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Arctic Cat Sno Pro 120 Service Manual

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FOREWORD

This Arctic Cat Service Manual contains service and maintenance information for the Model Year 2012 Arctic

Cat Snowmobiles (except the Sno Pro 120). The manual is designed to aid service personnel in service-oriented

applications.

This manual is divided into sections. The sections cover specific snowmobile components or systems and, in addition

to the standard service procedures, includes assembling, disassembling, and inspecting instructions. When using this

manual as a guide, the technician should use discretion as to how much disassembly is needed to correct any given con-

dition.

The service technician should become familiar with the operation and construction of the components or systems by

carefully studying the complete manual. This will assist the service technician in becoming more aware of and efficient

with servicing procedures. Such efficiency not only helps build consumer confidence but also saves time and labor.

All Arctic Cat publications and snowmobile decals display the words Warning, Caution, and Note to emphasize impor-

tant information. The symbol ! WARNING identifies personal safety-related information. Be sure to follow the

directive because it deals with the possibility of severe personal injury or even death. A CAUTION identifies

unsafe practices which may result in snowmobile-related damage. Follow the directive because it deals with the possi-

bility of damaging part or parts of the snowmobile. The symbol  NOTE: identifies supplementary information worthy

of particular attention.

At the time of publication, all information, photographs, and illustrations were technically correct. Some photographs

and 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.

All materials and specifications are subject to change without notice.

Keep this manual accessible in the shop area for reference.

Product Service and Warranty Department

Arctic Cat Inc.

© 2011 Arctic Cat Inc.

®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN

December 2011

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Alain Trudel

April 12, 2025

What is the clutch puller parts number for a bearcat Z1 XT 2011 1100cc

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Mr. Anderson

April 12, 2025

The clutch puller part number is 0644-480.

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Summary of Contents for Arctic Cat Sno Pro 120

