle from the ropc. Account for the cap. 3. On the carbureted model, re movc the knurl ed nut securing the choke assembly to the console: then slide the choke cable oul of the console. 4. Di sconnect the wiring harness from the ignition sw itch. 5. Re move the torx-head screws securing the console; then remove the console.
INSTALLING
Place the console into position; then secure the console with the torx-head screws.
2. Connect the wiring harness to the ignition switch. 3. On the carbureted model , slide the choke cable through the console. Secure the choke assembly to the console with the knurled nut. 4. Thrct'ld the recoil starter rope through the console and handle. Tie a knot at the end of the recoi I rope. Scat the cap. Remove the slip-knot and allow the rope to retmcl.
Page: 417
7-35
Console
(Standard Carbureted Models)
NOTE: Determine which type of console is being removed and installed and refer to the appropriate illustration for component details; then remove and install accordingly.
KEY 1. Console 2. Door 3. Ignition Switc h
KEY 1. Console 2. Door
3. Igoilioo Swilch
4. Key
5. Spacer
6. 1. 8. 9. 10.
Lock Washe r Decal- Right Nul Cho ke Ca ble Cho ke Lever Kit
11 . Choke Nul 12. Decal - Left 13. Sell-Tapping Sc rew
6. Lock Washer
7. Decal Right
8. Nul 9. Choke Cable 10. Choke Lever Kit
,t , Choke Nut 12. Accessory Oulie l wh'l ut

13. Deca l - Left 14. Sell-Tapping Sc rew
I 9 t'I 1k '~1J
'
II
12
4. Key
S. Spacer
[\.
II
10
o
2
/
0738-654 9. 10. 11 . 12. 13.
'7 ,- ,
~
"
KEY 1. Console
~ @
0738-511
,,-
3. Ignition Switch
4. Key
5. Spacer 6 . Lock Washer 1. Decal- Righi
B. Nul Choke Cab le Choke Levet Kit Choke Nut Decal - Lei! Self-Tapping Sc rew
13
KEY
1. Console
2 . Door 3. Ignition Switch
4. Key
S. Spacer
6. Lock Washer
8. 9. 10. 11 . 12.
Nut Choke Cable Choke Leve r Kit Choke Nut Decal Left
~lii".
1
@J
11
"
j;;
i~
3 5
13. Sell-Tapping Sc rew
7. Decal - Right
"i
g/
5
tfl
, ,
10 &
23
V
@ ~
0 738-341
"
Q ,
"
REMOVING
I. Remove the sel f-tapping screws securing the console; then raise the console. 2. Di sconnect the wiring harness from the ignilion switch and the outlet (i f applicable) . Remove the choke nut securing the choke assembl y to the console; then slide the choke cable out of the console. 3. Remove the console.
, @J @
~
0738-391
7-36
Page: 418
INSTALLING
I. Place the console into positio n. 2. Connect the wiring harness to the ignition switch and the o utlet (if applicable). Secure the choke assembly to the console with the choke nut. 3. Secure the console with the self- tapping screws.
Belly Pan
(AWSV)
NOTE: The following procedure is for a typical
4. O pen the belt guard: then remove the speedometer Ct'lble from the speedometer dri ve .
Arctic Cat snowmobile belly pan. Some compo~ nents will vary from model to model. The technician should use discretion and sound judgment.
5. Cut the cable lies securing the speedometer cable to the bell y pan ; then route the speedo meter cable away from the belt guard . 6. Remove the left-side front bell y pan cap screw.
REMOVING LEFT-SIDE
I Remove the left-side IOllver.
2. Rcmo\'c the lert-side louver foam.
7. Using a pi ece of cardbomd to protect the finish, tip the snowmobile on the ri ght side; then remove the to rx-he<ld screws securing the bell y pan to the frame and tunnel.
3. Remove the left-side cap screw sec uring the bumper to the air-Intake silencer plenum.
8. Remo\'c the screws securing the left-side steering tie rod boot; then remove the boot.
Page: 419
7-37
9. Remove the shock absorber boll.
12. Remove the rront bell y pan-to-nosepiece torx-
head screws.
10. Remo\'e the torx-head screws sec uring the bell y
pan underneath the shock mounl.
13. Remove
the bell y p,,1n assembl y from the snowmobile.
INSPECTING LEFT.SIDE
I . Inspect for gouges, cul"s, and tears.
2. Inspect all bell y pan threaded bosses that they arc in good shape.
INSTALLING LEFT.SIDE
I. Place the bell y pan assembl y
III
position in the
frame. 2. Secure the rront belly pan to the nosepiece with torx-head sc rews.
II. Remo\'e the rront belly pan-Io-nosepiece Phillips-
head screws.
7-38
Page: 420
3. Sec ure the front belly pan to the nosepiece with Phillips-head screws.
4. Install the torx- head screws securing the bell y pan underneath the shock mount.
7. Install the torx-head screws securing the belly pan 1 0 the frame and tunnel; then return the snowmobile to an upri ght position.
8. Install the left-side front bell y pan cap sc rew.

5. Install
the shock absorber bolt. Tightcn to specifications.
6. Install the len -side steering tie roo boot. Secure with the screws.
9. Route the speedometer cable through the belt guard ; then install cable ti es to secure the speedometer cable to the bell y pan. 10. Place the speedometer cable through speedometer dri ve; then close the belt guard. the
II . Install the left -side cap screw securing the bumper to the air-intake silencer plenum.
Page: 421
7-39
12. Insel1 the left -side louver foam.
0llver. 2. Remove the right-side 1
13. Install the left-side louver.
3. Remove the right-side louver foom.
REMOVING RIGHT.SIDE
I. Remove the right-side front bell y pan cap screw.
4. Remove the right-si de ca p screws securing the bumper to the ai r-intake silencer plenum .
Account for a nat washer and a lock nut.
7-40
Page: 422
5. Using a piece of cardboard to protect the fini sh, tip the snowmobile on the left side; then remove the ri ght-side bell y pan torx-head screws from the center bell y pan and tunnel.
8. Remove
the bell y pan underncath the shock mount.
torx-head
sc rews
9. Remove the front belly pan-to-nosepiece Phillipshead screw. 6. Remove the screws securing the right-side steering lie roo boot; then remove the boot.
AL181D
10 Remove the front bell y pan-to-nosepiece torx head screws. 7. Remove the shock absorber.
Page: 423
7-41
4. Install the belly pan torx-head screws underneath the shock mount.
11 . Remove the bell y pan from the frame.

INSPECTING RIGHT-SIDE
Inspect for gouges, cuts, and tears. 2. Inspect all belly pan threaded bosses that they are in good shape.
INSTALLING RIGHT-SIDE
I. Place the bell y pan assembly in position in the
5. Install the shock specifications.
absorber.
Tighten
to
frame. 2. Install the nosepiece torx-he.'ld screws to the front belly pan.
6. Install the righi-side sleeri ng tie rod boot. Secure with the screws.
3. Install the nosepiece Phi llips-head screw to the front belly pan.
7. Install the right-side belly pan torx-head screws to the center belly pan and tunnel; then return the snowmobile to an upright position.
7-42
Page: 424
10. Install the right-side louver.
8. Install the right-side cap sc rews securing the bumper to the air-intake silencer plenum .
II. Install the ri ght-side front bell y pan ca p screw, washer, and lock nul.
AL1 86D
9. Insert the right-side louver foam.
Belly Pan
I. Remove the hairpin clips from the hO<Xl pins; then remove the pins securing the hO<Xl to the front bumper.
NOTE: On the M-Series, remove the access panels.
Page: 425
7-43
,&, CAUTION
To avoid damage to the hood, carefully close it and rest it on the handlebar.
4. Remove the torx-head screws securing the center

bell y pall to the frame. Note the locatio n of d iffere nt-le ngt h screws for installing p UfJXlSCS.
2. Remove the tOD. -head screws securing the air silencer to the front bumper.
5. Remove the center belly pan.
3. Remove the remaining torx-hcad screws securing

the front bumper. A ccount for the center bell y pan
screen.
7-44
Page: 426
_ NOTE: If removing the rightside belly pan only, the resonator must be removed . If removing the left side belly pan only, the clutch guard must be removed .
6. Remove the torx- head screws securing each side belly pan to the fram e. 7. Using a 3116 in. drill bit, drill out the rivets sec uring eac h side bell y pa n to the fram e; then remove the belly pans.
INSPECTING
I. Inspect for gouges, cuts, and tears.
2. Inspect all belly pml threaded bosses that they are III good shape.
INSTALLING
_NOTE : Steps 12 should be used for each side belly pan.
5. Place the air silencer into position on the front bumper; then secure with the torx-head screws.
I. Place the side bell y pan into position on the fram e; then secure wi th the torx-head screws. 2. Using an appropriate ri vet gun, secure the side belly pan with six ri vets. 3. Place the rear belly pan into position; then sec ure with the torx-head screws. 6. Place the hood into position on the front bumper; then install the two hood pins and hairpin clips.
4. Place the front bumper into position; then secure with the eight torx-head screws. Place the center belly pan screen into position.
_ NOTE: If applicable, install the resonator and/or the clutch guard.
Page: 427
7-45

(AWSV)
NOTE: On EFI models, the fuel hoses must be connected to their respective fittings and tight ened securely or leakage will result.
S. Secure the seat to the tunnel with two cap screws,
washers, and lock nuts . 6. Install the console (see the appropriate Console in tlti s sectio n).
REMOVING
NOTE: If so equipped, turn the gas tank valve to the CLOSED position.
shut~off

lAWS VIIM.Series) REMOVING
I. O n Firecat models from inside the rear co ml:k1.rtment, remove the nut and washe r securing the assembly to the tunnel; then remove the seat assembl y.
I. Re move the console (sec the appropriate Co nsol e in this sectio n).
2. Remove the t wo cap sc rews, washers, and lock
nuts (located in the rear compartment) securing the

scat to the tunnel. 3. Remove the vent hose from the gas tank .
4. O n EFJ models, di sconnect the wiring harness from the fuel pump. Llbclthc fuel hoses "suppl y"
and " return" ; thell remove the hoses from the fuel
pump.
&.
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 fuel. 5. Rai se the rear o f the seat high enough to di sco nnect the taillight wiring harness. 6. O n the carbureted model s, slide the gas tank/seat assembly back far eno ugh to access the fuel hose: then di sco nnect the fuel hose. 7. Rcmove the gas tank/seat assembly. 2. O n Sabcrcat models, unhook the hold-dow n straps and remove the storage cOmlx 'l11ment ; then trip the seat latches and remove the seat.
NOTE: On the M-Series models, trip the seat latches inside the storage compartment and remove the seat.
INSTALLING
Place the seat in position on the tunnel : then on carbureted models, connect the fuel hose. 2. Connect the vcnt hose to the gas tank. 3. O n ER models, connect the fuel suppl y and return hoses to the fuel pump. Secure with clamps: then connect the wiring harness to the fuel pump. 4 . Raise the rear of the se.. 'lt hi gh enough to connect the taillight wiring harness making sure the harness is positio ned into the groove o f the seat base.
3. Remove the console (see the appropriate Co nsole in this section). 4. Drain the gasoline from the gas tank.
S. Re move the two loc k nuts and two to rx-hcad cap
screws with nuts sec uring the steering post mo unting block. Account fo r the plastic steering post mounting block and the retaining plate.
NOTE: On the M-Series models, remove the two lock nuts securing the steering post mounting blocks to the gas tank; then remove the two lock nuts securing the gas tank to the chassis. Disconnect the fuel hose and remove the gas tank.
7-46
Page: 428
6. On AWS VI models, remove the nine lock nuts securing the gas tank to the tunnel and root rests; then remove the four torx-head screws sec uring the side bell y pans to the tank. Account ror all mounting hardware.
INSTALLING
I. On AWS VI models, install the fuel hose to the
lower right-side comer of the gas tank ; then place the gas tank assembly into position on the tunneL
2. On AWS VI mooel s, secure the side bell y pans to the tank with the fo ur lorx-head screws; then secure the tank to the root rests and tunnel wi th the nine lock nuts.
7. On AWS VI models, remove the ruel hose from the lower right-side corner of the tank ; thell remove the gas tank assembl y.
Page: 429
7-47
5. On Firecat models from inside the rear compmtment, secure the seat assembly to the tunnel with the nut and washer.
3. On AWS VI moods, place the steering lX)st mounting block and retaining plate into lX)sition taking care not to pinch any wiring and making sure thc brakelinc hosc is positioncd behind the retaining plate, Tightcnto specifi cations.
6. On Sabercat mood s, placc thc scat into lX)sition and securc with the latches; then install the storage compartmcnt.
NOTE: On MSeries models, place the seat into position and secure with the latches inside the storage compartment.
Seat Cushion
REMOVING
NOTE: Steps 1-3 do not apply to Sabercat models.
Remove the gas tankisCo:'lt assembly (see the appropriate Gas Tank/Scat Assembly in this scction). 2. Rcmove thc two scrcws scc uring thc t.a illi ght covcr; then rcmove the covcr. 3. Remove the two sc rews securing the front of the seat cllshion to the seat base .
NOTE: On MSeries models, install the gas tank onto the steering post mounting blocks and the steering support ; then secure the gas tank to the chassis and to the steering support with the four lock nuts. Connect the fuel hose.
4. On Sabercat models, remove the three self tapping screws securing the seat panel to the back of the scat assembl y. 5. Using a sharp tool, pry out all staples securing the scat cover to the plasti c seat base. 6. From beneath the seat foam, remove the seat wire from the two elastic loops; then remove the cover from the seat base and scat foam.
4. Install the console (see the appropriate Console in this section).
7-48
Page: 430
INSTALLING
NOTE: If the seat cover was removed , position the cover over the seat foam and plastic seat base. Check to make sure it is positioned straight; then fold the rear edge of the cushion down and around the base. Using a staple gun and 6 mm (1/4 in.) sta~ pies, staple the rear flap of the cushion to the base In the same areas as the original staples were located. Position staples 2.5 em (1 in.) apart. Fold the sides of the cushion down around the bottom edge of the base. Position the staples in the same areas as the original staples were located.
4. Fold the front c ushion material back and onto the plastic seat base. Chec k for wrinkles and sec ure with stapl es and two screws. 5. O n Sabercat models, secure the seat panel to the scat assembl y with the three self-tapping screws. 6. Install the taillight housing and secure wi th the screws. 7. Install the gas tankiseat assembly (see appropriate Gas Tank/Seat Assembly in this sectio n).
&
CAUTION
On AWS V models, beneath the seat base is a dotted guideline to follow when stapling the seat cover. 00 not staple inside this guideline or perforation of the gas tank may occur.
KEY
1. Seat Cover 2. Foam
Taillight Housing
REMOVING
I. Remo\'e the four screws securing the tailli ght lens
to the housing. Account fo r a gasket 2, Remove the fo ur machine screws securing the backing plate to the taillight ho using.
3. 4. S. 6.
Seat Wire S taple Seat Wire
Foam 7 . Foam Inse rt 8. Seat Pad Insert
."""
3. Remove the two screws, lock washers, and washers securing the seat base to the tunnel. Lift the scat from the tunnel. Disconnect the taillight wiring harness. 4. Remove the two lock nuts and washers sec uring the tailli ght hOlL<;ing to the rear of the scat base. Pull the housing free of the base ,
INSTALLING
KEY
73 4302A 1. 2. 3. 4. S.
I. Position the cover over the seat foam and scat base: then pull the two elastic loops through the slots in the seat foam and secure with the seat wire. C heck to make sure it is positioned straight. 2. Fold the rear edge of the cushion down and around the plaslic base. Using a staple gun and 6 mm ( 1/4 in .) staples, slapl e the rear nap of the cushion to the plastic base in the same areas as the origi nal stapl es were located. Position staples 2.5 cm ( I iO. ) apart. 3 . Fold the sidcs of the cushion down around the boUom edge of the plastic scat base. Position the staples in the same area as the o riginal staples were located.
NOTE: Note the cushion fit If any wrinkles are noted, remove by pulling the cushion material in the appropriate direction before securing with sta pies.
Taillight wlSooket Assy Bulb Gasket Lens Retaining Screw
728-384B
I. Connect the wi ring harness and place the scat into
position, Secure with two sc rews, loc k nuts, and washers. 2. Place the taillight ho using into positio n and secure to the seat base with two lock nuts and washe rs. Tighten securely. 3. Install the tailli ght bulb, gasket, and lens. Secure lens with four screws. 4. Secure the backing plate to the tailli ght housing with the ex isting machi ne screws.
Page: 431
7-49
I. Remove the O-rings securing wi ndshield to the
Windshield
REMOVING
KEY
1. 2. 3. 4. 5. Wi nd shield O-Ring Expans io n Nut Machine Screw Snap and Cap
hood.
2. Remove the caps covering the screws; then
remove the screws w/snaps.
3. Rcmo\'c the wi ndshield .
INSTALLING
I. Place the windshield into position and install the O-rings .
l'
2. Secure the windshield to the hood with screws wI sna ps. Install the caps_
731-74SA
Backrest/Rack/Taillight Assembly
REMOVING
KEY
1. Wind shield
2. Machine Screw
3. 4. 5. 6. Snap and Cap e_panslon Nut O-Ring Mirror
739-527A
I. Remove the cap screws, washers, and cap nuts securing the rack to the backrest. 2. In turn on each side, remove the two cap sc rews (inside the lunnel) securing the backrest assembly to the tunnel. Account for the washe rs. 3. tr applicable, di sconnect hand warmer wiring harness. the passenger
4. Remove the backrest assembly from the tunne l. Account for the two spacers.
KEY 1. 2. 3. 4.
I
MachlneSctew Snap and Cap Expansion Nut Windshield
S. ORillg
737-892A
7-50
Page: 432
INSTALLING
Kev
L
,. Backrest ,.
Cover
,. Cup Was her

Adjuster ArmSpacer
...
27. Warmer
". ". Lens ". ". ". ". ".

". ". ". ". ". ". ".
".
5. Tension Block ,. Screw ,. Machine ,. Righi ,. Machine Screw
". ... '" ". lever ...

". ". ...
,..
Harness - Left Wils her Retainer
Bracket Left E-Ring Retainer

Was her Was her Reflector Clip
Retaining Screw
Gasket Bulb Housing
".
.,.
". ".
>S. Handgrlp
Retainer Self-Tapping
s,~
Covet Washer H . No< Bracket

Decal Decal
... .,.
". ... ... ". ... .,.
a-Ring
Wa rmer Element
Handgrlp Lever
Was her Handhold T-Nut Self-Tapping
s,~
Machine Screw
Lock Nul Switch
Bracket - Righi
>S. Cap Screw Warmer Harness - Right
Washer Deflector 50. Retaining Clip
0739-536
Kev
". ". Cap Screw ". Washer ". ". ".

Bracket Rivet
,. ,. Foom ,. Machine Screw 5. ,. ,. D.", ,. ,. D.", Machine Screw

L
Backrest Cover
Cap Not Rock
Handgrip Tube Closure

11 - -
KEY
0737-198
, . ,. ,. ,. ,.
Backrest
COVet
,. Foom
Latch
5. Bushing Spring
Lock Nul
,. ,. """ ". ". "". ".
Decal Machine Sc rew Lens Bulb HOllSiog Not wlWasher
". ". H. ". ". ".

". ".
Cap Screw
Lock Nul
Insert
Rock Cap Screw Cap Not Ri vet Cover
0739-930
I. Placc the backrest assembly and spacers (located on the rear hole on each side) into position and align holes with tunnel mounling holes. 2. Inslall the cap screws with washers from the inside of the tunnel and secure wilh the washers and lock nuts. Tighlcn securcly.
7-51
3. In turn on each side, install the 1/4 -m. ca p screw in the front hole and the S/ 16-in. ca p screw in the rear hole. Secure with a Oat washer and loc k nut. Tighten securely. 4. If appl icable, connect the passenger handwanner wiring harness. 5. Place the rack into posi tion and sec ure wi th the cap screws, washers, and cap.
NOTE: Determine which style tunnel assembly is being disassembled and refer to the appropriate illustration for component details; then remove! disassemble and assemble/install accordingly. Some components will vary from model to model. The technician should use discretion and sound judgment.
Tunnel/Rear Bumper/ Snovvflap

(AWSV)
Ko,
1. TUnnel Assy 2 . Bracket 3 . Ri vet 31. Pin
32. Ri vet
4. Plale Fron!
5. Ri vet 6. Tunnel Roll
7. Footrest 6. Ri vet 9. Plate

10. Clamp 11. Bracket 12. Ri vet
13. Plug
14. Bumper 15. Snowllap 16. Mac hine SCrew 11. Washer 18. Cap Sc rew 19. Cap Nut 20. Cap Sc rew 21. Clip 22. Ref lector 23. Decal 24. Hitch 25. Pin 26. Clip 27. Lock Nut 28. Spri ng 29. Latch 30. Cap Sc rew
0739519
7-52
Page: 434
KEY
1. Tunnel Assy
19
2. Bracket
3. Rive! 4. Plate - Front 5. Tunnel Roll
6. Rivet
7. Footrest
8. Bracket 9. Rivet
10. Clamp 11 . Plug
12. Bumper
13. Snowflap 14. UNul 15. UNut
10:;-.,[ ')
'"'-.
16. Decal
17. 18. 19. 20. 21 . 22. 23. 24. 25. Decal Machine Screw Machine Screw LOCk Nut Washer Was her Machine Screw Reflector Clip
. ":
26. Decal
0739-491
KEY
Clamp II . Hole Plug 12. Bumper 13. U-Nut U-Nut
".
,. Bracket 3. ,. ,. Tunnel Rol l ,. 7. 9. Ri vet

Ri vet Footrest Bracket
1. Tunnel Assy Ri vet Plate - Front
". 23.
H . Machine Screw 18. Machine Screw 19. Washer 20. lOCk Nul ,1. Washer Snowllap
". D.'" ". 16. """
11-,
"""
0739-627
Page: 435
7-53
KEY
. ,
Tunnel Assy Bracket
'h
,. Mounting Plate ,. ...

Rivet
Plate - Rear Tunnel Alve!
P'", ". ". 13. Rear Bumper ". IS. D.'"

UNul UNul
Front Rivet Rivet Bracket Clamp
,.,
OO" ". oo" ".
". "'. ". Washer ". ".
YO. 0." 17. Machine Screw IS. Machine Screw

Was her Lock Nut
~23 ~--24
22. Snowflap
Reflecto r Retaining Clip
0738-399
KEY
...
. ,. 3. ,. ,. ,.
Clamp ". ". ". ". IS.

H . Decal
Tunnel Assy Tunnel Plale - Rear Bracket Backing Plate - Rear Ri vet Ri vet Ri vet Rivet Mou nting Plale - Front Tunnel Ro ll
Plug Rear Bumper U-Nut U-Nut
24
YO. Snowllap IS. Decal Y9. Cap SCrew Machine SCrew

Washer
Lock Nul
11
"
...
"'. ". ". 23. Washer

". 0.,,' ".
Decal
24. Decal
It=, .~~ ,
. 20
8
..
0739-62 1
7-54
Page: 436
KEY
,. ,.
1. TUnnel Assy 2. Tunnel- Front Tunnel - Rear 4. Stud 5. Rivet
... ". "",,

33.
30. Was her

Mac hine Screw
34. CableTte
6. Rivet
os.
"""
Rivet
". ". ".

".
".
Bracket - Rear 8. Rivet 9. Roll Mounting PlateFro nt Alvet Bracket Dri ven Shatt Cover
, 11
",(J
0.", ". 23. Machine Screw

n
2Q.
". ". ". 0.",

U Nul U Nul
Backing Plate 15. P'''' P,,"

H. Bumper
Machine Screw
". w.
asher 24. W
Lock Nut Washer
14 ~
". Strap
28. Alvei
28. Soowflap
0739-291
REMOVING/DISASSEMBLING
NOTE: The snowflap can be removed without removing the bumper by removing the three bumperlsnowflap cap screws.
ASSEMBLING/INSTALLING
I. Remove the cap screws securing the bumper assembly to the tunnel . Aceount for the U-nuts and ca p screws. 2. Slide the bumperlsnowOap ofT the tunnel. 3. Remove the cap screws securing the snowllap to the bumper and sepal'ate the bumpe r and snowflap. Account for cap screws, washers, and lock nuts.
I. Secure the snowllap to the bumper with the ca p SCfcWS, washers, and lock washers taki ng care to place the washers next to the underside or the sllowllap. Finger-tighten the cap screws to the lock nuts; then li ghte n the cap screws securely. 2. Place the bumper assembly into position o n the tunnel and secure with the cap screws and U-nuts. Tighten the eap screws securely.
Page: 437
7-55
Tunnel/Rear Bumper/ Snovvflap

(AWS VI/M.Series)
KEY
NOTE: Determine which style tunnel assembly is being disassembled and refer to the appropriate illustration for component details; then remove! disassemble and assemble/install ac cordingly. Some components will vary from model to model. The technician should use discretion and sound judgment.
,. ,. Plate Rivet 5. Rivet ,. Bracket
t , Tunnel Assy 2. Sracket - Rea r
CapSctew ". ".
OKal ". 32. Foam
".
Loc k Nul Foil
7. Self-Tapping Sc rew
,. ". ". ". """ 'oom ". ".

9. Rivet
Harness Protector Lock Nut Machine Screw
18
Machine Screw 15. Lens 16. Taillight w/socket
');l
);)
\..-29
17. Housing
18. Bulb 19. Speed Nut
20. Bumper
21, 22. 23. 24. 25. 26. 27. Sell-Tapping Sc rew Lock Nut Machine Screw Machine Screw Speed Nut Washer Snowflap
"
28. Decal 29 , Decal 30. Foam

0739-782
7-56
Page: 438
KeY
2. Tunnel - Front
,. 1. Rivel Rivet ". Rl vel ". Plug ". ". ". Rack
Tunnel Assy Insert 4. Stud

Insert
". Snowilap
33.
3 .. Deeal
Machine Sc rew
Tunnel - Rear Bracket - Rear
". Machine Sc rew

Lock Washer
31.
34. Support 33. Washer
39. Deeal 39.
~"
18
29
Tunnel Roll
"""
Spacer
". ". ". ".

n
23.
Machine Screw
Machine Screw
Speed Nut Taillight Assy
H. Pod
20. Housing
!\
12
"'. Self-Tapping Screw 24. Washer ". "'.

,,"Ib
Ho using
Sook"
.~r~: -
.,{13
14
'--16
Machine Screw
~
0739-505
"'. ".
KEY
21. Bumper
Decal D",
30. Machine Screw
Tunnel Assy 2. Bracket - Rear

3. Plate 4. Rivet . Self-Tapping Screw Foil 1. Rivet Harness Protector Machine Sc rew Lock Nut
". ".
Decal Clamp
". ".
Foam
20. Foam n Lock Nut 22. Machine Screw
". ". ". ". Sell-Tapping Screw ". ".

Taillight wlSoeket
12. Mac hine Screw Lens
\.:11
28,
Housing
Bu lb 11. Speed Nut
>i.
Bumper
A'--29
21
". Strap
23. Washer 24. Machine Screw

Speed Nut
"'.
20.
21. Snowflap
Decal ". 30. Decal
""".,
0739-726
Page: 439
7-57
KEY
2. Bracket - Rear 3. Plate
Tunnel Assy
31. Strap
32. Clamp 33. Self-Tapping Screw
<.
...
". ...
". ". Housing ". ".

,~,
Rivet Self-Tapping Screw 6. Foil 7. Rivet Harness Protecto r Machine Screw Lock Nut Foam Machine Screw
,.
, c::n~ :l~ "

11 ' .
'
,'
\.. 16
Taillight wlSocket
Bulb
".
2Q.
U. Speed Nut
".
".
".
22.
". "'.
".
20. 23.
2<.
30.
Self-Tapping Screw Bumper Foam Lock Nut Machine Screw Washer Machine Screw Speed Nut Snowflap Decal Decal Decal Deeal
26
0739-730
REMOVING
I . Remove the tor x-head screws sec uring the snowfl ap 1 0 the bumper; then remove the snowflap.
2. Rcmo\'c the torx-hcad screws securi ng the bumper

to the tuonel.
3 . O n AWS
VI
models
from inside the rear
compartment, remove the nut and washer securing
the seat assembly to the tunnel; then disconnect the tai lli ght wiring harness .
NOTE: On the M-Series after removing the torxhead screws, remove the taillight housing from the bumper assembly ; then disconnect the taillight wiring harness.
4. Rcmo \'c thc tai lli ght/bumpe r assembly rrom the tunnel.
7-58
Page: 440
5. On AWS VI models from the underside of the bumper, re move the four torx-he. .'d screws securing the tailli ght assembly to the bumpe r.
3. On the AWS VI models, secure the tailli ghli bumpe r assembly to the tunnel with the 10 torxhead screws. 4. On the AWS VI model s, connect the tailli ght wiring harness; then lX'lsition the seat assembl y onto the tunnel.
NOTE: On the M-Series, remove the two cap screws securing the taillight assembly to the housing.
INSTALLING
I. On the AWS VI models, place the taillight
_NOTE : On the M-Series, connect the taillight wiring harness; then install the taillight housing onto the bumper assembly.
assembly into lX'lsition on the bumper; the n sec ure with the four toc'\ -head screws.
5. On the AWS VI model s from inside the rear compa rtment, secure the seat assembl y to the tunnel with the nut and washer.
NOTE: On the M-Series, install the bumper assembly to the tunnel ; then secure with the six torx-head cap screws.
6. Secure the snow nap to the bumper with the torxhead screws.
2. On the AWS VI models, place the tailli ghlibumpe r assembly into lX'lsition on the tunnel.
7-59
4. Remove the laillightJbumper assembl y from the
Heat Exchanger
NOTE: The cooling system must be drained for this procedure.
I. O n the AWS VI models, remove the three torx-
tunnel.
head screws securing the snownap to the bumpe r; thell remove the sllowllap.
2. Remove the torx-head screws securing the bumper
to the tuonel.
3 . O n the AWS VI models from inside the rear compartment. remove the nul and washer sec uring the scat assembl y to the tunnel; then di sconnect the taillight wi ring harness_
NOTE: When removing the rightside belly pan, the resonator must be removed. When removing the leftside belly pan, the clutch guard must be removed.
5, O n the AWS VI mode ls from each side, remove the torx-head screws securing the side belly pan to the frame. 6. On the A\VS VI models from each side using a3/ 16 in. drill bit, drill o ut the ri vets securing the side belly pa n to the fram e; then remove the belly pan. 7. Remo\'c the cla mps and coolant hoses o n each end of the heat exchanger.
8 . Fro m beneath the running board using a ball-lx:en hammer and a ch isel, shear o ff the ri vets sccuring the heat exchanger.
NOTE: At this point on M~Series models, the seat and gas tank must be removed (see appropriate Gas Tank/Seat Assembly sub-section in this sec tion) and the slide rail must be removed (see Section 9) to continue this procedure, NOTE: On the M-Series models, the heat exchangers are located at the upper corners of the tunnel.
7-60
Page: 442
NOTE: On the MSeries, position the exchangers at the top of the tunnel; then install the coolant hoses and new clamps. Tighten the clamps securely NOTE: Installing the coolant hoses and clamps at this time will aid in holding the heat exchanger against the running board (AWS VI) or tunnel (M Series) .
NOTE: On the MSeries models, it is advisable to drill the rivets out of the tunnel to avoid scratching the tunnel surface.
9. O n the AWS VI models from beneath the running board using a punch , drive out the sheared rivets; then remove the heat exchanger.
2, Using all appropriate rivet gUll, sec ure the heat excha nger to the running board (AWS VI) or the tunnel (i\II-Series) .
NOTE: On the MSeries after the exchangers have been secured, install the hose protectors.
3. O n AWS VI models on each side, place the side bell y pall into position 011 the frame; then secure with the torx-hC<ld screws. 4. O n AWS VI models on each side usmg an appropliate rivet gun, secure the side bell y pall with ri vets.
5. O n AWS VI models, place the tailli ght/bumper assembly into position on the tunnel.
INSTALLING
I. O n the AWS VI models, place the heat exchanger
into position against the running board; then on each end of the heat exchanger, install the coolant hoses and new clamps. Tighten the clamps securely.
Page: 443
7-61
6. Secure the t.'lillightJbumpe r assembly to the tunnel with the torx-head screws. 7. On AWS VI models, connect the tailli ght wiring harness; then position the seat asse mbl y onto the lUlmel.
NOTE: At this point on the M-Series, install the slide rail (see Section 9); then install the gas tank and seat (see appropriate Gas Tank/Seat Assembly sub-section in this section).
10 Fill the cooling syslem with the recommended coolant ; the n use the following procedure.
_NOTE : Use a good quality, glycol-based, automotive-type antifreeze. While the cooling system is being filled , allow enough time for the coolant to pass through the " weep hole" in the thermostat and into the system ; then fill the tank and run the engine for five to ten minutes after the initial fill (until the thermostat opens). Add more coolant if necessary. _NOTE : Because the coolant fills slowly into the engine, it is necessary to wait for 10 minutes after filling the coolant tank to allow the engine to fill with coolant.
8. On AWS VI models from Inside the rear compmtment, secure the scat assembl y lo the tunnel with the nut and washer.
II . Recheck the coolant level. If the level is low after 10 minutes, re peal step 10. 12. Install the coolant cap to the "first" position. 13. Stmt the engine. Do not exceed 3000 RPivl.
NOTE: After the engine has run for about 3-5 minutes , the right- side running board heat exchanger should feel warm to the touch. This is a sign that the thermostat has opened .
14. Shut ofT the engine. 15. Ti ghten the coolant cap to the "second" position. 16. Recheck the coolant level. If the coolant levc1 is low, repeat ste p 10. 17. Install the coolant cap to the "first" position.
NOTE: On M-Series models, connect the taillight wiring harness; then install the taillight assembly to the rear bumper assembly. Secure with the torxhead cap screw.
18. Place the snow mobile onto a safety stand. 19. Start the engine and run fo r 1 to 2 minutes. Do not exceed 5000 RPM . 20. ivlonitor the heat exchanger te mpe rature by touch. 2 1. Shut ofT the engine for 5 minutes.
9. On AWS VI model s, secure the snow Oap to the bumpe r with the tluee torx-head screws.
7-62
Page: 444
22. Start the e ngine and run for about 3-5 minutes; then repeat steps 14-22 an additional 2-3 times. 23. Take the snowmobile for a test dri ve. Do not exceed 5O(X) RPM during the test ride. Le t the engi ne cool down ; then recheck the coola nt level and add if necessary.
M-Series
&
CAUTION
After operating the snowmobile for the initial 510 minutes, stop the engine, allow the engine to cool down, and check the coolant level. Add coolant as necessary.
KEY
,-, ,- .
",L~,
* -10
~,
10. Lock NUl
II . Foam
Air Silencer Assembly

(AWS VIIM.Ser;es) REMOVING
I. 2. 3. 4.
Alrlntake - Right Bezel Foam s<:rew
S. Foam 6. Push Clip 7. Sc reen 8. Push Nut 9. Washer
12. Air Intake - Left 13. Plug 14. Hairpin Clip

740-144A
I. Remove the connector clamp securing the intake connector (hose) to the hood screen (right-side on the M-Seri es).
m
I . Air Silencer Assy
2. Intake 3. Silencer 4. IntakeConnector (Hose)
S. Connector Clamp 6. Self-Tapping Screw 7. HoldDown Bracket
9. sell-Tapping Screw 9. Boot 10. Retaining Clip
_NOTE : Steps 24 are for the AWS VI models. On M-Series models, proceed to step 5.
737-994A
AWSVI
2. Remove the two O-rings from the front mounting tabs of the hood cover; then carefull y close the hood while supporting the hood cover. 3. Rai se the front of the hood cover; then carefull y pull forward on the cover to release the rear cover locking tabs from the hood.
m
1. 2. 3. 4. S. 6. Hood Cover Assy O-Ring Decal Hood Cover Decal Decal
7. Foil
8. Decal 9. Hood Screen
737-997A
Page: 445
7-63
4. Using a Oat-blade screwdriver, carefull y pry up (in multiple locations) o n the hO<Xl screen to remove it from the hO<Xl cover.
FC251
3. While sUPIx>rting the hood covcr, carefull y ope n the hood; then inst.all the two O-rings o nto the front mounting tabs of the cover. 4. Place the intake connector (hose) onto the hO<Xl screen; then secure with the connecto r damp.
NOTE: Steps 57 are for the MSeries models.
5. With the hO<Xl closed, loosen the headlight adjustment knobs. 6. O lrefull y push the headlight lenses rearward far enough to remove the torx-hend screws sec uring the air silencer plenum to the hO<Xl. 7. O pe n the hO<Xl; the n remove the a -rings securing the air silencer plenums to the hO<Xl and remove the ai r silencer ple nums.
INSTALLING
NOTE: Steps 1-4 are for the AWS VI models. On MSeries models, proceed to step 5.
I. Place the hO<Xl screen into Ix>sition o n the hO<Xl cover; then carefull y push down (in multiple locations) until the screen is correctly and firml y scated in the hO<Xl cover. 2. Place the rear hood cover locking tabs into positio n o n the hO<Xl; then carefull y lower the hood cover into position o n the hood.
NOTE: Steps 58 are for the MSeries models,
5. Prcss the a ir silencer ple nums into place 011 the hood and secure with the a-rings; then close the hood. 6. C'u efull y push t.he headlight lenses rearwa rd far enough to install the torx-head screws. Tighte n the screws securely. 7. Tighten the headlight adj ustme nt knobs, 8. Check headlight aim (see appropriate Adjusting Headlight Aim in thi s sub-sectio n).
7-64
Page: 446
Headlight Assembly
(AWSV) REMOVING HEADLIGHT BULB
NOTE: The bulb portion of the headlight is frag
ile. HANDLE WITH CARE. When replacing the headlight bulb, the bulb assembly must first be removed from the housing. 00 not touch the glass portion of the bulb. If the glass is touched, it must be cleaned with a dry cloth before installing. I. Pull the wiring harness retaining clip away from
Headlight Assembly
(AWS VI/M.Series)
NOTE: On the MSeries models, the air silencer must be removed for this procedure (see Air Silencer Assembly in this section).
REMOVING HEADLIGHT I. Remo\'e the adjustment screw w!knob at the console.
the headlight bulb base and disconnect the w iring harness from the bulb.
2. From benealh the hood , unplug the wiring harness connectors rro m the bulbs.
0733-178
2 . Rotate the headlight bulb b..1se counte rclockwise and remove the bulb from the headlight housing.
INSTALLING HEADLIGHT BULB
Lh
CAUTION
00 not touch the glass portion of the bulb. If the glass portion is touched, it must be cleaned with a dry cloth before installing.
I. W hile ho lding the bulb by its base. Insert the bulb
into the headlight ho using and rotate it clockwise until it locks into the housing. 2. Plug the wi ring harness into the headlight bulb base making sure the retaining clip locks o nto the base. 3 . Check headlight aim (see Adjusting Headlight Aim in thi s section). 3. Remove the hairpin clips securing the headlight assembl y to the hood. Account ro r the adjuster spnng.
Lh
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.
Page: 447
7-65
INSTALLING HEADLIGHT
Beneath the hood, place the headlight assembl y into lX)sition ill the mounting tabs _
I . Remove the bulb from the headlight housi ng and disconnect the w iring harness from the bulb.
737-299A
INSTALLING HEADLIGHT BULB (AWSVI) 2. Place the adjuster spring into position ; then thread the adjustme nt screw into the headlight assembly.
&
CAUTION
00 not touch the glass portion of the bulb. If the glass portion is touched, it must be cleaned with a dry cloth before installing.
I. Plug the wiring harness into the headlight bulb. 2. Insert the bulb into the headli ght ho using. 3. C heck headlight aim (see Adjusting Headlight Aim III thi s section).
& WARNING
3. Install the hairpin clips to secure the headlight assembly to the hood; then plug ill the bulb wiring connecto rs.
00 not operate the snowmobile unless headlight beam is adjusted properly. An incorrectly adjusted beam will not provide the operator the optimum amount of light.
REMOVING HEADLIGHT BULB

(M ..Series)
NOTE: The bulb portion of the headlight is frag il e. HANDLE WITH CARE. When replacing the headlight bulb, the bulb assembly must first be removed from the housing. 00 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 headli gh t bulbs , use th e followin g procedure.

I. With the hood closed, loosen the
headli ght
adjustment knobs_ REMOVING HEADLIGHT BULB (AWS VI)

NOTE: The bulb portion of the headlight is trag ile. HANDLE WITH CARE. When replacing the headlight bulb, the bulb assembly must first be
2. G lrefull y push the headlight lenses rearward far enough to remove the to rx head screws securing the air silencer ple num to the hood . 3. O pen the h(xxL then remove the O rings securing the air silencer plenum to the hood and remove the air silencer pl enum to access the bulbs_ 4. Remove the bulb from the headli ght housing and disconnect the wiring harness from the bulb.
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.
766 Page: 448
2005 Arctic Cat Service Manual all models . www.ReadManuals.com
INSTALLING HEADLIGHT BULB

(M.Series)
A CAUTION
00 not touch the glass portion of the bulb. If the glass portion is touched, it must be cleaned with a dry cloth before installing. I. Plug the wiring harness into the headlight bulb, 2. Insclt the bul b into the headli ght housing.
3. Press the air silencer plenum into place on the

hood and secure with the O-rings; then close the hood.
0 740-153
4. Carefull y push the headlight lenses rearward far

enough to install the toc'\ -head screws. T ighte n the screws securely. 5. Tighten the headli ght adjustment kno bs.
7. Adjust the headlight ho using mo unting sc rews (on AWS V mooel s) or the console adjustment knobs (on the AWS VIIM-Series moocJs) until correct aim is o btained. Shut the engine off.
6. Check headli ght aim (see Adjusting Headlight

A im in thi s sub-section).
Torque Specifications
(AWSV)
Adjusting Headlight Aim

The headli ght ca n be adjus ted fo r vertica l aim o f the HI G H/LOW bea m . The geo me tri c ce nte r o f HI G H bea m zone is to be lIsed for ve.tical aiming.
I. Positio n the s nowmobile on a level fl oor so the headli ght is approx imatel y 8 m (25 ft) fro m an aiming surface (waU o r simil ar surface).
ITEM
Ski Handlebar Adjuster Block Steering Post Bearing Housing Steering PostfTie Rod' Drag LinkfTie Rod' Drag LinklSteering/ldler Arm" Spindle ArmfTie Rod' Tie Rod Jam Nut" Suspension ArmslSpindle' Shock AbsorberlSpindle Front Suspension Arm' (Upper) Front Suspension Arm" (Lower) Steering PostiChassis' Tie RodlSteering Arm' Steering ArmlChassis" ft-Ib kg-m ft-Ib kg-m ft-Ib kg-m ft-Ib kg-m ft-Ib kg-m ft-Ib kg-m ft-Ib kg-m ft-Ib kg-m ft-Ib kg-m ft-Ib kg-m ft-Ib kg-m ft-Ib kg-m ft-Ib kg-m ft-Ib kg-m ft-Ib kg-m
TORQUE
21-26 2.9-3.6
10 1.4 18 2.5 30 4.2 20 2.8 30 4.2 30 4.2 12-15 1.7-2.1 30 4.2 20 2.8 30 4.2 40 5.5 30 4.2 30 4.2 30 4.2
NOTE: There should be an " average" operating load on the snowmobile when adjusting headlight aim. 2. Measure the di sta nce fro m the Il oor to midpo int of the headligllt. 3 . Using the measurement o bl"ained in step 2 , make a hori zontal mark on the aiming surface. 4. Make a vertical mark whic h intersects the hori zontal mark on the aiming surface directly in front of the headlight. 5. Start the engine. Select the headli ght dimmer sw itc h HI G H beam position. 00 NOT US E LOW
BEA M.
6. O bserve the headli ght beam aim. Prope r aim is when thc most intense beam is centered on the ve.tica l mark 5 em (2 in.) below the hori zontal mark on the aiming s urface.
wiGreen Loctite fffl09 .- wlBlue Loctite #243
Page: 449
7-67
(AWS VI/M.Ser;es)
(Gen era l Bolts)
ITEM
Ski
Handlebar Adjuster Block Cap
ft-Ib
TORQUE kg-m ft-Ib

kg-m ft-Ib kg-m
21-26 2.9-3.6
Type of Bolt
I DIameter Th,ead
(mm)
Torque kg-m 0.2-0.4 0.4-0.7 1.0-1.6 2.2-3.5 0.3-0.6 0.8-1.2 1.8-2.8 4.0-6.0
ft-Ib
lAWS VI)
Handlebar Adjuster Block
25 3.5 1.4
15 10
(Conventional or 4 Marked Bolt)
5 6 8
10
1.5-3.0 3.0-5.0 7.0-11.5 16.0-25.5 2.0-4.5 6.0-8.5 13.0-20.0 29.0-43.5
Steering Post Mounting Block Steering Post Mounting Block

(M-Series)
tl-lb kg-m ft-Ib kg-m
2.1
10
1.4 30 4.2 30 4.2 30 4.2 40 5.5

12-15 1.7-2.1
(7 Marked Bolt)
Steering PostlStop' Steering Tie AodlShaft Arm'

Steering PostfTie Rod'
ft-Ib kg-m
ft-Ib kg-m
ft-Ib
5 6 8 10
kg-m
ft-Ib kg-m ft-Ib kg-m
Spindle ArmlTie Rod'

Tie Rod Jam Nut"
Suspension ArmlSpindle'
(Upper)
tl-lb
kg-m
tl-lb
30 4.2 40 5.5 20 2.8 30 4.2 30 4.2 30 4.2 20 2.8 40 5.5
Suspension ArmlSpindle'
(Lower) Shock Absorber/Spindle
kg-m ft-Ib kg-m

ft-Ib kg-m ft-Ib kg-m
Front Suspension Arm'
(Upper) Front Suspension Arm'

(Lower)
Steering PostlChassis'
ft-lb kg-m
Steering SupportiChassis"
(M-Series)
ft-Ib kg-m
Tie Rod (Center)/Steering Arm'

wiGreen Loctile 1609 .. wlBlue Loctile #243
ft-Ib
kg-m
7-68
Page: 450
SECTION 8 - DRIVE TRAIN AND BRAKE SYSTEMS
TABLE OF CONTENTS
g~:n ~:!~~~rfo~~~~~~I~peCji"icaiio~s ................. 8-6
Dri ve System Specifications .................................... 82
With Tension Pad Tightener System .. ................. 8-7 Chains & Sprockets ................................................. 88 Arctic Cat Dri ve Belt Dimension Chart .................... 89 Arctic Cat Drive Belt Replacement Chart .............. 8 10 Center-To-Center/Offset Specifications ................. 8- 11 Drive Train and Brake Systems ......... .... ................ 8- 12 Drive BelL ............................................................. 8-12 Drive Clutch ........................................................... 8- 12 Roller Driven Pulley (STD) .................................... 822 Drive Clutch/Dri ven Pulley (8TD).. ............ .. 828 ACT Roller Driven Pulley (ZR 900/Firecat/MSeries) ...................... ........... 830 Drive C lutch~Dri ven Pulley (ZR 900/FlrecatlMSenes) ................................. 8-38 Removing/lnstalling Drive Belt (ACT ~o ll er D r ive~ Pulley) ................................ 840 Dri ve Train SchematiCS (wlAeverse) ..................... 841 Drive Train Schematics (w/o Reverse) .................. 8-45 Dri ve Train Schematics (w/ACT Drive) ............ ...... 849 Dri ve Train/Brake Disc (Standard w/Reverse) ....... 851 Dri ve Train/Brake Disc (Standard w/o Reverse) .... 861 Dri ve TrainlBrake Disc (ZR 900 Models) ............... 8-66 Drive Train/Brake Disc (Firecat Models) ................ 8-80 Dri ve TrainlBrake Disc (M-Series Models) ............ 8-95 Rep-lacing Driven Shaft PTO-End Bearing (Rrecat rlSabercat Models) ............................. 8 109 Chain Adjuster ..................................................... 81 12 Brake System (Hydraulic) .................................... 81 16 Brake LeverlMaster Cylinder Assembly (Hyd raulic System) .......................................... 8- 127 Brake System (Mechan.icallOu.ick-Adjust) ........... 8- 130 Brake Control (Mechanical/QUick-AdJust) ........... 81 37 Arctic Cat Cam Arms ........................................... 8140 Torque Specifications .......................................... 8143 Trou bleshooting Drive Clutch/Driven Pulley ........ 8- 144 Trou bleshooting Dri ve Belt ................................ 8- 145 Trou bleshooting Hydraulic Brake System ............ 8-146
Page: 451
8-1
DRIVE SYSTEM SPECIFICATIONS

MODEL
IALTITUDE
~5000
CLUTCH
PIN
0725397
DRIVE
ORNE SPRING
PIN
0646-149
CAM ARM
DRIVEN PULLEY
PIN
0726-159
COLOR
PIN
0746-687
0746-692
GRAMS
57.0
SO.O
SPRING
0648-114
COLOR
RedlWhlle
Rod
Bearca1570
5-9000
0725-463
~""',
~5000
0646-229
Yellow/Whlte
0746-670
0746669 0746-702 0746671 0746694 0746702
0726-182
0748-025
Green
65.0
Firecat 600 EFI r
5~000
~O"'''
0-5000
Firecat 700 EFI r
5~000
0725-465
0646229
YellowlWhile
"'.0
57.5
70.0
0726-193
0748025
Green
~O"'''
~5000
0725301
0646149 0646-147
Rod
Yellow/Green
"'.0
57.5 SO.5 49.5
0726-162
0148-227
0746527
Pan1era 550
>9000
gOver
~5000
0725-326
0746538
0746-523 0746-592
0646-149 0646-147
Rod
Yellow/Green
47.0
0126-179
0648-114
"""" RedlWhlle
Paolera 600 EFI
59000
0725344
0746 538
0746607 0746-502
0746525
0746503
52.0 49.5
46.0
44. 5 44.0
41.0
~""', 0-5000
Panlher370
0646-147
YeliowlGreen
0726-160
0648-012
Blue
>9000
~""',
~5000
0725357
0646149
Rod
0726162
0148227
0746539 0746585 0746607 0746692 0746-690 0746691 0746-670 0746669 0746702 0746668 0746744 0746748 0746671 0746694 0746669 0746672 0746670 0746694 0746672 0746-695 0746694
"'.0
49.0 46.0
SO.O 47.0
0148-227
Panlher 570
5~000
~O"'''
05000 Sabercal 500/500 LX
~9000
0725-402
0646149
Rod
0726-170
0648114
"""" """" RedlWhlie
~""',
~5000
0725-388
0646147 0646229
YeliowlGreen YellowlWhne
44 .0 64.5
0726174
0748025
Green
Sabercal 600 EFIJ\..XIEXT
>9000
9Over
~5000
0725-445
0646229
YellowlWhne
"'.0
57.5 55.0
SO.O
0726-194
0648693
WhO,
Firecal 500/500 Sno Pro
'~OOO ~O,,"
0725-439
0646229
YellowlWhne
46.0 70.0
0726196
0648732
Green
EXT
Flrecal 600 EFIISno Prol
~5000
>9000
~""',
~5000
0725441
0646-229
YellowlWhne
"'.0
60.0 75.0 65.0 63.0 75.0 67.0 63.0
0726195
0648-732
Green
Firecal 700flOO Sno Pro
~9000
~""',
Firecal700 EFI/Sno Pro!
~5000
0725-441
0646229
YellowlWhne
0726195
0648732
Green
EXT
5-9000
~""',
8-2
Page: 452
MODEL
I ALT'TUDE~
~5OO0
GEAR RATIO
18/44
0648-002 0648-126
Bearca1570
5-9000
~Ow,
53' 53151
0648-002 0148-222
53'
22140 19/39
~ "
1602-042 0627-013
ENGAGEMENT RPM
3000
PEAK RPM
71-7300
<200
78-8000
, ,
~5OO0
EFI r
5--9000
~O~, ~5OO0
0148-222
EFI r
5-9000 9-0ver
~5OO0
0648-025
, , ,
Panlher 570
'"""= ,,. '"

'r ,..
"
" " "
1602-042 1602-041
0627-020
"-"'00
""'
22140
I ''''-''''
5-9000 9-0ver
""' -
I 062'~" 1''''-'''' I ""-"" 1602-042
'''''' "'00 '''''' 3500 3500
"00
82-8300
~5OO0
5-9000 9-0ver
~5OO0
0648-014 0648-002
,,.
<S'
""' 18/44
" "
" "
-
I "-8300
"00
'''''' '500
3800
53'
0627-021
5-9000 9-0ver
~5OO0
0648-026 0648-014
,,. ,,.
OZOfffl"
19/39
1602-041
0627-021
3500
71-7300
5--9000
~O~, ~5OO0
0648-681 0648-014
I:::
1602-041
0627-020
78-8000
Sabercal 500/500 LX
5-9000 9-0ver
,,.
53'
19_~&
0648-002
(EXn
1602-042 1602-041
0627-020
'''''' 'Il00
78-8000
~5OO0
23140 ~J~2T
5-9000
~Ow,
1''''= ~~' .
-
"'"' '"- '" -
,::~?
"
"
''''''
'500
Flreca15OO1500 SIlO Pro
5--9000 9-0ver
~5-000
0648-448 0648-733 0648-448
36'
4800 46/38" 0702-675
Firecat 600 EFII Sno ProlEXT
5--_ 9-0ver
36'
"
0702-707
0215->1
0702-693
"
0627-034
3800 '000 <200
78-8000
Flreca17oo(700 Sno Pro Firecat 700 EFII Sno ProlEXT
5--_ 9-0ver 5--_ 9-0ver
0648-448
36'
<000
0648-448
36'
4200
<300
Page: 453
8-3
DRIVE SYSTEM SPECIFICATIONS

MODEL
IALTITUDE
0-5000
5-9000
9-0~,
DRIVE
CLUTCH
ORNE SPRING
CAM ARM
DRIVEN PULLEY PIN

0726-182
PIN
0725-396
Sabercal 700 EFIII...XIEXT
PIN
0646-229
COLOR
YellowIWhne
PIN
0746-671 0746-694 0746-702 0746502
0746602
GRAMS
70.0
63.0
SPRING
0748-025
COLOR
Green
0725344
0646-147
Yellow/Green
57.5
44.5 42.5 50.5 46.5 44.0 53.0
0726-160
0648-012
0148-227
Blue
0-5000
Z 370/370 LX
59000
9-Ow,
0-5000
Z 440 LX
0725301
0646149
R""
0746527 0746-540 0726-525 0746539
0726-161
0148-227
'-9000
9-0ver
0725-357
0646149
0726-162
0148-227
""''''' ""''''' """" nanlum
0-5000
Z 5701570 LX
59000
9-Qver
~3000
King Cat 900 EFt'
3<000
0125-399
0646-373
R""
0746585
0726607 0746-715 0746-710 0746689 0746-699
0746715 0746-710
49.0 46.0 77.0

72.0
0726-168
0548674
69000
g-Over
YeliowlGreen
0-3000 3_
King Cat 900"
0725-399
0646373
69.0 66.0
77.0 72.0
0726-168
0648674
RedlWhile
69000
YeliowlGreen
0746689 0746699 0746-702 0746662 0746-744 0746713 0746-671 0746670 0746694 0746669 0746672 0746671 0746703 0746670 0746672 0746671 0746-703 0746670 0746742 0746-673 0746672 0746-742 0746673 0746672
69.0 66.0 57.5

"'.0
9-0ver
0-3000 3<000
M'-
0725-470
0646-149
R""
0646-147
0726189
0648693
WMe
WMe
69000
9-0~,
YeliowlGreen
50.0 48.0 70.0 65.0 63.0 60.0 75.0 70.0 68.0 65.0 75.0 70.0
"'.0
03000
"'Mr
3<000
0725-472
0646229
0726189
0648693
WMe
69000 9-Qver
0-3000 3<000
Yellow/wh~e
0725-474
0646-229
Yellow/wh~e
0726-153
0648693
Hanium
69000 9-0ver
~3000
M7 (LE)'
3<000 '-9000
0725-476
0646-379
Hanium
0726-190
0648-718
9-0ver 05000 ZR 9001900 EFI 59000

9-0~,
0725-467
0646-155 0646-147
Purple YeliowlGreen
65.0 83.0 80.0 75.0 83.0 80.0 75.0
0726176
0648693 WMe
0725467
0646155 0746147
Purple YeliowlGreen
0726176
0648693 WMe
05000 ZR 900 Sno Prol9OO EFI Sno Pro 59000 9-0ver
Initially sel up allhe factory for operation between 6000-9000 feel.
8-4
Page: 454
TORQUE BRACKET MODEL

Sabercal 700 EF11 LXIEXT
ALTITUDE
GEAR RATIO
24139 22140
(EXT)
CHAIN
ORNE BELT
ENGAGEMENT RPM
PEAK RPM
78-8000
~"""
5-9000
0648-002 0048-682 0148-222

, ~n
".
58'''''
(L.X1EXT1
,5-9000
9-0ver
""0648-014 0148-222 0648-014 0648-014
"" ".
-
""
22'"
22/40
""""" -
"-
1602-042
0627-035
"'" "m
""~, 19139
,W
" 70
0627-021
""'"
"00 <300
3800
"00
""" 7000
"40'"
~SOOO
5-9000
9-0ver
~5OO0
". ".
49" 49"
49"
3500
70
""00
71-7300
1602-041
5-9000 9-0ver
00'
19/40
19/43
70
0602-972
,,"' C" 900
m-
0"'"00 3-W00 '-0000

9-0ver 0648-024
55'/53'
'''40
-
"70
0627-020
3000
73-7000
3800
0602-972
""' C" 900-
0-3000 3_
6-9000
~O~,
0648-024 55"/53"
'''40 19/43
-
0627-020
3500
7,.,SOO
" -
3800
3-6000 '-9000
9-0ver 0648-448
". ". ". ".

50'138'
3800
0702-675
" " " "

" "
0702-712
""" "'" """ "'" "'"
0702-688
" " " "

" "
0627-036
4600
4800
4000
3-6000 '-9000
9-0ver 0648-448
0702-675
0702-712
0702-688
0627-036
"00
3-6000 '-9000
9-0ver 0648-448
3800
0702-675 0702-712 0702-688 0627-036
'000
3-6000 '-9000
9-0ver
~5000
3800
0702-675 0702-712 0702-688 0627-036
0648-448
'000
0627-032
0648-727
0702-645
0702-703
0702-697
3500
73-7500
ZR 900t900 EFI
5--9000
~5000
0648-727
ZR 900 Sno Prol 900 EFI Sno Pro
""."".
42"/36'
0702-645
0702-703
0702-697
0627-032
3500
73-7500
5--9000
9-Over 0648-689
3800
Initially set up at the factory lor operation between 600D-9000 feet.
Page: 455
85
Drive System Components

Below is :I list of Comet Drive C lutch, Arctic Drive Clutch, and Dri ven Pulley components that life available through the Arctic Cat Servi ce Parts Department. Hopefully, thi s infonnatioll wi ll be useful when doing any IInc-tuning 011 the dri ve system. Now there is virtuall y a cam ann weight for all needs.
SPRINGS - ARCTIC DRIVEN
ARCTIC CAT ORNE CLUTCH CAM ARMS
pin
0148-025
0648114 06486740148-227
Color Green
RediWhile RediWhile
Rate @ 1 7/16 in.

1571b 1161b 1051b 921b
pin
0746-500 0746-501 0746-502 0746-503 0746-523 0746-524 0746-525 0746-526 0746-527 0746-528 0746-529 0746-530 0746-531 0746-532 0746-533 0746-534 0746-535 0746-536 0746-537 0746-538 0746-539 0746-540 0746-546 0746-549 0746-559 0746-560 0746-561 0746-562 0746-565 0746-566 0746-568 0746-570 0746-576 0746-579 0746-581 0746-582 0746-583 0746-584 0746-585 0746-586 0746-587 0746-588 0746-589 0746-590 0746-591 0746-592 0746-593 0746-594 0746-595 0746-596 0746-597 0746-598
Grams 54.0 48.5 44 .5 41.0 47.0 48.5 44 .0 42.0 SO.5
pin
0746-600 0746-602 0746-604 0746-605 0746-606 0746-607 0746-608 0746-609 0746-610 0746-611 0746-614 0746-615 0746-616 0746-617 0746-618 0746-619 0746-629 0746-633 0746-634 0746-635 0746-636 0746-638 0746-640 0746-642 0746-645 0746-646 0746-647 0746-650 0746-653 0746-655 0746-662 0746-663 0746-659 0746-670 0746-671 0746-673 0746-687 0746-689 0746-690 0746-691 0746-692 0746-694 0746-695 0746-699 0746-702 0746-704 0746-710 0746-715 0746-716 0746-742 0746-744
Grams SO.O 42.5 41 .5 52.0 48.4 46.0 47.5 52.0 SO.O 47.0 64.0 62.0 66.0 60.0 51.5 47.0 75.0' 58.0 70.5 58.0 63.0 47.5 71.5 SO.5 52.0 57.0 49.0 67.0 63.5 56.5 52.0- 52.0" 60.0" 65.0" 70.0-80.0' 57.0" 69.0" 47.0" 44 .0- 50.0 " 63.0" 67.0" 66.0" 57.5" 51.0- 72.0" 77.0" 73.0" 83.5" 50.0"
Yellow
Blue While Black RedlBlack
0648-012 0648-010 0148-176
nib
581b 421b
Titanium
pin
0646-154 0146-526 0646-083
0648702
..
..
140-240 Ib @ 1.1-2.2
In .
SPRINGS - COMET DRIVE
46S
49,S' 53.5" 44.5 44.0"
Color
Purple
Rate @ 23/8 in.

