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

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Summary of Contents for Arctic Cat 500 Sno Pro

  • Page 1 SHARE OUR PASSION. 500 Sno Pro Operator's/ Performance Manual Performance Manual...
  • 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

    Track Tension/Track Alignment ......18 Preparation for Storage ........74-75 Ski Alignment............19 Preparation After Storage......... 75 Handlebar Alignment ..........21 Genuine Arctic Cat Products ....... 75-76 Handlebar Height Adjustment....... 21 Special Tools ............76-85 Steering Speed Ratio Adjustment......22 Drive Belt .............. 22 Hydraulic Brake System........
  • 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 50:1 Injection Oil Chain Case Lubricant Transmission Lube Suspension Grease Low-Temperature Brake Fluid High-Temp DOT 3...

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

    Torque Conversions Electrical Specifications (ft-lb/N-m) NOTE: The ignition system is a Normally Open ft-lb ft-lb ft-lb ft-lb Ignition (NOI). 35.4 69.4 103.4 36.7 70.7 104.7 Resistance Test 38.1 72.1 106.1 Description + Test Connections - Test Value 39.4 73.4 107.4 Ignition Coil 0.27-0.41 ohm orange...

  • 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

    NOTE: The drive clutch on this model is “uncalibrated.” DRIVE CLUTCH DRIVE SPRING CAM ARM DRIVEN PULLEY DRIVEN SPRING MODEL COLOR GRAMS SPRING COLOR 500 Sno Pro 0746-215 0646-035 Orange/ 0746-698 64.0 0726-297 0648-790 Black/Light Blue Black TORQUE DRIVE BELT...

  • Page 13: Drive Clutch Spring Chart

    Drive Clutch Spring Drive Clutch Cam Arms Chart ARCTIC CAT DRIVE CLUTCH CAM ARMS Grams Grams Grams ARCTIC CAT DRIVE CLUTCH SPRING CHART 0646-100 52.5 0746-585 49.0 0746-663 52.0** Rate @ 2 9/16 in. Rate @ 1 5/16 in. Color 0646-162 44.0...

  • 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- 2602-215 cations. This chart was compiled to assist technicians 2602-244 in fine-tuning the Arctic Cat rear suspension when the 2602-216 original springs are not optimum for the conditions 2602-254 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) 2703-705 Ski Shock 1.300 x 0.006 in. 1.100 x 0.008 in. Extended Length: 19.72 in. Rebuild Kit - p/n 2603-795 1.300 x 0.008 in. 0.700 x 0.008 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: Wiring Diagram (Hood)

    Wiring Diagram Hood Harness (p/n 1686-587) NOTE: At the time of publication, the Hood Harness (p/n 1686-587) diagram was not available; however, the diagram will be available in the near future from your Arctic Cat Snowmobile dealer.

  • Page 21: Wiring Diagram (Ignition/Main)

    Wiring Diagram Ignition/Main Harness (p/n 1686-585) NOTE: At the time of publication, the Ignition/Main Harness (p/n 1686-585) diagram was not available; however, the diagram will be available in the near future from you Arctic Cat Snowmobile dealer.
  • Page 22 NOTES...

  • Page 23: 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 24: Installing Sway Bar

    3. With the rubber damper and damper plate installed 1. Place the snowmobile up on a shielded safety in the ski saddle, place the ski into position on the stand. Check to make sure the track is 5-8 cm (2 - spindle axle and slide the cap screw with washer 3 in.) off the floor.

  • Page 25: Ski Alignment

    5. When proper track deflection is attained, loosen 11. Loosen the right-side rear axle nut just enough to the right-side rear axle nut just enough to apply apply blue Loctite #243 to the axle threads; then blue Loctite #243 to the axle threads; then tighten tighten the nut to 40-45 ft-lb.
  • Page 26 4. Place a long straightedge against the outside edge 8. If ski alignment is not as specified, adjust the of the track so it lies near the inside edge of the alignment of the ski(s) not parallel to the straight- left-side ski.

