Arctic Cat Sno Pro 500 Operator's Manual
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Arctic Cat Sno Pro 500 Operator's Manual

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Summary of Contents for Arctic Cat Sno Pro 500

  • Page 1 Operator's/ Performance Manual Sno Pro 500 SHARE OUR PASSION.
  • Page 3 At the time of publication, all information and illustrations were technically correct. Some illustrations used in this manual are used for clarity purposes only and are not designed to depict actual conditions. Because Arctic Cat Inc. constantly refines and improves its products, no retroactive obligation is incurred.

  • Page 4: Parts And Accessories

    Your Arctic Cat Dealer: ________________________ Address: ____________________________________ When in need of replacement parts, oil, or accesso- ries for your Arctic Cat Snowmobile, be sure to only Phone: _____________________________________ use GENUINE ARCTIC CAT PARTS, OIL, AND ACCESSORIES. Only genuine Arctic Cat parts, oil, and accessories are engineered to meet the standards and requirements of your Arctic Cat Snowmobile.

  • Page 5: Table Of Contents

    Performance Tips ............. 78 Hydraulic Brake System........25 Preparation For Storage ........78-79 Recommended Gasoline ........25 Preparation After Storage......... 79 Checking Headlight Aim........25 Genuine Arctic Cat Products ....... 79-80 Preoperation Checks ..........25 Special Tools ............80-90 Test Ride ............... 26...
  • Page 6 NOTES...

  • Page 7: Specifications/Charts/Patterns/Diagrams

    38.2 l (10.1 U.S. gal.) Chain Case Lubricant Level 236 ml (8 fl oz) Gasoline (Recommended) 87 Octane (minimum) Non-Oxygenated Pre-Mix Oil (32:1 Ratio) Arctic Cat Formula 50 Injection Oil Chain Case Lubricant Transmission Lube Suspension Grease All-Temperature Brake Fluid High-Temp DOT 3...

  • Page 8: Torque Conversions (Ft-Lb/N-M)

    Tightening Torque (General Bolts) Thread Tightening Type of Bolt Diameter A Torque (mm) (Grade 8.8) 60 in.-lb 96 in.-lb 20 ft-lb 40 ft-lb 65 ft-lb 0738-201 (Grade 10.9) 12 ft-lb 28 ft-lb Torque Conversions 50 ft-lb (ft-lb/N-m) 95 ft-lb Electrical ft-lb ft-lb ft-lb...

  • Page 9: Component Voltage/Resistance Chart - Coolant Temperature

    Component Voltage/ Resistance Chart - Coolant Temperature TEMP/C TEMP/F VOLTAGE OHMS TEMP/C TEMP/F VOLTAGE OHMS 0.115 1.377 1800 0.129 1.459 1950 0.143 1.541 2100 0.157 1.623 2250 0.171 1.705 2400 0.185 1.806 2670 0.192 1.907 2940 0.199 2.008 3210 0.206 2.109 3480 0.213...

  • Page 10: Component Voltage/Resistance Chart - Air Temperature

    Component Voltage/ Resistance Chart - Air Temperature TEMP/C TEMP/F VOLTAGE OHMS TEMP/C TEMP/F VOLTAGE OHMS 1.230 8540 0.113 1.322 9530 0.121 1.413 10520 0.128 1.505 11510 0.136 1.596 12500 0.143 1.716 14020 0.151 1.836 15540 0.162 1.955 17060 0.173 2.075 18580 0.184 2.195...

  • Page 11: Crankshaft Runout/Repair Specifications

    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 illustration, 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 crankshaft is still supported on the outer bearings using V blocks.

  • Page 12: Drive System Specifications

    Drive System Specifications DRIVE CLUTCH DRIVE SPRING CAM ARM DRIVEN PULLEY DRIVEN SPRING MODEL COLOR GRAMS SPRING COLOR Sno Pro 500 0746-232 0646-229 Yellow/ 0746-826 64.0 0726-297 0648-790 Black/Light Blue White TORQUE DRIVE BELT CHAIN ENGAGEMENT/ GEAR BRACKET MODEL MAXIMUM RPM...

  • Page 13: Drive Clutch Spring Chart

    Drive Clutch Spring Drive Clutch Cam Arms Chart NOTE: All listed cam arms are w/set screw. ARCTIC CAT DRIVE CLUTCH SPRING CHART ARCTIC CAT DRIVE CLUTCH CAM ARMS Rate @ 2 9/16 in. Rate @ 1 5/16 in. Color Grams...