136lb 134 Ib
"Ib 581b 781b 851b
120 Ib
Rale @
1 318 In.
254 Ib
YellowlGreen
","Ib =Ib 19l1b 1781b 1691b 270lb
R,d
BluelRed While
47S 51S
52.5 45.0" 39.5" 49.5 "'.0 46.5 48.0 46.0 55.5 55.0 SO.O 42.0 43.5 48.0 SO.O 47.0 46.0 46.5 52.5 48.5 46.5 45.0 49.0 45.0' SO.O 54.5 45.0
0646097 0646-084 0646096

0646-192
Sliver
Orange
ARCTIC CAT DRIVE CLUTCH SPRING CHART
pin
LIGHT 0646148 0646150 0646-149 0646-376 0646-147 0646-673" 0646-155 0646-229 0646-248 0646-684
Ra te @
29116 in.
531b 721b 741b 751b 1141b 1141b 1211b 1221b 1431b 158lb
Rate @
1 5/16 in .
2241b 188lb 2281b 2751b 2671b 2671b 240lb 2851b 290 Ib
Co lor RedlBlue SilVer
R,d
Go"
YellowlGreen YellowlGreen Purple
YellowlWh~e OrangelWh~e
"" "
Black
Titanium
NOTE: The Arctic Cat drive clutch spring has a smaller 0 .0 . than the Comet and cannot be inter changed.
DRIVEN CAMS (Torque 8racke~)
pin
0148-222 0648-001 0648-002 0648-005 0648-006 0148-180 0648-{111 0648-014 0648-016 0648-026 0648-025 0648-024
Deg~
52/44
" "
" " " "
40S
44 .0 52.0 45.5 44.5 41.5 44.5 43.5 44 .0
48/44
57150 42 47 55153
NOlched Cam Arm
.. wlSel Screw
0648-101'
0648-125 0648-126 0648-656 0648-681 0648-682 0648-683 0648-696
5,.,
57/50 51/49
62/54
62150 58"
58/50 6$15010.27 66/5210.27 0648-719 68/4210.34 68/44,1:).32 Base IS 0.100 thicker than that of pm 0648-016.
86
Page: 456
2005 A rctic Cat Service Manual - all models - www_ReadManuals_com
Chain Case Performance Specifications vvith Tension Pad Tightener System

(9 ..Tooth Drive Sprockets)
CHAIN CASE PERFORMANCE SPECIFICATIONS' SPROCKETS
24135 22133
I
6000 7000
102.7 99.9 95.2 92.1 89.1
RPM (Engine)
RATIO
0.686 0.667 0.636 0.615 0.595
CHAIN PITCH
8000
117.4 114.0
9 000
132.0
10,000
146.6 142.7 136.0 131.6 127.3
21133
24139
22137
20135
0.571
0.568
21137
19135
20139
0.543 0.513 0.512 0,488 0.486
21141 20/41
18137 16133 19/41
70 68 68 72 70 68 70 68 70 72 72
68 66
sa.o
85.6
128.4 122.4 118.4

114.5
81.6 78.9 76.3 73.3 72.9 69.7
108.8 105.2 101.8 97.7 97.0 92.9 87.8 87.6 83.5 83.2 82.8 79.2 78.9 78.5
65.8
65.7 62.6 62.4 62.1
59.4
0.484
0.463 0,461 0.459 0.487 0.475 0.550 0.536 0.575 0.522 0.634
18139
17137
72 70
68
59.1
58.9 62.8 61 .2 70.9 69.1 74.1 67.3 81.8
85.5 85.0 81.3 76.8 76.6 73.1 72.8 72.5 69.3 69.0
68.7
109.9 109.3 104.5
122.0
121.5
116.2 109.7 109.5

104.4
98.8 98.6 93.9 93.6 93.2 89.1
104.0
sa.7 sa.4
94.2 91.9 106.4 103.7 111 .2 101 .0 122.7
103.5 99.0 98.6

98.2 104.7 102.1 118.2 115.2 123.6 112.2 136.3
19/59 19/40
22140
22141
23/40 23/44 26/41
70 70 72 72 72 74 74
73.3 71.5 82.7 80.6 86.5 78.5 95.4
83.7
81.7 94 . 92.2 98.9 89.8 109.0
USE AS A GUIDE ONLY
RPM x Ratio x 0.239 x 1.12 = MPH
(10.Tooth Drive Sprockets)

CHAIN CASE PERFORMANCE SPECIFICATIONS' SPROCKETS RATIO CHAIN PITCH
7400
7800
8000
8200
8400
8700
USE AS A GUIDE ONLY
RPM x Ratio x 0.239 x 1.12 = MPH
Page: 457
8-7
CHAINS & SPROCKETS

For reference, all spockets and chains available from Arctic Cat are listed below.
_NOTE : Added to the list are wide 15 link chains with corresponding wide sprockets. These chains and sprockets are 3 mm (118 in.) wider than the 13 link chains and corresponding sprockets and approximately 25% stronger.
WIDE SPROCKET (w115 Link Chain) (UPPER)
Reverse and 2-Speed Sprocket
WIDE CHAIN (13 Link)
.
4
WIDE CHAIN (15 Link)
Reverse and 2-Speed Sprocket

"These are Borg Warner chains and they must be
used with Borg Warner sprockets only or dam-
WIDE
NUMBER
PROCKET (w/13 link Chain)

(UPPER)
F EEl
age to the chains or sprockets will result.
PN
"'These are Borg Warner sprockets and they must be used with Borg Warner sprockets (upper or lower) and chains or damage to the sprockets and chains will result. Sixteen-tooth inner spline wi th a 37.5 0 angle. Cannot be used on a 2003 Sno Pro.
.. Borg Warner sprockets used in 2003. Fifteentooth inner spline with a 30 0 angle. Cannot be used on a 2004 Sno Pro.
88
Page: 458
Arctic Cat Drive Belt Dimension Chart

BELT PIN
0100-022
LENGTH
41 318:t 3164 inch
WIDTH
1 3/16 inch
431(2.3"4io'" 46 314. 3"4 'och 46 9/16. 45 06. 44'18.3/8 '0'" 43 , /8 <311"0'" 43'3116. 47 '12 <311"ooh 43 114. 311"ooh 49.311"0'" 44.311"0'" 45 311"ooh 45 116. 42'3116 43 114. 311"ooh 46 116. 451 (2. 311"ooh , '/8 'ooh 43 114. 311"ooh 43 114. 311"ooh 43 311"ooh 43 5/8. 311"ooh 45112.311"ooh 435/16 ,31'"0''' , 311"ooh , 311"ooh 43 5/16. , 31'"0''' , 311"ooh 311"ooh , 311"ooh , 31'"0''' 47314. 311"ooh 49.311"ooh 49.311"ooh 47314.311"ooh , 311"ooh 311"ooh
449116
, 311"0'" , 311"ooh , 311"ooh 1311"ooh 1311"0'" 1311"ooh 114 'ooh 114 'ooh 11410'" 114 'ooh 114 'ooh 114 'ooh 11410'" 114 'ooh , 114 'ooh , 114 'ooh , 11410'" , 114 'ooh , 114 'och , 114 'ooh 13/8 loch , 3/8 'och 13/8 'och 13/8 'och 13/8 loch , 3/8 'ooh , 3/8 'ooh 13/8 'och 13/8 loch 13/8 'och , 3/8 'ooh , 3/8 'ooh , 3/8 10'" , 3/8 'ooh , 7I1"ooh , 711"ooh
'12.
'12.
50 5/16. 44.311"ooh 47314.311"ooh 45.311"ooh
, 711"ooh
, 711"0'"
High Pertormance Belt Double-Cog High Pertormance Belt
....... Double-Cog High Performance Belt w/Hard Compound

NOTE: The difference between Drive Belt (pin 0627-010) and Drive Belt (pin 0627-020) is width. If one of these belts is substituted for the other, the driven pulley will need a shim added or a shim removed to obtain correct belt deflection. Both of these belts are constructed of "hard compound " and should be used only when recommended. If these belts are used when a softer compound belt is recommended (such as a pin 0627-012 or 0627-021), the engine will run at a higher RPM.
Page: 459
8-9
Arctic Cat Drive Belt Replacement Chart

1996
Puma. Puma Deluxe, Puma 2-Up ....... 0227-103 Jag. Jag DeluK9, Jag LftJ .. ................... 0227-103 Z440. Panlhet Deluxe, Panther LtC ..... 0627-012 Bearcat 340 .... ..................... ................ 0627013 Beatcal 440 & 550 .............................. 0627014 Cougar. Cougar 2-Up, Cougar M,c ..... 0627012
1999
Jag 340 DLX, Panther 340 .................. 0627-012 Jag 440. Jag 440 DLX ........................ 0627-012 Panther 440 ........................................ 0627-012 Panther 550 ........................................ 0627-021 Bearcat 340. Bearcat 440 I ................. 0627-013 Bearcat 440 II, Bearcat Wide Track .... 0627-014 Pantera 5SO EFI ................ .................. 0627-021 Pantera 800 ...................... .................. 0627-020 Triple Touring 600 .......... ..................... 0627-020 Powder Special 500 EFI ..................... 0627-020 Powder Special 600 Models ............... 0627-020 Powder Special 700 ............................ 0627-020 Thundercat. Thundercat MIC .............. 0627-020 Z 370 ............ ....................................... 0627-021 Z 440 ............ ....................................... 0627-021 ZL 440 ............................... .................. 0627-021 ZL 500 Models. ZL 600 Models .......... 0627-020 ZR 500 Models ................................... 0627-020 ZR 600 Models ................................... 0627-020 ZR 700 ................................................ 0627-020 ZRT 600. ZRT 800 .............................. 0627-020
2002
Bearcat WfT ................ ........................ 0627-014 Mounlaln Cal Models .......................... 0627-020 Pantera 550 ................. ........................ 0627-021 Panlera Models (EFI) .......................... 0627-020 Panther Models ........... ........................ 0627-021 Thundercal .......................................... 0627-020 Z Models ..................... ........................ 0627-021 ZL Models .................... ........................ 0627-020 ZR Models ........................................... 0627-020 ZRT 600 ........................................... ... 0627-020
Panlera ............................. ................... 0627012

EXT EFt Models .................................. 0627012
EXT 580 .............................................. 0627012 EXT 580 Powder Speclal ..................... 0627-01O Wildcat Models .................................... 0627-010
Thundercal, ZAT 800. ZRT 600 .......... 0627-010 ZR 580 Models. ZR440 ....................... 0627 012
2003
Flrecal Models .................................. ... 0627-020 Mounlain Cal Models ....................... ... 0627-020 Panlera 550 ......................................... 0627-021 Panlera Models (EFI) .... ...................... 0627-020 Panther Models ................................... 0627-021 Z Models ............................................. 062H12t ZL Models ............................................ 0627-020 ZR Models ........................................... 0627-020
1997
Puma Puma Deluxe. Puma 2Up ....... 0627012 Jag. Jag Delu xe ................................... 0627012 Panlher. Panther LiC ........................... 0627012 Z440. ZL440 ........................................ 0627012 Bearcat 340 ......................... ................ 0627013 Bearcat 440 & 550 ........... ................... 0627014 Cougar. Cougar MIC ........ ................... 0627012 Pantera ................................................ 0627012 EXT EFI Models .................................. 0627012 Powder Special EFI ............................ . 0627012 ThundercaL ZRT SOO. ZRT 600 .......... 0627010 ZR 580. ZR440 .................................... 0627 010 EXT 600. Powder Extreme .................. 0627010 Powder 580 Carb ................................ 0627010
2000
Bearcat 340 ........................................ 0627-013 Bearcat 440 1 /440 IIlWide Track .......... 0627-014 Pantera Models ................................... 0627-020 Panther 340/440 ................................. 0627-012 Panther 550 ........................................ 0627-02t Powder Special Models ...................... 0627-020 Thundercat Models ........... .................. 0627-020 Triple Touring 600 ............................... 0627-020 Z Models ............................................. 0627-021 ZL 4401550 ......................................... 0627-021 ZL 5001580";001700 .......... .................. 0627-020 ZR Models .......................................... 0627-020 ZRT Models ........................................ 0627-020
2004
Bearcat 570 ................. ........................ 0627-013 Flrecat500 Models ...... ........................ 0627-020 Firecat 600/700 Models ....................... 0627-03t King Cat .............................................. 0627-020 Mountain Cat Models .. ........................ 0627-020 Pantera 550 ......................................... 0627-021 Panlera Models(EFI) .......................... 0627-020 Panther Models ................................... 0627-021 Sabercat 500 ....................................... 0627-020 Sabercat 600!700 Models ................... 0627-031 Z Models .......................................... ... 0627-021
1998
Jag 340. Panther 340 .......................... 0627012 Jag 440. Jag 440 DLX ......................... 0627-012 Z 440, Panther 440 ........ ...................... 0627-012 Panther 550 ......................................... 0627-021 Bearcat 340 ......................................... 0627-013 Bearcat 440. Bearcat Wide Track ........ 0627014 Cougar, Cougar DLX . Cougar MJC ...... 0627-021 Pantera 580 .... ..................................... 0627-02 1 Pantera 800 ........................... .............. 0627-020 EXT EFI ............................................... 0627-020 EXT EFI DLX ....................................... 0627-021 EXT 600. EXT 600 Touring .................. 0627-020 Powder Special. Powder Special EFI .. 0627-020 Powder Extreme .................................. 0627-020 ThundercaL Thundercat MIC .............. 0627-020 ZRT 600. ZRT 800 .............................. 0627020 ZR 600. ZR 600 EFI ............................ 0627-020 ZL 440 ................................................. 0627-021 ZL 500 , ZR 500 .................................. . 0627-020 ZR 440 .................................. .............. 0627-020
2001
Bearcat wrr ...................... .................. 0627-014 Mountain Cal Models .......................... 0627-020 Pantera Models ................................... 0627-020 Panther 370 Models ............................ 0627-013 Panther 440 Models ............................ 0627-012 Panther 550 ........................................ 0627-021 Thundercal .......................................... 0627-020 Triple Touring 600 ............................... 0627-020 Z Models ............................................. 0627-021 ZL Models ........................................... 0627-020 ZR Models .......................................... 0627-020 ZRT Models ........................................ 0627-020
2005
Bearcat 570 ................................... ...... 0627-013 Firecal 500 Models ...... ........................ 0627-034 Flrecat 600!700 Models ....................... 0627 -034 King Cat .............................................. 0627-020 M-Serles ........................ ...................... 0627-036 Pantera 550 ......................................... 0627-021 Pantera 600 EFI .......... ........................ 0627-020 Panther Models ........... ........................ 0627-021 Sabercat 500 ....................................... 0627-020 Sabercat 600!700 Models ................... 0627-035 Z Models .......................................... ... 0627-021 ZR 900 Models .................................... 0627-032
8-10
Page: 460
Center-to-Center/Offset Specifications
YEAR MODELS
CENTER TO CENTER OFFSET
YEAR
MODELS
CENTERTO CENTER
OFFSET
em
'990
In
mmm
34.67 34.67 1.365 1.365
em
' 997
Puma Models. Jag Models. Panll"\ef Models. Z440 Cougar. Panlera. AI EXT Models. ZR440. Tl1undercat ZRT&OO. ZRT800. Zl440 Bearcal Models
In
mm
34.67
In
Jog'"
2&7
AFS.
25. 9
11 .300 10.200
30.9 30.9
Panther. ~Iit. Panlora. EI fO EXT. Cheetah Touring.
super~. Jag
,,"'"
>'365 >.365 >.367

1.365 0.454 1.365
,,"'" ,,"'"
,,"00
3<.67
".,
""
1993
Wlkicat 650. Prowler
Jag 340 Mounlm Cal lynl(, Jag AFS. Super Jag .

Panther. CO\Igar. Pantel'a.
30.9 30.9 30.9 30.9
34 .72 34.67 11 .53 34.67
28.7 25.9
11.300 10.200
34.67 34.67
1.365 1.365
Powd6f Special. PowOOr ElIIreme. Powder EFI
EI Tigre exT. Prowl8f.

Clleetah Touring. Prowler Special. EXT Special. WIldca1700 1998
ZRS80EFI
Jag Models. Panther Models.
Z 440. Cougar MOdels. Panlera Models. EXT Models. Powder Special MOdels. Powder ElIIreme. Thundercat MOdels. ZRT600. ZRT800. ZR600. ZL440. Zl500. ZRSOO. ZR44Q Bea rcal Models
12.200 12.200
Touring. Supor Jag. EXT.

Wildcat EFt
Wildcat AW$
Lynl(. Jag. Panthor, Cougar. Panlala. PrOWler. Choo1ah
25.9
10.200
34.67
1.365
28.9 25.9
11.375 10.200
34 .67 34.67
Pamela, towler. Cheetah

Tour ing. EXT Modols Wildcat AWS Models
Lynx. J~ Panther. Cougar.
>.365 >.365
1.365
30.9 30.9
12.200 12.200
34.72 34.67
1.367 1.365
1999
Jag Models. Panther Models.

Z Models. Pantera MOdels. Triple Touring 600. Powder Special Models. Thundercat Models. Zl Models. ZR ModelS. ZRT Modets
28.9 30.9 25.9
11 .375 12.200 10.200
34.67 34.67 34.67
Thundercat
""
' 995
-!&g. Puma. Panther.

Cougar, PaOlOf8. Prowlef.
>.365 >.365
2CMXl
1.365
Beascal
Models
30.9 30.9 30.9 30.9 30.9 30.9 30.9 30.9 30.9 30.9
27.9
12.200 12.200 12.200
34.72
1.367 1.367 1.365 1.367
Cheelah ModelS
Wildcat EFt Models (AWS) EXT Model$. ZR MoOeIs,
28.9 11 .375 12.200 10.200 34 .67 34.67 34.67 34.67
Beascal MO<Ie1s AI Remaining Models Beascal WIT AI Remanlng MOdels Bearcat WIT AI Remaining Models AI Models Al2Stroke Models (except ZR 900 MOdels) StalldardOdve Mo<IeIs ACT-DrNe Flrecal Models ACTOrNe M-Serles Models ACTOrNe ZR 900 Models
3<.72
34 .67
Tt)(lIloorcat Models Puma MOOeIs. Jag Models.

Panltler
COugar. Plowlei' 2-Up. Pantale. AI EXT Models.
30.9
25. 5
>.365 >'365 >.365
2001
2002
2Q03
,,"'" ,,"'" ,,"'"

12.200 12.200 12. 200 12.200 11.000 11.500 11 .273
3<.72
34.67 34 .72 34 .67 34 .67 34.67 34.67
30.9
,,"00
2440. ZASSO. ZA440.

Thundefcat, ZR700. Wildcat. ZRT 800
2004
200S
>.365 >.367 >'365 >'365 >'365 >.365

0.708
",.
Bea/cal Models
Puma Model$.
30.9
25.5
12.200 10.200 12.200
34.67 34.67 34.67
1.367
2005 2005 2005
17.98 17.98 17.98
Jag MOdels
>.365
1.365
Panther. cou~ar. Panlerl\, All EXT Mode So 440, ZRSSO, ZR440.ThundorC81. ZRT600 Wildcat ZRT800
Bearcel Models
30.9
",
28.6
0106
0.708
30.9
12.200
34.72
1.367
Page: 461
8-1 1
Drive Train and Brake Systems

This secti on has been organized into sub-sections for servici ng drive train and broke systems; however, some
components may vary from model to model. The technician should lise discretion and sound judgment w hen
Drive Clutch
CHANGING CAM ARMS (9.Pos. S.yle)
T he ca m arms on the dri\'e clutch can be changed without disassembling thc cl utch. To changc the cam anns , use the following procedure. I. Check to make sure the ignition sw itch is in the OFF position. 2. Remove the dri ve bell. 3. Compress the mo\'ablc sheave approxi mately 2.5 cm ( I in.) and whil e holding it in thi s position, insert a nat t)(Jr firml y betwecn the bottom side of the spider and the inner surface of the movable sheavc. Slow ly release the movablc sheave. 4. Remove the lock nuts from the three cam ann pins. 5. Remove the cam arm pins one at a time; then remove the cam arm with bushing and account for the washers.
NOTE: When installing cam arms, always use new lock nuts. Make sure the head of each cam arm pin is positioned towards the direction of drive clutch rotation. Tighten nuts until they contact the shoulder of the cam arm pin ; then tighten an additional 1/8 turn.
KEY
1. Lock Nut
removi ng and installing components.

NOTE: Some illustrations and photographs used in this section are used for clarity purposes only and are not designed to depict actual conditions. NOTE: Critical torque specifications are located on page 143 of this section.
Drive Belt
The belt dimensions and construction are two fa ctors
that influence the performance of the dri ve system. The two belt dimensions that are important to the per-
fo rmance of the snowmobile are the outside circumfere nce and the width . Both of these dimensions will innuence shifting characte ristics.
If the dri\'e belt is longe r than s pecified, the dri ve clutch and driven pull ey wi ll not have the full s hift rati o. Also, a too- long dri\'e belt wi ll cause lX)()r acceleration and a decrease in top speed. If the drive be lt is shorte r than s pecified , the dri ve clutch and dri ven pulley will have a different shift pattern because they are in diffe re nt ratios from those for which they were ori ginall y matched. A too-short dri ve belt wi ll cause a loss in performance and a bog on engagemc nt.
NOTE: A drive belt that is worn thin may produce the same effect as one that is too long.
2. Cam Arm
3. Bushing 4. Washer 5. Pin
Dri ve bell construction has an influcnce on the way the dri ve clut c h and dri ve n pulley will shift and on the amount of power that wi ll be trans mitted through the sys te m . O N LY A RC TI C CAT DRI VE BELTS SHOULD BE USED. Different brands of bells may not have the same constructi on causing eithcr more friction or more slippage when the belt is wedged between the sheaves and, thus, a loss of effici ency.
NOTE: A stiff belt causes a HP loss to the track. As a belt warms up, it gets more flexible and transmits power with less HP loss.
6. Change the ca m arms and secure with new lock nuts and existing pins making sure the head of each pin is positioned toward the direction of dri ve clutch rotation.
NOTE: The drive clutch rotates counterclockwise.
Do not run the engine with removed or the bar in the clutch.
8-12
Page: 462
CHANGING CAM ARMS

(6-Pos~ S~yle)
T he cam arms o n the dri\'c clutch can be changed without di sassembling the clutc h. To change the cam arm s, usc the roll ow ing procedure. I. C heck to make s ure the ignition sw itch is in the OFF position.
2. Remove the dri ve belt .
3. Using
Clutch
Compressor
(pin
0644-420),
compress the mo vable sheave inward ; then inscI1
the compressor clamp and slowl y release the

compressor locking the movable sheave.
NOTE: Heat must be applied to the cam arms in order to remove the set screws.
6. A rter the lock Iluts and sct screws have been removed , remove the cam ann pins o ne at a time noting the position of the ali gnment notches for assembling purposes. Account for the O-rings.
0739038
7. C hange the cam arms with existing pins making sure the head of each pin is positioned toward the directi on o f dri ve clutch rotation .

8 . With the cam arm pin alignment notch pro perly positioned to the cam arm set screw, install the new cam arm set screws ( pre-co.. 1ted with Loctite) and tighten securel y. 9. Secure the cam ann pins with new lock nuts and lighten to specifications.
4 . Re move the lock nuts from the three cam ann

pillS.
5. Using a small torch , appl y heat to the cam ann sct screws to loosen the Loctile lIsed in assembl y.
A CAUTION
When installing cam arms, always use new lock nuts and cam arm set screws.
REMOVING
(9-Pos~ S~yle)
I. O pe n the belt gua rd ; the n remove the dri ve belt and the plug fro m the bell y pan. 2. Re mo \'c the bolt and lock washe r sccuring thc dri ve clutch to the cranks haft .
8-13
3. Using Clutch Compressor (pin 0644-420), compress the movable sheave inward; then inselt the compressor clamp and slow ly release the compressor locking the movable sheave.
NOTE: Before installing the clutch puller, apply oil to the threads of the puller and a small amount of grease to the tip of the puller.
3. Using the Clutch Puller (pin 0644-207) and an impact wrench or a breaker bar and the Drive Clutch Spmmer Wre nch (pin 0644- 136), tighten the puller. If the drive clutch wi ll not release, sharpl y strike the head of the puller. Repeat this ste p until the clutch releases.
NOTE: Before installing the clutch puller, apply oil to the threads of the puller and a small amount of grease to the tip of the puller.
4. Remove the drive clutch from the engllle compartment. Account for any spacers.
REMOVING 16.Post Style)

I Open the belt guard; then remove the drive belt and the plug from the belly pan. 2. Remove the bolt and lock washer securing the drive clutch to the crankshaft.
4. Using the Clutch Puller (pin 0644-207) and an impact wrench or a breaker bar and the Dri ve Clutch Spanner Wrench (pin 0644-136), I"ighten the puller. If the drive clutch will not l"dease. sharpl y strike the hC<ld of the puller. Repeat this step until the clutch releases.
5. Remove the drive clutch from the engllle compartment . Account for any slxlcers.
8-14
Page: 464
DISASSEMBLING
NOTE: Note the timing marks on the cover, spi-
der, and movable sheave. These must be aligned when assembling the drive clutch for balance purposes.
I. Loosen the machine screws securing the cover.

Remove every other cap sc rew and lock washer from the cover: then whil e firmly holding the
cover, remove the remaining screws and lock washers equally.

FC055
3. Position the dri ve clutch over the Chllch Holder (pi n 0644-058) .
NOTE: The holder should either be secured in a vise or bolted to a sturdy work bench.
AM063D
2. Remove the cover and spring.
4. Secure the dri ve clutch to the ho lde r uSing the cl ulch bolt and lock washer.
AM061D
Page: 465
8-15
:" ~
""
'
.......
.,f::::::J
0 739-038
7. O n the 6-IX)st style using a suitable dri ving tool, remove the cam arm pin bushings from the movabl e She..1VC.
5. O n the 6-IX)st style. remove the cam ann pin lock nuts; then using a small torch, apply heat to the ca m arm set screws to loosen the Loctite used in assembly.
&
CAUTION
Care must be taken not to damage the inner bore of the movable sheave.
8. Using the Thin Wall Deep Socket (pin 0644- 138),
remove the spider retaincr nul.
NOTE: Heat must be applied to the cam arm in order to remove the set screws.
6. O n the 6-IX)sl style a ner the lock nuts and set screws havc been removcd, removc the cam arm pins one at a time noting the lX)si tion of the ali gnment notches for assembly pUI'JX)ses. Account fo r the O-rings.
8-16
Page: 466
MS405
9. Using a small torch, heat the threaded area of the spider. Place the Spider Removal Tool (pIn 0644085) over the heated spider and break spider loose by turning it counterclockwise.
NOTE: The spider is a non-serviceable component and must be replaced with a new one.
12. On the 9-post sty le. remove the three cam arm pins and lock nuts securing the cam arms to the movabl e sheave; then remove each cam arm and account for the bushings and the washers.
KEY
1. 2. 3. 4. Look Nut Cam Arm Bushing Washer 5. Pin
733-4526

1. Using pmts-cleaning solvent, wash grease, dilt ,
and foreign matter olT all components: dry with compressed air.
FeOS6
NOTE: Applying heat to the spider threaded area will aid in clutch disassembly. The heat will loosen the Loctite used during assembly.
2. Remove any dri ve belt dust accumulation from the stationary sheave, movabl e sheave, and bushings using parts-cleaning solvent only.
&, CAUTION
00 not use steel wool or a wire brush to clean components having a bushing ; damage to the bushing will result.
10. Remove the drive clutch from the clutch holder using the clutch puller and the same procedure as pulling the drive clutch from the crankshaft. II. Remove the spider assembly, spacer washers, and movable sheave.
3. Inspect stationary sheave, movable sheave, and cover for cmcks or imperfect ions in the casting. 4. Inspect the cam ann pins for wear or bends.
Page: 467
8-17
5. Inspect the bushing in the cover for wea r, damage. or cracks. p,lleasure the inside diameter of the bushing and the outside diameter of the stationary sheave hub. The difference (clearance) must be less than 0.20 mm (0.008 in.). If cover bushing is not within specifications, replace the cover.
6 . Inspect the bushing in the movable sheave for
wear, damage, or cracks. Measure the inside diameter of the bushing and the outside diameter of the stationary sheave hub. T he difference (clearance) must be less than 0.20 mm (0.008 in.). If movable sheave bushing is not within specifications, replace the mm'abJc sheave.
7. Inspect the spring for proper compression rate
qualities (see Drive System Components page). 8. On the 9-post style, inspect the ca m arms for any uneven wear pattern or damage to the bushings. 9. Inspect aU threaded areas for any cracked or stripped threads.
10. Inspect the stationary sheave and shaft for d'lmage
or wear.
8-18
Page: 468
ASSEMBLING
KEY
1. 2. 3. 4. LockNut Cam Arm Bushing Washer
5. Pin
733-452B
'"
6 WARNING
6. Lock Nut
1. Stationary
Sheave
7. Cam Ann
8. Bushing 9. Washer
2. Movable Sheave 3. Cover 4. Retainer Nut
12. Lock Washer 13. Machine Screw 14. Spring
00 not reuse a spider assembly that has been removed. Always replace a used spider assembly with a new one.
S. Pin
10. Spacer Washer 11 . Spider Assy

0736321
2, Ali gn the spider assembly and movable sheave timing marks .
r~
. ~'~"~. ~~ :
6. Cam Arm 7. set Screw
8. Lock Nul
KEY
1. Stationary
ult '"
MS406A
Sheave
2. 3. 4. 5. Movable Sheave
Bearing
Pin O-Ring
9. Spacer Washer 10. Spider Assy
11 . 12. 13. 14.
Spring Nut Cover Lock Washe r
6 CAUTION
Failure to align the spider and movable sheave timing marks will cause drive clutch to be out of balance resulting in clutch and crankshaft damage.
15. MachlneSCtew
0738469
I. O n the 9 -pOSL style, place a cam arm with bushing and washe rs into position o n the movable sheave;
then secure with the ca m arm pin and lock nut.
Carefull y lighten the lock nul until it contacts the ca m arm pin sho ulder: then tighten an additional 11
8 turn. Repeat procedure on the other two cam
arms making sure the head or each pin is positioned towmd the direction or dri ve clutch rotation.
3 . Place the movable sheave, sp.acer washers, and spider into posit io n on the stationary sheave hub. Ma ke sure all threads are clean a nd rree of o il y residue. Apply green Loctite 116fYJ to the enlire threaded area o r the shan and thread the spider o nto the shart. Tighten the spider using the spider removal tool to specificat ions .
NOTE: Allow the Loctite to cure at room temperature for 24 hours.
_NOTE : The drive clutch rotates counterclock wise.
Page: 469
8-19
NOTE: Grasp the movable sheave and lift it upwa rd; then release it. It must move freely and not bind at any point.
5. O n the 6 -posl style with a suitable dri ving tool, carefull y install the new cam arm pin bushings into the movable s heave.
6. With the head of each cam arm pin positioned towa rds the direction of the dri ve clutch rotation, install the cam arms.
c
FC089A
4. A pply green Loclile #609 to the threads of the stationary shaft above the spider. Install the spider retainer nut and tighten to specifications.
7. O n the 6-I):)sl style with the cam ann pin properly posi tioned, install the new set screws (pre-coated with Loctite) and tighten securely.
-739-040A
8. O n the 6-I):)SI style, secure lhe ca m a nn pi ns wi th new lock nuts and ti ghten to specifications.
&
CAUTION
When installing cam arms, always use new lock nuts and cam arm set screws.
9. Place the spring and cover into position making sure the timing mark o n the covcr is properl y aligned: then compress the spring and install the nine machine sc rews and lock washers. In a crisscross pattern , lighten evenly to speci fi cations.
FC089
8-20
Page: 470
INSTALLING
I. Install any spacers as accounted for in re moving; then insert the clutch bolt with lock washer .
NOTE: Be sure to wipe the clutch taper and crankshaft taper clean of any oil film or dirt before installing the drive clutch.
2. Place the clutch into position on the crankshaft. 3. Using a IZ-point liZ-in. socket and the dri ve clutch slmnner wre nch, tighlen the clulch boll to specifications.
&
CAUTION
When installing the drive clutch, do not tighten the clutch bolt with any kind of impact tool. Tighten clutch bolt using a hand torque wrench only. Failure to do so could result in stationary sheave or crankshaft damage.
MS402A
...
4. Cheek alignment belween the dri ve clulch and driven pulley (see Drive ClutehJDriven Pulley !O thi s section).
&
CAUTION
Care must be taken when installing the cover not to damage the bushing.
Page: 471
8-21
3. Slide a new bushing onto one of the cam arm pins; then position the pin through the ca m arm bushing.
4. Using the new bushing as a tool, dri ve the worn bushing from the cam ann. Whe n the head of the cam ann pin contacts the cam ann , the new bushing will be prope rl y seated.
5. Install the dri ve belL Check dri ve belt denection (see Dri ve Clutc hlDriven Pulley in this section). Secure the belt gumd and install the plug in the belly pan.
Never operate the engine without the belt guard secured.
6. Eithe r test dri ve the snow mobile or run the engine for fi ve minutes; then ti ghten the drive clutch bolt to specifications.
Roller Driven Pulley

(STD)
REPLACING CAM ARM BUSHINGS (9-Post Style)

Using a vise, spread the jaws just enough to allow room for the bushing to l)';l SS between. 2. Position the cam ann over the spread jaws.
REMOVING
I. O pen the hcxxl: then o pen the belt guard. 2. Re move the dri ve belt. 3. Re mo\'e the cap screw and washer securing the dri\'en pulley; then account for and note the position of any ali gnment washe rs.
8-22
Page: 472
4. Slide the dri ven pulley ofT the dri ven shaft ; then remove pulley from the e ngine compartment.
NOTE: If the driven pulley is tight on the shaft, pull the driven pulley off using the Driven Pulley Puller (pin 0744023).
NOTE: To aid in driven pulley servicing, use a roll of duct tape as a work fixture. The work fixture will increase the stability of the pulley during the repair procedure .
5. Remove the key, alignment washers, and stub shaft from the dri ven shaft.
3. Rcmove the three lock nuts securing thc roller platc; thcll ca rcfull y slidc the platc off the stationary shaft allowing the spring to release tension .
.6.
WARNING
The roller plate is under spring pressure. Care must be taken when removing the lock nuts to prevent the plate from ejecting prematurely.
DISASSEMBLING
Scribe a line across all dri ven pulley components to ensure correct assembly and pulley balance. 4. Remove the spring.
2. Place the dri ven pull ey on a work rixturc so the rollcr plate is dircctcd upward,
Page: 473
823
5. Slide the movable sheave off the stationary shaft; then remove a ny thrust washers located between the sheaves noting the position of washers for assembling purposes.
8. Using a 118-in. punch, remove the spring pm
securing the roller, roller pin, and thrust washer to the plate.
8460
6. Rc move the three socket head screws and lock washers securing the torque bracket (cam) to the stationary sheave; the n remove torque bracket.
9. Using the Roller Pin Remova l Tool (pin 0644-276) fro m inside the platc, dri ve the roller pin out of the plate. Account for the pin, thrust washer, and roller.
7. Place the roller plate on a work fi xture (roll of duct tape, etc .).
8-24
Page: 474
6. Inspect the roller plate, rollers, pins, a nd spring mounting holes fo r cracks, damage, or wear. 7. Inspect the roller plate and movable sheave bearings for wear. For each respecti ve bearing, measure the outside diameter of the shaft and the inside diameter of the bearing. Compare the readings. Clearance between the shaft and the respective bearing must not exceed 0.5 mITI (0.020 in.) , If the cl earance exceeds the specification, the bearing must be replaced.

Using parts-cleaning solvent, wash grease, dri ve

belt dust, and foreign maHer off all components.
A CAUTION
Do not use steel wool or a wire brush to clean driven pulley components. A wire brush or steel wool will cause the sheaves to be gouged (thus, the drive belt may not slide properly between sheaves). Decreased performance and possible accelerated drive belt wear will result.
2. Inspect the rollers for damage, cracks, or wear.
3. Inspect the sheaves for any gouges, cracks, or othe r damage. Also, inspect threaded areas of sheaves for damaged or stripped threads.
4. Inspect the torque bracket (cam) for cracks or
damage. The ramp p0l1ions of the bracket and ca ps must be free of gouges and damage. Minor scratches may be repaired using #320 grit wet-ordry sandpaper.
6467
REMOVING BEARINGS
To re move dri ve n pulley bearings, use the Bearin g Removal and Installation Tool (pIn 0644- 167) and the followi ng procedure .
NOTE: To remove the movable sheave bearing, heat must be applied around the bearing.
I. Place the movable sheave (or roller plate) flat on a
press.
6465
5. Inspect spring for dist0l1ion, crystalli zation , or breaks.
2. Using the bearing tool , press the bearing Olii.
Page: 475
8-25
INSTALLING BEARINGS
NOTE: Before installing a bearing , apply red Loctite 6271 to the outside face of the bearing.
I. Place the movable sheave (or rol1er plate) nat press .
0 11
3. Place the lorque bracket (cam) into position o n the stationary sheave maki ng sure the degree number o n the bracket ali gns with the part number on the statio nary sheave. Install the three soc ket head screws and loc k washers. 00 NOT ti ghte n at this time.
2. Using the ocaring too!, press the bearing mto positio n. The be...-aring mllst be Ilush with the
o utside o f the bearing boss.
3. Wipe off excess Loctitc. Allow the Loctite to c ure for 24 hours at room temrx:rature.
ASSEMBLING
4. Place any thrust washers (as noted during disassembly) o n the stationary sheave shaft.
, "
KEY
1. Movabie Sheave 2. Bearing
3. Thrust Washer
6. Look Washer 7. Socket Head

S,"~
12. Spring Washer 13. Roller

14. Lock Nut
4. Stationary
Sheave
8. Spring 9. Roller Plate

10. Spring Pin
5. Torque Bracket
(Cam)
15. Covet 16. Cover 17. Self Tapping

Screw
0737913 6460
11 . Roller Pin
I. Place the ro lle r and thrust washer (toward the

outside o f the roller plalc) and secure w ith the roller pin.
5, Ali gn the scribed line made during di sassembly; then slide the movable sheave onto the stationary sheave shart.
2. Secure the roller, thrust washer, and pin into posilion with the spring pin . Dri ve the pin in until it is Ilush with the plate.
8-26
Page: 476
10. Rotate the movable sheave to ensure free movement without binding. II. Rotate the torque bracket (cam) until it is ti ght ; then using a long hex wrench, tighten the three socket-head cap screws (from step 3) securing the bracket to specifications.
6. Place the sheaves on a work fi xture (roll of duct tape, etc.). 7. Place the spring over the stationary sheave hub and hook the turned down end of the spring into the hole in the casting of the stationary sheave.
INSTALLING
I. Slide the ali gnment washers onto the end of the dri \'en shaft 2. Install the key in the dri ven shaft keyway; then place the stub shaft into the driven pulley. Place the driven pulley on the shaft. Align its keyway with the driven shaft keyway.
_NOTE : A small amount of Loctite Anti~Seize Thread Compound (pIn 0678~146) applied to the driven shaft will aid in future driven pulley removal.
8. Place the roller plate over the spring and hook the turned-up e nd of the spring in the 3rd hole (standard spring te ns ion) of the pl ate. 9. While holding the sheaves to prevent them from rotating , grasp the roller plate and rotate it approximately 1200 cloc kwise until the mounting holes align; then push the plate into position and install the three lock nuts. Tighten the lock nuts to specifications.
NOTE: The line scribed during disassembly should be aligned.
3. Secure the driven pulley by installing any alignment washers, the washer, and cap screw (coated with blue Loctite 11243). Tighten the cap screw to specifications.
SC013D
4. C heck dri ve clutch/dri ven pulley alignment (see Drive Clutch/Dri ven Pulley in this section); adj ust as necessary. 5. Install the drive belt and check drive belt deOection (see Dri ve Clutch/Dri ven Pulley in this section). Secure the belt guard .
Page: 477
8-27
Drive Clutch! Driven Pulley

(STD) CHECKING OFFSET
If premature dri ve be lt wear is ex pe ri e nced or if the driv e be lt turn s over, paralleli s m /offset Olli s t be c hecked . Also, paralleli sm/offset Ollist be chec ked whenever ei ther the dri ve clutch or dri ven pulley is serviced. To check the paralleli sm/oITse!, usc the Clutch A lig nme nt Bar (pIn 0644-003) and the following procedure.
I . O pen the belt guard and remove the dri ve belt.
l Ii
l ill
-.t'
m
7339126
CORRECTING OFFSET
I. To correct o ffset, the driven pulley must be moved
2. Install the clutch alignment bar between the dri ve clutch sheaves and against the o utside edge of the dri ven pulley statio nary sheave. 3. Allow the aliglUncnt bar to rest o n the drive clutch shaft
laterall y o n the dri ven shaft. Remove the cap screw and washers securing the dri ven pulley; then remove the driven pul ley. NOTE : If the driven pulley is tight on the driven shaft, pull the driven pulley off using the Driven Pulley Puller (pin 0744-023). 2. To move the dri\'cn pulley inward on the shaft, remove washe r(s) as required from behind the pull ey.
1
TI
-'t
ffi Wft I~
3. To move the dri ven pulley o utward o n the shaft , add alignment washcr(s) as required behind the dri ven pulley. NOTE: Make sure the keyways match when instaJJing the driven pulley, Arrange washers to allow the least amount of "float" on the driven shaft. A maximum of 1.5 mm (0.060 in.) of float is acceptable.
lli1 l fJJ I
0733912
NOTE: The alignment bar must extend beyond the front edge of the drive clutch.
4. Install the driven pulley and secure with a eap screw and washers. Tighten the ca p screw to specificatio ns.
4. With the tmr against the outside edge o f the driven pulley stationary sheave at points A and S, the Ixlr should just clear the inside edge o f the stationary sheave o f the drive clutch and rest on the stationary shaft. If the bar docs not clear the inside edge or is more than 1.5 mm (0.060 in .) from the inside edge, the offset must be corrected .
CHECKING PARALLELISM
I. Check paralleli sm of the drive c lutch/dri ven pulley using the alignment bar and reference points X and Y with the alignment bar against the dri ven pulley at po ints A and B. Using a calipe rs or a machinist's scale, measure X and Y from the back side of the alignment bar. Measurements X and Y must be equal or measurement Y must be more than measure ment X, but Y must not exceed measurement X by mo re than 1. 6 mm (0.062 in.).
8-28
Page: 478
--TI
---
-j
'1
Itf
UJJ
--y-tr
--- t
733-91 2A
2. Recheck both offset and parallelism to ensure accuracy and make fUi1her adjustments as necessary.
NOTE: After parallelism and offset have been corrected, check for proper drive belt deflection. This is critical for optimum performance.
CORRECTING PARALLELISM (Torque

BURlper w'/Shinls) I. To correct j:mrall elism. mino r adjustments can be made by remov ing shims from o r insta lling shims o n the left-rear engi ne mount.
NOTE: The offset must be correct before checking parallelism. A. Loosen the cap screws securing the engine
mounting brackets to the front end .
2. tr parallelism is not within specifi cations, the parallelism must be corrccted.
B. Add o r remove shims as needed to attain correct parallelism.

C. When p< Jrall elism is correct, secure the engine mounting brackets to the front end .
CORRECTING PARALLELISM (Torque

Bumper 'W/Bearing Support Bracket)
I. To correct parallelism, mino r adjustments can be made by adjusting the torque bumper on the leftrear engine moun!.
2. Recheck both offset a nd parallelism to ensure accuracy and make furth er adjustments as necesS<'lry.
NOTE: After parallelism and offset have been corrected, check for proper drive belt deflection. This is critical for optimum performance.
A. Loosen the
Ct.'! p
screws and nuts sec uring the
engi ne mounting brackets to the rront cnd. 8. Using the jam ollis on the torque bumper, adjust
parallelism and pe riodicall y check the parallelism. When the parallelism is correct, ti ghten the cap screws and Iluts securing the e ngi ne mounting brackets to the rront end; then ti ghlen the torque bumper j am nuts all ow ing 1.5 mill (0.060 in.) clearance between the torque bumpe r and the engine.
CORRECTING PARALLELISM (Engine

Snubber w/Engine Plate)
I. To correct parallelism, mino r adjustments can be
made by adjusting the engine snubber on the leftrear engine mount. A. Loosen the cap screws securing the engine plate to the engine mounts. B. Either lengthen or shorte n the snubber and pe riodica ll y check the para llelism When the parallelism measurement. measurement is correct, loosen the snubber to allow 1.5 mm (0.060 in.) clearance between the snubber and the engine; then lock the jam nuts o n the snubber and ti ghten the ca p screws securing the engi ne plate.
Page: 479
8-29
2. Recheck both offset and parallelism to ensure accuracy and make hU1her adjustmenlS as necessary.
NOTE: After parallelism and offset have been corrected , check for proper drive belt deflection. This is critical for optimum performance.
2. Remove the sheave adjuster from the end of the pulley. 3. Using a 9! 16in . socket and extension, re move the cap sc rew securing the dri ven pulley to the driven shaft. 4. Slide the dri ven pull ey otT the dri ven shaft.
DRIVE BELT DEFLECTION
Dri ve bell leng th , condition. and de ri ectio n are all important for peak performance. To check and adjust dri ve belt deflection. use the following procedure. I. Turn the e ngi ne off; then open the bell guard. 2. Make sure the dri ve belt is sitting at the top of the driven pulley sheaves. 3 . Place a straightedge on top of the dri ve belt . The straightedge should reach from the drive clutch to the top of the driven pulley. 4. Using a stifT ruler cente red betwee n the dri ve clutch and driven pulley, push dOWJl on the drive belt just enough to remove all slack. Note the amount of deflection on the rule r at the bottom of the straightedge. The denection should be within the range of 25-3 1 mm(l - l lJ4in.).
NOTE: Push down on the belt with the ruler only until the bottom of the belt flexes upward ; then read the amount of deflection.
NOTE: After removing the driven pulley, retrieve the cap screw washer from inside the pulley bore; then account for and remove any alignment wash ers. These washers must be used during installing.
DISASSEMBLING
I. Prior to disassembling , mark the dri ven pulley
sheaves and torque bracket.
5. To correct dri\'e belt denection, washe rs ca n be removed or added between the stationary and movable sheaves of the driven pulley.
NOTE: If the drive belt deflection is above speci fications, the snowmobile will bog and lack power at clutch engagement. For good performance, proper belt deflection is critical.
2. Using Dri ve Belt Dcllection Tool (pin 0644-4 12). remove the sheave adj uster. Account for an O-ring and shim washers.
6. Secure the belt guard.
ACT Roller Driven Pulley

(ZR 900/Firecat/M .. Series)
REMOVING
I. Remo\'e the drive belt.

NOTE: For removing drive belt, see Removing! Installin~ Drive Belt (ACT Roller Driven Pulley) in this section.
NOTE: On the MSeries models, the sheave adjuster has lefthand threads.
830
Page: 480
3 . Place the dri ven pulley on the Driven Pulley Compressor (pin 0644-444); then install the compressor Oange spacer and wing nut and compress the driven pulley spring.
4 . Remove the six ton.:-head cap screws securing the movable sheave to the pulley.
NOTE: To loosen the six torx-head cap screws, it may be necessary to insert a torx-bit and strike each screw with a hammer.
5. Release the compression of the spring by remov ing the wing nut ; then remove the movable sheave. Account for the spacer (retai ner) .
Page: 481
8-31
7. Re-:n0ve the plastic washer (spring seat) and the spnng.
NOTE: Note the location of the holes in the spacer for assembling purposes.
6. Remove the stalionary sheave.
8-32
Page: 482
NOTE: Premature wear will result if the plastic washer is not installed during assembling.
8. Rc movc thc thrce torx-hcad scrcws securing the covcr to thc to rque bracket.
I. Using pa rts-cleaning solvcnt, wash greasc, dri ve belt dust, and fo rc ign mattcr ofT all compo nc nts.
& CAUTION
00 not use steel wool or a wire brush to clean driven pulley components. A wire brush or steel wool will cause the sheaves to be gouged (thus, the drive belt may not slide properly between sheaves). Decreased performance and possible accelerated drive belt wear will result.
2, Inspect the ro llers for damagc , cracks, or wcaL
FS099
9. Using Drivcn Pulley Spring Adjustment Tool (pIn 0644-41 3 ), remove thc spring adjuster.
Page: 483
8-33
3. Inspect the sheaves for any go uges, cracks, or othe r damage. Also, Inspect threaded areas of sheaves for damaged or stripped threads.
4. Inspect the to rque bracket fo r cracks or d.:1mage.
The ramp po rti ons of the bracket and ca ps must be free of gouges and damage. tvlinor scratches may be repaired using #320 grit wet-or-dry sandpaper.
B465
5. Inspect spring for distOitio n, crystalli i' ..atio n, or
breaks.
6. Inspect the rollers, pin", and spring mo unting
holes for cracks, damage, o r wear. 7. Inspect the cover a nd movabl e sheave bea rings for wear. For eac h res l~cti "e bearing, measure the o utside diamete r of the shaft and the inside diameter of the bearing. Compare the readings. C learance between the shaft and the res l~cti ve bearing must not exceed 0.5 mm (0.020 in.). If the clearance exceeds the specification, the l~arin g must be re placed.
NOTE: The movable sheave bearing is a non-serviceable component.
REPLACING TORQUE BRACKET COVER BEARING
I. Remo \'e the snap ring fro m the cover. 2. Using a suitable dri ving tool, dri ve the bearing out of the cover.
Always wear safety glasses when using the bearing driver 3. '!1stall the new bearing: then secure with the snap
nng.
REPLACING ROLLERS
I. Dri ve the spring pins out of the stationary shea ve.
NOTE: Once a spring pin is exposed, it may be necessary to remove the pin using a pair of visegrips.
8-34
Page: 484
2. Using an Allen wrench and a nat-blade screwdriver, press the roller pin out of the stationary sheave.
4. Tap the spring pi n b<lck in10 place.
ASSEMBLING
,&, CAUTION
Care must be taken not to damage the driven pulley shaft. NOTE: Once the roller pin is exposed , it may be necessary to use a pair of vise-grips to remove the pin.
I. Using Dri ven Pulley Spring Adjustment Tool (pin 0644-4 13), install the spring adjuster.
2. Install the torque bracket cover and secure with three torx-head screws. Tighten to specifications. 3 . Place the new rolle r into position and tap the roller pin in far enough to install the spring pin.
Page: 485
8-35
NOTE: Premature wear will result if the plastic washer is not installed.
3. Place the torque bracket onto the Dri ven Pulley Compressor (p/n 0644-444); then place the spring and plastic washer (spring seat) into position,
4. Noting the ali gn ment marks made during disassembling, place the stationary she.'lve onto the torque bracket.
5. Place the spacer (retainer) into position on the stationary sheave noting the proper location of the holes from di sassembling.
8-36
Page: 486
6. Noting the alignment marks made during di sassembling, place the movable sheave onto the stationary sheave.
9. Remove the pulley from the compressor and install the sheave adjuster.
7. With the pulley in placc on thc compressor, install the compressor nange spacer and wing nut; then compress the driven pulley spring.
NOTE: On the MSeries models, the sheave adjuster has left-hand threads. NOTE: At this time, leave the ()..ring and shim washer off the sheave adjuster. They will be installed when installing the drive belt.
INSTALLING I. Set the brake lever lock.
2. Slide the dri ven pulley onto the driven shaft making sure alignment washers are in place. 3. Secure the pulley with the cap screw (coated with bluc Locl"itc #243) and washer. Tighten to specifications. 4. Install the drive belt. 8. Install thc six torx-hcad cap scrcws securing the movable shcavc. Tightcn to specifications.
NOTE: For installing drive belt, see Removing! Installing Drive Belt (ACT Roller Driven Pulley) in this section.
Page: 487
8-37
Drive Clutch! Driven Pulley

(ZR 900/Firecat/M.Series)
CHECKING OFFSET
If premature dri ve belt wea r I S ex perienced or If the dri ve be lt turn s over, parall e li s m /offse t mu st be c hec ked. Also, paralleli sm/offset Ollist be checked w henever e ither the dri ve clutch o r driven pull ey is se rviced . To ch eck the paralleli sm/offset, usc the Clutch Ali gnment Bar (pIn 0644-(03) and the following procedure.
I . O pen the belt guard and remove the dri ve belt.
_NOTE : For removing drive belt, see Removing/ Installing Drive Belt (ACT Roller Driven Pulley) in this section.
11
2. Install the clutch alignment bm between the dri ve clutch sheaves and against the o utside edge of the driven pulley statio nary sheave.
3. A llow the alignment b..1r to rest on the dri ve clutch
lUJ f7i
-LJIlil
733-9126
shaft.
CORRECTING OFFSET
I
TI
,
I
1.
/
I
I. To correct o ffset, the driven pulley must be mm'cd laterally o n the dri ven shaft Remove the cap screw and washers securing the dri ven pulley; then remove the driven pulley.
_NOTE : If the driven pulley is tight on the driven shaft, pull the driven pulley off using the Driven
Pulley Puller (pin 0744023).
rFi\~mr =
I
l hU fIiJ
u:>
0 733912
2, To movc the driven pulley inward 011 the shaft , remove washcr(s) as req uired from behind the pulley. 3 . To move the dri ven pulley o ut ward on the shaft , add alignment washcr(s) as required behind the driven pulley.
NOTE: Make sure the keyways match when installing the driven pulley. Arrange washers to allow the least amount of "float" on the driven shaft. A maximum of 1.5 mm (0.060 in.) of float is acceptable.
NOTE: The alignment bar must extend beyond the front edge of the drive clutch.
4. W ith the bar against the outside edge of the driven
pulley stationary sheave at po inlS A and B, the b.:'lr should just clear the inside edge o f the stationary sheave o f the dri ve clutch and rest 0 11 the statio nary shaft. If the bar does not clear the inside edge or is mo re than 1.5 mOl (0.060 in.) from the inside edge, the offset must be corrected.
4. Install thc dri vcn pulley and sec ure with a cap screw (co.ated with blue Loctite #243) and washcrs. Tighten the cap screw to specifications.
838
Page: 488
CHECKING PARALLELISM
C heck paralleli sm o f the dri ve clutchJrlrivcn pulley using the ali gnment bar a nd reference points X and Y with the aligmllcnt b<lr against the dri ven pulley at points A and B, Using a calipers or a machinist's scale. measure X and Y from the back side of the aligmncnt bar. Measurements X and Y must be
equal or measurement Y must be more than measurement X, but Y Ollist not exceed measurement X by more than 1.6 mm (0.062 In.).
y X
ism. When the paralleli sm is correct, tighten the cap screws and nuts securing the engine mounting brackets to the front end : then adjust the to rque bumper jam nuts allow ing the torque bumper to li ghtly contact the engine.
--TI
I~
---I
UJJ
--- t --VIT
733-912A
2. Recheck both offset and parallelism to ensure accuracy and make further adjustments as necessary.
NOTE: After parallelism and offset have been corrected , check for proper drive belt deflection. This is critical for optimum performance.
DRIVE BELT DEFLECTION

Dri ve belt length, conditi on, and deflection arc all impol1ant for peak performance. To c heck and adjust drive belt deflection, use the following procedure . I. Turn the engine off; then open the belt guard . 2. tvlake sure the dri ve belt is sitting at the top of the dri ven pulley sheaves. 3. Place a strai ghtedge o n top of the drive belt. The straightedge sho uld rc.1Ch from the drive cl utch to the top of the driven pulley . 4. Using a stiff ruler centered between the dri ve clutch and driven pulley, push down on the dri ve belt just enough to remove a ll slack. Note the amount of dellection on the ruler at the bottom of the straightedge. The defl ection sho uld be at 3 1 mm ( 1 1I4in.).
NOTE: Push down on the belt with the ruler only until the bottom of the belt fl exes upward; then read the amount of deflection.
NOTE: The offset must be correct before check

ing parallelism.
2. If parallelism is not within specifications, the parallelism Ollist be corrected.
CORRECTING PARALLELISM
I. To correct parallelism, minor adjustments call be made by adjusting the torque bumpe r on the leftrear engine moun!.
A. Loosen the Ct'l P screws and nuts sec uring the e ngi ne mounting brackets to the front end. 8. Using the jam nuts o n the torque bumpe r, adjust paralleli sm and periodi cally check the parall el-
5. To correct dri ve belt deflection, remove the sheave adjuster from the pulley, remove o r add shim washers to the adjuster, and install the adjuster.
Page: 489
8-39
NOTE : On the M-Series models, the sheave adjuster has left-hand threads.
6. With the O-ring and shim washers removed,
Belt Guard
Drive Bell '}
carefully thread the sheave adjuster back into the dri vcn pulley; then ti ghten the adjuster with the denection tool until it bottoms against the dri \'cn shaft. NOTE : By bottoming the sheave adjuster against the driven shaft, the sheaves of the driven pulley will spread far enough to allow the removal of the drive belt.
7392678
J ~~i\:" Sheave Movable

Driven Polley
NOTE : Adding shim washers will decrease belt deflection; removing shim washers will increase belt deflection . NOTE : If the drive belt deflection is above specifications, the snowmobile will bog and lack power at clutch engagement. For good performance, proper belt deflection is critical.
7. Remove the dri ve belt from the dri ve clutch and drivcn pulley.
Belt Guard
Drive Belt
Removing/Installing Drive Belt

(ACT Roller Driven Pulley)
Driven Pulley
7392678
Tum ignition key to the OFF position and wait for all mov ing part:; to stop. 2. Set the brake lever lock. 3. Opcn thc hood ; then opcn thc belt guard. 4. Rcmove thc drivcn pullcy access pancl from the belly pan. 5. Using the Dri ve Belt Dellection Tool (pIn 06444 12), remove the sheave adjuster from the end of the dri ven pulley. Aceount for and remove the 0 ring and shim washers. Note thc oricntation of the compo nents fo r instal li ng purposcs.
8. Place the dri ve belt (so the 1 :>"1 11 number can be read) between thc sheavcs of thc drivc clutch first; then between the sheaves of the drivcn pul ley. 9. Using thc dellection tool , remove thc sheave adjuster from the end of the dri ven pulley. 10. Place the shim washers and O- ring (as noted in remov ing) onto the sheave adj uster; then carefull y thread the sheave adjuster back into the dri ven pulley. Ti ghten the adjuster sec urel y using the deneclion tool. II. Closc the belt guard ; then install the drivcn pulley plug.
Never operate the snowmobile without the belt secured in

Belt Guard
12. Releasc the brakc lcvcr lock.
Drive Clutch Drive Belt 8 ell Deflecti on Tool / .. Driven Pulley

7392668
8-40
Page: 490
Drive Train Schematics

(vv/Reverse)
NOTE: Determine which type of drive train is being serviced and refer to the appropriate illustration for component details; then disassemble and assemble accordingly. Some components will vary from model to model. The technician should use discretion and sound judgment when removing and installing components.
m
1. Sprocket Assy
2. Sprocket 3. Spring Retainer

4. Slip Pin 5. Compression
Spring
6. Cap S<: rew

7. Lock Nut 8. Bearing 9. Shaft Spacer
Plale ". Flange Bearing ". aRlng 34. lock Nut l ock Nut ". Sprocket ,..
33.
Chain Case Assy
,..
".
37. S pr ing Washer lock Nut Beari ng
10. Chain
11. Dri veshatl
Extension
12. ReverseGear 13. Thrust Washer 14. Thrust Bearing
301". . .'<- '-'!

v
15. Retaining Ring 16. Cap S<:tew 11. Tab Lock Washer
18. 19. 20. 21. Was her Shaft Retainer Spring Pin Return Spring
1~
11 18
19
21
20 13
". Assy ". ". 27. "'.
22. Reverse S haft Reverse Idler
15
14
Bearin g Aligner Pin 2<. Revet5e Idler Bearing Thrust Washer 29. Reverse Idler
Spacer
30. Cap Sc rew
Page: 491
8-41
KEY
,. ,.

Track Drive Assy Drive Sprocket 3. Dtlveshaft Drive Bushing
"-
,.
Flange Plate Beating

Flange Plate
". ". """. ". ". ". "'.

"-
Carriage Boll Solder Ring Drive Adapter

Grease Fining Cable Adapter Lock Nut
"'. ". ". ". ". ".
". ". ".
Brake Pad Set 32. Brake Pad Piston 33. Cap Screw Brake Cable Bracket Alignment Ball Brake Caliper Assy
Drive & Driven Shaftsl Quick-Adjust Brake Assy
CompressiOO
Spr ing Was her Brake Caliper Nut
Washer
Brake DIs<:
Driven S haft
". K., ". Ko,
Cap setew
Bearing/Lock
...
". ... ...
".
Collar
". ". ". ".

"'.
". ".
Flange Plate Was her Stub Shaft Driven Pulley Was her 26. Washer Was her Cap S<:rew 29. Snap Ring Staliooar~ Pad Backing late
40. Spring Pin Return Spring Brake Adjuster Kno b Compress ion Spring Brake Adjuster Screw E-Ring 46. CleviS Pin Act ivator Arm Clevis Pin Washer 60. Cotter Pin Washer Brake Caliper Mounting Bolt
~ ./
51----"
"'-"
'
- , ....it
" -. ' , ~ "- l~
... " ,
~.... .
,Ij < ~
" .r ", .
',.~ . r @
-" -15
;"" <' , -'-'." '

,~ -. ~ - )f
'''I .,-r,_
...,
. YO . ja '9'
31 ...!.
II 11
....,
'1';
& . /.
35 ' 1 31
40 '1
~
...~ "
\. __ ~1
31"'~'5'~ ,' 49~ ,,.---;~
,.
r
~
!IO ____ ~
'
II
"'14 ~' - 33
- ~
.... .. '... '1 -~ 41. / 4S " ' J /

1O .... _-21
'@-, ..,
". ".
. r" ~~~ C"

'8
1' _ _ ~
~ " ... 12
.....
" 1--
' ./ ~ n ,,\3 -_J
13 __ :-
0738-367
KEY
.. ,
,.
,. ,.
". ". ". ". ".
,.
". ". Ko, ". ". K., ".

". ".
Track Drive Assy Dri ve Sprocket Driveshaft Dri ve Bushing Flanl,le Plate! Beaflng Assy Flange Plate Carriage Bolt Bea ring Solder Ring Lock Nut Cable Adapter Dri ve Adapter Grease Fitting Cap Screw Brake DI s<: Dri ven Shaft
". ". " . " . ".

".
"'. ". ". ". ".

". ".
". ". ...
Dri ven Pulley Washer Washer Was her Cap S<: rew Brake Caliper Assy Housing Housing Cap S<: rew Bleed Screw Brake Pad Set 36. Retaining Pin Housing a-R ing O-Ring Piston Was her Adapter Fitting
Drive & Driven Shafts/ Hydraulic Brake Assy
,..- "
,, ~
Cap Screw 20. Bearing Flange Plate Washer "- Stub Shalt
0738-426
8-42
Page: 492
KEY
..
"'
I. Chain Case
".
Bearing
2. 3. O-Ring
Carriage Bolt 1 . Lock Nut
,. "''',
..
M. Ro ller Shaft 35. Was her
Chain Tensioner Assy
Carriage eon ... Cap S<:rew ". Guard .,.
8. Carriage Bolt Washer
" . "'. ... ". " .
3<. Roller Arm Cap Sc rew l ock Nul 39. Ro ller Arm Not Washer
Bracket
Lock Nul
". ".
Adapter
S~I
)~
I
29 26
16. Washer
16. N" 11. Adj uster IS. Drain Plug
7- ,
~~l
@
'~
,--42
". ".
20. Drain Plug 21. Cap Sc rew 22. Covet 23. Shin Fork Shaft O-Ring Spring Pin 26. Vent Cover 21. Self-Tapping
".
O-Ring
"'. ...
S,,,_ 28. Shift Fork 28. S~I
Oil Level Slick O-Ring 32. Roller

0739-458
KEY
1. Chain Case
2. Stud
31 . Cap Sc rew
32. 0 11 Level Stick 33. Tube 34. SalfTapping Screw 35. SeIfTapplng
Chain Tensioner Assy
3. O-R ing 4. Boll 5. Boll

6. Look Nut
7. Carriage Boll B. Carri age Boll 9. Washer

10. 11 . 12. 13. Drain Plug O-ring Drain Plug Adjuster Housing
"'. 31.
S,,,_
14. Covet
15. Adjuster Spring 16. Self-Tapping Screw 17. Adjuster Shaft
". ". ". ... ". ...
O-Ring Lock Nut 38. Bracket 39. Cap Sc rew 40. Nut Washer Roller Arm Washer Roller Beating Roller Shaft
.~
~:
r:"
18. Adjuster Sc rew 19. O-Ring 20. Compression

Spring
21. Rivet
22. Machine S<:rew
23. Covet
Shift Fork Shaft ORing Spring Pin Vent Cover SelfTapping Sc rew 29. Shift Fork 30. Seal 24. 25. 26. 27. 28.
0739863
Page: 493
8-43
KEY 1. Lever
Shift Lever Assy
2, Clevis Pin
3. Cotter Pin 4. Cap Screw
5. Shift Pivot
6. Axle
7. Washer
B. External Tooth Lock Washer
9. Cap Screw
10. Bracket
11 . AlarmSwilch 12. Switch Boot

13. Reverse Alarm
14. Retaining Ring

15. Cap Screw 16. Lock Nut
17. Shift linkage Assy

18. 19. 20. 21 . 22. Rod End - Left Jam Nut - Left Linkage Rod Jam Nut - Righi Rod End - Right
~ 18't
8 9 19 20 10
11
16
17
22
21 ~
16
15) ,
0739-453
KE Y
1. Lever 2. Clevis Pin 3. Cotter Pin
Shift Lever Assy

15
4. Cap Screw
5. Shift Pi vot 6. Bushing
7. Axle 8. Washer
9. External Tooth Lock Was her 10. Cap Screw 11 . Switch Boot
G~
'~>0\ '.J .... ,I
'--
_ .:.'.
~'.' .C ' . _
-'::~~.::.
.,.. ~ .... ICC"'.....
12. Alarm Switch 13. Reverse Alarm 14. Retaining Ring

15. Lock Nut
16. Shift Linkage

17. Rod End - Left 18. Jam Nut - Left 19. Linkage Rod 20. Jam Nul - Right 21 . Rod End - Right 22, Cap Screw
24 ~
25 ,-- \
23. Decal
24. Harness
25. Cable Tie
16 12 15
0738_714
8-44
Page: 494

(w/o Reverse)
KEY
1. ChalnCasewl
Studs
32. Sprocket
33. Look Nul 34 . Tightener Arm Assy 35. Bushing 36. Lock Nut 37 . Tightener Arm 38. Washer 39. Tightener ROller 40. Bearing 4t . Washer 42. Washer 43. Spring Assy 44. Cotter Pin 45. Chain Adj uster
S<~
Chain Case Assy
2. Ribbed Bolt
3. Stud aRlng
4. 5. 6. 7. 9. 9.
Ribbed Bolt Stud Washer Nul Washer Carriage Boll
10. Carriage Bolt 11 . LockNut 12. Plug
13. Cap Screw 14. Chain Case

COVet
15. Vent Cover
16. SellTapping Screw

17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. Plug aR ing
46. 47. 48. 49. so.
Nut Washer Seal Adapter Lock Nut
Oil Level Slick

O-Ring
Seal Cap Screw Chain

Look Nut Washer
Sproc ket
Flange
Bearing Seal Bearing Lock Nul

0739283
Page: 495
845
KEY
". ... ".

".
,. Ribbed Boll ,. Ribbed Bolt 5 '''' ,. N., Cover ASsy 9. Vent Cover ". $<,_
O-Ring
1. ChainCasewl S lucls
...
". ".
Tightener Arm
5. 6. Washer
".
Assy l ock Nut Mm Washer
Chain Case Assy
35. Roller
Self-Tapping
Plug
O-Ring Oi l Level Slick O-Ring
... ... N.,

43.
".
" . M . Washer
M . Beari ng
Was her
Spring ASsy
40. Cotter Pin Cap Sc rew 42. Adjuster

Washer 45. 5~'
1S. Seal
16. Cap Sc rew 17. Chain
18. Cap Screw
19. !J:,amldal
asher
...
".
".
46. Adapter
Carriage Bolt 48. Washer Carriage Bolt SO. Lock Nut
11--
". ". 2<. ". ".
20. Sprocket 21 . Lock Nut 22. Spring Washer 23. Sprocket

Flange Plate
51 . Carriage Bolt
G uard
~ 12
8
f ::
d'
6
IS
Lock Nut
Lock Nul Bearing O-Ring
t6 ,
29. Beating 3<1. Bushing
"",
~
50
"'--51 51
0739-908
KEY
1. Chain Case wI
,. ,.
Stud s
. .II
O-R ing
". Screw P'", ". ". H. ". ". w. SN'

21 . Chain
". ". ... ".
. .II Nul Lock ,. Washer Look Nul 9.

5. Stud
". " . ". " . N.' ". ". 50,_
Bearing l ock Nut Tlg hlener Assy Bushing Chain Rol ler
Chain Case
Was her Carriage Bolt
Carriage Bolt
Cover Assy
Vent Cover Self-Tapping
ORing Oil Level SUck O-Ring
Cap Sc rew
".
". ".
". ".
>2. l ock Nut

Spring Washer Sprocket Sprocket 2<. lock NUl Flange ORing 29. Bearing
12
0739861
8-46
Page: 496
KEY
Track Drille Assy 2. Drive Sprocket 3. Driveshafl Drive Bushing Flange Plate Flange 7. Carriage Bolt Bearing Solder Ring Cable Adapter Drive Adapter Grease Fitting
,. lock Nut ...
... ".
". ".
33. Bleed Screw

Brake Pad set Retaining Pin O-Ring 37. O-Ring Piston
Washer
Drive & Driven Shafts/ Hydraulic Brake Assy
". ".
Adapter Fitting
,..
,..
"-
"'. ". Washer ". ,..

22. 25. Washer
... ... ... ". K" ... '" .o. K" ...
"-
Cap Screw
Brake Disc
Driven Shaft
Cap Sc rew Bearing Flange Stub Shaft Driven Pulley
". ". 29. Brake Caliper

Washer
Washer
Cap Sc rew
Assy Housing Housing
32. Cap Screw
0738-426
KEY
1. 2. 3. 4. 5. 6. 7. 9. Track Drive Assy" Drive Sprocket Driveshaft Dri ve Sprocket Drive Bushing Flange Plate Flange Plate Carriage Bolt
,.. ". ,.. ". ". "
9. Bearing 10. Solder Ring

11 . Cable Adapter 12. Drive Adapter 13. Grease Fmlng
... ...
33. Brake Pad Set Retaining Pin Housing Q.Ring Q.Rlng Piston . Washer Adap1er FiHlng Cap SCrew
Dri ve & Driven Shaftsl Hydraulic Brake Assy
Sprocket s1yle will vary from model to model .
14. Lock Nut

15. Brake Disc
16. Key
17. Drl venShalt
l B. Key 19. Bearing 20. Flange Plate

21 . Cap Screw 22. Washer 23. Siub Shaft 24. Driven Pulley 25. Washer 26. Washer 27. Washet 29. Cap Screw 29. Brake Caliper Assy 30. Housing 31 . Cap Screw 32, Bleed Screw
0738604
Page: 497
8-47
KE Y '- Track Dri ve Assy
,. ,. ,. ,. ""'om ,.
Drive Sprocket Driveshaft Flange Plate Bearing
". ". ". ". ". ". ".

". ". ".
".
Bea ring Spacer H . Washer Stub Shaft a-Ring Driven Pull ey Washer Washer Washer Cap Screw Brake Cali per Assy 26. Cap SCrew Washer Adapter Fitting HoUSing
". ". ". ". ".
,. ". n.
Voltage Regulatorl Speedometer Pickup Module Lock Nut Cap Screw Washer Brake Disc
". ". " . ". ". ". ...
a-Ring a-Ring Piston Bleed SCrew Housing Brake Pad Set Retaining Pin
Drive & Driven Shaftsl
Hydraulic Brake Assy
Koy
Driven Shaft
K.y
0739-675
8-48
Page: 498

(w/ACT Drive)
KEY
1. Gear Case
2, 3. 4. 5.
011 Seal Dowel Pin Oil Seal D-Rlng
Gear Case Assy
6. Plug
7. Ring Gear
B. Bearing
9. Input Shaft
10. Bearing
11 . Planetary Gear
12. Retaining Ring
13. Trans'etGeat 14. Bearing

15. Cover
16. Bea ring
17. Oil Seal 18. Machine S<: rew
0739602
Page: 499
8-49
KEY
',. Seal ,. Oil Dowel Pin Oil Seal 5. ,. ,. Sensor ,. Clip ,. Bearing ". Retainer ". ". ". Planetary Gear
Gear Case
D-Ring Plug Speedometer
Gear Case Assy
Ring Gear
Transfer Gear H . Bearing
Seal ". Oil Machine Sc rew ".
". ". ". ". ".
Input Shaft Bearing
Retaining Ring
Cover
Bearing
0739-741
KEY
". ". ".

H.
',. ,. ,. ,. Collar ,. ,. ". ". ".

5. Plug
Pin Plug
Track Dri ve Assy Drive Sprocket Driveshafl

Drive Bushing
DriveshafVBrake Assy
look Collar
O-Ring Grease Fitting Set Sc rew Retaining Nut
". ". ". ". ". ". ". ". ,'".
". look Not Washer ". ". "'.