Page 1 FOREWORD This Arctic Cat Service Manual contains service and maintenance information for the Model Year 2012 Arctic Cat Snowmobiles (except the Sno Pro 120). The manual is designed to aid service personnel in service-oriented applications. This manual is divided into sections. The sections cover specific snowmobile components or systems and, in addition to the standard service procedures, includes assembling, disassembling, and inspecting instructions.
Page 2: Table Of Contents
2012 Service Manual 2012 Service Manual TABLE OF CONTENTS Snowmobile Section 1. General Information/Specifications 2. Engine 3. Engine-Related Items 4. Fuel Systems 5. Electrical Systems 6. Drive Train/Track/Brake Systems 7. Rear Suspension 8. Steering and Body SHARE OUR PASSION.
Page 3: Table Of Contents
SECTION 1 — GENERAL INFORMATION/ SPECIFICATIONS TABLE OF CONTENTS General Specifications ............1-2 Snowmobile Identification..........1-2 Recommended Gasoline and Oil ........1-2 Engine Break-In..............1-2 Drive Belt Break-In ............1-3 Genuine Parts ..............1-3 Varying Altitude Operation..........1-3 Preparation For Storage ............1-5 Preparation After Storage..........1-6 After Break-In Checkup/Checklist...........1-6 Engine Specifications ............1-8 Crankshaft Runout/Repair Specifications (2-Stroke)..1-9 Arctic Power Valve (APV) System Specifications (800 cc) ...1-9...
Page 4: Engine
Identification The recommended oil to use in the oil-injection system is Arctic Cat Formula 50 Injection Oil for 500/570 cc models or either Arctic Cat APV Synthetic 2-Cycle Oil or Formula SS Semi-Synthetic Oil for 800 cc models. These oils are...
Page 5: Drive Belt Break-In
4-STROKE CAUTION The Arctic Cat 4-stroke engine (when new or rebuilt) requires a short break-in period before the engine is sub- On the 570 cc, carefully follow the Carburetor Jet Chart jected to heavy load conditions. recommendations for proper carburetor calibration for altitude, temperature, and gasoline being used.
Page 6 TURBOCHARGING Many possible variables and adjustments to the rear sus- pension exist depending on snow conditions, riding style, Turbocharging is one method of compensating for loss of and type of terrain. These adjustments can be made to indi- air density that works extremely well when applied to vidualize the snowmobile to the riding style of the operator.
Page 7: Preparation For Storage
Sealed batteries require charging if left for extended non- until the engine starts to drop in RPM. Turn engine start periods. Arctic Cat recommends trickle charging once a off. Install the intake boots. month. Follow the manufacturer’s instructions and cautions.
Page 8: Preparation After Storage
 NOTE: On the 2-stroke models after prolonged stor- track off the floor by blocking up the back end mak- age, Arctic Cat recommends one tankful of 100:1 gas/ ing sure the snowmobile is secure. Loosen the track oil mixture be used in conjunction with the oil-injec- adjusting bolts to reduce track tension.
Page 9 TRACK TENSION AND ALIGNMENT — A certain  Check throttle cable tension amount of stretch occurs on all tracks during the first 500  Check oil-injection pump adjustment (2-stroke) miles. The track must be inspected/adjusted after the first  Check engine idle 50 to 100 miles to the specifications given in the Track Specifications sub-section of this section and periodically ...
Page 10: Engine Specifications
Engine Specifications 4-Stroke 2-Stroke ITEM 1100 cc ITEM Engine Model Number (Non-Turbo) AA11L5 Engine Model Number (500 cc) AX50L9 (Turbo) AB11L5 (570 cc) AA56A9 (800 cc) AB80L4 Displacement 1056 cc Displacement (500 cc) 499 cc Bore x Stroke 98 x 70 (570 cc) 565 cc (800 cc)
Page 11: Crankshaft Runout/Repair Specifications (2-Stroke)
Crankshaft Runout/ Arctic Power Valve (APV) Repair Specifications System Specifications (2-Stroke) (800 cc) To use the specifications, first refer to the drawing; then VALVE POSITION CYCLE RPM find the letter indicating the specification and refer to the Mid-Open 67-7500 (Low/High Alt) chart below the illustration.
Page 12: Electrical Specifications
Electrical Specifications Component Test Value + Test Connections - Spark Plug Cap 4000-6000 ohms cap end cap end Oil Level Sensor Less than 1 ohm (float end down) terminal terminal Ignition Switch Less than 1 ohm (key in OFF position) terminal terminal 570 cc (Normally Open Ignition) Ignition Coil...
Page 13: Ignition Timing Specifications (2-Stroke)
570 cc Ignition Timing BTDC - 20° @ 2000 RPM - 0.099" Specifications (2-Stroke)  NOTE: Ignition timing shown with engine warm. Ignition timing is not adjustable. 500 cc BTDC - 13° @ 2000 RPM - 0.040" For timing verification, use a dial indicator and scribe a mark on the flywheel for 13°...
Page 14: Drive System Specifications
*** Best Compression Resistance; Best Heat Resistance A list of Drive System components that are available through the Arctic Cat Service Parts Department can be found in the Quick Reference Guide. This information will be useful when doing any fine-tuning on the drive system.
Page 15: Gear Case Performance Calibrations
Gear Case Performance Calibrations Engine RPM Drive Gear Ratio 6200 6400 6600 6800 7000 7200 7400 7600 7800 8000 8200 8400 8600 8800 9000 Sprocket Vehicle Speed (mph) 9 Tooth (2.52” pitch) 10 Tooth (2.52” pitch) 8 Tooth (3.0” pitch) Shaded rows indicate existing tooled gear ratios 1-13...
Page 16: Chain Case Performance Calibrations
Chain Case Performance Calibrations ENGINE RPM DRIVE CHAIN CHAIN RATIO 7200 7400 7600 7800 8000 8200 8400 8600 8800 SPROCKET SPROCKETS PITCH VEHICLE SPEED 0.408 0.429 0.458 0.512 0.526 10 TOOTH (2.52 0.553 PITCH) 0.571 0.575 0.595 0.639 0.686 0.408 0.429 0.458 0.512...
Page 17: Suspension Specifications
SHOCK ABSORBERS XT (10 lb). Below is a list of shock absorbers used on the front and rear suspensions of Arctic Cat snowmobiles. If replacing a shock absorber, always select a shock absorber with the same length, both collapsed and extended.
Page 18: Torque Specifications
STEERING/FRONT SUSPENSION/CHASSIS Torque Specifications F/M/XF Spindle Wearbar 96 in.-lb  NOTE: Torque specifications have the following tol- Ski Handle 54 in.-lb erances: Handlebar Adjuster Block (Stan- Post dard) Torque (ft-lb) Tolerance Handlebar Adjuster (Sno Pro) Post 0-15 ±20% Steering Support Mounting Block 96 in.-lb 16-39...
Page 19: Torque Conversions
REAR SUSPENSION REAR SUSPENSION Bearcat/T-Series M/XF (cont) Torque Item Secured to Torque ft-lb Item Secured to ft-lb Wear Strip Rail 50 in.-lb Rail (M Turbo/HCR) Rail Brace End Cap Rail 80 in.-lb Rear Idler Wheel Rear Idler Wheel 80 in.-lb Mounting Block Rail Rear Shock Link...
Page 20 NOTES 1-18...
Page 21 SECTION 2 — ENGINE Table of Contents Engine Removing/Installing - Bearcat 570/F570/T570..2-2 Assembly Schematic - 570 cc ........2-8 Engine Removing/Installing - F5 LXR......2-10 Assembly Schematic - 500 cc ........2-18 Engine Removing/Installing - F/M/XF 800 ....2-20 Assembly Schematic - 800 cc ........
Page 22 3. Remove the springs securing the expansion chamber Engine Removing/ to the exhaust manifold and resonator and remove the expansion chamber; then remove the cap screw, Installing - lock nut, and washer securing the resonator to the Bearcat 570/F570/T570 front upper frame and remove the resonator. 4.
Page 23 FZ008 0743-921 11. Remove the ground wire from the starter motor; then 14. Move the engine forward enough to remove the cap remove the two cap screws (A) securing the MAG- screws (C) securing the rear MAG-side engine side starter motor bracket to the engine. Remove the mounting bracket to the engine;...
Page 24 19. Remove the cap screw and lock nut securing the wir- ing harness clamp to the chassis; then remove the spark plug wires from the spark plugs. Disconnect the coil wire and CDI connectors and route and secure the harness to the engine to avoid damage when removing the engine from the chassis.
Page 25 8. Install the headlight support bracket and secure the bracket with the cap screws and lock nuts. 9. Install the rear MAG-side engine mounting bracket to the engine with the three cap screws (C). Tighten to 20 ft-lb; then position the engine to the chassis mounts.
Page 26 FZ024A FZ012A 20. Install the grommets into the spark plug opening of 14. Apply a thin coat of high-temperature silicone sealant the engine shroud; then connect the spark plug wires to each exhaust port; then install the exhaust gaskets. and install the negative cable to the battery. 15.
Page 27  NOTE: When installing the exhaust manifold CAUTION springs, the long hook portion of the spring must be attached to the exhaust manifold or premature spring Do not allow the driven pulley to “float” on the input shaft. Damage to the driven pulley will occur. failure will result.
Page 28 Assembly Schematic - 570 cc Torque Specification Tolerances Torque (ft-lb) Tolerance 0-15 ±20% 16-39 ±15% ±10% 570-ENG12...
Page 29 570ENG12...
Page 30  NOTE: Disconnect the negative cable from the bat- This engine sub-section has been organized to show a tery. progression for the removing/installing of the Arctic Cat 500 cc (F) engine. For consistency purposes, this sub- 4. With the seat adjusted to its lowest position, remove section shows a complete and thorough progression;...
Page 31 9. Remove the belt guard; then using Drive Clutch Bolt Tool, remove the cap screw and lock washer securing the drive clutch to the crankshaft. 10. Using Drive Clutch Puller and Drive Clutch Spanner Wrench, tighten the puller. If the drive clutch will not release, sharply strike the head of the puller.