  • Page 14: Chain Case Performance Calibrations

    Chain Case Performance Calibrations NOTE: The following table should be used as a guide only. Drive Sprocket Chain Case Performance Specifications RPM (Engine) Sprockets Ratio Chain Pitch 7400 7800 8000 8200 8700 20/46 0.435 81.1 85.5 87.7 89.9 95.4 20/45 0.444 82.8 87.3...

  • Page 15: Chains And Sprockets

    Below is a list of rear suspension springs and specifi- 2602-244 cations. This chart was compiled to assist technicians 2602-216 in fine-tuning the Arctic Cat rear suspension when the 2602-254 original springs are not optimum for the conditions 1602-414 and a softer or firmer ride is desired.

  • Page 16: Installed Spring Rate Chart

    Installed Spring Rate Ski Shock Springs Chart Free Rate Part No. Active Coils Total Coils Length (lb/in.) Suspension Fully Suspension Fully 2703-385 13.00 in. 8.50 10.50 Extended Extended 2703-386 13.00 in. 8.00 10.00 (In lb - Adjuster (In lb - Adjuster Set 1 &...

  • Page 17: Valve Stacks/Specifications

    Valve Stacks/ Specifications Part Number Description Compression (Piston Side) Rebound (Piston Side) 2703-809 Ski Shock 1.300 x 0.006 in. 1.100 x 0.006 in. Extended Length: 20.12 in. Rebuild Kit - p/n 2604-815 1.300 x 0.006 in. 0.600 x 0.004 in. Collapsed Length: 13.93 in.

  • Page 18: Rebuildable Shock Accessory Part Numbers

    0603-883 Valve: [1.250 OD X 0.377 ID X 0.012 TH] 0603-889 Valve: [1.250 OD X 0.377 ID X 0.015 TH] shocks is available from Arctic Cat Service Parts 0603-348 Valve: [1.300 OD X 0.377 ID X 0.006 TH] Department. 0603-349 Valve: [1.300 OD X 0.377 ID X 0.008 TH]...

  • Page 19: Fraction/Decimal Conversion Chart

    Fraction/Decimal MM/IN. Conversion Conversion Chart Chart 8ths 16ths 32nds 64ths 64ths (cont) 1/8 = .125 1/16 = .0625 1/32 = .03125 1/64 = .015625 33/64 = .515625 .00039 .02008 .03937 2.00787 1/4 = .250 3/16 = .1875 3/32 = .09375 3/64 = .046875 35/64 = .546875 .00079 .02047 .07874...
  • Page 20 NOTES...
  • Page 21 NOTES...

  • Page 22: Wiring Diagram (Hood)

    Wiring Diagram Hood Harness (p/n 1686-587) 0744-201...

  • Page 23: Wiring Diagram (Ignition/Main)

    Wiring Diagram (Ignition/Main) (Harness p/n 1686-628) (Insert 11 x 17 Ill. 0745-605 in color here.) 0745-605...

  • Page 25: Setup Instructions

    INSTALLING SPINDLE/A-ARM Setup Instructions This snowmobile has been prepared at the factory to minimize required setup items; however, there are some items and inspections that must be done at a dealership or by the owner/operator. Please pay close attention to all items on the following pages. Be sure to read these instructions thoroughly before starting to set up the snowmobile.

  • Page 26: Installing Sway Bar (Optional)

    TRACK TENSION/TRACK 3. With the rubber ski damper and damper plate ALIGNMENT installed in the ski saddle, place the ski into posi- tion on the spindle axle and install the spacers CAUTION (positioning the spacers for the desired ski stance); then slide the cap screw with washer through the Track tension has been initially adjusted at the factory outside of the ski and spindle assemblies.

  • Page 27: Ski Alignment

    NOTE: Always loosen the right-side rear axle nut 9. Loosen the right-side rear axle nut; then on the side of the track which has the inner track drive when adjusting track tension/alignment. The left- lugs closer to the rear idler wheel, rotate the side rear axle nut is secured with green Loctite adjusting bolt clockwise 1-1 1/2 turns.
  • Page 28 Adjusting NOTE: The following procedure can be used to adjust the alignment of either ski. 1. Unlock the steering tie rod by loosening the jam nuts (A). NOTE: The inside jam nuts are left-hand thread. Care should be taken to rotate them in the proper direction.