Washer
Brake Disc Cap Sc rew Gear Case Assy
Driven Pulley Washer
Cap Screw
O-Ri ng Sheave Adj uster Cap Sc rew
". ". ". ". ". ". ". ". ". ". ". ". ".
". ".
Cap Screw Washer

Spacer
Cap Screw
Housing
D-Rlng Cli p Pin Piston D-Rlng Brake Pilei Set Clip Bleeder Fitting Fitting Housing Bearing
". Lock Nul ". Cable Adapter

Drive Adapter
Look Nul
Bracket Cap Sc rew Brake Caliper Assy
". ". Sleeve

SO. Ring
0739-601
8-50
Page: 500
KE Y
1. Track Dri ve Assy 2. Drive Sprocket
3. Driveshaft 4. Colfar
5. In sert 6. Spacer 7. Srake Disc
8. CapSctew
9. Retaining Nut
33. 34. 35. 36. 37. 38. 39. 40.
Clip Clip Bteeder Fitting Fining Housing Bearing S leeve Ring
DriveshaWBrake Assy
10. Mounting Plale

11 . GearCaseAssy 12. Lock Nut
13. CapScrew
14. Cable Tie 15. Washer
16. Driven Pull ey

17. Washer l B. Cap Screw
19. Washer 20. O-Ring 21. Sheave Adjuster
22. Machine Sc rew

23. Brake Caliper
Assy
24. Carriage Bolt
25. Cap Screw

26. Washer
27. Housing
2B. O-R ing
29. Pin
30. Piston 31. O-Ring 32. Brake Pad Set
0739783
Drive Train/Brake Disc

(Standard vv/Reverse)
DISASSEMBLING
I. Remove the chain -case drain plug located
011 the lower back side of the chain case inside the tunnel and drain the c hai n case lubricant.
2. Disconnect the battery cables. Remove the battery and lk1ucry tray.
NOTE: On AWS VI models, the expansion cham ber and resonator must be removed prior to step 2.
3. Open the belt guard and remove thc drive belt. 4. Remove the cap sc rew and washe r securing the d ri vcn pulley; then account for and note the position of any a li gnment washers.
5. Slide the dri ven pulley off the dri ve n shaft ; then remove the driven pulley fro m the engine compmtmenl. Account fo r the key. stub shaft . and ali gmnent washers.
NOTE: If the driven pulley is tight on the driven shaft, pull the driven pulley off using the Driven Pulley Puller (pin 0744023).
Page: 501
851
NOTE: Tip the snowmobile on its left side posi tioning the chain case side of the snowmobile up. Place a piece of cardboard under the side of the snowmobile to prevent scratching of bumper and belly pan.
9. Re move the screw from the chain adjuster housing and install an 8-32 set screw to lock the chain adjuster in lX"lsition,
&
CAUTION
On models with mirrors before tipping the snowmobile on its side, position a block of wood under the side of the snowmobile to keep the mirrors from contacting the floor or damage may occur.
6. Di sconnect the shift linkage from the arm on chain case. 7. Re move the cap screw from the center of the chain case. 10. Remove the shim washer from the idl er sproc ket.
8. Re mo\'e the cap sc rews securing the chain case cover; the n remove the cover by pulling outward and lifting lip so the shift fork clears the large inne r washer.
II . Remove the outer idl er sprocket from the shaft.
8-52
Page: 502
12. Slide the small rubber alignment pin from the face of the inner idler sprocket and place in safe location until assembl y.
15. Set the brake lever loc k. Remove the cap screw and large \vasher securing the bottom sprocket.
NOTE: The bottom sprocket cap screw and washer are spring loaded.
13. Remove the lock nut securing the top sprocket. 16. Remove the reverse gear.
14. Remove the spring washer in front of the top sprocket. 17. Remo\'c the top sprocket, c hain , and idler gear. Account for one shim washer located behind the idler gear.
Page: 503
853
NOTE: If the chain is too tight and wont allow the top sprocket to be removed , remove the PTO-side driven shaft bearing. This will allow the driven shaft to be lifted at the PTO-side and will loosen the chain.
18. Remove the driveshaft extension, bottom sprocket,
22. Re move the three lock nuts securing the bottom bearing na nge plate. Remove the nange plate, sC<ll , and bearing. NOTE: Steps 23-27 are for standard models. 23. Re move the screw securing thc air-intake silencer to the steering support; thcn pull the silcnccr forward and placc it on the carbureto r/throttle Ixxlyassembly. NOTE: Using a hold-down strap, secure the airintake silencer to the engine.
and spacer washer.
24. Loosen the set screw o n thc I'TO-side driven shaft collar. Dri ve the collar clockwisc (oPIX)site shaft rotation) until it is free.
NOTE: A fine file should be used to remove any burrs left by the collar set screw. 25. Re move the lock nuts and carriage bolts securing the PTO-side dri ven shaft nange plates .
19. Check the idler gear sha fl. If thc shaft surface is rough, re mo \'c the shaft using a pa ir of visc-grip plic rs. Rotatc the shaft counterclockwise .
20. Rc move thc shoulder nut securing the chain
tightener arm ; then remove the arm fro m the chain casc.
26. Force the driven shaft toward thc PTO-side (rotating the shaft to prevent the brake di sc from binding o n the sha ft ) unlil brake di sc is free. Account fo r the key. 27. Continue to slide the driven shaft until it is o ul of the PTO-side. Account fo r a bearing, two nange platcs, and the PTO-side d ri ven shaft collar. 21. Re move the three loc k nuts securing the top bearing na ngc plate. Re move the nange plate, se..'l l, a nd bearing. 8-54
Page: 504
NOTE: Steps 28-31 are for Firecat rlSabercat models.
28. Re move the three bearing retainer nub from the PrO-side plate brace; then remove the machine screws sec uring the PTO-side plate brace and remove the brace.
32. Remove the skid frame from the tunnel (see Section 9). 33. Re move the three prO-sidc lock nuts securing the dri\'cshaft Oange bea ring assembl y a nd cabl e adapter. Re move the adapter and spcedometer cablc.
29. Remove thc two largc-hcad ri vets below the leftside air-out vent on the left-sidc bell y pa n.
30. Using a rubber mallet (or suita ble substitute), tap thc dri ven shaft from the chain case side until free.
34. Tap the driveshaft toward the c hain case to unseat the ivlAG -side bearing. Remove the bearing. 35. Slide the dri veshaft toward the i\'IAG -side until the prO-side of the dri veshaft is out of its mounting hole. Tilt the end of the dri veshaft a way from the tunnel and slide the driveshaft free of the tunnel. Remove the track.
3 1. Pull dow n on the side pan by the left -side hood latch : then slide the dri ven shaft out the PTO-side of the chassis.
Page: 505
855
36. Scribe a line on the driveshaft along the edge of each sproc ket to aid in assembly. Loosen the set screw on the collar and drive the collar clockwise until free; then remove the bearing and nange plates from the dri veshafl. 37. Press the sprockets off the dri veshaft.

I. Thoroughly wash al l metallic components in pmtscleaning solvent. Dry using com pressed air. 2. Wash all nOll- metallic components with soap and water. 3 . Inspect the dri veshaft and dri ven shaft for damaged splines or stripped threads. 4. Inspect the beari ngs for any roughness or d'lmage. 5. Inspect the seals for any brC<lks or damage. 6. Inspect the track for cuts, gouges, or wear. 7. Inspect the keyways in the driven shaft for wear or damage. 8. Inspect the brake di sc for wear or cracks. 9. Inspect the track drive sprockets for wear or damage. 10. Inspect the top sprocket fo r any chipped or worn teeth.
il. Inspect the bottom sprocket teeth for wear. Tum
14. Inspect the idler gear sprocket teeth and bearings. Rotate the inner bearings by hand. Check each sprocket tooth for any signs of chipping and wear. 15. Closely inspect the dri\'e chain for broken links. 16. Inspect the reverse gear. Inspect the teeth for wear and chipping. Inspect the edges of drive pin holes for any signs of chipping and wear. 17. Remove the snap ring from the reverse gear. Remove the outer thrust washer, thrust bearing, and inner thrust washer. Inspect the thrust bearing by pl acing it between the two tluust washers and rotating the thrust washe r. Rotation must feel smooth. If any rough ness is noted , replace the thrust washers and bearing as a set. 18. Inspect the chain tightener bearing. Rotate the tightener roller and check for smooth rotation. If rotation feels rough, replace roller and bearing assembly.
ASSEMBLING
I. Press the sprockets on the driveshaft noting the
the inner sprocket lJc.l ring by hand and inspect for any signs of being rough. 12. Inspect the three bottom sprocket dri ve pins. Check the pin edges for chippi ng and wear. i3. Inspect the drive pin springs for tension by pushing each pin into the sprocket and releasing il. It must snap back out without any signs of binding. If any of these items (pins, bearing, sprocket , teeth) appear worn, replace the sprocket as an assembly.
scribed marks on the shaft and the timing mark found on one tooth of each sprocket. T he timing mark is an arrow molded into the outer surface of one dri ve tooth. All the arrow markings must be in alignment.
NOTE: Sprocket style will vary from model to model.
---739"()57A
8-56
Page: 506
NOTE: Make sure all sprockets are installed correctly to ensure correct timing of the sprockets. The bearing is positioned between the flange plates. 2. Assemble the dri vcshaft comrxmcnts o n thc PTOside of the dri veshaft. 3. Install the bea ring lock collar; thcn install thc Oange bearing assembl y with the bolts facin g towards the llmnel. 4. Positio n the front o f the track up into the tunnel. iUl the splined end through Install the driveshaft W it s mounting hole in thc c hain casc.
8. Slide the brake disc into positio n o n the splined end of the dri ven shaft. 9. Install the PTO-side bearing with collar and Oange plates on the drive n shaft ; do not tighten the collar at thi s lime. Placc thc dri ven shaft into position making sure the brake di sc and Oange platcs arc pro perl y positi oned. Sccure the PTO-sidc bearing and Oange pl ates with two carriage bolts and loc k llutS. Tightcn to spccificatio ns. 10. O n the MAG -side dri ven shaft , install the bearing, O-ring, and Oange plate. Secure with three lock nuts. Ti ghten to specificatio ns. NOTE: Prior to installation, lubricate the O-ring with Low-Temp Snowmobile Grease (pIn 0636593).
&
CAUTION
Tighten the flange plate nuts evenly or the O-ring seal may be damaged . NOTE: If washers were removed from behind the upper sprocket, install them at this time. 11 . Installthc spacer washer o n thc dri vcshaft.
5. Place the PrO-side o f the dri veshaft into position by sliding the bolts of the Oange bearing assembl y through the ho les in the tunnel. 6. Place the cable adapte r into position o n the Oange bearing asscmbly bolts. Sccure with three lock nul"s. Tightcn to spccifi cati ons.
NOTE: Steps 1214 are for Firecat rlSabercat models. 12. Pull dow n on the side pan by the left -side hood latch; then slide the d ri" en shaft into the chasis and into the chain casc .
NOTE: Steps 7-11 are for standard models. 7. Slide the MAG -side bearing o nto the dri veshaft (inner race Oange must be positio ned toward dri ve chain); the n install the a -ring and Oange plate. Secure with threc carriage bolts and lock nuts. Tighten to specifications . NOTE: Prior to installation, lubricate the O-ring with Low-Temp Snowmobile Grease (pIn 0636593).
Page: 507
857
13. Place the prO-side plate brace into posilion; then install the three bearing retaining nuts on the pro side plate brace. Tighten nuts securely.
14. Secure the brace with machine screws.
17. Position the chain around the lower reverse sprocket; then place the idler sprocket and top sprocket into the chain. Slide sprockets into position on the idler shaft and dri ven shaft.
15. Install the extension.
bottom sprocket
and
dri veshaft
NOTE : If the chain tension is too tight to allow installation of the top sprocket, remove the PTOside driven shaft bearing. This will allow the driven shaft to be lifted at the PTO-side and will allow the sprocket to slide onto the splined end of the driven shaft. 18. Secure the top sprocket with a spring washer (w ith the high side directed away from the sprocket) and lock nut (coated with green Loctite #6(9). Ti ghten the lock nut to specifications.
16. Position one shim washer on the idler gear shaft.
8-58
Page: 508
NOTE: If the PTO-side driven shaft bearing was removed to make the sprocket installation easier, install the bearing and flange plate. Lock the bearing collar by driving it in the direction of rotation to lock the collar to the bearing and shaft. Tighten the collar set screw.
19. Place the rubber alignment pin into position in the idler sprocket; then slide the ollter idler gear on the shaft. Install shim washer on the shaft .
22. Install the chain tensioner arm , appl y blue Loctite 11243 to the stud threads, and tighten the shoulder nut to specifications. 23. Remove the set screw from the c hai n adjuster housi ng and install the adjuster plug. 24. C heck that the chain-case a -ring seal is positioned correctl y on the housing. 20. If the lower re\'e rse sprocket was di sassembled, assemble the thrust washer, bearing, and thrust washer. Secure with the snap ring. Appl y transmission lube to the bearing and rotate by hand. 25. Position the shift fork behind the large thrust washe r and bearing on the reverse gear; then position the cover on the housing.
21 . Slide the reverse 2ear onto the driveshaft extension; then positiOil the spring into the reverse gear and sec ure with heavy washer and cap sc rew (coated with blue Loctite #243). Tighten to specifications.
26. Appl y blue Loclite 11243 to the threads of the cap screw; then install the cap screw through the center of the cover and into the idler shaft. Tighten the cap screw enough to draw the idle r shaft into the cover. 27. Place the shift pi vot and reverse switch bracket into position on the cover; then sec ure the chaincase co\'er with ca p sc rews and lock washe rs. Tighten the cap screws to specifications. 28. Place the shift linkage into position on the back side of the ann and secure with a cap screw and lock nut . Tighten to specifications. 29. Place the reverse lever into position on the shi ft pi\'ot and secure with a clevis pin and cotle r pin. 30. On the PTa-side of the track driveshaft, slide the lock colla r aga inst the bearing, drive the collar in the direction of rotation until tight, and tighten the collar set screw.
Page: 509
859
36. Insta ll the drive belt and check belt defl ection. Secure the belt guard.
37. Install and secure the b.:'lltery tray and baltery ; then co nnect the balte ry cables making sure to connect the positive cable fi rst.
NOTE: On AWS VI models, install the resonator and expansion chamber.
ADJUSTING REVERSE LINKAGE

I. Start the engine; then test the s hifting charactcristics of the reverse trans missio n.
3 1. Install the s kid frame (see Section 9).
32. O n standard modcls, remove the hold-down strap securing the air-intake silencer; thcll place the silencer into positio n making sure the boot is properl y positioned o n thc carburetorfthrottlc body assembly. Secure the sil encer to the steering support with the two screws .
2. If adjustment of the reverse gear is necessary. stop the engine and re movc the chain case inspectio n plug located behi nd the o il levcl stick ; then insel1 the Reverse Gear Adjustment Gauge (pIn 0644244) completely into the Inspection hole.
Linkage ~ dju . tm.nt
33. Apply a light CO<.ll of grease or Loctite Anti -Seil..e Thread Compo und (pin 0678- 146) to the dri ven shaft: then install the dri ven shaft alignment washers (as required) and key. Install the stub shaft a nd the dri ven pulley, ali gnment washers (as required) , washer, a nd cap screw (cO<.lted wi th blue Loctite #243). T ightcn to specificatio ns.
Insen R... e,se GN,

AdJu.t .... nt Gaug.
~ i .. "..-cUon hOle
e""'~lyinto
NOTE: Make sure the keyways match when installing the driven pulley. Arrange washers to allow the least amount of float on the driven shaft. A maximum of 1.5 mm (0.060 in.) float is allowable.
0731 734
3 . Pull the shift lever into the reverse positi on whil e holding the adjustment gauge firml y against the chain case cover. Slight outward pressure s ho uld be felt on the gauge as the lever locks into reverse. 4. If no contact is noted, loosen the jam nuts securing the lower s hift linkage and adjust the linkage rod until the ga uge is pushed o ut o f the chain case 0.254-0.38 1 mm (0.0 10-0.0 15 in.). Lock the adjustment by tightening the jam nuts securely against the tie rod c nds .
NOTE: To adjust the linkage rod, the shift lever must be moved to the forward position.
5. Install the ins pectio n plug. 34. C heck the alignment of thc drive cl utc h/d ri ven pulley (see a ppropriate Dri ve C lutc h/Dri ven Pulley in thi s section).
35. Assure that the chain case drain plug is tightened to specificatio ns; then pour 354 ml ( 12 n oz) of Arctic Ca t T ransmi ssio n Lube (pIn 0636-8 17) into the chain case.
6. Start the engme; then test the s hirting characteristics o f the reve rse transmi ssion. Adjust as necessary.
& CAUTION
The linkage must be properly adjusted. If the linkage is too short, damage to the shift fork may occur. If the linkage is adjusted too long, the gears will not shift totally into reverse,
8-60
Page: 510

(Standard vv/a Reverse)
5. Re move the cap screws and lock washe rs securing the chain-case co ver; then remove the co ver.
CAUTION Never use an impact driver on models with a

composite chain case. Damage to the chain case
&.
will occur.
DISASSEMBLING
Remove the c1min-case drain plug (located on the
lower back side of the chain case inside the tunnel)

and drain the chain case lubricant. 2. O pen the belt guard and remove the dri ve belt.
3. Re move the cap screw and washe r securing the driven pulley; then account for and note the position of any ali gnment washers.
6. Looscn the mcchanical chain te nsio ner bolt ; then remove the cotte r pillS and washers securing the te nsio ner spring to the link pins. Remove the spring, ro ll ers, and washers.
4. Slide the dri ven pulley off the dri ven shaft ; then
remove the driven pulley from the engine compartment. Account for the stub shaft , key, and ali gmncnt washers.
NOTE: On AWS VI models, account for the inner and outer O-rings.
NOTE: If the driven pulley is tight on the driven
7. Re move the nex nut securing the rront ro ller cage and roll er. Remove the cage and roll er. 8. Set the brake lever l oc k ~ then remove the lock nut and spring washer securing the bottom sprocket and the lock nut and spring washer securing the top sprockeL.
shaft, pull the driven pulley off using the Driven Pulley Puller (pin 0744-023).
Page: 511
861
14. Force the dri ven shaft toward the PTa -side
(rotating the shaft to prevent the brake di sc from binding on the shaft) unlil the brake di sc is free. Account for the key.
15. Continue to slide the dri ven shaft until it is out of
the F'f O-side. Account for a bearing. flan ge plate, and the prO-side driven shaft collar.
16. Remove the skid frame from the tunnel (see Section 9).
17. On standard models. remove the three PTa -side
9. Slide both sprockets with chain off the shafts. Account for washer(s) behind the top sprockct Release the brake lever lock.
NOTE: If a sprocket will not slide off the shaft, thread the nut onto the shaft; then use a puller to loosen the sprocket. The nut will prevent damage to the threads.
10. Remove the six lock nuts securing the top and
lock nuts securing the dri veshaft flan ge bearing assembly and the speedometer cable adapter. Remo\'e the cable ada pter and speedometer cable.
bottom chain case flange plates. Remove the flange plates, seals, and bearings.
_NOTE : On AWS VI models, remove the three lock nuts securing the voltage requlatorlspeedometer pickup module; then remove the module.
li On standard models, remove the screws securing the air-intake silencer to the steering SUpp0l1: then pull the silencer forward and place it on the carburetorsft hrottle body.
NOTE: Using a hold-down strap, secure the airintake silencer to the engine.
12. Loosen the set sc rew on the prO-side dri ven shaft 18. Tap the driveshaft toward the c hain case to unseat
collar. Drive the collar clockw ise (opposite shaft rotation) until it is free.
NOTE: A fine file should be used to remove any burrs left by the collar set screw.
13. Remove the two lock nuts and carri age bolts
the ivlAG -side bearing. Remove the bearing.

19. Slide the drivesrulft toward the MAG-side until the
sec uring the prO-side dri ven shaft flange plate.
prO-end of the driveshaft is out of its mounting hole. Tilt the end of the dri veshaft away from the tunnel and slide the drivesrulft free of the tunnel. Remove the track.
8-62
Page: 512
- -739057A
20. Scribe a line on the dri veshart along the edge of each sproc ket to aid in assembly. Loosen the set screw on the collar and drive the coll ar clockwise until free; then rcmovc thc bearing and Oange plates from thc drivcshaft. 21 Press the sprockets off the dri veshaft.

I. Thoroughly wash all metallic components in partscleani ng solvent. Dry using compressed air. 2. Wash all non-metallic components with water.
SOt ' ll'
7390S9A
and
NOTE: Make sure the sprockets are installed correctly and the bearing is positioned between the flange plates ensuring correct timing of the sprockets.
3. Inspect the dri veshart and dri ven shart for damaged splincs or stripped thrcads. 4. Inspcct the bearings for any roughness or damage.
S. Inspect the seals for any breaks or damage.
2. Assemble the dri veshaft components on the PTOend of the dri veshaft. 3. Install the bearing lock collar; then install the Oange bearing assembl y wit h the bolts facin g towards the tunnel. 4. Position the front of the track into the tunnel. Install the driveshart with the splined end through its mounting hole in the chain case.
6. Inspect the track for cuts, gouges, or wear. 7. Inspect the keyways in the driven shaft for wear or damage. 8. Inspect the brake disc for wear or cracks. 9. Inspect the chain, sprockets, and chain tensioner components for wear or damage. 10. Inspect the track drive sprockets for wear or damage.
ASSEMBLING
Press the sprockets on the driveshart noting the scribed marks on the shart and the timing mark fou nd on one tooth of each sprocket. The timing mark is an arrow molded into the outer surface of one drive tooth of the inside sprockets and on the inside surfacc of thc outside sprockets. All the arrow markings must be in alignment.
NOTE: Sprocket style will vary from model to model.
Page: 513
S. Place the PTO-end of the dri veshart into position by sliding the bolls of the !lange bearing assembl y tllJough the holes in the tunnel.
863
6. On standard models, place the cable adapter mto position on the fl ange bea ring assembl y bolts. Secure with three loc k nuts. Tighten to specifications.
II . On the J\I IAG -side of the dri ven shaft, install the bearing, seal , and Ilange plate. Secure with three lock nuts. Tighten to s~c ific ati on s. NOTE : If washers were removed from behind the top sprocket; install them at this time,
12. Loop the chain around the bottom sprocket and
slide the top sprocket with chain onto thc driven shafl. Sec ure the top sprocket with a lock nut (thre< :lds coated with green Loctite #609) and spring washer. Ti ghten to specifications. Tighten the bottom sprocket lock nut (from step 8) to specifications.
NOTE : On Firecat rlSabercat models, place the voltage regulator/speedometer pickup module into position. Install and tighten the three lock nuts to specifications.
7. Slide the MAG -side bearing onto the driveshafl (inner race fl ange must be positioned toward dri ve chain); then install the O-ring seal and fl ange plate. Insel1 the cap screws from the inside of the tunnel through the chain case, seal , and fl ange. Secure with three loc k nuts. Tighten to specifications.
8. Place the bottom sprocket onto the splines. Finger-
13. Cheek the alignment of the sprockets using the
fol low ing procedure. A. Place a straightedge aga inst the fac es of the sprockets.
tighten a lock nut (threads coated with blue Loctite #243) and spring washer. 00 NOT TIGIITEN AT THI S TIME 9. Install the P"rO-side bearing with collar and fl ange plate on the dri ven shaft ; do not ti ghte n the collar at this timc.
10. Place the dri ven shaft into position making sure
B. Using a feeler gauge, chcck for clearance along the faces of both sprockets. If cl earance exceeds 0.8 mm (0.030 in .), shimming IS nccessary.
the brake disc and flange plate are pro~rl y posilioned. Secure the p rO-side bearing and flange plate with two carriage bolts and lock nuts. Tightcnto speci fi cations.
8-64
Page: 514
D.I mm (D.D3OIln.)
0725-171
NOTE: Sprockets can only be shimmed out.

14. O n standard models on the p rO-side of the dri ven
19. Check the ali gnment of the dri ve cl utch/dri ven
pulley (sec appropriate Pulley in thi s section).
Dri ve ClutchlDri ven
shaft and the track dri veshafl , slide the lock collar against the bearing, dri ve the collar in the di rection of rotati on until tight, and tighten the coll ar set screw securely.
20, Tip the snowmobile onto the PTO-side using cardboard to prevent scratching the bell y pan; then install the washers, rollers, and spring. Sec ure with two washe rs and colter pins.
15. Install the skid frame (see Section 9).
2 1, Ti ghten the mecha nical chain tensioner tlnger-
16. O n standard models, remove the hold-down strap
tight ; then lock the jam nut against the chain case.
securing the air-intake silencer; then place the silencer into position making sure the boot is pro perly positioned on the carburetors/throttl e
body_
17. O n standard models, sec ure the silencer to the
steering SUpp0i1 with the two screws.

18. Apply a light co. '!l of grease or Loctite Anti -Seiz.e Thread Compo und (pIn 0678- 146) to the dri ven
shaft ; then install the dri ven shaft ali gnment washers (as requi red) and key. Install the dri\'en pulley, stub shaft , ali gnment washers (as required) , washer, and cap screw. Tighte n the cap sc rew (coated with blue Loctite #243) to spe cifications.
NOTE: Make sure keyways match when installing the driven pulley. Arrange washers to allow the least amount of float on the driven shaft, A maximum of 1,5 mm (0.060 in.) float is allowable.
22. Place the front roller cage and roller into position and secure with the nex lock nul. 23. Check the position of the c hain-case cover O-ring seal; then place the cha in-case cover into lX)sition and secure with six cap screws and loc k washe rs. Ti ghten to spec ifications.
Page: 515
865
2-t Install the drain plug and ti ghten to specifications; then pour 236 ml (8 n oz) of Arctic Cat Transmission Lube (pin 0636-8 17) into the chai n casc. 25. Install the drive belt and check drive belt denection (sec appropriate Dri ve ClutchlDri vell Pulley in thi s section). Secure the bell guard.
4. Using a 9/ 16 -10. socket and extension, remove the
cap sc rew securing the driven pulley to the driven sha ft. 5. Slide the driven pull ey otT the dri ven shaft.
NOTE: Account for and remove any alignment washers. These washers must be used during installing.

(ZR 900 Models)
Removing Gear Case ........................................... 866 Removing Track Dri veshaft .................................. 867 Installing Track Driveshaft ............... ....... 869 Disassembling Gear Case .............................. ...... 872 Cleaning and Inspecting Gear Case ..................... 874 Removing Dri ve Sprockets .................................... 8-74 Installing Drive Sprockets ...................................... 875 Assembling Gear Case ...................................... 876 Installing Gear Case ............................................. 879
REMOVING GEAR CASE
Remove the springs sec uring the resonator and ex pansion chamocr; then remove from the engine compmtment. 2. Remove the dri ve belt (sec Removillgf1nstal1ing Drive Belt (Ael' Ro11er Driven Pulley) in this section). 3. Remove the air-intake louvre from the left-side belly pan; then remove the hardware securing the left side bell y pan to the chassis .
NOTE: Completely loosen the track tension to aid in removinglinstalling the gear case.
NOTE: Tip the snowmobile on its right side posi tioning the gear case side of the snowmobile up. Place a piece of cardboard under the side of the snowmobile to prevent scratching of bumper and belly pan.
6. Remove the lock nut and cap screw (with shim if applicable) and the remaining five lock nuts securing the gear case to the chassis.
866
Page: 516
740-161A
NOTE: If there is a shim (A), note its location for installing purposes.
9. Remove the gear case from the chassis.
7. Looscn thc AlIcn-hcad scrcw from the drivcshaft lock coUaL
NOTE: Account for the cap screw and lock nuts on the gear case. NOTE: If removing the lock collar from the driveshaft, account for the three locking pins.
REMOVING TRACK DRIVESHAFT

I. Remove the springs securing the rcsOTmtor and
ex pmlsion chamber; thcll remo\'e from the cnginc compartment . A. At thi s point, rcmove the two All cn-head cap screws securing the speedometer dri ve adapter assembly to the brake caliper; thcn remove the adaptcr assembl y.
8. Rotate the lock collar in forward shaft rotation to allow the locking pins to recess mto the dri veshaft.
Page: 517
867
8. At this point , engage the brake lever lock; then using Brake Di sc Soc ket Wrenc h (p/n 06444 15), remove the retaining nut from the dri veshaft.
6. Slide the dri ven pulley off the dri ven shaft.
NOTE: Account for and remove any alignment washers . These washers must be used during installing.
7. Place a SUpp0l1 stand under the rear bumpe r; then whil e holding the fl ared bushing, remove thc rear cap screws securing the skid frame to the tunnel. Account for lock washcrs and nat washers.
NOTE: The support stand should hold the snowmobile level but not raised off the floor.
8. Remove the front cap screws securing the skid framc to thc tunnel. Account for a nat washcr and a lock washer. 9. Remo\'c thc support stand; thcll tip the snowmobile onto one side using a piecc of cardboard to protect aga inst scratching. Remove the skid frame.
_NOTE : Tip the snowmobile on its right side positioning the gear case side of the snowmobile up. Place a piece of cardboard under the side of the snowmobile to prevent scratching of bumper and belly pan.
2. Removc the dri vc belt (see Removing/Installing Dri\'e Belt (ACf Roll er Driven Pulley) in this section). 3 . Remove the air-intake louvre from the left-side belly pan. 4. Remove the hardware securing the left -side belly pan to the chassis.
NOTE: Completely loosen the track tension.
10. Remove the lock nut and cap screw (with shim if applicable) and the remaining five lock nuts securing the gear case to the chassis .
5. Using a 9/ 16-in. sockct and extension, remove the ca p scrcw securing the dri\'en pulley to the drh'en shaft.
NOTE: If there is a shim (A), note its location for installing purposes.
8-68
Page: 518
II . Loosen the Allen-head screw from the dri veshaft lock collar.
NOTE: Account for the cap screw and lock nuts on the gear case.
14. Engage the brakc levcr lock (lca\'ing it lockcd for installing puqx>scs); thc n removc thc track! dri veshaft assembl y from the brake calipe r housing.
INSTALLING TRACK DRIVESHAFT

I. If removed . place the loc k collar onto the dri veshaft (with thc three locking pins extended from the dri veshaft); then scribe a line on the dri\'cshaft in line with the set sc rcw . T urn the lock collar until the locking pins are reccssed into the dri veshafl. 12. Rotate the lock collar in forward shaft rotati on to allow the locking pins to recess into the dri vcshaft.
f orvl arG
1'\0\3\\01\
~ ~ LOCking Pins
e. /.'"
Lock Collar
740-161A
NOTE: At this point, lightly snug the collar set screw to keep the collar in place.
13. Di scOlUlcCt the dri vcshaft coupler; then remove thc gcar casc from lhe chassis.
Page: 519
869
ACAUTION
If the locking pins are protruding into the splined area, the gear case cannot be properly installed onto the drives haft and component damage may
3. Place the track/dri veshan assembly into the tuonel and install the dri veshaft into the brake caliper housing assembl y.
NOTE: When installing the driveshaft into the housing, keep the driveshaft approximately 9.5~ 12.7 mm (318-1/2 in.) from bottoming into the housing to aid in installing the gear case.
occur.
740-161A
2. O n the splincd end or the dri vcshaft , apply a coat or Anti-Seize Thread Compound (pin 0678- 146) to the e nds of the splines.
4. Place the gear case onto the dri veshaft ; then press the gear case toward the chassis unlil it is in position .
NOTE: When the driveshaft is properly seated onto the gear case, there should be a clearance of 6.76.9 mm (0.265-0.272 in.) between the gear case and the lock collar.
MS313B
NOTE: Prior to installing the driveshaft, apply a coat of grease to the brake caliper housing seal.
8-70
Page: 520
5. Install the ri ve lock nuts onto the cap sc rews securing the gear case to the chassis. Tighten to specifications.
6 . Install the remaining cap screw (with the shim if
NOTE : The driveshaft should now be locked into place. Pull outward on the gear case for verification . If the gear case cannot be moved outward , the driveshaft is properly locked .
8. Install the skid frame (sec Section 9).
applicable) and lock nul. Tighte n to specifications.
9. Place the snowmobil e in the upright position; then engage the brake levCf loc k.
10. Slide the dri ven pulley onto the dri ven shaft
making sure ali gnment washers arc in place.
_NOTE : If a shim was on the cap screw at removing, make sure to install the shim on the cap screw (A)j it is important for drive system alignment.
11. Secure the pull ey with the cap screw (co.l ted with blue Loctite 11243) and washer. Tighten to specifications. 12. Install the dri ve belt. NOTE : For installing drive belt, see Removing! Installing Drive Belt (ACT Roller Driven Pulley) in this section. 13. Place the left- side bell y pan into position and secure with ex isting hardware; then install the airintake louvre. 7. Loosen the set screw and rotate the lock collar so the set screw is di rectl y in line with the mark scri bed on the dri veshaft ; then tighte n the set screw. 14. Appl y Anti-Seize Thread Compound (pIn 0678146) to the splines of the brake di sc and to the threads of the retaining nut ; then install the dise and nul. Using Brake Di sc Socket Wre nch (pi n 0644-41 5), tighten nut to speci fi cations. NOTE : The brake lever lock must be engaged for this procedure.
Page: 521
15. Place the speedometer dri ve adapter assembly onto the brake calipe r: then install the Allen-head cap screws and ti ghte n to specifications.
2. Inselt two flat -blade screwdri vers into the notches (A) on the gearcase located near the upper and lower dowl pins (8) of the gear case; the n worki ng back and forth, pry the co\'er up and off the gear case.
16. Place the ex pansion chamber and resonator into position and secure wi th the springs. 17. Adjust the track for alignment and recommended tension (see Section 9), then tighten the cap sc rews securely.
3. Drai n the gear case fluid into a suitable container. 4. With a cap screw threaded into the input shaft and using a soft hammer, drive the input shaft out of the gear case cover.
DISASSEMBLING GEAR CASE
I. Remove the cleven toc'\-head cap screws sec uring the gear case cover to the gear case assembl y.
5. Using a suitable bearing press and fi xture, press the input shaft bearing out of the gear case cover. Account for a bearing and a seal.
872
Page: 522
8. Using a suitable bearing press and fixture, remove the outer bearing from the tran<;fer gear.
MS334A
9. Remove the retaining ring securi ng the planetary gear assembly to the gear case.
6. Remove the transfer gear assembly from the gear case.
MS335
10. Note the position of the larger spacing between the tabs for assembling purposes; then remove the planetary gear assembly from the gear case.
7. Using a suitable bearing press and fixture , remove the main bearing fro m the transfer gear assembl y.
MS336
II . Using a suitable press and fi xture, remove the ring gear assembly fro m the gear case.
Page: 523
12. With a suitable bearing press and fi xture, remove the bearing from the ring gea r.
CLEANING AND INSPECTING GEAR CASE

I. Wash the gear case hal ves in pmts-cleaning solvent. 2.

In s rx~ct the gear case halves for scoring, pitting, scuffing, or any impc rfections in the casting.
3. Inspect all threaded areas for damaged or strippcd threads. 4. Inspect the bearing areas for cracks or excessive bearing movement. If ev idence of excessive bearing movement is noted, replace the component . 5. Inspect the scaling surfaccs of the gcar case halves for trueness. 6. Wash the unsealed gear case beari ngs cleaning solvent.
III
pmts-
7. Inspect the bearings for wear, scoring. scuffing, damage, or discoloration. Rotate the bearings. Bearings mllst rotate freely and must not bi nd or feel rough. If any abnormal condition is noted , replace the bea ring.
MS340
13. Using an appropriate seal removing tool, remove the ring gear seals from the gear case.
8. Appl y a light film of Arctic Cat ACr Drive Fluid (p/n 4639-027) to the unsealcd bearings pri or to assembling.
REMOVING DRIVE SPROCKETS
I. For installing purposes, scribe a linc on the
dri \'eshaft (A) next to the dri \'c sprocket for proper ali gmnent ; thell scribe a line on the drivcshaft directly in line with the timing arrows (8) on the drive sprockets for proper sprocket timing.
MS341
8-74
Page: 524
I. Thoroughly wash all metallic components in partscleaning solvenl. Dry using compressed air. 2. Wash all non-metallic components with so.ap and water. 3. Inspect the dri veshaft for damaged splines or stripped threads. 2. Using a suitable press positioned against the tension-collar of the drive sprocket (located on the gear case) and of the driveshaft , press the dri ve sprockets off the driveshaft 4. Inspect the bearings for any roughness or damage. 5. Inspect the seals for any breaks or damage. 6. Inspect the track for ClltS, gouges, or wear. 7. Inspect the brake disc for wear or cracks. 8. Inspect the track dri ve sprockets for wear or damage.
INSTALLING DRIVE SPROCKETS
NOTE: Prior to installing the sprockets onto the driveshaft, it is advisable to lightly chamfer the inside edge of the sprocket to avoid binding.
&CAUTION
Always press against the tension-collar of the drive sprockets or damage to the components will occur.
I. Properl y align the scribed line on the driveshaft
(from removing) with the timing arrow on the dri ve sprocket: then slide the sproc ket onto the dri veshaft as far as it will go.
MS3S9A
NOTE: The drive sprockets must be removed from the gear case end of the driveshaft.
Page: 525
2. Using a suitable press and fi xture, press the driveshaft into the sprocket until it aligns with the line scribed in removing.
4. Using a caiirx:rs, measure di stances between the sprockets and from the sprockets to each end of the driveshaft for proper location (see illustrations).
3. Slide the remaining sprocket onto the driveshaft making sure the timing arrow/lines (from remov ing) are aligned ; then using the press! fixture. press the sprocket to the remaining alignment line.
ACAUTION
0739-397
ASSEMBLING GEAR CASE

I. Using an appropriate seal install ation tool, install
the two oi l seals into the ring gear opening of the gear case .
NOTE: Grease must be applied to the inner seal prior to installing.
MS359A
NOTE: The drive sprockets must be installed on the gear case end of the driveshaft.
876
Page: 526
4. Noting the location of the large spacing (A) between the tabs of the planetary gear assembly, install the assembly to the ring gear/gear case.
0
MS341
6 2. Using a sui table bearing press, install the bearing onto the ring gear.
..

MS346A
MS343 MS336
5. Install the retaining ring securi ng the planeta ry gear assembly to the gear case.
3 . Using a suitable press, install the ring gear assembly to the gear case.
MS335
6. Using a suitable bearing press, install the outer bearing to the transfer gea r assembly; then install the inner bearing to the assembly.
Page: 527
2005 A rctic Cat Service Manu al - all models - www. ReadManuals.com
9. Using a suitable bearing press and fi xture, instal! the input shan bearing to the gear case; then install the oil seal.
NOTE: Grease must be applied to the inner seal prior to installing,
MS334A
7. Install the transfer gear assembl y into planetary gear asscmbl y/gear casc.
the
MS 35 1
10. Using a suitable press, insh 'll! the input shaft to the gear case cover.
8. Using a suitable bearing press, install the inner bearing onto the input shrift.
II . Appl y a film of High-Temp Silicone Sealant (p/n 4639-030) to the scaling surfaces of the gear case.
MS334 A
878
Page: 528
MS350A
& CAUTION
Care must be taken not to allow silicone sealant into the cap screw holes and dowel pin holes or damage to the gear case may occur when tightening the cap screws.
& CAUTION
If the locking pins are protruding into the splined area, the gear case cannot be properly installed onto the driveshaft and component damage may occur.
12. With the dowel pins in place, install the cover to the gea r case and secure with clevcn torx-head cap screws; then in a c risscross pattern, tighten to specifications.
740-16 1A
2. Loosen the seLscrew and roLaLe the loc k collar so
the set sc rew is directly in line with the mark scribed on the dri veshart ; then ti ghten the set screw.
INSTALLING GEAR CASE
I.
Ir removed, place the lock collar onto the driveshart (with the three locking pins extended rrom the dri veshart) ; then scribe a line on the driveshart in line with the seLscrew. Turn the lock collar unLil the locking pins are recessed inLo Lhe dri veshaft .
NOTE: At this point, lightly snug the collar set screw to keep the collar in place.
3. Place the gear case onto the dri veshaft; the n press the gear ease toward the chassis until it is in position.
Page: 529
NOTE: When the gear case is properly seated onto the driveshaft, there should be a clearance of 6.7-6.9 mm (0.265-0.272 in.) between the gear case and the lock collar.
4. Inslall the ri\'e lock nuts onto the cap sc rcws
securing the gear case to the chassis. Ti ghtcn to specifications.

5. Install the remaining cap screw (w ith the shim if applicable) and lock nul. Ti ghte n to specifications. NOTE: If a shim was on the cap screw at removing, make sure to install the shim on the cap screw (A); it is important for drive system alignment.
10. Place the left-side belly pan into position and secure with cx isting hardware; then install thc airintake louvrc. II. Place the ex pansion cha mber and rcsonator into position and secure with the springs.
12. Adjust the tmck for alignment and recommended tension (see Section 9) .

(Firecat Models)
Removing Gear Case ............................................ 880 Removing Track Driveshaft ...... ..., .. .. ... .. ................ 8-82 Installing Track Driveshaft .......... ........... .... ............ 8-84 Disassembling Gear Case ... .................. ................ 8-85 Cleaning and Inspecting Gear Case ............ ......... 8-87 Removing Drive Sprockets .................................... 888 Installing Drive Sprockets. ........ .. . .. ..................... 8-89 Assembling Gear Case ......................................... 8-90 Installing Gear Case ............ .................. ................ 8-93
REMOVING GEAR CASE

NOTE: The gear case should now be locked into place. Pull outward on the gear case for verification . If the gear case cannot be moved outward, the gear case is properly locked.
I. Rcmove the springs securing the resonator and ex pansion chamber; then remove from the engine coml:k1.rtment.
2. Remove the dri ve bell (see Remov ing/Installing Dri ve Bell (AC T Roller Dri ven Pulley) in thi s section). NOTE: Completely loosen the track tension to aid in removinglinstalling the gear case.
6. Place the snowmobil e in the upright position; then engage the brake lcvcr lock.
7. Slide the dri ven pulley onto the driven shan making sure alignment washers are in place.
8. Securc thc pull ey with the cap scrcw (coated with blue Loctitc 11243) and washcr. Tighten to specifications. 9. Install the dri ve bell.
3. Rcmove the access panel from the left-side belly pan. 4. Using a 9/ 16-in. sockct and ex tension, rcmove the cap sc rew securing the driven pullcy to the dri vcn shrift.
8~80
Page: 530
NOTE: Tip the snowmobile on its right side posi tioning the gear case side of the snowmobile up. Place a piece of cardboard under the side of the snowmobile to prevent scratching of bumper and belly pan.
8. Remove the cap sc rew (A) and the remaining loc k nuts (8) sec uring the gear case to the chassis. Account for a rubber bumper and an oil-hose clamp.
5. Slide the dri ven pully 00' the dri ven shaft
NOTE: Account for and remove any alignment washers. These washers must be used during installing.
6. Remove the speedometer sensor connector from behind the coolant hose protector; then disconnect the sensor.
7. Loosen the long cap screw (from the brake-disc side of the dri veshaft) until it is compl etely free of the gear case shaft .
9. Using a nat-blade sc rewdri ver, carefull y pry the gear case until it clears the studs; then remove the gear case from the chassis.
Page: 531
881
NOTE: Account for the cap screw, lock nuts, and the gear case mounting plate.
4. Loosen the long gear case cap screw completely.
REMOVING TRACK DRIVES HAFT
I. Remove the springs sec uring the resonator and ex pansion chamber; then re move from the engine comp.t'lltment. 2. Engage the brake lever lock; then loosen the long cap screw enough to release pressure from the nat washer.
5. Using the Rear Suspe nsion Spring Tool (pIn 01443 11 ), re move the spring from the adjusting cam.
NOTE: Releasing pressure from the flat washer (A) will allow it to become centered on the driveshaft when the brake disc retaining nut (8) is removed .
6. Place a SUpp0l1 stand under the rear bumpe r; the n while holding the narcd bushing, removc the rear cap screws securing the skid frame to the tunnel. Account for lock washers and nat washers.
NOTE: The support stand should hold the snow mobile level but not raised off the floor.
3. Using Brake Disc Socket Wrench (pIn 0644-4 15), remove the retaining nut from the driveshafl.
8-82
Page: 532
7. Remove the front cap screws securing the skid frame to the tunnel. Account for a flat washe r and a lock washer .
8. Re move the support stand; then tip the snow mobile onto the left side using a piece of ca rdbo.ard to protect against scratching. Remove the skid frame.
NOTE: Avoid tipping the snowmobile onto the right side. If left on the right side for more than five minutes, air may get into the oil hose. If air is apparent in an oil hose, the system will eventually have to be bled (see Section 2 Bleeding Oillnjec tion System Firecat Models).
II . Pull the dri veshaft toward the brake assembly side of the chassis until it is free of the gear case; then remove the lrack/dri veshaft assembl y.
9. Remove the four lock nuts (A) from inside the tunnel and cap screw (with lock nut B) securing the brake housing to the chassis.
NOTE: The four remaining cap screws will come out with the brake housing.
740188A
MS31 3
NOTE: Releasing the weight of the track from the driveshaft will aid in removing the brake housing.
NOTE: Account for the four cap screws (A) on the brake housing.
10, With mounting hardware re moved, use a flat-blade screwdriver and carefull y pry (from side to side) the brake housing from the chassis; thell remove the housing and brake di sc from the chassis and driveshafl. Account for a spacer.
740-1 88B
Page: 533
883
INSTALLING TRACK DRIVESHAFT NOTE: Prior to installing the driveshaft, apply a coat of grease to the internal splines of the driveshaft.
3. With the brake disc positioned in the brake hOllsing assembly, prope rly align the spli nes o f the dri veshaft with the brake disc; then place the brake housing on the chassis. Using a soft hammer, carefull y ('ap the housing (from side to side) until it scats prope rl y.
I. Insert the ca p screw into the drivcshart and place
the trackldri vcshaft assembly into the brake housing side of the tunnel.
NOTE: It is important that the cap screw is
4. Install the four lock nuts onto the cap screws (A ) and the cap sc rew and lock nut (8) securing the inner brake housing to the chassis; then III a crisscross pattern, tighten to specifications .
inserted into the driveshaft prior to installing the assembly into the tunnel.
740186A
5. 2. With the splines of the gear case and drivcshaft

properl y aligned, push the drivcshaft toward the
Apply Anti-Sei ze Thread Compo und (pfn 0678146) to the splines of the brake di sc and to the threads of the retaining nut ; then install the spacer, disc, and nul. Do not tighten at thi s time.
gear case uolillhe driveshaft is properl y seated. 6. Install the skid frame (see Section 9). 7. Place the snowmobile in the upright position; then engage the brake le \'er loc k. 8. Secure the dri veshaft to the ring gear wi th the cap screw (cO<lted with blue Loctite 11243 for a sl"andard cap screw) and washer. T ighten to specifications.
A CAUTION
If the long cap screw has a silver coating, it has been pre-treated with Scotch Grip and does not need Lactite applied.
8-84
Page: 534
2. Inselt two flat-blade screwdri vers into the notches (A) on the gearcase located near the upper and lower dowl pins (8) of the gear case; then working back and fOith , pry the cover up and off the gear case.
9. Using Brake Disc Socket Wrench (pin 0644-4 15) , tighten the brake disc retaining nut (from step 6) to
specifications.
3. Drai n the gear case fluid into a suitable contai ner.

4. With a cap screw threaded into the input shaft and
using a soft hammer, drive the input shaft out of the gea r case cover.
10. Place the ex pansion chamber and resonator into
position and secure with the springs.

II . Check the track for alignment and recommended
tension: thell ti ghte n the cap SCfCWS securely.

I . Remove the cleven torx-head cap screws sec uring
5. Using a suitabl e bearing press and fi xture, press
the gea r case covel' to the gear case assembl y: then cut the cable tie securing the speedometer sensor wire to the gea r case cover.
the input shaft bearing out of the gear case cover. Account for a bearing and a seal.
Page: 535
885
MS334A
9. Remove the retaining ring securing the planetary gear assembly to the gear case.
MS335
7. Using a suitable bearing press and fixture, remove lhe main bearing from the transfer gear assembl y.
10. Note the position of the larger spacing between the tabs for assembling purposes; then remove the planetary gear assembl y from the gear casco
MS333A
8. Using a suitable bearing press and fi xture, remove the outer bearing from the transfer gear.
MS336
II. Using a suitable press and fixture , remove the ring
gear assembly from the gear case.
8-86
Page: 536
MS340
& CAUTION
After the ring gear has been removed if bearing removal is required, the speedometer magnet retainer must be removed from the ring gear to avoid damaging the retainer.
13. Using an appropriate seal remov ing tool, remove the ring gear seals from the gear case.
MS 341
MS338A
12. With a suitable bearing press and fi xture, remove

the beari ng f rom the ring gea r.

I. Wash the gear case hal ves in pm1s-cleaning solvent. 2. Inspect the gear case halves for scoring. pitting. scurring, o r any impe rfections in the casting. 3. Inspect al1thrcaded arcas fo r damaged o r stripped threads.
Page: 537
887
4. Inspect the bc.1ring areas for cracks or excessive bearing moveme nt. If ev idence of excessive bearing movement IS noted, replace the component 5. Inspect the scaling surfaces of the gear case halves for trueness. 6. Wash the unsealed gear case bearings in partscleani ng solvent. 7. Inspect the beari ngs for wcar, scoring , scuffing , damage, or discoloration. Rotate the bearings. Bearings must rotate frcely and must not bind or feel rough. If any abnormal condition is noted, replace the bearing. 8. Appl y a li ght film of Arctic a lt ACf Drive Fl uid (pin 4639-027) to the unsealed bearings prior to assembling.
2. Using a suitable press, re move the spacer/collar from the dri veshaft. Note that the tape red side of the collar fac es outward.

I. Install Crankshaft Bearing Remover (pin 0144-
302) onto the dri veshaft between the spacer/collar; then install the brake disc retai ning nut with the /lat side facing outward.
MS356A
3. For installing purposes, scribe a line on the dri veshaft (A) next to the drive sprocket for proper alignment; then scribe a line on the driveshaft directly in line wi th the timing arrows (B) on the drive sprockets for proper sprocket timing.
MS357A
MS354
&CAUTION
Make sure to install the retaining nut with the flat side facing outward or damage to the driveshaft will occur.
4. Using a suitable press positioned against the te nsion-collar of the dri ve sprocket (located on the gear case) and of the driveshaft , press the dri ve sprockets off the dri veshaft
8-88
Page: 538
NOTE: Prior to installing the sprockets onto the driveshaft, it is advisable to lightly chamfer the inside edge of the sprocket to avoid binding.
& CAUTION
I. Properly align the scri bed line on the driveshaft (from removing) with the timing arrow o n the d ri ve sproc ket: then slide the sproc ket o nto the dri veshaft as fa r as it will go.
MS359A
NOTE: The drive sprockets must be removed from the brake disc end of the driveshaft.

NOTE: Whenever a part is worn excessively. cracked , or damaged in any way, replacement is necessary.
I. Thoroughly wash all metallic components in partscleaning solvenl. Dry using compressed a ir.
2. Wash all non-met<'lilic components w ith saap and water.
2. Using a suitable press and fi xture, press the driveshaft into the sprocket unti l it ali gns with the line scribed in removing.
3. Inspect the dri veshaft fo r damaged splines or stripped threads. 4. Inspect the bearings for a ny rough ness or damage.
5. Inspect the seal s for any bre.'lks or damage.
6. Inspect the tmck for clIls, gouges, or wear.
7. Inspect the brake disc fo r wear o r cracks. 8. Inspect the track drive sprockets for wear or damage.
Page: 539
889
3. Slide the remaining sproc ket onto the driveshaft making sure the timing arrow/lines (from remov ing) are aligned; then using the pressl fi xture, press the sprocket to the remaining ali gnment line.
ACAUTION
0 740-042
5. Using Crankshaft Bearing Remover (pIn 0 1443(2) and a suitable press, install the spacer/collar onto the dri veshaft until it is seated against the hex -sha ped hub of the dri veshaft.
MS359A
NOTE: The drive sprockets must be installed on the brake disc end of the driveshaft.
NOTE: Take note to install the spacer/collar with the tapered side facing outward.
MS 313C
4. Using a calipers, measure di stances between the sprockets and from the sprockets to each end of the dri veshaft fo r proper location (see Illustrations).

I . Using an appropriate seal installation tool, install
the two oil sea ls into the ring gear opening of the gear case .
890
Page: 540
NOTE: After the bearing has been installed into the ring gear, install the speedometer magnet retainer to the ring gear.
MS338A
3. Using a suitable press, install the nng gear assembly to the gear case.
MS341
2. Using a sui table bearing press, install the beari ng onto the ring gear.
4. Noting the location of the large spacing (A) between the tabs or the planetary gear assembly, install the assembl y to the ring gear/gear case.
MS343
.-
to
..

MS346A
Page: 541
8-91
7. Insta ll the transrer gear assembly iOto the planetary gCt'l r assembly/gear case.
MS336
5. Insta ll the retaining nng secunng the planetary gear assembly to the gear case. 8, Using a suitable bearing press , install the IIlner bearing onto the input shart.
MS335
6. Using a suitable bearing press, install the outer bearing to the transre r gea r assembly; then install the inner bearing to the assembly. 9. Using a suitable bearing press and fi xture, install the input shan bearing to the gear case; then install the oi l seaL
892
Page: 542
MS351
MS327A
10. Using a suitable prcss, install the input shaft gear case cover.
10
the
13. Secure the spcedometer se nsor wire to the gear c.."lse cover with a cablc lie.
II . Appl y a film of High-Temp Silicone Sealant ( pIn 4639-030) to the sealing surfaces of the gear c.."lse.
I. With the gear case mounting pl ate in place, place the gC<lr case onto the dri veshaft; Ihell press the gear case toward the sprocket until it properl y seal"s into place on the chassis.
_NOTE : Prior to placing the gear case onto the driveshaft, apply a light coat of grease to the splines of the ring gear shaft.
L!':.CAUTION
Care must be taken not to pinch or damage the oil hose when installing the gear case.
L!':. CAUTION
Care must be taken not to allow silicone sealant into the cap screw holes and dowel pin holes or damage to the gear case may occur when tightening the cap screws ,
12. With the dowel pins in place, install the cover to the gca r case and secure with clevcn lorx-hcad cap screws; thell in a c rissc ross pattern, tightcn to spccifications.
Page: 543
8-93
2. Install the torque bumper behind the engine mo unting block; the n carefull y work it into place with the aid of a Oat-blade screwdri ver.
NOTE: At this point, connect the speedometer sensor connector; then secure it behind the coolant hose protector with a cable tie.
5. Place the snowmo bile in the upright positio n; then engage the brake lever lock. 6. Install the long cap screw into the gear case shaft ; then tighten to specificatio ns.
NOTE: Use of a quality silicone spray will aid in installing the torque bumper.
3. Install the lock nuts (8 ) and cap screw with o il hose bracket (A) securing the gear case to the chassis. Do not tighten at thi s time.
7. Slide the dri ven pulley onto the driven shaft making sure ali gnment washe rs are in place.
8. Secure the pull ey with the ca p screw (coated with blue Loetitc #243) and washer. Tighte n to spccificatio ns. 9. Install thc dri ve belt.
10. Place the Icft -side access panel into positio n and sccure with existing hardware. 4. In a cri sscross pattern , tighten the cap screw and lock nuts (fro m ste p 3) to speci ficati o ns. I L Place the ex pansion chamber and rCSOIk'ltor mto positio n and secure with the springs. 12. Adjust the trac k for ali gnmcnt and recommcndcd tensio n; then ti ghten the cap screws to specificatio ns (see Sectio n 9).
894
Page: 544
5. Slide the dri ven pully off the dri ven shaft .

(M-Series Models)
Removing Gear Case . .. .. ......... .. 895 Removing Track Dri veshaft ................................... 8~96 Installing Track Driveshaft ..................................... 8-98 Disassembling Gear Case ...... .. ....... .. ..... ............ .. 8-99 Cleaning and Inspecting Gear Case .. ..... ...... ...... 8- 102 Removing Drive Sprockels .................................. 8- 102 Installing Dri ve Sprockets .................................... 81 04 Assembling Gear Case ....................................... 8 105 Install ing Gear Case ...... .......... .. . ....... 8 108
H .... . . .... .. . ... .. ... .
NOTE: Account for and remove any alignment washers . These washers must be used during installing.
6. Rcmo\'e the speedometer sensor connector from behind the coolant hose protector; then disconnect the sensor.
REMOVING GEAR CASE

I. Rcmo\'c the access panels from both sides or the snowmobile. 2. Remove the springs securing the resonator: then remove from the engine compartment.
NOTE: At this point, engage the brake lever lock.
3. Remove the dri ve belt (sec Remov ingf] nstalling Dri ve Belt (ACI' Rol1 er Driven Pul1ey) in this section) .
NOTE: Completely loosen the track tension to aid in removinglinstalling the gear case.
7. Remove the long cap screw (from the brake-disc side of the dri veshaft ).
4. Using a 9116-in. socket and extension, remove the cap screw securing the dri ven pulley to the dri\'en shaft.
NOTE: Tip the snowmobile on its right side positioning the gear case side of the snowmobile up. Place a piece of cardboard under the side of the snowmobile to prevent scratching of bumper and belly pan.
8. Remove the lock nuts sec uring the gear case to the chassis. Account fo r a rubber bumper.
Page: 545
8-95
9. Remove the gear case from the chassis .

NOTE: If the gear case will not come loose, use a pry bar between the track and the gear case to carefully pry the gear case until it clears the studs.
5. Using the Rear Suspension Spring Tool ( pIn 0 1443 11 ), remove the spring from the adjusting cam.
MS297
NOTE: Account for the lock nuts.

REMOVING TRACK DRIVESHAFT
Remove the access panels from both sides of the snowmobile. 2. Remo\'e the springs securing the resonator; then remove from the e ngine compm1ment. 3. Engage the brake lever lock, thell remove the long cap screw from the dri veshaft.
6. Remove the rear cap screws securing the skid fra me to the tunnel. Account for lock washers and nat washers. 7. Remove the front cap screws securing the skid fra me to the tunnel. Account for a nat washer and a lock nut. 8. Tip the snowmobile onto the right side position ing the gear case side of the snowmobile up. Place a piece of cardboard under the side of the snowmobile to protect against scratching. Remove the skid frame. 9. Using a 9/ 16-in. socket and ex tension, remove the cap sc rew securing the dri ven pulley to the dri ven shaft.
4. Using Brake Disc Socket Wrench (pin 0644-4 15), remove the retaining nut from the driveshaft.
896
Page: 546
13. Re move the gear ease fro m the chassis.
NOTE: If the gear case will not come loose, use a pry bar between the track and the gear case to carefully pry the gear case until it clears the studs.
10. Slide the dri ven pully 00" the dri ven shaft
NOTE: Account for and remove any alignment washers. These washers must be used during installing. II . Re mo ....e the s peedometer sensor connecto r from behind the coolant hose protecto r; then disconnect the sensor. NOTE: Account for the lock nuts.
MS297
_NOTE : At this point, loosen the five nuts securing the brake caliper housing such that the driveshaft will clear the housing.
14. With the gear case removed , pull the dri veshaft
toward the gear case side o f the tunnel until it cl ears the brake calipe r ho using; then remove the track and dri veshaft.
12. Remove the lock nuts securing the gear case to the chassis. Account fo r a rubber bumpe r and the lock nuts.
NOTE: It may be necessary to spread the tunnel slightly to remove the driveshaft from the brake caliper.
Page: 547
8-97
INSTALLING TRACK DRIVESHAFT NOTE: Prior to installing the driveshaft, apply a coat of AntiSeize Thread Compound (pIn 0678 146) to the internal splines of the driveshaft.
NOTE: Prior to placing the gear case onto the driveshaft, apply a light coat of Anti-Seize Thread Compound (pin 0678-146) to the splines of the ring gear shaft
3. Place the gear case onto the dri veshaft; thc n press the gear case toward the sprocket until it pro pcrl y scats into plnce o n the chassis. It may be necessary to rotate the driveshaft sli ghtly for pro pc r seating.
I. Place the track/dri vcshaft assembl y into the bearing of the brake housing just far eno ugh to allow the brake disc to be insta lled in the brake
hOllsing assembl y.
MS316A
MS317
NOTE: At this point, tighten the five nuts secur ing the brake caliper housing to specifications. 2. With the brake lever lock engaged and the brake di sc positi oned in the brake housing assembl y, pro pe rl y ali gn the splines of the dri\'cshaft with the brake disc ; the n push the dri veshaft the rest o f the way into the brake ho using until it is properly
scated.
4. Install the lock nuts securing the gear case to the chassis. Ti ghten in a cri sscross pattern to specificatio ns.
5. Install the torque bumpe r behind the engine mounting bl ock; then carefull y work it into place with the aid of a Oat-bl ade screwdri\'c r.
898
Page: 548
NOTE: Use of a quality silicone spray will aid in installing the torque bumper. NOTE: At this point, connect the speedometer sensor connector; then secure it behind the cool ant hose protector with a cable tie.
10. Place the resonator iOto position and secure with the springs. II. Slide the driven pulley onto the dri\'en shaft making sure alignment washers are in place.
6. Install the skid frame (see Section 9). 7. Apply Anti-Seize Thread Compound (pin 0678146) to the threads of the brake disc retaining nut ; then install the nul. 8. Using Brake Disc Socket Wrench (pIn 0644-4 15), tighten the brake disc retaining nut to specifications.
12. Secure the pulley with the cap screw (coated with blue Loctite 11243) and washer. Tighten to specifications. 13. Install the dri ve belt .
NOTE: After the retaining nut is tightened to specifications, peen the nut at the flat spot of the driveshaft.
14. Place the access panels into position and secure with existing hardware. 15. Check the track for ali gn me nt and recommended te nsion ; then ti ghten the cap screws securely (see Section 9).
9. Secure the dri veshaft to the ring gear with the cap screw (coated with blue Loctite #243 fo r a standard cap screw) and washer. Tighten to specifications.

I. Remove the cleven torx -head cap screws securing the gear case cover to the gear case assembl y; then cut the cable tie securing the speedometer sensor wire to the gear case cover.
Lh CAUTION
If the long cap screw has a silver coating, it has been pre-treated with Scotch Grip and does not need Loctite applied.
Page: 549
8-99
2. Insert two Oat-blade scrcwdrivers into the notchcs (A) on thc gearcasc l()(d'lted ncar the upper and lower dowl pins (8) of the gear case; then worki ng back and forth , pry the cover up and off the gear case.
3. Drain the gea r case Ouid into a suitable container. 4. With a cap screw threaded into the input shaft and using a soft hammer, drive the input shaft out of the gear case cover.
7. Using a suitable bearing press and fi xture, remove the main bearing from the transfer gear assembl y.
5. Using a suitablc bearing press and fi xture, prcss the input shaft bearing out of the gear case covcr. Account for a bearing and a seal.
MS333A
8-100
Page: 550
8. Using a suitable bearing press and fi xture, remove the outer bearing from the transfer gear.
MS334A
& CAUTION
After the ring gear has been removed if bearing removal is required, the speedometer magnet retainer must be removed from the ring gear to avoid damaging the retainer.
9. Re move the reta ining ring sec uring the planetary gear asse mbl y to the gear casco
MS335
10. Note the position of the larger spac ing between the tabs for assembling purposes; then remove the planctary gcar assembly from the gear case.
MS338A
12. With a suitable bearing press and fi xture, remove the bea ring from the ring gear.
MS336
II . Using a suitable press and fi xture, remove the ring gear assembl y from the gear case.
Page: 551
8-101
4.
the bearing areas for cmcks or excessive bearing movement. If ev ide nce of excessive bearing movemcnt is noted, replace the component .
In s rx~ct
5. Inspect the sealing surfaces of the gear case hal ves for trucness. 6. Wash the unsealed gear case bc<lrings in partscleaning solvent. 7. Inspect the bearings for wear, scoring, scuffing, damage, or discoloration. Rotate the bearings . Bearings must rotate freely and must not bind or feel rough. If any abnormal condition is noted, replace the bearing. 8. Appl y a light 111m of Arctic e 1t ACf Drive Fluid (pin 4639-027) to the unsealed bearings prior to assembling.
I. Install C mnkshaft Bearing Re mover (pin 0 144-
MS340
13. Using an appropriate seal remov ing tool, remove the ring gear seal s from the gc.:'lI" case.
302) onto the dri veshaft between the spacer/collar; thcn insta ll the bmke di sc retaining nut with the flat side facing outward.
MS341

Wash the gear case hal ves in parts-cleaning solve nt. 2. Inspect the gear case halves for scoring, pitting, scuffing, or a ny impe rfections in the casting. 3. Inspect all threaded areas for damagcd or stripped threads.
MS354
& CAUTION
Make sure to install the retaining nut with the flat side facing outward or damage to the driveshaft will occur.
8-102
Page: 552
2. Using a suitable press, remove the spacer/collar from the dri veshaft. Note that the tapered side of the collar faces outwa rd.
&CAUTION
3 . For installing purposes, scribe a line on the driveshaft (A) next to the drive sprocket for proper alignment : then scribe a lme on the dri veshaft directly in line with the timing arrows (8) on the drive sprockets for proper sprocket Liming.
MS359A
NOTE: The drive sprockets must be removed from the brake disc end of the driveshaft.
I. Thoroughly wash all metalli c components in partscleaning solvent. Dry using compressed air. 2. Wash all non-metallic components with soap and water. 3. Inspect the driveshafl for damaged splines or stripped thrC<lds.
MS357A
4. Inspect thc bearings for any rougJmcss or damage.

S.
4. Using a suitable press positioned against the tension-collar of the drive sprocket (located on the gear case) and of the driveshaft, press the dri ve sprockets off the dri veshaft.
Inspect the seal s for any breaks or damage.
6. Inspect the track for cuts, gouges, or wear. 7. Inspect the brake disc for wear or cracks. 8. Inspect the track dri ve sprockets for wear or damage.
Page: 553
8-103

NOTE: Prior to installing the sprockets onto the
3. Slide the remmning sproc ket onlo the dri veshaft

making sure the liming arrowflines (from
driveshaft, it is advisable to lightly chamfer the inside edge of the sprocket to avoid binding.
remov ing) are aligned; then using the pressJ fi xture, press the sprocket to the re maining aiignmenliinc.
L!':.CAUTION
Prope rly align the scribed Ime on the drivcshaft

(from removing) with the liming arrow on the
drive sprocket; then slide the sprocket onlo the driveshaft as far as it will go.
MS359A
_NOTE : The drive sprockets must be installed on the brake disc end of the driveshaft.
2. Using a suitable press and fi xture, press the dri veshaft inlo the sprocket until it aligns with the line scri bed in removing .
4. Using a calipe rs. measure di stances between the sprockets and rrom the sprockets to each end or the dri veshart for proper location (see il lustrations).
8-104
Page: 554
0 740042
5. Using Crankshaft Bearing Remover (pin 0 144302) and a suitable press, install the spacer/collar onto the dri veshaft until it is seated agai nst the hex -shaped hub or the dri veshart.
MS341
2. Using a suitable bearing press, install the bearing onto the ring gear,
NOTE: Take note to install the spacer/collar with the tapered side facing outward.
MS343
I. Using an appropriate seal installation tool, install the two oil seals into the ring gear ope ning or the gear case .
NOTE: After the bearing has been installed into the ring gear, install the speedometer magnet retainer to the ring gear.
8-105
MS338A
3. Using a suitable press, install the ring gear assembly to the gear case.
5. Insta ll the retaining ring securing the planetary
gear assembly to the gear case.
MS335
4. Noting the location of the large spacing (A)
6. Using a suitable bearing press, install the outer
between the tabs of the planetary gear assembly, install the assembly to the ring gear/gear case.
bearing to the transfer gear assembly; then install the inner bearing to the assembly.
.. .

MS346A
8-1 06
Page: 556
7. Install the transfer gear assembly mto planetary gear assembly/gear case.
the
MS351
10. Using a suitablc press, install the input shaft to the

MS332
gear case cover.
8. Using a suitable bearing press, install thc IIUlcr bearing onto the input shaft.
"""A
9. Using a suitable bearing prcss and fixture, install the input shaft bearing to thc gear case; then install the oil seaL
II . Appl y a film of High-Temp Silicone Sealant (pin 4639-030) to the SCt1 ling surfaces of the gear casc.
A CAUTION
Care must be taken not to allow silicone sealant into the cap screw holes and dowel pin holes or damage to the gear case may occur when tightening the cap screws .
12. With the dowel pins in placc, install the cover to
the gca r case and secure with eleven torx-head cap screws; then in a c risscross IX lttern, tighten to specifications.
Page: 557
8-107
3. Install the torque bumper behind the engine mounting block; then carerully work it into place with the aid or a Oat blade screwdri ver.
13. Secure the speedometer sensor wire to the gear case cover with a cable tic.
NOTE: Use of a quality silicone spray will aid in installing the torque bumper.
4. Install the long cap screw into the gear case shaft; then tighten to specificalions.
I. Place the gear case onto the dri veshaft ; then press the gear case toward the sprocket unti l it properly seals into place on the chassis. It may be necessary to rotate the dri\'eshart sli ghtl y ror proper seating.
NOTE: Prior to placing the gear case onto the driveshaft, apply a light coat of AntiSeize Thread Compound (pin 0678146) to the splines of the ring gear shaft.
5. Slide the dri ven pull ey onto the dri\'ell shaft making sure ali gnment washers are in place.
2. Install the lock nuts sec uring the gea r case to the chassis. Tighten in a cri sscross p.altern to specifications.
6. Secure the pulley with the ca p screw (coated with blue Loctite #243) and washer. Tighten to specifications.
8-108
Page: 558
7. Install the dri ve belt .

_NOTE : For installing drive belt, see Removing/ Installing Drive Belt (ACT Roller Driven Pulley) in this section.
8. Placc the acccss pancls into position and secure with existing hardwarc. 9. Placc the resonator into position and secure with the springs. 10. Check the track for alignment and recommended tension ; then ti ghte n the cap screws to specifications (sce Section 9). 5. Release chain tension; then remove the two loc k nuts and spring washers securing the top and bottom sprockcts. Account fo r and notc thc ori cntation of thc spring washcrs.
Replacing Driven Shaft PTO-End Bearing

(Firecat: rlSabercat Models)
REMOVING DRIVEN SHAFT
To re move th e dri ve n s haft , use the fo ll ow in g procedure: I. Remove the driven pulley.
2. Remove the two torx-head sc rews on the ik1.ckside pan near the left-side hood latch. 3. Drain the lubricant from the chain casco 4. Removc the six cap sc rcws from the cha in casc cover; thcll removc the cover. 6. Rcmo\'c the sprockcts and chain. 7. Remo\'e thc four torx-head screws at thc frontlcft side. Account for two lock nuts and cup washcrs.
Page: 559
8-109
NOTE : It may be necessary to use a magnet to aid in retrieving the hardware.

8. Remove the three bearing retainer nuts from the prO-side pl ate brace; then remove the machine screws sec uring the PTO-side plate brace and remove the brace,
II . Pull dow n on the side pan by the left -side hood latch; then slide the dri ven shaft out the PTa -side of the chassis_
REPLACING BEARING
NOTE : Do not remove the brake disc stop collar from the shaft. The stop collar is not a service part. If damaged, the driven shaft must be replaced. I. Using a suitable bearing press fi xture, press the bearing and spacer oil the shaft.
9. Remove the two large-head ri vets below the left side air-out vent on the left-side belly pan.
10. Using a rubber mallet (or suitable substitute), tap the dri ven shaft from the chain case side until free.
2. Apply green Loetite #609 to the inner race of the new bearing; then slide the bearing onto the shaft (raised side of bearing directed to the PTa -end) until it contacts the rai sed portion of the shaft.
8-110
Page: 560
NOTE: It is critical that the raised side of the bearing is facing the PTO-end of the shaft.
3. Slide the spacer onto the shan until it contacls the bearing; then usi ng a suitable beari ng press fixture , press the bearing and sp<'lcer onto the shan until the spacer is lOA cm (4, I in.) in from the end of the shaft .
2, Place the PTa-side plate brace into pos ition ; then install the three bearing retaining nuts on the proside pl ate brace. Tighten nuts securel y.
3. Secure the brace with the machine screws.