Page 32 FS177A FS183A 19. Remove the spark plug wires from the plugs; then 23. Remove the exhaust manifold from the engine. disconnect the two-wire plug-in for the coolant tem- Account for the flange nuts and gaskets. perature sensor (located below the ignition coil). 24.
Page 33 FS186 FS187A 2. Install the pinion bracket assembly to the engine with CAUTION two cap screws (coated with green Loctite #609). When removing the engine, take care not to damage the Tighten to 20 ft-lb. oil pump or the servomotor cables. 29.
Page 34 10. Connect the coolant hose to the outlet of the front heat exchanger and secure with the hose clamp. FS194A 6. Insert the flex-drive shaft into the pinion drive and secure with the two set screws. FS196A 11. Route the ignition harness and the coolant tempera- ture sensor two-wire connector between the coolant tank and the chassis;...
Page 35  NOTE: When the cable adjusting nut is adjusted correctly, the throttle lever will move approximately 1/ 8 in. before the oil-injection pump control arm begins to move. 16. Install the two coolant hoses to the MAG-side and PTO-side of the crankcase (below the exhaust ports); then tighten the coolant hose clamps and the throttle body flange clamps.
Page 36  NOTE: When installing the bracket plates, the wider end of the plate must be directed up. FS214A  NOTE: Before installing the drive clutch, be sure to wipe both the crankshaft taper and clutch mounting FS200A taper clean using a clean towel. 26.
Page 37 29. Connect the air temperature sensor and place the sen-  NOTE: When installing the exhaust manifold sor harness beneath the air-intake duct; then install springs, the long hook portion of the spring must be the duct into the silencer. attached to the exhaust manifold or premature spring failure will result.
Page 38 Assembly Schematic - 500 cc Torque Specification Tolerances Torque (ft-lb) Tolerance 0-15 ±20% 16-39 ±15% ±10% 500CC1A12 2-18...
Page 39 500CC2A_12 2-19...
Page 40 This engine sub-section has been organized to show a 3. Remove the cap screw from the driven pulley and progression for the removing/installing of the Arctic Cat slide the driven pulley (along with the drive belt) off 800 cc (F/M/XF) engine. For consistency purposes, this the driven shaft.
Page 41 9. Using a small needle-nose pliers, remove the servo- motor cable holder; then pull the cable housings down and out of the servomotor. PC135A ! WARNING The hose may be under pressure; remove it slowly to PC187A release the pressure. Place an absorbent towel around the connection to absorb gas.
Page 42 18. Remove the recoil starter from the engine. Secure it 23. Remove the torx-head screw securing the front belt out of the way. guard to the skid plate; then remove the three cap screws and carriage bolt nut securing the PTO-side chassis sup- 19.
Page 43  NOTE: Make sure to install the spring washer between the rear mount and the tunnel. 8. From step 7, tighten the four front screws to 30 ft-lb, the six top rear screws to 14 ft-lb, and the lower rear screw to 25 ft-lb using the following sequence.
Page 44  NOTE: When installing the manifold springs, the long hook portion of the spring must be attached to the exhaust manifold or premature spring failure will result. 32. Install the exhaust temperature sensor into the expan- sion chamber. Tighten to 34 ft-lb. 33.
Page 45 NOTES 2-25...
Page 46 Assembly Schematic - 800 cc Torque Specification Tolerances Torque (ft-lb) Tolerance 0-15 ±20% 16-39 ±15% ±10% 800_12_1 2-26...
Page 47 800_12_2 2-27...
Page 48 3. Remove the two screws securing the handlebar Engine Removing/ close-off panel (B); then remove the three screws (C) securing the left- and right-side rear spar panels to Installing - the seat support tubes. Remove the screws (D) secur- Bearcat Z1 XT/TZ1 ing the front spar panels to the front bumper;...
Page 49 12. Remove the two cap screws securing the headlight support bracket to the right-side upper frame. ZJ292 9. Using Drive Clutch Puller and Drive Clutch Spanner Wrench, tighten the puller until the drive clutch TZ070A releases from the crankshaft. Remove the drive 13.
Page 50 TZ073A TZ071A 15. Remove the five cap screws and lock nuts securing the support gusset/left-side upper frame to the steer- ing support; then remove the support bracket and left-side upper frame. TZ077A  NOTE: On the non-turbo models, remove the MAP sensor from the left-side upper frame.
Page 51 TZ076A TZ081A 17. On the non-turbo models, remove the two coolant  NOTE: On the non-turbo TZ1, note the location of hoses from the throttle bodies. the resonator mounting pin for installing purposes. 20. Remove the separator tank assembly from the right- side upper frame;...
Page 52 TZ083A ZJ020A  NOTE: On the Bearcat Z1 XT, remove the four cap screws securing the close-off panel and account for the exhaust pipe mounting tab (A) from the left front cap screw. TZ084A CAUTION Any time hoses are removed from the turbocharger, always close-off the inlets and outlets of the turbo to avoid dirt or foreign objects from entering the turbo- TZ078A...
Page 53 30. Loosen the flange clamps securing the intake mani- fold to the cylinder head; then remove the manifold and throttle body assembly along with the two flanges. TZ085B TZ090A 31. Remove the positive cable from the starter motor. 32. On the non-turbo models, disconnect the harness plug-ins from the ignition coils (A) and camshaft timing sensor (B).
Page 54 34. Remove the three cap screws securing the oil reser- voir to the chassis. 743-993A  NOTE: Lift the engine at an angle (with the PTO-side upward) to allow clearance for the oil reservoir to be ZJ021A removed from the chassis with the engine. ...
Page 55 1. Using an appropriate engine hoist, carefully lower the engine into the engine compartment until the rear mount studs are into the rear mounts just far enough to hold the engine in place. 2. Pry the front engine mount forward until the engine and mount are in proper alignment;...
Page 56 ZJ024A TZ099A  NOTE: Prior to securing the left-side upper frame to  NOTE: Place the upper frame into position and the steering support, make sure the ECU harness is install the clip securing the wire harness to the steer- directed below the upper frame.
Page 57 743-995A TZ075A 15. Install the four remaining cap screws securing the 17. Connect the harness plug-ins to the ignition coils (A) upper frame/support gusset to the steering support. and camshaft sensor (B); then route the main harness to the proper connector locations and secure with 16.
Page 58 22. Install the close-off cover to the front end with the  NOTE: To aid in coolant bleeding procedure, do not two cap screws (A) noting the mounting tab (non- secure the upper heat shield to the manifold at this turbo only) (B) is installed with the right-side cap point.
Page 59 30. Place the drive clutch into position on the crankshaft and secure with the cap screw and lock washer. Tighten to 51 ft-lb.  NOTE: To aid in proper tightening of the drive clutch cap screw, apply a few drops of oil to the threads of the cap screw prior to installing.
Page 60 38. With the engine cool, loosen the bleed screw and allow the coolant level in the filler neck to drop; then with the bleed screw loose, add coolant into the filler neck until no air is visible or heard at the bleed screw.
Page 61 Engine Torque Patterns (1100 cc) 1100TorquePattern12 2-41...
Page 62 Assembly Schematic - 1100 cc Torque Specification Tolerances Torque (ft-lb) Tolerance 0-15 ±20% 16-39 ±15% ±10% 1100ccJAG12 2-42...
Page 63 1100ccZ1RV10 2-43...
Page 64 Engine Removing/ Installing - F/M/XF 1100 This engine sub-section has been organized to show a pro- gression for the removing/installing of the Arctic Cat 1100 cc (F/M/XF) engine. For consistency purposes, this sub- section shows a complete and thorough progression; how- ever, for efficiency it may be preferable to remove only those components needing to be addressed.
Page 65  NOTE: If the drive clutch will not release, sharply strike the head of the puller. Repeat this step until the clutch releases. 8. Disconnect the oxygen sensor and remove the spring securing the resonator to the chassis. Non-Turbo PC065 11.
Page 66 PC052A PC059A 15. Remove the lock nuts and screws (A) securing the rear intercooler brackets to the chassis and remove the brackets from the intercooler; then carefully pry the intercooler out from the front brackets (B) and remove the intercooler with the air bypass valve and hoses.
Page 67 18. Remove the cap screws and nuts securing the front spars to the steering support; then remove the torx- head screws securing the steering post bracket to the steering support. Remove the steering support. PC057A PC030 19. Remove the cap screws (F) or (G) securing the shock mounting bracket support to the shock mounting brackets;...
Page 68 22. Remove the throttle body coolant hoses. PC032  NOTE: Steps 25-27 are for the non-turbo models ZJ018B only. Turbo 25. Loosen the clamps securing the air silencer to the throttle bodies; then disconnect the harness connec- tor from the air temperature sensor and remove the air silencer.
Page 69 28. Disconnect the throttle position sensor, air tempera- ture sensor, boost sensor, and cam position sensor. PC034A 743-999A 29. From the opposite side of the throttle body, discon- nect the idle speed control and the throttle cable; then remove the spark plug caps from the spark plugs. PC243 32.
Page 70  NOTE: After removing the PTO-side chassis sup- Non-Turbo port, re-install the cap screw securing the rear PTO- side engine to chassis mount (bearing bracket) to secure the bearing. 0746-313 Turbo PC209A 38. Remove the cap screws securing the PTO-side engine to chassis mount (bearing bracket).