  • Page 29: Handlebar Alignment

    Verifying 1. Verify ski alignment by measuring across from the outside edge of the left-side ski to the outside edge of the right-side ski (without using the straight- edge) in two places: approximately 35.5-38.1 cm (14-15 in.) in front of the spindle and 35.5-38.1 cm (14-15 in.) behind the spindle.

  • Page 30: Steering Speed Ratio Adjustment

    STEERING SPEED RATIO 2. Using Drive Belt Deflection Tool (p/n 0644-424), ADJUSTMENT thread the tool clockwise into the driven pulley until the movable sheave opens far enough to NOTE: The lower steering post bearing housing install the drive belt. is not symmetrical; therefore, rotating it 180° moves the steering post closer to or farther away from the drag link which changes the steering ratio.

  • Page 31: Hydraulic Brake System

    2. If the brake fluid level is below the low mark, 3. Using the measurement obtained in step 2, make a remove the reservoir cover and add Arctic Cat horizontal mark on the aiming surface. approved brake fluid until the fluid level is just 4.

  • Page 32: Test Ride

    These numbers are required by the dealer to complete C. Low Fuel warranty claims properly. No warranty will be allowed by Arctic Cat Inc. if the engine serial number or VIN is D. Fuel Level removed or mutilated in any way.

  • Page 33: Diagnostic Codes

    ! WARNING operator does not feel qualified to service the cooling Tighten cap screws according to specifications to pre- system, see an authorized Arctic Cat Snowmobile vent unexpected “fold-down” of the handlebar during dealer for this service. operation over rough terrain. DO NOT offset the han- dlebar so steering capabilities are altered or throttle and brake controls will be affected.

  • Page 34: Drive Belt

    If the operator does not feel qualified to service cold temperature (0° or below), the engine should be the drive chain, see an authorized Arctic Cat Snowmo- allowed to idle for a period of 8 to 10 minutes allowing heat from the engine compartment to soften the drive bile dealer for this service.

  • Page 35: Efi System

    Always tighten fuel hose clamps securely. perature. This EFI system will provide quick and easy starting under all conditions. The Arctic Cat EFI System operates off a series of coils located on the stator and is made up of the fol- lowing components.

  • Page 36: Coolant Temperature Sensor

    2. Air Temperature Sensor If the ECU is not receiving current from one of the output coils on the stator, that circuit will not operate. 3. Coolant Temperature Sensor Coils on the stator are the charge coils operating the ECU, the injector coil which operates the injectors, the 4.

  • Page 37: Shock Absorbers

    Arctic Cat has a variety of studding products available from your authorized Arctic Cat CAUTION Snowmobile dealer.

  • Page 38: Braking

    Add Arctic Cat approved brake fluid as necessary. operation or heavy loads. Do not idle the engine for excessively long periods of time. The engine should be allowed to idle at least 1-2 minutes before it is oper- ated at more than 1/2 throttle.

  • Page 39: Emergency Stopping

    IMMEDIATELY to stop the engine. DO NOT start the engine until the malfunction in the car- Use only Arctic Cat approved brake fluid. Never sub- buretor/ throttle system has been located and cor- stitute or mix different types or grades of brake fluid.

  • Page 40: Front Suspension

    REAR SUSPENSION 1. Shut engine off and wait for all moving parts to stop. 2. With the gas tank nearly empty (less than 1/4 full), lay the snowmobile on its side. A piece of card- board should be used to protect the finish on the hood and belly pan.

  • Page 41: Maintenance

    Maintenance The longevity and safety of the snowmobile can be increased by making periodic checks of the items in the follow- ing checklist. Perform maintenance checks more often if the snowmobile is used under severe conditions. PERIODIC MAINTENANCE CHECKLIST EVERY EVERY EVERY INTERVAL...