FC145
4. Place the sprockets wi th chain into the chain case,
Lb. CAUTION
00 not press the bearing and spacer beyond the given specification. Damage may occur to the bearing , spacer, and shaft.
S. Sec ure the top sprocket with a lock nut (threads
coated with green Loctite #609) and spring washer. Tighten to specifications. Tighten the bottom sprocket loc k nut (threads coaled with blue Locti te #243) with spring washer to speci fi cations.
INSTALLING DRIVEN SHAFT

1. Pull down on the side pa n by the left-side hood latch; then slide the driven shaft into the chassis and in10 the chain case.
8-111
9. Install the rour torx -head screws at the rront lert side making sure the two lock nuts and the cup washers are correctl y positioned. 10. Install the lWO torx -head screws on the backside pan ncar the lert-side hood latch. II. Replace the two large-head rivets below the leftside air-out vent on the left-side bell y pan. 12. Install the dri ven pulley.
6. Tighten the mechanical chain te nsioner fingertight ; then lock the jam nut against the chain case.
Chain Adjuster
NOTE: Some photographs used in this sub-section are used for clarity purposes only and are not designed to depict actual conditions.
7. Check the position or the cha in-case cover D-ring seal ; then place the chain-case cover into position and secure with six cap screws. Tighten to specifications.
REMOVING AND DISASSEMBLING

I. Remove the small plug rrom the adjuster housing and install an 8-32 set screw into the threaded hole of the adjuster housing.
8. Install the drain plug and tighten to specifications; then pour recom mended amount or Arctic Cat Transmission Lube (pin 0636-8 17) into the chain case.
2. Using a 3/4-in. wre nch, remove the chain adjuster rrom the chain casco
8-112
Page: 562
3. Remove the adjuster stem from the end of the
adjuster screw.
6. Slowly and carefull y lift the end cap from the adjuster housing until it is free of the hooked end of the spring.
4. Using a small piece of wire, remove the small spring from the end of the adjuster screw.
7. Remove the O-ring SCt11 from the adjuster housing. 8. C1refull y lift the spring from the housing and sec ure the spring using a cable tie .
5. While holding the end cap in position, remove the three cap screws securing the end cap to the adjuster housing. 9. Remove the set screw from the adjuster housing; then remove the adjuster socket from the housing by pulling it free of the adjuster bolt.
Page: 563
8-113
2. Slide the adjuster socket over the end of the adjuster bolt and push the socket down firml y into position. Rotate the adjuster soc ket clockwise until its Oange seats against the hOllsing inner surface.
10. Rotate the adj llster bolt counterclockwise until it is free of the hOllsing ; then remove the adjuster bolt .
3. With the Oat surface of the adjuster socket located under the threaded hole in the housi ng, install all 8-32 set screw.
II . Wash all components in pmts-cleaning solvent and inspect all components for any signs of wCt'lr.
I. Apply a light co.at of oil to the threads of the
adjuster boh; then turn the adjuster boh clockwise into the housing a few turns.
4. Install the ocnttab of the spring into the slot of the adjuster socket with the outer hooked e nd of the spring positioned in the clockwise direction.
8-114
Page: 564
5. With the spring in position, remove the cable tie used to prevent it from unwrapping. 6. Place the O-ring seal into position; then set the end cap into position. Make sure its tab is hooked into the end of the spring.
9. Apply a thin coat of grease to the spring and place the spring into position in the end of the adjuster
bolt
10. Use a thin coat of grease on the stem shaft to hold
it in position; then place the stem into the end of the adjuste r boll. 7. While holding the end cap down mto position, rot~te the end cap 20 turns clockwise to tension the spnng.
-'"'---~ A'F418
11 . Securely tighten the adj uste r assembl y to the chain case.
8. Install the three cap screws (co..1ted with blue Loctite 8242) and tighten to I kg-m (7 fI -Ib).
Page: 565
8-115
3. If the distance is less than specified , chec k the brake iluid level (see Checki ng and Adding Brake Fluid iO this sub-section), inspect for leakage, and check the brake pads (see Checking a nd Re placing Brake Pads in thi s sub-section).
6 WARNING
00 not operate the snowmobile if the distance between the compressed brake lever and hand Iebar is less than 2.54 em (1 in.). Brake loss may occur. Brake loss can result in severe personal injury,
12. Re move the set screw from the adj uster housing
CHECKING AND ADDING BRAKE FLUID

I . With the master cylinde r in a level position, check
and install the cap screw.
iluid level in the reservoi r. T he brake tluid level must be just below the high mark.
H igh Mark Low M ark
~rake Fluid
Reservoir
- -
I
740-1S9A
Brake System
(Hydraulic)
CHECKING BRAKE LEVER TRAVEL

I Compress the brake lever fu lly.
2. If the brake tluid level is below the low mark, remove the rescrvoir co\'cr and add apprO\'cd brake iluid until the iluid level is j ust below the high mark. Install and scc ure the reservoir cover. DO NOT allow moisture to contaminate thc brake system.
NOTE: Do not pump the brake lever as it will produce an inaccurate reading.
6 CAUTION
Brake fluid is highly corrosive. Do not spill brake fluid on any surface of the snowmobile,
2. l\'leasure the di stance between the brake lever and the handlebar. The distance must be greater than 2.54cm ( 1 in.).
6 WARNING
00 not overfill the master cylinder reservoir. Overfilling the reservoir may cause the brake system to hydraulically lock. Use only app'roved brake fluid. Never substitute or mix different types or grades of brake fluid , Brake loss may occur. Brake loss can result in severe injury or even death.
Lever L ock Lever
CHANGING BRAKE FLUID

T he brake fluid must be c hanged o n a regular basis andl o r whe never the brake fluid ha s bee n overheated or contaminated. The brake iluid sho uld be changed every 1000 miles o r at the end of the snowmobiling season, whiche\'er occurs first.
7401596
2 .54 em (1 i .
8-116
Page: 566
Arctic Cat recommends the remova l and di sassembl y of the brake calipe r assembly when changing the brake fluid (see Removingll nstalling Caliper iO thi s sub-section),
4. When the brake fluid is free of all air and the brake \ever feel s firm when compressed, fill the reservoir to a level just below the high mark; then install and sec ure the eover. Remove the tube from the bleeder valve. 5. Proceed to bleed the brake system (sec Bl eeding Brake System in thi s sub-section).
CAUTION
Brake fluid is highly corrosive. 00 not spill brake fluid on any surface of the snowmobile.
BLEEDING BRAKE SYSTEM

If the brake lever feel s spongy when applied, the brake syste m may need to be bled. To bleed the brake system, use the foll ow ing procedure. I. Slide a piece of flexible tubing over the ball of the bleeder valve and direct the other end into a container.
Brake Pads Va llie
I. Remo\'e the master cylinder resen 'oir cover and
fill the reservoir to the high mark wi th approved brake fluid.
A
STO
'f\\1'ru'S\ ,'=t'~~
CAUTION
Bleeder ~
3.2 mm (0. 125 in.)
."k. OI"1:'J~~3~~Jf~1~ , ~~;1 I-
Use only approved brake fluid. result in a loss of brakes.
Hydraulic Brake Caliper

730434 E
A WARNING
Do not use brake fluid from a container that has been opened for a long period of time. Unsealed brake fluid containers will absorb moisture and can contaminate the fluid inside,
Brake Pads
ACT
2. Slide a piece of fl ex ible tubing over the ball of the blecder valve and direct the other end into a conl"ainer.
t~~~i~~'Y
Brake
i s.Omm
Brake Pads (0.20 In.) Valve
STO
3.2mm (0 .125 in.)
Bleeder ~
Oisc
~HydraUIiC
Brake Disc
F"F'1
I~ -!
Brak, Caliper
739269A
1-
I.
2. Slowly compress the brake lever and hold . Open the bleeder va lve to release the fluid: then compress the brake lever repeatedly until al l brake fluid is ex pcJled. Close the b\eedcr val vc. 3. Add new approved brakc Iluid to the resen'oir; thcn compress the brake lever and hold Ope n the bleeder valve. Repeat the compression until brake fluid fl ows free of air bubbles and appears clean.
NOTE: It may be necessary to refill the reservoir a number of times to eliminate all air bubbles in the system.
Hydraulic Brake Caliper

730-434E
Page: 567
8-117
ACT
Brake Pads
S .Omm r- (0.20 In.)
Brake Disc
tfydrauJic Brake Caliper

739-269A
3. Slowly compress the brake lever and hold . Open
the bleede r val ve to release the fluid a nd air. When the fluid stops now ing. close the bleeder va lve; thell release the brake lever.
4. Repeat step 3 until the brake nuid nows free of air bubbles.
NOTE: It may be necessary to refill the reservoir during the bleeding process.
4. Using a large sc rewdriver, slow ly push both brake pisto ns into the calipcr.
A CAUTION
Care must be taken not to pry against the brake disc when pushing on the pistons or severe damage may occur.
5. Positio n the new brake pads !Ilto the caliper and secure with the retaining pin.
5. When the brake fluid is free o f all air and the brake lever feels firm when compressed , fill the reservoir to a level just below the high mark ; then install and secure the cover. Remove the tube from the bl eeder valvc .
NOTE: When installing new brake pads, always install them as a set. Never install just one pad or use brake pads which have been used in another snowmobile.
CHECKING AND REPLACING BRAKE PADS (STD)

To check and re pl ace the brake pads, usc the following
procedure.
I. Measure the thickness o f both brake pads. The brake p<:ld thickness must be greater than 3 ,2 mm (0. 125 in. ). If the brake pad thickness is less than specified, replacement of both pads is necessa ry.
Brake Pad s Valve
Bleeder~
3.2 mm
Brake
Dis:'~:1~~~~~~~J if;=ll~~(O=~ll5_j n .)
Hyd rillllic Brake Cilliper
07 30-434
6. Compress the brake lever repeatedly to ensure correct positioning of the brake pads; then release .
NOTE: When new brake pads are installed, a bur nishing process is required. Drive the snowmobile slowly and compress the brake lever repeatedly until the pads just start to heat up; then allow them to cool down. This process stabilizes the pad material and extends the life of the pads.
REMOVING CALIPER (STD)

I. Slide a piece of n ex ible tubing over the ball of the bleeder valve and direct the other end into a container.
2. Remove the retai ning pin securing the brake pads to the calipe r assembl y. 3 . Pull bot h brake pads out of the calipe r assembly.
8-118
Page: 568
Brake Pads Va l ve
Bleeder ~
Brake
DISi ' ~:~T ~~ {(f {t~f;d ~~-~~1~~(O=J ~1 25_in. ) _ Hydraulic Brake Caliper
0730-434
3.2 mm
5. Loosen the upper cap screws sec uring the caliper hal ves; then remove the two cap sc rews, lock washers, and Oat washers securing the brake caliper to thc chain case.
Lb. CAUTION
Never use an impact driver on models with composite chain case. Damage to the chain case will occur.
=~
2. Open the bleeder valve and compress the brake lever several times to drmn the reservoir of Ouid. 3. Removc the brake hose from the ca li per. Use an absorbent towel to collect any remaining brake Ouid.
6. Remove the caliper assembly from the engine compmtment .

Disassembling
I. Position a piece of woocl between the pistons. Using low-pressure compressed air, blow into the caliper brake hose fittin g to remove the brake pistons.
Lb. CAUTION
4. Remove the retai ning pin securing the brake pads to the caliper a sse mbl y~ then remove the brake pads.
2. Remove the two cap sc rews securing the caliper hal ves. Account fo r the small O-ring. 3. Remove the piston O-rings and discard .
Page: 569
8-119

Inspect the brake pi sto ns fo r gouges, cracks, pitting , sculTing, or corrosio n. If any o f these conditions exist, replace the piston. 2 . C lean the piston o uter surface by lIsing a ScotchBrite pad and clean brake fluid as a cleaner.
5. Inspect the condition o f the brake p..1ds. Replace if damaged o r worn. The brake pad thickness must be greater than 3. 2 mm (0.125 in.). If the brake pad thickness is less than s pecified , replaceme nt of both pads is necessary. 6. Inspect the brake hose for c racks and deterioration and check the condition o f the threaded connecto rs.
Assembling
&
CAUTION
00 not use any sharp cleaning tool on the piston surface as it may cause damage. Parts-cleaning solvent must not be used as it can damage the piston O-ring,
~ ~.~13 14
"
IA I ~" '- , 5
2J :
I
, ?-/
lFM\...
10. Hou sing 11. Ho using
KEY 1. Ralaining Pin
2. Cap Screw 3. Washer 4. Brake Caliper Assy
5. Housing O-Ring 6. O-Ring
7. Piston
8. Bleed Screw 9. Brake Pad Set
12. Cap Screw 13. Lock Was her 14. Was her
736-850A
I. Apply approved brake fluid to the new O -ring; then install the O-ring into the groove of each calipe r half.
3 . Inspect the brake caliper fo r gouges, cracks, pining, scuffing, o r corrosio n. If any o f these conditions ex ist, replace the caliper. 4 . Clean the caliper inner wall surface using a soft Scotch-Brite pad and clean brake fluid . Wipe cali pe r wall clean with a clean rag and brake fluid .
NOTE: Always use a new O-ring when assembling the brake caliper,
8-120
Page: 570
2. In each caliper half. apply approved brake Ouid to the brake piston; then whil e twi sting, install the piston with the open side facing aliI.
2. Install the brake hose on the calipe r and tighten securel y.
3 . Place the small O-ring into posilion; then assembl e the two calipe r hal ves. Secure with the cap screws. Do not tighten at this time.
3. Install the brake pads. Secure with the retaining pin.
INSTALLING CALIPER (STD)

Secure the caliper assembl y on the chain case using two cap screws, loc k washers, and Oat washers. Tighten the cap screws to specifications. Tighten the upper cap screws to specifications.
Page: 571
8-121
4. Bleed the brake system (see Bleeding Brake System in thi s sub-section).
NOTE: If new brake pads were installed, a burnishing process is required. Drive the snowmobile slowly and compress the brake lever repeatedly until the pads just start to heat up; then allow them to cool down. This process stabilizes the pad material and extends the life of the pads.
4. Using a needle-nose pliers, remove the brake pads from the caliper.
REPLACING BRAKE PADS/BRAKE DISC/ BRAKE CALIPER (ZR 900)

Removing Components
I. Remove the springs securing the resonator and ex pansion chamber; then remove from the engine compartment. 2. Remove the two All en-head cap screws sec uring the speedometer drive adapter assembly to the brake caliper; then remove the adapter assembl y.
5. Install the new brake pads into the caliper; then secure with the retaining pin and hairpin clip.
NOTE: If replacing only the brake disc or only the brake caliper, proceed to step 6. NOTE: Measure the thickness of both brake pads. The brake pad thickness must be greater than 5.0 mm (0.20 10.). If the brake pad thickness is less than specified , replacement of both pads is necessary.
3. Remove the hairpin clip from the brake pad retaining pin; then remove the pin .
NOTE: When new brake pads are installed, a burnishing process is required. Drive the snowmobile slowly and compress the brake lever repeatedly until the pads just start to heat up; then allow them to cool down. This process stabilizes the pad material and extends the life of the pads.
FS129A
6. Engage the brake lever loc k; then lIsing Brake Disc Socket Wrench (pin 0644-4 15), remove the retaining nut from the dri veshaft.
8-122
Page: 572
2. Inspect the brake hose for cracks and deterioration and check the condition of the threaded connectors.
Installing Components
NOTE: To aid in installing the inner caliper housing, completely loosen track tension.
I. Place the inside caliper housing into place on the chassis; then install the fi ve nuts and ti ghten to specifications.
2. Apply Hi gh-Temp Silicone (pIn 1048-052) to the
7. Di sengage the brake lever lock and slowly compress the brake lever; then lock the lever in the fi rst notch.
NOTE: Locking the lever in the first notch will limit brake fluid loss when separating the caliper housings.
splines of the brake di sc and to the threads or the retai ning nut; then install the disc and nut.
NOTE: At this point, tighten the retaining nut only until snug .
3. Place the outside caliper housing into position with two spacers and install the Allen-hc..1d ca p screws; then ti ghten to specifications.
NOTE: Always use a new Oring when installing the outside housing.
8. Remo\'e the two All en-head cap serews securing the ca liper housings together. Account ror two spacers.
o ... ~!---FS132A
9. Remove the outside caliper housing from the inside caliper housing. Account ror the O-ring.
10. Remove the brake di sc from the dri veshart .
NOTE: To aid in removing the inner caliper hous ing, completely loosen track tension.
II Remove the rive nuts from the cap screws securing the illside caliper housing to the chassis; then remove the inside caliper housing.
4. Bleed the brake system (sec Bleeding Brake System in this sub-section). 5. Engage the brake lever lock; then using Brake Disc Socket Wrench (pIn 0644-4 15) , tighten the brake di sc retaining nut to specifications.
NOTE: The brake lever lock must be engaged for this procedure. 8-123
I. Inspect the condition of the brake pads. Replace if damaged or worn. The brake pad thickness must be greater than 5.0 Illlll (0.20 in.). Jr the brake pad thickness is less than specified, replacement of both pads is neces5<'lry.
Page: 573
2. Remove the hairpin chp rrom the brake pad retaining pin; then remove the pin.
6. Place the speedometer dri ve adapter assembl y onto the brake caliper; thell install the All en-head cap screws and ti ghl'e n to specifications. 3. Using a needle-nose pliers, remove the brake pads rrom the calipe r.
7. Place the ex pansion chamber and resonator into posilion and secure with the springs.
8. Adjust track alignment and tension (see Section
9).
REPLACING BRAKE PADS/BRAKE DISC/

BRAKE CALIPER (Firecat/M-Series) Removing Components
4. Install the new brake pads into the caliper; then sec ure with the retaining pin and hairpin clip.
I. Remove the springs sec uring the resonator and ex pansion chamber; then remove rrom the engine compartment.
NOTE: If replacing only the brake disc or only the brake caliper, proceed to step 6 . NOTE: 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.
8-124
Page: 574
7. Disengage the brake lever lock and slow ly compress the brake lever; then loc k the lever in the first notch .
NOTE: Locking the lever in the first notch will limit brake fluid loss when separating the caliper housings.
8. Remove the four All en-head cap screws securing the caliper housings together.
NOTE: When new brake pads are installed, a bur nishing process is required. Drive the snowmobile slowly and compress the brake lever repeatedly until the pads just start to heat up; then allow them to cool down. This process stabilizes the pad material and extends the life of the pads.
5. Engage the brake lever lock; then loosen the long driveshartiring gear ca p sc rew e nough to take pressure orf the nat washer. 9. Remove the outside caliper housing from the inside caliper housing. Account for the O ring. 10. Remove the brake di sc and spacer from the dri vesha fl.
NOTE: Releasing pressure from the flat washer will allow it to center itself to the driveshaft when removing the brake disc retaining nut
6. Engage the brake lever loc k; then llsing Brake Di sc Socket Wrench (pin 0644-4 15), remove the retaining nul from the dri veshafl.
MS323
NOTE: To aid in removing the inner caliper hous ing, completely loosen track tension.
Page: 575
8-125
I. Place the inside caliper hOllsing into place on the chassis; then install the four loc k nuts (1-\) and the Phillips-head cap screw with lock nut (8) and tighten to specifiCt'l tions.
II. Remove the fo ur lock nuls (A) and the Phillipshead cap screw with lock nut (8) securing the inside calipe r housing to the c hassis; then remove the inside caliper housing. 2. Apply Anti -Seize Thread Compound (pin 0678146) to the splines of the brake disc and to the threads of the retaining nut ; then install the disc and nut.
NOTE: At this point, tighten the retaining nut only until snug.
3. Place the outside calipe r housing into position and install the Allen-head ca p screws; then li ghten to specifications.
NOTE: Always use a new O-ring and make sure the O-ri ng is properly seated in the outer brake housing.
I. Inspect the condition of the brake pads. Replace if damaged or worn. The brake pad thickness must be greater than 5.0 mm (0.20 in.). tr the brake pad thickness is less than specified. replacement of both pads is necessary. 2. Inspect the brake hose for cracks and deterioration and check the condition of the threaded connectors.
Installing Components
MS320A
NOTE: To aid in installing the inner caliper, com pletely loosen track tension.
8-126
Page: 576
4. Bleed the brake system (sec Bleeding Brake System in thi s sub-section). 5. Engage the brake lever loc k; then using Brake Di sc Socket Wrench (pIn 0644-4 15), tighten the brake disc retai ning nut (from step 2) to specifications.
NOTE: The brake lever lock must be engaged for this procedure.
Brake Pads
STO
Bleeder Valve
Brake Disc
=~
D~~=W=lt Hyd raulic Brake CalJpe

730-434E
1TJ~-~ - ~~iTI
3.2 mm
(o.1i
in.)
ACT
Brake Pads
Disc
Ttg~~~~~~I
" - Hydraulic Brake Caliper
Mmm
(0.201 .(
6. Tighten the long driveshaftJring gear cap screw (from ste p 5 of Removing) to speci fi cat ions.
739-269A
2. On standard models to remove the switch, use a small screwdri ver to compress the plastic locking tabs by pushing in on the tabs: then slide the sw itch free of the brake control.
7. Place the ex pansion cha mber and resonator into position and secure with the springs. 8. Adjust track alignment and tension (see Section
9).
Brake Lever/Master
Cylinder Assembly
(Hydraulic Systetn)
3. On models equipped with a brake lever actuated dimmer sw itch to remove the sw itch, remove the Allen-head cap screw from beneath the master cylinder and free the sw itch from the master cylinder assembly. 4. Place all absorbent towel around the connection to absorb brake nuid . Remove the brake Ouid hose from the master cylinder.
REMOVING
Slide a piece of nex ible tubing over the ball of the bleeder valve and direct the other end into a container. Remove the reservoir cover; then open the bl eeder \'alve. Allow the brake Ouid to drain completely.
Page: 577
8-127
,&, CAUTION
3. Remove the two sc rews sec uring the reservoir to
the master cylinder.
5. Remove the two torx-head screws and clamp securing the brake assembl y to the handlebar; then remove the assembl y from the handlebar.
4. Compress the locking tabs of the reservoir and remove the reservoir from the maste r cylinder. Account for an O-ring seaL
INSPECTING DISASSEMBLING
I. Re move the screw and lock nut securing the brake lever. NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. I. Inspect the screw securing the brake lever for wear and for cracked, stretched , o r damaged threads. 2. Inspect the O-ring for deterioration and di sto rtio n.
2. Remove the two screws securing the reservoir

cover ; then remove the cover.
3. Inspect the reservoir fo r cracks and leakage.
8-128
Page: 578
4. Inspect the brake Ouid hose for cracks, deterioration, and the condition of the fittin gs (threadcd and compression).
ASSEMBLING
I. Apply approved hi gh temperature brake Ouid to
the O - ~in g seal; Lhen insLall the seal on Lhe resen 'olr.
KEY
1. Brake Assy 2. Brake Lever 3. Lever Mounting
s,,~
2. Install the reservoir on the master cylinder. Secure with two screws.
9. 10. 11 . 12. 13. 14. 15. Machine S<:rew O-Ring Mastel"Cytinder Lock Washer Screw Clamp Dimmel" Control Assy 16. Dimmer Control Housing 11. S.... ltch Assy 19. Dimmer Knob 19. Handwarmer S.... ltch 20. Cover Plate 21. Sell-Tapping
4. 5. 6. 1. 8.
Lock Nul Reservoir Gasket Cover S<: rew
s,_
22. Brakeline
0737-603
3. Install the brake lever. Secure wiLh a screw and a new lock nut. Tighten the lock nut just to the point of ensuring free brake levcr movcment.
6 WARNING
00 not over-tighten the lock nut. Over-tightening the lock nut will cause the brake lever to bind. The lever must work freely and fully return to its stop after installation,
KEY
Assy Brake ,. Brake Lever 7. COVel" 8. Screw S. Machine S<: rew O-Ring Master Cylinder Lock Washer 13. Screw 14. Clamp 15. Brakellghtl Dimmer S....ltch 16. Brakeline 11. Spring Assy 0739-125
3. Lever Mounting
Loc k Nut s. Reservoir Gasket
5"~
". ".
".
Page: 579
8-129
A new lock nut must be used to secure the brake lever.
INSTALLING
I. Position the brake assembl y 011 the handlebar. Secure with two torx-head mach ine sc rews and clamp; tighten securely. 2. Install the hose on the master cylinder. Ti ghten securely. 2. Remove the recoil stm1er rope from the brake Ct'lble bracket. 3. Loosen the jam nut on the brake cable and remove the cable from the bracket. 4.
~ell and remove the two mounting cap screws (account for the front alignment ball) and remove the brake caliper.
3. On standard models, slide the brakelight sw itch into the brake control until the self-locking tabs snap into position. Lightly pull on the switch to make sure it is properly secured. 4 . On models equipped with a brake lever actuated dimmer sw itch, place the switch into position beneath the master cylinder assembly making sure the alignment pins are properly positioned; then secure the sw itch with the Allen-head screw. 5. Bleed the brake system (see Brake System Hydraulic sub-section).
Brake System
(Mechanical/Quick-Adjust)
REMOVING
I. Remove the cotter pin, washer, pin, and clevis from the brake actuator arm.
DISASSEMBLING
I. Remove the snap ring on the stationary side of the calipe r.
8-130
Page: 580
2. Remove the brake l:k'ld support plate.
6. Remove the brake actuator arm return spring.
AF351A
3. Remo\'e the stationary brake pad.
7. Loosen and rcmo\'e the three cap screws securing the brake cable bracket and remove the brackel.
4. Removc the movable brake pad . 5. Remove thc brake piston. 8. Remove the brake actuator ann assembly from the cal ipe r.
Page: 581
8-131
9. Pull out on the quick-adjust knob and turn counterclockw ise to remove.

I . Using a calipers, measure the stationary and
movable brake pads. T he movable brake pad thickness must exceed 12.7 mm (0.500 in.). The stationary brake pad thickness must exceed 6.22 mm (0.245 in.).
10. Remove the adj ustment bolt and spring from the quick-adjust knob.
"1~I",u .. thi< ~ _ Io, T~i<~

M;~;",u .. thi<~_Io, T~;~
Pad. ':.T ...... IO.~l".1 Pad . i.22 ..m 10.2.5 ;n.)
0730504
NOTE: When replacing brake pads, always replace both pads as a set.
2. Wash all brake components with parts-cleaning solvent and dry thoroughly. 3. Inspect a ll brake components for signs of wear, fa ti gue. cracks. or stripped threads. II. O n the rear of the caliper, loosen and removc the jam nut, washer, spring, and ball assembly. 4. Inspect the spring for cracks. stretching, or unusual bends. 5. Inspect the bra ke ca ble for any signs of fra ying or broken strands. Replace as needed.
ASSEMBLING
I. In
the rear mounting hol e of the cali pe r, tc mporarily install the mounting cap screw. In sequence, install the alignment ball (appl y a small amount of grease to the 11:1.11), spring, washer, and jam nut. Turn the jam nut in until sli ght spring pressure is felt ; then remove the mounting ca p screw.
8-132
Page: 582
2. Apply Arctic C'lt I-li-Temp Wheel Bearing Grease (pin 0436-0(4) to the actuator shaft.
5. Place the brake cable bracket and rOI~ guide into position and secure with the three cap screws and lock washcrs,
3. InSC11 the adjustme nt bolt with spring and quickadjust knob into the actuator assembl y and turn in 2 or 3 turns,
6. Install the brake arm actuator return spring.
4. With thc actuator shaft a nn in the 11 oclock position (located over the front mounting hole), install the actuator shaft into the brake calipc r asscmbly.
7. Install the brake pi ston making sure that thc slot in the piston ali gns with the roll pin in the calipe r.
Page: 583
8-133
8. Install the movable (thick) brake pad into the ca lipe r making sure that the slot in the pad aligns with the roll pin ill the cal ipe r.
11. Install the stationary (thin) brake pad into the Ct'l li per making sure the slot in the pad aligns with the small tab on the support plate. Use a rubber band to hold the pad and plate in position.
INSTALLING
1. With the rubber band holding the stationary pad and SUpp011 plate in position, install the caliper assembly over the bra ke disc. Remove the rubber band.
9. Install the snap ring into the calipe r making sure that the sharp edge of the snap ring fa ces out and the opening faces down.
WARNING
Be sure the snap ring is fully seated. Personal injury may result if the snap ring isnt seated properly within the slot of the caliper.
CAUTION
Make sure that the brake pads are properly positioned in the caliper or damage to the brake system will result.
2. Apply blue Loctite 11243 to the rear mounting cap screw with washer and install. DO NOT TIGHTEN AT TI-IIS TI ME.
10. Install the brake pad SUpp0l1 plate with the large
tab located in the opening of the snap ring.
8-134
Page: 584
3. Appl y a small amount of grease to the ali gnment ball and install into the front of the calipe r. Apply blue Loctite 11243 to the front cap screw with washer; then install and tighten both cap screws to specifications.
6. Pull out on the quick-adjust knob and turn clockwise until there is 6- 13 mm (1 /4- 1/2 in.) freeplay at the brake lever.
Brake Lever
613 mm
(1 f4~- "'''''.,
Brake Switch
0727 45 1
7. Set the brake lever lock; then securely tighten the jam nut on the uppe r mounting cap screw. 4. Place the brake cable into the rear slot of the brake cable bracket and tighten securely.
5. Insert the cablc end into thc rea r slot of the clcvis. Install the pin through the clev is and actuator arm ; then install the washer. Install a new cotle r pin into the clevis pin and spread the cotte r pin .
8. Release the brake levcr lock and rec heck the brake levcr frce-play (adjust as necded); then place the recoil stm1er ropc into the guide p0l1ion of the brake cable bracket.
ADJUSTING BRAKE LEVER TRAVEL

I. Rotate the brake disc altcrnately forward and backward while slowly comprcssing the brake levcr.
Page: 585
8-135
2. At the point where the di sc is loc ked, check the distance between the brake lever and lever stop. The distance must be within a range of 6- 13 mm ( 1/4- 1/2 in.).
Brake Lever
4. To increase brake lever travel (loosen the brake), pull out on the quick-adjust knob and rotate the knob counterclockw ise periodicall y checking the brake lever travel . Once the desired brake lever travel is obtained, release the knob into a secured position.
REPLACING BRAKE PADS
613 mm
(114 -112 In.)
Lever Stop Brake Switch
lC
CAUTION
The brake pads must be replaced as a set. 00 not under any circumstances ever replace only one of the brake pads,
I. Using a 1I2-in. socket , re move the front brake
0727451
assembly guide pin. Slowl y pull the pin from the assembl y and catch the ali gn ment ball as it drops from the hole in the front of the calipe r assembly. 2. Remove the rear guide pin ; then slide the brake calipe r assembly fonvard free of the brake di sc. 3 . Remove the stationary brake pad from the caliper assembly. 4. Tip the caliper on its side and allow the movabl e brake l)';ld to drop free of the ca lipe r assembly. 5. Place the new mo\'uble brake pad into position; then te mporarily secure with a rubber band to hold it in place. 6. With the backing plate III position (wide tab positioned between the snap ring ears), install the stationary brake pad making sure the notch in the pad is ali gned with small tab of the backing plate. Using a rubber band , tcmporaril y sccure the pad. 7. Place the brake assem bl y back into position over the brake disc. Apply green Loctite #6rf:) to the rear guide pin ; then install the rear guide pin. 8. Insert the alignment ball into the hole at the front of the calipe r, appl y green Lactite #609 to the front guide pin, and install the front guide pin. Tighten the two alignmcnt pins to spccifications. Cut and remove thc two rubber tmnds.
_NOTE : When new brake pads have been installed, a burnishing process is required, Drive the snowmobile slowly and compress the brake lever repeatedly until the pads just start to heat up; then allow them to cool down. This process stabilizes the pad material and extends the life of the pads.
WARNING
Before making any adjustment, make certain the brake quick-adjust knob isnt hot. If the snowmobile has just been used, allow some time for the knob to cool or burns may result.
3. To decrease brake lever travel (set up brake), pull out on the spring-loaded quick-adjust knob and rotate the knob clockwi se periodicall y c hecking the brake lever travel di stance until the correct lravel distance is attained. Once the correct brake lever travel has been obtai ned, release the knob into a secured position.
_NOTE : If the quick-adjust knob has reached its maximum adjustment (cannot be rotated any further clockwise), both brake pads must be replaced .
WARNING
00 NOT attempt to adjust the brake with the flange nuts on the brake cable bracket. Incorrect brake adjustment may occur causing possible brake failure.
Brake Cable
Brake Disc
0 73015 1
8-136
Page: 586
Brake Control
(Mechanical/Quick.. Adjust)

I. Re move the Phillips-head screws securing the
handlebar pad to the handlebar.
4. Disconnect the brake cable from the scat in the

brake lever and remove the lever; then slide the
brake cabl e free of the brake controL
2. Remove the retaining ring, washer, and pin

securing the brake lever.
5. Remove the bmke lever from the brake control housing. 6. Remove the fo ur screws securing the console; then
rai se the console to gain access to the main wiring harness_ 7. Disco nnect the brake control wiring harness from the main wiring harness.
3. Loosen the jam nut securing the bmke cable to the

brake cabl e bracket.
8. Cut the cable ti cs holding the wiring harnesses and cables to the steering post noting the ir locations for installing purposes. 9. Using a sharp knire, cUllhe grip o rr the handlebar; then lIsing a solvent , clean adhesi" e rrom the handlebar.
Page: 587
8-137
10. Re move the machine screw securing the brake control to the handlebar: then slide the brake control ofT the handleb.1.r.
2 . Connect the wiring harness at the console.
3. Connect the brake control wi ring harness to the main wiring harness; then secure the harnesses with cable tics.
4. Place the console into position and secure with
four sc rews making sure all wiring harnesses arc posi tioned under the console .
Koy 1. Spring 2. Brake Cable 3. Brake lever 4 . Axte 5. Knob 6. Handwarmer Control 7. MachineScrew 8. Spring 9. Sell-Tapping SC rew 10. Retaining Ring 11 . Cover Plate
12. Actuator 13. Pin 14. Dimmer Switch 15. Washer 16. Retaining Ring 17. Grip lB. Housing 19. Flange Nut 20. Brake Control Assy 21. Handwa rmer Element
735-B20A
NOTE: Secure wiring harnesses and cables to the steering post with cable ties as noted in remov ing.
5. Connect the end of the brake cable to the seat of the brake lever.
Slide the brake control onto the handlebar and secure with the machine screw.
6. Secure the brake ca ble to the bracket by tightening the jam nut.
8-138
Page: 588
7. Secure the brake lever with the pin, washe r, and retaining ring.
8. Secure the handlebar pad to the handlebar with the Phillips-head screws.
9. Appl y I-Iandletmr Grip Adhesive (pin 0636-07 1) to the bore o r the handlebar grip; then using a rubber hammer, dri ve the grip into positio n.
WARNING
The handlebar adhesive is extremely flammable, The product contains acetone and the vapors, when released, can be easily ignited, Keep away from heat, sparks, and open flame. Use only in a well-ventilated area. Avoid prolonged breathing of vapor. Avoid eye and skin contact. Keep container closed when not in use.
AL1 38D
Page: 589
8-139
Arctic Cat Cam Arms
43.5 grams
47.0 grams
AR-CAM
8-140
Page: 590
Arctic Cat Cam Arms
~ ~
"
415grams
~
44.5 grams
---455 grams
46.5 grams 48.5 grams
~
~
~ ~
~
44 o grams
~ ~
"
45.0 grams
" ~
44
a grams
~
4 1.5 grams
------" ...... ~ ......

54.S grams
~
48.4 grams
~
~
68.0gram5
~ ~
a. 0 grams
70.5 grams
SO.O gram.
58 o grams
~ ~
Page: 59 1
7 1.5 grams
ggCAM
2005 Arctic Cat Service Man ual - all m odels www.ReadManuals.com
8-141
Arctic Cat Cam Arms
~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~
04-CAM
8-142
Page: 592
ITEM
Drive Clutch
Spider"
NOTE : STD refers to chain case dri ve models ; ACT refers to gear case drive models.
TORQUE fHb kg-m fHb kg-m ft-Ib kg-m ft-Ib kg-m ft-Ib kg-m fHb kg-m ft-Ib kg-m fHb kg-m fHb kg-m fHb kg-m fHb kg-m fHb kg-m fHb kg-m fHb kg-m ft-Ib kg-m ft-lb kg-m ft -Ib kg-m 50 6.9 250 34.5 85 11 .8 10 1.4 10 1.4 22 3.0 24 3.3 32 4.4 20 2.8 10 1.4 40 5.5 35 4.8 35-40 4.8-5.5 30 4.2 8 1.1 15 2. 1
ITEM
TORQUE fHb kg-m ft-Ib kg-m ft-lb kg-m ft-Ib kg-m ft-lb kg-m fHb kg-m fHb kg-m ft-Ib kg-m ft-lb kg-m ft-lb kg-m ft-Ib kg-m fHb kg-m ft-lb kg-m ft-lb kg-m ft-Ib kg-m ft-lb kg-m fHb kg-m 35 4.8 25 3.5 50 6.9 15 2.1 11 1.5 11 1.5 5.5 0.75 5.5 0.75 17 2.4 20 (5116-in.) 2.8 15 (1I4-in.) 2.1 20 2.8 16.5 2.3 9 1.2 35 4.8 70 9.7 120 16.6
Chain Case Drain Plug Shift Linkage Arm (STO)

Brake Caliper/Chain Case" Flange Plate - AWS 5 (Lower) Flange Plate - Sabercat (Lower) Flange Plate - STD (Upper) Torque Bracket Cover (ACT) Movable Sheave (ACT) Speedometer Drive Adapter (ACT) Gear CaselChassis Gear CaselChassis (ZR) Brake Caliper Housing/Chassis (ACT) Outside Caliper Housint Inside Caliper Housing ACT) Gear Case Cover Gear Case Drain Plug DriveshafURing Gear Cap Screw Driveshafl/Brake Disc Retaining Nut (ACT)
. wIBlue Loctite 1243 w,(>reen Loctite 1e09
Spider Retainer Nul"

Drive Clutch Cover
Cam Arm Pin Lock Nut (6-Post) Drive Clutch (6-Post)/Ring Gear Damper" Driven Pulley'
Driven Pulley' (ZR)

Driven Pulley Roller P1ale (STO) Torque Bracket (STO) Chain Case Top Sprocket" Chain Case Bottom Sprocket' (w/Reverse) Chain Case Bottom Sprocket' (w /o Reverse) Reverse Gear' (STO) Chain Tensioner Arm' (STD) Chain CasefTunnel Chain Case Cover
1215 1.7-2.1
Page: 593
2005 Arctic Cat Service Manual - all models - www. ReadManuals .com
8-143
Troubleshooting Drive Clutch! Driven Pulley

Problem: Midrange Shift-Up (Too QUickly - Lowers RPM) Condition 1. Drive clutch spring weak 2. Driven pulley spring weak 3. Driven pulley spring preload tension Remedy 1. Replace drive clutch spring 2. Replace driven pulley spring
3. Increase spring preload tension 4. Adjust center-la-center distance

5. Replace bearing - movable sheave
inadequate 4.
Center~to-cente r
distance too close
5. Driven pulley bearing worn - damaged
Problem: Midrange Shift-Up (Too Slowly - Raises RPM)
Condition
1. Drive clutch components dirty 2. Driven pulley components dirty 3. Driven pulley spring preload tension excessive 4. Driven pulley bearing worn - dirty Problem: Excessive Belt Deposits Condition 1. Offset adjusted incorreclly 2. Drive clutch/driven pulley sheaves rough damaged - dirly 3. Driven pulley movable sheave travel impaired 4. Driven pulley bearing worn - dirty Condition 1. Drive clutch components dirty - damaged 2. Drive belt does not meet measurement specifications Condition 1. Cam arm pin bent damaged 2. Cam arm damaged - broken 3. Drive clutch out of balance Problem: Driven Pulley Vibrates Condition 1. Sheave rivets loose broken 2. Driven pulley out of balance
Remedy
1. Clean drive clutch components 2. Clean driven pulley components

3. Decrease spring preload tension 4. Clean - replace bea ring - movable sheave
Remedy 1. Adjust offsel 2. Repair - replace - clean drive clutch/driven pulley 3. Service driven pulley 4. Clea n - replace bea ring - movable sheave Remedy 1. Clea n - replace drive clutch co mponents 2. Replace drive belt
Problem: Excessive Belt Drag-Impaired Drive Clutch Disengagement
Problem: Engine RPM Suddenly Increases-Drive Clutch VIbrates Remedy 1. Replace pin 2. Replace ca m arm 3. Align - replace co mponents - drive clutch
Remedy 1. Replace sheave 2. Service - replace driven pulley
8-144
Page: 594
Problem: Drive Clutch Engagement (Before SpecIfied RPM) Condition 1. Drive clutch spring weak - bent 2. Cam arms incorrect - worn Condition 1. Drive clutch spring incorrect 2. Spider buttons worn Problem: Drive Clutch Sticks Condition 1. Drive clutch components dirty 2. Movable sheave bent - binding 3. Spider buttons worn Problem: Drive Clutch Jerks-Shifts Erratically Condition Drive clutch dirty Rollers worn Cam arms rough Spider buttons worn 5. Sheaves dirty 1. 2. 3. 4. Remedy 1. 2. 3. 4. 5. Clean - drive clutch components Replace rollers Polish - replace cam arms Replace buttons Clean sheaves Remedy 1. Clean drive clutch components 2. Clean - replace movable sheave 3. Replace buttons Remedy 1. Replace spring 2. Replace cam arms Remedy 1. Replace spring 2. Replace buttons
Problem: Drive Clutch Engagement (After Specified RPM)
Troubleshooting Drive Belt

Problem: Dnve Belt Glazed Condition 1. Drive belt does not meet measurement specifications 2. Drive clutch spring tension inadequate 3. Drive clutch components dirty - damaged 4. Offset - parallelism - center-to-center distance adjusted incorrectly Condition 1. Drive belt does not meet measurement specifications 2. Offset - parallelism - center-to-center distance adjusted incorrectly 3. Drive clutch engagement - idle RPM too high 4. Drive clutch components dirty - damaged 5. Driven pulley/shaft rotation impaired 6. Drive belt damaged from improper break-in
Page: 595
Remedy 1. Replace drive belt 2. Replace drive clutch spring 3. Clean - replace drive clutch 4. Adjust offset - parallelism - center-la-center distance Remedy
1. Replace drive belt
Problem: Drive Belt Lugs Torn Off-Frayed-Worn In One Spot
2. Adjust offset - parallelism - center-to-center distance 3. Service drive clutch - reduce idle RPM 4. Clean - replace drive clutch components 5. Service driven pulley/shaft - chain-case components 6. Replace drive belt
8-145
Troubleshooting Hydraulic Brake System
Problem: Caliper leaks
Condition
1. Caliper Qring deteriorated 2. Piston - O-ring damaged Condition
1. Brake system air bubbles present
Remedy
seve red
1. Replace O-ring 2. Repair piston - replace piston - O-ring
Problem: Lever Spongy - Bottoms Out

Remedy 1. Bleed brake system 2. Replace master cylinder
2. Master cylinder damaged - faulty

Problem: Oscillation Feedback in Lever Condition
1. Brake pad residue prese nt on brake disc 2. Caliper loose 3. Brake disc wa rped - cracked - damaged misaligned
Remedy 1. Replace pads - clean disc 2. Tighten mounting bolts 3. Replace disc - drive n shaft bea ring
Problem: Loss of Brake Condition

1. Brake fluid overheated - co ntaminated 2. Master cylinder damaged - faulty 3. Caliper - brake hose leaking Remedy 1. Replace fluid 2. Replace master cylinder 3. Replace ca liper O-ring - repair piston replace piston - O-ring - brake hose 4. Remove obstruction - replace air ducts 5. Repair - replace lever - mounting bolt
4. Air ducts obstructed - missing

5. Brake lever linkage damaged Problem: Brakes Drag Condition 1. Master cylinder damaged - faulty 2. Brake disc wa rped - damaged - misaligned 3. Brake pads worn - tapered
Remedy 1. Replace master cylinder 2. Replace disc - drive n shaft bea ring 3. Replace pads
Problem: Snowmobile Won't Stop - Have to Pull Too Hard on Lever Condition 1. Padslbrake disc glazed 2. Brake lever binding 3. Caliper pistons binding Remedy 1. Replace pads - clean disc 2. Loosen pivot bolt - replace master cylinder 3. Se rvice ca liper assembly
8-146
Page: 596
SECTION 9 - TRACK/REAR SUSPENSION
TABLE OF CONTENTS
Undersla,nding the Suspension ............................... 9-2 Suspension Setup BasIcs ....................................... 9-3 Suspension Mounting Location Chart ., ................. .. 9-6 Chassis and Skid Frame
Mounting Locations ....... .. ..... ... ... 9-7 Servicing Chart ...... ......... ........... . ...... ........ .. .. .. ..... 9-11 Slide Rail Schematics ..... .. .. ..... ... ...... .......... ......... 9-12 Front Arm Schematics ........................................... 9-17
Rear Arm Schematics ......................... " ................ 921 Idler Wheels Schematics ....................................... 925 Repair Procedure 1 ........ ..... ... . .......... 9-30 Repair Procedure 2 .... ..... ........... ... .......... ..... ......... 9-61 Repair Procedure 3 ... ...... ......... ..... ......... ...... ......... 9-95 Repair Procedure 4 ............................................. 9-129 Drive Sprocket Locations .................................... 9-159 Drive Track Usage Chart ..................................... 9-1 66 Drive Track Lug Patterns ............ ......................... 9-168 Track Warranty Guidelines ....... .............. .... ......... 9-169 Idler Wheel Selection Chart ....... ......................... 9-170 Torque Specifications .......................................... 9-172 Rebuildable Shock Accessory Part Numbers ...... 9 -173 Shock Absorber Usage Guide ............................. 9-175 Rear Spring Selection Chart .... .............. ............. 9-178 Front Suspension Ski Springs .... .................. ....... 9-180 Front Suspension Sway Bar ....... ......................... 9-183 Rear Suspension (Front Arm Springs) ................ 9-1 83 Suspension Stiffening Kits (AWS VI Models) ...... 9-1 83 Standard Shock & Spring Chart 2005 Models .. 9184 Optional Rear Arm Spring Chart - 2005 Models . 9-185 Rebuildable Shock Tools Required ............. .. ....... 9-186 Rebuildable Shock Rebuild Kits .. ........... ............. 9-186 2005 Rebuildable Shock Specifications .............. 9 187 Servicing IFP Style Shocks ........................ .... .... 9190 Servicing Position Sensitive Shock ..................... 9194 RebuildinglRecharging Fox Air Shocks ...... .. ....... 9-199 Servicing Fox Zero Pro Shock Absorbers ........... 9-205 Installing Internal Travel Limiting Spacers .. .. ....... 9-21 0 Servicing Rebuildable Shocks & Remote Reservoir ......................................................... 9212 Bearing Cap and Shaft Seal ................................ 9216 Shaft Eyelet ............... ............................. ............. 9-217 Ski Shocks Bottom-Out Bumper.......................... 9-217 Pressurizing Rebuildable Shocks ........... ............. 9-218 Troubleshooting Track ......................................... 9219
Page: 597
91
Understanding the Suspension

GENERAL
Q uick acceleration and the abilit y to go through the turns with power are the most impC lI1ant handling qual ities. Thi s sect io n explains how the skid fram e func tions to provide these Iwo impOJ1anl handling qlL:'l lities. Before proceeding, however, note these terms.
Weight Transfer - A shift in the center of grav ity in any direction depends on the force applied. Track Tension - The amount of tightness or looseness or the track when correctly mounted in the chassi s.
Spring Tension - The amount of force exerted on the spring by either fork tension adjustment o r eye bolt adjustment. Ski Pressure - The a moun t of fo rce exerted downward o n the skis.
Good weight transfer characteristics arc needed for fa st acceleratio n (shirt o f weight from ski s to track) and for cornering (shirt o f weight baek to skis to hold the fro nt end in turns) . Effective weight transfer depe nds on SllSpension te nsio n, position o f rider, and the position of the front arm limiter. To understand how the suspension system works, think of the e ntire systc m in ter ms o f three points; the skid frame rear ax le center, the skid frame front arm, and the ski saddle center. Assumc that the front arm fun ctions as a stat iOnary pi vot point between the rear axle cente r and the ski saddle center. Also assume that the ski saddle center is the same height off the ground as the rear axle center. This proollces the standa rd positio n arrangement.
0728-190
Undcr acceleratio n when the center of gravity is lransferred to the rear o f the machine, the rear sllspe nsio n collapses slightl y. This brings the rear arm point downward and with the fro nt arm statio nary, the teeter-tolter effect reduces the pressurc on the ski s, position A. However, for contro ll ed corne ring, more pre ssurc is needed on the ski s. So w hen the driver dccelerates coming into a corner, the cente r of grav it y is tra nsferred fo rwa rd , puuing thc rcq uired pressure on to the ski s and reduci ng the pressure o n the rea r suspensioll , IXlsition C.
0728-181
T hi s is essentially w hat weight transfer is all about the shift o f weig ht to the rear of the machine for IXlsiti ve tractio n and good acceleration or to the front of the machine for IXlsitive handling and cornering control.
92
Page: 598
Suspension Setup Basics

FRONT ARM SPRING TENSION
NOTE: Read the following information closely as
it pertains to all suspensions used in the last
sev~
FRONT ARM LIMITER STRAPS

Under no circ um stances sho uld the front arm li miter strap be lengthened. If lengthened , it may calise shock absorber travel problems. The two limite r straps o n AWS model s can be sho rt cncd if dcsired. T his adj ustmcnt must be made to suit dri ving style and some test driving time. Wit h thc rear ann in its present mounting location, no advanl"age has becn no tcd from c ha nging the strap length. If thc fro nt arm straps a re shortcned, thc result will bc more ski pressure and aggressive stecring.
eral years, If there are any questions, please contact the Arctic Cat Service Department.
It is desirable to fUll with vcry li g ht front arm spring tens io ll . Whell ridin g in4 in . or more of snow, th e machine wi ll be quicke r if the front sprin g tensioll is adj usted lightly.
If the spring tension is adjusted too stifr, the track anglc at the front o f the skid frame is steep. Thi s sleep angl e prevents the snowmobile from getting lip on plane and slows dow n by 510 8 mph. When riding in sticky snow (springtime o r warm days) o r hill climbing Oil hard snow, it may be desirable to stiffen the front arm spring tensioll. Whe n thi s is dOllc. wcight is transfcrrcd back qui c ke r. Thc problc m wit h too much front ann spring tension is that thc fccl ofthc snowmobi le becomes \'e ry short . T he reason for thi s is the front arm beco mes the pi vot point bet wee n the spindles and rear of the machine. With dominant spring tension o n the front arm , the suspe nsion is basicall y contacting the snow from a po int below the front arm to the ski s or the spind le pressure point. Thi s makes for a very s hort and darting machine on the trail. Thi s is espec iall y true whe n decelerating and the cent e r of gravity is transfcrred fo rward . A good method for adjustin g thc front spring tcns ion fo llows. NOTE: On those models having a coil spring over the front arm shock absorber, the spring ten sion should be set as soft as possible when oper ating on trails and in deep snow,
SKI SHOCK ABSORBER SPRINGS

T he shock absorber springs havc been matc hed to the shock valving and rear suspe nsion. These springs arc the result o f hours o f testing and compari son riding trying many diffcrent combinati ons of springs and shocks. If there is a need to make changcs, therc are sevcral spring a nd shoc k sizes to choose from . W hile maki ng these changes, keep the fo llow ing points in mind.
Heavier Or Stiffer Springs

I. These wi ll require shocks with more rebound control, or the front cnd wi ll becomc like a IX)go stick.
2. With stiffer springs, the front end wiil become more aggressive in the corne rs as more weight will be transferred to the ski s when decelerating. Also, more weight is transferred to the rear on accele ration and can cause the rear shocks and spring to bottom o ut.
3. If the springs are too stiff for general riding

conditions and sty le, the ride comfort is gone.
Spring Tension Too Soft

I. Front e nd bottoms out: hard on front e nd p..1 11S.
2. Less aggressive steering III corners on dcccleratio n, and less wcight is transferred to thc skis because of soft er springs.
3. Less weight gets transferrcd to rear of thc machine

lIpon acceleration . NOTE: When softening the ski springs, also soften the rear to match entire suspension,
0729-662
& CAUTION
If the ski shock spring is adjusted too loose, the spring retainer may fall out. If the spring is adjusted beyond specification , the spring will coil bind and spring adjuster damage will occur.
Page: 599
93
ADJUSTING FRONT SHOCKS (Fox Air Shocks)

The air shocks are individuall y adjustabl e for the te rrain conditi ons a nd drivin g style o f the o perato r. The shocks are preset at 3 .5 kgfcm2 (SO psi) as an initial setting (4.2 kg/cm2 (60 psi) o n the M7 LE); however, it is poss ible to " fin e tunc" the shocks to malch the operator's weight, riding sty le, and tcrrain conditions. NOTE: Care should be taken to have equal pressure in the shocks before operating the snowmo-
NOTE : It has been our experience that a tight front arm works well under only two conditions: sticky snow conditions in the spring of the year and in hill climbing on hard packed snow. It has also been our ex perience with A FS model s that with the front a nn adjusted too soft , the sprin g ma y come off the roller. There haven't been any other pro blems in handling caused by a soft front arm.
REAR ARM SPRING TENSION

T he rear spring tension is adj usted for the weight of the dri ver. T here arc three possible adjustments. I st block posi tioIl- set fo r up to ISO Ib 2nd block position - set for ISO to 200 Ib 3 rd block position set for over 200 Ib
bile. To increase o r decrease air pressure, use the following

procedure.
NOTE: Adding air pressure will increase the air spring force; reducing air pressure will decrease air spring force.
Adjusting
Cam
I . Remove the air val ve cap from the shock.
2. Thread the valve of A ir Shock Pump ( pIn 2603-
324) onto the shock air val ve approximately six rotations. NOTE : As the pump is being attached to the shock, the hose will fill with air. This will result in a lower gauge pressure 0.143.52 kg/cm 2 (2-5 psi). 3. To deClease air pressure in the shock, press the black bleed valve butto n half way down and hold until desired pressure is attained. _NOTE : Pressing the button fully down and releasing it will allow only a small amount of air to escape (micro-adjust). 4. To increase air pressure in the shock, pump until desired pressure 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. 6. Install the air valve cap onto the shock.
721-720A
REAR ARM MOUNTING POSITION (Bet"ween Rails)

There are several mounting holes found in the rails for installing the rem arm. T he holes have been added to the suspension to prov ide adjustment to fin e- tun c the s uspens ion to dri vin g styles. If the ride is too so fl , m ov in g the rea r arm ba c k bel ween the rail s wiII stiffe n the ride. By mov ing the rear arm forward. it will collapse quicker and allow more transfer of weight to the back of the suspension. This will also affect the handling by providing a softer ride and also easie r steering. T he drawbacks of moving the rear arm forward are that the suspe nsion may bottom out quicker and some travel is lost. NOTE : When making any changes to the front or rear suspension, the change should be made at both ends to keep the suspension balanced . For example, installing stiffer springs in front may require installing the next step stiffer spring in back to keep everything in balance.
FRONT ARM SPRING TENSION TOO STIFF

I. Slows machine down in loose snow. 2. C1uses the machine to dalt and dive as a result of less track on the gro und on deceleratio n.
94
Page: 600
ADJUSTING REAR ARM COUPLER (Groove Style)

NOTE: The couplers are installed in the 2groove position at production.
The rear arm coupl er prov ides ad vantages over the
3 . Place a 4-in. block o f wood under the rear of the s uspe nsion just in fro nt of the rear idler wheels. This will assist in collapsing the suspe nsion. 4. Collapse the rear suspension until the rear arm is firml y against the couple r blocks. This will align the two blocks squarely with the arm . W hile in this lX)sition, tighten the two cap screws securing the bl ocks.
standard s uspe nsio n. First, with the co upl er system , ski lift under accele ration is g reatl y reduced whic h provides improved handling. Second , whe n riding thro ug h rough te rrain , the rear s lispe nsio n arm receives some needed ass istance
from the front arm shock and spring. Thi s happens as
ADJUSTING REAR ARM COUPLER (Number Style)

The rear arm coupl e r prov ides ad vantages over the standard s uspe nsio n. First, with the coupler system, ski lift under accele rati on is g reatly reduced whi c h prov ides impro \'ed handling. Second, when riding thro ugh rough terrain , the rea r suspe nsio n arm receives some needed a ss istance fro m the fro nt arm shock and s pring. Thi s happe ns as th e rea r a rm is full y collapsed a nd loc ked up by the coupler blocks. The front arm then starts to collapse the shocks and s pring which ass ist the rear s prings. The result is a smoother ride fo r the ope rato r.
the rear arm is full y co llapsed and locked lip by the

coupler blocks. The front arm then starts 1 0 collapse the
shoc ks and spring which ass istlhe rear springs. The

result is a smoother ride for the o perator. Each of the coupl er blocks has fo ur positio ns (notched g roov es o n the o Ulside s urface o f the blo ck). W he n c hanging t he bl oc k positi o n, c hange both to the same groove number. To make coupler adjustme nt, fo llow the procedure below.
I. Using a 9/16- in. wrench, loosen the two cap
screws tlk'lt secure the coupler blocks to the inside of the sus pension rail s. 2. Rota te the coupler bl ocks to the desired lX)siti on making sure both are set the same.
If additi o nal co upl e r acti o n is d es ired , the co upl e r blocks can be sct to the number 2 or 3 1 X)sitioll. B lCh o f the coupl er bl ocks has three IX)sitio ns num bered o n the inside s urface o f the bl ock. W hen c hanging the bl ock lX)sitio n, change both to the same number. To make the coupler adjustment, fo llow the procedure below,
1. Using an 8 mm Allen-wre nch, loosen the two cap screws that secure the coupler blocks to the inside of the sus pension rail s. 2. Rotate the coupler blocks to the desired lX)sition making sure both are set the same.
Rear Arm
'-
(1,2,01' 31
.......
Idler Arm
7382306
NOTE: When setting the block, the chosen groove position must be directed toward the idler arm.
738230A
3 . Place a 4-in. block o f wood under the rear of the suspe nsion just in fro nt of the rear idler wheels. T his will assist in collapsing the suspe nsion. 4 . Collapse the rear suspension until the rear arm is firml y against the couple r blocks. This will align the two blocks squarely with the arm . W hile III this lX)sition, tighten the two cap screws securely.
738230C
Page: 601
95
Suspension Mounting Location Chart

NOTE: The Rear Arm Mounting Position refers to where the rear arm mounts into the tunnel. The Rear
Arm To Rail Position refers to where the lower po rtion of the rear arm mounts between the slide rails.
TRACK LENGTH & lUG HEIGHT
lS" xl56"xl.00" lS" xl36"xl.00"
IS' x 136" x 1.00"
MODEL
Bearea1570 Panlara Models
Panlher Models
SKID FRAME
Fasltack - Slamped Rail w~h Torque Link
FRONT ARM MOUNTING POSITION
REAR ARM MOUNTING POSITION
REAR ARM
SHOCK
LINK ROO LENGTH
12.60010. (320.04 mm)
TO RAil
POSITION
No AdjusUnent
Upper Upper
Upper
Running Board
Abow Running Board Abow Running Board Abow Running Board Abow Running Board Abow Running Board
Abo~
Abow
FaSirack Slam~ Rail wkh Torque ink

Faslrack Stamped Rail
No AdjuS1ment
No AdjuSlmenl
12.600 In.
(320.04 mm) 12.600 in. (320.04 mm) 11.750 In. (298.45 mm) 11 .750 in. (298.45 mm) 11.750 In. (298.45 mm) 11.750 in. (298.45 mm) 11.750 In. (298.45 mm) 11 .050 in. (280.67 mm) 11.050 In. (280.67 mm) 11 .750 in. (298.45 mm) 11.050 In. (280.67 mm) 11.750 in. (298.45 mm) 11.750 In. (298.45 mm) 11.750 In. (298.45 mm) 11 .750 In. (298.4S mm)
with Torque Link Z 3701370 LX/440 LX Models

Z 570 Models Sabercal Models (STO) Sabercat EXT Models Flrecal EXT Models Firecal Models (STD) Flrecal Sno Pro Models ZR Models (STD) ZR Sno Pro Models King Cat 900
lS" x 121"x.75O"
IS' xI21 x.85O" 13.5' x 128' x 1.00" 13.S' x t44' x 1.25' 13.5' x 144' x 1.25' 13.5' x 128' x 1.00' 13.5' x 128' x 1.375' 13.5" x 128' x 1.000" IS' xI21xl.00" IS" xI21xl.25 tS' x 162" x 2.25' IS" xI41xl.6O" IS' x 141 ' x 2.25' IS" x 153' x 2.25' IS" x t41' x 2.25' IS' x 153' x 2.25' IS" x 162" x 2.25'
FaSirack SlamITrd Rail wnh Torque ink Faslrack Stamped Rail wnh Torque link Faslrack Faslrack FaSirack Fastrack Fasllack Slamped Rail Stamped Rail Slamped Rail Stamped Rail Slamped Rail
Upper Upper Upper Upper Upper Upper Upper Upper Upper Upper Upper Upper Upper
Second Hole Back Second Hole Back Second Hole Back First Hole Back First Hole Back Second Hole Back Second Hole Back Second Hole Back Second Hole Back No Adjustment No Adjustment No Adjustment No Adjustment
Running Board
Abow Running Board Abow Running Board Abow Running Board Abow Running Board
Abo~
Faslrack Stamped Rail wnh Torque link FaSirack Slamped Rail wnh Torque Link Faslrack Stamped Rail wnh Torque link FaSirack Slam~ Rail wnh Torque ink Fastrack Stamped Rail wtth Torque link Fasltack Slame:;:: Rail wnh Torque ink
Running Board Below Running Board Below Running Board
M5
'" "'
Bek>.
Running Board Below Running Board
96
Page: 602
2005 A rctic Cat Service Manual - all models - www. ReadManuals.com
Chassis and Skid Frame Mounting Locations

T he suspe nsions have severa l possible mounti ng locations in the slide rai ls and tunnel. However, it is recommended by Arctic Cat Inc. that whell di sasse mbling a nd asse m bling the suspe ns ion , all stock mount ing loca tions be used as showil in the ro ll ow ing ill ust ra tions.
A CAUTION
It is extremely important that all stock mounting locations be used. If any alterations to the skid frame are made, shock absorber and suspension damage may occur.
Z 370/440/570 Models
0:
o.
......
Front SI\oO;k Mil HoI< ~
RN. SIIoc~
~. -
front Shock Mil
~
o
0
00.
R Nt
Shod< Mia Hole
Rea. Shot k Mta
.-
Sprinl Block MI& Moll Mil I rkl
Outslcle Idler _
D ',
:~
ReJ' Ann Mil Hole
Rubber Bumpe. M II.HoIts
739214A
FirecaVSabercat Models
' :' ...

F..... I ~ MI&-_ ~
"".,""" 101\1._
Front Shock Mil. Rea, Shock Mil.
ttou
a,_ Mil. _
I4Iot _
M il.
a_
.~-
._Z
--
-c:::::::> ..~
~.'-
Rut .... m tG<>pIot IIIodt
10111. _
..-
Ru, Atm M il. _

IcIItI WheoIMII. B_ MII. - '
1011&-_'
'--< ....10 101...
0739-202A
Page: 603
97
Fireca! EXT/Saberca! EXT Models
Ft,. Arm Mil. Britt.
, - "'. . .,~ Mil. Hok

, Block
,._
'.m ,~
,,_,
M IC _
MII_
739203B
Pantera/Panther Models
REAR ARM MTO HOLE FRONT ARM MTG HOLE
"
SPRING BLOCK MTG HOLE
REAR SHOCK MTO HOLE
FRONT SHOCK MTG HOLE
REAR SHOCK LINK MTG HOLE
r3
FRONT SHOCK MTG
IDLER WHEEL MTO HOLE FRONT ARM MTO HOLES
REAR SHOCK MTG
OVERLOAD SPRING MTG HOLE
IDLER WHEEL
MTG HOLE
00
IDLER WHEEL MTO HOLE

RUBBER BUMPEI' MTG HOLE
CROSS BRACE MTG HOLE

RUBBER BUMPER FRONT SHOCK BRACKET-LOWER REAR SHOCK LOWER AXLE MTG HOLE
.=
REAR ARM MTG HOLE
OVERLOAD SPRING TENSION BLOCK MTO
MfG HOLE
AXLE MTO HOLE
73S-31SA
9-8
Page: 604
Bearcat 570
'. . .
"
0 ,
. . . . .
' )C
~
Fronl Arm Mig. Hole
Rear Shock MIg. Hole ~ '>a Mig. Hole
.~
Rea' A ,m M Ho"
RearShoCklink~ /~
Front Shock Mil.
Fro nl Shock M ig. Hole
Cross Brace MIg. Hotes
Y1~ ~Ll
F S 'B ,.
Idler Wheel Mig. Holes
Front Arm Brk!. MIg. Holes ~e ar Spring BI~ek overroad"Sprme:, Mil . Hole _ ~
Overload Spring Btock MIg. Hole
2i\!:
M-Series
~ Rea r Shock MIl-
Idler Wheel Mig Hole
~ RearBumperMlg. Hole
'
~ ~~'-' := ) 0... . ~Rea;Arm Mlg. Hole

Idler Wheel Idler Wheel Rea r Shock L ower Axle M H. MIg. Hole Ig. 0 e
Rubber Bumper Mig Holes .
ron ""e r. lower Axle M Ig. H ole
0739989
Front Arm Mig. Hole
.. ~
,:',
, Q '
..
'0 '
..
Shock Mig. Hole

~ Real
Rear Suspension Mig. Blkt Arm, Pivot Idler Mig. Hole
. '
'
Real Shock Mig. Hole Shock Link Mig. Hole
~ Fronl
Front Shock Mtg. Front Arm Mig. Brkt. Mtg. Hole Rubber Bumper Mtg. Holes
Rear Shock Mtg.
Spring Block Mig. Hole Idler WheeVRear Shock Pivot Mig. Hole Crossbrace Mtg. Hole
.=
Crossbrace Mig. Holes Front Idler Wheel Mig. Block Mig. Holes Crossbrace Mig. Hole Fronl Shock Lower Axle Mig. Hole
=
Rubber Bumper Mig. Hole
:=
Crossbrace Mig. Hole (153',162' ) Rear Arm Mig. Hole

0739828
Page: 605
g.g
King Cat 900
_""_.f.F~'",A'mM~ H ,','" ~
Rear Suspension Mig. Brk! Arm, Pivot Idler MIg. Hole
~ Rear
Shock Mtg. Hole
~ Fron t Shock Mtg. Hole ~
r ~ o ~ Rear Shock Link Mtg. Hole
Front Shock Mtg.
Front Arm Mtg. Brkt.
Mtg. Holes
Rubber Bumper MIg. HOles \ \\
fi 0
Rear Shock Mtg.
Spring Bl ock Mig. Hole
Idler WheeVRear Shock

Pivot Mig. Hole
Crossbrace Mtg.
Crossbrace ~
H ote7
C""b,,,, Mtg. H ,'"
-----o.
J~C''''b''''~ L
Mtg. Hole
Mtg. Hole
Mtg. H ,',
"-
--~--0740127
---Rubber Bumper
.\
ZR900
".
o~
FRONT SHOCK MTG
REAR SHOCK MTG HOLE
'RO" SHOC"'GHOLE
REAR SHOCK LINK MTG H e U
tJ:0/
0
REAR S HOCK MIG

CROSSBRACE MIG H O LE REAR COUPLER
OUTSIDE IDLER WilER MTG H O LES
CROSSBUCUITGHOLES
RUBBER BUMPER MTG HOlES
:~~~~~:!~~~~~~~~~~~~~*:i:i~;~~;~~~;.r~(~~~~);:8LOCKMTGHOlE
o
0 0 000 0 0 00
fRONT ARM MTG HOlES IDLER WHEEL NIGHOLf
Cl 0
o.
0 0
REAR ARM MIG MOLE REAR SHOULOWER M IG AXLE HOLE

RUBBn BUMPER MTG HOLES
FRONT SHOCKLOWER AXlEillIG M OLE
737-323C
910
Page: 606
Servicing Chart
Thi s c hart is designed to direct the technician to the appropriate S kid Frame Schematics and Repair Procedure for servicing the rear susp;:: nsio n. Select the snowmobi le model fro m the li st and f oll ow the chart to
attain schemati c designatio n and repair procedure.