Page 71 PC038A PC040A PC039A PC047A 2. Tip the engine forward enough to install the cables to  NOTE: At this time, verify all components connect- the starter motor and tighten the ground cable to 19 ing the engine to the chassis are disconnected and ft-lb and the positive cable to 42 in.-lb.
Page 72 4. With the front engine/chassis mount into position, 6. Install the belly pan and secure with four screws (C) lower the engine back until the engine is in line with tightened securely; then secure the PTO-side engine PTO-side engine/chassis mount (bearing to chassis mount (bearing bracket) with two cap bracket).
Page 73 14. Connect the harness connectors to the regulator/rec- tifier and magneto and with the harness properly routed, secure the harness to the engine with cap screw and routing clamp; then tighten the cap screw securely. Non-Turbo PC036A PC037A Turbo PC243 ...
Page 74 ZJ094A PC211A 20. With the spark plug wires routed properly, install the CAUTION spark plug caps to the spark plugs. Make sure the harness is routed away from the exhaust  NOTE: Make sure the caps are firmly seated on the or any moving parts.
Page 75 743-999A SNO-231C 24. With the battery cables and solenoid harness prop-  NOTE: At this time, secure the wire harness to the erly positioned in the channel of the gas tank assem- locations noted during disassembly. bly, install the gas tank (see Section 4). 23.
Page 76 F. Shock mounting bracket support to shock mount- ing brackets (non-turbo) = 2 cap screws, inserts, and 2 lock nuts. Tighten to 20 ft-lb.  NOTE: On the turbo models, secure the front heat shield to the chassis with the screws. PC061A 28.
Page 77 PC055A PC052A 32. Install the exhaust resonator to the chassis support and secure with the spring; then secure the resonator to the exhaust pipe and tighten the cap screws and flange nuts to 12 ft-lb.  NOTE: Steps 33-34 are for the non-turbo models only.
Page 78 35. Install and secure the drive clutch with the cap screw (lightly coated with oil); then tighten the cap screw to 51 ft-lb. CAUTION When installing the drive clutch, do not tighten the clutch cap screw with any kind of impact tool. Tighten cap screw using a hand torque wrench only.
Page 79  NOTE: At this time, connect Hood Harness Exten- sion to the hood and connect the main harness con- nector to the extension. CAUTION After running the engine to the proper operating tem- perature, shut the engine off; then inspect for any signs of coolant, gasoline, or oil leakage.
Page 80 Assembly Schematic - 1100 cc Torque Specification Tolerances Torque (ft-lb) Tolerance 0-15 ±20% 16-39 ±15% ±10% 1100ccJAG12 2-60...
Page 81 1100ccZ1RV10 2-61...
Page 82 Engine Torque Patterns (1100 cc) 1100TorquePattern12 2-62...
Page 83 This engine sub-section has been organized to show a progression for servicing of the Arctic Cat 570 cc engine. For consistency purposes, this sub-section shows a com- plete and thorough progression; however, for efficiency it may be preferable to disassemble only those components needing to be addressed.
Page 84 8. Remove the rubber insulator grommet from the crankcase; then remove two Phillips-head cap screws securing the ignition timing sensor. MD0275 CAUTION To prevent damage to the crankshaft, install a protective MD0075 insert into the end of the crankshaft. The puller must bottom on the insert and not on the crankshaft.
Page 85 10. Remove the four Allen-head cap screws securing the 13. Remove the eight cap screws, two nuts, and two stator plate. Remove the stator plate. washers securing the cylinder head to the cylinders; then remove the cylinder head. Discard the cylinder head gasket.
Page 86 MD0230 MD0208  NOTE: Always replace with new piston rings and as a complete set. Note the identification on the tapered side of each ring for installation purposes. MD0096 16. Using an awl, remove the outside piston-pin circlip and remove the piston pin using Piston Pin Puller. 726-306A MD0094 ...
Page 87 MD0092A MD0283 18. Remove the oil-injection pump driveshaft retainer. Account for an O-ring. MD0204 22. Remove the two cap screws; then remove the crank- shaft assembly from the upper crankcase half making MD0100A sure to hold both ends of the crankshaft to keep the 19.
Page 88 4. Place the head surface of each cylinder on the sur- face plate covered with #400 grit wet-or-dry sandpa- per. Using light pressure, move each cylinder in a figure eight motion. Inspect the surface for any indi- cation of high spots. A high spot can be noted by a bright metallic finish.
Page 89 CRANKSHAFT  NOTE: Care must be taken not to remove an exces- sive amount of aluminum, or the crankcase must be  NOTE: If any servicing of the connecting rods, cen- replaced. If excessive aluminum is removed, too ter bearings, or oil-injection pump drive gear is nec- much pre-load will be exerted on the crankshaft bear- essary, take the crankshaft to a qualified machine ings when assembled.
Page 90 2. Place the protective cap on the crankshaft end; then remove the bearing from the end of the crankshaft. Account for any shim(s). Note the position of the dowel pin hole. AN151A REED VALVE ASSEMBLY 1. Inspect the reed valves, stoppers, and cages for cracks or any deterioration.
Page 91 Measuring Critical Components  NOTE: Critical engine specifications chart can be found in Section 1 of this manual. CYLINDER HEAD VOLUME (Squish- Gap Method) To check the squish gap, a micrometer and two heavy pieces of solder will be needed. MD2493 1.
Page 92 CONNECTING-ROD SMALL END 2. Using a feeler gauge, measure each piston-ring end gap. Acceptable ring end gap must be within 0.0120- BORE 0.0196 in. 1. Insert a snap gauge into each connecting-rod small end bore; then remove the gauge and measure it with a micrometer.
Page 93 6 mm cap screws to 96 in.-lb using the pat-  NOTE: When the use of a lubricant is indicated, use tern shown. recommended Arctic Cat Injection Oil. 1. Place the upper crankcase half (with its bottom side up) on two blocks of wood.
Page 94 MD0212 MD0251 10. Place pistons over the connecting rods with the  NOTE: Check the reed valve on each cylinder. Make arrow (or indicator dot) pointing toward the exhaust sure they are clean and closing completely. port; then secure with an oiled piston pin. Install new piston pin circlips with the open ends up or down.
Page 95 12. Rotate each piston ring until the ring ends are prop- erly positioned with the pins in the ring grooves; then apply 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 firmly onto the crankcase.
Page 96 18. Place the stator wiring through the hole in the crank- case; then install the stator. Lightly coat the three Allen-head cap screws with blue Loctite #243; then tighten to 48 in.-lb. MS385 16. Position the seal retainer plate on the PTO-side; then install the four cap screws.
Page 97 MD0073 MD0278 20. Install the rubber insulator grommet into the crank- 23. Using Flywheel Spanner Wrench to hold the starter cup, case. tighten the three cap screws (from step 21) to 28 ft-lb. MD0262 TZ067A 21. Place the starter pulley into position on the flywheel 24.
Page 98 27. With a new O-ring (lightly coated with oil) in place, install the oil-injection pump driveshaft retainer. MD0269 MD0273 28. With a new O-ring (lightly coated with oil) in place, install the oil-injection pump aligning the slot on the oil pump with the flat on the end of the oil-injection pump driveshaft.
Page 99 Engine Servicing - 500 cc This engine sub-section has been organized to show a progression for servicing of the Arctic Cat 500 cc engine. For consistency purposes, this sub-section shows a com- plete and thorough progression; however, for efficiency it may be preferable to disassemble only those components needing to be addressed.
Page 100 CM013 FC021  NOTE: To ensure the cleanliness of the flywheel magnets, place the flywheel (with the magnets facing upward) on a clean bench. 4. Remove the ignition timing sensor and clamp. FC065  NOTE: The stator plate screws had Loctite applied to the threads during assembly.
Page 101 10. Remove the eight nuts securing the cylinders to the crankcase; then using a rubber hammer, gently tap the cylinders and remove from the crankcase by lift- ing them straight up off their studs. Account for gas- ket(s) and any alignment pins. 11.
Page 102 22. Lift the bottom half of the crankcase off the top half. CAUTION Care must be taken to not allow the connecting rods to drop onto the sealing surface of the bottom case half. 23. Lift the crankshaft free from the top half of the crankcase and slide the crankshaft oil seals off the crankshaft.
Page 103 AN327D CM018 CAUTION Cleaning and Inspecting Water or parts-cleaning solvent must be used in con- junction with the wet-or-dry sandpaper or damage to the sealing surface may result. CYLINDER HEAD CYLINDERS 1. Using a non-metallic carbon removal tool, remove any carbon buildup from the combustion chambers 1.
Page 104  NOTE: If any servicing of the connecting rods, cen- ter bearings, or oil-injection pump drive gear is nec- CRANKCASE essary, Arctic Cat recommends the crankshaft be  NOTE: The coolant temperature sensor must be taken to a qualified machine shop for that service.
Page 105  NOTE: 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. FC039 3. Inspect the connecting-rod bearings by rotating them.
Page 106 5. To assemble, place the reed valves on the cage with Readings may vary from side to side. its clipped corner positioned to the lower right hand  NOTE: Make sure the smaller reading is 0.059 in. or corner of the cage. Place the reed stopper assembly into position and secure with the screws tightened to less.
Page 107 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 0.8661- 0.8665 in. Take two measurements to ensure accu- racy. AC091 PISTON-RING END GAP 1. Place each piston ring in the wear portion above the exhaust port of its respective cylinder.