  • Page 42: Pre-Race/Practice Checklist

    DO NOT OPERATE THE SNOWMOBILE. Immediately diagnose and repair any component. If the operator does not feel qualified to service the suspension, see an authorized Arctic Cat Snowmobile dealer for this service. IO033A...
  • Page 43 2. Remove the six cap screws securing the recoil to the engine and note the location of the ground wire for assembling purposes. 3. Using Drive Clutch Bolt Tool (p/n 0644-281), remove the cap screw and lock washer securing the drive clutch to the crankshaft; then remove the cap screw securing the driven pulley to the shaft.
  • Page 44 NOTE: The intake boot must be compressed enough to allow room to move the throttle body assembly forward and out of the intake flanges. 10. Remove the clamp from the vent hose; then loosen the clamps of the cylinder head coolant hoses and remove the hoses.
  • Page 45 0744-860 FC014 14. Remove the cap screw (B) securing the upper MAG-side engine mount to the chassis; then remove the lower cap screw (C) securing the engine to the chassis. 15. Move the engine up far enough to gain access to the coolant hose clamps securing the hoses to the lower crankcase and thermostat housing;...
  • Page 46 CM013 FC021 NOTE: To ensure the cleanliness of the flywheel magnets, place the flywheel (with the magnets fac- ing upward) on a clean bench. 4. Remove the ignition timing sensor. FC065 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.
  • Page 47 10. Remove the eight nuts securing the cylinders to the CAUTION crankcase; then using a rubber hammer, gently tap the cylinders and remove from the crankcase by DO NOT use any type of punch to drive the piston pin lifting them straight up off their studs. Account for free of the piston;...
  • Page 48 16. Remove the six screws securing the water pump cover to the crankcase and remove the cover. Account for the O-ring gasket and the alignment pins. 17. Remove the cap screw securing the water pump impeller; then slide the impeller free of the shaft. 18.
  • Page 49 FC036 FS270 26. Using a pair of snap ring pliers, remove the snap 4. Place the cylinder heads on a Surface Plate (p/n ring securing the inner seal in the crankcase. 0644-016) covered with #400 grit wet-or-dry sandpaper. Using light pressure, move each cylin- 27.
  • Page 50 Crankcase 4. Place the head surface of each cylinder on the sur- face plate covered with #400 grit wet-or-dry sand- paper. Using light pressure, move each cylinder in 1. Wash the crankcase halves in parts-cleaning sol- a figure eight motion. Inspect the surface for any vent.
  • Page 51 Crankshaft NOTE: If any servicing of the connecting rods, center bearings, or oil-injection pump drive gear is necessary, Arctic Cat recommends that the crank- shaft be taken to a qualified machine shop for that service. 1. Wash the crankshaft with bearings in parts-clean- ing solvent.
  • Page 52 3. Inspect the reed stopper height. Using a caliper, 3. Pull the recoil rope and crank the engine over sev- measure the distance from the seat to the bottom eral times while the solder is being held firmly in outer tip edge of the stopper. Measurement must place.
  • Page 53 Piston Pin And Piston-pin Bore 1. Measure the piston pin diameter at each end and in the center. Acceptable piston pin measurement must be within 0.8659-0.8661 in. If any measure- ment varies by more than 0.001 in., the piston pin and bearing must be replaced as a set.

  • Page 54: Crankshaft Runout

    Always wear safety glasses when drying components with compressed air. NOTE: When the use of a lubricant is indicated, use Arctic Cat Synthetic APV 2-Cycle Oil. 1. Apply a thin coat of grease to the inner seal lips of 0742-727 the water pump seal.
  • Page 55 4. Using the seal driver, carefully install the outer water pump seal. Gently tap the seal down into position until it seats itself against its flange. CM045A  NOTE: To check the bearing for proper position, place the point of a sharp tool into the dimple found in the bearing race.
  • Page 56 NOTE: At this point if the coolant temperature sensor was removed, install the sensor (threads coated with white Loctite #575). Tighten to 18 ft-lb. NOTE: Use only Arctic Cat High-Temp Sealant to seal the crankcase halves. 10. Assemble the crankcase halves making sure that the crankshaft gear and oil-injection pump driveshaft gears mesh.
  • Page 57 20. Apply high-temperature sealant to the crankcase/ CAUTION water pump cover seam; then install the dowel pins into the crankcase. 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 compo- nents are not aligned.
  • Page 58 24. Install the dowel pins into the crankcase; then place the cylinder base gasket into position on the crankcase. 25. Install the piston rings on each piston so the letter on the top (inclined surface) of each ring faces the dome of the piston.
  • Page 59 27. Place each piston over the connecting rod so the indicator dot on each piston will point toward the intake/exhaust ports; then secure with an oiled pis- ton pin. NOTE: The indicator dot is found on the piston dome top. FC076 31.
  • Page 60 35. Place new O-rings onto each of the head cap screws. Place four of these cap screws into the cyl- inder head. Thread the spark plugs in part way; then while holding the head above the cylinder, carefully start and finger-tighten all four cap screws while observing the cylinder O-rings to make sure they remain in position.
  • Page 61 Installing Engine 1. With the spacer (A) and related cap screws prop- erly oriented, install the lower MAG-side and PTO-side engine brackets to the crankcase; then install the left-side mounting bracket to the mag- neto housing and tighten all cap screws (coated with blue Loctite #243) to 40 ft-lb.
  • Page 62 IO043A IO048A 8. Place the oil tank into position and secure with the 11. Connect the gasline supply hose to the delivery four cap screws and lock nuts. Tighten securely. pipe of the throttle body assembly; then secure with the clamp. IO036A 9.
  • Page 63 20. Install the resonator and secure it to the chassis with the springs and hairpin clip. IO034A 14. Lubricate the drive clutch bolt with a light film of oil; then place the drive clutch into position on the IO033A crankshaft and secure with the cap screw and lock 21.