Snowmobile Models Slide Ratl Style Front Arm Style Rear Arm
Style
Idler Wheets Style
Repair Procedure
Bearcat 570
Firecat (STD)
A
D E D B B B
A
D E D B B B
Firecat Soo Pro Firecat EXT M5 M6 M7 King Cat 9001900 EFt Pantera 550 Pantera 600 EFt Panther 370 Panther 570 Sabercat (STO)II...X Sabercat EXT
F G H B B B C D D D D F H
C F G F
D D D E B B B B F
2
4 4 4 4 4 4
C A A A A
D D
C A A A A
D D
3 2 2 2 2
4 4
Z 3701370 LX
Z 440 LX
Z 5701570 LX ZR 9001900 EFt

ZR 900 Soo Pro!900 EFt Sno Pro
A A A
I J
A A A
F G
A A A
F G
A A A
H I
, , ,
3 3
Page: 607
9-11
Slide Rail Schematics
NOTE: Some components illustrated in this sub section may vary from actual cond itions. The tech nician should use discretion and sound judgment when removing and installing components.
KEY 1. Formed Rail
Style A
2. Rail S upport
3. Lock Nut 4. Washer 5. End Cap
6. Cap Sc rew
7. MachineScrew 8. Wear Strip
,..
"-
... " ... "... ...

.
". "-
9. Cap Screw 10. Rivet 11. Bracket

Shock Pad
Cap Screw
Bracket Lock Nut
Cap Screw
Axle
Cap Sc rew
Adjuster Track Assy Wear Clip .... /Guide
0739432
KEY 1. Formed Rail
Style B
7. End Cap Nut Lock Machine Screw WearSltlp ...
2. Rail Support 3. Spacer Spacer S. Cap Sc rew Washer
,.. ". Cap Screw ". ,..

22.
... ... ... ". ... ... ...

"-
Cap Sc rew Rivet
Shoek Pad Retaining Bracket
Inse rt
Axle
H . Cap Screw
Loek Nut Pod Machine Screw Track Adjuster Track Assy
Guide Clip
912
Page: 608
KEY
,. ,. ,.
Formed Rail - Stamped
Style C
Rail Support
Spacer Spacer
5. Cap Screw 6. Washer ,. ,. Lock Nul

End Cap
". ". Look Nul ". ". ". ". ,,. Lock Nul ". ". ".
Axle
". ". ". ". ".
9. Machine s<:rew
Wear Strip
Cap Screw
Rivet
Shock Pad Retaining Bracket Mounting Bracket
Cap Screw
Cap Screw
Shock Pad Machine s.::rew
Track Adjuster Cap Screw
25. Track Assy 26. Guide Clip
0739-702
KEY
,. ,. ,.
Formed Rail
Style D
Rail Support
6. s<:tew ,. Machine Sc rew ,.

Cap WeerStrip
Lock Nut Was her 5. End Cap
". ". ". ". ".

". ". ". ". ". ,,.
9. Cap s<:tew
Rivet
Bracket
Shock Pad
Lock Nut Bracket

Cap Screw Cap Screw
19
Tension Block Lock Nut Lock Nut
30
". ". ". ". ".

". ". ". ".
20. Shock Pad Machine Sc rew
Rear Arm Stop Cap Screw

Cap Screw
25. Washer
Couplet Block
Bushing
28. Lock Nut Cap Screw Track Adjuster
Track Assy
GuideClip
0739-484
Page: 609
9-13
KEY 1. Formed Rail
Style E
2. Rail Support 3. Look Nul 4. Washer

5. End Cap
6. Cap Sc rew
7. MachlneScrew 9. Wear Strip
9. Cap Sc rew 10. Rivet

11 . Retaining Bracket
12. Pad 13. Mounting Bracket

14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. Lock Nut Cap Screw Cap Screw Tensio n Block Lock Nut Look Nut Pad MachineSc rew Cap Screw Arm Stop Cap Screw Track Adj uster Track Assy Wear Clip GuideClip
' fiJb
11
12
27
::'7-~ ~"::5~~
8 7
,.
0739-509
KEY
1. Formed Rail
2. Rail Support
Style F
3. Cap Sctew
4. Spacer
5. Cap Screw 6. Washer
7. 8. 9. 10. End Cap Look Nut Machine Sc rew Wear St rip
". ". Bracket
11 . SOlid Rivet 12. Pad

Push Nul Cap Screw
". ". 23. Bushing ". ". 27.
20. Cap Sctew

Washer Coupler Block
". ". ". ". ""
Look Nul Bracket
H . Rivet
~5 3
L"
24. Look Nul

Track Adjuster Cap Screw Track Assy 28. Guide Clip
0739681
914
Page: 610
KEY 1. Formed Rail 2. Axle
Style G
3. Cap Strew
4. 5. 6. 7. 8. Spacer Cap Screw Washer End Cap Look Nut
,. Machine Screw ". ". Rivet

Wear Strip
12
Po, ". ".

16. 17. 18. 19. 20.
11-",
J3-----,p
~
Push Nut 14. CapScrew 15. Mounting Bracket
3../
Look Nul Rivet Retaining Bracket Pad Cap Screw
'"
1i:!::~~
2
4
21 . Washer
22. Coupler Block

23. 24. 25. 26. 27. Bushing Lock Nut Track Adjuster Cap Screw Track Assy
28. Gulcle Clip 29. Wear Clip
q;;v
.
5~_.
10 ' - - -9
0739-771
KE Y 1. Formed Rai l 2, Rail Support
Style H
3. 4. 5. 6. 1. 8. 9. 10. 11 . 12. 13.
Cap Screw Spacer Cap Screw Washer End Cap Lock Nul Machine Se rew Wear Strip Rivet Push Nut Pad
20. Track Adjuster 21 . CapScrew 22, Track Assy
23. Gulcle Clip
5 JItifl
10
:~j
9 -1
/" ~3
0739-683
Page: 611
9-15
KEY
I. Form rt 2 Rail Suppa

Lock Nut Washer End Cap Cap Screw Wear Strip Machine Screw Cap Screw
ed Rail
Style I
,.
3: 4. 5 6" 7' 9.
to. Rivet
11 Bracket 12: Shock Pad 13. Bracket
14. Look Nul

15. 16. 17 tS: 19. 20. Cap Screw Brace Cap Screw Lock Nut Cap Screw Axle
21
22' 23: 24. 25
Rivet
Shock Pad Push Nut Cap Screw Washer
Coupler Bloc ". 27. Bushing 28. Lock Nul

29 Adjuster 30' Cap Screw ,, ' Track Assy
Weare 0' 32. 'P
... _
W/GUlutS
0739-604
KEY 1 Form edRail
Style J
2: Rail Support
3. Lock Nut 4. Washer 5 End Cap
6 : capsct~
10.
11
7 Wear Stnp s " Machine Screw
9: CapScrew
Aetam Shook Pad 12, 13. Moun tlng Bracket 14. Lock Nul
RIV~
ing Bracket
15. 16. 17. 18.
Cap SCrew Brace Cap Screw Cap Screw
19. Axle
20. Rivet
"
22: Push Nul

25. Coupler 61
Pod
23. Cap Screw 24. Washer ock 26. Bushing Lock Nul 27. 28. Trac k Adjuster
29. Cap Screw

30. Track AS~Y 1 GuideChp
~2:
Wear Clip
0739-630
916
Page: 612
. Manual - al I m odels 2005 Arctic Ca t Service
Front Arm Schematics
KEY
1. Front Arm
Style A
,.
2. Grease Fitting Bushing
4. Beating 5. A_ Ie Tube
". ". ". 13. l ock Nut ". ".
,. Cap Screw 9. l ock Nut

Shock Absorber Bushing Ax le Cap Screw Cap Sc rew
6. Axle Washer
, - - -'
". ". ". Spring ". Limiter S trap ".

Retainer Sleeve 20. Retainer Nul Shoc k Cover
16. Ax le H. Lock Nut
:---' 0-" r(~ 3 6~ W ~ !8~

5 19
11
21
25
~\ ,
;:::;--16
,",,,,15 "it
9 27 10
28 Y~
30~
"'. ". Washer "'. 29. "'.

KEY
1. 2. 3. 4. 5. 6.
24. Lock Nut 25. Washer
29------' f'1'
Cap Sc rew Inner Axle

L ock Washer Cap Sc rew
Y;
14
~ 12 lll~~
0739434
\l
,.
13.
". ".
".
17. 19. 19.
Front Arm Washer Grease Fitting Bushing Bushing Ax le Ax le Cap Screw 9. Cap Screw
Style B
Washer
Lock Nul Adjuster Knob Washer Limiter Strap Wing Nut Lock Nut Cap Serew Cover Spring
". ".
16.
20. Lock Nul

21 . Retainer 22. A_ Ie 23. Cap Screw
24. Shock Absorber
13
11J"
0739841
Page: 613
9-17
KEY
1. Front Arm
2. 3. 4. 5. 6. Grease Fitting Bushing Cap5erew Allie Washer
Style C
7. look Nut
8. Cap SCrew
9. Spacer
lock Nul Shook Cover Spring Shock Absorber u. Cap Sc rew A_Ie Retainer H. Cap Sc rew Washer Look Nul 20. Wing Not Adjuster Knob n. Limiter Strap 10. 11 . 12. 13.
". ". ". ".
".
0739-961
KEY
1. Front Arm 2. Bushing 3. Lock Nut 4. Cap Screw
Style 0
5. Spacer 6. Cap SCrew 7. Cap SCrew
". ". Cap SCrew ...

LOCk Nut
Washer
8. Washer Limiter Strap
". lock Nut ". Retainer ". Cap Screw ".
Shock Absorber
Lock Nut Spring 20. Cover
". ".
H. Axle
0739-744
918
Page: 614
'" Front Arm ,. ,. ,. Lock Nul

L
Bus hi ng
Style E
Lock Nul ". ". ". look Nul ". ". ".
,. ,. W asher 9. limiter Strap

Cap Sc rew Cap Sc rew Cap Sc rew Washer
Shoc k Absorber Retainer
Cap Screw 5. S"'~
0\
10
". H.
". ".
Cap Screw
A_ Ie
Loc k Nul
Spring
20. Cover
0739-860
KEY
Style F
Fro nt Arm Grease Fitting
,. ,. ,. ,. ,.
Bushing Washer
5. Lock Nut
Axle
Washer
Cap Sc rew Cap Sc rew
...
". ". "'.
n
H.
s.
". ". ". Rivet ". Retainer ". ". Axle

n.
Washer
Spacer
Lock Nut G uide Bumper Sllook Absorber
Cap Sc rew
LOCk Nut Spring

Shock Cover Cap Sc rew
". ". ". ". ".
l ock Nut limiter S trap

Cap Screw Adju ster
LOCk Nut
0739-607
Page: 615
9-19
KEY
,.
Style G
Front Arm
2. Grease Fitting
Washer ,. lock Nut Axle 7. Washer Cap Screw Spacer ...
Cap Screw
3. Bushing
...
,.. ". Clamp

". ". 29.
... ". ... ... ". ... ... ...
Lock Nut Guide Bumper
Rivet
Shook Absorber Retainer Cap Screw H. Axle Lock Nut Spring Cover
22. Cable Tie n. Umiler Strap

Cap Screw
28 19 23
~22
25. Washer
Cap Screw Lock Nut Adjuster
" J'
2S
26. Lock Nut
~2S ,.-26
'"
21~/
920
Page: 616
Rear Arm Schematics
KEY 1. Idler Ann 2. Bushing
Style A
"" 15 29 ~.::::. r24 28 21 ..
... ". ". ... ... ". ... ...

".
". ". ".
,. Grease Fitting Arm ,. Rear WaSher Nul ,. Lock Bushing A. le TUbe 9. Cap SCrew
~20
11
...
KEY
'" ".
Washer 11. Cap Screw A. le Adjuster Block Ring 15. Sleeve Spring Idler Wheel Bearing Ring 20. Spacer 21 . A. le Washer Pivot Arm Bushing 25. CapSCtew Lock Nul "- Washe r 28. Look Washer 29. Cap SCrew Cap SC rew Ax le Link
22 21J
24
~13 ~
26 19
/~
",
18' i
". ... ". ". ... ...
Spacer Lock Nut OS. Cap Sctew Lock Nut Shock Absorber Sleeve Bushing
0 739435
1. Idler Arm 2. BUShing 3. Was her 4. Grease Fitting 5. Rear Arm 6. Cap SCrew 7. Washer B. Bushing 9. Axle Tube 10. Lock Nut 11 . Cap SC rew 12. Axle 13. Adj uster Block 14. Ring 15. Sleeve 16. Spring 17. Id ler Wheel 19. Bearing 19. Ring 20. Spacer 2 1. Axle 22. Washer 23. Pivot Arm 2 4. Bushing 25. Cap Screw 26. Lock Nut 27. Cap SC rew 2B. Cap Screw 29. Axle 30. Link 31 . Sleeve
Style B
/ :, /~<II1\t/>;;.;~
~~?j~~'~"~ ~
J"
.<..r
,,-'1>-
,,----'
32. 33. 34. 35.
Look Nul Lock Nul Cap SC rew Shock Absorber
0739B42
Page: 617
9-21
KEY
".
20. Axle 21 . Washer 22. Pi vot Idler Arm

Bushing
... ... ... ... ... ". ... ...
,. Rear Arm S. Cap Screw ,. 9. Look Nut

5.
Bushing
1. Idler Arm 2. Bushing
StyleC
Washer Grease Fitting
Axle Tube
Cap Screw
Axle
12. Spring Block Retaining Ring
Sleeve 15. Suspension Spring

Idler Wheel Bearing
Retaining Ring
S""~
2<. Cap Sc rew
25. l ook Nut 26. Cap Screw
",..
,.. ...
".
KEY
Cap Sc rew Link Axle 29. Link
Sleeve lock Nul
32. Cap Sc rew Shook Absorber
0739-558
Retaining Ring 20. Sleeve
... ... ... ... ... ". ... ...
1. Idler Arm ,. Bearing Grease fitting l ook Nut ,. Bushing 9. Axle Tube
Bushing
Style 0
3.
5. Rear Arm
Washer
Washer
Cap Screw 12. Cap Screw l oc k Nul

A xle
15. Adju ster Block Retaining Ring

Idler Wheel Bearing
21 . Suspension Spring
".
22. Washer Look Washer 2< . Cap Screw

25. Axle 26. Cap Sc rew
",..
.
" ...
Link Link Ax le 29. Sleeve
Lock Nul Cap Sc rew 32. Shock AbSOrber
0739-687
922
Page: 618
KEY
,. , . Grease Fitting 5. Rear Arm . lock , Bushing A. leTube ... " . Cap Screw ...
Idlet Ann
Bushing Bearing Washer
Style E
Nul
Washer
Cap Sc rew
lock W asher ". Cap ,.. Screw
". ... ". ". ". "". ".
". ... " ... ". ... ...

.
Look Nul
Axle Adjuster Block Retaining Ring Idler Wheel Bearing Retaining Ring
Sleeve Suspension Spring

Washer
Ax le
Cap Sc rew
Link Link Ax le
". '" Shook AbSOrber ".

Lock Nul Cap Sc rew
0739-851
Sleeve
KEY
,.
. ,.
Style F
Idle r Arm Bushing Grease Fitting Rear Ann Cap SCrew
". ,..
". ... ". ". ". ". ". ". ".

".
... ". ... ". ... ". ... ". ... ...
Washer ,. Washer ,. Bushing Axle Tube

Lock Nut Axle Ring
Cap S<:rew
Adluster Block
Sleeve Spring
Idle r Wheel Bearing
Ring
Axle Washer
Spacer
". ". washer

Link
Axle
Pivot Arm Bushing
Cap Screw Lock Nut Lock Was her Cap Screw Cap Screw
". ,..
34. Lock Nut

Lock Nut Cap Screw
Sleeve
". ".
Spacer
Shook Absorber
0739-608
Page: 619
9-23
KE Y
Idlet Arm G rease Fitting Rear Arm
,.
Style G
,. Washer ,. 6. A_ Ie Tube ,. ,.
Bushing
2. Bushing
Cap Screw
".
Ring 20. Spacer Ax le
". ". ". ". S leeve ". ". ". Bearing ". ".
Axle
9. Washer 10. Look Nut

Cap Screw
Adjllster Block Ri ng
Spring Idlet Wheel
". ". 25. Cap Screw

Pi vot Arm Bushing
22. Washer
". Loc k Washer ". 29. Cap Sctew 20. CapSctew ,,. Link Shook Absorber ". ". Spacer ". ". ". Lock Nul
Washer Ax le
26. Lock Nut
Cap Sc rew
Sleeve
".
Lock Nul
".
0739-634
924
Page: 620
Idler Wheels Schematics
KEY 1. Cap S<:rew
Style A
Lock Nut Mounting Block Idler Wheel Mo unting Bracket Axle 20. Washer
... ".
,. s. Beating 6. Cap Screw ,. Washer 9. Pivot ". ". ".

Lock Nut
2. Washer Idler Wheel Retaining Ring
Mounting Block
Grease Fitting Washer Axle
". 16. ". ". ".
Cap Screw
"'. ". 28. Spacer "'.

KEY
29. Washer Spring Slide 25. Slide Block Axle Washer
Cap SCrew ". ". ".

Cap Screw
31. Nut
32. Cap Screw

33. Idler Wheel
29. Idler Wheel

Bushing
34. Cap Strew 35. Cap
0739433
Cap Screw 2. Washer
3. Idler Wheel
,. Cap S<:rew
8. Lock Nut
Bearing s. Retaining Ring 6. Mounting Block
...
16. 20.
U
". ".
9. Cap
Cap S<:rew Washer Moonliog Block Idler Wheet Bracket Axle Lock Nut Pivot Grease Fining Washer Axle Spacer Spacer Washer Idler Wheel Insert Bearing Retaining Ring Insert Axle Spacer Cap s<:rew Axle
". "" Cap Screw ". ".
35. Idler Wheel M. Adjuster Bushing 38. 39. Idler Wheel

Overload Spring Assy Wear Block Machine Screw Lock Nul Retaining Clip Was her Bushing Spacer Spring Slide Was her
". Spacer ".
Was her
Style B
". ". ". ... ". ".

22.
". ". ". os. ". ".

". ".
". os.
28. 29. 30.
23.
"'. ".
". ".
0739485
Page: 621
9-25
KEY
1. Cap serew ,. ,. ,. Bearing ,. l ook Nut Cap S<:rew ...
Was her Washer
Idler Wheel
Retaining Ring
Mounting Block Cap Screw
... ... ... "... ... ...

"-
11. Mounting Block

Idler Wheel
Bracket
Axle 15. Lock Nut
Washer
Idler Wheel Insert Bearing
... ". ., ... ". ... ... ... " ... ...
. .
,.. " . N", ,..
33. Spacer
Idler Wheel Adjuster Bushing
Style C
37. Cap Sctew

Idler Wheel
Cop
Overload Spring Assy

Wear Block
Machine Screw
Lock Nul
Retaini ng Clip Bushing Spacer
45. Washer
Spring Slide
Washer
Retaining Ring
Space!"
". ". ,..

".
". Axle ". Spacer

Cap S<:rew
Spacer
21 . Insen
"
Axle ". Pivot ,..
...
29. Grease Fining Washer
".
Axle
Was her
0 739-5 10
KEY
"'. "". ". ". ". ,.. ". ,.. ,.. ... ". ". ,..
... ". ... ... ... ... ...

"-
,. 3. ,. Washer ,.
Was her Axle
1. Cap Screw
Style 0
Spacer Lock Nul
Mounting Block
Idlet Wheel Bearing Retaining Ring
11 . Cap Screw Was her

Cap Screw Was her
15. Spring Slide

Slicle Block Cap Sc rew Was her
Spacer Washer
Idler Wheel Insert Bearing
Retaining Ring
Insert Axle
Pivot
". ...
Idler Whee l
Bushing
Grease Fitting Was her Spacer Lock Nut 32. Washer Spacer Axle
". ... ". ...
". 39. N",
37. Spacer Lock Washer

Cap Screw Idl er Whee l Cap Screw
C'p
926
Page: 622
KEY
". ". Washer ". CapSctew ". ".

Washer
,. CapScrew ,. ,. Washer ,. ,. Spacer ,. 9. Bearing

1.
Washer A xle
". "'. ". ".
Bushing Spacer
Lock Washer
Style E
Lock Nul Mou nting Block Idler Wheel Retaining Ring
41. CapSc rew
...
No<
Idler Wheel
39. Cap Screw
42. Cap
Cap Screw
15. Spring Sli de
". ". ". ". ".
". ". Washer

25. '~rt
Axle
16. Slide Block n . Cap Screw

Washer Spacer
Idler Wheel Insert Bearing Retaining Ring
". 27. Pivot
". ". ".
". ". Spacer
29. Grease Fitting 29. Washer

Spacer Washer
Ax le Idler Wheel
0738-916
KEY
Style F
Was he r Idler Wheel Bearing Retaining Ring Loc k Nut
,. ,.
1. CapScrew ,. ,.
33 . Spacer 34 . Lock Washer
35. Nul 3S. Cap Screw
". ". S,.,M "- Was her "l oc k ". ". p,,,,, ". "- Grease FItting ". ".
Was he r
,. 9. CapSerew
Ax le
6. Mounting Block Cap Screw
Nul
Axle
Was he r Bearing
20.
S,.,~
". ".
"'. "-
". ". Cap Screw

25. Ax le
"-
Slide Block Spring Slide Was he r
"'. ". C,p
Spacer Idler Wheel Adju ste r Bushing 29. Adjuste r Bushing Idler Wheel
".
Cap Sc rew
0739684
Page: 623
9-27
1. CapScrew 2 . Washer 3. Idlet Wheel 4. BearIng 5. RetaIning Ring 6 . Mounting Block 7. lock Nut 8. CapSctew 9. Cap SCrew 10. Washer 11. Spacer 12. Washer 13. A_Ie 14. lock Nut 15. Axle 16. Pi vot 17. GreaseF'nl 1 I ng 8. Washer 19. Bearing 20. Spacer 21 . Slide Block 22. Spring Slide 23. Washer 24. Cap SCrew 25. A_ Ie 26. Spacer 27. Idler Wheel 28. Bushing 29. Bushing 30. Idler Wheel 31 . Cap SC rew 32. Cap 33. Spacer
34. Lock Washer 35. Nut 36. Cap Screw
Style G
KEV
1. Idler Wheel
0739-606
928
Page: 624
2005 Arctic Cat Service M anual - all models
www. ReadManuals .com
KEY
1. Idler Wheel
Style I
". ". 27. ". ".
Bearing Retaining Ring I~'" I~'" Spacer
30. Look Nut
". N.' ". ". Loo k Washer

Cap Screw
31 . Idler Wheel
45. Washer 46. Cap Sc rew 47. Cap
48. Cap Screw

0739-63 1
Page: 625
9-29
Repair Procedure 1 Track/Rear Suspension

This Trac k/Rcar Suspension sub-section (Repair Procedure 1) has been organ ized so each procedure can be compl eted indi viduall y and effici entl y. Each sub-section has (as necessa ry) Removi ng, Di sasse mbling, Clea ning and Inspecting, Assembling , and Installing
procedures . Some components may vary f rom model 1 0
2. Loosen the jam nuts and two trac k-tension adjusting bolts.
mooel. The technician should lise disc retio n and sound

judgment w hen removing and installing components .
3. Place a suppo rt stand under the rear bumpe r; then while holding the llared bushing, re move the rear Ct'lP screws securing the skid fram e to the tunnel. Account I'o r lock washers and nat washers.
Removing Skid Frame

NOTE: Many service procedures can be performed without removing the skid frame. Closely
4. Remo\'c the rront cap scrcws securing the skid fra mc to the tunnel. Account for a nat washe r and a lock washer. 5. Remove the support stand ; then ti p the snowmobile onto o ne side using a piece of cardboard to protect against scratching. Remove the skid frame.
observe the note introducing each sub-section for this important information.
To avoid having the adjuster bushings binding when loosening the trac k. remove the rear idler wheel ca ps and loosen the cap sc rews o n the rcar axle.
MSOOl
930
Page: 626
Wear Strips
REMOVING
NOTE: The skid frame does not have to be removed for this procedure; however, if wear strip binding or slide rail damage has occured, the skid frame should be removed for this procedure (see Removing Skid Frame in this sub-section).
I . Remove the machine screw and loc k nut securing
I. Clean the slide rail using palts-cleaning solvent and compressed air.
pair of safety glasses air. 2. Inspect the slide rai l for cracks. If any cracks are found . replace the slide rail. 3. Using a straightedge, inspect the slide rail for any unusual bends. With the slide rail removed, place the straightedge along the bottom surface o f the slide rail. If the rail is fo und to be bent, it must be replaced.
the wear strip to the front o f the slide mil.
MS016B
NOTE: If the skid frame has been removed due to difficulty in removing the wear strip, it may be necessary to use a pipe wrench, start from either end, and hook the edge of the wear strip with the pipe wrench jaw and twist the wear strip off the slide rail. Move the pipe wrench 7.5 em (3 in.) and again twist the wear strip off the rail. Repeat this procedure until the wear strip is free of the rail.
INSTALLING
NOTE: Critical torque specifications are located on page 172 of this section. NOTE: Apply a light coat of grease to the slide rail surface to aid in installing a new wear strip. If there are any sharp edges on the lower portion of the rail, use a file to remove them. Ali gn the wear stri p with the openings (windows) in the track and from the back, st.lIt the wear strip o nto the rail ; then lIsing a block o f wood and a hammer, dri ve the wea r strip forward into position.
2. Align the wear strip with the o penings (windows) in the track; then us ing a suitable driving tool, dri ve the wear strip rearward off the slide rail.
739884A

739-884A
9-31
2. Sec ure with a machine screw and lock nul. Tighten to specifications.
End Caps
NOTE: The skid frame does not have to be removed for this procedure.
REMOVING
I. Remo\'e the lock nut , washers. and cap sc rew securing the end cap. 3. Clean both the slide rail area and the end ca p. Using compressed air, clean the areas of dirt and gravel.
4. Inspect the cap screw for cracked, stretched, or damaged threads. Use a new lock nut when assembling.
INSTALLING
MS016A
2. Using a hammer, tap the end cap off the rail.
NOTE: Critical torque specifications are located on page 172 of this section.

Position the end cap on the slide rail ; then align the hole in the end cap with the hole in the slide rail. 2. Secure with a cap screw, washers, and lock nul. Tighten to specifications.
Inspect the end ca p area of the slide rail for cracks and wear.
Shock Pads
REMOVING
NOTE: The shock pads should be removed only if being replaced.
I. Using a 3116-in. drill bit , drill out the ri vets
MSOl1A
securing each shock pad to the slide rail. Account for the retaining brackets.
2. Inspect the end cap for any signs of cracking or wear.
932
Page: 628
Fron1: Ou1:er Idler Wheels

REMOVING
Remove the cap sc rews and lock nuts securing the fro nt outer idler wheel and the idle r wheel mounting block. Account for nat washe rs and two shi m washe rs (if appl icable).
2. Remove the shock pads.
INSPECTING
Inspect the pads and retaining brackets for damage or wear. 2. Inspect the ri vet holes or elongation.
III
the slide rail for damage
INSTALLING
I. Place the pads and retaining brackets into position on the slide rail 2. Secure the pads with rivets.
2. If appli cable, note the locations of the shim washers for assembl y purposes. T he shim washers arc to be install ed to the inside of the idler wheels.
Page: 629
9-33
NOTE: On the idler wheels with inserts, account for a spacer.
D. Install the snap ring making sure the "sharp side" IS directed away rrom the bearing.
MSOO5
MSOO7A

E. Instalilhe insert (i r applicable).
I. Clean the bearing with a clean cloth. 2. Inspect each idler wheel and each plastic hub for cracks or damage. 3 . Rotate Ihe idler wheel bea ring (by hand) and inspect ror binding or roughness. 4. If a bearing must be replaced, use tlu s procedure.
&
CAUTION
INSTALLING
00 not remove the bearing unless it is absolutely necessary. The bearing will be damaged during removal.
A. Remo~e the wheel illselt (ir applicable) and the snap ring. B. Using a hydraulic press, press the bearing out the inside or the wheel.
C. Press the new bearing (on its ouler race) IIlto
I. Secure the mounting block on the slide rail with a ca p screw and loc k nut. Tighten 1 0 specifications.
the idler wheel.
NOTE: For proper alignment, it is advisable to install an idler wheel cap screw into the top mount ing block hole prior to tightening.
MSOO6A
934
Page: 630
2. Place the two shim washers (if appliCt 'lble), idler wheel, and ax le against the mounting block making sure there is a flat washer on the outside of the idler wheel.
Rear Inner Idler Wheels

- ... c~,
REMOVING I. Re move the ca p screws, washers. and lock nuts securing the rear inner idler wheel and the idler wheel mounting bloc k. Account for all mounting hardware.
MSOO4
NOTE: On idler wheels with inserts, install spacers,
2. Note the location of the Oat washer for asse mbl y purposes.
MSOO5
3. Secure the idle r wheel assembl y with a cap sc rew and a lock nul. Tighten cap screws to specifications.
Page: 631
9-35

I. Clcanlhe bearing with a clea n cloth.
E. Install the insert (i f applicable) .
2. Inspect eac h idler wheel and pl astic hub fo r c rac ks

o r damage.
3. Rotate the idler wheel bearings (by hand) and inspect fo r binding or roughness.
4. If a bearing must be re placed , usc thi s procedure.
,1; CAUTION
A. Remove the w heel inscI1 (if applicable) and the
INSTALLING
_NOTE : Critical torque specifications are located on page 172 of this section.
I. Secure the mo ullting block o n the slide rail with a cap screw and lock nut. Tighten to spe cificatio ns.
snap ring. 8. Using a hydraul ic press, press the bearing out the inside of the wheel.
C. Press the new bearing (on its ollter race) mto
the idler wheel.
MSOOOA
D. Inslall the snap ring making slire the "sharp side" is directed a way from the bearing.
MSOO7A
936
Page: 632
2. Place the idler wheel into position against the mounting block making sure there is a nat washer on the cap screw. Tighten to specifications.
3. Remove the cap screws securing the offset pivot idler arm assembl y to the idler arm ; then remove the offset pi vot arm idler assembly. Account for a !langed axle, !lared bushing, idler spacer coilaI', and lock nuts.
Rear Upper Idler Wheels/Rear Springs

_ NOTE: The skid frame must be removed for this procedure (see Removing Skid Frame in this sub section).
REMOVING
I. Using the Rear Suspe nsion Spring Tool (pIn 01443 11 ), remove the spring rrom the adjusting cam.
4. Remo\'e the idler wheel.

_NOTE : Use Idler Wheel Puller Kit (pin 0644-122) to remove the wheel.
2. Mark the offset pi vot idler and the idler arm for assembly purposes.
MS011
5. Remove the cap screw and !lat washer securing the front outer idler wheel to the mounting block and remove the idler wheel.
Page: 633
9-37
7. Remove the spring and sleeve from the idler ann.
MSOO2B
6. Remove the cap screw, Oat washer, and loc k nut
securing the spring slide to the slide rail. Account for the spring slide and all mounti ng hardware.
NOTE: Use the same procedure for the other side.
INSPECTING
I. Clean the bearing with a clean cloth .
2. Inspect eac h idler wheel and plastic hub for cracks

or damage.
3. Rotate the idler wheel bea rings (by hand) and ins pect for binding or rOllglmcss. 4. If a bearing must be replaced, use this procedure,
&
removal.
CAUTION
00 not remove the bearing unless it is absolutely necessary. The bearing will be damaged during
Rc m o~'e the wheel inscI1 (if applicable) and the snap nng_
B. Using a hydraulic press, press the bearing o ut

the inside o f the wheeL
C. Press the new bearing (on its outer race) IOto
MS014
the idler wheel
MSOO6A
938
Page: 634
D. Install the snap ring making sure the "sharp side" is directed away rrom the bearing.
2. Place the spring slide and slide block (w ith spring in slide block) into position on the slide rail . Secure with a cap screw, lock nut, and washer. Tighten to specifications.
MSOO7A
E. Install the insert (i r applicable).

MS014
MSOO5
5. Inspect the spring, spring slide, sleeve , washers, slide block iTlSClt, and shart area for wear. 6. Inspect the adj usting cams and arms ror cracks. 3. Install the rear upper idler wheel on the idl er arm.
INSTALLING
I. Slide the sleeve and spring onto the idler arm.
L1:.
CAUTION
When driving the idler wheel onto the idler arm, use a tool to contact the inside race of the bearing or damage to the wheel or bearing may occur.
Page: 635
9-39
NOTE: When tightening the pivot idler arm lock nuts, tighten the lower lock nut first or binding may occur.
4. Install the idler spacer collar onto the idler arm.
Rear Axle and Idler Wheels

NOTE: The skid frame must be removed for this procedure (see Removing Skid Frame in this sub section).
DISASSEMBLING
5. Place the fl ared bushings with a thin fl at washer through the notched side of the offset pi vot idler arm assembl y.
NOTE: If the flared bushings in the offset pivot idler arm is loose, it must be cleaned and green Loctite #609 must be applied to it prior to installa tion.
I. Re move the cap screw and large flat washer securing the outer rear idl er wheel. Remove the oul"e r idler wheel from the shaft.
6. Align the marks on the idler arm to the centerline of the offset pivot idle r arm assembly. Secure the offsct pi vot idler arm to the idler arm with cap screws and lock nuts. Tighten to specifications.
NOTE: The large flat side of the wheel insert is positioned next to the inner plastic adjuster bush 109. The idler wheel must be installed with the wheel insert properly positioned .
2. Loosen the track adjusting bolts. Slide the outer adjuster bushings off the ax le.
MS146A
940
Page: 636
2005 Arctic Cat Service Manual all models . www. ReadManuals.com
4. 5. 6.
In s l~ct
the plastic insert o f each idler wheel for the s haft for wear and damaged threads.
cracks.
In s l~ct
In s l~ct all idl er wheel bearings. Turn each bearing (by ha nd) and if any roughness o r binding is noted, repl ace the bearing.
7. If a bearing must be replaced, use thi s procedure.
& CAUTION
A.
Remo~'e the whee! insel1 (i f applicable) and the snap nng.

thc inside o f the wheel.
C. Press the new bearing (on its o llter race) into

the idler wheel.
3 . Ca refull y slide the shan out from the inner idler wheels and note the position of the spacers and washers.
MSOOOA
D. Install the snap ring making slire the "sharp side" is directed a way from the bearing.

NOTE: Whenever a part is worn excessively. cracked, or damaged in any way, replacement is necessary.
I. Clean the bearings with a clean cloth. 2. Inspect all idler wheel inscrts (inner and o llter) for any cracks. 3 . Inspect the o uter rubber portion of the idler wheels for cracks and Ix>or bonding.
MSOO7A
E. Install the inscI1 (if appli cabl c).
Page: 637
941
ASSEMBLING
L In order rrom the ri ght-hand side , slide the ax le through the slide rail axle slot; thell place a bushing. inller idler wheel with inscI1 (if applicable), and long spacer with a nat washe r on the axle. Slide the axle through the opposite slide rail axle slot. Place the plastic adjuste r bushings o n the axle (on the o utside o f each ax le slot).
NOTE: It is advisable to tighten the rear idler wheel axle only until snug until the skid frame has been installed and track tension has been adjusted ; then the axle assembly must be tight ened to specifications.
3. Install the skid fram e (see Installing S kid Frame in thi s sub section). NOTE: It is advisable to install the rear arm springs onto the adjuster blocks after the skid frame has been installed. 4. Adjust track align ment (sec Track Alignment in tlti s sub-section). 5. Adjust track tension deflection (see Track Tension in this sub-section).
Idler Arm/Rear Arm

NOTE: Make sure the slot in the adjuster bushing is aligned directly with the adjusting bolt.
DISASSEMBLING
I. Rcmo\'c thc rear upper idler wheels and springs
(see Rear Upper Idler W heels/Rear Springs in thi s sub-section).
2. Place the ollter idler wheels on the axle (with the large nat o f the inscI1 directed inward) and secure with two cap screws (coated with blue Loclile #243) and large n at washe rs. Tighten cap sc rews
o nly until snug.
9-42
Page: 638
2. Re move the cap screw and loc k nut sec uring the uppe r shock eyelel to the idler arm. Accounl for a spacer, lock nUl , and bushings.
--,, - .- ~
-. ~
AG553D
MS031
4. Remove the cap screw and loc k nul securing the 0 Ihe slide rail. Accounl for the serrated rear ann 1 ax les and ax le tube .
NOTE: Mark the hole that the upper shock links are mounted in for assembly purposes.
NOTE: If applicable, note the mounting hole from which the rear arm was removed for assembly purposes.
3. Re mo\'e the ca p screw and lock nul securing the upper shock links to Ihe idler ann. Accounl for a lock nUl , spacer, nal washe rs, a nd axle links.
_NOTE : To remove the rear arm, it may be necessary to loosen the rear arm stop.
Page: 639
943

_NOTE : Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary.
I. Clean the bearings with a clean cloth. 2, Inspect each idler wheel for cracks or damage. 3 . Inspect the bushings (located in the arm pivot area) for wear or damage. 4. Inspect all welds and the tubing of the upper arm for cracks or unusual bends. 5. Inspect the two adj usting cams for damage. 6. Rotate the idl er wheel bea rings (by hand) and check for binding or roughness. 7. If a bearing must be replaccd, lise this procedure.
L!':. CAUTION
MS028
5. Remove the two cap screws securing the rear ann to the idler arm. Account for the aluminum axle and bushing assemblies.
A. Remove the wheel insel1 (i f applicable) and the snap ring.
B. Using a hydraulic press, press the bearing out the inside of the wheeL
C Press the new bc<lring (on its outer race) into the idler wheel.
MS029A
--. -
MSOO6A
D. Install the snap ring making sure the "sharp side" is directed away from the bearing.
9-44
Page: 640
MSOO7A
E. Install the insert (if applicable).
NOTE: Install the rear arm assembly into the appropriate mounting hole as noted during disassembly.
3. Place a support beneath the rear arm ; then tighten the two cap screws (from step I) to specifications.
ASSEMBLING
I. Install the rear arm onto the idler arm with an
aluminum a"\ le, bushing assemblies, and two cap screws (coated with blue Loctite 11243 ). Tighten only until snug.
4. Position the shock links in the appropriate holes of the idler arm brackets (see Chassis and Skid Frame Mounting Locations in this section). Place a slx l cer bet ween the center of the brackets. insel1 the axle links into the upper shock link eyelets ; then insert the cap screw with washer through the eyelets. Secure with a cap sc rew, washer, and lock nul. Tighten sec urely.
2. Place the rear arm assembly into position between the slide rails. Secure with a cap screw and lock nul. Tighten to specifications.
MS031
Page: 641
945
Front Arm/Front Shock Absorber/Front Inner Idler Wheels

NOTE: The skid frame must be removed for this procedure (see Removing Skid Frame in this sub section), and the rear springs must be removed from the adjusting cams.
REMOVING
5. Place the upper shock eyelet with bushings between the idler arm brackets making sure the spacer is properl y lX)Sitioned between the brackets. Secure with a cap screw and lock nut. Tighten securely. I. Remove the upper cap screws and loc k nuts securing the limiter straps to the mil support. Account for nat washers.
NOTE: Do not overtighten the shock absorber cap screw as the shock eyelet must be free to pivot.
2. Remove the cap screw and loc k nut securing the upper front shock absorber eyelet to the front arm. Pull the shock eyelet free of the bracket. Account. for a serrated axle .
6. Grease the idler arm and rear arm grease fittings with a low-temperature grease. 7. Install the rear upper idler wheels , rear springs , and offset pi vot idler (see Rear Upper Idler Wheels/Rear Springs in this sub-section).
8. Inst.all the skid fram e (see Installing Skid Frame in
this sub-section) .
NOTE: It is advisable to install the rear arm springs onto the adjuster blocks after the skid frame has been installed.
3. Remove the cap screw and loc k nut securing the front arm to the front arm mounting brackets.
9-46
Page: 642
4. Remove the front arm and account for an axle tube and serrated ax les.
NOTE: To aid in disassembling, loosen the cap screws and lock nuts securing the pivot (A) and the front shock absorber (8) .
-.
7. Wilh the mounting blocks and idler wheels removed from the assembly, relUO\'e the cap screw securing the front shock mounting bracket to the rear shoc k pivot. Account for an ax le, cap screw, and lock nuL
5. Re move the ca p screw and loc k nul securing the shock roo links and shock absorber to lhe pi vot assembl y. Account for the cap screw and lock nuL
6. Re move the ca p screw and lock nut securing the front inner idler wheel assembl y to the slide rail s. From one side, gently lap the assembly rearward until the mounting blocks clear the slide rails; then remove the assembly.
8. Remove the cap screw securing the front shock to the mounting bracket.
Page: 643
947
INSPECTING
I. Inspect a ll front arm weldmcnts for cracks or
unusual bends.
CAUTION Take care when clamping the bracket in a vise not to damage the bracket.
2 , Securely tighten the shock eyelet to the front shock mounting bracket.
&
2. C losely inspect all tubing fo r cracks o r unusual bends. 3 . Inspect the bearings, bushings, and front arm spacers for wea r or damage.
4. Inspect the shock absorber for any signs of oil

leakage especiall y at the point whe re the shock shaft e nte rs the shock body.
5. Inspect the shock absorber eyelet welds (at each end) for any cracks, signs of separation, or for
untlueadi ng.
6. Inspect the shoc k absorber for damage.
INSTALLING
I. Secure the front shock mounting bracket in a \'isc; then install the rear shock pivot with axle to the mounting bracket with the cap screw and lock nut. Tighten securel y.
3. Place the idler wheels with mounting blocks o nto the bracket assembly.
MS044
4. Slide the fro nt inner idler wheel assembly into position o n the slide rail : then align the assembly with the proper hole (as noted in remov ing). Inst.'lll the cap sc rew, n at washer, and loc k nut : then tighten to specificatio ns.
9-48
Page: 644
NOTE: Do not over~tighten the shock absorber cap screw as the shock eyelet must be free to pivot.
7. Place the rear shock absorber and shock links into position on the pi\'ot; then install the ax les, cap screw, and lock nul. Tighten securel y.
5. Position the front arm with sp"'lcers, an axle tube, and serrated axles to the mounting brackets. Secure with the cap screw and lock nul. Ti ghten to specifications.
8. Secure the limiler slraps with cap screws, washers, and lock nuts. Ti ghte n to specifications.
6. Position the upper shock eyelet and serrated axle in the front arm . Secure with a cap screw and lock nul. Tighten securely.
9. Install the skid fram e (see Installing Skid Frame in thi s sub-section ).
Page: 645
949
Rear Shock Absorber and Shock Links

DISASSEMBLING
I. Using the Rear Suspensio n Spring Tool (pin 01443 11 ), remove the spring from the adjusting cam.
4. ivlark the hole that the uppe r shock links are mo unted in fo r assembly purposes; then remove the cap screw and lock nut securing the shock links to the uppe r ann bracket. Acco unt ro r all mounting ha rdware.
WARNING
Care must be taken when removing the spring
from the adjusting cam or damage or injury could result.
2. Re move the cap screw securing the lower shock eyelet and shock links. Account fo r shock sleeves, ax le links, and a lock nut.

L Clean shock pivot and idl er wheel axle in partcleaning solvent. Dry with compressed air.
2. Clean the idler wheel bearings with a clean cloth.
3. Closely inspect the idler wheel ax le ror wear, bends, or damaged threads at either end .
NOTE: Lay components out in order as they are removed .
3 . Remove the cap screw and loc k nul securing the
4 . Inspect the idler wheels ror signs of cracking,
wear, 0 1' outer rubber separation rrom plastic wheel. 5. Rotate the idl er wheel bearings (by hand) and inspect ror any signs or binding o r roughness_
shock absorber at the uppe r eyclet and remove the shock absorber. Account fo r a sleeve and bushings.
950
Page: 646
6. If a ocaring must oc replaced, lise this procedure.
II. Inspect the axle surfaces for any signs of
A CAUTION
A . Remo~e the wheel inselt (if applicable) and the
corrosion. If corrosion is found , li ghtly buff the surface of the axle with #400 wet-or-dry sandpaper; then apply a li ght coat of grease.
ASSEMBLING
snap ring. B. Using a hydraulic press, press the bearing out the inside of the wheel. C. Press the new bearing (on its outer race) into the idler wheel.
I. Secure the shock eyelet to the idler arm with bushings, sleeve, lock nut , and a cap screw Tighten securel y.
MS027
MSOOOA
2. Secure the rear shock links and the lower shock absorber eyelet to the shock pivot bracket by placing the bushings and shock sleeve into the shock eyelet; then install the <l.x le links into the rear shock links. Secure the assembl y by installing a cap screw through the shock link assembl y, shock pi vot bracket and shock eyelet assembl y, and shock link assembl y. Secure the assembl y with a loc k nut. Tighten securel y.
NOTE: 00 not over-tighten the shock absorber cap screw as the shock eyelet must be free to pivot.
MSOO7A
E. Insl" allthe insert (if appli cable).
7. Inspect the shock absorber for any signs of oil leakage especially at the point where the shock shaft enters the shock body. 8. Inspect the rubber shock bushings located in the shock absorber eyelets for cracks or deterioration. 9. Inspect the shock absorber eyclet welds (at eac h end) for any cracks or signs of separation.
10. Inspect the welds securing the eyelets of the shock
links for cracks or signs of separation. Either weld the eyclet or replace the shock link.
3. Position the shock links in the appropriate holes of the idler arm brackets (see Chassis and Skid Frame Ivlollnting Locations III this section). Place a SIl.:1Cer (A) between the center of the brackets. Insert the ax le lin ks (B) into the upper shock link eyclets; then inselt the cap screw with washer through the eyelets. Secure with a cap screw, washer, and lock nut. Tighten securel y.
Page: 647
951
Slide Rails
REMOVING
NOTE: When it is necessary to replace one or both slide rails, it is recommended that one slide rail be removed at a time. The remaining slide rail will then hold the rail supports, axles, and brackets in their correct assembly order. Always mark the mounting hole locations during disassembly to speed up the assembly process and to prevent any damage. This method is much quicker than to completely disassemble the entire skid frame. To replace either rail, use the following procedure.
I. Remove the end eap rrom the slide rail Accounl
MS031A
for a cap screw, lock nul, and two nat washers.
4. Inslall the upper shock absorber eyelel to the appropriate hole in the idler ann as nOled in disassembling.
MS016A
2. Remo\'e the machine screw and lock nut sec uring the wear strip to the front of the slide rail ; then using a suitable dri ving tool. dri ve the wear strip rearward off the slide rail.
5. Inslaillhe skid rrame (see Inslalling Skid Frame in this sub-section).