Page 108 5. Position the upper crankcase half upside-down on two wooden blocks; then install the C-ring, the four  NOTE: When the use of a lubricant is indicated, use bearing retaining pins, and the two crankcase dowel Arctic Cat Synthetic APV 2-Cycle Oil. pins. 2-88...
Page 109 6. Place the PTO-side crankshaft bearing into position making sure the bearing retaining pin hole is posi- tioned inward.  NOTE: The bearing retaining pin hole is the hole that doesn't go entirely through the bearing case. CM036A  NOTE: At this point if the coolant temperature sen- sor was removed, install the sensor (threads coated with white Loctite #575) and tighten to 18 ft-lb.
Page 110  NOTE: Secure the connecting rods with rubber bands on the cylinder studs. 13. Apply a thin coat of grease to the sealing surface of the oil-injection pump/water pump driveshaft; then place the Oil Seal Protector Tool at the end of the shaft.
Page 111 IO050A FC134 CAUTION When installing the ceramic/rubber seal into the impel- ler, never touch the ceramic part of the seal. Make sure components are clean and free of any dirt or contami- nants. 19. Place the impeller into position and secure with a cap screw and washer.
Page 112 24. Install the dowel pins into the crankcase; then place the cylinder base gasket into position on the crank- case. 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 113 35. Place new O-rings (lightly coated with oil) onto each of the head cap screws. Place four of these cap screws into the cylinder head. Thread the spark plugs in part way; then while holding the head above the cylinder, care- fully start and finger-tighten all four cap screws while observing the cylinder O-rings to make sure they remain in position.
Page 114 42. Secure the starter pulley to the flywheel with three cap screws and using the spanner wrench, tighten the cap screws evenly to 19 ft-lb; then tighten the fly- wheel cap screw (from step 41) to 50 ft-lb. FC018 39. Install the key in the crankshaft. 40.
Page 115 Engine Servicing - 800 cc This engine sub-section has been organized to show a progression for servicing of the Arctic Cat 800 cc engine. For consistency purposes, this sub-section shows a com- plete and thorough progression; however, for efficiency it may be preferable to disassemble only those components needing to be addressed.
Page 116 CM140 IO016A 6. Remove the Allen-head cap screws securing the sta-  NOTE: To ensure the cleanliness of the flywheel tor to the stator plate. Route the stator lead wire out magnets, place the flywheel (with the magnets facing of the crankcase; then remove the stator assembly. upward) on a clean bench.
Page 117  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. 11. Remove the four nuts and four cap screws securing the cylinders to the crankcase; then using a soft ham- mer, gently tap the cylinders and remove from the crankcase by lifting them straight up off their studs.
Page 118 16. Remove the lower union cap screw securing the lower check valve assembly to the crankcase; then remove the two screws securing the oil-injection pump to the crankcase. Remove the pump, retainer, and O-ring and account for the two gaskets from the lower union.
Page 119 CM157A 742-198B 18. Remove the seven screws securing the water pump 21. Turn the engine upside down on support blocks, cut cover to the crankcase and remove the cover. the cable tie, and remove the coolant temperature Account for the O-ring gasket and the alignment sensor switch.
Page 120 30. Using the hooked end of the tool, pry the seal ring from the backside of the water pump impeller. IO023A  NOTE: The end bearings are not pressed onto the AN327D crankshaft. After removing the seals, use care not to allow the bearings to slide off the crankshaft.
Page 121 CYLINDERS 1. Using a non-metallic carbon removal tool, remove carbon buildup from the exhaust ports. 2. Wash the cylinders in parts-cleaning solvent. 3. Inspect the cylinders for pitting, scoring, scuffing, and corrosion. If marks are found, repair the surface with the Ball Hone and honing oil. ...
Page 122  NOTE: The end bearings are not pressed onto the essary, Arctic Cat recommends the crankshaft be taken to a qualified machine shop for that service. crankshaft. The bearings can be removed simply by sliding them off the crankshaft.
Page 123 REED VALVE ASSEMBLY Measuring Critical 1. Inspect the reed valves, stoppers, and valve blocks Components for cracks or any deterioration.  NOTE: Critical engine specifications chart can be found in Section 1 of this manual. CYLINDER HEAD VOLUME (Squish-Gap Method) To check the squish gap, a micrometer and two heavy pieces of solder will be needed.
Page 124 2. Using a feeler gauge, measure each piston-ring end gap. Acceptable ring end gap must be within 0.0120- 0.0196 in. FC044 2. The trueness (out-of-roundness) is the difference between the highest and lowest reading. Maximum trueness (out-of-roundness) must not exceed 0.004 in. FC045 PISTON PIN AND PISTON-PIN BORE...
Page 125 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 the water pump seal.
Page 126  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. CM043A 7. Lubricate the inner lips of the crankshaft oil seals with grease; then slide the seals onto the crankshaft making sure the spring side of each seal faces inward.
Page 127 14. Apply a thin coat of grease to the sealing surface of the oil-injection pump/water pump driveshaft; then place the Oil Seal Protector Tool at the end of the shaft. CAUTION Be very careful not to damage the seals when installing the oil pump driveshaft.
Page 128 17. With the new O-ring (lightly coated with oil) in 19. With new gaskets, install the reed valve assemblies place, install the oil-injection pump making sure the and intake flanges using the pattern shown. Tighten pump shaft slot (A) and pump driven gear shaft (B) to 96 in.-lb;...
Page 129 CM171A CM168 22. Using a suitable tool, 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. CM171B 25. Apply a thin film of low-temp grease to the water pump cover O-ring;...
Page 130 CM157A TZ068  NOTE: The shoulder side of the washer must seat to the needle bearing. CM155A 27. Install the dowel pins into the crankcase; then place the cylinder base gasket into position on the crank- case. CM172A 30. Place each piston over the connecting rod so the indi- 28.
Page 131 CM174 0738-206 CAUTION  NOTE: Always use new cap screws when installing the cylinders. Make sure the circlips are firmly seated before continu- ing with assembly. 35. Install the two cylinder O-rings (lightly coated with 32. Rotate each piston ring until the ring ends are prop- oil) on the top of each cylinder making sure they are erly positioned on either side of the ring keeper;...
Page 132 37. Start and finger-tighten the remaining cap screws being very careful not to move the cylinder head; then tighten the cap screws in two steps to 25 ft-lb using the pattern shown. CM143A 41. Secure the upper ignition timing sensor (white dot/ connector) with cap screws (coated with blue Loctite #243).
Page 133 47. Using the spanner wrench, tighten the flywheel cap screw (from step 45) to 50 ft-lb. 48. Install the coolant inlet hose to the cylinder head and water pump; then tighten the hose clamps securely. CM180  NOTE: Before installing the flywheel, be sure to wipe the crankshaft and flywheel tapers clean using a clean, lint-free towel.
Page 134 This engine sub-section has been organized to show a discard the gaskets. progression for servicing of the Arctic Cat 1100 cc engines. For consistency purposes, this sub-section shows a complete and thorough progression; however, for efficiency it may be preferable to disassemble only those components needing to be addressed.
Page 135 ZJ029A 9. On the turbo models, remove the four cap screws securing the manifold adapter assembly; then remove the manifold. 743-780C 6. Remove the lock nuts and washers securing the exhaust pipes to the cylinder head; then carefully remove the turbocharger and exhaust pipes assembly. If needed remove the cap screws securing the lower heat shield to the exhaust pipes and turbocharger.
Page 136 ZJ031A ZJ034 11. Remove the eighteen cap screws securing the mag- 14. Remove the flywheel key from the crankshaft; then neto cover to the engine; then remove the cover and remove the starter gear. account for the starter torque limiter (A), spacer (B), idler gear (D), inner spacer (C), and outer spacer (E).
Page 137 ZJ049B ZJ038A 19. Remove the cap screws securing the camshaft covers  NOTE: If cleaning or replacing the cylinder head to the cylinder head; then remove the covers. cover is necessary, the cam position sensor must be Remove both camshafts. Account for the dowel pins. removed.
Page 138 ZJ051B ZJ041A 21. Remove the six nuts and two cap screws (A) from 23. Remove the fourteen cap screws securing the oil pan outside the cylinder head; then remove the six cap to the engine; then remove the oil pan and note the screws (B) from inside the cylinder head.
Page 139 31. Remove the oil separator plates for the lower crank- case half and account for the eight Allen-head cap screws. ZJ052B  NOTE: Because the connecting rods and connect- ing rod caps are unique, note the I.D. marks and keep all associated parts together for assembling pur- ZJ047A poses.
Page 140 If valves, valve guides, or valve seats require servicing or replacement, Arctic Cat recommends the components be taken to a qualified machine shop for servicing. IO051A 1. Install the drive clutch; then using Drive Clutch Spanner Wrench, rotate the engine two full revolu- tions.
Page 141 SNO2152 2-121...