  • Page 64: Individual Efi Components

    INDIVIDUAL EFI COMPONENTS 3. Test between the two yellow leads. NOTE: With the Arctic Cat EFI System, the ECU 4. The meter must show 0.08-0.12 ohm. must receive the proper current output from four NOTE: If reading is out of tolerance, recheck to coils (two charge coils, an injector coil, and a fuel confirm reading.
  • Page 65 Checking TPS 2. Connect the wiring harness to the ECU; then con- nect the battery. NOTE: Before using the TPS adjustment tool, NOTE: Make sure all connectors are clean and verify its battery condition. tight. 1. Using Throttle Position Sensor (TPS) Adjustment Throttle Position Sensor Tool Kit (p/n 3639-891), connect its wiring har- ness to the TPS.
  • Page 66 Testing Fuel Injector Resistance CM203A Installing Fuel Injector IO031 1. Disconnect the fuel injector wiring harness. 1. Apply a light coat of oil to all O-rings; then install the upper and lower O-rings onto each injector. 2. Set the meter selector to the OHMS scale. 2.

  • Page 67: Electric Fuel Pump

    Testing Ignition Timing Sensor Resistance AO053 NOTE: A short piece of 3/8 in. I.D. hose will be needed for this procedure. 0729-627 NOTE: This sensor is located inside the magneto 2. Pressurize the regulator to 2.0-2.2 kg/cm² (28-31.3 case next to the flywheel, and the recoil starter and psi).
  • Page 68 Testing Air Temperature Sensor CAUTION Resistance Since the fuel supply hose may be under pressure, NOTE: The component temperature must be remove it slowly to release the pressure. Place an known before conducting this test. Allow the absorbent towel around the connection to absorb fuel. engine to reach room temperature.

  • Page 69: Individual Fuel System Components

    7. Remove the throttle cable ends from the throttle CAUTION lever and from the throttle control housing. When installing the throttle bodies, make sure the Installing/adjusting Throttle Cable gasline hose is properly routed to avoid premature wear and/or contact with exhaust components. 1.
  • Page 70 NOTES...

  • Page 71: Troubleshooting Fuel System

    Troubleshooting Fuel System Problem: Too Rich Condition Remedy 1. Diagnostic trouble code activated 1. Replace problem sensor 2. Fuel pressure too high 2. Replace regulator 3. Fuel return hose obstructed 3. Service — replace hose — remove obstruction 4. Injectors leaking 4.
  • Page 72 3. Attach a suitable length of clear oil-supply hose to Inspecting/adjusting/ the oil pump; then using Oil Injection Usage Tool Synchronizing Oil-injection Pump (p/n 0644-007), fill the hose with Arctic Cat For- mula SS Semi-Synthetic Oil. 1. With the engine off, disconnect the throttle cable from the throttle lever.

  • Page 73: Spark Plugs

    Checking Spark Plugs NOTE: After testing the oil pump, the oil pump must be correctly synchronized with the throttle To check spark plug condition and to aid in determin- bodies (see Synchronizing Oil-Injection Pump in ing correct fuel/air mixture, pull the spark plug caps this section).

  • Page 74: Hydraulic Brake

    2. If the brake fluid level is below the low mark, 8. Remove the track and drive assembly. remove the reservoir cover and add Arctic Cat approved brake fluid until the fluid level is just NOTE: At this point, inspect the bearings for below the high mark.