  • Page 27: 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 28: Steering Speed Ratio Adjustment

    STEERING SPEED RATIO 2. Using Belt Removal/Installation Tool (p/n 0644- ADJUSTMENT 424), thread the tool clockwise into the driven pul- ley until the movable sheave opens far enough to NOTE: The lower steering post bearing housing install the drive belt. is not symmetrical;...

  • Page 29: Hydraulic Brake System

    2. If the brake fluid level is below the low mark, aim. remove the reservoir cover and add Arctic Cat approved brake fluid until the fluid level is just 2. Measure the distance from the floor to midpoint of below the high mark.

  • Page 30: Test Ride

    These numbers are required by the dealer to complete warranty claims properly. No warranty will be allowed F. High Beam by Arctic Cat Inc. if the engine serial number or VIN is removed or mutilated in any way. G. Not Applicable...

  • Page 31: Diagnostic Codes

    Tighten cap screws according to specifications to pre- operator does not feel qualified to service the cooling vent unexpected “fold-down” of the handlebar during system, see an authorized Arctic Cat Snowmobile operation over rough terrain. DO NOT offset the han- dealer for this service.

  • Page 32: 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 33: 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 34: 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 35: Shock Absorbers

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

  • Page 36: 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 37: 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 38: 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 39: 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 40: 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 41 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 42 NOTE: The intake boot must be compressed enough to allow room to move the throttle body assembly forward and out of the intake flanges. IO039A 8. Loosen the clamp and remove the gasline hose from the delivery pipe of the throttle body assem- bly.
  • Page 43 Disassembling Engine NOTE: It is advisable to loosen the spark plugs prior to disassembling the engine. 1. Using the Flywheel Spanner Wrench to secure the flywheel, remove the flywheel cap screw and flat washer; then remove the three starter pulley cap screws and remove the pulley.
  • Page 44 3. Using Flywheel Puller or suitable substitute, remove the flywheel from the crankshaft by tight- ening the puller bolt, striking the head of the puller bolt with a hammer, and tightening again. Repeat this procedure until the flywheel is free. Account for the key.
  • Page 45 NOTE: For proper assembly, keep all MAG-side components and all PTO-side components sepa- rated. Assemble them on their proper sides. FC026 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/crank- FC029 case water jacket.
  • Page 46 FC030 FC033 15. Remove the three cap screws securing the thermo- 20. With its bottom side up on two support blocks, stat cap; then remove the cap, gasket, and thermo- remove the cap screws securing the crankcase stat. halves. 21. Separate the crankcase halves by installing two crankcase cap screws in opposite corners leaving the heads approximately 6 mm (1/4 in.) out.
  • Page 47 Cleaning and Inspecting Engine 24. Remove the oil-injection pump/water pump drive- shaft from the lower crankcase half. Account for NOTE: Whenever a part is worn excessively, the thrust washer on the outer end of the shaft. cracked, or damaged in any way, replacement is necessary.
  • Page 48 2. Snap an old piston ring into two pieces; then grind the end of the old ring to a 45° angle and to a sharp edge. Using the sharpened ring as a tool, clean car- bon from the ring-grooves. Be sure to position the ring with its tapered side up.
  • Page 49 NOTE: If any servicing of the connecting rods, Removing/installing Outer center bearings, or oil-injection pump drive gear is Crankshaft Bearings necessary, Arctic Cat recommends that the crank- NOTE: The end bearings are not pressed onto shaft be taken to a qualified machine shop for that service.
  • Page 50 NOTE: Install the bearings by sliding each bear- 4. Inspect the reed-to-seat clearance. Using a feeler gauge, measure the clearance. Clearance must be ing onto the crankshaft making sure the dowel-pin less than 0.008 in. If clearance is not within speci- hole in the outer race is properly positioned and fications, replace the reed valve.
  • Page 51 NOTE: Measure from PTO to MAG-side of the pis- ton to accurately measure the squish gap. Never measure across piston, exhaust side to opposite side, as the piston will rock and the reading won’t be accurate. Readings may vary from side to side. NOTE: Make sure the smaller reading is 1.5 mm (0.059 in.) or less.