Page 142 SNO2153 2-122...
Page 143 B. Find the Present Shim Size (three-digit-number) at the top-side horizontal column of the table. C. Match the clearance in the vertical column with the present shim size to obtain the recommended replacement shim.  NOTE: At this point, complete steps 33-40 of Assembling in this sub-section before proceeding to step 5.
Page 144 Measuring Piston-Ring End Gap (Installed) 1. Place each piston ring in the wear portion of the cyl- inder. Use the piston to position each ring squarely in the cylinder.  NOTE: Remove any carbon; then clean the top of the cylinder bore before inserting the piston rings. 2.
Page 145 Installing Piston Rings Cleaning/Inspecting/Measuring Cylinder Block 1. Install a thin oil ring, oil ring expander, and thin oil ring in the bottom groove of the piston. Stagger the 1. Wash the cylinder block in parts-cleaning solvent. end gaps of the upper and lower thin oil rings until they are on directly opposite sides of the piston.
Page 146 Bearing Selection Charts To select the correct main or balancer shaft bearing insert, read the letter stamped for the bearing location on the crankcase; then read the letter stamped on the crankshaft or balancer shaft corresponding to the same bearing location. ...
Page 147 Connecting Rod Bearing Selection Crankshaft Assembling Green Black Brown p/n 3007-109 p/n 3007-110 p/n 3007-111  NOTE: Arctic Cat recommends that new gaskets, Black Brown Yellow seals, and O-rings be installed whenever assembling p/n 3007-110 p/n 3007-111 p/n 3007-112 the engine.
Page 148 4. Using Ring Compressor and a soft hammer/hammer handle, carefully drive each piston into the cylinder until the top of the piston is flush with the engine case. ZJ055A 7. With the proper bearings selected, install the half- bearings into the upper engine case; then lubricate the bearing faces liberally with engine-assembling grease taking care not to get any grease between the ZJ072...
Page 149  NOTE: Rotate the crankshaft one revolution to ver- ify free movement. 13. With the O-ring lubricated with engine oil, install the oil-relief valve. ZJ053 9. Lubricate the thrust bearings with engine oil; then with the grooved side of the bearings (A) facing out- ward towards the crankshaft counterweights, install the first bearing and roll it into place.
Page 150 ZJ042A 741-582A 23. For initial tightening of the engine case cap screws, use this sequence: A. Cap screws 1-6 (10 mm) to 13 ft-lb. B. Cap screws 7-24 (8 mm) to 120 in.-lb. C. Cap screws 25-28 (6 mm) to 96 in.-lb. 24.
Page 151 28. Install the cam chain tensioner; then install the wash- ers between the engine case and guide/tensioner and secure with two Allen-head cap screws (coated with blue loctite #243). Tighten to 84 in.-lb. 741-584A  NOTE: Prior to installing the oil pan, ensure the oil strainer is cleaned thoroughly.
Page 152 32. Install the flange nuts and cap screws (cap screws 1- 6 threads coated with oil); then using the pattern shown, tighten in the following sequence: A. Cap screws 1-6 initially to 18 ft-lb. B. Flange nuts 7-8 to 18 ft-lb. C.
Page 153 741-624A 741-580A 38. Remove the tensioner ball, spring, and bolt.  NOTE: At this point, install the spark plugs. 42. Place the starter gear on the crankshaft; then install the flywheel key. ZJ086 39. Install the cam chain tensioner adjuster by first com- pressing the locking clip;...
Page 154 0742-125 ZJ090A 45. With the two pins installed in the engine case, first 47. Install the coolant hose inlet fitting and secure with install the starter torque limiter (A) and spacer (B); the two cap screws. Tighten to 84 in.-lb. then install the inner spacer (C), idler gear (D), and outer spacer (E).
Page 155 ZJ093 746-517A  NOTE: On the turbo models, install the intake flange  NOTE: At this point, assembly of the non-turbo assembly; then tighten the cap screws evenly to 96 engine is complete. in.-lb.  NOTE: Steps 53-59 are for the turbo models only. 53.
Page 156 743-991A 59. With the turbocharger secured, install the oil feed pipe with the banjo bolts and two new crush washers on each side of the union. Tighten to 11 ft-lb. 743-780A 57. Tighten the two lock nuts (from step 53) to 30 ft-lb. 58.
Page 157 Troubleshooting Engine (2-Stroke Carbureted) Problem: Engine Does Not Start (No Spark at Spark Plugs) Condition Remedy 1. Ignition switch malfunctioning — not in RUN position 1. Replace ignition switch — turn switch to RUN position 2. Wiring harness shorting — connection poor 2.
Page 158 Problem: Engine Backfires Condition Remedy 1. Throttle/ignition monitor switch adjusted incorrectly 1. Adjust throttle cable free-play — service spring 2. Spark plugs fouled — damaged 2. Clean — gap — replace spark plugs 3. Spark plug heat range too hot 3.
Page 159 Troubleshooting Engine (2-Stroke EFI) Problem: Engine Does Not Start (No Spark at Spark Plugs) Condition Remedy 1. Ground connections dirty — loose 1. Check all ground connections — clean and tight 2. Throttle/ignition monitor switch malfunctioning — 2. Replace faulty switch — turn switch on ignition switch not on 3.
Page 160 Problem: Engine Loses Power or Runs on One Cylinder Condition Remedy 1. Sensor faulty 1. Check LED for trouble code — repair — replace problem circuit or sensor 2. Spark plug fouled 2. Replace spark plugs 3. External coil faulty 3.
Page 161 Problem: Engine Overheats Condition Remedy 1. Spark plug heat range too hot 1. Install lower heat-range spark plugs 2. Coolant low — absent 2. Add coolant 3. Heat exchanger obstructed 3. Remove obstruction 4. Intake flange to cylinder air leak 4.
Page 162 Problem: Engine Loses Power Condition Remedy 1. Sensor faulty 1. Check engine light for trouble code — repair — replace problem circuit or sensor 2. Spark plug fouled 2. Replace spark plugs 3. External coil faulty 3. Service — replace coil 4.
Page 163: Engine-Related Items
SECTION 3 — ENGINE-RELATED ITEMS TABLE OF CONTENTS Engine-Related Items............3-2 Water Pump (500 cc)............3-2 Water Pump (800 cc)............3-5 Water Pump (1100 cc)............3-9 Pressure Testing Engine (2-Stroke).........3-11 Checking Compression (1100 cc) ........3-11 Changing Oil/Filter (F/M/XF 1100 cc) ......3-11 Changing Oil/Filter (Bearcat/T-Series 1100 cc) ....3-12 Testing Oil Pressure (1100 cc) ........3-13 Oil Flow Chart (1100 cc)..........3-14 Liquid Cooling System (500/800 cc)........3-14...
Page 164 1. Remove the cap screws securing the water pump Engine-Related Items cover; then remove the cover and account for the O- ring seal.  NOTE: Critical torque specifications can be found in Section 1 of this manual.  NOTE: Some illustrations and photographs used in this section are used for clarity purposes only and are not designed to depict actual conditions.
Page 165 FC124 FC121 8. Using the hooked end of the long seal driver, pull the 5. Remove the oil-injection pump retainer and shaft inner seal free of the crankcase. from the opposite side of the crankcase. Account for the thrust washer located between the retainer and ASSEMBLING shaft flange.
Page 166 FC127 FS233A 4. Using a pair of snap ring pliers, install the snap ring 7. Position the shim on the oil pump end of the shaft; securing the inner seal in the crankcase. then with the O-ring installed on the retainer, install the oil-injection pump retainer.
Page 167  NOTE: When installing the lower check valve, assure that the washer gaskets are installed on each side of the valve. FC072B 12. Position the O-ring into the water pump cover; then install the cover. Install the cap screws; then using the pattern shown, tighten to 96 in.-lb.
Page 168 FS219A FS220A  NOTE: When servicing the water pump, use Water  NOTE: Leave the two upper check valves secured to Pump Bearing and Seal Tool Kit and Oil Seal Protec- the pump. tor Tool. 1. Loosen the clamps securing the coolant hose to the water pump and cylinder head;...
Page 169 FS225 FS227 8. Using a pair of snap ring pliers, remove the snap ring  NOTE: If the impeller will not slide off the shaft, securing the oil seal in the crankcase. start the cap screw into the shaft and tap on the cap screw driving the shaft back out of the impeller.
Page 170 FS230 FS233A 3. Apply a small amount of grease to the oil seal lips. 4. Using a pair of snap ring pliers, install the snap ring securing the oil seal in the crankcase. IO025B 7. Position the shim (A) on the oil pump end of the shaft;...
Page 171 FS220A FC133A 11. Position the O-ring into the water pump cover; then  NOTE: When installing the lower check valve, install the cover. Install the cap screws; then using assure that the gaskets are installed on each side of the pattern shown, tighten to 96 in.-lb. the valve.
Page 172 CAUTION Do not apply excessive heat to the housing or the bushing next to the bearing may be damaged. 4. Using the bearing puller, remove the bearing (F) from the inner housing.  NOTE: Apply heat to the housing to aid in removing the bearing.
Page 173: Pressure Testing Engine
 NOTE: This test must be done with the engine at operating temperature and “full-cranking RPM” and the decompression system active. With the spark plugs removed, install the compression tester gauge with adapter into the spark plug hole; then with the throttle valve in the full-open position, crank the engine over to get the psi reading.
Page 174 12. Without starting the engine, place the handlebar emergency stop switch to the RUN position and the ignition switch to the ON position. The Oil Pressure Warning Icon should illuminate immediately on the standard gauge or after the three seconds on the pre- mium gauge.