MS016B
952
Page: 648
2005 Arctic Cat Service Manual all models . www. ReadManuals.com
NOTE: If binding of the wear strip occurs, it may be necessary to use a pipe wrench, start from either end , and hook the edge of the wear strip with the pipe wrench jaw and twist the wear strip off the slide rail. Move the pipe wrench 7.5 cm (3 in.) and again twist the wear strip off the rail. Repeat this procedure until the wear strip is free of the rail.
3 . Remove the front arm limiter straps from the front arm of the skid frame.
6. Account for a Oat washer and two spacer washers.
4. Remove the cap screws securing the two front rai l supports to the slide rail.
MS051
7. Removc the cap screw and Oat washcr securmg the spring slide to the rail. Account for a spacer and the slide block.
5. Remove the cap screws and lock nuts securing the front outer idJcr wheel and the idl er wheel mounting bl ock.
NOTE: If not already done, remove the short spring leg from the adjusting cam. Also, it is rec om mended that the cap screw be removed from the front shock absorber to the front arm to aid in slide rail installing.
R Remove the lock nut , cap screw, and nat washer securing the inner idler wheel assembly to the slide rail. Di scard the lock nut.
NOTE: If it is necessary to remove the cap screws from the center components for replacing the slide rail, install the cap screw from the opposite side into the assembly to secure components and aid in replacing the slide rail.
Page: 649 2005 Arctic Cat Service Manual all models www.ReadManuals.com
953
II . Note the mounting positions of the rear arm limiter (A) and rear ann (8); then remove the cap screws, lock washers, and lock nuts from the rear arm limiter and rear arm.
9. Note the mounting position of the front arm mounting bracket and remove the cap screws securing the front arm mounting bracket. Account for loc k nuts.
MS054A
10. Note
the mounting location for installing purposes; then remove the cap screw and lock nut securing the rear inner idler wheels and mounting block.
12. tvlark the location of the rear coupler block < if
applicable); then remove the block. Account for the block, bll<;hing, cap screw, and lock nut.
13. Remove the idl er wheel inscl1 , then remove the
cap screw and nat washer securing the rear idler wheel. Remove the idler wheel; then remove the adjuster bushing.
954
Page: 650
INSPECTING
I. Inspect the slide rail for cracks (A), elongated holes (8), or unusual bends.
NOTE: The adjusting bolt may have to be loosened to remove the adjuster bushing. NOTE: At this point, the slide rail should be free of the skid frame components and can be removed.
14. Re move the cap screws and lock nuts securing the track adjuster bracket.
2. Inspect the wear strip for wear. The wCt'lr strip must be 10.7 mm (0.42 in.) thick or thi cke r. If the wear strip measurement is less than specified, replacement of both wear strips is necessary.
NOTE: The shock pads should be removed only if being replaced .
15. Using a drill and a 3116-in. drill bit , drill out the ri vets and remove the shock pads. Note the shock pad location for installati on. Account for the retaining brackets.
Minimum Thickness 10.7 mm (0.42 in.)
~~~~ ~
INSTALLING
i@1 ~ 1~
0 727-726
I. Install the shock pads and retaining brackets ; then secure with ri vets.
955
2. Secure the track adjuste r bracket with the cap screws and lock OlltS. Ti ghten onl y until snug,
NOTE: Care must be taken that the adjuster bushing slot is aligned properly with the adjuster bolt. NOTE: It is advisable to tighten the rear idler wheel axle only until snug until the skid frame has been installed and track tension has been adjusted ; then the axle assembly must be tight ened to specifications.
4. Install the rear arm limiter cap screw (A) in the appropri ate hole (as noted during disassembl y); thell insta ll the rear arm in the appro priate hole as noted during disassembl y. Install cap screw (8) and lock nut. Tighten onl y until snug.
3. Place the mil into position: the n install the adjuster bushing and rear idler wheel . Install the cap screw and l1at washer. Tighten only until snug.
5. If appli cable, install coupler block w/bushing. Secure with cap screw and lock nut. Tighten to specifications.
956
Page: 652
6. Install the rear inner idler wheel mo unting block in the appropriate holes as noted during disassembly and secure with cap sc rew and lock nul. Tighten to specificatio ns.
8. Install the cap screw and lock nut (if removed) securing the front inner idler wheel assembly to the slide rail s. Tighten to specificatio ns.
NOTE: To obtain proper alignment for the idler wheel cap screw, place the cap screw in the top hole through the rail and mounting block prior to tightening.
NOTE: At this point, tighten the cap screws A and B (from step 4) to specifications .
9. Place the spring into the slide block; then place the spring slide and slide block assembly into position o n the slide mil. Secure with a cap screw and washer. Tighten to spec ifications.
7. Secure the front ann mounting bmcket with the ca p screws and lock nuts. Ti ghten to specificat io ns.
10. Secure the outer idler wheel mounting bl ock with the ca p screw and lock nul. Tighten to specifications.
MS054A
NOTE: At this point if the front arm shock absorber was removed from the front arm, install it and tighten securely.
Page: 653
957
II . Secure the oute r and inner idler wheels 1 0 the mounting blocks with existing hardware. Tighten to speci fi cations.
13. Secure the e nd cap onto the slide rail using a cap
screw, nat washers, and a lock nut. Tighten to specifications.
MS""A
12. Secure the rml SUpp0l1S with cap screws (coated with blue Locti te 8243). Tighten to specifications.
14. From the back, stm1 the wear strip onto the rail ; then using a soft hammer, dri ve the wear strip forwa rd into position. Secure with a machine screw and lock nut. Tighten to specificalions .
NOTE: Apply a light coat of grease to the slide rail surface to aid in installing a new wear strip. If there are any sharp edges on the lower portion of the rail, use a file to remove them.
958
Page: 654
Installing Skid Frame

I. Place a piece of cardbo.."lrd on the Iloor to protect against scratching and tip the snowmobile onto one side. 2. Pull the track away from the tunnel and sprC<ld open; then pl ace the skid frame into the track. 3. Posi tion the front of the skid frame into the tunnel and align the front ann with the appropriate mounting hole in the tunnel. Insert the cap screw with washers through the tunnel mounting hole and through the front arm. 00 NOT T IGHTEN AT T1-II S TUvlE. Repeat this procedure on the other side .
MS01 6B
15. Inslalilhe skid frame (see Installing Skid Frame in this sub-section).
A CAUTION
When installing the skid frame, make sure the rear arm shock mounting location on the pivot! axle is positioned correctly above the axle or component damage will occur.
16. Adjust track tension denection (see Track Tension III thi s sub-section) and track ali gnment (see Track Ali gnment in this sub-section).
A CAUTION
After proper track tension and alignment have been attained, make certain that the rear axle assembly is tightened to specifications or component damage will occur.
739-992A
NOTE: To aid in centering the front arm with the hole in the tunnel , position the skid frame and track at a 45 angle to the bottom of the tunnel.
4. Elevate the rear of the skid frame and the track into position in the tunnel. 5. Ali gn the pivot idle r arm assembly with the appropriate hole in the tunnel. Secure the pi vot idler arm assembl y with a ca p screw (coated with red Locti te #27 1), lock washer, and nat washer. DO NOT T IGHTEN AT THI S TIME.
NOTE: 00 not install the short legs of the rear springs onto the adjusting cams at this time.
6. At thi s time. tighten all four skid frame mounting cap sc rews securely. 7. Using the Rear Suspe nsion Spring Tool (pIn 0 1443 11 ), insl"allthe short legs of the rear springs onto the adjusti ng cams making sure the cams are in the same adjustment lX)sitions.
Page: 655
959
8. Tighten the two track tension adjusting bolt evenly until track defl ection is within specifications; then lock the jam nuts to secure the adjustment. 9. Check track tension defl ection and alignment: adjust if necessary (see Track Tension and Tmck Alignment in this sub-section).
ADJUSTING DEFLECTION I. Place the snow mobile up on a shielded &1.fety stand. Check to make sure the trac k is 2-3 in. off the noor. 2, If the measurement is not as spec ified, loosen the jam nuls of the adjusting bolt's.
Track Tension
Jam Nut
CHECKING DEFLECTION I. Tip the snow mobile on its side. look a spring scale around a track clip at mid2. 1 span ; then pull the track dow n with the scale to 9 kg (20 Ib) and measure the di sl'ance between the bottom of the wear strip and the inside surface of the tmck clip. Track de nection must be within specifications.
Rear Suspension Style
FasTrack wrrorque Sensing Link (121 in. Track)
J
Rear Idler Wheel
Adjusting Bolt
072 7 456
Setup Tension
3238 mm (11/41112 in.)
After Break-In Tension

3844 mm
(1 1121314 in.)
3. If the measurement obtained in step 2 is more than specified, tighten the adjusting bolts. If the measurement obtained is less than specified, loosen the adjusting bolts. When the measurement is within specification mnge, lock the adjustment by bouoming the jam nuts aga inst the axle housings.
NOTE: If the track tension must be loosened, it may be necessary to loosen the rear axle assembly slightly. NOTE: Vigorously push the underside of the track up and down. Track must not hit the top of the tunnel or slap the skid frame.
4. After correct track tension is obtained, check track ali gnment (sec Track Alignme nt in this subsection).
20 Ib (9 kg)
729429A
_NOTE : Track tension and track alignment are interrelated; always check both even if only one adjustment seems necessary. Always establish correct track tension before checking and/or adjusting alignment.
NOTE: If the track is new, it will stretch slightly and take a " set" within the first 300 to 500 miles of operation.
& CAUTION
After proper track tension and alignment have been attained, make certain that the rear axle assembly is tightened to specifications (see page 172) or component damage will occur.
960
Page: 656
Track Alignment
_NOTE : Proper track alignment is when the rear idler wheels are equidistant from the inner drive
NOTE: Make sure correct track tension is maintained after adjusting track alignment
6 CAUTION
After proper track alignment has been attained, make certain that the rear axle assembly is tightened to specifications (see page 172) or component damage will occur. NOTE: Field test the track under actual condi~ tions and, after the field test, check track alignment and track tension ; adjust as necessary.
lugs on the inside surface of the track.
CHECKING
I. Using a shielded safety stand, rai se the rear the snowmobile o fr the n oor making sure the track is free to rotatc.
or
WARNING
The tips of the skis must be positioned against a wall or similar object for safety. Keep hands, feet, and clothing away from moving components.
2. Start the engine and accelerate sli ghtl y. Usc o nly enough throttle to rotate the track several revolutions. SH UT TH E ENG INE OFF.
NOTE: Allow the track to coast to a stop. 00 not apply the brake because it could produce inaccurate alignment conditions.

T hi s Track/Rcar Sus pension sub-section (Rcpa ir Procedure 2) has been organi zed so eac h procedure can be completed indi vidua ll y and effi cientl y. t..'lch s ub-sec tion has (a s necessary) Removing, Di sassembling , C leaning and Ins pecting, Assembling , and Installing procedures. Some compo nents may vary from mooel to model . The technician s ho uld use di scretion and sound judgment when removi ng and ins talling compo ncnts. NOTE: Some illustrations and photographs used in this sub-section are used for clarity purposes only and are not designed to depict actual conditions.
3 . W hell the track stops rotati ng. check the relationship of the rear idler whee ls and the inner track dri vc lugs. If the distancc rro m thc idler whcels to the inner drivc lugs is thc samc on both sidcs, no adj ustme nt is ncccssary.
, - _ ,'""'" T",k Drive L'9' ---,
Removing Skid Frame

NOTE: Many service procedures can be performed without removing the skid frame. Closely observe the note introducing each sub-section for this important information. I. To avoid having the adjuster bus hings binding during removal, rcmovc the rear idler whccl caps and loosen the cap screws on the rear ax le.
L. Wt, ..,,,,,",,,,,, between Drive Lugs
4 . O n the side of the track which has the inner dri ve lugs closcr to the rcar idlcr wheel, looscn the adjusting bolt jam nut ; then rotatc the adj usting bolt clockwise I - I 112 turns . NOTE: If track alignment must be adjusted, it may be necessary to loosen the rear axle assembly slightly. 5. Continue to check the track alignment and make the necessary adjustments unti l prope r alignment is obl'ained. 6. Artcr propcr track ali gnme nt is obtained , lock thc jam nut against the ax le housing.
Page: 657
961
2. Loosen the jam nuts and two track-tension adjusting bolts.
Wear Strips
REMOVING
NOTE: The skid frame does not have to be removed for this procedure; however, if wear strip binding or slide rail damage has occured , the skid frame should be removed for this procedure (see Removing Skid Frame in this sub section).
I. Re move the machine screw and loc k nut securing the wear strip to the front of the slide rail.
3. Place a SUpp0l1 sl'and under the rear bumper ; then while holding the fl ared bushing, remove the rear cap screws securing the skid frame to the tunnel. Account for lock washers and flat washe rs.
4. Re move the front cap screws securing the skid frame to the tunnel. Account for a flat washer and a lock washer_ 5. Re move the support stand ; then tip the snowmobile onto one side using a piece of cardboard to protect against scratching. Remove the skid fram e.
MS016B
NOTE: If the skid frame has been removed due to difficulty in removing the wear strip, it may be necessary to use a pipe wrench, start from either end , and hook the edge of the wear strip with the pipe wrench jaw and twist the wear strip off the slide rail. Move the pipe wrench 7.5 cm (3 in.) and again twist the wear strip off the rail. Repeat this procedure until the wear strip is free of the rail.
2. Ali gn the wear strip with the o pen ings (windows) in the track; then using a suitable driving tool. drive the wear strip rearward off the slide rail.
MS066
Wear 'StriP
~
739884A

NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. 962
I. Clean the slide rail using parts-clea ning solvent
and compressed air.
2. Secure with a machine screw and loc k nul. Tighten to speci fi cations.
pair of safety glasses air.
End Caps
2. Inspect the slide rail for cracks. If any cracks are found , replace the slide rail. 3 . Using a strai ghtedge, inspect the slide rail for any unuSlk'll bends. With the slide rail removed, place the straightedge along the bottom surface of the slide rail. If the rail is found to be bent, it must be replaced.
REMOVING
I. Remove the lock nut, washers, and cap screw securing the end cap.
MS016A
INSTALLING
NOTE: Critical torque specifications are located on page 172 of this section. _NOTE : Apply a light coat of grease to the slide rail surface to aid in installing a new wear strip. If there are any sharp edges on the lower portion of the rail, use a file to remove them.
2. Using a hammer, tap the end cap off the rai l.

NOTE: Whenever a part is worn excessively, cracked , or damaged i n any way, replacement is necessary.
I. Inspect the end cap area of the slide rail for cracks and wear.
Align the wear strip with the openings (windows) in the track and from the back, start the wear strip onto the rail ; then using a block of wO<Xi and a hammer, dri" e the wear strip forward into position.
2. Inspect the end ca p for any signs of cracki ng or wear.
739884A
Page: 659
963
Shock Pads
REMOVING
I. Using a 3/16-in. drill bit , drill out the ri vets
3. Clean both the slide rail area and the end cap. Using compressed air, clean the areas of dirt and gravel.
securing each rront shock pad to the slide rail . Account for the retaining brackets.
4. Inspect the cap screw for cracked, stretched, or damaged threads. Usc a new lock nut when assembling.
INSTALLING
Position the end cap on the slide rail : then align the hole in the end cap with the hole in the slide rail. 2. Secure with a cap screw, washers, and lock nul. Tighten to specifications.
2. Remove the torx-head sc rews and loc k nuts securing the rear shock pads to the slide rail .
3. Remove the shock pads.

INSPECTING
I. Inspect the pad and retaining brackets ror damage
or wear. 2. Inspect the ri vet holes in the slide rail for damage or elongal"i on.
964
Page: 660
INSTALLING
I Place the front pads and retaining brackets into
posi tio n 011 the slide rail.
Fron1: Ou1:er Idler Wheels

NOTE: The skid frame does not have to be
removed for this procedure.
2. Secure the front pads with rivets.
REMOVING
Remove the cap sc rews and lock nuts securing the fro nt olller idler wheel and the idler wheel
mounting block. A ccount for Oat washers and t wo shim washe rs (if appl icable).
3 . Place the rear pads into position on the slide rails. 4. Secure the rear pads with the torx-head screws.
2. If appli cable, note the locations of the shim washers for assembl y purposes. T he shim washers arc to be install ed to the inside of the idler wheels.
NOTE: On the idler wheels with inserts, account for a spacer.

965
D. Install the snap ring making sure the "sharp
side"
IS
directed away from the bearing.
MSOO5

I. Clean the bearing wilh a clean cloth.
MSOO7A
E. Install the insert (i f applicable).
2. Inspect each idler wheel and each plastic hub for cracks or damage. 3. Rotate the idler wheel bea ring (by hand) and inspect for binding or roughness. 4. tr a bearing must be re placed, use thi s procedure.
&
CAUTION
INSTALLING
A. Remove the wheel insel1 (if applicable) and the snap ring.
B. Using a hydraulic press, press the bearing out the inside of the wheel.
C. Press the new bearing (on its ollter race) into
I. Secure the mounting block on the slide mil with a ca p screw and loc k nut. Tighten to specifications.
the idler wheel.
MSOOOA
966
Page: 662
2. Place the two shim washers (if appliCt'lble), idler wheel, and ax le against the mounting block making sure there is a flat washer on the outside of the idler wheel.

- ... c~,
REMOVING I. Remove the ca p screws securing the rear IIUler idler wheel and the idler wheel assembly. Account for four !lat washers, three spacers, and an axle.
MSOO4
NOTE: On idler wheels with inserts, install spacers,
2. Note the locations of the washers and spacers for installing purposes .
NOTE: The washers (A) must be installed next to the idler wheels. The short spacers (8) must be installed against the slide rail.
MSOO5
3. Secure the idler wheel assembl y with a cap sc rew and a lock nul. Tighten cap screws to specifications.
Page: 663
967

the inside of the wheel.
C. Press the ncw bearing (on its Oliler race) mto the idler wheel
(A)
MS210A
MSOO6A
o
MS210B
D. Install the snap ring making sure the "sharp side" is directcd away from the bearing.

I . Clean the bearing w ith a clean cloth.
2. Inspect eac h idler wheel and plastic hub fo r cracks

or damage.
E. Inslallihe insert (i f applicable).
3. Rotate the idl er wheel bearings (by hand) and inspect fo r binding or ro ughness. 4. If a bearing must be replaced, usc thi s procedure.
& CAUTION
A. R e m o~e the wheel illSC lt (if applicable) and the snap ring.
968
Page: 664
INSTALLING

NOTE: The skid frame must be removed for this procedure (see Removing Skid Frame in this sub
I. Place the long spacer o n the axle; thell fro m each side, install a washer (A), idl er wheel, washe r, and a sho rt spacer (8 ). T ighte n to specificatio ns.
section).
REMOVING
I. Using the Rear Suspe nsion Spring Tool (p/n 0 1443 11 ), remove the spring frolll the adjusting cam .
0'=
==F === (A)=

MS210A
(8)
MS 210B
2, Mark the offset pi\'ot idler and the idler ann for assembly purposes.
2. Place the idler wheel and axle assembly into positio n between the slide rails. Ti ghte n 10 specificatio ns.
3. Re mo \'c the cap screws securing the offset pivot idler ann to the idler ann ; then remove the offset pi vot idler arm assembly. Account for a flanged axle, washer, flared bushings, idler spacer collar,
aod lock outs.
Page: 665
969
6. Remove the spring and sleeve from the idler ann.
4. Using Idler Wheel Puller Kit (pIn 0644-122), remove the wheel.

I. Clean the bearing with a clean cloth. 2. Inspect e.ac h idler wheel and plastic hub fo r cracks o r damage. 3. Rotate the idler wheel bea rings (by hand) and inspect for bind ing or roughness. 5. Remove the cap screw, lock nut , and flat washer sec uring the spring slide to the rail. Account for a slide block and washer. 4. tr a bearing must be replaced, use thi s procedure.
& CAUTION
A. Remove the wheel insel1 (if applicable) and the snap ring.

the inside or the wheel.
C. Press the new bearing (on its ollter race) into the idler wheel.
MSOOOA
MS068
970
Page: 666
2. Place the slide spacer and slide block (with spring in slide block) into position on the slide rail . Secure with a cap screw, Oat washers, and lock nut. Tighten to specifications.
NOTE: Make sure the spring is located above the spring slide mounting bolt.
MSOO7A
E. Install the insert (i r applicable).
5. Inspect the spring, spring slide, sleeve , washers, slide block iTlSClt, and shart area for wear.
MS06B
6. Inspect the adj usting cams and arms ror cracks.
INSTALLING
I. Slide the sleeve and spring onto the idler arm.
3. Using a suitable driving tool, install the rear upper idler wheel on the idler arm.
Page: 667
L!':. CAUTION
When driving the idler wheel onto the idler arm, use a tool to contact the inside race of the bearing or damage to the wheel or bearing may
NOTE: When tightening the pivot idler arm lock nuts, tighten the lower lock nut first or binding may occur.
7. Insta ll the skid fram e (see Installing S kid Frame in thi s sub-sectio n).
occur.

NOTE: The skid frame must be removed for this procedure (see Removing Skid Frame in this subsection).
DISASSEMBLING
5. Place the Oared bushings w ith a thin Oat washer
through the notched side of the o ffset pi vol idler

arm assembl y.
I. Remove the cap screw and large flat washer sec uring the o uter rear idler wheel. Remove the o ule r id ler wheel from the shaft.
NOTE: If the flared bushing in the offset pivot idler arm i s loose, it must be cleaned and green Loctite #609 must be applied to it prior to installation.
6. A lign the marks on the idler arm to the centerline
o f the o ffset pivol idler arm assembly. Secure the o ffset pi vot idl er arm to the idler arm with cap screws and lock ouls. Tighten to specifications.
NOTE: The large flat side of the wheel insert is positioned next to the inner plastic adjuster bushing. The idler wheel must be installed with the wheel insert properly positioned.
2. Loosen the track adjusting bolts. S lide the outer adjuster bushings off the ax le.
9-72
Page: 668
4. 5. 6.
In s l~ct
the plastic insert o f each idler wheel for the s haft for wear and damaged threads.
cracks.
In s l~ct
In s l~ct all idl er wheel bearings. Turn each bearing (by ha nd) and if any roughness o r binding is noted, repl ace the bearing.
7. If a bearing must be replaced, use thi s procedure.
& CAUTION
A.
Remo~'e the whee! insel1 (i f applicable) and the snap nng.

thc inside o f the wheel.

the idler wheel.
3 . Ca refull y slide the shan out from the inner idler wheels and note the position of the spacers and washers.
MSOOOA
D. Install the snap ring making slire the "sharp side" is directed a way from the bearing.

I. Clean the bearings with a clean cloth. 2. Inspect all idler wheel inscrts (inner and o llter) for any cracks. 3 . Inspect the o uter rubber portion of the idler wheels for cracks and Ix>or bonding.
MSOO7A
E. Install the inscI1 (if appli cabl c).
Page: 669
NOTE: It is advisable to tighten the rear idler wheel axle only until snug until the skid frame has been installed and track tension has been adjus ted ; then the axle assembly must be tight ened to specifications.
ASSEMBLING
L In order rrom the ri ght-hand side , slide the ax le through the slide rail axle slot; thell place a bushing. inller idler wheel with inscI1 (if applicable), and long spacer with a nat washe r on the axle. Slide the axle through the opposite slide rail ax le slot. Place the plastic adjuste r bushings o n the axle (on the o utside o f each ax le slot).
3. Install the skid fram e (see Installing S kid Frame in thi s sub-section). NOTE: It is advisable to install the rear arm springs onto the adjuster blocks after the skid frame has been installed. 4. Adjust trac k alignment (see Track Ali gnment ill tlli s sub-section). 5. Adjust track tension deflection (see Track Tension in this sub-section).
Idler Arm/Rear Arm

NOTE: Make sure the slot in the adjuster bushing is aligned directly with the adjusting bolt.
DISASSEMBLING
I. Remove the rear upper idle r wheels and springs
(sec Rcar Upper Idler W heels/Rear Springs in thi s sub-section).
2. Place the ollter idler wheels on the axle (with the large nat o f the inscI1 directed inward) and secure with two cap screws (coated with blue Loclile #243) and large n at washe rs. Tighten cap sc rews
o nly until snug.
9-74
Page: 670
2. Remove the cap screw and loc k nut sec uring the upper shock eyelet to the idler arm. Account for a spacer, lock nut , and bushings .
AG553D
MS031
4. Remove the ca p screw, washer, and lock nut securing the rear mm to the slide rail. Account for the serrated axles and axle tube.
3. Remove the cap screw and loc k nut securing the upper shock links to the idler ann. Account for a lock nut , spacer, and axle links.
MS028
_NOTE : At this point on the Bearcat 570, remove the rear arm limiter strap.
5. Re move the cap screw and loc k nut sec uring the rear arm to the idler arm . Account for the aluminum axle and bushing assemblies.
A. Remove the wheel insel1 (if applicable) and the snap ring. B. Using a hydraulic press, press the bearing out the inside of the wheel.
C. Press the new bearing (on its outer race) into
the idler wheel.
- -- MSOO<A

I. Closely inspect the rear annJidl er ann tubing and brackets for c rac ks or unusual bends.
E. Install the inscl1 (if appli cabl e).
MSOO7A
2. Clean the bearings with a clean cloth . 3 . Inspect each idler wheel for cracks or damage. 4. Inspect the bushings (located in the ann pivot area) for wear or damage. 5. Inspect all welds and the tubing of the upper ann for cracks or unusual bends. 6. Inspect the two adjusting cams for damage. 7. If a bearing must be replaced, lise this procedure.
A CAUTION
Do not remove the bearing unless it is absolutely necessary. The bearing will be damaged during removal.
976
Page: 672
ASSEMBLING
I. Install the rear arm onto the idler ann with an
3. Place a support beneath the rear ann ; then lighten the cap screws (fro m SICp I) to specificalio ns.
aluminum ax le, bushing assembli es, two cap 2 43), and a lock screws (coated with blue '-,o ctile #nul, Tighten o nl y until snug .
.....
MSOBO
4. Position the shock links in the appropriate holes of the idle r arm brackets (see Clk'lssis and Skid Frame Mounting Locations in this section). Place a spacer between the cente r of the brackets. Inscl1 the axle links into the uppe r shock link eyelets; then insel1 the cap screw through the eyelets. Secure with a cap screw, washer, and lock nut. Tighten securely.
.
-~-,
-""
...
--
MS029
NOTE: At this point on the Bearcat 570, install

the rear arm and the idler arm; then secure with the cap screws, flat washers , and lock nuts. Tighten to 1.4 kgwm (10 ftlb).
MS031
2. Place the rear arm assembly into position. Secure with a cap screw, washer, and lock nut. Tighten to specificatio ns.
5. Place the upper shock eyelet wi th bushings between the idl er ann brackets maki ng sure the slx'lcer is properly positioned between the brackets. Secure with a ca p screw and lock nut. Tighten securely.
Page: 673
MS082A
2. Remo \'c the ca p screw and lock nut. securing the uppe r front. shock absorber eyelct. to the rront a rm. Pull t.he shock eyelet. rree o r t.he bmcket. Account. for a serrated axle.
6. G rease the idler arm and rear arm grease fillings with a low-tempemture grease. 7. Install the rear uppe r idle r wheels, rear springs, and offset pi vot id ler (see Rea r Upper Id ler Wheels/Rear Springs in thi s sub-sectio n). 8. Inst.a llt.he skid rmme (see Inst.alling Skid Frame in this sub-sectio n).
NOTE: It is advisable to install the rear arm springs onto the adjuster blocks after the skid frame has been installed,

NOTE: The skid frame must be removed for this procedure (see Removing Skid Frame in this sub section), and the rear springs must be removed from the adjusting cams,
3. Re move the ca p screw and loc k nut securing the fro nt arm to the front arm mo unting bmckets.
REMOVING
I. Remove t.he lower cap screws and lock nuts securing t.he limit.e r straps t. o the rail support. Account ro r nat washers. 4. Re move the front arm and account fo r the sermted ax les, bushings, and an axle tube.
9-78
Page: 674
2005 Arctic Cat Service Manual all models www. ReadManuals.co m

MS086A
5. Re move the ca p screw and lock nut securing the front inner idler wheels to the slide rail_
MS042A
INSPECTING
6. From o ne side, tap the idler assembl y rC<Hward

until the mounting blocks clear the slide rail ; then remove the assembl y.
L Inspect all front ann weldme nts for cracks or unusual bends. 2. Closely inspect all tubing for cracks o r unusual bends. 3. Inspect the bearings, bushings, front arm spacers, and mounting blocks fo r wear or damage. 4. Inspect the shock absorber for any signs of oi l lea kage especiall y at the point whe re the shock shan e nte rs the shock body. 5. Inspect the shock absorber eyelet welds (at each end) fo r any cracks, signs of separation, or for unthreading.
INSTALLING
7. Remove the mounting blocks and slide the axle O llt of the shock bracket ; then remove the cap screw and lock nut securing the shoc k absorber to
_NOTE : Critical torque specifications are located on page 172 of this section.
the bracket.
I. Secure the shock absorber to the shock bracket with the ca p screw and lock nul. Tighten sec urely.
Page: 675
MS08<
2. A ppl y grease 1 0 the axle; then install the axle mlo the shock bracket. Install the mounting blocks to
NOTE: At this point, tighten the lock nut (from step 3) to specifications.
the axle.
MS042A
3 . Place the idler wheel assembl y into position on the skid frame making sure the moullting blocks arc properl y positioned. Secure with the cap screw, washer, and a new lock nul. Tighte n only until snug.
5. Secure 1he uppe r shock eyelet and serrated ax Ie in the mounting ho le of the fro nt arm . Secure with a cap screw and lock nut. Tighten securel y.
NOTE: Do not over-tighten the shock absorber cap screw as the shock eyelet must be free to pivot. 4. Position the front arm into the mounting brackets. Secure with cap screws and lock nuls. Tighten to specificatio ns. 6. Secure the limiter straps to the rail supports with cap screws, washers, and lock nuts. Tighten to specificatio ns.
980
Page: 676
MS082A
7. Install the skid rrame (sec Installing Skid Frame in this sub-sectio n).
_NOTE : It is advisable to install the rear arm springs onto the adjuster blocks after the skid frame has been installed.
NOTE: For ease of disassembling, it is advisable at this point to place a block of wood between the idler arm and the overload springs.

NOTE: Before removing the skid frame by using the Rear Suspension Spring Tool (pin 0144311), remove the spring from the adjusting cam.
A CAUTION
Care must be taken when removing the spring from the adjusting cam or damage or injury could result. _NOTE : The skid frame must be removed for this procedure (see Removing Skid Frame in this sub
section).
DISASSEMBLING
NOTE: When removing center components from the skid frame, it is advisable to loosen all cap screws/Jock nuts from one side of the slide rail to make removing easier.
MS091
I. Di sengage the shoc k absorber at the uppe r eyelet and remove the shock absorber. Account for a sleeve, cap sc rew, lock nut , and bushings.
2. Mark the hole that the uppe r shock links are mounted in fo r assembl y purposes; then remove the cap screw and lock nut sec uring the shock links to the upper arm bracket. Account fo r all mo unting hardware.
Page: 677
981
4. Tap one side or the idl er wheel/pivot assembl y rorward until it clears the slide rails: then lift the assembly upward and out from between the rails .
NOTE: lay components out in order as they are removed,
5. With the idler wheeIJ pi vot assembly removed, remove the three spacers, an axle, and washers from the pivot bracket. 6. Remove the ca p screw, loc k nut , and washer securi ng the shock rod links to the pi vot ann. Account ror all components and mounting hardware.
MS093
3. Note the hole location that the center inner idler wheel/pi vot assembly is in: then remove the cap screw, nat washer, and lock nut securing the assembly to the rails.
MS097

I. Clean shock pi vot and idler wheel axle in pm1-
cleaning solvent. Dry with compressed air.
982
Page: 678
2. Clean the idler wheel bearings with a clean cloth. 3 . Closely inspect the pi vot bracket arm and axles for wear, bends, or damaged splines at either end. 4. Inspect the idler wheels for signs of cracking, wear, or outer rubber separation from pl astic wheel, 5. Rotate the idler wheel bearings (by hand) and inspect for any signs of binding or roughness. 6. If a bearing must be replaced, use this procedure.
8.
In s rx~ct the rubber shock bushings located in the shock absorber eyelets for cracks or deterioration.
9. Inspect the shock absorber eyelet welds (at each end) for any cracks or signs of separation. 10. Inspect the welds sec uring the eyelets of the shock links for cracks or signs of separation. If either condition exists, replace the shoc k link. II. Inspect the axle surfaces for any signs of corrosion. If corrosion is found , li ghtly buff the surface of the axle with #400 wet-or-dry sandpaper: then appl y a li ght coat of grease. 12. Inspect the pivot assembly for signs of cracks or elongated holes. ASSEMBLING
L!'. CAUTION
A. Remove the snap ring. B. Using a hydraulic press, press the bearing out the inside of the wheel. C Press the new bearing (on its outer race) into the idler wheeL
I. Secure the shock rod links (w ith axles) and the lower end of the shock absorber to the idler wheel! pivot assembly with the cap screw and loc k nut. Ti ghten securely.
MSOO6A
MS096A
NOTE: 00 not over-tighten the shock absorber cap screw as the shock eyelet must be free to pivot.
2. Apply a thin coat of low-temperature grease to the axle and slide the axle and spacer into the shock pivot bracket. Have equal amounts of the axle ex posed on either side of the pi vot bracket tube.
MSOO7A
7. Inspect the shock absorber for any signs of oil leakage especially at the point where the shock shaft enters the shock body.
Page: 679
983
3. From eac h side of the pi vot, install a washer, idler wheel, washer, and spacer.
5. Position the shock links in the appropriate holes of the idle r arm brackets (as marked during disassembling). Place a spacer between the center of the brackets: then insert the link axles into the uppe r shoc k link eyelets. Sec ure with a cap screw, washer, and lock nut. Tighten securel y.
4. Lower the idler wheel/pi vot assembly down between the rail s. Ali gn the ax le with the mounting hole (as noted during disassembl y). Secure with the cap screw a nd a new lock nut. Tighten to specifications.
6. Secure the shoc k absorber to the idler ann with bushings, sleeve, loc k nut, and a cap screw. Ti ghten sec urely.
7. Install the skid fram e (sec Installing Skid Frame in thi s subsection).
NOTE: It is advisable to install the rear arm springs onto the adjuster blocks after the skid frame has been installed,
984
Page: 680
Slide Rails
NOTE: The skid frame must be removed for this pro-
cedure (see Removing Skid Frame in this sub-section).
REMOVING
NOTE: When it is necessary to replace one or both slide rai ls, it is recommended that one slide rail be removed at a time. The remaining slide rail will then hold the rail supports, axles, and brackets in their correct assembly order. Always mark the mounting hole locations during disassembly to speed up the assembly process and to prevent any damage. This method is much quicker than to completely disassemble the entire skid frame. To replace either rail, use the following procedure.
I . Remove the end cap from the slide rail. Account for a cap screw, loc k nut, and Iwo nat washers.
NOTE: If binding of the wear strip occurs, use a pipe
wrench, start from either end , and hook the edge of the wear strip with the pipe wrench jaw and twist the wear strip off the slide rail. Move the pipe wrench 7.5 cm (3 in.) and again twist the wear strip off the rail. Repeat this procedure until the wear strip is free of the rail.
4. Remove the cap sc rews and lock nuts securing the front arm limiter straps to the rail support. 5. Remove the ca p screws securing the rai l suppo rt.. to the slide rai l.
MS016A
2. Remove the machine screw and loc k nut securing the wear strip to the front of the slide rail .
6. Remove the cap sc rews and lock nuts securing the front outer idler wheel and the idler wheel mounting block. Account for Oat washers.
MS017B
3 . Using a suitable dri ving tool, drive the wear strip off the rail.
Page: 681
985
9. Remove the cap screw and flat washer securing the spring slide and overload spring to the rail. Account for a spacer, the slide block, overload spring , retainer clips, bushing, one small \vasher, and two large washers .
NOTE: If not already done, remove the short spring leg from the adjusting cam. Also, it is rec ommended that the cap screw be removed from the front shock absorber to the front arm to aid in slide rail installing.
7. Remove the cap screw and lock washer securing the front inner idler wheel assembl y to the slide rai l.
I o
o
III
10. Remove the cap screw and loc k nut securing the overload spring tension block to the slide rail.
'-
8. Note the mounting position of the front ann mounting bracket; then remove the cap sc rews securing the front ann mounting bracket Account for lock nuts.
II . Remove the ca p screw and loc k nul securing the center inner idler wheel/pi vot assembly to the slide raiL
NOTE: If it is necessary to remove the cap screw for replacing the slide rail , install the cap screw from the opposite side into the assembly to secure the components and aid in replacing the slide rail.
986
Page: 682
- NOTE: If it is necessary to remove the cap screw for replacing the slide rail , install the cap screw from the opposite side into the assembly to secure the components and aid in replacing the slide rail.
12. Remove the cap screw and loc k nul securing the
MS113A
15. Remove the idler wheel cap; the n remove the cap screw and nat washer securing the rear idler wheel. Remove the idler w heel; then remo\'c the adjuster bushing.
rear inner idle r wheel assembl y to the rail .
13. Remove the cap screw from the rear arm S lOp.
NOTE: The adjusting bolt may have to be loos~ ened to remove the adjuster bushing.
MS112A
14. Remove the cap screw and loc k nul securing the
rear ann to the rai\.

NOTE: If it is necessary to remove the cap screw for replacing the slide rail , install the cap screw from the opposite side into the assembly to secure the components and aid in replacing the slide rail.
NOTE: At this point, the slide rail should be free of the skid frame components and can be removed. NOTE: If applicable, remove the cap screw and lock nut securing the coupler block to the slide rail.
16. Re move the cap screws and lock nuts securing the track adjuster bracket.
Page: 683
all models
www.ReadManuals.com
987
17. On the front shock pads using a drill and a3116-i n. drill bit, drill out the ri\'ets and remove the shock pads. Note the shock pad location fo r installation. Account for the retaining brackets.
2.
In s rx~ct the wear strip for wear. T he wear strip must be 10.7 mm (0.42 in.) thick or thicker. If the wear strip measurement is less than specified, repl acement of both wear strips is necessary.
18. On the rear shock pads, remove the torx-head screws and loc k nuts securing the shock pads to the rails.
Minimum Thickness 10.7 mm 10.42 in.)
~~l~
~.
0727-726
INSTALLING
NOTE: Critical torque specifications are located on page 172 of this section,
I. Install the front shock pads and retaining brackets;
INSPECTING
then secure with ri vets. 2. Install the rear shock pads and secure with the torx- head sc rews and lock nuts.
988
Page: 684
3. Secure the track adj uste r bracket with the cap screws and lock nuts. Tighte n to specifications.
NOTE: Care must be taken that the adjuster bushing slot is aligned properly with the adjuster bolt.
4. Place the slide rai l into lX)siti on; then install the ca p screws securing the front inner idler wheel assembly (A), the center inner idler wheel/pivot assembly (B), and the rear arm assembly (C) into the proper holes in the slide rail. Insta ll the loc k nuts and tighten only until snug.
NOTE: If applicable, install coupler block wI bushing . Secure with cap screws and lock nuts. Tighten securely.
NOTE: Take care that all the shim washers and spacers are in place on the center components of the slide rail.
6. Insta ll the cap screw (cooted with bl ue Loctite #243) securing the rear inner idler wheel assembl y to the slide rai l. Tighten only until snug.
NOTE: On the Bearcat 570, also install a cap screw (coated with blue Loctite #243) securing the rear-most inner idler wheel assembly to the slide rail. Tighten only until snug.
5. Install the adjuster bushing and rear idl er wheel. Secure with a cap screw (coated with blue Loctite #243) a nd flat washe r. Tighten only until snug.
Page: 685
989
7. Place the overload spring with retain ing clips and bushing to the proper hole in the slide rail .
9. Insta ll the overl oad spring tension bl ock with a cap screw and lock nut. Tighten securely.
8. Place the spring into the slide blocks; then place the spring slide and slide block assembly into position on the slide rail. Secure with a cap screw, washer, spacer, two large nat washers, and a lock nul. Tighten to specifications.
10. Secure the front arm mounting bracket with the cap screws and lock nuts. Tighten to specifications.
I o
o
~
MS108
NOTE: At this point if the front arm shock absorber was removed from the front arm, install it and tighten securely.
11 Secure the outer idler wheel mounting block with the cap screw and lock nut. Tighten to specifications.
NOTE: When tightening the mounting block lock nut, it is recommended that idler wheel cap screw (A) be installed to maintain proper alignment.
990
Page: 686
12. Secure the outer idler wheel to the mounting block with a ca p screw, nat washers, idler wheel, and a lock nut . Tighten to speci fi cations.
15. Tighten the cap sc rew and lock nut securing the rear ann assembly (from step 4) to specifications.
13. Secure the front rail supports with cap screws (coated with blue Loctite #243) . Tighten to specifications.
16. Tighten the cap screw securing the rear inner idler wheel assembl y (from step 6) to specifications.
NOTE: On the Bearcat 570, also tighten the rear most inner idler wheel assembly to the slide rail to specifications.
14. Install the rear arm stop with a cap screw (coated with blue Loctite 11243). Tighten to s{X:cifications. 17. Tighten the center inner idler wheel/pivot assembly (from step 4) to specit""ications.
Page: 687
9-91
18. Tighten the front inner idler wheel assembly cap screw (from ste p 4) to specifications.
20. From the back, start the wear strip onto the rail ; then using a soft hammer, dri ve the wear strip forward into position. Secure with a machine screw a nd lock nut. Tighten to specifications.
19, Secure the e nd cap onto the slide rail using a ca p screw, !lat washers, and a lock nul. Tighten to specifications.
MS016B
os,...
NOTE: Apply a light coat of grease to the slide rail surface to aid in installing a new wear strip. If there are any sharp edges on the lower portion of the rail, use a file to remove them.
2 1. Install the skid fra me (see Installing Skid Frame in thi s sub-section).
22. Adj ust track tension dellection (see Track Tension in thi s sub-section) and track alignment (see Track Ali gnment in this sub-section).
992
Page: 688

I. Place a piece of cardboard on the Ooor to protect against scratching and tip the snowmo bile onto o ne side. 2. Pull the track away from the tunnel and spread o pe n; the n pl ace the skid fram e into the track.
3. Position the front of the skid frame into the tunnel
8 , Ti ghten the two track tension adjusting boh evenl y until track dellectio n is within specifications; then lock the jam nuts to secure the adjustment. 9. Check track tension dc llection and ali gnment ; adjust if necessary (see Track Tensio n and Track Ali gnment in this sub-section).
Track Tension
and align the front ann with the appropriate mo unting ho le in the tunnel. Insert the cap screw
w ith washers through the tunnel mounting hole and through the front ann. 00 NOT TIGI-rrEN
AT TI-II S TIivlE. Repe at thi s procedure on the othe r side.
CHECKING DEFLECTION
I. Tip the snowmo bi le on iL" side . 2. I-look a spring scale around a track clip at midsp.an ; then pull the track dow n with the scale to 9 kg (20 Ib) and measure the di stance between the bollolll o f the wear strip and the inside surface of the track. Track de ll ection must be within specificatio ns.
Rear Suspension Style Setup Tension
38- 44 mm (1 1/2-1 3/4 in.)
A CAUTION
When installing the skid frame, make sure the rear arm shock mounting location on the pivot! axle is positioned correctly above the axle or
component damage will occur.
After Break-In Tension

50.8-57.2 mm
(2-2114 in.)
~ ,
.739992A
FasTrack wrrorque Sensing Link (136 in. , 156 in. Track)
20 Ib (9 kg)
4. Elevate the rear of the skid frame and the track into position in the tunnel. 5. Align the pi vot idler arm assembly with the appropriate hole in the tunnel. Secure the pivot idler ann assembl y with a cap screw (coated with red Loctite 11-27 1), lock washer, and nat washer. DO NOT TIGHTEN AT THIS T IME
729-429A
NOTE: If the track is new, it will stretch slightly and take a " set" within the first 300 to 500 miles of operation.
ADJUSTING DEFLECTION
I. Place the snow mobile up o n a shielded safet y stand, Check to make sure the track is 2-3 in. o ff the Iloor. 2_ If the meas urement is not as specified , loosen the jam nuts o f the adjusting bolts.
6. At this time, tighten all four skid fram e mo unting cap screws securely. 7_ Using the Rear S tls ~ns i o n Spring Tool (pIn 0 1443 11 ), install the short legs o f the rear springs onto the adjusting cams making sure the cams are in the same adjustme nt lX'lsitions.
Page: 689
9-93
Jam Nut
Lh
WARNING
J
Rear Idler Wheel
Adjusting
2. Start the e ngi ne and accelerate slightl y. Use only enough throlile to rotate the track several revolutions. SI-llIT TH E ENGINE OFr.
NOTE: Allow the track to coast to a stop. Do not apply the brake because it could produce inaccurate alignment conditions.
0727-456
Bolt
3. If the measurement obtained in step 2 is more than specified, ti ghte n the adjusting bolts. If the measurement obl'ained is less than specifi ed, loosen the adjusting bolts. When the measurement is within spccii1cation range , lock the adjustment by bottoming the jam nuts against the ax le housings.
NOTE: If the track tension must be loosened, it may be necessary to loosen the rear axle assembly slightly. NOTE: Vigorously push the underside of the track up and down. Track must not hit the top of the tunnel or slap the skid frame.
3. When the track stops rotating, check the relationship of the rear idler wheels and the inner track dri ve lugs. If the distance from the idler wheels to the inner dri ve lugs is the same on both sides, no adj uslme nt is necessary.
r--',"",n'~"Drive
L",,---,
L.
W'",". centered between Drive Lugs j

72S0 70 A
4. Aft er correct track tension is obtained, check track alignment (see Track Alignment in this subsection).
NOTE: Track tension and track alignment are interrelated; always check both even if only one adjustment seems necessary. Always establish correct track tension before checking andlor adjusting alignment.
4. On the side of the track, which has the inner dri ve lugs closer to the rear idl er wheel, loosen the adjusting bolt jam nut ; then rO~'l t e the adjusting bolt clockwise I- I 1/2 turns. 5. Continue to check the track alignment and make the necessary adjustments until proper alignment is obtai ned. 6. Afte r proper track ali gnme nt is obtained, lock the jam nut against the axle housing.
NOTE: Make sure correct track tension is maintained after adjusting track alignment
Lh
CAUTION
Track Alignment
NOTE: Proper track alignment is when the rear idler wheels are equidistant from the inner drive lugs on the inside surface of the track.
& CAUTION
After proper track tension and alignment have been attained, make certain that the rear axle assembly is tightened to specifications (see page 172) or component damage will occur. NOTE: Field test the track under actual conditions and after the field test, check track alignment and track tension; adjust as necessary.
CHECKING
I. Using a shielded safety stand, raise the rear of the snowmobile off the 0001' making sure the track is free to rotate.
994
Page: 690

This Trac k/Rcar Suspension sub-sectio n (Repa ir Procedure 3) has been organ ized so each procedure can be compl eted indi viduall y and effici entl y. Each sub-sectio n has (as necessa ry) Removi ng, Di sasse mbling, Clea ning and Inspecting, Assembling , and Installing
procedures . Some compo nents may vary f rom model 1 0
2. Loosen the jam nuts and two track-tension adjusting bolts.
mooel. The technician should lise disc retio n and sound

judgment w hen removing and installing components.
3. Place a SUpp0l1 stand under the rear bumper; thc n while holding the nared bushing, re move thc rear cap screws securing the skid frame to the tunnel. Account for lock washers and nat washers.
Removing Skid Frame

NOTE: Many service procedures can be performed without removing the skid frame. Closely observe the note introducing each sub-section for this important information.
4. Rcmove the front cap scrcws sccuring the skid fra me to the tunnel. Account for a /lat washe r and a lock washer.
5. Removc the support stand ; then tip the snowmobile onto o ne side using a piece of cardboard to protect against scratching , Removc thc skid framc.
To avoid having the adjuster bushings binding d uring loosening of the track, remove the rear idler whccl ca ps and looscn thc cap sc rcws o n thc rear axle.
Page: 691
9-95
Wear Strips
REMOVING
NOTE: The skid frame does not have to be removed for this procedure; however, if wear strip binding or slide rail damage has occured, the skid frame should be removed for this procedure (see Removing Skid Frame in this sub-section).
I . Remove the machine screw and loc k nut securing
I. Clean the slide rail using palts-cle.aning solvent and compressed air.
2. Inspect the slide rail for cracks. If any c racks are found , replace the slide rail . 3. Using a straightedge, inspect the slide rail for any unusual bends. With the slide rail removed, place the straightedge along the boltom surface of the slide rail. If the rail is fo und to be bent, it must be replaced.
the wear strip to the front of I79the slide rail.
MS016B
_NOTE : If the skid frame has been removed due to difficulty in removing the wear strip, it may be necessary to use a pipe wrench, start from either end, and hook the edge of the wear strip with the pipe wrench jaw and twist the wear strip off the slide rail. Move the pipe wrench 7.5 em (3 in.) and again twist the wear strip off the rail. Repeat this procedure until the wear strip is free of the rail.
INSTALLING
NOTE: Critical torque specifications are located on page 172 of this section. NOTE: Apply a light coat of grease to the slide rail surface to aid in installing a new wear strip. If there are any sharp edges on the lower portion of the rail, use a file to remove them.
I. Ali gn the wear strip wi th the o penings (windows)
2. Align the wear strip with the o penings (windows) in the track ; then using a suitable driving tool , drive the wear strip rearwa rd off the slide rail.
in the track and from the back, start the wear strip o nto the rail ; then using a block of wood and a hammer, drive the wcar strip forward into position.
Wear Strip
739884A

996
Page: 692
Wear Strip
739-884A
2. Sec ure with a machine screw and loc k nul. Tighten to specifications.
End Caps
REMOVING
I. Rc move the lock nut , washers, and ca p sc rew securing the end cap. 3. Clean both the slide rail area and the e nd cap. Using eompressed air, clean the areas of dirt and gravel.
INSTALLING
MS016A
2. Using a ha mmer, tap the end cap off the rail .

I. Position the end cap on the slide rail : then align the hole in the end cap with the hole in the slide rail. 2. Secure with a cap screw, washers, and lock nut. Tighten to specifications,
I. Inspect lhe e nd cap area of the slide rail for cracks and wear.
Shock Pads
REMOVING
I. Using a 3J16-in. drill bit , drill out the ri vet:>
securing the front shock pads to the slide rail . Account for the retaining brackets.
MSOl1 A
2. Inspect the e nd cap for any signs of cracking or wear.
2. Twistlhe push nuts off the solid ri vets securing the J<lds. rear shock 1 3. Remo\'c the shock pads.
INSPECTING
9-97
I. Inspect the pads for damage or wear. 2. Inspect the ri vet ho les in the slide rail for damage o r elongation.
2. Note the locatio n of the spacer (A) o n standard model s for assembl y purposes. The spacer is to be installed to the inside of the idler wheel
INSTALLING
I. Place the rear pads into positio n on the slide rail. 2. Secure the rear pads with new push nuts. 3. Place the front pads and retaining brackets into positio n on the slide rail. 4. Secure the front pads with ri vets.
Front Outer Idler Wheels

MS13SA
REMOVING
Remove the ca p screw and loc k nut securing the front outer idler wheel and the idler whee l mounting block. Account for flat washers and spacers.
I. Clean the bearing with a clean cloth. 2. Inspect eac h idler wheel and each plastic hub for cracks o r damage. 3. Rotate the idler wheel bearing (by hand) and inspect fo r binding or ro ughness. 4. If a bearing mtlst be replaced, use this procedure.
A CAUTION
A, Remo~'e
the wheel insel1 (if applicable) and the snap rmg.
13. Using a hydraulic press, press the bearing o ut the inside of the wheel.
C. Press the new bearing (on its o uter race) into the idler wheel.
998
Page: 694
NOTE: For proper alignment, it is advisable to install an idler wheel cap screw into the top mount ing block hole prior to tightening .
MSOOOA
2. Place the idler wheel to the mounting block: then secure the idle r whecl assembly with a cap screw, !lat washe r, and a lock oul. Tighten to specifications.
MSOO7A
E. Install the insert (irapplicablc),
MS136
NOTE: On standard models, spacer (A) must be installed to the inside of the idler wheel.
INSTALLING
Secure the mounting block on the slide rail with a cap screw and lock nut. Ti ghte n to speci ficati o ns .
Page: 695
9-99
4.
tr a
bearing must be replaced, use thi s procedure.

L!':. CAUTION
A.
Remo~'e the w heel insel1 (ir applicable) and the snap nng.
REMOVING
I . Remove the cap screws, washers, and lock nuts
securing the rear inner idler wheel and the idler

w heel mounting block. Account for all mounting hardwa re.
B. Using a hydraulic press, press the bearing o ut the ins ide o f the w heel.

the idler wheel.
-~
2. Note the locatio ns of the flat washer for assembl y purposes.
MSOO6A
D. Install the snap ring making s ure the "sharp side" is directed a way from the bearing.
MS138

I . Clean the bearing w ith a clean cloth.
MSOO7A
E. Instalilhe insel1 (if appli cable) .
2. Inspect eac h idler wheel and plastic hub fo r cracks or damage. 3 . Rotate the idl er wheel bearings (by hand) and inspect fo r binding or roughness.
9100
Page: 696
INSTALLING
NOTE: Critical torque specifications are located on page 172 of this section. I. Secure the mounting bloc k o n the slide rail with a

NOTE: The skid frame must be removed for this
procedure (see Removing Skid Frame in this sub
cap screw and lock nuL Ti ghte n to specificatio ns.
section).
REMOVING
I. Using the Rear Suspe nsion Spring Tool (pIn 0 1443 11 ), remove the spring rrolll the adjusting cam .
NOTE: For proper alignment, it is advisable to

install an idler wheel cap screw into the top ing block hole prior to tightening.
mount~
2. Mark the offset pivot idler and the idler ann for assembly purposes.
2. Place the idler wheel into positio n against the mo unting block making sure the re is a fl at washer o n the cap screw. Tighten to specifications.
Page: 697
9-101
3. Remove the cap screws securing the offset pi vol idler arm assembly 1 0 the idler arm; then remove the offset pi vot arm idl er assembly. Account for a nanged ax le, nared bushing, idl er spacer collar, and lock nllts.
6. Rcmove the cap screw, fl at washer, and loc k nut securing the spring slide to the slide rail. Account for thc spring slide and all mounting hardwarc.
4 . Remove the idler wheel.

_NOTE : Use Idler Wheel Puller Kit (pin 0644122) to remove the wheel.
MS014
7. Rcmove the spring and sleeve from the idler arm .
5. On standard models, remove the ca p screw and nat washer securing the front outcr idler wheel to lhc mounting block; thcll rcmo\'c the idl er whed
_NOTE : On Sno Pro models if it is necessary to remove the spring slides, the cap screw and lock nut securing the front inner idler wheel assembly must be removed ,
9102
Page: 698
D. Install the snap ring making sure the "sharp side" IS directed a way from the bearing .
MSOO7A

E. Installihe inselt (i f applicable).
Clcan the bearing with a clea n cloth. 2. Inspect each idler wheel and plastic hub for cracks or damage. 3. Rotate the idl er wheel bea rings (by hand) and inspect for binding or roughness. 4. If a bearing must be re placed. use thi s proccdure.
A CAUTION
5. Inspect thc spring, spring slide, sleeve, washe rs, slide bloc k insert , and shaft area for wcar. 6. Inspect the adjusting cams and arms for cracks.
INSTALLING
A.
R e m o~' e the wheel insclt (if a pplicable) and the snap ring.
B. Using a hydraulic press, press the bearing out the insidc of the wheel. C Press the new bearing (on its outer race) into the idler wheeL
I. Slide the sleeve and spring onto the idler arm .
MSOO6A
Page: 699
9103
2. Place the spring slide and slide block (w ith spring in slide block) into position on the slide rail. Secure with a cap screw and washe r. Tighten to specifications.
NOTE: On Sno Pro models, install the spring slide block assembly with the cap screw and lock nut securing the front inner idler wheel assembly. Tighten to specifications.
MS01 5
3. Install the rear uppe r idler wheel
011
the idler arm.
&
CAUTION
5. Place the flared bushing with a thin flat washer through the notched side of the offset pi vot idler arm assembl y. NOTE: If the flared bushing in the offset pivot idler arm is loose, it must be cleaned and green Loctite #609 must be applied to it prior to installa tion.
9104
Page: 700
6. Align the marks on the idle r arm to the centerline of the offset pivot idler arm assembl y. Secure the offset pi vot idler arm to the idler arm with cap screws and lock nuts. Ti ghten to specifications.
NOTE: The large flat side of the wheel insert is positioned next to the inner plastic adjuster bush ing. The idler wheel must be installed with the wheel insert properly positioned. NOTE: When tightening the pivot idler arm lock nuts, tighten the lower lock nut first or binding may occur.
2. Loosen the track adjusting bolts. Slide the outer adjuster bushings off the axle.

DISASSEMBLING
I. Remove the cap screw und large nut washe r securing the outer rear idl er wheel. Remove the outer idler wheel from the shaft. 3. Carefull y slide the shaft out from the inner idler wheels and note the position of the spacers and washers.
Page: 701
9105
C Press the new bc<lring the idler wheel.
(011
its outer race) into
MS149

MSOOOA
side" is directed away from the bearing.
I. Clean the bearings with a clean cloth. 2. Inspect all idler wheel inserts (inner and outer) for any cracks. 3 . Inspect the outer rubber portion of the idler wheels for cracks and poor bonding. 4. Inspect the plastic insel1 of each idler wheel for cracks. 5. Inspect the shaft for wear and damaged threads. 6. Inspect all idler wheel bearings. Turn each bearing (by hand) and if any roughness or binding is noted , replace the bearing. 7. If a ocaring must oc replaced, use this procedure.
MSOO7A
E. Install the insert (i f applicable).
A CAUTION
A. Remove the wheel insel1 (i f applicable) and the snap ring. B. Using a hydraulic press, press the bearing oul the inside of the wheel.
9106
Page: 702
ASSEMBLING
In order from one side, slide the axle through the slide rail ; then place a !lat washer, short spacer with bushings, inner idler wheel with insert eif applicable), long spacer wit h bushings, and nat washer 011 the axle. Slide the axle through the o pposite slide rail axle bracket Place the plastic adjuster bushings o n the ax le (all the o utside of each axle bracket). ivlakc sure the hole in the adjuster bushing is aligned directl y with the adjusting bolt .
NOTE: It is advisable to tighten the rear idler wheel axle only until snug until the skid frame has been installed and track tension has been adjus ted ; then the axle assembly must be tight ened to specifications.
3. Install the skid frame (sec Installing Skid Frame in thi s sub-section). 4. Adjust track alignment (see Track Alignment in liti s sub-section). 5. Adjust track tension deflection (see Track Tension in this sub-section).
Rear Arm/Idler Arm

DISASSEMBLING
I. Remove the rear uppe r idler wheels and springs (see Rear Upper Idler W heels/Rear Springs in thi s sub-section).
2. Place the outer idler wheels 011 the axle and secure with two cap screws (coated with blue Loclile #243) and large flat washers. Tighten cap scrC\\l S only until snug.
2. Remove the cap screw and loc k nut securing the upper shock eyelet to the idler arm . Account for a spacer, ca p screw, and lock nut.
9107
3. Rcmovc the ca p screw and lock nut securing the uppe r shock links to the idlcr ann , Account for a ca p scrcw, lock nUl, spacer, and axle links.
NOTE: To remove the rear arm, it may be necessary to loosen the rear arm limiter.
FS083A
NOTE: Note the mounting hole from which the rear arm was removed for assembly purposes.
MS031
4. Rcmove the ca p scrcw and lock nut securing the rear arm to the slide raiL Account for the scrrated axles and axle tube.
'---=
MS028
5. Rcmo\'c the ca p screw and lock nut securing the rear arm to thc idler arm , Account fo r the aluminum ax le and bushing assembli es.
9108
Page: 704
C. Press the new bc<lfing
(011
its outer race) into
the idler wheel.
MS029A
MSOOOA
side" is directed away from the bearing.

MSOO7A
Clcan the bearings wilh a clean cloth. 2. Inspect each idler whcel for cracks or damage. 3. Inspect the bushings (located in the arm pi\'ot area) for wear or damage. 4. Inspect all welds and the tubing of the upper arm for cracks or unusual bends. 5. Inspect the two adjusting cams for damage. 6. Rotate the idl er wheel bcarings (by hand) and check for binding or roughness. 7. If a bearing must be replaced, usc this procedure.
ASSEMBLING
NOTE: Critical torque specifications are located on page 172 of this section. I. Install the rear arm onto the idler arm with an
aluminum axle, bush.ing assembli es, and two cap screws (coated with blue Loclite #243). Tighten only until snug.
A CAUTION
00 not remove the bearing unless it is absolutely necessary. The bearing wilt be damaged during removal. A. Removc the wheel snap ring.
MS029A
B. Using a hydraulic press, press the bearing oul the inside of the wheel.
2. Place the rear arm assembly inlo position between the slide rails. Secure with a cap screw and lock nul. Tighten to specifications.
Page: 705
9109
MS031
3. With the rear arm secured to the slide rails, ti ghten the two cap screws (from step I) to specifi cations.
NOTE: Install the rear arm assembly into the appropriate mounting hole as noted during disassembly. NOTE: If the rear arm limiter was loosened (after
step 4 of disassembling), treat the threads of the cap screw with blue Loctite #243 and tighten to specifications.
5. Place the upper shock eyclet with bushings between the idl er ann brackets making sure the spacer is properly positioned between the brackets. Secure with a ca p screw and lock nul. Ti ghten sec urely.
NOTE: Do not over"tighten the shock absorber cap screw as the shock eyelet must be free to pivot.
&
4. Position the shock links in the appropriate holes of the idl er ann brackets (see Chassis and Skid Frame Mounting Locations in this section), Place a spacer between the center of the brackets; then place a Oat washer on the cap screw. Insert the axle links into the upper shock link eyelets; then insert the cap screw through the eyelets. Secure with a cap screw and lock nut. Tighte n securely.
CAUTION
Make certain that the shock pivot assembly is properly positioned prior to securing the shock absorber to the idler arm.
9110
Page: 706
NOTE: On models with remote reservoir, cut the cable ties securing the front shock absorber hose to the front arm ; then loosen the two clamps securing the remote reservoir with hoses.
739992A
6. G rease the idl er arm and rear arm grease fittings with a low -temperature grease. 7. Install the rear uppe r idler wheel s, rear springs, and offset pi vot idler (sec Rea r Upper Idler Wheels/Rear Springs in this sub-section).
&
CAUTION
Care must be taken when removing the remote reservoir that the hoses are not kinked or damaged.
Front Arm/Front Arm Brackets/Front Shock Absorber

NOTE: The skid frame must be removed for this procedure (see Removing Skid Frame in this subsection), and the rear springs must be removed from the adjusting cams.
2. Remo\'c the cap screw and lock nut sccuring thc upper front shock absorber eyelct to the front arm. Pull thc shock eyelet free of the bracket. Account for a serrated ax le.
REMOVING
Remove the lower cap screws and lock nuts securing the limite r straps to the rail SUpp0i1. Account for nat washers. 3. Remove the cap screws and lock nUl,> securing the front arm to the front arm mounting brackets.
Page: 707
9-111
4. Re move the fro nt arm and account for the two front arm space rs.
MS164
5. Remove the cap screws securing the front outer idler wheels to the idler wheel mounting block. Account for lock nuts, cap screws, shim washcrs (if a pplicable), and nat washers.
MS167
7. Remo\'c the lock nut and cap screw securing the rear shock pi votJ inner idl er wheel assembl y to the slide rail. 6. Remove thc cap screw, washer, and lock nut from the fro nt shock ;x\ le; then fro m o ne side, tap the assembly rearward far enough fo r the axle assembl y to clear the slide rails. Account for an axle, two space rs, a nd two shim washers .
NOTE: It is advisable to loosen the front rail sup~ port cap screws enough to gain clearance to remove the front shock axle.
9112
Page: 708
all models
www.ReadManuals.com
8. rvlove the assembl y rearward far enough to gain access to the front arm mounting bracket lock nuts; thcn remove the cap screws and lock nuts securing the bracket.<; to the slide rails.
I. Install the front arm mounting brackets to the slide rails. Secure with cap screws and lock nuts tightened to specifications.
INSPECTING
I. Inspect all front arm wcldments for cracks or
2. tvlove the rcar shock pivotlinner idler wheel assembly to the appropriate mounting location. Secure with cap screws and lock nuts tightened to specifications.
unusll<'ll bends; then inslX)ct the front arm moullting brackets for cracks and for elongated holes. 2. Closely inslX)ct all tubing for cracks or unusual bends. 3. Inspect the bearings, bushings, and front arm spacers for wea r or damage. 4. Inspect thc shock absorber for any signs of oil leakage especially at the point wherc the shock shaft cnters the shock body. 5. Inspect the shock absorber eyelet welds (at each end) for any cracks, signs of separation, or for unthreading. 6. Inspect the shock absorber and reservoir hoses (on models with remote adj uste r) for damage.
INSTALLING
3. Install the ax le into the lower shock eyelet bushing assembl y; then install the two spacers and the two shim washers.
Page: 709
9113
Fe17S
4. Place the front ann shock axle assembly into posilion on the skid fram e making sure the spacers and washers are prope rly positioned. Sec ure with the cap screw, washe r, and a new lock nut. Tighten to specifications .
NOTE: If the front rail support cap screws were loosened (after step 6), treat the threads with blue Loctite #243 and tighten to specifications.
6. Secure the uppe r shock eyelet and serrated a x.le in the appropriate mounting hole of the front ann (sta ndard arm mounting position). Sec ure with a cap screw and lock nut. Tighten securely.
5. Position the front ann with spacers into lhe mounting brackets. Secure with cap screws and lock nuts. Ti ghten to specifi cati ons.
NOTE: On models with a remote reservoir, place the remote reservoir into position making sure the hose is directed to the left-side of the skid frame. Secure with clamps ; then secure the shock hose to the left-side slide rail using cable ties.
7. Secure the limiter straps with cap screws , washers, and lock nuts. Ti ghte n to specifications.
9114
Page: 710
DISASSEMBLING
NOTE: When removing center components from the skid frame, it is advisable to loosen all cap screws/lock nuts from one side of the slide rail to make removing easier.
I. Disengage the shock absorber at lhe upper eyelet and remove lhe shock absorber. Account for a sleeve, cap screw, loc k nut, and bushings.
MS161 A
8. Secure the front outer idler wheel s to the idler wheel mounting blocks wilh ca p screws, nat washers, shim washers (if applicable), axles, and lock nuts. Tighten to specifications.
Rear Shock Absorber and Shock Links/Front Inner Idler Wheel Assembly
NOTE: Before removing the skid frame by using the Rear Suspension Spring Tool (pIn 0144311), remove the spring from the adjusting cam.
o o
AG66SD
2. Remove the ca p screw and loc k nut securing the shock rod links to the idler arm. Account fo r a spacer and two axle links .
A CAUTION
Care must be taken when removing the spring from the adjusting cam or damage or injury could result. NOTE: The skid frame must be removed for this procedure (see Removing Skid Frame in this sub section). .NOTE: Mark the hole that the upper shock links are mounted in for assembling purposes.
Page: 711
9115
o
3. Remove the ca p screw and lock nut securing the front inner idler wheel assembly to the slide rails; then from one side, tap the assembly rearward far enough to clCt'lr the slide rails and mounting brackets. Remove the assembly.
==0
MS179
NOTE: Lay components out in order as they are removed.
5. With the pivot assembly removed, remove the cap screw and lock nut securing the lower shock eyelet and links to the pi vot bracket. Account for a spacer and two link a xles.
NOTE: On standard models to access the front inner idler wheel assembly, the front outer idler wheels must be removed.
MS180
.- ...
MS181
4. Remove the axle from the shock pi vot. Account for an ax le. three spacers, and four washers.
9116
Page: 712

NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is
necessary.
D. Install the snap ring making sure the "sharp side" IS directed away from the bearing .
I. Clean shock pivot and idl er wheel axle in pal1-
clean ing solvent Dry with compressed air.
2. Clean the idler wheel bearings with a clean cloth. 3. Closely inspect the torque link ann and axles for wear, bends, o r damaged splines at ei ther end.
MSOO7A
4. Inspect the idler wheels for signs of cracking , wear, or o llter rubber separation from plastic
w heel.
E. Installlhe insel1 (if applicable).
5. Rotate the idler wheel bearings (by hand) and inspect fo r any signs of binding o r roughness.
6.
tr a bearing must be replaced , usc this procedure.
&
removal.
CAUTION
A. Remove wheel insert (if applicable) and the
snap ring. B. Using a hydraulic press, press the bearing out the inside of the wheel.
7. Inspect the shock absorber for any signs of oil leakage especially at the po int whe re the shock shaft e nters the shock body. 8 . Inspect the rubber shock bushings located in the shock absorber eye lets for cracks or deterioration. 9. Inspect the shock absorber eyelet welds (at each end) fo r any cracks or signs o f separation.
10. Inspect the welds securing the eyelets of the shock
the idler wheel.
links fo r cracks or signs o f separation. Either weld the eyelet o r re place the shock link.
11. Inspect the axle surfaces
for any signs of corrosioll. If corrosio n is found , li ghtl y buff the surface of the ax le with #400 wet-o r-dry sandpaper; then apply a li ght coat of grease.
ASSEMBLING
MS""'A
NOTE: Critical torque specifications are located on page 172 of this section. I. Secure the shoc k rod links (with axles) and the lower end of the shock absorber to the pi vot assembl y with the cap screw and lock nul. Tighten securely.
Page: 713
9117
NOTE: On Sno Pro models to install the spring slide blocks, include them in step 4.
MS180
NOTE: Do not over-tighten the shock absorber cap screw as the shock eyelet must be free to pivot.
MS993
2. Appl y a thin coat or low-temperature grease to the axle and slide the axle into the shock pivot bracket. I-lave equal amounts or the axle ex posed on either side of the bracket tube.
5. Position the rear ann/idl er ann so the rear springs can be installed into the slide blocks. 6. Position the shock links in the appropriate holes of the idle r arm brackets (as noted in dis.. 1ssembling) . Place a space r between the cente r of the brackets; then insert the link axles into the upper shock link eyelets. Secure with a cap screw, washe r, and lock nul. Ti ghten securely.
3. Install a washer (A), idler wheel (B) , washer (C) , and spacer (D) to each side or the pi vot bracket
(E).
7. Secure the shoc k absorber to the idler arm with bushings, sleeve, lock nut , and a cap screw. Tighten securel y.
MS119A
4. Lower the pi vot assembl y down between the rail s. Ali gn the axle with the mounting hole (as noted during di sassembly), Secure with the cap screw and a new lock nut. Tighte n to specifications.
9118
Page: 714
2. Remove the machine screw and loc k nut sec uring the wear strip to the front of the slide rail.
Lb. CAUTION
When installing the shock and shock rod links to the idler arm, make certain that the pivot assembly is positioned correctly (in the UP position).
3. Ali gn the wear strip with the openings (windows) in the track; then lIsing a suitable dri ving tool, dri ve the wear strip rearward off the slide rail .
NOTE: If binding of the wear strip occurs, it may be necessary to use a pipe wrench, start from either end, and hook the edge of the wear strip with the pipe wrench jaw and twist the wear strip off the slide rail. Move the pipe wrench 7.5 em (3 in ,) and again twist the wear strip off the rail. Repeat this procedure until the wear strip is free of the rail.
739-992A
Slide Rails
4. Remove the ca p scrcws and lock Iluts with nat washcrs from thc lower limitcr straps.
REMOVING
NOTE: When it is necessary to replace one or both slide rails, it is recommended that one slide rail be removed at a time. The remaining slide rail will then hold the crossbraces, axles, and brackets in their correct assembly order. Always mark the mounting hole locations during disassembly to speed up the assembly process and to prevent any damage. This method is much quicker than to completely disassemble the entire skid frame. To replace either rail, use the following procedure.
I. Remove the end cap from the slide raiL Account
for a cap screw, lock nut, and two nat washe rs.
5. Rcmo\'c the cap screws securing the rail the slide rail .
SUppOl1
to
MS016A
Page: 715
9119
6. Re move the cap screws and lock nuts securing the front o uter idler wheels and the idler wheel mo unting blocks. Acco unt for Oat washcrs and spacer washcrs.
NOTE: The idler wheel mounting block should be removed only from the slide rail being replaced.
8. O n standard models, remove the cap screw and Oat washer securing the spring slide to the rail . Account for a space r and the slide block.
9. Note the mo unting location for installing purposes; then remove the cap screw and lock nut securing the front inner idler wheel assembly to the slide rail s.
7. Re move the cap screw, washers, and loc k nut securing the fro nt shock mo unt axle.
NOTE: On Sno Pro models, the spring slide block will come off along with the assembly,
NOTE: If it is necessary to remove the cap screw for replacing the slide rail, install the cap screw from the opposite side into the assembly to secure components and aid in replacing the slide rail. NOTE: If not already done, remove the short spring leg from the adjusting cam. Also, it is rec ommended that the top cap screw be removed from the front shock absorber to aid in slide rail installing ,
MS990A
10. Note the mounting positio n of the fro nt arm mo unting bracket ; the n remove the cap screws securing the fro nt arm mo unting bracket. Account for loc k nuts.
9120
Page: 716
12. Remove the cap screw securing the rail suppo rt to the slide rail.
NOTE: After removing the mounting bracket cap

screw, install the front inner idler wheel assembly cap screw from the opposite side slide rail ( not
being replaced) to hold center components in
place.
NOTE: On the Soo Pro models, there are two rail
supports.
13. Note the mounting positions of the rear arm limiter

(A) and rear arm (8): then remove the cap screws,
lock washers, and lock nuts from the rear arm limite r and rcar arm.
11 Note the mounting location for inst.1.11ing purposes; then remove the cap screw and lock nul
securing the rear inner idler wheels and mounting block.
14. Remove the idler wheel cap; the n remove the cap screw and Oat washer securing the rear idler wheel. Remove the idler w heel; then remove the adj uster bushing_
Page: 717
9121
MS193A
17. Using a drill and a 3/ 16-in. drill bit , drill out the ri vets and rcmove lhc front shock pads. Note the shock pad locations for installation. Account for the retaining brackets. 18. Twist the push nuts off the solid rivets securing the rear shock pads; then remove the pads.
19. Rcmovc the ca p scrcw and lock nut securing the brace to the slide nlli.
NOTE: The adjusting bolt may have to be loosened to remove the adjuster bushing.
15, Mark the locati on of the rcar coupler bloc k (if applicable); then remove thc block. Account for the block, bushing, ca p screw, and lock nul.
INSPECTING
FS"""
NOTE: At this point, the slide rail should be free of the skid frame components and can be removed .
16. Remove the cap screws and lock nuts securing the track adjuste r bracket.
9122
Page: 718
I. Inspect the slide rail for cracks (A), elongated
holes (B), or unusual bends.
MS193A
3. Place the rail into position; thcll install the adjuster bushing and rear idler wheel. Install a cap scrcw and nat washer. Tighten only until snug. 2. Inspect the wear strip for wear. The wear strip must be 10.7 mm (0.42 in.) thick or thicke r. If the wear strip measurement is less than specified, replacement of both wear strips is necessary.
NOTE: Make certain the adjuster bushing is properly positioned.
Minimum Thickness
10.7 mm (0.42 in.)
~ ~~~~~
INSTALLING
J@I ~ I~
0727726
I. Install the shock pads and secure with ri vets (front) or with new push nuts (rear) . 2. Secure the track adj uster bracket with the cap screws and lock nuts. Tighten to specification s.
Page: 719
9123
NOTE: It is advisable to tighten the rear idler wheel axle only until snug until the skid frame has been installed and track tension has been adjusted; then the axle assembly must be tight ened to specifications.
6. Install the cap screw securing the mil SUpPOlt to the slide mil. Tighten onl y until snug.
4. Install the rear arm cap screw (1\) in the appropriate ho le (as noted during disassembly); thell install the rear arm limiter cap screw (8) in the appro priate ho le as noted during disassembl y. Tighten o nly until snug.
NOTE: The Sno Pro models have two rail supports.
7. Inst.all the rear inner idler wheel mounting block in the appropriate holes as noted during disa ssembl y and secure with ca p screw and lock nul. Tighten to specifications.
MS200A
5. Install coupler bl ock w/bushing. Secure with cap screw and lock nul. Tighten securely.
MS196A
8. Secure the front arm mo unting bracket with the cap screws and lock nuts. Tighten to specifications.
9124
Page: 720
9. Install the cap screw (if removed) and lock nut securing the front inner idler wheel assembl y to the slide mil s. Tighten only until snug.
12. Secure the outer idler wheel mounting block with the ca p screw and lock nul. Tighten to specifications.
NOTE: On Sno Pro models to install the spring slide blocks, include them in step 9. NOTE: To obtain proper alignment for the idler wheel cap screw, place the cap screw in the top hole through the rail and mounting block prior to tightening.
10. O n standard models, install the front arm shock axle to the proper hole as noted in removi ng; then seeure with the cap screw, washers, and the lock nul. Tighten onl y until snug.
13. Secure the oute r and inner idler wheel s to the mounting bloc ks with ex isting hardware. Tighte n to speci fi cations.
MS201A
11 . O n standard models, position the rear arm spring to the rear arm and place the spring into the slide block ; then place the spring slide and slide block assembly into position on the slide rail. Secure with a cap screw and washer. Tighten to specifications.
14. Install the upper shock mount to the front a rm. Tighten securely.
Page: 721
9125
17. Secure the end cap onto the slide rail using a cap screw, nat washers, and a lock nut. Tighten to specifications.
MS""A
15. Secure the rail supports with ca p screws (coated with blue Loctite #243). Tighten to specifications.
NOTE: Apply a light coat of grease to the slide rail surface to aid in installing a new wear strip. If there are any sharp edges on the lower portion of the rail, use a file to remove them
NOTE: At this point, tighten the mounting hardware from the following steps to specifications: 4, 6, 9, and 10.
16. Install the front arm limiter straps to the front rail support'). Tighten to specifications.
18. From the back, start the wear strip onto the rail ; then usi ng a soft hammer, drive the wear strip forwa rd into position. Secure with a machine screw and lock nut. Tighten to specifi cations.
9126
Page: 722
4. Elevate the rear of the skid frame and the track into position in the tunnel. 5. Ali gn the pivot idler arm assembly with the appropri ate hole in the tunnel. Secure the pivot idler ann assembly with a ca p screw (coated with red Loetile #27 1), loc k washer, and flat washer. DO NOT TIGHTEN AT THI S TI J'v lE.
MS016B
19, Aft er thc skid fram e has becn installed, adjust track tcnsion deflection (sec Track Tc nsion in this sub-section) and track alignment (see Track Alignment in this sub-section).
6. At tlti s time. tighten all four skid frame mounting cap sc rews securely. 7. Using the Rear Suspe nsion Spring Tool (pIn 0 1443 11 ), install the short legs of the rear springs onto the adjusting cams making Slife the cams are in the same adjustment positions. 8. Tighten the two track tension adjusting boll evenly until track deflection is within speci fi calions; then lock the jam nuts to sec ure the adjustment. 9. Check track tension dell ecti on and ali gn ment , adjust if necessary (see Track Tension and Track Ali gnment in this sub-section),

Place a piece of cardboard on the fl oor to protect against scratching and tip the snowmobile onto one side. 2. Pull thc track away from the tunnel and spread ope n; thcn place the skid fram e into the track. 3. Position the front of the skid frame into the tunnel and align the front ann with the appropriate mounting hole in the tunnel. Insert the cap screw with washers through the tunnel mounting hole and through the front arm. IX) NOT TIGHTEN AT THI S THvIE. Repeat thi s procedure on the othe r side.
Track Tension
A CAUTION
CHECKING DEFLECTION
I. Tip the snowmobil e on its side. 2. Hook a spring scal e around a track clip at midspan ; then pull the track down with the scale to 9 kg (20 Ib) and measure the di stance between the bottom of the wear strip and the inside surface of the track clip. Track deflection must be within specifications.
Rear Suspension Styte FasTrack wfTorque Sensing Link (12 1 in. Track) @201b FasTrack wfTorque Sensing Link (162 in. Track) @ 121b Setup Tension 32-38 mm (1 1/4-1 1/2 in.) After Break-tn Tension 38-44 mm (1 112-1314 in.)
63.Smm
NfA
(2112 in.)
739992A
Page: 723
9127
NOTE: If the track tension must be loosened, it may be necessary to loosen the rear axle assembly slightly_ NOTE: Vigorously push the underside of the track up and down. Track must not hit the top of the tunnel or slap the skid frame.
20 Ib (9 kg)
4. Arter correct track tension is obtained, check track aligmnent (sec Track Alignmenl in this subsectio n).
NOTE: Track tension and track alignment are interrelated; always check both even if only one adjustment seems necessary. Always establish correct track tension before checking and/or adjusting alignment.
729-429A
& CAUTION
oeflec~;~~:r ~
rn -121b (5 kg)
7294296
Track Alignment
NOTE: If the track is new, it will stretch slightly and take a " set" within the first 300 to 500 miles of operation. NOTE: Proper track alignment is when the rear idler wheels are equidistant from the inner drive lugs on the inside surface of the track.
I. Place the snowmobile up o n a sh ielded safety stand_ Check 10 make sure the lrack is 2-3 in. off the noor.
2. Ir the measurement is not as speci fi ed, loosen the jam nuts of the adjusting bolts.
Jam Nut
CHECKING
I . Using a shielded safety stand, raise the rear of the
snowmobile off the Ooor making sure the track is free to rotate.
& WARNING
2. Slart the e ngine and acceicrate slightl y. Use o nly
enough throttle to rotate the track several revolutio ns. SHUT TH E ENG INE OFF.
)
Rear tdler Wheet Adjusting
NOTE: Allow the track to coast to a stop. Do not apply the brake because it could produce inaccu rate alignment conditions.
Bolt
0727456
3. If the measurement obulined in step 2 is mo re than specified, ti ghte n the adjusting bolts. If the measure me nt obtained is less than specified, loosen the adjusting bolts. When the measurement is within specification range, lock the adjustment by botto ming the jam nuls against the axle housings.
9-128
Page: 724
3. When the track stops rotating, check the rciatio nship of the rear idler wheels and the inner track dri ve lUllS. If the distance from the idler wheels to the in ner dri ve lugs is the same o n both sides, no adj ustme nt is necessary.
Removing Skid Frame

Inner Track Drive L"'I'--'
NOTE : Many service procedures can be performed without removing the skid frame. Closely observe the note introducing each sub-section for this important information. I. To avoid having the adjuster bushings binding during loosening of the track, remove the rear idler wheel caps and loosen the cap screws on the rear axlc.
L. Wlh.."
,,,olIO'" between Drive Lugs
72S070A
4. On the side of the track whi ch has the inner dri ve lugs closer to the rear idl er wheel, loosen the adjusting bolt jam nut ; then rotate the adjusting bolt clockwise I- I 112 turns. _NOTE : If the track tension must be loosened , it may be necessary to loosen the rear axle assembly slightly. 5. Continue to check the track ali gnment and make the necessary adjustments until proper ali gnment is obl'ained, 6. After proper track alignment is obtained, lock the jam nut against the axle housing. NOTE : Make sure correct track tension is maintained after adjusting track alignment.
2, Loosen the jam nuts and two track-tension adjusting bolts.
6 CAUTION
After proper track tension and alignment have been attained, make certain that the rear axle assembly is tightened to specifications (see page 172) or component damage will occur. NOTE : Field test the track under actual conditions and, after the field test, check track alignment and track tension ; adjust as necessary.

Thi s Trac k/Rear Suspension sub-section (Replur Procedure 4) has been organi zed so each procedure can be completed indi\'iduall y and erfi ciently. Each sub-secti on ha s (as necessa ry) Remov in g. Disassembling, Cleaning and Inspectin g. Asse mbling. and Installing procedures. Some comlxments may \'ary from model to model. Thc tec hni cian should usc di screti on and sound judgment when removing and installing components. NOTE: Some illustrations and photographs used in this sub-section are used for clarity purposes only and are not designed to depict actual conditions.
Page: 725
3. Place a SUpp0I1 stand under the rear bumper; then remove the rear cap screws securing the skid frame to the tunnel. Account for lock washers and nat washers. NOTE : The support stand should hold the snowmobile level but not raised off the floor. 4. Remove the front cap screws and lock nul", securing the skid rrame to the tunnel. Account for a nat washer and a lock washer. 5. Remo\'e the support stand ; then tip the s now~ mobile onto the left side using a piece of cardboard to protect against scratching. Remove the skid fmme.
9129
NOTE: Avoid tipping the snowmobile onto the right side. If left on the right side for more than five minutes, air may get into the oil line. If air is appar ent in an oil hose, the system will eventually have to be bled (see Section 4 Bleeding Oillnjection System).
Wear Strip
739884A

MS215
Wear Strips
REMOVING
NOTE: If the skid frame has been removed due to difficulty in removing the wear strip, it may be nec essary to use a pipe wrench, start from either end, and hook the edge of the wear strip with the pipe wrench jaw and twist the wear strip off the slide rail. Move the pipe wrench 7.5 cm (3 in.) and again twist the wear strip off the rail. Repeat this proce dure until the wear strip is free of the rail.
I. Clean the slide rail using paltsc!e. .ming solvent and compressed air.
2,
In s rx~ct the slide rail for c racks. Jr any arc found , replace the slide rail.
I. Re move the machine screw and loc k nut securing the wear strip to the front of the slide rail .
3. Using a strai ghtedge, inspect the slide rail for any unusual bends. Place the straightedge along the bottom surface of the slide rail. If the rail is found to be bent , it must be replaced.
MS218A
2. Align the wear strip with the openings (windows) in the track; then using a suitable driving tool. drive the wea r strip rearward off the slide rail.
INSTALLING
NOTE: Critical torque specifications are located on page 172 of this section. NOTE: Apply a light coat of grease to the slide rail surface to aid in installing a new wear strip. If there are any sharp edges on the lower portion of the rail, use a file to remove them.
9130
Page: 726
I. Align the wear strip with the openings (windows) in the track and from the back, stmt the wear strip onto the rail ; then using a soft hammer, drive the wear strip forward into position.
2. Inspect the end cap for any signs of cracking or wear.
Wear Strip
739884A
2. Secure with a machine screw and loc k nul. Tighten to specifications.
End Caps
REMOVING
I. Remove the lock nut, washers, and cap sc rew securing the end cap.
3. Clean both the slide rail area and the end cap. Using compressed air, clean the areas of dirt and gravel.
INSTALLING
I. Position the end cap on the slide rail ; then ali gn the hole in the end cap with lhe hole inlhe slide rai\. 2. Using a hammer, tap the end cap olTthe rail .

2. Secure with a cap screw, washers, and lock nut. Tighten to specifications.
Shock Pads
NOTE: The skid frame does not have to be removed for this procedure. 9131
I. Inspect the end cap area of the slide rail fo r cracks and wear.
Page: 727
REMOVING
I. Twist the push Iluts off the solid ri\'cts securing the front shock p< 1ds; then remove the p< lds. 2. Using a 3I1 G-in. drill bit , drill oul the ri\'cls securing the rcar shock pads; the n account for the retaining brackets. Remove the rear shock pads.
INSPECTING

I. Clean the bearing with a clean cloth.
FC152
I. Inspect the pads for damage or wear. 2. Inspccllhc ri vet holes in the slide rail for damage or elongation.
INSTALLING
I. If removed, place the pads into position on the
2. Inspect each idler wheel for cracks o r d.'lmage. 3. Rotate the idler wheel be.aring (by hand) and inspect fo r binding or ro ughncss. 4. If a bearing must be replaced, use this procedure.
slide rails. 2. Secure the front pad assembly with ri vets and new
push oulS.
3. Secure the rear pads with ri vets.
&, CAUTION
removal.
Idler Wheels
A. Remo~'e the wheel insel1 (if applicablc) and the snap ring.
B. Using a hydraulic press, press the bearing o ut the inside of the wheel.
C. Press the new bearing (on its o uter race) into
REMOVING
I. Re move the cap screws and lock nuts securing the
the idler wheel.
idler wheel (A) and the idler wheel mounting block (8) . Account for a Oat washer.
MSOO6A
MS223A
D. Install the snap ring making sure the "sharp side" is directed away from the bearing .
2. Note the location of the nat washer for installing 0 the purposes. The washer must be installed next 1 head of the cap screw.
9132

REMOVING
I. Using the Rear Suspe nsion Spring Tool (p/n 0 1443 11 ), re move the spring from the adjusting cam.
MSOO7A
INSTALLING
I. Secure the mounting block on the slide rail with a
ca p screw and lock nut. Ti ghte n to specifications .
2. Remove the spring and sleeve from the idler ann .

. . ._ - - MS224A
2. Place the idler wheel to the mounti ng block making sure there is a flat washer agai nst the head of the cap screw on the outside of the idler wheel.

FC152A
3. Using Idler Wheel Pull er Kit (pIn 0644-4(0), remove the idle r wheel.
&
CAUTION
3 . Secure the idle r wheel assembl y with a cap sc rew and a lock nut. Tighten cap screws to specifications.
It is advisable to place a flat washer between the puller bolt and idler arm to avoid damage to the arm axle.
Page: 729
9133
MSOOOA
4. Re move the cap screw and nat washer securing the spring slide to the rail. Account for a slide bloc k and washer.
D. Install the snap ring making sure the "sharp side" is directed a way from the bearing.
MSOO7A
5. Inspect the spring, spring slide, sleeve, washe rs, slide block insclt, and shaft area for wear. 6. Inspcctthe adjusting cams and arms for cracks.

I. Clean the bearing with a clean cloth.
INSTALLING
I. Install the idler wheel. 2, Slide the sleeve and spring onto the idl er arm .
2. Inspect each idler wheel for cracks or damage. 3. Rotate the idler wheel bearings (by hand) and inspect for binding or roughness. 4 . If a bearing must be replaced, use thi s proced ure.
,&, CAUTION
,&, CAUTION
00 not remove the bearing unless it is absolutely necessary, The bearing will be damaged during removal.
A. Remove the wheel snap ring.
8. Using a hydraulic press, press the bearing out the inside of the wheel.
C. Press the new bearing (on its outer race) IOto
the idler wheel.

9134
3. Place the spring slide and slide block (with spring in slide block) into position on the slide rail. Secure with a cap screw and washer. Tighten securely.
NOTE: Install the washer to the head of the cap screw.
2. Loosen the track adjusting bolts. Slide the outer adjuster bushings off the axle.
MSmA

NOTE: The skid frame must be removed for this procedure (see Removing Skid Frame in this sub section). NOTE: The large flat side of the wheel insert is positioned next to the inner plastic adjuster bush 109. The idler wheel must be installed with the wheel insert properly positioned.
DISASSEMBLING
I. Remove the cap screw and large flat washer securing the outer rear idler wheel. Remove the idler wheel from the shaft.
3. Remove the rear axle, idJcr wheels, spacer, and track adjuster bushings; thell account for a spacer and four adjuster bushings.
NOTE: Note the position of the opening in the adjuster bushings for assembling purposes.
Page: 731
9135
D. Install the snap ring making sure the "sharp side" IS directed a way from the bearing.
MS230

MSOO7A
ASSEMBLING
Clean the bearings with a clean cloth. 2. Inspect the outer rubber portion of the idler wheels for cracks and poor bonding. 3. Inspect the shaft for wear and damaged threads. 4. Inspect all idler wheel bearings. Turn each beari ng (by hand) and if any roughness or binding is noted , replace the bearing . 5. If a bearing must be replaced, use this procedure.
I. Place the two inner adjuster bushings, idler wheels, and center spacer into position between the slide rail s.
A CAUTION
MS231
A. Remove the wheel sllap ring. B. Using a hydraulic press, press the bearing out the inside of the wheel.
NOTE: The adjuster bushing with the longer sleeve (A) must be installed inside the slide rails.
the idler wheel.
NOTE: Make certain the inner adjuster bushings are properly positioned to the axle openings in the slide rails,
MS"""
9136
Page: 732
2. From one side, slide the axle through the slide rail and ce nte r components rar enough to install the oU lSide adjuster bushings and idler wheels.
NOTE: Make certain the slots in the adjuster bushings are aligned with the adjusting bolts.
3 . Install the outside adjuster bushings and idler wheels with cap screws (coated with blue Loctite /12 43). Tighten only until snug.
NOTE: It is advisable to tighten the rear idler wheel axle only until snug until the skid frame has been installed and track tension has been adjusted ; then the axle assembly must be tightened to specifications.
4. Install the skid rrame (see Installing Skid Frame in thi s sub-section). 5. Adjust track alignment (see Track Ali gnment in thi s sub-section). 6. Adjust track tension deflection (see Track Te nsion in this sub-section).
Rear Arm/Idler Arm

DISASSEMBLING
I. Re move the spring and sleeve rrom the idl er arm .
Page: 733
9137
4. Remove the two All en-head cap screws sec uring the coupler blocks.
2. Using Idler Wheel Pull er Kit (pIn 0644-400), remove the idl er wheels from the upper arm .
MS234
5. Noting the mounting location for assembling purposes, remove the cap screw and loc k nut securing the upper shock links to the idler arm. Account for a lock nul , spacer, flat washer, and axle links .
NOTE: It is advisable to place a support block between the idler arms and idler wheels.
3 . Remove the cap screw and loc k nut securing the upper shock eyelet to the idl er arm. Account for a spacer, ca p screw, and lock nul.
9138
Page: 734
MS237
6. Remove the ca p screw and loc k nut securing the rear arm to the slide rail. Account ror the serrated a" les and ax le tube.
7. Remove the cap screw and lock nut securing the rear ann to the idler ann. Account ror the aluminum ax le and bushing assembli es.
MS238A
MS240A
MS239
MS242
NOTE: It may be necessary to loosen the rear arm limiter to remove the rear arm from the slide rails.

I. Clean the bearings with a clean cloth. 2. Inspect each idler wheel ror cracks or damage. 3. Inspect the bushings (located in the ann pi vot area) ror wear or damage. 4. Inspect all welds and the tubing or the upper arm ror cracks or unusual bends. 5. Inspect the two adjusting cams ror d'lmage.
9139
6. Rotate the idler wheel bearings (by hand) and check for binding or roughness. 7. If a bearing must be replaced, use this procedure.
A CAUTION
A. Remoye the wheel insert (i f applicable) and the snap nng.
B. Using a hydraulic press, press the bearing out the inside of the wheel.
MSOO5
ASSEMBLING
the idler wheel.
I. Install the rear arm onto the idler arm with an aluminum ax le, bushing assemblies, cap screw, and a lock nut. Tighten to specifications.
MS""'A
D. Install the snap ring making sure the "sharp side" is directed away from the bearing. 2. Place the rear arm assem bly into position (with the grease fittin gs directed toward the rear idler wheels) between the slide rails. Secure with a cap screw a nd lock nul. Ti ghten to specifications.
MSOO7A
E. Install the wheel insert (if applicable).
MS238A
9140
Page: 736
NOTE: If the rear arm limiter was loosened for removing of the rear arm, tighten the cap screws to specifications.
4. Place the upper shock eyelet with bushings between the idler arm brackets makin!! sure the spacer IS properl y positioned bet\\'een the <; , Secure w ith a ca p screw and lock nul. brac keL Tighten to securely. NOTE: Do not over-tighten the shock absorber cap screw as the shock eyelet must be free to pivot. 5. G re... 'lsc the idler arm and rear arm gre.asc fillings w ith a low -temperature grease. 6. Install the rear upper idler w heels, rear spring, and sleeve (see Rear Upper Idler W heels/Rear Springs in this sub-section).
MS238B
3. Position the shock links in the appropriate holes of the idler ann brackets (see Chassis and Skid Frame Mounting Locations in this scction), Place a spacer between the center of the brackets: then place a nat washer on the cap screw. Insert the axle links into the upper shock link eyelets: then IOsert the cap screw with washer through the eyelets. Secure with a cap screw. washer. and lock nul. Tighten securely.

NOTE: The skid frame must be removed for this procedure (see Removing Skid Frame in this subsection), and the rear springs must be removed from the adjusting cams.
REMOVING
NOTE: On models with remote reservoir, cut the cable ties securing the front shock absorber hose to the front arm. I . Remove the cap sc rews and lock nuts sec uring the limiter straps to the front arm. Account for nat washers.
MS237
2. Remove the ca p screw and loc k nut securing the upper front shock absorber eyelet to the front arm. Pull the shock eyelet free of the bracket. Account for a bushing.
Page: 737
9141
3. Remove the cap screws and lock nuts securing the front arm to the front arm mounting brackets.
6. Tap the shock mount axle assembly from one side until there is room enough to rcmove it from between the slide rails.
4. Remove the front arm and account for the two front arm spacers.
7. Using a plastic mall et, tap the axle from the lower shock eyelet. Account for spacers and shim washers.
MS245
5. Remove the cap screw, lock nut , and washer securing thc shock mount axle.
NOTE: New lock nuts must be used when install ing the shock mount axle.
INSPECTING
I. Inspect all front ann weldmcnts for cracks or
unusual bends. 2. Closely inspect all tubing for cracks or unusual bends.
9142
Page: 738
3. Inspect the bearings, bushings, and front arm spacers for wear or damage. 4. Inspect the shock absorber for any signs of oil leakage especially at the point where the shock shaft enters the shock body. 5. Inspect the shock absorber eyelet welds (at each end) for any cracks, signs of se parati on, or for unthreadi ng.
3. Position the front arm with spacers into the mounting brackets. Sec ure with ca p screws and lock nuts. Tighten to specifications.
INSTALLING
NOTE: Critical torque specifications are located on page 172 of this section,
I. Install the axle into the lower shock eyelet bushing assembly. Apply grease to the axle; then install the spacers. 2. Place the shock mount axle into position between the slide rails making sure the spacers and washers are properly positioned. Secure with a cap screw, washers, and new lock nul. Tighten to specificat ions. 4. Secure t he upper shock eyelet and serrated ax Ie in the mounting hole of the front arm . Secure with a cap screw and lock nut. Tighten securely.
5. Secure the li mi ter straps with ca p screws, washers, and lock nuts. Tighten to specifications.
Page: 739
9143

NOTE: Before removing the skid frame by using the Rear Suspension Spring Tool (pin 0144-311), remove the spring from the adjusting cam.
o o
AG665D
CAUTION Care must be taken when removing the spring

from the adjusting cam or damage or injury could result.
NOTE: The skid frame must be removed for this procedure (see Removing Skid Frame in this subsection). NOTE: When removing center components from the skid frame, it is advisable to loosen all cap screwslSock nuts from one side of the slide rail to make removing easier.
&
2. Noting thc hole location for assembling purposes, remove the cap screw, lock nuts, and washers securing the shock rod links to the rear mm of the skid fram e, Account for a spacer and two link ax les.
DISASSEMBLING
NOTE: Using Idler Wheel Puller Kit (pin 0644400), remove the idler wheel from the side from which the cap screw for the shock rod links must be removed .
3. Disengage the shock absorber and rod links at the
pivot assembl y. Account for washers, link ax les, bushings, shock sleeve, cap sc rew, and a lock nul.
I. Di sengage the shock absorber at the upper eyelet and remove the shock absorber. Account for a sleevc, cap sc rew, lock /lut, and bushings.
4. Note the hole location for assembling purposes; then remove the cap screw and loc k nut securing the pi vot assembly to the slide rails.
9144
Page: 740

I. Clean shock pivot and idler wheel ax le in partcleaning solvent. Dry with compressed air.
2 . Clean the idler wheel be.arings with a clean cloth .
5. Tap the shtx k pivot assembl y forward until it clears the mo untin!l brackets; then lift the assembly upward untiT the s haft clears the rails _
3. Closely inspect the to rque link arm and axles for
wear, bends, or damaged splines at ei ther end.
4. Inspect the idler wheels for signs of cracking, wear, o r outer rubber separation from plastic wheel.
5. Rotate the idler wheel be.arings (by hand) and ins pect for a ny signs of binding o r roughness. 6. If a bearing must be replaced, usc thi s procedure.
A CAUTION
00 not remove the bearing unless it is absolutely necessary. The bearing will be damaged during removal. NOTE: Lay components out in order as they are removed . 6 . With the pi vot assembly removed , account for the two spacers, an axle, and the pi vot bracket.
e.;;; _
A. Remove the wheel snap ring .

the inside o f the wheeL C. Press the new bearing (on its o uter race) into the idler wheeL
MS256
MSOOOA
D. Install the snap ring making s ure the " sharp side" is directed away from the bearing.
Page: 741
9145
MSOO7A
7. Inspect the shock absorber for any signs of oil leakage especially at the point whe re the shock shaft e nte rs the shoc k body. 8. Inspect the rubber shock bushings located in the shock absorber eyelets for cracks or deterioration. 9. Inspect the shock absorber eyelet welds (at each end) for any cracks or signs of separation. 10. Inspect the welds securing the eyelets of the shock links for cracks or signs of separation. Either weld the eyelet or replace the shoc k link. I L Inspect the axle surfaces for any signs of corrosion, If corrosion is found , lightly buff the surface of the axle with #400 wet-or-dry sandpaper: then apply a light coat of grease.
ASSEMBLING
3. Lower the pivot assembly down between the rails; then align the axle with the mounting hole just below and forward of the front arm mounting brackets.
4. Install the cap screw and lock nut securing the pivot assembly to the slide rails. Tighten to specifications.
L Appl y a thin coat of low-temperature grease to the a.'de and slide the axle into the shock pivot bracket. I-lave equal amounts of the axle ex posed on either side of the bracket tube.
5. Secure the shock rod links (w ith axles) and the lower end of the shock absorber to the pivot assembly with the cap sc rew and lock nuts. Tighten sec urely. 2. Slide the shim washers and spacers onto the axle from each side of the pi vot.
9146
Page: 742
8. Install the idler wheel removed in disassembling.
&
CAUTION
6. Position the shock links in the appropriate holes or the idl er arm brackets (see Chassis and Skid Frame Mounting l...ocations in this section). Place a spacer between the center or the brackets_ Insert the link axles into the upper shock link eyelets; then insel1 the cap screw through the eyelets. Secure with a cap screw, washer, and lock nut. Tighten securel y.
Slide Rails
REMOVING
NOTE: When it is necessary to replace one or both slide rails, it is recommended that one slide rail be removed at a time. The remaining slide rail will then hold the crossbraces, axles, and brackets in their correct assembly order. Always mark the mounting hole locations during disassembly to speed up the assembly process and to prevent any damage. This method is much quicker than to completely disassemble the entire skid frame. To replace either rail, use the following procedure.
7. Secure the shoc k absorber to the idler arm with bushings, sleeve, lock nut , and a cap screw. Tighten securel y.
I. Remove the machine screw and loc k nut securing the wear strip to the rront of the slide rail ; then using a suitable dri ving tool, dri ve the wear strip rearward off the slide raiL
Page: 743 2005 Arctic Cat Service Manual all models www.ReadManuals.com
MS21 8A
9147
NOTE: If binding of the wear strip occurs, it may be necessary to use a pipe wrench, start from either end , and hook the edge of the wear strip with the pipe wrench jaw and twist the wear strip off the slide rail. Move the pipe wrench 7.5 cm (3 in.) and again twist the wear strip off the rail. Repeat this procedure until the wear strip is free of the rail.
3. Re move the cap sc rews and lock nuts sec uring the limiter straps to the front arm.
4. Remove the cap screws securing the rail supports to the slidc rai l.
MS219A
NOTE: If not already done, remove the short spring leg from the adjusting cam. Also, it is rec" ommended that the cap screw be removed from the front shock absorber to the front arm to aid in slide rail installing.
2. Re move the end cap rrom the slide rai l. Account for a cap screw, lock nut, and two nat washers.
5. Removc the cap sc rews and lock nuts securing the ilUler idl er wheel and the mounting block. Account for cap screws, washers, and lock nuts.
9148
Page: 744
MS262A
6. Remove the cap screw and loc k nut securing the front shock mount axle.
NOTE: If it is necessary to remove the cap screw for replacing the slide rail , install the cap screw from the opposite side into the assembly to secure components and aid in replacing the slide rail.
8. Remove the cap screw and loc k nut securing the
rear shock pivot assembl y to the slide rail .
MS263A
NOTE: If it is necessary to remove the cap screw for replacing the slide rail, install the cap screw from the opposite side into the assembly to secure components and aid in replacing the slide rail.
7. Remove the cap screw and nat washer sec uring the spring slide to the rail, Account for a spacer and the slide block.
9. Noting the locations for installing purposes, remove the cap screws and lock nuts securing the center inner idler wheel and mounting bl ock. Account fo r ca p screws, nat washers, and lock nuts.
10. Noting the position of the front arm mounting bracket, remove the cap screws securing the bracket to the slide rail . Account fo r lock nuts.
Page: 745
9149
II. Noting the locations for installing purposes, remove the cap screws and lock nuts securing the rear inner idler wheels and mounting blocks.
o
12. Remove the cap screws, lock washers, and lock nuts from the rear arm limiter (A) and rear arm
(8).
14. Remove the cap sc rew and flat washer securing the rear idler wheel. Remove the idler wheel ; then remove the adjuster bushing.
MS272A MS270A
NOTE: If it is necessary to remove the cap screw for replacing the slide rail , install the cap screw from the opposite side into the assembly to secure components and aid in replacing the slide rail.
13. Remove the coupler block. Account for the block , bushing, cap screw, and lock nut.
9150
Page: 746
MS275
15. Re move the idler wheel assembl y. Place all components in order for installing purposes.
INSPECTING
MS229
NOTE: At this point, the slide rail should be free of the skid frame components and can be removed .
16. Re move the cap screws and lock nuts securing the track adjuste r bracket.
2. Inspect the wear strip for wear. T he wear strip must be 10.7 mm (0.42 in.) thick or thicker. If the wear strip measurement is less thrlO specified, replacement of both wear strips is necessary.
MS293
17. Twist the push nuts 01T the solid ri vets securing the front shock pads: the n re move the pads. 18. Using drill and a 3/1 6-in. drill bit , drill out the ri vets and remove the rear shoc k pads. Account for the retai ning brackets.
Page: 747
9151
Minimum Thickness 10.7 mm (0.42 in.)
~~~~ ~
INSTALLING
J@I ~ I~
0727-726 739992A
I. If re moved, install the shock pads; then secure w ilh ri vets and new push nuts.
3. Secure the front arm mounting bracket w ith the crlp screws and lock nuts. Tighten 1 0
specifications.
2. Position the slid rail into the fro nt arm mounting bracket; then align the fro nt shock ax le, rear shock pi vot axle, and the rear ann with the appro priate
mounting holes. Install the lock nuts. Tighten only
until snug.
4. Secure the rour rail SUPPOl1S and rear arm limiter with cap screws , Tighten to specificati ons.
MS200A
MS277A
&.
CAUTION
When installing the slide rail, make sure the rear arm shock mounting location on the pivot/axle is positioned correctly above the axle or component damage will occur.
9152
Page: 748
5. At thi s point , tighten the lock nuts (from step 2) 1 0 specifications. 6. Install the upper shock eyelet to the front arm with the cap sc rew and lock nut ; then tighten securely.
8. Place the spring slide and slide block into position on the slide ra il. Seeure with a cap screw and washer. Tighten to spec ifications,
7. Insta ll the inner idler wheel mount ing bl ocks in the appropri ate hole as noted during disassembly and secure with cap screws a nd lock nuts. Tighten to specifications.
9. Install coupler block w/bushing. Secure with ca p screws and lock nuts. Tighten securely.
Page: 749
2005 Arctic Cat Service Manu al all models www. ReadM anu als.co m
9153
MS""A
10. Install the track adjuster bolts and lock nuts wI washers. Tighten to specifications.
12. From one side, slide the axle through the slide rail and center components far enough to install the outside adjuster bushings and idler wheels.
MS286
11 . Place the two inner adjuster bushings into position between the slide rails.
13. Install the outside adjuster bushings and idler wheels with cap screws (coated with blue Locti te Il243). Tighten onl y until snug.
MS231
NOTE: The adjuster bushing with the longer sleeve must be installed to the inside of the slide rail.
NOTE: Make certain the slot in the adjuster bushing is aligned with the adjusting bolt.
9154
Page: 750
NOTE: Apply a light coat of grease to the slide rail surface to aid in installing a new wear strip. If there are any sharp edges on the lower portion of the rail, use a file to remove them .
NOTE: It is advisable to tighten the rear idler wheel axle only until snug until the skid frame has been installed and track tension has been adjusted ; then the ax le assembly must be tight~ ened to specifications.
14. Secure the limiter straps to the front arm with cap screws, lock nuts, and washers. Tighten to specifications.
16. From the back, start the wear strip onto the rail ; then using a soft hammer, dri ve the wear strip forward into position. Secure with a machine screw and lock nut. Tighten to specifications.
MS289
15. Secure the end cap onto the slide rail using a cap screw, fl at washers, and a lock nut. Tighten to specifications.
MS259A
17. Place the spring into the slide blocks; then place the spring into position on the slide rail and rear arm.
Page: 751
all models
www.ReadManuals.com
9155
739992A
NOTE : It is advisable to install the rear arm springs onto the adjuster blocks after the skid frame has been installed.
18. Arter the skid fram e has been install ed, install the
NOTE : To aid in centering the front arm with the hole in the tunnel , position the skid frame and track at a 45 angle to the bottom of the tunnel. 4. Elenlle the rear of the skid fram e and the track into position in the tunnel. 5. Secure the rear arm to the tunnel with a ca p sc rew (c0.: 1ted with red Loctite 1127 1); then tip the snowmobile onto the opposite side, align the front arm with the appropriate mounting hole in the 1ted with red tunnel, and IIlstali the cap screw (c0.: Loctite #27 1). 00 NOT TIGHTEN AT THI S TI ME. NOTE: Do not install the short legs of the rear springs onto the adjusting cams at this time. 6. At thi s time, li ghten all skid frame mounting cap screws securely. 7. Using the Rear Suspension Spring Tool (pIn 0 1443 11 ), install the short legs of the rear springs onto the adjusting cams making sure the cams arc in the same adjustment positions. 8. Ti ghten the two track tension adjusting boll') evenly until track defl ection is within specifications; then lock the jam nuts to secure the adjustment. 9. Tighten the rear axle assembly (threads coated with blue Loctite 11243) to spec ifications. 10 Check track tension deflection and alignment , adj ust if necessary (see Track Tension and Track Ali gnment in this sub-section).
short spring leg onto the adjusting cam; then adjust track tension deflection (see Track Te nsion in this sub-section) and track alignment (see Track Alignment in this sub-section).