  • Page 52: 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. 0742-727 1. Using the V Blocks, support the crankshaft on the 1. Apply a thin coat of grease to the inner seal lips of surface plate.
  • Page 53 2. Using the seal driver, position the inner water 5. Position the upper crankcase half upside-down on pump shaft seal onto the seal driver and gently tap two wooden blocks; then install the C-ring, the the seal down into position. four bearing retaining pins, and the two crankcase dowel pins.
  • Page 54 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 55 IO025A CM168 15. Position the shim (A) on the oil-injection pump CAUTION end of the driveshaft; then with a new O-ring in When installing the seal into the impeller, assure that place, install the oil-injection pump retainer (B). all components are clean and free of any dirt or other contaminents.
  • Page 56 FC133A FC134 NOTE: Do not allow sealant into the breather hole in the crankcase. If sealant gets into the hole, care- fully remove before proceeding. 0742-304 22. Noting the alignment dots, install the thermostat housing with thermostat. Secure the housing with cap screws and tighten to 96 in.-lb.
  • Page 57 27. Place each piston over the connecting rod so the 24. Install the dowel pins into the crankcase; then indicator dot on each piston will point toward the place the cylinder base gasket into position on the intake/exhaust ports; then secure with an oiled pis- crankcase.
  • Page 58 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 59 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 60 IO046A IO043A 6. Connect the two coolant hoses to the elbow fit- 8. Place the oil tank into position and secure with the tings of the crankcase and tighten the hose clamps; four cap screws and lock nuts. Tighten securely. then install the coolant hose and vent hose to the cylinder head and secure with hose clamps.
  • Page 61 IO048A IO034A 11. Connect the gasline supply hose to the delivery 14. Lubricate the drive clutch bolt with a light film of pipe of the throttle body assembly; then secure oil; then place the drive clutch into position on the with the clamp.

  • Page 62: Individual Efi Components

    2. Set the meter selector to the OHMS scale. 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...
  • Page 63 Activating ECU Memory NOTE: If the snowmobile is in warranty, breaking the seal on the idle screw jam nut or the Phillips- 1. Connect the analyzer test harness to the ECU diag- head screws on the TPS will void warranty. nostic connector.
  • Page 64 3. With the throttle in the idle position, compare the reading on the voltmeter to the chart. If the reading is within prescribed specification, proceed to step 4. Idle Position Wide-Open Position 0.710-0.818 3.472-4.048 4. Compress the throttle lever slowly to the full-open position.

  • Page 65: Fuel Pressure Regulator

    NOTE: If the fuel pump fails to operate, the pump is defective and must be replaced. Fuel Pressure Regulator 1. Using the Fuel Pressure Test Kit, connect the tes- ter to the delivery pipe and gasline hose. CAUTION The fuel supply hose may be under pressure. Place an absorbent towel around the connection to absorb fuel;...
  • Page 66 Removing Throttle Body 3. Compare the resistance reading to the Voltage/ Resistance Chart - Coolant Temperature in this NOTE: The expansion chamber and air silencer manual. If resistance is not within the specifica- must be removed for this procedure. tion, replace the sensor. NOTE: A coolant temperature sensor voltage test 1.

  • Page 67: Individual Fuel System Components

    6. Connect the wiring harness to each injector and 4. Loosen the oil-injection cable jam nuts. throttle position sensor. 5. Remove the handlebar pad. NOTE: Install the air silencer and the expansion 6. Remove the cable ties securing the throttle cable. chamber.
  • Page 68 NOTES...

  • Page 69: 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 70 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 fill the hose with Arctic Cat Synthetic APV 2- Cycle Oil. 1. With the engine off, disconnect the throttle cable from the throttle lever.