Page 175 4. Remove the drain plugs and allow the oil to drain Testing Oil Pressure completely. Remove the strainer from the oil reser- voir to allow the oil to drain completely. (1100 cc) 5. Install the oil strainer, drain plugs, and new washers and tighten to 15 ft-lb.
Page 176 5. After verifying oil pressure, remove the adapter and Liquid Cooling System gauge from the engine, install the sensor, and tighten to 120 in.-lb. Start the engine and check for oil leaks. (500/800 cc)  NOTE: Before installing the sensor, it may be neces- sary to apply thread sealant or teflon tape to the sen- The liquid cooling system consists of heat exchangers, sor threads.
Page 177 5. Check the coolant level. Add coolant as required to the coolant tank (coolant tank should be filled to coolant level line). Repeat procedure until coolant level stabilizes in the coolant tank. CAUTION The cooling system must be properly filled. If the sys- tem isn’t properly filled, piston damage will occur.
Page 178 SNO-728A 744-032A 4. Apply 5-8 psi to the coolant system through the cool- 6. Start the engine and allow it to run for five minutes. ant overflow tube and continue until the coolant 7. With the engine cool, loosen the bleed screw and stops draining from the system.
Page 179 Cooling System Schematics The following schematics are representative of the differ- ent styles of cooling systems in the Arctic Cat snowmo- biles. Some components may vary from model to model; therefore, the technician should use discretion and sound judgment when servicing a particular cooling system.
Page 180 F5 LXR 0742-314 800 cc 0746-520 3-18...
Page 181 Recoil Starter (500 cc) ! WARNING Care must be taken when lifting the roller free of the case. 7. Remove the main spring (H) from the case by lifting the spring end up and out. Hold the remainder of the spring with thumbs and alternately release each thumb to allow the spring to gradually release from the case.
Page 182 8. Place the friction spring into position on the friction 800 cc plate making sure the head of the spring is opposite the flat of the inner hole. Apply a low-temperature grease to the plate. 9. Place the plate into position making sure the flat of the inner hole is correctly positioned in the hub.
Page 183 9. Apply a low-temperature grease to the friction plate. Place the pawl activator into position on the friction ! WARNING plate making sure the arms of the activator are prop- Care must be taken when lifting the roller free of the erly positioned to the pawl.
Page 184 Air Silencer (F5 LXR) REMOVING 1. Remove the hood and the left-side and right-side access panels; then remove the torx-head screws securing the console. 742-207A  NOTE: The right-side rear spar panel will remain secured to the chassis. 7. Remove the cap screw located directly above the ECU securing the air-silencer duct to the front upper panel;...
Page 185 2. Place the front bumper assembly (with spar panels) into 7. Install the seat; then install the machine screw position on the snowmobile; then secure the front and (threads coated with blue Loctite #243) to the right rear spar panels together with the torx-head cap screws side of the seat support.
Page 186 741-744A ZJ010A 2. Remove the torx-head cap screws securing the upper 7. Disconnect the fuel pump four-wire connector; then front/rear panels (C) and the handlebar close-off slide the gas tank rearward enough to gain access to panel (B) along with the body screws securing the the gasline hose connector.
Page 187: Fuel Systems
ZJ013A ZJ125 10. Remove the breather hose from the air silencer. 13. Remove the air temperature sensor from the air silencer. ZJ096B 11. Move the air silencer far enough to the right to ZJ126A bypass the air silencer mounting bracket; then slide 14.
Page 188  NOTE: Install the air silencer at an angle positioning it to the PTO-side throttle body first and tightening its clamp; then working it back and forth and with an angle tool, slide the mag-side air silencer boot onto the throttle body and tighten its clamp. Once in place and secured, carefully inspect that the boots are properly seated to the throttle bodies.
Page 189 3. Loosen both clamps securing the air silencer to the throttle bodies; then remove the air silencer assembly. 4. Install the air silencer assembly and secure to the throt- tle bodies using the clamps. 5. Install the gas tank (see Section 4) and seat (see Sec- tion 8).
Page 190 4. Remove the intercooler, air bypass valve, and air CAUTION duct as an assembly by removing the intercooler from the four mounting brackets. Do not carry the turbocharger by the hoses or by the waste gate control rod. Damage could occur. 5.
Page 191 PC230A PC234A  NOTE: If the oil hose has to be removed from the engine, note the banjo bolt securing the hose to the turbocharger has the smaller feed holes. 11. Remove the lock nuts and washers securing the exhaust manifold to the cylinder head; then carefully remove the turbocharger and exhaust manifold assembly.
Page 192 2. Install the mounting bracket to the turbo; then with 8. Using a crisscross pattern, tighten the lock nuts the backing plate properly positioned as shown, (from step 3) securing the turbocharger to the secure the bracket to the turbocharger with the lock exhaust manifold to 30 ft-lb.
Page 193 SNO-232A SNO-231A 12. Install the inlet boot and the inlet hose and secure 17. Connect the oxygen sensor; then install the cap using the existing clamps. screws, nuts, new gasket, and spring securing the resonator to the chassis. SNO-232A 13. Secure the front left-side facia to the chassis using the existing torx-head screws.
Page 194 CAUTION Do not run a turbocharged engine with the intake hose removed from the compressor inlet. Dirt, foreign objects, or loose clothing can be ingested causing tur- bocharger failure and engine damage. CAUTION Do not spin the turbocharger with compressed air as bearings will be damaged.
Page 195 TZ086B 10. Remove the banjo bolt with two crush washers securing the top oil feed pipe to the turbo. Discard the two washers. 743-780C 13. Remove the lock nuts and washers securing the exhaust manifold to the engine cylinder head; then carefully remove the turbocharger and exhaust mani- fold assembly.
Page 196 TZ091A TZ093A 16. Remove the four lock nuts securing the turbocharger 2. Inspect the waste gate linkage for signs of wear or to the exhaust manifold. Account for the gasket and damage. flat washers. INSTALLING 1. With the turbocharger secured in a suitable vise and the gasket in place, secure the turbocharger outlet to the turbocharger with the washers and lock nuts.
Page 197 5. With the gaskets in place, install the exhaust mani- fold and turbocharger assembly to the engine; then using the pattern shown, tighten the exhaust mani- fold to 19 ft-lb. 743-991A 9. With the turbocharger secured, connect the top oil feed pipe with the banjo bolt and two new crush washers.
Page 198 TZ060A 743-983B 13. Connect the air bypass hose and the air bypass control 16. Position the intercooler into the grommets of the valve hose to the intake pipe and secure with the clamps. mounting bracket; then connect the intercooler hoses to the turbocharger and to the intake plenum.
Page 199 Exhaust Valve Cables The exhaust valves are connected to the actuating cables and, along with the return springs, are contained inside the APV housing on the exhaust side of each cylinder. The other end of the actuating cable is connected to the servo- motor.
Page 200 E. Voltage Regulator/Rectifier. 4. While holding the cable housing, lightly pull on one cable end to remove any slack; then measure the  NOTE: For testing individual APV system compo- amount of exposed cable from the cable housing to the end of the cable. nents, see Section 5.
Page 201 REMOVING/DISASSEMBLING Replacing Oil Seal  NOTE: To avoid a parts mix-up, only remove one 1. Carefully pry the seal up from beneath taking care not to damage the valve plate. valve assembly at a time from the engine. 1. Remove the exhaust valve assembly from the engine. FC116 2.
Page 202 FC114 CM147  NOTE: Make sure that the small cable end spring stays in place at the end of the cable. 2. With the cover gasket properly positioned, place the valve stopper on the cable end and slide it down until the cable end is inside the stopper.
Page 203 The fail-safe mode is an ECU operated engine RPM lim-  NOTE: The 800 cc has a three-stage exhaust valve iter. When activated, the fail-safe mode will be seen as an system. The stages are closed, mid-open, and full- immediate loss of engine horsepower.. open.
Page 204 NOTES 3-42...
Page 205 SECTION 4 — FUEL SYSTEMS TABLE OF CONTENTS Fuel Systems..............4-2 Fuel System (Carbureted) ..........4-2 Changing Main Jets ............4-2 Carburetor..............4-3 Throttle Cable ..............4-10 Choke Cable ..............4-11 Fuel Pump ..............4-11 Troubleshooting............4-12 Fuel System (EFI) ............4-13 Individual Components ..........4-13 Self-Diagnostic System/Codes ........4-16 Fuel Pressure Regulator..........4-17 Throttle Body Assembly ..........4-17 Throttle Cable ..............4-22 Fuel Filter (1100 cc) .............4-22...
Page 206 Fuel Systems This section has been organized for servicing the fuel systems; however, some components may vary from model to model. The technician should use discretion and sound judgment when removing/disassembling and assembling/installing components. Whenever any maintenance or inspection is made on the fuel system where fuel leakage may occur, there should be no welding, smoking, or open flames in the area.
Page 207 0728-054 TZ104A 5. Install and secure each carburetor. 4. Loosen the carburetor-flange clamp; then remove the carburetor. Carburetor REMOVING 1. Remove the hood and left-side access panel; then remove the torx-head screws securing the console. TZ102A  NOTE: Slide the carburetor into the air silencer boot until free of the flange;...