  • Page 75: Bleeding Brake System

    To bleed the brake, use the following procedure: 1. Remove the reservoir cover and fill the reservoir to the high mark with Arctic Cat approved brake fluid. CAUTION Brake fluid is highly corrosive. Do not spill brake fluid on any surface of the snowmobile.

  • Page 76: Drive Belt

    6. When the belt is free of driven pulley, remove the NOTE: Drive belts should be purchased from an. belt from the drive clutch. authorized Arctic Cat Snowmobile dealer, as Arctic Cat drive belts are made to exact specifications Installing Drive Belt and of quality material.

  • Page 77: Driven Pulley

    DRIVEN PULLEY Disassembling 1. Remove the four torx head cap screws securing the cam to the movable sheave; then grasp the cam and by working the movable sheave back and forth, lift it up and off the shaft. CM089A NOTE: It is advisable to secure the compression tool in a vise or to bolt it to a sturdy workbench.
  • Page 78 NOTE: If clearance exceeds the limit, the bushing NOTE: While compressing the roller assembly, it must be replaced. may be necessary to work the spider assembly back and forth to properly mate the splines. Assembling 5. With the “X” mark on the movable sheave lined 1.

  • Page 79: Ski Shock Absorber Springs

    SKI SHOCK ABSORBER SPRINGS NOTE: Some illustrations and photographs used in the following sub-sections are used for clarity The shock absorber springs have been matched to the purposes and are not designed to depict actual shock valving and rear suspension. These springs are conditions.
  • Page 80 14. Remove the body assembly from the vise and clean all internal components; then set body assembly aside on a clean, lint-free rag or towel. 15. Clamp the shaft eyelet securely in vise with the piston end up. 16. Remove the piston lock nut from the end of the shaft.
  • Page 81 6. Thread the bearing assembly onto the shock body and hand-tighten until the O-ring is seated against the body. 7. Fully extend the shaft; then clamp the shock in the vise by the shaft eyelet. 8. Fill the shock body with Shock Oil (p/n 5639-240) to approximately 1/2 in.

  • Page 82: Adjusting Rear Transfer Adjuster Cams

    LIGHTS The correct taillight/brakelight bulb is p/n 0409-056. The correct headlight bulbs are p/n 0409-073 and 0409-045. Removing and Installing Taillight/ Brakelight Bulb 1. Remove the screws securing the taillight/brake- light lens; then remove the lens. FS285 ! WARNING Charge the shock using nitrogen gas only. DO NOT CHARGE WITH ANY OTHER TYPE OF GAS.

  • Page 83: Ski Wear Bar

    Arctic Cat recommends that the wear strips be checked the ski wear bar will wear faster. To maintain positive weekly and replaced as necessary. Measure the wear steering characteristics, Arctic Cat recommends that strips at 25.4 cm (10 in.) intervals.

  • Page 84: Performance Tips

    4. Start the engine and allow to idle. With the engine Performance Tips idling, spray Arctic Cat Engine Storage Preserver (p/n 0636-177) into the throttle bodies until the engine exhaust starts to smoke heavily or until the engine starts to drop in RPM. Turn engine off.

  • Page 85: Preparation After Storage

    Arctic Cat Snowmobile engines. Arctic Cat and hours of trouble-free snowmobiling. Arctic Cat Oil is the only oil authorized by Suzuki and Arctic Cat recommends the following procedure. engineers for use in Arctic Cat Snowmobile engines.