Place a piece of cardboard on the fl oor to protect against scratching and tip the snowmobile onto the left side. NOTE : Avoid tipping the snowmobile onto the right side. If left on the right side for more than five minutes, air may get into the oil line. If air is apparent in an oil hose, the system will eventually have to be bled (see Section 4 Bleeding Oillnjection System). 2. Pull the track away from the tunnel and spread open; then place the skid fram e into the track. 3. Position the front of the skid frame into the tunnel and align the front ann with the appropriate mounting hole in the tunnel. Insert the cap screw with washers through the tunnel mounting hole and through the front arm. 00 NOT TIGHTEN
AT THIS TI ME.
L!'. CAUTION
9156
Page: 752
Track Tension
NOTE: If the track is new, it will stretch slightly and take a "set" within the first 300 to 500 miles of operation.
I. Place the snow mobile up o n a shielded safet y stand . Chcck to make sure the track is 2-3 in. o ff the Ooar. 2. If the measurement is not as specified, loosen the jam nuts of the adjusting bolts .
NOTE: The axle nut must be loosened for this procedure.
CHECKING DEFLECTION
I. Tip the snow mobile o n its side.
NOTE: Avoid tipping the Firecat models onto the right side. If left on the right side for more than five minutes, air may get into the oil line. If air is appar ent in an oil hose, the system will eventually have
to be bled (see Section 2 Bleeding Oillnjection System).
Rear Idler ./J Wheels
2. I-look a spring scale around a track clip at midspan ; then pull the track down with the scale to 9 kg (20 Ib) and measure the distance between the
bottom of the wear strip and the inside surface of the track dip. Track de Oection must be within
Track 26=_=~
specificatio ns.
Rear Suspension
Style
FasTrack (128 in. Track) @20lb FasTrack
Adjuster AdjuStin g Bo t
Cap Screw
Setup
Tension
25-32 mm (1-1 1/4 in.)
38- 44 mm (1 112-13/4 in.)
After Break-in Tension

32-38 mm (1 114-' 112 in.) 50.8-57.2 mm
(2-2114 in .)
739636A
(144 in. Trad() @201b FasTrack wrrorque Sensing Link (1 44, 153, 162in . Track)@12Ib
63.5 mm
NIA
(2112 in.)
3. If the measurement obtained in step 2 is more than specified. tighten the adjusting bolts. If the measurement obtained is less than specified, loosen the adjusting bolts. When the measurement is within specificatio n range, lock the adjustment by bottoming the jam nuts against the axle housings.
NOTE: Vigorously push the underside of the track up and down. Track must not hit the top of the tunnel or slap the skid frame.
20 Ib (9 kg)
4. Aft er correct track tension is o btained, check track alignment (see Track Alignment in this subsection).
_NOTE : Track tension and track alignment are interrelated; always check both even if only one adjustment seems necessary. Always establish correct track tension before checking andlor adjusting alignment.
729429A
& CAUTION
Deflection
729-4296
Page: 753
9157
Track Alignment
_NOTE : Proper track alignment is when the rear idler wheels are equidistant from the inner drive lugs on the inside surface of the track.
Relr Idler W huls
CHECKING
I. Using a shielded safety sta nd, rai se the rear or the snow mo bile ofr the noor making sure the track is free to rotatc.
Inner Track Drioe Lugs
0 739 637
WARNING
4. O n the side of the track which has the inner dri ve lugs closer to the rear idl er wheel, loosen the adjusting bolt jam nut ; then rO~"lt e the adjusting bolt cloc kwi se I-I 1/2 turns. 5. Continue to check the track a li gnment and make the necessary adjustments until prope r ali gnment is obtained. 6. Afte r prope r track alignme nt is o btained, lock the jam nut against the ax le housing . 7. Tighten the rear ax le assembly (threads coated with blue Loctite 11243) to spec ificatio ns.
2. Start the engine and accelerale sli ghtl y. Usc o nly enough throttle to rota Ie the track several revolutio ns. SHU I' TI-IE ENG INE OFF.
NOTE: Allow the track to coast to a stop. Do not apply the brake because it could produce inaccurate alignment conditions.
3. When the track stops rotating, check the relatio nship of the rear idler wheels and the inner track dri ve lugs. Ir the distance rro m the idler wheels to the inner dri ve lugs is the same on both sides, no adjustme nt is necessary.
6 CAUTION
After proper track tension and alignment have been attained , make certain that the rear axle assembly is tightened to specifications or component damage will occur. NOTE: Make sure correct track tension is maintained after adjusting track alignment NOTE: Field test the track under actual conditions and, after the field test, check track alignment and track tension ; adjust as necessary.
9158
Page: 754
Drive Sprocket Locations

The fo llowi ng illustratio ns wi ll provide all necessary information to relocate s prockets 011 the dri veshaft. W he n informatioll is req uired to assemb le the dri vcshaft , refer to the parts manual for model being worked W he n pressing new s procket s Oil the drivc s haft , re me mber to a lign the sprocket alignment marks o r the s prockets won '( be timed correctly. Sec following illustrations.
on; the n refer to the following illustrations using the pm1 number listed in the parts manual as a reference.
0728351
Sprocket Timing Marks
737-fJ70A
0727-829
Page: 755
9159
Timing Marks
727-8296
740043A
740044 A
9160
Page: 756
0728-041
0735-366
0728-042
0738-014
0728-043
0 738-015
0728-047
0738-016
Page: 757
2005 Arctic Cat Service Manu al - all models - www. ReadM anu als.co m
9-161
0728-048
0738-0 17
0728-049
0136-018
0728-050
0738-019
0728-065
..
0738-355
9-162
Page: 758
0728-067
"
0738-356
0728-072
0738-357
0728-076
0738-358
0728-081
0738-359
Page: 759
9-163
0728-082
---,,--
- .. ..
--;;;;;-----,
,.
0739-219
0728-083
0738-360
0728-084
0738-361
0728-111
0739-220
9164
Page: 760
0728-114
0739-22 1
0728-127
.,..
'
0740-041
0728-1 31
0740-042
Page: 761
9-165
Driv e Track Usage Chart

Below is a listi ng of drive tracks for Arctic Cat snow mobi les. This chm1lists each track with ilS speci fi cations such
as length, pitch , width, rail centers, and bar grip design,
F rom the information provided in this chm1, note what other tracks can be substituted as a repl acement track if a 0 all critical specifications w hen choosing an alternati ve recommended track isn' t avai lable. Pay close attention 1 track.
PIN
length
1"'131 136"
WIdth
RaIl Center
Bar DesIgn
Lug HeIght
~
725" .725'
".15" 15'
16"
-8:84"
NfA
FiillBiOok
''''
136" 136' 121 121" 136' 136" 121 136" 121 121 121 136" 136' 136' 121 " 121 121 121 " 156' 156" 121 121
15' 15" 15' 15" 15' 15"

16'
'''' ''''
15' 15' 15" 15'

20'
15' 15" 15' 15' 15' 15" 15' 15" 20' 16" 15' 15' 15' 15"
11 "
~1922
~ ~ ~
~: ~:
121 121 68' 136" 121 121 121 121 144" 144" 144" 156" 151 151 121 121 136" 121 121 136"
15' 15' 15" 15' 15' 15' 15" 15' 15' 15' 15" 15' 15' 15' 15" 15' 15'
8.84" 8.84" 8.84' 8.84" 8.84' 8.84" 8.84' 8.84' 8.84" 8.84" 8.84' 8.84" 8.84' 13.50" 8.84' 8.64' 8.84" 8.84" 8.84' 8.84" 8.84' 8.84" 13.50' 8 .84' 8.84" 8.84" 8.84' 8 .84" 8 .84' 8 .84" 884' 8 .84' 884' 8.84" 8.84' 8 .84" 8 .84' 8 .84" 884' 8 .84' 884' 8.84" 8.84' 8 .84" 8 .84' 8.84"
F," Blook F," Blool< ~"' F," Blool< F," Blool< F,,, Blool< W"e F," Blook F," Blool< F," Blool< F,,, Blool<
F~
W.""
NfA
~
725' .725' .725' .920" 725' .725'
lAO 1.60" 1.25'

.850 .725' lAO" 1.60' 2.00 .725' lAO" .850' .725' 1.00' 1.00" .850' 1.00
F," Blool< F," Blool< F,,, Blook """ Blook F," Blook F," Blool< F," Block
""" Blook Blook Blook
I ,W"e W"e
T,f.
.690' .850 1.00' .850" .850' .850 2.1 1.25' 2.00 2.1 .850' 1.375' 1.375' 1.25" .850' .725'
Coolo. Sto'
F," F,"
F," Blook
Deep L'g Deep Log Deop Lug W."" I ,W."" Deep Lug
De,p Lug Deep Lug
~ ~
F," Blook
W.""
9166
Page: 762
Driv e Track Usage Chart (cant)

PIN
1602-1 91
Length
144"
Width
15" 15" 15" 15" 15" 15" 15" 13.5" 13.s15" 15" 15" 15" 15" 135 15" 13.5" 13.5" 15" 13.5" 13.5" 13.5" 13.5" 13.5" 13.5" 15" 15" 15" 15" 13.5" 13.5" 13.5" 13.5" 15" 15" 13.5" 13.5" 15" 15" 13.5" 15" 13.5" 13.5" 15" 13.5" 15" 15" 13.5" 15" 15" 15" 15" 15"
w~h
Rail Center
8.84"
Bar Design
i
Wave
Lug Height
1.25"
1.25" 1.00" .8SO" 1.' 2 .00" 2 .00" 1.375" 1.00" 2.25" 2.25" 2.25" 2.' 200" .725" 2 .00" l.SO" 150"
151 121 121 13a" 144" 151 128" 128" 138" 144" 151 144" 151 128" 159" 144" 151 158" 128" 1802"41 128" 144" 128" 128"
8.84" 8.84" 884" 8.84" 8.84" 8.84" 8.84" 8.84" 8.84" 8.84" 884" 8.84" 8.84" 8.84" 8.84" 8. 84" 8.84" 8.84" 884" 8.84" 8.84" 884" 8.84" 8.84" 8.84" 884" 884" 8.84" 8.84" 884" 8.84" 8.84" 8.84" 884" 884" 8.84" 8.84" 884" 8.84" 8.84" 8.84" 8.84" 884" 8.84" 8.84" 884" 8.84" 8.84" 8.84" 884" 884" 8.84"
I , W", I , Wa~
F"" Blo,'
Co"'~1
S,"' Dep log

Dep L"g
F"" Blook F"" Blo,'

Co",~1
S,"d S,"'
,Wa~ ,Wa~
Co"'~1
I I I I
'Wa~
F"" Blook
,Wa~
Dep L"g Dep L"g Dep L"g
2.00" l.SO" 1.85" 1.25" 1.00" 1.375" 1.00" 1.00" 3 .00" 2.25"
~ ~ ~ ~ ~ ~
128" 136" 162" 144" 151 128" 128" 128" 128" 121 121 144" 151 141 153" 128" 141 144" 144" 121 128" 141 162" 128" 136" 121 136" 136" 121
F"" Block F"" Bloc' I 'Wa~ F"" Block

I ,W", Doep log Doep L"g
F ""Block I 'Wa~ F"" Bloc' I F"" Blod<

D.,p L" g I I
~
1.375" .00" 1.375" 1.00" 1.375" 2.25"
~
2.25" 1.70" 1.60" 1.25" 1.25" .70" 1.25"
I ,W", I
Wa~
2.00" 1.70" 1.SO" 200" 2.00" 1.25" 1.25"
Deep log Deep L" g
W". I ,Wa",
This track can only be used on AWS V chassis
a Torque Sensing Link Rear Suspension.
Page: 763
9-167
Drive Track Lug Patterns

Below are illustrations of the lug patterns available samples o nl y, and the actual patterns may vary.
011
Arcti c Cat dri ve tracks. T hese patlerns arc rcprcsentati\'c
,.,
"\!I
~
IYJ\
TAACK01
9168
Page: 764
Track Warranty Guidelines

Fatlure Mode
Descnpt'Ofl
CondlHon In which the track fabric cleanly separates or spreads apart from Ihe rubber. Condition in which lhe lugs are 10m. cracked . worn. or separate d. material
Cause
Warranty Covered
Oelamlnallon
(A)
Resun of poor adhesion between fabric and tubber

Most often a resuft 01 riding/spinning on rugged terrain . -rocks.
TreadlExlernal
Not Covered
lug Damage
(6)
-jagged ice,
-metalobjeds, ~tavel roads, igh speed running
w~h
poor lubrication may produce

Covered
Edge Tearing
(e)
Tracllon Product and Clip Damage
A track failure that OC(:urs alonj;llhe side 01 the track in which tearing occurs etther parallel or perpendicular to the track edge.
Cutting lhal occurs where a SlUd or pick Is attached 10 lhe lrack. This Includeslearlng due 10 slud pul~lhrough as well as lrack clips Ihat are lorn off. Condi1ion In which Inlernallugs are torn. worn . or cracked . Condllion in which lracks are found to have broken rods. Gumrrtf lread sometimes accompanies broke n rods. Wear clip and rod section broken out and missing.
gummy eKlemallrack lugs leading 10 separation. Rods oul of center. 1111 rod Is posiHoned off-cenler during
track manufacturing. tearing along the side of the track may occur 112 in. hom the edge.
011en lhe resull of conlaCl having been made whh a solid or jagged objecl (e.g. rocks. ice. melal. gravel. elc.).
NOI Covered
Inlernal Lug Damage
Resuh of oonlact being made
w~h
a foreign object.
NOI Covered
Track derailmenl can also cause this damage. Broken Rods! Missing Clip (0) Typically. rewhs from track Impacts and overheating. OIIE!rheatlnQ o11he rod can resuh from friction bUI~ due 10 poor lubncalion 01 riding al high continuous sp s tor long periods of time in minimal snow conditions. Gummy tread and brown 01 dark brown rod color at Ihe oenter somellmes accompanies this failure. Signs of wear strip malerlal melted and slicking to the edges of lhe wear Clip. Also. wear clips lhal have Slarted 10 turn blue in color from overheatin~ are all signs 01 operaling the snowmobile on min mal snow. Large Deform~lesofthe Track or Air Bubbles Lugs Torn Off Outer BeH (6) Condilion In which a lrack has large deformllies which may include air bubbles!pocketslvoids w~hln Ihe traCk. Condilion normally found on deep lug hacks. Manufacturing flaw. Covered NOI Covered
TY'pIcaI~; the resull of operallng a dee~ lug track on mrnima snow at high rates of speed. T is track is designed for deep snow mounlainous areas only.
N01 Covered
73 4-Snc
Page: 765
9169
Idler Wheel Selection Chart

PIN
0114-209
0114-159 0114-245 0604-004 0604-225 0604-226 0604-227 0604-235
0604-332 0604-334 0114-240 0604-205 0604-234 0604-239
0604-240 0604-281 0604-327 0604-328 0604-333 0604-374 0604-450 0604-459 0604-981 0638-550 0114-223 0114-206 0114-210 0604-210 0604-222 0604-223 0604-237 0604-238 0604-331 0604-670 0604-969 0604-980 0638-431 0104-298 0604-275 0604-276 0604-284 0107-137 1604-837 1604-838 1604-839 1604-745 1604-765 1604-744 1604-766 DIameter 4.25 in.
10
Insert Part Number 0104-340 0104-340 0104-341
WIdth
Color Spoke
0.625 in.
0.625 in.
5.00 in.
5.25 in. 5.35 in. 5.35 in. 5 .35 in. 5.35 in. 5.35 in. 5.35 in.
0104-341
0104-341 0104-341 0104-341
0.625 in. 0.625 in. 0.625 in. 0.625 in. 0.625 in. 0.625 in.
0104-340 0104-340
0104-340
0.75 in. 1.05 in. I.ODin. I .ODin.

1.12 in. 1.33in. 1.33 in. 1.12 in.
Not spoked Not spoked

Not spoked
0604-220 0604-220 0104-340

0104-304
0104-341 0104-341 0104-341
0.625 in.
0.625 in.
5.35 in. 5.63 in.

5.63 in. 5.63 in. 5.63 in. 5.63 in. 5.63 in. 5.63 in. 5.63 in. 5.63 in. 5.63 in. 5.63 in. 5.63 in. 5.63 in. 5.63 in. 5.83 in. 6.38 in. 6 .38 in. 6.38 in. 6.38 in. 6.38 in. 6.38 in. 6.38 in. 6.38 in. 6 .38 in. 6.38 in. 6.38 in. 6 .38 in. 7. 125 in . 7.125 in. 7. 125 in . 7. 125 in . 7.625 in. 5.630 in. 6.380 in. 7.120 in. 7.125 in . 6 .38 in. 6.38 in. 6.38 in.
0604-220
0104-340 0604-220 0104-340 0104-340 0604-220 0604-220 0604-220 0604-220 0104-340 0104-340 0104-340 0104-340 0104-342 0104-340 0104-342 0104-340 0604-224 0604-224 0604-220 0604-220 0604-224 0604-220 0604-220 0604-220 0604-224 0104-342 0604-220 0604-220 0104-341 0104-342 0104-340 0104-343 0104-343 0104-341 0104-341 0104-341 0104-341 0104-343 0104-341 0104-343 0104-341 0104-341 0104-341
1.12 in. 1.33 in.

1.00 in. 1.00 in. 1.33 in. 1.12 in.
1.12 in. 1.33in. 1.12 in. 1.12 in. 1.12 in. 1.00in. 0.875 in . 1.00 in. 1.12 in. 1.12 in. 1.00 in. 0.875 in. 1.00in. 1.00in. 1.46 in. 1.46 in. 1.46 in. 1.46 in. 1.46 in. 1.12 in. 1.00 in. 1.12 in. 1.46 in. 0.95 in. 1.46 in. 1.46 in. 0.95 in. 1.00in.
Not spoked Chrome Chrome Gold Gold Black
Black
Not spoked Not spoked - has hole for wrench Gold Gold Chrome Silver Chrome Gold Black Not spoked - S/A 0604-205 wlo hole Not spoked - aluminum center Nol spoked Green Purple Not spoked Not spoked - aluminum center Not spoked Not spoked Chrome Gold Gold Chrome Black Black Nol spoked Green Purple Not spoked Silver Gold Not spoked Not spoked Not spoked Nol spoked Nol spoked Green Orange Black Purple
0.625 in.
0.984 in. 0.625 in. 0.625 in. 0.625 in. 0.625 in. 0.625 in. 0.625 in. 0.625 in. 0.984 in. 0.625 in. 0.625 in. 0.625 in. 0.625 in. 0.750 in. 0.625 in. 0.750 in. 0.625 in. 0.750 in. 0.750 in. 0.625 in. 0.625 in. 0.750 in. 0.625 in. 0.625 in. 0.625 in. 0.750 in. 0.750 in. 0.625 in. 0.625 in. 0.625 in. 0.750 in. 0.787 in. 0.787 in. 0.787 in. 0.625 in. 0.625 in. 0.625 in. 0.625 in.
1604-774 1604-774 1604-774 1604-774
1.44 in. 1.44 in . 1.44 in. 1.44 in.
9170
Page: 766
Idler Wheel Selection Chart (cant)

PIN
1604-767
1604-683
DIameter
10
Insert Part Number
WIdth
Color Spoke
Red
6.38 in.
7.125 in .
0.625 in.
0.625 in.
1604-774
1604-774 1604-774 1604-774 1604-774 1604-772 1604-772 1604-774
1.44 in.
1.44 in.
Black
Orange
Purple Red
1604-776 1604-777 1604-778 1604-686 1604-685 1604-694
7. 125 in.
7. 125 in. 7.125 in. 7.125 in . a.3ain. a.3ain.
0.625 in. 0.625 in. 0.625 in. 0.625 in. 0.625 in. 0.625 in.
1604-773
1604-773
1.44 in. 1.44 in. 1.44 in. 1.19 in. 1.19 in. 1.44 in.
Not spoked Not spoked

Silver
1604-692 1604-684 1604-690 1604-691

1604-693 1604-848 1604-971 1604-987 2604-037 2604-117 2604-122 2604- 123 2604-124 2604-143 2604-150 2604-196 2604-197 2604-198 2604-199 2604-251 2604-263 2604-264 2604-273 2604-408 2604-547 2604-548 2604-549 2604-550 2604-551 2604-552 2604-553 2604-554 2604-555 2604-525 2604-526 2604-564 2604-594 2604-595 2604-534 2604-617
a.3ain. 5.63 in. 5.63 in. 5.63 in. 5.63 in.

6.38 in. 7. 120 in . 5.630 in. 5.630 in. 7.125 in. 5.630 in . 6.380 in . 7.120 in . 5.350 in. 6.380 in. 5.630 in . 7.120 in. 5.630 in. 7. 120 in . 6.380 in . 5.630 in. 6.380 in. 5.630 in. 7.120 in. 5.630 in . 5.630 in . 6.380 in. 6.380 in. 6.380 in . 6.380 in . 7.120 in. 7. 120 in . 7. 120 in . 8.000 in. 8.000 in. 8.000 in. 8.000 in. 8.000 in . 6.380 in . 8.000 in.
0.625 in. 0.625 in. 0.625 in. 0.625 in.

0.625 in. 0.625 in. 0.625 in. 0.375 in. 1.00 in. 0.984 in. 0.625 in. 0.625 in. 0.625 in. 0.984 in. 0.787 in. 0.787 in. 0.787 in. 0.787 in. 0.787 in. 0.787 in. 0.787 in. 0.787 in. 0.787 in. 0.787 in. 0.787 in. 0.787 in. 0.787 in. 0.787 in. 0.787 in. 0.787 in. 0.787 in. 0.787 in. 0.787 in. 0.787 in. 0.787 in. 0.787 in. 0.787 in. 0.787 in. 0.787 in. 0.787 in.
1604-774 1604-772
NONE
1604-773 1604-773
1604-773
1.44 in. 1.14 in.

1.14 in.
Green
Not spoked
Not spoked
1604-772
1604-772 1604-774 1604-774 1604-501
1.22 in.
1.22 in. 1.19 in. 1.44 in. 1.22 in. 1.22 in. 1.07 in.
Green
Silver Not spoked Black Green Orange Not spoked - Black Yellow Yellow Yellow Not spoked - Black Green Silver Silver Green Green Silver Yellow Yellow Red Orange Purple Orange Green Red Purple Orange Yellow Red Purple Green Red Orange Silver Yellow Not spoked Black
1604-772 1604-774 1604-774
1604-773
1.22 in. 1.44 in. 1.44 in. 1.00 in. 1.49 in. 1.34 in. 1.49 in. 1.34 in. 1.49 in. 1.49 in. 1.34 in. 1.49 in. 1.34 in. 1.49 in. 1.34 in. 1.34 in. 1.49 in. 1.49 in. 1.49 in. 1.49 in. 1.49 in. 1.49 in. 1.49 in. 1.49 in. 1.49 in. 1.49 in. 1.49 in. 1.49 in. 1.49 in. 1.49 in.
Page: 767
9-171
Idler Wheel Selection Chart (cont)

PIN
2604-740 2604-749
2604-751 2604-752 2604-824 2604-825
2604-826
DIameter
10
Insert Part Number
WIdth
1,49 in.
1.34 in. Fire Red Fire Red
Color Spoke
6.380 in. 5.630 in .

5.630 6.380 7.120 7.120 7. 120
in. in. in. in . in .
0.787 in. 0.787 in.

0.787 in. 0.787 in. 0.787 in. 0.787 in. 0.787 in. 0.787 in.
2604-827
2604-828 2604-829 2604-830 2604-831 3639-811
B.ODin.
1.34 in. 1.49 in. 1.49 in. 1.49 in. 1.49 in. 1.49 in.
Pearl Cat Green Pearl Cat Green Pearl Cat Green Orange
Fire Red
Pearl Cat Green

Fire Red
3639-812
3639-813
3639-814
B.OOin. 5.630 in . 6.380 in . a.OOin. 7.125 in. 7.125 in. 7. 125 in .

B.OOin. B.OOin. B.OOin.
0.787 in. 0.787 in. 0.787 in. 0.787 in. 0.787 in. 0.787 in.
0.787 in.
0.7B7 in.
0.787 in. 0.787 in.
1.49 in. 1.34 in.

1.49 in.
1.49 in.
Orange Orange Orange Silver Black
Black
Silver Black Black
3639-BI5 3639-BI6
ITEM End Cap Wear StripJRail Idler WheelIMounting Block Idler WheelIMounting Block (F-Chassis) Spring Slide BlocklRail Spring Slide BlockJRail (F-Chassis) Pivot Idler/Idler Arm Rear ArmJRail Rear Armlldler Arm' ft-Ib kg-m ft-Ib kg-m ft-Ib kg-m ft-Ib kg-m ft-Ib kg-m ft-Ib kg-m ft-Ib kg-m ft-Ib kg-m ft-Ib kg-m ft-Ib kg-m ft-Ib kg-m
TORQUE
7 1.0 5 0 .7 40 5.5 35 4 .8 45 6 .2 34 4 .7 18 2.5 45 6 .2 45 6.2 50 6.9 30 4.2
ITEM
Front Inner Idler Wheel Assy (TouringlZ) Front Rail Support' ft-Ib kg-m f1-lb kg-m ft-Ib kg-m ft-Ib kg-m ft-Ib kg-m ft-Ib kg-m ft-Ib kg-m ft-Ib kg-m ft-Ib kg-m ft-Ib kg-m ft-Ib kg-m
TORQUE
45 6.2 30 4.2 15 2.1 34 4 .7 10 1.4 50 6.9 34 4.7 10 1.4 50 6 .9 45 6.2 45 6.2
IZAI
Front ArmIMounting Brackets (TouringlZ) Front ArmIMounting Brackets (F-ChassisIZR) Limiter Straps Rail SupportlRail Rear Arm/Idler Arm (F-Chassis) Track Adjuster BracketJRail Rear Arm Limiter/Rail" Front Arm Shock AxlelRail Front Shock Pivot Axle
lAWS VI
Rear Axlelldler Wheel" Front Arm Mounting BracketlRail
wlBlue Locme 6243
9172
Page: 768
2005 Arctic Cat Serv ic e Manual - all models - www. ReadManual s.com
Rebuildable Shock Accessory Part Numbers

1991 & NeW'er Shocks
NOTE: When rebuilding Fox shock s, use only Fox valves and/or pistons.
FOX 0375 In J O. Shaft
FOX - 0 504 In
ID Shaft DESC.
PM
0603348 0603-349 0603350 0603891 0603-890 0603-346 0603-347
0603-883
OESC
Valve, Shock
Valve, Shock Valve, Shock Valve, Shock Valve, Shock
PIN
2604-500 2604-501 2604-502 2604-631 2604-503 2604-504 2604-495 2604-496 2604- 497 2604-647 2604-498 2604-632 2604-633 2604-499 2604-490 2604-491 2604- 492 2604-493 2604-494 2604-484 2604-485 2604-486 2604-487 2604-488 2604-489 2604-483 2604-478 2604-479 2604-480 2604-481 2604-482 2604-472 2604-473 2604-474 2604-475 2604-476 2604-477 2604-471 2604-469 2604-470 2603-224 Valve, Shock Valve, Shock Valve, Shock Valve, Shock Vallie, Shock Valve. Shock Valve, Shock Valve, Shock Valve, Shock Valve, Shock Valve, Shock Valve, Shock Vallie, Shock Valve. Shock Valve, Shock Valve, Shock Valve, Shock Valve, Shock Valve, Shock Valve, Shock Vallie, Shock Valve. Shock Valve, Shock Valve, Shock Valve, Shock Valve, Shock Valve. Shock Valve, Shock Vallie, Shock Valve. Shock Valve, Shock Valve, Shock Valve, Shock Valve, Shock Valve, Shock Valve, Shock Valve, Shock Valve, Shock Valve, Shock Valve. Shock Valve, Shock
1.300 Dia. x .006 in. Thk

1.300 Dia. x .008 in. Thk 1.300 Dia. x .010 in. Thk 1.300 Dia. x .012 in. Thk 1.300 Dia. x .015 in. Thk 1.250 Dia. x .008 in. Thk 1.250 Dia. x .010 in. Thk 1.250 Dia. x .012 in. Thk 1.250 Dia. x .015in. Thk 1.100 Dia. x .004 in. Thk 1.100 Dia. x .006 in. Thk 1.100 Dia. x .008 in. Thk 1.100 Dia. x .010 in. Thk 1.100 Dia. x .012 in. Thk
1.600 Dia. x .006 in. Thk 1.600 Dia. x .OOS in. Thk 1.600 Dia. x .010 in. Thk 1.600 Dia. x .010 in. Thk 1.600 Dia. x .012 in. Thk 1.600 Dia. x .015 in. Thk 1.425 Dia. x .006 in. Thk 1.425 Dia. x .OOS in. Thk 1.425 Dia. x .010 in. Thk 1.425 Dia. x .010 in. Thk 1.425 Dia. x .012 in. Thk 1.425 Dia. x .012 in. Thk 1.425 Dia. x .015 in. Thk 1.425 Dia. x .015 in. Thk 1.350 Dia. x .006 in. Thk 1.350 Dia. x .OOS in. Thk 1.350 Dia. x .010 in. Thk 1.350 Dia. x .012 in. Thk 1.350 Dia. x .015 in. Thk 1.100 Dia. x .006 in. Thk 1.000 Dia. x .OOS in. Thk 1.000 Dia. x .010 in. Thk 1.000 Dia. x .012 in. Thk 1.000 Dia. x .015 in. Thk 1.000 Dia. x .020 in. Thk 1.000 Dia. x .020 in. Thk .950 Dia. x .006 in . Thk .950 Dia. x .008 in . Thk .950 Dia. x .010 in . Thk .950 Dia. x .012 in . Thk .950 Dia. x .015 in . Thk .800 Dia. x .006 in.
I
Valve, Shock Valve, Shock Valve, Shock
0603-889 0603-892 0603342

0603-343
, Shock
Valve, Shock Valve, Shock Valve, Shock Valve, Shock Valve, Shock
0603-344 0603-882
I I
0603-339
0603340 0603341 0603-881 0603-887 0603-894 0603-336 0603337 0603-338 0603-880
Valve, Shock Valve, Shock Valve, Shock Valve, Shock
1.000 Dia. x .006 in. Thk 1.000 Dia. x .008 in. Thk 1.000 Dia. x .010 in. Thk 1.000 Dia. x .012 in. Thk 1.000 Dia. x .015in. Thk .900 Dia. x .004 in. Thk
, Shock
Valve, Shock Valve, Shock Valve, Shock Valve. Shock Valve, Shock
Thk .900 Dia. x .OOS in. Thk .900 Dia. x .010 in. Thk .900 Dia. x .012 in. Thk
.900 Dia. x .006 in.
I I
0603-333 0603-334 0603-335 0603-879 0603-885 0603-731 0603330 0603-331 0603-332 0603-878 Valve, Shock Valve, Shock Valve, Shock Valve, Shock .800 Dia. x .006 in. Thk
. Shock
Valve, Shock Valve, Shock Valve, Shock Valve, Shock Valve, Shock
Thk .800 Dia. x .010 in. Thk .800 Dia. x .012 in. Thk .800 Dia. x .015 in. Thk .700 Dia. x .004 in. Thk .700 Dia. x .006 in. Thk .700 Dia. x .OOS in. Thk .700 Dia. x .010 in. Thk .700 Dia. x .012 in. Thk
.800 Dia. x .OOS in.
Thk
.800 Dia. x .008 in . Thk .800 Dia. x .010 in . Thk .800 Dia. x .012 in . Thk .800 Dia. x .015 in . Thk .800 Dia. x .020 in . Thk .750 Dia. x .020 in . Thk .700 Dia. x .010 in . Thk .700 Dia. x .020 in . Thk .620 Dia. x .015 in . Thk
Page: 769
2005
Arctic Cat Service Manual - all models - www. ReadManuals.com
9-173
Rebuildable Shock Accessory Part Numbers ( cant)

1 991 & NeW'er S hock s
NOTE: When rebuilding Fox shock s, use only Fox valves and/or pistons.
ACT - 0 375 rn 1 0 Shaft FOX- 0 375
PIN
0603-204 0603-206 0603-207 0603-208 0603-209 0603-388 0603-418 0603-512 0604-531 0604-536 0603-551 0603-601 0604-627
2603-093
In
ID Shaft DESC.
PM
2603-130 2603-132 2603-134 2603-135 2603-136 2603-137 2603-120 2603-122 2603-124 2603-125 2603-126
DESC
Valve, Valve, Valve, Valve, Valve, Valve,
Valve, Valve, Valve, Valve,
Shock Shock Shock Shock Shock Shock

Shock Shock Shock Shock
1.300 Dia. )( .004 in. Thk 1.300 Dia. )( .006 in. Thk
1.300 Dia. x .008 in. Thk 1.300 Dia. )( .010 in. Thk
Pislon Piston Piston Piston Piston Piston Piston Piston Piston Piston Piston Piston Piston Piston Piston Piston
.041 in. Orifice .059 in. Orifice .076 in. Orifice .078 in. Orifice .081 in. Orifice .070in. Orifice .043 in. Orifice .098 in. Orifice .067 in. Orifice .052 in. Orifice .125 in. Orifice .093 in. Orifice .046 in. Orifice .067 in. Orifice .093 in. Orifice .063 in . Orifice
1.300 Dia. x .012 in. Thk 1.300 Dia. )( .015 in. Thk
1.250 i x .004 1.250 Dia. l( .006 1.250 Dia. )( .008 1.250 Dia. )( .010 1.250 Dia. x .012
i in. Thk in. Thk in. Thk

in. Thk
2603-094 2603-095
2603096 2603097 2603-070 2603-072 2603074 2603075 2603076
Valve, Shock Valve, Shock Valve, Shock

Valve, Shock
1.100Dia. )( .006 in. Thk 1.100Dia. x .008 in. Thk
0604-636 0604-741 0604-742
1.1000ia. 1.100Dia. 1.100Dia.
j( j( j(
.010 in. Thk .012 in. Thk .015 in. Thk
ACT - 0 375
PIN
1603-314 1603-273 1603-189 0603-952 1603-875 0603-953 1603-996 1603-190 Piston Piston Piston Piston Piston Piston Piston Piston
In
I 0 Shaft DESC.
.039 in. Orifice .041 in. Orifice .046 in. Orifice .059 in. Orifice .081 in. Orifice .093 in. Orifice .120 in. Orifice No Orifice'
Valve. Shock Valve, Shock Valve. Shock Valve. Shock
1.000 i x .004 i 1.000 Dia. j( .006 in. Thk 1.000 Dia. x .ooa in. Thk 1.000 Dia. j( .010 in. Thk 1.000 Dia. x .012 in. Thk 1.
i
2603062 2603-064 2603-065 2603066 2603067 2603050 2603-052 2603054 2603055 2603-056 2603040 2603-042 2603-044 2603045 2603-046 2603047 2603030 2603032 2603-034 2603-035 2603036 2603-037 Valve, Shock Valve, Shock Valve. Shock Valve. Shock Valve. Shock Valve. Shock Valve, Shock Valve. Shock Valve. Shock Valve, Shock Valve. Shock Valve. Shock Valve, Shock Valve, Shock Valve, Shock Valve, Shock Valve, Shock Valve, Shock Valve. Shock Valve, Shock .900 Dia. .900 Dia. .900 Dia. .900 Dia. .900 Dia.
j( j( j( j( j( j( j( j( j( j(
i
.006 in . Thk
Thk .010 in. Thk .012 in . Thk .015 in. Thk

.008 in. .004 i .006 in . Thk .008 in.
'Onflce must be dnlled to SUit operator need.
.800 i . .800 Dia. .800 Dia. .800 Dia. .800 Dia.

.700 Dia. .700 Dia. .700 Dia. .700 Dia. .700 Dia. .700 Dia. .600 Dia. .600 Dia. .600 Dia. .600 Dia. .600 Dia. .600 Dia.
NOTE: Shock Oil (pin 1639-245) is available from Arctic Cat Service Parts Department.
Thk
.010 in . Thk .012 in . Thk .004 in . Thk .006 in . Thk .008 in . Thk .010 in . Thk .012 in . Thk .015 in.
j( j( j( j( j( j( j( j( j( j( j( j(
Thk
.004 in . Thk .006 in . Thk .008 in . Thk
Thk Thk .015 in . Thk

.010 in. .012 in.
9-174
Page: 770
Shock Absorber Usage Guide

Below is a list of shock absorbers used on the front and rear suspensio ns of m any Arctic Cat snowmobiles.
Specifications given for each shock absorber include collapsed and extended length , stroke, and both rebound and compression valving ratings.
When using the shock absorber guide, always select a shock absorber with the same length , both collapsed and extended. Shock valving selection will depend on personal preference.
PIN
0603-555
Collapsed length
9.410'
Extended Length
13.540"
Stroke
4.13'
0604-599
1604-101 0603-117 1603-253
1604-455
1604-369 0703-997 0703-996 0703-929 0703-825 0703-824 0703-810 0703-756 0703-753 0704-760 0704-758 0704-743 0704-738 0704-712 0704-635 0704-617 0704-530 0704-529 0704-519 0704-518 0704-512 1703-199 0704-903 0704-906 1703-208 1703-209 0704-930 0704-932 0704-948 0703-829 0704-870 0704-869 1703-090 0703-959 0704-800 0704-790 0704-802
7.060' 7.670' 7.060' 10.840' 9.560'

8.420' 11.470' 11.470' 11.470' 11.470' 11.470' 11.470' 10.300' 11 .470' 10.050' 8.070' 9.890" 7.970" 7.990' 7.340' 7.970" 9.880" 9.880' 8.070' 10.050' 9.890' 12.600' 7.970" 9 .890" 12.660" 12.660" 7 .980" 9.860" 9 .890" 11.460' 8.070' 10.050" 10.500' 10.500" 7.980" 7.980' 9.900'
10.100" 11.420" 10.030" 16.300" 15.010"

12.490"
3.04" 3.75" 2.97"
5.46' 5.45'
4.07' 6.52' 6.52' 6.52' 6.52' 5.43' 5.00' 6.52' 4.40' 3 .20' 4.60' 3.25' 3.66' 3 .52' 3.25' 4.47' 4.47' 3.20' 4.40' 4.60' 6.71 ' 3.25" 4.64" 6.15" 6.15" 3.60" 4.66" 4.60" 5.72' 4.64" 4.64' 5.30" 5.30" 3.24" 3.24" 4.49"
17.990" 17.990' 17.990' 17.990' 17.990'

16.900' 15.300" 17.990" 14.450' 11.270" 14.490' 11.220" 11.650" 10.860" 11.220" 14.350" 14.350" 11 .270" 14.450' 14.490" 19.300' 11.220' 14.530" 18.860" 18.860" 11 .630' 14.530' 14.490' 17.200' 11.270' 14.450' 15.800' 15.800' 11.220' 11 .220' 14.390'
Page: 771
9-175
Shock Absorber Usage Guide (cant)

PIN
0704-797 0704-852 1703-449
1703-484 1703-485 1703-449 1703-520 1704-116 1704-117 170 4-1 42 1704-140
Collapsed Length
9.900' 9.970' 12.620' 12.660' 12.660' 12.620' 10.500' 7.870' 9.890'
Extended Length
14.390" 14.630"
Stroke
4.49"
9.030'
18.860" 18.860" 19.300-
15.BOO"
11.220" 14.530"
4.66' B.6S" 6.20' 6.20' 6.68' 5.30' 3 .35'

4.64"
7.870'
7.990'
10.130'
11.220"
11.630" 14.530" 14.630" 14.630"
3.35' 3.64'
4.40'
4.66"
1704-141
1704-138
1704-139 1704-150
1704-154 1704-153 2604-160 2604-200
9.970' 9.970'
4.66'
7.870'
9.S90 9.890' 7.830' 10.760'
11.220"
14.530'
14.530" 11.280" 16.540"
3.35'
4 .64' 4.64' 3.45' 5.78'
9-176
Page: 772
Shock Absorber Usage Guide (cant)

Ryde FX
PIN
0604-756 0604-757
Collapsed
Length
9.590' 9.590'
Extended Length
14.200' 14.200'
Stroke
4.61 ' 4.61 '
4.61" 5.02"
0604-758 0604-909
0603-649
1604-001
9.590' 9.550'
9.560' 9.550' 9.550'
14.200' 14.570'
13.100' 14.570' 14.570'
3.84" 5.02"
5.02"
1604-011
1604-092
0604-997 1604-085
9.580'
7.490'
14.700'
10.110'
5.12'
2.8?" 6.12" 4.85" 5.12" 5.12"
10.590'
9.460' 9.540' 9.540'
16.710'
14.300' 14.660' 14.660'
0603-843 1604-176
1604-212
1604-216
0603-901
10.570'
9.940' 9.960'
9.080' 10.460' 11.330'
16.640' 15.170' 14.300'

13.790' 16.300' 17.060'
12.110'
6.0T
5.24" 4.35" 4.47"
1603-172 1603-173
1603-174 1603-175
5.85" 5.73"
3.74" 6.12"
1604-368
1604-370 1604-371
1604-372 1603-200 1603-201 1604-460 1604-369 1603-597 1604-995 1603-436 1604-730 1603-614 1604-093 1604-243 2603-220 2603-259 2604-161 2604-614 2604-637
8.380' 10.550' 9.550'

9.550' 9.080' 9.96010.5508.42011.3608.420' 9.990' 10.550' 9.9907.670' 7.80012.62011.540' 9.77010.76010.760'
16.670'
14.670'
14.67013.790' 14.30016.67012.49017.06012.49015.31016.67015.310' 11.37011 .26019.00015.75014.38016.540' 16.540'
5.12'
5.12" 4.47" 4.35" 6.12' 4.07" 5.70' 4.07" 5.32" 6.12" 5.32" 3.70" 3.74" 6.38" 4.21 ' 4.61 ' 5.78" 5.78"
Page: 773
2005 Arctic Cat S ervice Manual - a ll models - www. ReadManuals.com
9-177
Rear Spring Selection Chart

Follow ing is a li st o f rear suspe nsio n springs and specifi catio ns. This chatt was compiled to assist technicians in fine-tuning the Arctic Cat rcar suspensio n w he n the
origi nal sprin gs arc not satisfactory and a so rte r or

firm er ride is desired.
A longer spring in areas (0) and (E) can be selected if cuI off to match the ori ginal spri ng. T he replacement spring must match the original spring in areas (D) and
(E).
0730-218
PIN
1704-174/175 0604-272/273
WIre DIameter (A)
Angle (8)
Number of COlts
Coli Width
(C)
4.75 4 .80
Length (0)
Length (E)
0604-2821283 0604-2881289 0604-2901291 0604-314/315' 1704-182/183 0604-454/455' 1704-0721073 0604-4921493 0604-5921593 0604-7461747 1704-184/185' 0604-9701971' 1704-2921293" 1704-3001301 " 1704-088!U89 1704-2901291" 1704-083!U82 1604-065!U64 1704-3441345 1704-2891288'" 1704-135/134'"
1704-3021303"~
.460 .437 .437 .460

.490
45' 90'
75"
9.00
9.00
9.00
17.50 17.50
4 .50 5.50
.460 .406 .437 .406 .406 .460

.390 .421 .421 .437 .437
.460
.460 .460 .421 .437 .460 .452 .437 .437 .452 .405 .375 .375
60' 60' 90' 90' 90' 90' 90' 83' 90' 90' 90' 83' 83' 90' 83'
75"
9.00
9.00 9.00
4.80 4.75 5 .02 5.03

4.32 4.80 3 .88 4.32 4.80 4.32
17.50 17.50 17.50 17.50

17.50 17.50 17.50 15.75 15.75 19.75 18.10 15.90 16.00 21.00 16.00 21.00 18.00 18.00 20.75 22.00 22.00 22.00 16.00 18.75 18.50 18.50 18.50 18.75
.... Square wire
5 .50
4.50
4.50 5.50
5.50 4.50 4 .50 5.50 5.50 5.70 5.70 5.70 5.70 5.70 6 .70 5.70 5.50 5.50 5.70 8 .00 8.00 8.00 5.50 5.50 5 .50 5.50 5.50 5 .50
....nanium
8.75
9 .00 7 .75 8.75 8.75 8 .75 8.75 8.75 8.75 8.75 8 .75 8.75 8.75 8.75 8 .75 8 .75 8.75 8.75 8 .75 8.75 5.75 7.75 7.75 4.75
4.43 4.43
4.59
4.56 4.53 4.53

4.83 4.45 4.59 4.84 4.97 4.52 4.60 4.68 4.00 3.80 3.80 3.40
W 83'
77' 77' 77' 75' 90' 70' 80' 80' 80'
1604-7391740" 2604044!U45 1704-3601361 .. 1704-3541355
1704-3521353 2604-898/899
.465
-Long leg 01 spring is bent inward
"Short leg of spring is bent inward
"'Must be cut to correct length
NOTE: The wire diameter and length of the spring have a large influence over the valving of the shocks.
9178
Page: 774
Rear Spring Selection Chart (cant)

PIN
2604-5661567" 2604-5881589'"
0704-876/877""
WIre DIameter (A) Angle (8) Number of COlts Coli Width
(C)
Length (0)
18.75
Length (E)
.488
.421
.375
.406 .480 .437 .359 .405 .452 .452 .406
.437 .452 .437
0704-8941895 0704-8861887"
0704-8881889"
85 77" 90 06
6.00 8.75 5.75

4.48
4.00 4.52
3.00 2.45
77
75 90 75 90 75 90 90 90
8.75
B.7S 5.75
B.7S
4.85
4 .60
3.00
22.00 15.62 06.03 20.00

18.50 15.62
19.00 16.00
5.50 8.00 5.12 4.57 5.50

5.50 5.12 5.50 5.70 5.50 5.70
0704-8901891 0704-892f893'
u O
0704-938/939
0704-9441945"
0704-986/987
0704-9881989"
B.75 B.7S B.7S
4.32 4.53 4.62 4.32
18.75
18.10 18.10
B.7S
B.7S 8 .75 7.75 8.75 5.75 5.75 6 .75 8.75 7.75 9.00 6.75 7 .75 7.75
0704-8221821 0704-8561857
0704-9021901 0704-9081909 0704-9261927'u,

0704-9341935 .. 0704-9681969 .... 0704-9901991' 1704-044iU45 1704-074/075" 1704-146/147 .. .. 1704-148/149 .. 1704-172/173
.405 .437
.375
.405 .437 .421 .405 .460 .405 .437 .406
83 80 W 80
90 90
4.59 4.75 4.59

3.92
18.75
20.00
5.70 5.50
5.70
4.80
3.00 3.00 3.50 4.32 3.91 4.53 4.00 4.25 3.88
77
75 97 70 80 115
19.00 18.50 18.50 18.50 18.50 20.00 19.00 16.00 18.50 18.50 17.50
....Square wire
5.50 5.50
5 .12 5.12 5.12 5.50 5.50 5.70 5.50 5.12 4 .50
....nanium
'Long leg of spring is bent inward
"Short leg of spring is bent inward
'''Must be cut to correcllenglh
NOTE: The wire diameter and length of the spring have a large influence over the valving of the shocks.
Page: 775
9-179
Front Suspension Ski Springs PART NUMBER

0603090 0603-426
0603_665 2 0603279 0603860 0603-836 2
AWS Models
WIRE DIAMETER
FREE LENGTH INCHES

10.50 11 .35
10.50
RATE LBIINCH
11 OF COILS
TAB
3"
.331
.331
'" 80
80-125 Dual Rate 80-125 Dual Rate
13.5 11.0 10.0 14.0 14.0 10.0 13.0 14.0 15.5
"
.312
""
.300 .300 .313 .280 .312 .312

.312
'''' '''' 11.50

11 .50
'" '"
'" " '" '" '" '"
00
'"
"
YES NO YES YES YES YES YE' NO YES YE' YE' YES NO YES YES YES YE' YE' YES YES YES YES YES YE' YES YES YE' YE' YES YES YES YES YES YE' YE' YES YES YE' YES YES NO YES YES YES YE' NO YES YES YES NO NO
0603-837 0603760 0603-602 0603-718 0603-766 2

1603891 1603254
9.15 11.40
11.30 11.30
.33'
.312
1603225
1603239
'''' '''' 12.25

10.50 11 .30
10.0 14.9 11.34 14.0 14.9 14.9 17.0 11.11'113.11' 11.2"113.2"
"
.281
3D
80-120 Dual Rate 80-120 Dual Rate 80-120 Dual Rate 801120
1603-2402 1603-2753
1603_2842
.312 .312 .312

.312 200
12.61 12.61
14.13 12.61 12.50 13.00 11 .50 14.125 11.40 11.40 13.00 10.50 14.21 12.50 11 .40 14.13 11.40 14. 13
'"
160339~
1603_5064
1600-581 2
.300 .300 .300 .312
1603599
1603-602 4
'" "0
771205 601175 601175
14'116" 15'117' 11'114" 11 ' / 14"
"
1603-6041
1603-611 4
1603-61 ;il
33' 33'
.300 .336 .312 .300
.331 .312
'"
1603-8602
1603-871 1603-8745
1603-8777
801120 Dual Rale
'" '"
'"
10.0 18.5 11.2"/ 13.2" 11114" 17.0 11"14" 17.0
"
1603-90-,6
601175 80-120 Dual Rate 601175 80-120 Dual Rate
1603-9386
1603-971 7
.33'
.312 .312
.312 .312
1603-97s7
0703-4Sil
0703_579 2
0703-588 2
,.'"
'''' 11.50
10.50
'" 3D
" '.0
13.0 10.5
0703-59il 0703-597 2
0703-599 2 0703-6302 0703-619 2
.331 .331 .312