  • Page 71: 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). ing correct fuel/air mixture, pull the spark plug caps off the spark plugs, remove the spark plugs, and exam- Testing Oil-Injection Check Valves ine the condition of the center electrode insulator of...

  • Page 72: 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 73: 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 74: 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 75: 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 76 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 77 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 78: 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 79: Ski Wear Bar

    Arctic Cat recommends that the wear strips be checked operated on terrain where the snow cover is minimal, weekly and replaced as necessary. Measure the wear the ski wear bar will wear faster.

  • Page 80: Performance Tips

    4. Start the engine and allow to idle. With the engine understand this entire manual especially the section on idling, spray Arctic Cat Engine Storage Preserver spark plugs, track tension and alignment, and suspen- (p/n 0636-177) into the throttle bodies until the sion.

  • Page 81: Preparation After Storage

    Arctic Cat Oil - Developed, tested, and proven espe- Preparation After cially for Arctic Cat Snowmobile engines. Arctic Cat Oil is the only oil authorized by Suzuki and Arctic Cat Storage engineers for use in Arctic Cat Snowmobile engines. Arctic Cat Oil ensures warranty coverage for lubricat- ing related incidents.

  • Page 82: Special Tools

    Flywheel Puller p/n: 0744-040 (Complete Set) p/n: 0643-086 (Body) p/n: 0643-087 (Bolt) p/n: 0423-482 (6 mm Cap Screw) p/n: 0423-483 (8 mm Cap Screw) Usage: Pull flywheel off crankshaft on all Arctic Cat 2- stroke models. 0644-291 0744-040...
  • Page 83 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 84 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 85 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 86 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 87 Bellcrank Centering Tool p/n: 0644-541 Usage: Center the steering bellcranks to properly align the steering on the 2008 and newer 600 Sno Pro and 2010 500 Sno Pro. 0644-122 Floating Piston Location Gauge p/n: 0644-350 Usage: Precisely locate and measure floating piston depth without use of a calipers.
  • Page 88 Gas Shock Retaining Blocks Inflation Needle Replacement p/n: 0644-486 p/n: 0644-162 Usage: Hold shock secure during disassembly and Usage: Replacement needle assembly for Inflation Nee- assembly. dle (p/n 0744-020). 0644-162 0644-334 Nitrogen Regulator Gas Shock Shaft Clamping Tool p/n: 0644-151 p/n: 0644-543 Usage: Recharge rebuildable gas shock absorbers.
  • Page 89 Axle Nut Spanner Wrench Hex Bits (1/4 in. Hex Drive) p/n: 0644-454 p/n: 0644-317 (5 mm) Usage: Adjust track alignment/tension (2005 440 Sno p/n: 0644-316 (6 mm) Pro). Usage: With Quick-Disconnect Coupler (p/n 0644-308), remove and install bolts and screws. 0644-454 0644-316 Axle Nut Spanner Wrench...
  • Page 90 Quick-Disconnect Coupler Toggle-Switch Wrench p/n: 0644-308 p/n: 0644-566 Usage: Hold 1/4 in. hex drive Torx Bits (page 85), Hex Usage: Remove/install a toggle switch on 2010 500 Sno Bits (page 83), and Phillips-Head Bits (page 83). Pro. 0644-308 0644-566 Rivnut Tool Insert Bit Replacement Rivnuts p/n: 0623-557 (1/4 x 20) p/n: 0644-233 (1/4 x 20)
  • Page 91 T-Handle Wrench Torx Bit Insert (5/16 in. Hex Drive) p/n: 0644-257 (8 mm) p/n: 0644-314 p/n: 0644-024 (10 mm) Usage: With Insert Holder (p/n 0644-315), remove and install torx-head screws. p/n: 0644-025 (12 mm) p/n: 0644-026 (14 mm) Usage: Remove and install nuts and bolts. 0644-314 Torx Bits (1/4 in.
  • Page 92 NOTES...
  • Page 93 NOTES...
  • Page 94 NOTES...
  • Page 95 Printed in U.S.A. Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701 p/n 2258-721 ®™...

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