  • Page 86: Special Tools

    Arctic Cat snow- p/n: 0744-040 (Complete Set) mobile engine cylinders. p/n: 0643-086 (Body) p/n: 0643-087 (Bolt) p/n: 0423-482 (6 mm Cap Screw) p/n: 0423-483 (8 mm Cap Screw) Usage: Pull flywheel off crankshaft on all Arctic Cat 2- stroke models. 0644-291 0744-040...
  • Page 87 Spring Tool Oil Seal Protector Tool p/n: 0644-072 Usage: Remove/install exhaust springs. p/n: 0644-219 Usage: Protect the oil seal when installing the water pump driveshaft on liquid cooled 2-stroke Arctic Cat engines. 0644-072 Stud Runner p/n: 0644-018 (6 mm) 0644-219...
  • Page 88 Compression Tester Kit p/n: 0644-016 p/n: 0444-213 (Complete Kit) Usage: True sealing surfaces. p/n: 0444-207 (10 mm Adapter) p/n: 0444-093 (12 mm Adapter) Usage: Test cylinder compression on all Arctic Cat engines. 0644-016 V Blocks (Large) p/n: 0644-535 0444-213 Usage: Check crankshaft runout.
  • Page 89 Carburetor Adjustment Screwdriver (90°) Clutch Compressor p/n: 0644-289 p/n: 0644-420 Usage: Make carburetor adjustments on all twin and tri- Usage: Compress and hold drive clutch in the com- ple cylinder engines. Will be especially useful for adjust- pressed position for changing cam arms and removing/ ing the pilot circuit screw on all TM-style carburetors.
  • Page 90 Drive Clutch Spanner Wrench Spider Removal Kit p/n: 0644-136 p/n: 0644-449 (Complete Kit) Usage: Hold Comet and Arctic round-shaft drive clutch in p/n: 0744-037 (Handle) place during removal and installation. p/n: 0744-036 (Removal Tool) p/n: 0644-380 (Clutch Holder - 33 mm) p/n: 0744-035 (Clutch Holder - 30 mm) p/n: 0644-138 (Thin Wall Deep Socket - 1 7/16 in.) Usage: Disassemble/assemble/remove spider on Arctic...
  • Page 91 Track Stud Hole Drill (7 mm) Idler Wheel Puller Kit p/n: 1639-629 p/n: 0644-122 (Complete Kit - 6 in.) Usage: Drill 7 mm hole through rubber tracks for install- p/n: 0644-400 (Complete Kit - 8 in.) ing studs. p/n: 0644-114 (A. Handle - 6 in.) p/n: 0644-401 (A.
  • Page 92 Gas Shock Retaining Blocks Inflation Needle Replacement p/n: 0644-486 p/n: 0644-554 Usage: Hold shock secure during disassembly and Usage: Replacement needle assembly for Inflation Nee- assembly. dle (p/n 0744-020). 0644-162 0644-334 Inflation Needle Replacement Tip Gas Shock Shaft Clamping Tool p/n: 0644-539 p/n: 0644-543 Usage: Update earlier inflation needles for Fox Float-...
  • Page 93 Piston Location Tool Rear Suspension Spring Tool p/n: 0644-169 p/n: 0144-311 Usage: Precisely locate the floating piston in the rebuild- Usage: Install/remove rear suspension springs. able gas shock absorber. 0144-311 0644-169 Hex Bits (1/4 in. Hex Drive) Axle Nut Spanner Wrench p/n: 0644-317 (5 mm) p/n: 0644-454 p/n: 0644-316 (6 mm)
  • Page 94 Phillips-Head Bits (1/4 in. Hex Drive) Replacement Rivnuts p/n: 0644-319 (#2) p/n: 0623-557 (1/4 x 20) p/n: 0644-318 (#3) p/n: 0623-582/627 (1/4 x 20) Usage: With Quick-Disconnect Coupler (p/n 0644-308), p/n: 0623-581 (5/16 x 18) remove and install Phillips-head screws. p/n: 0623-699 (3/8 x 16) p/n: 0623-874 (8-32) p/n: 0623-529/779 (10-32)
  • Page 95 Rivnut Tool Insert Bit Oil Injection Usage Tool p/n: 0644-233 (1/4 x 20) p/n: 0644-007 p/n: 0644-405 (10-32) Usage: Measure exact amount of oil used by the oil injec- tion pump during a given time period. p/n: 0644-430 (5/16 x 18) p/n: 0644-431 (3/8 x 16) Usage: With Rivnut Tool (p/n 0644-232) and Replace- ment Rivnuts, replace rivnuts.
  • Page 96 Torx Bit Insert (5/16 in. Hex Drive) Torx Bits (1/4 in. Hex Drive) p/n: 0644-314 p/n: 0644-312 (#25) Usage: With Insert Holder (p/n 0644-315), remove and p/n: 0644-393 (#27) install torx-head screws. p/n: 0644-215 (#30) p/n: 0644-313 (#40) Usage: With Quick-Disconnect Coupler (p/n 0644-308), remove and install torx-head screws.
  • Page 97 NOTES...
  • Page 98 NOTES...
  • Page 99 Printed in U.S.A. Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701 p/n 2258-802 ®™...

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