.331 .312
'''' ''''
12.25 10.50 10.50
" 3D '" 3D
'" 00
3D
"
' .0
10.0 14.9 11.3
''''
0703-6202 0703-6642
0703-750 2
.281
.343
.312
.243
.312 .312 .312
0703-80il
0703-418 0703704
'''' ' .00

9.14 12.25 14.12 13.00
0703_742 2
801120
'" '" " '" "

'20
20
'.5
11.0 10.0 14.9 18.5 14.4
"
0703-744 0703-745 2
.33'
.120
2.0
1.7 87*13.787"
9180
Page: 776

0703-81~
0703821 0703-872 4
0703-8944
AWS Models (cant)
WIRE DIAMETER
.295
.331
FREE LENGTH INCHES

9.0
10.5 10.5
RATE LBIINCH
11 OF COILS
TAB
''0
90
90
"'''
" , ,
" 9
6.5'/8.5"
6.5"/8.5"'
.331
9.5
0703-937 4 1703-0044
1703-014 2
1703-0154 1703-037
.343
.336 .312
.312
10.5 10.5 9.36 9.36

12.50 10.50
'"
90 90
'" '"
"
1703-872 4
1703-0452
.331
"'"
'"
90
11.2"/13.2"
'.0 ' .0
10.5
12.44'/14.44"
6' /8"
.331 .312
.331 .331 .331
10.50 9.36
13.0 10.50
90 90
1703-0074
1703-08:t' 1703-0626
''0
90
1703-080' 1703-083' 1703-1 2s7

1703_201 6
1703-2162
9.50 9.36 9.00

14.25 10.00 13.00
.312 .295
.312
'"
90
8'/10"
7 .75"19.75"
''0
50
9.8'/11.8"
17' / 19" 9.1'/ 11.1"
1703-2256 1703-2572 1703-2Ss7 1703-2647

1703_2766
1703013
"'" ."'"
.312 .312
9.50 9.50
10.00 13.00
'" '" ''0

''0
11.1' 13.1" 9.1/11 .1" 9.1'/11 .1"

9.7"111.7" 12.4' f I4.4"
6.5"18.5"
"'" "'''
.312 .312
'" ''0
90
9.36 9.50 9.50

10.00
1703-1277 1703-139 1703-277' 1703-279

1703_2886
1703-3226
.312 .312
.331 .312
'"
"'"
"'''
9.50 9.50 9.36 9.50

14.25 10.50 11 .00 14.25
'" '" '" ''0

90
11.7 5
" "
8'/10"
6.5"/8.5"'
"
1703-3307 1703-3545 1703-400 9

1703-4142
1703440
'" .331
.312
.343
.312 .312
'"
50
90 501'901150
8 ' /10" 18.5
7.5
11.75 18.5 11.0 9.625 13.375
'"
'" 90
1703-4578
1703_4867
9.50
10.11 11.25
1703540 1703-541 6
1703-5566
.33'
.243 .312
.312 .312 .312
"5
' .50
13.00 13.00 9.14 14.25 14.25 12.00 14.13 11 .40
'"
50 50
' .5
13.5 13.5 10.0
17"/ 19" 17'/ 19"
1703-5575
1703656 1703-6582
'"
'"
''0
'"
8020 Dual Rate
1703-660'2 1703-6777 1703-692' 0

1703-76810
.312 .331 .312

.331
12. 75 17.0 11"14"
60/175
YES YES YES NO YES YES NO NO YES YES YES YES NO YES NO NO YES YES YES YES YES YES YES NO NO YES YES YES NO NO NO NO YES YES YES YES YES NO NO NO YES YES YES YES YES YES YES YES
Page: 777
9181

1703-7032 1703-129 1703_7697
AWS Models (cant)
WIRE DIAMETER
FREE LENGTH INCHES

12.00
300
14.25 14.25
RATE LBIINCH
11 OF COILS
TAB
'" ,,,
.312 .312
1703-7926 1703-7932
.312 .360 .312
14.25 10.00
11 .00
2603-248 2603375 2603_304 4
'"
'" '" '" '" '"

80/120 Dual Ra1e
'"
12.75
11.8
17"/ 19"
17*/ 19"
17"19"
9.25
3.00
YES YES YES YES YES

NO NO
14.13
'"
18.5
YES
1 Orange Color Green Color 3 White Color

2
4 Platinum Color 5 Siliver Color 8 Yellow Color 7 Red Color
8 Gold Color 9 Taupe Color 10 RedlBlack Color

11 Fire Red Color 12 Blue Color Active Coils Total Coils
9182
Page: 778
Front Suspension Svvay Bar

PART NUMBER
0703-185 0703-202
0703-193
DESCRIPTION
318" diameter 7/16" diameter
112" diameter
PART NUMBER
1703-143 1703-144 1703-145 1703-146
DESCRIPTION
318" diameter
1(2" diameter 5/8" diameter
0703-194 0703-190 0703-189
518" diameter
Chrome Moly 5/8 hex
7/16" diameter
Rear Suspension
PART NUMBER
0604-624' 0604-534 0604-413' 0604-740 0604-658' 0604-587 0604-697 0604-776 0704-178' 1604-125 1604-197 0603-860' 1603-01S' 1603-267 1604-509" 0704-855" 1603-171 0704-960 0704-936 0704-523
1603-8911860
(Front Arm Springs)

RATE LBANCH
130 130 130
FREE LENGTH INCHES

5.0 7 .0 7.0 7 .0 7.0 7 .0
170 170
250
7.1
6.0 15 7 .0 7.0
275 290 25 220

190
9.5 9.5 8.5

7.0 7.0 84
110
90
110
160 (.343 wire dia.) 180 (.360 wire dia.)
90
8.0
7.0
8.0 9.5
14.25 7 .0
110 170 110 110

50-90-150
1603-983
1604-788
110
140
160 (.343 wire dia.)
1703-072
1704-158
9.5
7.0 6.0
1704-170 2603-319 2604-059

2604-373
13 7.5
7.0
250 NIA 180 140
2604-565
8.0
110
Tab on Bouom 1 AFS Models

" This spring only f~s shock (pin 1604-480), non-adjuster sleeve shock
Suspension Stiffening Kits
(AWS VI Models)
T he fro nt and rear suspe nsions have been calibrated for a rider weight range of 180 to 200 lb. If a firmer ride is desired, there are two kits a vailable to stiffe n the suspensio ns on these models by 20 percent. It is impol1antto order the correct kit beca use these kits do not intercha nge. Do not use the standard model kit o n the Sno Pro model because the shoc ks are din'erent o n these two models. The two stiffening kits include everything required and the part num bers arc as follows:
Page: 779
9183
S1:andard Shock & Spring Chart - 2005 Models

Models Sway Bar
BEARCAT570
PANTERA 550
1603910 1603-175
1603-175
1703-457 1703660
1703660
1604-369 1604-369
1604-369
0603860 0603860
0603-860
2604-200 2604637
2604637
1704-044,1:)45
1704-146/ 147 1704-146f 147
NfA
0703202
0703202 NfA
PANTERA 600 EFI

PANTHER 370 PANTHER 570
1603-253 1603-253
1703-494
1703-818 1703-665
NfA
1604-369 1604369
1704-294 2604-741 1704318
0603-860 0603-860
2604565
2604614 260461 4
1704-298
2604-161
1704-044i\)4 S
1704-044J1)4S
2604-566/567
0703-202
NfA NfA NfA NfA NfA NfA NfA 0703202 1703-616 1703-616 1703-616 1703-616 1703616 1703-616 1703618 1703618
KING CAT 900
MS M.
M7
2603385
1703-783
1703786
1703787 1703-786 (R) 1703-787 (0)
1704-259
0704523
1704-3521353
1704321 1704-321 1704322 1604-455 1604455 1604455 0704852 0704852 1704139 1704117 1704141 1704117 1704257 1704266
1704352!353
1703-783
1703-716 1603-253 1603253 1603253 1703795 1703795 1703795 1703795 1703684 1703449 1703657 17036901691
1703-786 (RI
1703-787 (0) NfA 1703288 1703288 1703322 1703354 1703354 2603304 1703201 NfA 1703201 1703-658 (G) 1703769 (R) 1703-907 (G) 1703768 (R)
1704-318
1704318 1604-995 1604995 1604-995 1704142 1704142 1704142 1704116 1704308 1704116 1704255 1704265
0704-523
2604565 1603018 1603018 160301 8 0704523 0704523 0704523 0704523 0704936 0704523 0704523 0704855
17043521353
26048981899 0704-888/889 07048881889 07048881889 0704926J927 0704926J927 0704926J927 0704926J927 0704926J927 0704926J927 1704901t902 0704938iW9
M7 LE
Z 370/370 LX Z 440 LX
Z 570/570 LX SABERCAT 500 SABERCAT 600 EFII700 EFI SABERCAT EXT FIRECAT (STO) FIRECAT SNO PRO FIRECAT EFI EXT ZR900 ZR 900 Sno Pro
9184
Page: 780
Optional Rear Arm Spring Chart - 2005 Models

NOTE: Optional rear arm springs (L = Light; H = Heavy) marked with the must have the legs cut to size. Always cut the optional spring legs to the same length as the stand ard s pring legs.
Model
Bearcat 570 Pantera Model Panther Models
Rear Arm Sprmg (Right/Left)
Rear Arm Spring Type

Square
L 0704-9261927 H 1604-3811380 L 0704-0441 045 H 1604-3811380L 07049261927 H 1604-38 11380 -
Round
Square
Round
Square
Round
Square
M5/617
N /A
H 0704-8 18/819 L 1604-608/609-
M7LE
King Cat Z Model Sabercat Models Firecat 500 (8T O) Firecat 600!700/EXT Firecat Sno Pro Mode ls
N /A N /A N /A
Round Round Round Round

Square Square Square Square Square Square
L 1604 -224/225L 1604146/147' H 0704-944/945-
H 0704-9341935
N /A
H 0704-9681969
N /A
H 0704-9341935
N /A
H 0704-9681969 L 0704-892/893 H 1604-3881389 L 1604-739/740 H 1604-1 94/195
ZR 900
ZR 900 Sno Pro
These springs must be cut oN or damage to the track may occur
Round Round Round
Page: 781
91 85
Rebuildable Shock Tools Required

Part Number
0644-268 0644-057
Shock Tool Shock Bearing Cap Installation Tool

Shock Spring Removal Tool Shock Inflation Needle Gas Shock Retaining Blocks Replacement Needle
0644-158
0644-334
0644-162
0644-169 0644-151
Shock Piston Location Tool

Nitrogen Regulator Shock Rod Clamping Tool
0644-277
0644-348
0644-350 0644-402 0644-403
IFP Removal Tool IFP Depth Setting Tool Floating Piston Removal Tool Kit Bearing Cap Seal Protector (112-in.) Bearing Cap Seal Protector (SIB-in.) Gas Shock Rod/Body Clamping Tool
0644-404 0644-425
Rebuildable Shock Rebuild Kits

Part Number Shock RebUIld KIt
IFP Front Arm Quick-Adjust Clicker Shock SkilFrontlRear Suspension Shocks (Firecat)
1639-769
1639-770 1639-771 3639-111
9186
Page: 782
2005 Rebuildable Shock Specifications

Ski Shock (pin 1703-795)
SabercatlSabercat EXT
Compression: Rebound :
1.
8. 1.30 x.OO6
Ski Shock (Fox Air) (pin 1703-716)

M7LE
Compression: 10. 1.30x .OO8 1.10x.OO6 .900x.Ol0 . .800x.Ol0 6 1.25 x .008 1.25 x.OO6 1.10x .008 1.00 x .010 3 Rebound : 1. 2. 3. 4. 5. 6. 7.
,. ,.
3. 2.
.8(0)( .006 .700x.015
2.
3.
1.25 x .008
1.1OK.Ol0
..
1.00 x .010 .900)(.010 .800" .010

PISlon Deplh 7.50 In.lPislon
Or~lce
,.
,. ,. ,.
x .006 1.25 x .006 .900 x .006 1.25 x .010 1.10 x .010

1.25
1.00 x.Q10
, , ,
2
1.25 x .008 1.25 ~ .008 1.10x .008 1.00 x .010 1.00 x .010
1.125 x .093 Top Oul
.900 x.010 .800 x.010 .620 x .093 Backup
,.
.900 ~ .010 .800 x .010 .620 x .093 Bacllup
.120 In.
Exlended Lenglh 18.70 in./collapsed Length 12.62 in.

ZR 900
1.
.9OOx.010 .800 x .010 1. 125 x .093 Top Out Pislon Deplh 6.68 in.lPiston OrHice.093 in. Exlended Length 17.55 in .iCotlapsed Length 12.00 in.

x .006 1.25 x .006 .900 x .006 1.25 x .010
1.25
1.10x.01O
1.00 x.Q10 1.00 x.Q10
..
3. 2.
, ,
,. ,.
9.
1.30 x.OO6
1.00x .006
King Cat
Compress io n: Rebound : 10. 1.30x.008 1. 1.25 x .008 . 1.10 x.OO6 2 1.25x.008 .900x.Ol0 1.10x.008 3. .800 ~ .010 1.00 x .010 1.00x .010 6 1.25 x .008 .900 x .010 1.25 x.OO6 6 . 1.10x.008 .800 ~ .010 .620 X .094 Bacllup 3 l.oox .010 2 .9OOx.010 .800x.Ol0 1.125 x .094 Top Out Piston Deplh 5.940 in.lPiston Or ~ice .093 in. Extended Lenglh 15.80 in .iColiapsad Length 10.50 in.
2.
3.
.900 x .006 .700)( .008 1.25 x .010
..
1.125
1.10 x .008 1.00" .008 .900" .010 .800 x .010
,. ,. ,. ,.
9. .620 J(
Or~lce
, ,
x .094 Top OUI

PISlon Depth 7.2Sln.lPislon
.900 x.010 .800 x.010 .094 Backup
,.
, ,
, ,
.093 in.
Exlended Length 17.95 in.iColiapsed Length 11.49 in.
Ski Shock (pin 1703-6901691)

ZR 900 Sno Pro
Compression:
10. 1.30 )(.006
Rebound :
, , ,
9.
,.
3. 2.
1. 1.25 x .006 1.00 x.OO6 2. 1.25 x .006 .900 x .006 3. 1.25 x .008 .700 x .008 1.25 x .008 1.25x .006 1.10K.01O 1.25 x .006 6. 1.00 x .010 1.10x .008 .900 x .010 1.00 ~ .008 .800 x .010 .900x.Ol0 .800 x .010 PISlon Deplh 3.00 In.lPislon Or~loo .081 In. Exlended Lenglh 17.99 in .iColiapsad Length 11.47 in.

Firecat(STD)
Compressio n: 8. 1.30 x.OO6 .800 x .006 .7oox .015 6 Rebound :
1.
,
3 2
,.
,.
,.
3. 1.25 x .008 1.10x.Ol0 1.10x .010 1.00 x .010 6 1.00x.01O .900x.Ol0 .900x.Ol0 7 .800x .Ol0 .800x.Ol0 Piston Deplh 7.500 in.lPislon Or~ice .120 in. EKlended Length 19.30 in .iCottapsed Length 12.62 in.
1.25x.006 1.25 x .006 .900 x .006 1.25 x .010

M6iM7
Compress io n: Rebound : 8. 1.30 x.OO6 1. 1.25 x .008 1.10x.OO6 2. 1.25 x .010 .900x.Ol0 3. 1.10K.008 .800x.Ol0 1.00 K.010 1.25 K .008 .900 x .010 3. 1.10x .008 6. .800 x .010 2. 1.00 ~ .010 1. .9OO x.010 PISlon Deplh 1.25In.lPislon Or~loo .093 in. Exlended Lenglh 17.575 in.iColiapsed Length 12.00 In.
, , ,
, ,
Page: 783
9187
Ski Shock (pin 1703-684) Flrecat $no Pro (Air Chamber 50 psil1 cc of Shock Oil)
Compress io n: Rebound : 1.30x .008 1.25 K.008 1.10 K.OO8 1.25 K.008 1.10 K .010 .900K .006 3. 1.00 K .010 7. .700 K.OO8 6. 1.25 K.008 5. .900 K .010 5. 1.25K .008 6. .800 K .010 .620 x .093 Backup 1.10K.008 3. 1.00 K.008 .900 K.010 .800 x .Ol0 1.125 x .093 Top Oul Pislon Deplh 6.790 in.!Piston O r~ice .093 in. Extended Lenglh 18.80 inJColiapsed Length 12.60 in.
Front Arm Shock (pin 1704-294) King Cat

Co mpress io n: l.30x.012 5. 1.10x.012 l.00x .012 3. .900x.Ol0 .800x.Ol0 1.25 x .010 PIsl0n Deplh .650 In.!PISlOn Rebound : 1.25x .010 1.10x .010 1.00x.Ol0 1.00 x .010 .900x.Ol0 .800 x .010
" ,
,.
,.
,.
, ,
, , ,
3. 5. 6.
, ,.
Or~lce
.059 In.
Exlended Lenglh 11 .22ln.!Coliapsed Length 7.87 In.
Front Arm Shock (pin 1704-142) Sabarcat ($TO)

Compression: 1.30x .008 5. Rebound :
,.
Front Arm Shock (pin 1704-255)

ZR 900
Compression: 1.30x .012 5. 1.10K.012 1.00x.012 3. Rebound :
,.
,.
.900 x .010 .800 K.010 1.125 K.094 Top OUI
1.25 K.010 1.10 x .010 3. 1.00 x .010 .900 x .010 5. .800 K.010 .620 x .094 Backup
,. ,
1.10x .010 1.10x.OO8 1.00 K.010 3. 1.00 x .010 3. .900x.Ol0 .900 K.010 .800x.Ol0 5. .800x.Ol0 1.125 x .093 Top Oul .620 K .093 Backup Piston Deplh 4.26 in .!Piston Or~ice.093 in. EKlended Lenglh 11.22 in./collapsed Length 7.87 in .
,
,
1.25x .010
Front Arm Shock (pin 1704-11 6) Rrecat (STDIEXT)

Co mpressio n: Rebound : 5. l.30x.012 1.25x .010 1.10x .012 1.10x.Ol0 3. 1.00 x .010 3. 1.00x.01O .900x.Ol0 .900x.Ol0 .800x.Ol0 5. .800x.Ol0 1.125 K.093 Top OUI .620 x .093 Backup PIsl0n Deplh 4.26 in .!Piston Ornlce .093 In. Exlended Lenglh 11.22 In.!Collapsed Length 7.87 In.
Piston Deplh 4.26In.!Piston Or~lce .093 In. Extended Length 11 .22 in.!collapsed Lenglh 7.97 in .
,.
, ,

ZR 900 $no Pro
Compress io n: 5. 1.30x.012 1.10x.012 3. 1.00 K.012 .900x .Ol0 .800x.Ol0 Rebound : 1.25 x .010 1.25 K.010 1.10 x .010 1.00 K.010 .900 x .010 .800 x .010
, ,
,.
,.
5.
3.
6. PISlOn Deplh 2.50 In.!Piston Or~lce .059 in. Extended Lenglh 1O.86lnXOliapsed Lenglh 7.34 In.
Front Arm Shock (pin 1704-308) Rrecat Sno Pro

Compression: l.30x.012 5. 1.10 x.012 l.00x.012 .90 x .010 3. .80 x .010 1.25 x .010 1.125x.093TopOut Rebound : 1.25x.012 1.25x .010 3. 1.10x .010 1.00x.01O 5. 1.00x.Ol0 6. .900 x .010 .800 x .010 7. .620 x .093 Backup .055 In .

M-Series
CompressiOn: 1.30 K.012 5. 1.10x.012 Rebound :
, , ,
1.25x .010 1.10 x .010 1.00 x .012 3. 1.00 x .012 3. .900 K.010 .900x.Ol0 1.25 x .010 5. .800 K.010 1.125 x .093 Top Oul .620 x .093 Backup Piston Deplh .650 in.!Piston Or~ice .059 in. Extended Lenglh 11 .22 in.!collapsed Lenglh 7.87 in .
, , ,
, , ,
,.
PIsl0n Deplh .821 In.!PISlOn
Or~lce
Exlended Lenglh 11 .29ln.!Collapsed Length 8.00 In.
Rear Arm Shock (pin 1704-322) King Cat

Compression: l.30x .Ol0 7. 1.10 K.010 6. 5. , .900 x .006 1.25 x .010 I.lOx .012 l.00x.012 .900x.Ol0 Rebound : 1.25x .015 1.25 K.015 1.25 x .015 1.10x .015 1.10x .015 1.00x.012 .900 x .012
, ,. ,.
3. 5. 6. 7.
, ,
3.
Pislon Deplh .900 in.!Piston Or~ice .039 in. Extended Lenglh 14.37 in./collapsed Length 9.88 in .
9188
Page: 784
Rear Arm Shock (pin 1704-321)

M6iM7
L

Flreeat $no Pro Co mpress io n: 1.25 K .010 1.25 K .015 1.25 K .010 1.25 x .010 1.10 K .010 1.00 K .010 .900 x .010 Rebound :
L
,. , ,. ,.
2
L
7.
1.30 K.OO8 .lOOK .012 1.25 K .010 1.10K.Ol0 1.00 x .010 .900K.Ol0 .800 K .010
2.
, ,.
7.
,.
". w. , ,. 7. ,
1.60x.OlO 1.60x.OlO 1.60 x .010 .900 x .008

.800 x .008
1.42 x .015 1.42 x .012 1.30x.012 1.10 K .012 1.00 x .012 .900 x .015
.800
1.60 x .010 1.60 x .010 1.42 K .010 l.30x .Ol0 1.00 K .010 .900x.Ol0
, , ,.
2
.800 x .010
PISlon Deplh .900 In.!Pislon Ornlce .039 In. Exlended Lenglh 14.37 In.~ollapsed Lenglh 7.87 In.
,
2
L
5. ,
7.
x .015
.620 x .093 Bacllup

SabeteaV5abercat E XT Compressio n:
1.125 x .093 Top Out Piston Deplh 5.700 in.!Piston OrHica .055 in. Exlended Length 14.53 in JColiapsed Length 10.13 in. 1.25 K.Q15 1.25 K .012 1.25 x .012 1.10 x .010 1.00 x .010 ,900 K .010 Compressio n: 1.30x .006 1.00x .006 .900 x .008
.800 x .008
,. ,. ,. ,
2.
L
Rebound :
L
1.30 K .010 l.25x.Ol0 1.10K .Ol0 1.00 K .010 .900x.Ol0 .800x.Ol0
,. ,. ,.
7.
2.

Z R 900
1.125 K .093 Top Out
.800 K .010
.620 K .093 Backup
, , ,
Rebound :
L
1.25 x .010 1.10x.01O 1.00 x .010 .900x.Ol0

.800 K .010
7.
2.
,.
Piston Deplh 5.90 In./Pislon OrHlce .039 In. Exlended Lenglh 14.63ln.!Coliapsed Lenglh 9.97 In.
,
L
,.
2.
5.
1.25 K .010 1.10x .Ol0 1.00 K .010 .900x.Ol0

.800 x .010
,.
.620
X
5.
.700 x .010 .094 Bacllup
Rear Arm Shock lD'n 1704-322)

M7 L~
L
1.125 x .094 Top Oul 1.25 K .010 1.25 K .015 1.10 x .010 1.10 x .010 1.00 x .010 .900 x .010 .800 x .010 Compression: Pislon Deplh 5.80 in.!Piston OrHice .046 in. Exlended Lenglh 14.38 in.,collapsed Length 9.89 in .
,. ,. , ,
2.
L
7.
1.30 K .008 .700 K .012 l.25x.Ol0 1.10x.Ol0 1.00 x .010 .900x.Ol0 .800x.Ol0
,.
,. ,.
7.
2.

Z R 900 $no Pro
1.125 x .093 Top Out
.620 x .093 Backup
,
2
L
,.
Rebound :
L
1.25 x .010 I.lOx.Ol0 .900x.Ol0 .100 x .008
1.25x.012
.800 x .004
Piston Depth .900 in.!Piston OrHi09 .046 in. Extended Length 14.37 in.!collapsed Length 9.88 in.
1. 125 x .094 Top Out

FlrecatlFirecat E XT Compression:
,.
5.
14.53In.~ollapsed
,.
1.25 x .015 1.25 x .015 1.10 xO.15 .800x .016 .620 x .094 Bacllup
,.
7.
Rebound :
L
Pislon Depth 5.85In,!PISlon OrHlce .070 In. 1.25 x .012 1.25 x .012 1.10 x .012 1.00 x .012 .900 x .010 Exlended Lenglh Length 9.89 In.
1.30 K .010 1.10x .OO8 .900 K .010 .700x.004 1.25 x .010 1.10K.01O 1.00 K .010 .900 K .010
, , ,
2.
L
,.
,.
2.
,.
.800 K .010
.620 x .093 Backup
1.125 x .093 Top Out Piston Deplh 5.800 in.!Piston OrHi09.039 in. Extended Lenglh 14.53 in.!Collapsed Length 9.89 in.
Page: 785
9189
Servicing I.F.P. Style Shocks

NOTE: Some illustrations and photographs used
in the following sub-sections are used for clarity purposes and are not designed to depict actual conditions.
4, Re move the screw from the bladder housing on the bottom o f the shock. Discharge all the pressure fro m the shock using the S hoc k InOation Needle (pi n 0644- 158). Ope n the valve in fill er handle unti l all pressure is released .
WARNING
Before servicing a gas shock absorber, first discharge all pressure from the shock. Remove the screw from the bottom of the shock and insert the Shock Inflation Needle (pIn 0644-158). Open valve until all pressure is released. Failure to do this may cause personal injury.
DISASSEMBLING
I. Re move the shock rro m the snowmo bile. 2. Wash the shock body in parts cleaner; then dry with compressed a ir to re move sand and dirt. 5. Using a 9/ 16 -in. wrenc h, re move the brass bladder housing from the lower e nd cap. Acco unt fo r an a -ring.
3. Place the shock into the Gas Shock Retaining Blocks (pIn 0644-142); thell remove shock eyelet mo unting axle and bushings rrom end cap.
6 CAUTION
it is important that the Gas Shock Retaining Blocks (pin 0644-142) are used during both disassembly and assembly. Any other method of securing the shock body during these procedures may deform the shock body cylinder.
NOTE: A paper shop towel between the shock body and retaining blocks will help prevent scuffing of the shock body.
6. Using a large adjustable wrench (12-in. or l4-in.), remove the end cap .
NOTE: 1994 and older shocks have Loctite on the lower end cap. Heating the lower end cap may be necessary. Use care not to overheat.
7. Using a I-in . ope n end wre nch. loosen the shock shaft hearing cap a couple of tums.
9190
Page: 786
NOTE: 00 not remove the bearing cap at this time.
NOTE: 00 not lay shock parts on a rag as it may transfer lint to the parts causing internal shock problems.
13. Remo.vc the pi sto n ring from the pisto.n. Loosen (but do. no.t remo.ve) the lock nut from the botto.m o.f the shock shaft ; then cl ean the pisto.n area with clean parts-cleaning so.lvent to. re mo.ve dirt o.r fo.reign material fro.m octween the va lves. Dry the pisto.n and valves co.mpletel y lIsing co.mpressed air. 8. Turn the shock so that the o pe n end is up. T hen remove the All en-head screw located in the center o.f the OO<lting pi sto.n. Acco.unt fo.r a small O-ring.
NOTE: If for some reason the piston must be removed from the shock shaft, it must be installed with its large seven slots located next to the lock nut side of the shock shaft.
9. Using a pair 0.1' pliers, pull the Oo.ating pisto.n assembl y o.ut 0.1' the shock body. Acco.unt fo.r a pisto.n ring and a n O-ring, 10. Po.ur the o.i l out o.f the shock body. 11. Unscrew the shaft ocaring ca p and lift the shaft assemble fro m the shock body.
12. Clean the inside o.f the shoc k body using clean parts-clean ing solvent. Blow dry using co.mpressed air.
NOTE: If shock valving must be removed for cleaning, remove all valvinI;J as a complete assembly and place on a 5/16 x 3-,". cap screw to keep in proper order. Note which side is the top side for assembly purposes.
Page: 787
9191
ASSEMBLING
I. Place the shock shaft eyelet into the vise; then assemble val ves and piston and ti ghte n the lock nut to 2.1-2.8 kg-m ( 15-20 ft-Ib).
L1:.
CAUTION
00 NOT OVER TIGHTEN. If excessive torque is applied, damage to the piston and valves will occur.
AP032
2. Place the shock body between the two Gas Shock Ret.'lining Blocks (pIn 0644-142) and secure in a vise.
14. Items to inspcct: A. Shock shan for straightncss, nicks, or bUlTs. B. Shan bearing end cap replace. excessive wear. D. Piston rings for cuts, chippe d or nicked edges, or excessive wear. E. O-rings for nicks, cut'>, or cracks.
F. Valves for kinks or waves.
G. Rubber dampe r (ski shocks onl y) for chipping,
L1:.
CAUTION
cl ean, inspect, or
C. Inside of shock body for sc ratches, burrs, or
It is important that the Gas Shock Retaining Blocks (pin 0644142) are used during both disassembly and assembly. Any other method of securing the shock body during these procedures may deform the shock body cylinder.
3. Appl y a li ght coat of oil on the O-ring and pi ston ring and install pi ston into shock body.
cracking. or being mi ssing. 15. Items to replace: A. Bleed sc rew O-ring on the nooting pi ston. B. Shock shaft bearing cap if any signs of oillcaks or damage.
C. Any part worn or damagcd.
NOTE: For shaft, shaft eyelets, or shaft bearing cap replacement, see Shaft Eyelet or Bearing Cap and Shaft Seal subsection.
4. Place the shaft bearing cap into the body and tighten securely.
5. Loosen vise and reposition the shock body and retaining blocks so the bottom of the shock body is " up" a nd in a veltical position. Extend the shoc k shaft full y and fill the shock body with Shock Oil (pin 1639-245) to within I- I 112-in. from the to p.
9192
Page: 788
6. Slowly move the shock shaft up and down a few times keeping the piston under oil at all times. Thi s is to remove the air from under the pi ston. Extend the shock shaft full y; then fill the shock txxly with oil to within 11 2-3/4-in. from the top. NOTE : After filling the shock body with oil, allow 5 minutes for all air bubbles to rise to the top.
7. Apply a light coat of oi l on the tloating piston ring and O-ring and install the noating pi ston in the shock Ixxly.
9. Using the tool as a handle, push the piston down into the shock Ixxly until the adjustment knob comes in contact with the shock txxly. Give the tool a quarter turn to free it from the pi ston. The piston should now be located correctl y.
NOTE : Oepending on which shock absorber is being worked on, adjust the piston location tool to the specification indicated in the Rebuildable Shock Specifications sub-section in this section.
729-085C
_NOTE : As the floating piston is pushed into the shock absorber body, air and excess oil will come out through the hole in the piston. If no oil comes out through the hole in the piston, remove the piston and add more oil to the shock body. 10. Install the Allen-head screw and O-ring into the bottom of the Ooating piston. While securing the piston with a 9/ 16-in. wrench, ti ghten the Allenhead screw.
8. Attach the Shoc k Piston Location Tool (pin 0644-
169) to the pi ston by placing its slotted end over the Oats on the top of the piston and givi ng the tool a quarter turn. Pull gentl y on the tool to make sure it is secure to the piston.
I I. Pour out the excess oiI from the shock txxly. 12. Install the lower end cap on the shock body.
9193
13. Using Shock Retaining Blocks (pIn 0644- 142) to hold the shoc k in place and lIsing an adjustable wrench, lighten the end cap sec urely.
2. Wash the shock body in parts-cleaning solvent ; then dry with compresscd air to remove sand and dirt.
DISASSEMBLING
I. Re move the screw rrom the bladder housing on the bottom or the shock. Discharge all the pressure from the shock lIsing the Shock !nOation Needle (pIn 0644- 158). Ope n the valvc in fillcr handle until all pressure is released.
14. Applya light coot or oil on the bladder housing 0 ring; then install the brass bladder housing inlo the lower end cap. Tighten securel y.
--~
"",
. -.
--'
Fsoe,
AP014
15. Pressurize the shock (see Pressuri l..ing Rebuildablc Shocks section). After shock has been pressuri zed, install screw into bladder housing. T ighten securel y. 16. Install shock eyelet bushings and ax le.
Servicing Position Sensitive Shock
WARNING
Before any service is performed on the gas shock absorber, first discharge all pressure from the shock remote reservoir. Remove the valve screw from the pressure valve and insert the Shock Inflation Needle (pin 0644-158). Open valve until all pressure is released , Failure to do this may cause personal injury.
REMOVING/CLEANING
I Remove the shock rrom the snowmobile.
9194
Page: 790
2. Using a I-in. wre nch, loosen the end cap and remove the shock rod and valve assembl y from the shock body.
_NOTE : Account for a set screw, 5116-in. ball, spring, spring rod, and a 1I4-in. ball.
I,mmm!mlntf
3. Pour the oil from the shock body into a suitable conl'ainer. 5. Rcmovc the pressure valve assembl y. Account for the O-ring.
4. Using a 3/1 G-in. Allen wrench, re move the set screw.

G. Using IFP Remo\'al Tool (pin 0644-348), remove
the nO<:lting piston.
Page: 791
9195
7. Items to inspect: A. Shock shan for straightness, nicks, or bUlTs. B. Shan bearing end cap replace. excessive wear. D. Piston strap for ClltS, chipped or nicked edgcs, or excessive wear. E. O-rings for nicks, cut'>, or cracks.
F. Valves for kinks or waves.
2. Lubricate the O-ring and Tetlon strap on iloating piston ; then press the iloating piston into shock until tlush with the top of the body.
clean, inspect, or
C. Inside of shock body for scratches, burrs, or
G Rubber dampe r (ski shocks only) for chipping , cracking. or being mi ssing. 8. Items 10 replace: A. Bleed sc rew O-ring and iloating piston O-ring. B. Shock shaft bearing cap if any signs of oil lea ks or damage.
C. Any part worn or damagcd .
NOTE: For shaft, shaft eyelets, or shaft bearing cap replacement, see Shaft Eyelet or Bearing Cap and Shaft Seal subsection.
ASSEMBLING
I.
~e l
In.
IFP Depth Setti ng Tool (pIn 0644--402) to 5.90
3. Install IFP tool onto iloating piston ; then press fl oati ng pi ston into shock body 5.90 in .
9196
Page: 792
6. Install by-pass components: lI4-i n. ball , spring rod, spring, and 5/16-in. ball.
4. Install bladder assembl y and tighten to 2. 1-2.5 kgIII (15-1 8 n-lb) ,
5. Fill shock Ixxly with light weight synthetic Shock O il (pin 2639- 151 ) to bottom of threads.
7. Install the set screw and ti ghten to 1.0 kg-Ill (7

Ib).
n-
9197
8. Install shock rod/piston assembly into body.

NOTE: End cap should be down to piston assembly (rod fully extended).
10. Using a I-in. wrench, lighten end cap.
II . Pressuri ze the shock with nitrogen to 200 psi (see Pressurizing Rebuild.'lble Shocks sub-section). 9. While holding up on the eyelet, screw end cap into lhe body.
12. Install the set screw (with O-ring) into the bladder housing.
NOTE: Air will bleed out of flat area on end cap.
9198
Page: 794
.. .
FS141
13. Test operation of the shoc k.

NOTE: Shock should feel soft on compression; constant on rebound.
2. Whil e holding the end cap; un screw the air c ha mbe r.
. . .. .. .. . . . .. ..... . . ... .. .. . . . .... ... . ... ... .
... . . . ... .. . ...... ... .... ...... .... .. . ... .. .. ... .... . ..... .. . . .. . . . . . . .... . .. . . ...... .... .
. .. .. . . ..... . . . . . . ... . . . . . ... ... . . . . .... .
FS142
NOTE: The air chamber should only be hand tight.
INSTALLING
I. Place the shock into position on the snow mobile. 2. Secure with ex isting hardware. Tighten to 3.2 kgTn
3. Drai n the oil from the air c hamber.
(23 rt- Ib).
Rebuilding/Recharging Fox Air Shocks
DISASSEMBLING
I. Remove the valve cap; then bleed the air from the air chamber.
4. Remove the ai r chamber from the bottom of the shock body.
Page: 795
2005 Arctic Cat Service Manual - all models - www. ReadM anu als.com
9199
5. Using a pick, re move the nylon pellet from the nitrogen bladder.
8. Using a 5/64-in. Allen-wrench , removc the set screw from the bea ring cap.
FS1<1SA
FS1<18
6. Using a 3fl6-in. Allcn-wrcnch , loosen the nitrogen bladder Y.>: tllrn.
9. Using a magnet on an Allen-wrench, rc mo\'e the

check ball.
7. Using Innation Needle (pIn 0744-020), remove all the nitrogen from the shock.
10. Using Spanner Wrench (pIn 0644-453), loosen the bearing cap.
9200
Page: 796
1 I. Remove the shock rod from the shock body.

14. Clean a nd inspect all com lxments.
ASSEMBLING/CHARGING
I. Lubricate the O-ring and wiper on the Oo."lting piston with shock o il.
12_ Drain the oi l rro m the shock body into a suitable container. 13. Using Removal Tool (pin 0644-4 16) rrom FlO<:lting Pi ston Removal Tool Kit (pIn 0644-402), remove the Ooating piston.
2. Cm'Cfull y install the Omlting piston into the shock body until it is below the threads .
NOTE: For ease in removing the piston, use the inflation needle to help vent the shock body.
3. Using Location Gauge (pIn 0644-4 17) rrom the Floating Pi ston Removal Tool Kit (pIn Q644--l..()2), install the floating pi sto n whil e using the inOation needle to vent the shock body.
NOTE: Refer to the 2005 Rebuildable Shock Specifications sub-section in this section.
Page: 797
9201
FS159
4 . Using standard Arctic O lt Shock O il , fill the shock txxIy to the bottom of the threads; then, allow to sit 1-2 minutes to ensure no air is !O the oil.
7. While keeping the shock rod full y extended, thread the bearing cap into lX)sition.
5. Lubricate the O-ring on the underside of the end cap with shock oil .
8. Using Spanne r Wrench (pIn 0644-453), tighten the bearing cap.
9..
FS158
6. Lower the shock rod into lhe shock txxIy until the piston is submerged in oil.
_NOTE : When tightening the bearing cap, note air and excess oil being bled from the hole in the cap.
9202
Page: 798
II. Us ing a 3/ 16- in . All en -wre nch , tighten Lhe nitroge n bladder.
9. Install the check ball and set screw into the bearing ca p. 12. Install the nylon pellet by gentl y tapping it with a plastic mallet.
13. Test the shock ror proper operation. 14. Using compressed air, blow all oi l rrom the holes in the bearing cap.
10. Charge the shock with nitrogen to 200 ps i.
15. Lubricate the seal on the air chamber wit h Fox Roat Fluid (pin 4639-012).
FS164
Page: 799
9203
... .
..
16, Slide the air cham ber onto the shock body.
19. Invel1 the shock and secure by the end cap to
assure the air cham ber is tight
17. Add I cc of Fox Float Fluid (pin 4639-012) into the chamber for Firecat models or 8 cc for MSeries models. 20, Us ing a hand pu mp , innate the air c ha mber to 50 psi for Firecat models or 60 psi for MSeri es models.
18. Thread the air chamber into the end cap until hand-li gill.
21. Install the valve cap.
9204
Page: 800
When using compressed air to dry components, always wear safety glasses. _NOTE : If compressed air is not available, use clean towel to dry the shock assembly.
3. Clamp the body eyelet o f the shock securely in vise with shan side up. 4. Remove the button-head screw from the nitrogcn valve in the shock body.
Servicing Fox Zero Pro Shock Absorbers

Thi s proced ure show s the proper methods for di sassembling, rebuilding , and assembling the pro shock
absorbers with no external damping adjustments,
WARNING
5.
hlSClt the needle squarel y into center o f the nitrogen va h'c to releasc the pressure.
Before starting , read through all of these instructions first to become familiar with the procedure.
Make sure the work area is clean and all of the necessary tools are available. These shocks contain high pressure nitrogen gas. Always use proper safety equipment such as latex gloves and safety glasses when working on shock absorbers .
NOTE: Some illustrations and photographs used in the following sub-sections are used for clarity purposes and are not designed to depict actual conditions.
DISASSEMBLING
I. Remove the sleel sleeve and polyurethane bushings from the eyelets o n both c nds of the shock. 2. Clean the entire shoc k assembly with soapy water. Dry the shock assembl y with compressed air.
WARNING
CAUTION
Point the nitrogen valve away from face and body to avoid injury when discharging or charging the shock.
Use a softbristle brush to remove as much dirt and debris as possible. Do not pressure wash the shock as this can force water and debris inside causing damage to the seals.
6. When the shock is full y di scharged , pull the ncedle away from the reservoir in a straight , smooth motion. 7. Loosen (but do not remove) the bearing bleed screw.
Page: 801
9205
13. Remove the shock body from the vise; then invert
the shock body and place it on a folded shop towel open e nd down.
14. Using compressed air (NEVER USE 1 -1101-1
PRESS URE NITROGEN), inscl1 the air gun nozzle into the nitrogen valve POl1 a nd blow the IFP out of the shock body and onto the folded shop towel.
8. Loosen and unsc rew the bearing assembly from
the shock body.
15. Clean the body tube, reservoir tube, and the IFP
with solvent. Dry with com pressed air in a wel l ventilated area.
16. Set body assembly aside on a clean, lint-free
9. Remo\'e the shaft assembl y from the body tube and place it on a clean, lint-free paper towel.
10. Remove the shock from the vise and pour shock
towel . 17. Clamp the shaft eyelet sec urely in vise with the piston end lip.
18. Remove the piston lock nut from the end of the
oil from body tube into a proper disposal container. 00 NOT REUSE OLD SHOC K OIL. II . Clamp the body cap of the shock securcJy ill vise with the open end of the body tube poi nt ing up.
12. Loosen and remove the nitorgen valve from the
shaft.
body_
19. Hold the tip of a screwdri ver against the end of
shaft ; then hold the pi ston assembly under the topoul plate and lift upwards.
FS014
9206
Page: 802
FS011
NOTE: Keeping the components in order is criti cal for proper performance of the shock absorber. Doing steps 20-21 properly ensures that proper order is kept.
20. Slide the piston assembly onto the shaft of the
L!'.
CAUTION
screwdri ver. Pull the sc rewdri ver away from shock shaft while SUppol1ing the piston assembly and set this on a clean, lint-free towel.
Care must be taken when using a scribe to remove a seal. Always spear the seal with the point of the scribe. Do not attempt to wedge the scribe behind the seal as this could cause damage to the seal groove and compromise the performance of the shock.
2. Using a scribe, re move the Uc up wiper and 0 -
ring seals from the bearing housing.

3. Thoroughly clean the FI ST bearing, bearing
housing. and pi ston assembly with solvent. Dry with compressed air in a wel l ventilated area. 4. Using a scribe. remo\'e the O-ring seal from the IFP. 5. Install the new. well lubricated O-ring into the FIST bearing. Check to make sure the O-ring is properl y seated and is not twisted .
NOTE: To aid in proper seating of the Oring, it may be advisable to use a soft, blunt object (non writing end of a pen, etc.) to push it in.
21. Slide bearing assembl y off of shaft.
L!'.
CAUTION
Use care when passing the bearing over the shaft threads not to scratch the inside of the bearing assembly.
22. Remove the bleed screw from the bearing and set
6. Install the new, well lubricated O-rings into the bearing housing making sure the shaft O-ring is in the groove next to the DU bushing and that Ihe 0 rings are properly seated and not twi sted. It may be advisable 10 use a soft , blunt object to push it in. 7. Insta ll the new V-cup seal into bearing. U-cup should be installed so the cupped end is facing the DU bushing inside of bearing. C heck to make sure seal is prol~rl y seated. It may be advisable to use a soft , blunt object to push it in. 8. Install FIST bearing into housing. Check for prol~r orientation of the FI ST beari ng. The s t e pl~d side of the FIST beari ng should be visible. 9. Using a pair of snap ring pliers, install the snap ring into the bearing housing. Check for proper ori entation of the snap ring. T he nat side of the snap ring should be visible. Check to make sure the snap ring is prol~ rl y seated.
them both on a clean , lint free towel.
REBUILDING
I. Using a IXlir of snap ring pliers. remove the snap
ring from the bearing housing. Using fin gers, remove the FIST scraper from the housing. Using a scribe, remove the O ring from the IIlside of the FI ST scrape r by "spearing" the seal with the point of the scribe and pulling it out.
Page: 803
9207
10. Instalilhe new, well greased O-ring onto Ihe IFr. 11 Replace the bearing bleed screw O-ring.
ASSEMBLING
7. Using Location Gauge (pIn 0644-4 17) rrom the Floating Pi ston Removal Tool Kit (pIn 0644-402), install the floatin g pi ston whil e using the inflation needl e to vent the shock body.
NOTE: Refer to the 2005 Rebuildable Shock Specifications sub-section in this section. NOTE: Depth is measured from the edge of the body opening to the outside edge of the IFP (not the center depression of the IFP).
Clamp shaft eyelet securely in vise and place a seal tool on end or shart. 2. Lubricate the beari ng assembly seals wilh an assembly lube. Slide the bearing assembl y onto shaft with the R ST bearing racing the eyelet. T his should be done in a single smooth motion to avoid damaging the seals. 3. Hold the piston assembly rrom underne.'lth the topout plate and place the end or the screwdri ver onlo Ihe e nd or the shoc k shart. Slide the piston assembly onlo the shaft end . Check to make sure the piston assembly is seated properly and install Ihe piston lock nut. Tighten nul to 2.5 kg-m ( 18 ft- lb). Remove shaft assembl y rrom vise and set it aside on a clean, lint- rree paper towel .
8. Lubricate the O-ring on the nitrogen \'al ve with assembl y lube and thread it into the body. Tighten securel y.
Fsooe
9. Fill the body tube with oi l to the bottom or the bearing threads. Wrap the new pi ston band around the piston maki ng sure the rounded edges face out. Insert the shaft assembly into the body tube. Slowly push shaft into body until piston assembl y is approximately 12.7 mm (0.5 \0. ) below the oil surface. 10. Slowly stroke the shaft assembly up and down over about a I-inch range two to three times being very careful not to pull the pi ston assembly out of the oil .
NOTE: At this point, there should be no air bubbles rising from the piston assembly.
4. Clamp the Ixxly of the shock securely in the vise with the ope n end of the body facing up. 5. Lubricate the IFP O-ring with assembl y lube and wra p a new pi ston ring around it. 6. Insert the IFP into the shock body (w ith the dished side racing up toward the open end or the shock body) to just below the bearing threads.
11 . Top olT the shock body with oil a nd slow ly pull the sha ft up until the piston assembly is about in the middle or the bearing threads.
9208
Page: 804
12. Holding the shalt
In that position, slide the bearing assembl y down the shaft and stal1 threading it into the body by hand . Oil should fl ow out of the bearing blecd holc.
17. If the re is any interfere nce while pushing the shaft
into the body, the IFP is in the wrong location.
WARNING
13. As the bearing assembly is being threaded down, it
will contact the damping piston assembl y and pull it down into the shock body with it. As the bearing is being threaded in from this po int , be sure the damping piston assembl y stays in cont.act with the beari ng.
14. Whe n the bearing is threaded all the way down,
If there is interference, unthread the bearing assembly from the body and repeat steps 4-16 of Assembling. Failure to repeat the steps and rid the shock of the interference may cause damage to the shock resulting in improper shock performance and could cause operator injury.
18. If there is no interference, proceed to step 19. 19. Ivlaintain the shock in the vise.
thread the bleed screw into the bearing assembly and tighten it securely.
20. Make sure the nitrogen valve is directed outward. 21. Insert the needle squarel y into the center of the nitrogen \'ah'e (taking care that the nh'e is directed away from fac e and body) and pressuri ze the reservoir to 200 psi. The shock shaft should be full y extended from the press ure before the final pressure reading is taken. Continue charging while pulling the reservoir away from the needle llsing a smooth, straight motion. Keep the reservoir as strai ght as possible to prevent the needle from bending. As the reservoir and needle separate, a "popping" sound should be hea rd.
15. Tightellthe bearing assembl y into the body.
FS016
6
16. PtL"h the shaft all the way down until thc eyelet
WARNING
lightl y contacts the FI ST scrape r on the bearing assembly. It should go all the way down withollt any feeling of contact or interference .
NOTE: At this point, DO NOT attempt to pull the shaft up out of the body.
Charge the shock using nitrogen gas only. 00 NOT CHARGE WITH ANY OTHER TYPE OF GAS. Doing so will compromise the performance of the shock and may be EXTREMELY DANGEROUS.
22. Install the button-head screw into the nitrogen
valve.
Page: 805
9209
AP032
23. C lean all oi l residue from the shock a nd reservoir with solvcnt and dry with compressed air in a well ventilated area. 24. Install the polyurethane bushings and steel sleeves into the eyelets.
NOTE: If the piston assembly should become mixed , the large slots of the piston must be located next to the lock nut of the shaft. Refer to the appropriate Illustrated Parts Manual for valve plate location. NOTE: If a rubber washer is found on the shock shaft next to the bottom side of the bearing cap, it must be removed before installing the limiting spacers. The rubber washer must not be used with the spacers installed.
Ins'lalling In'lernal Travel Limi'ling Spacers

T hese s pace rs arc used to shorten the tra vel of the shock absorber to fine tune the suspension to the o perator's driving style. If installing the spacers in the inte rnal fl oating pi ston shock absorbers, follow these steps. I. Di s. 1.ssemble the shock absorber as covered in this manual. 2. Place the shock shaft eyclet into a vise and remove the nut securing the pi ston to the shoc k shaft.
4. Measure the length of the limiting sp<lcer(s) that are being install ed on thc shock shaft. Write down thi s measure me nt as it will be required to prope rl y calculate the fl oating pi ston depth later in the assembl y process.
5. Install the desired number of limiting spacers on the shock shaft.
3. G HduU y remove the piston and its ,'al ving plates stacked on either side of the piston from the end of the shock shaft.
NOTE: When removing the plates from the shock shaft, assembly on a 5/16 x 3in. cap with a nut to keep the assembly piston and valve place the piston screw and secure in its proper order.
9210
Page: 806
6. Install the heavy sl:k1.cer washer and then the piston with valve plates located on either side onto the shock shaft. Check to make sure the pi ston has been installed with its large slots positioned next to the lock nut which secures the assembly to the shaft . 7. Inslall the lock nut and tighten to 2. 1-2.8 kg-m
( 15-20 ft-Ib)
10. Remove the shock body from the vise and reposition the shock body and holding blocks in the vise so its open e nd is " up." Extend the shock shaft full y out; then fill the shock body with Shock Oil (pin 1639-245) to within I-in. from the top. Slowly stroke the shaft up and down to remove ai r fro m unde r the pi ston. Oil may need to be added to keep the shock full. Fill shock to with in 1/4-in. from the top. Allow 5 minutes for all air bubbles to ri se to the top.
,1; CAUTION
00 not over-tighten the lock nut. If excess torque is applied , damage to the piston and valves will occur. NOTE: For installing spacers on an IFP shock, proceed to step 8. For installing spacers on a remote reservoir shock, proceed to the appropriate assembly procedure for the type of shock being serviced.
NOTE: Before installing the internal floating piston, refer to the illustration below and calculate the new piston depth using the measurement taken earlier of the spacer(s) installed and the formula provided in the illustration .
8. Appl y a light coat of oi l on the O-ring and pi stoll ring. Install piston and the shock shaft assembly into the shock body.
When usi ng shoc k Internal travel limiting spac ers on rebuildable shocks ..... ith IFP's (Intern at Fl oati ng Pi s to n), th e tFP depth selling mu st be reduced to compensate lor tha spacer heig ht. Use the following Ionnula to adjust your shock depth setting. Example: Spacer height = .500 in. Old IFP depth = .750 in. tFP Deplh Adjustment = .11 65 x .5OO = .058 In. New tFP depth = .750 .058 = .692 in. 0730266
II . Aft er calculating the new piston depth, measure out this distance on the shock pi ston location tool; then adjust and sec ure the location knob.
9. Place the shaft bearing cap into the shock body and tighten securely.
Page: 807
9211
12. Apply a light coat of oil on the n oating pi sto n ring and a -ring and insta ll the n oating pi sto n in the shock body.
Servicing Rebuildable Shocks & Remote Reservoir
.6. WARNING
Before servicing a gas shock absorber, first discharge all pressure from the reservoir. Remove the screw from the top of the reservoir and insert the Shock Inflation Needle (pin 0644-158). Open valve until all pressure is released. Failure to do this may cause personal injury.

13. Using a long needle-nose plie rs, insel1 the Ooating pi sto n into the adjuster body until the pisto n is nus h with the top o f the body; then using the pi sto n location tool as a handle. push the pi sto n dow n into the adjuste r body until the adjustment sto p of the tool comes in contact WiUl the adjuster body. The pi sto n s ho uld now be located correctly. I. Re move the s hock absorber fro m the snowmo bil e. Re move the mounting bus hings and bearings from the s hock. 2. Wash the shoc k body and reservoir III partscleaning solvent; then dry with compressed air to remove sand and dirt.
.6. WARNING
When working with Shock Inflation Needle (pin 0644-158), use extreme care. Misuse of this tool may cause personal injury or death. Avoid puncturing skin with needle. Pressurized air injected through the skin may be fatal. Do not release safety mechanism unless red nose piece is inserted in shock absorber air valve.
3 . Re move the screw from the bl adder housing on bottom of s hock resen 'oir; then discharge all press ure from the s hoc k reservoir using Shtx k Innatio n Needle (pin 0644- 158). O pen valve in fill er handle unti l all pressure is released.
NOTE: As the floating piston is pushed into the shock absorber body, air and excess oil will come out through the hole in the piston. If no oil comes out through the hole in the piston, remove the piston and add more oil to the shock body.
14 . Install the Allen-head screw and a -ring into the boUom of the Oo.. l ling pi ston. Ti ghten the All enhead screw. 15 . Pour o ut the excess o il from the shock body. 16 . Install the lower end cap on the shock body. 17. Using Retaining Blocks (prn 0644- 142), ho ld the shock body in place and ti ghte n the end cap using an adjustable wrcnch. Pressurize the shock follow ing the shock pressuri zing procedure.
9212
Page: 808
4. C lamp the shock body eyelet in a vise; then using a 1-10. wrench, unscrew the shaft bearing cover.
NOTE: If the shock body turns in lower end cap, use shock blocks to hold the shock.
NOTE: Do not remove the self-locking nut from the bottom of the shock rod unless piston or piston valve changes are needed as it is very important the valving on either side of the piston stay in the proper position.
8. Insta ll the piston ring on the pi ston. 9. Push down on the reservoir e nd cap compressi ng it 2.5 cm ( I in.) into the reservoir; then remove the reservoir Ct'lP retaine r ring. Use care not to scratch the inside of the reservoir.
5. With the bearing cover loosened, lift the shaft assembly from the shock body.
NOTE: With the retainer ring removed, wipe the ring area clean to remove any foreign materials.
10. Remove the reservoir end cap by grasping the bladder housing with a pliers and pulling the cap slowly Ollt of the reservoir body.
6. Remove the piston ring from the pi ston. 7. Looscn (BUr DO NOT REIVIOVE) the selflocking nut from thc bottom of the shock shaft ; thcn clean the pi ston arca with clean parts cleaner to remove any di l1 or foreign materia l from between the valves . Dry the pi ston and valves completely using compressed air. Tighten selflocking nut to 2. 1-2.8 kg-m (15-20 ft -Ib) . Do not over-tighten! If excess torque is applied, the piston and va lves will be damaged.
11. Remove the Allcn-hC<ld screw and a -ring from the center of the pi ston. Remove the piston from thc reservoir by grasping the raised a re.1 of thc piston using a pliers. Pull the piston from the resen 'oir and account for the piston ring.
Page: 809
9213
NOTE: If filling shock with a remote reservoir, hold the reservoir lower than the shock , By holding the reservoir low as oil is added to the reservoir, air in the hose will be forced into the shock body and out of the system.
2. With the Allen-head sc rew and a -ring install ed in the reservoir pi ston and the reservoir full of shock oil, compress the piston ring into position with fingers and slowly push the pi ston down into the reservoir until the a -ring is dow n in the reservoir housing.
12. Pour the oil out of the shock and reservoir; then clean the inside of the reservoir and shock body using clean P< 1I1 S washer solvent. Blow dry using compressed air.
NOTE: If the shock bearing cap does not show signs of leakage or damage, do not remove from the shaft.
13. Inspect shock shan for strai ghtness, nicks, or burrs. Inspect shock and reservoir bodies for dents or scm tches. Ins]X:ct pi ston valves fo r bending or cracking . Inspect all a-rings and seals for nicks, cuts, or cracki ng. Inspect rubber bottom-out bum]X:rs for wear or damage. Replace any worn or damaged parts.
NOTE: If changing or removing shock shaft seal, bearing cap, eyelet. or bottom-out bumper, refer to those sub-sections.
3. Let the resen 'oir hang down for a few minutes to let air bubbles rise to the top and into shock body. 4. Using a clean pair of pliers, grasp the hex area at the center of the piston and slowly push the piston down into the reservoir until it bottoms in the reservoir. Onee the pi ston has bottomed out in the reservoir, slowly pull up on the piston approximately If.! in. Next, slow ly push the piston back down until it once again bottoms. Repeat this procedurc sevcml times until no air bubbles are secn rising in the oi l in the shock body.
NOTE: The oil in the reservoir will remove any air in the hose or passageway between the reservoir and shock body.
ASSEMBLING
Place the shock into a vise at a sli ght angle and fill the shock reservoir with Shock Oil (pIn 1639245).
5. Once all air has been removed from the reservoir body, bottom the pi ston in the reservoir and thell pull the piston upward approximately 118 in. Allow the reservoir to hang down below the shock absorber in the vise to permit any air that mi ght remain in the reservoir to ri se into the shock body.
9214
Page: 810
6. Install the reservoir end cap and O -ring down mto the reservoir approximate ly 2.5 cm (l in.). Install the retainer ring making sure it is firml y in place.
12. G ive the end of the shock rod a few light taps with
the palm of the hand to help release air bubbles from the piston valves. 7. G rasp the bladder housing with a pli ers and pull it up into place against the retainer ring.
8. Slowly pour oil into the shock body until it is 114 in. fro m the top of the shock Ixxly. Again, allow fi ve minutes to elapse befo re proceeding.
9 . Space the
NOTE: Be careful not to damage the piston ring and watch that the piston ring ends are overlapped and in place as the piston is installed.
13. Install the end cap very slowly to allow excess air
botto m edge of the bearing cap approximately 112 to 1 in. away from the piston assembly. wear ring e nd gap with the low-speed o rifice cutaway positioning the c utaway so it faces the upward angle of the shoc k body which will allow air to escape.
and oil to come out the threads; then using a I-in. wrench, tighten the bearing cap firml y down in place. Do not push down on the shock shaft until the reservoir has been pressurized. Pressuri ze the resen 'olr.
10. To install the shock rod , ali gn the valve piston
14. Di scharge all press ure from the shock reservoir using Shoc k Inllation Needle (pIn 0644- 158).
O pen val ve m fille r handle until all pressure is released .

11. Compress the piston ring into position with fin gers
and slowly start the piston assembl y down into the shock body.
15. Push down o n the reservoir end cap compressing it 2.5 em (I in .) into the resen'o ir ~ then remove the resen 'oi r cap retaine r ring. Use care not to scratch the inside of the reservoir.
16. i\'leasure the pi sto n depth from the to p of the
reservoir body to the to p of the iloating pisto n. tvleasurement sho uld be within specificatio n (see Rebuildable Shock Pisto n Depth Chait in this sectio n). If measurement is not correct, pour I inch of shock oil on top of the piston. Remove the Alle n-head sc rew ; then move the piston to the p.ro per depth and install Allen-head screw with 0 rIng.
Page: 811
9215
17. Install the reservoir end cap and O-ring down mto the reservoir approximately 2.5 cm (l in.). Install the retainer ring making sure it is firml y in place. 18. Pressurize the reservoir. 19. Install the shock mounting bushings and bearings in eyelets.
4. Remove the outer plastic wiper: then remove the inner rubber wiper rrom the bearing cap.
Bearing Cap and Shaft Seal

I. With shaft assembly removed rrom shock body,
clamp shaft eyelet in vise and remove the lock nul.
5. Using a small paper clip bent on one end, remove the inner O-ring.
2. Lift the piston valve assembly.

NOTE: When removing the plates from the shock shaft, assembly on a 5/16 x 3-in. cap with a nut to keep the assembly piston and valve place the piston screw and secure in its proper order.

I. Install new O- ring and inner rubber wiper into the
shaft bearing cap: then install outer plasti c wi per.
AP032
3. Remo\'e the bearing cap (on rront arm adjuster shocks, remove the adjuster pi ston and a spacer washer first).
2. Inspect the shoulder or step or the shaft ror sharp edges or a burr. Smooth up with 6400 grit sand paper or emery cloth. 3. Put Bearing Cap Installation Tool (pIn 0644-268) over the threaded end or the shart.
9216
Page: 812
Shaft Eyelet
REMOVING
1. Using Shock Rod Clamping Tool (pin 0644-277) to prevent damage to the shaft surface, place the shock shaft into a vise. 2. Heat thc shart eyclet with a torch to sortCIl the Loctite.
4. Put a small amount of light grease on the seal and slide the bearing cap over the tool and onto the shaft
NOTE: The eyelet must be heated up to 3000 for the Loctite to soften.
3. Using a wrench , unsc rew the eyelet from the shaft 5. On a front arm adjuster shock, install the spacer washer on shan and install adjuster piston in the same manner as bearing cap; then remove the installation tooL 6. Install pi ston valvc asscmbly. Tighten thc sclflocki ng nut to 2.1-2.8 kg-m (15-20 rt-lb).
INSTALLING
1. Clean shart threads and eyelet threads. 2, Appl y red Loctite #271 to both threads, install the eyelet, and tighten securely,
Ski Shocks Bottom-Out Bumper

Bottom-o ut bumper ca n be replaced by removi ng shock eyclet or by removi ng pi ston va lving assembl y and bearing cap_
9217
Pressurizing Rebuildable Shocks

To pressuri ze the gas shock absorber, a regulator system and a nitrogen tank wi ll be needed.
2. Turn the nitrogen tank va lve o pen and slowly rotate the regulator T-handle inward until the gauge reads 200 lb o r pressure; then close fill er valve and remove inflatio n needle .
NOTE: On remote reservoir shocks, use a needle nose vise grips to hold the bladder housing to keep the end cap from pushing into the reservoir when inserting the inflation needle.
WARNING
Never have a nitrogen bottle in the area without having it chained or secured. If the bottle should tip over and the regulator break off, the gas inside it is under 1800 Ib of pressure and per sonal injury may result.
D WARNING
Always rotate the regulator Thandle to its loose position each time when finished using the system. Each time before the nitrogen tank valve is opened , check to make sure the regulator Than die is turned out. When opening the nitrogen tank valve, never stand in front of the regulator in case there should be a problem.
_NOTE : Before inserting the needle into the bladder, lubricate the needle with light oil to make installation easier.
3. Install the screw into the bladder ho using and tighten securely. 4. With the reservoir pressuri zed, push down o n the shock shan until it nearl y botto ms and release it. The shan sho uld return to its extended lX1sition smoothl y.
NOTE: If a soft spot or a mushy area is felt as the shaft is pushed down, this would indicate air in the shock body. If there is air in the shock body, discharge the reservoir gas pressure. Disassemble the shock to the point that the "filling with oil" and the "bleeding air" procedures can be redone. Assemble and repeat the pressurizing procedure. To test the shock absorber for nitrogen gas leaks, submerge in water.
I. Insert the Shock Inflation Needle (pin 0644- \58)
into the shock bladder; then ope n the val ve o n the fill er handle.
9218
Page: 814
Troubleshooting Track
Problem: Track Edge Frayed - Drive lugs Worn
Condition
1. Track alignment adjusted incorrectly
Remedy 1. Align - replace track
Problem: Track Worn Adjacent to Outer Drtve Lugs
Condition
1. Track tension adjusted incorrectly 2. Rear idler wheels dirty - damaged Problem: Track Ratchets - Slaps Tunnel
Remedy 1. Adjust track tension 2. Clea n - replace idler wheels
Condition
1. Track tension adjusted incorrectly (too loose) 2. Drive sprockets misaligned - damaged
Remedy 1. Adjust track tension (lighten) 2. Align - replace sprockets
Problem: WearMStrip Wear ExcessIVe
Condition
1. Slide rail bent - bro ken - damaged 2. Track alignment adjusted incorrectly
Remedy
1. Repair - replace slide rail 2. Adjust track alignment
Page: 815
2005 Arctic Cat Service Manu al - all models - www. ReadManuals.com
9219

Arctic Cat 2005 Snowmobile Service Manual All Models

Hochgeladen von

Dokumentinformationen

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

Arctic Cat 2005 Snowmobile Service Manual All Models

Hochgeladen von

Copyright:

Verfügbare Formate

- -_-.!

tel ?nn4 4 r,.ti,.,

SECTION 1 - GENERAL INFORMATION

... 1-2 .. 1-2

2005 Arctic Cat Service Manual - all models - www.ReadManuals.com

RECOMMENDED GASOLINE (EFI Models)

Recommended Gasoline and Oil

2005 Arctic Cat Service Manual - all models - www.ReadManuals.com

High Altitude Operation

Preparation For Storage

2005 Arctic Cat Service Manuat - all models - www.ReadManuals.com

it/them to the lead(s), and ground it/them on the cylinder head(s).

19. Clean and polish the hood, console, and cik"lssis

Preparation After Storage

2005 Arctic Cat Service Manual - all models - www. ReadManuals.com

After Break-In Checkup

B. Dri ve belt dell ection/Break-ln

2005 Arctic Cat Service Manual - all models - www.ReadManuals.com

After Break-In Checkup Checklist

2005 Arctic Cat Service Manual - all models - www.ReadManuals.com

13.0 13.1 13.3

13.6 13.7 13.8

0.2-0.4 0.4-0.7 1.0-1.6 2.2-3.5 0.3-0.6

2005 Arctic Cat Service Manual - all models - www. ReadManuals.com

Fraction/Decimal Conversion Chart

kg-m x 7.235 = ft-Ib ft-Ib x 0 .1383 = kg-m

118= 114 _ 318 112 518 314 _ 718 -

.1 25 .250 .375 .500 .625 .750 .875

.65625 .71875 .78125 .84375 .90625 31132 - .96875

21132 23132 _ 25132 _ 27132 _ 29132 -

33164 = 35164 37164 39164 41164 -

Drill Bit Sizes (NulTlber) Chart

SIze of Dnll In Inches

SIze of Dnll Inches

.1800 .1770 .1730 .1695 .1660 .1610

.1065 .1040 .1015 .0995 .0980

2005 Arctic Cat Service Manual - all models - www. ReadManuals.com

.0 1614 .0 1654 .01693 .01732

.73 .74 .75 .76 .77 .78 .79 .80

.82677 .86614 .90551 .94488 .98425 1.02362 1.06299 1.1 0236

1.1 8 110 1.22047

3.34645 3.38582 3.42519 3.46456 3.50393 3.54330 3.58267 3.62204 3.66141

3.74015 3.77952 3.81889 3.85826 3.89763 3.93700

2005 Arctic Cat Service Manual - all models - www.ReadManuals.com

Lubricate with Arctic Cat Low-Temp Grease (pIn 0636-593)

2005 Arctic Cat Service Manual - all models - www.ReadManuals.com

2005 Arctic Cat Service Manual - all models - www.ReadManuals.com

::2::2::2::2 a... a... a... 0.. [(a: er a:

2005 A rctic Cat Service Manual - all models - www.ReadManuals.com

12.0 12.2 12.3 12.5 12.6 12.8 12.9

10.5 10.7 10.8

13.6 13.7 13.8

2005 Arctic Cat Service Manual - all models - www. ReadManuals.com

Piston Replacement Guide

PISTON & RING SET

500 cc w/APV 500 cc wlo APV

570 cc 600cc (8TD)

2005 2005 2005 2005

3003-760 3006-004 3005-714 3006-004 3006-394

Not a Service Part

Assembly Schematics Table of Contents

570 cc ............. ..................................................... 2-10

Lubricate with Arctic Cat Low-Temp Grease (pIn 0636-593)

2005 Arctic Cat Service Manual - all models - www. ReadManuals.co m