Page 208  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 float towers; then remove the floats. Remove the drain screw and O-ring. CM047 DISASSEMBLING VM-34 B344...
Page 209 9. Remove the Phillips-head screw securing the throttle cable retainer to the piston valve; then remove the retainer. Account for the jet needle with E-clip and washer. AH084 6. Remove the pilot jet. AH074A CM052 7. While counting the rotations for installing purposes, rotate the pilot air screw clockwise until lightly seated;...
Page 210 4. Dry all components with compressed air only mak- 2. Install the pilot air screw and spring. Rotate clock- ing sure all holes, orifices, and channels are unob- wise until lightly seated; then turn counterclockwise structed. the same number of turns as noted in disassembling for an initial setting.
Page 211 CM051 B344 6. Place the float arm into position and secure with the 9. Place the gasket and float chamber into position and pin. secure with the four screws and lock washers making sure the hose plates are properly positioned on the two front screws.
Page 212: Electrical Systems
AH075 TZ102A  NOTE: The round part of the cable end must come  NOTE: Slide the carburetor into the air silencer through the hole in the plate/piston valve. If it boot; then slide the carburetor into the flange. doesn’t, the cable isn’t assembled to the piston valve CAUTION correctly.
Page 213 6. Install the air silencer boots making sure they are properly seated to the carburetor. Synchronizing Piston Valves  NOTE: Arctic Cat recommends using a suitable car- buretor synchronizer. If a carburetor synchronizer is 0732-848 not available, use the following procedure.
Page 214  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.
Page 215: Fuel Pump
INSTALLING 1. Route the throttle cable from the throttle switch assembly to the carburetors and oil-injection pump; avoid any sharp bends or moving parts. 2. Install the oil-injection adjustment cable on the oil- injection pump; secure with the jam nuts. 3.
Page 216 TESTING VACUUM 2. With snowmobile on a safety stand, start the engine and accelerate to 2000-3000 RPM for a period of 30  NOTE: Make sure adequate fuel is in the carburetor seconds. Note maximum reading of gauge. Reading for this test. must be 7-10 in.-hg.
Page 217 INTRODUCTION and applying it to the ECU Diagnostic Codes chart (see The Arctic Cat EFI System operates off a series of coils Self-Diagnostic System/Codes in this section). located on the stator and is made up of the following ...
Page 218: Fuel Injectors
THROTTLE POSITION SENSOR 3. Remove the two torx-head screws securing the ECU to the mounting bracket. This sensor is a potentiometer (essentially, a resistor). This sensor transforms the throttle-valve position into Installing (F/M/XF 1100 cc) output voltage to the ECU. In addition, the sensor detects 1.
Page 219 FUEL PRESSURE REGULATOR 800 cc The fuel pressure regulator maintains the fuel pressure at a constant specified level. The turbo models maintain pressure from the manifold pressure. EXHAUST AIR TEMPERATURE (EAT) SENSOR This platinum, thin-film sensor detects the exhaust air temperature in the exhaust system.
Page 220 The ECU uses the MAP sensor for many other calculations, Standard but the base fuel map is the main one. Gauge WASTEGATE CONTROL VALVE (1100 cc Turbo) The wastegate control valve adjusts the wastegate position based on input from the ECU. The wastegate does not require any input from the ECU to operate at base boost levels.
Page 221 INSTALLING (500/800 cc) The fuel system and the ignition system remain two sepa- rate systems. In a no-start situation, first determine if the 1. Attach the throttle cable to the throttle body; then problem is caused by lack of spark or by a fuel delivery secure with jam nut.
Page 222 ZJ018A ZJ290  NOTE: For assembling purposes, note from which side the fuel injectors were removed. ASSEMBLING/INSTALLING (1100 cc Non-Turbo) 1. Install the fuel injectors onto the throttle body assem- bly; then secure the fuel rail and injectors to the throttle body assembly with the two screws and the retaining clips.
Page 223 ZJ103A TZ108A 6. Remove the harness connector from the throttle posi-  NOTE: To finalize this procedure, install the air tion sensor (A); then place a towel under the throttle silencer (see Section 3). On the F/M/XF, install the gas body coolant hoses (B) and with a suitable clamping tank and seat.
Page 224 TZ109A TZ111A 9. Remove the four screws securing the ISC valve to  NOTE: After removing the fuel rail, account for the the throttle body. four injector gaskets. 13. Remove the four harness connectors from the injec- tors; then carefully remove the injectors from the fuel rail.
Page 225 2. Install the injectors into the fuel rail; then install the four harness connectors to the injectors and connect the injector harness to the main harness connector. TZ110A 5. With a new throttle body gasket, secure the throttle body with the cable support bracket to the intake ple- TZ116A num with the four caps screws;...
Page 226 5. Remove the throttle cable ends from the throttle lever and from the throttle control housing. INSTALLING/ADJUSTING 1. Install the throttle cable into the throttle control assembly making sure the cable snaps into place. 2. Install the throttle cable end on the throttle lever. 3.
Page 227  NOTE: Before removing the fuel filter, take note of the filter inlet and outlet for installing purposes. REMOVING (F/M/XF) 1. Remove both access panels, hood, seat, and gas tank to access the fuel filter. ZJ135B SNO-699A TZ118A 2. Remove the hose clamps and discard; then slowly remove the gasline hoses from the fuel filter.
Page 228 WARNING 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 gas- oline; then remove the hose slowly to release the pres- sure. Always wear safety glasses when removing the fuel hoses.
Page 229 SNO-791 SNO-704 4. Make sure the front pickup will sit flat on the bottom 2. Carefully push the fuel pump assembly down and of the tank with no kinks in the fuel hose. back into the fuel tank until the white fuel sensor (below the fuel pump) is flush with the fuel pump mounting surface.
Page 230  NOTE: If the fuel pump still fails to operate, the WARNING pump is defective and must be replaced. Since the fuel supply hose may be under pressure, remove REMOVING it slowly to release the pressure. Place an absorbent 1. Using a gasline hose equipped with a one-way check towel around the connection to absorb gasoline;...
Page 231 3. Position the oil-injection pump on the engine making Oil-Injection Pump sure the oil-injection pump gear is correctly aligned with the oil-injection pump drive gear. 4. Secure the pump with two screws (coated with blue CAUTION Loctite #243). Tighten screws to 48 in.-lb (570 cc) or to 96 in.-lb (500/800 cc).
Page 232 Oil Injection Usage Tool, fill the If an engine problem occurs due to lack of lubrication, hose with Arctic Cat Synthetic APV 2-Cycle Oil. the check valves should be tested using a vacuum pump to make sure they are operating properly.
Page 233: Gas Tank
1. Remove the check valves from the oil-injection pump. 2. Attach the Vacuum Test Pump hose to the check valve. 3. Squeeze the vacuum pump handle and watch the pump gauge. The check valve should release at 4.5-5 lb and again reset itself at 3.5-4 lb. If “release” and “reset”...
Page 234 INSTALLING (Bearcat/F-Series/T- Series) 1. Install the gasline hose onto the tank and press down on the connector until it snaps into place; then install the vent hose to the outlet and secure with the hose clamp. ZJ010A 4. Disconnect the fuel pump four-wire connector; then slide the gas tank rearward enough to gain access to the gasline hose connector.
Page 235 SECTION 5 — ELECTRICAL SYSTEMS TABLE OF CONTENTS Electrical Systems .............5-2 Ignition System..............5-2 Throttle Position Sensor ............5-4 Electrical Resistance Tests..........5-7 Voltage Regulator/CCU Tests..........5-10 Chassis Control Unit (CCU)/Codes (F5 LXR) ....5-11 Testing Oil Level Sensor (2-Stroke) .........5-11 Testing Fuel Gauge Sender..........5-12 Emergency Stop Switch ..........5-12 Starter Relay Solenoid ............5-12 Fuse ................5-13...
Page 236: Ignition System
2. Crank the engine over and check for spark. If no spark is present, check to make sure the throttle cable Description is properly tensioned. Compress the throttle control Arctic Cat Diagnostic System Manual 2256-974 and while holding the throttle control in this position, Laptop Diagnostic Tool 0744-048 crank the engine over and check for spark.
Page 237 3. Move the throttle lever to the wide open position. The 1. Inspect the cable free-play gap between the throttle meter must read OL (infinite resistance). If the meter lever and the control housing at idle. Adjust the reads less than 1000 ohms, replace the control assem- throttle cable swivel adapter at the top of each carbu- bly.
Page 238 VERIFYING TPS ADJUSTMENT TOOL 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.
Page 239 8. If the TPS is within the prescribed specification, dis- ANALYZER TOOL connect the adjustment tool harness from the TPS. Engine TPS TOOL (DC VOLTS) (DC VOLTS) Connect the snowmobile TPS harness to the TPS. 500 cc Full-Closed 0.412-0.414  NOTE: Before installing the TPS harness connector, Idle 0.710-0.818 0.710-0.818...
Page 240 Removing 3. Install the sensor to the throttle body. Do not tighten at this time.  NOTE: On the F/M/XF non-turbo, remove the hood, 4. Adjust the TPS (see appropriate Adjusting TPS in seat (see Section 8), and gas tank (see Section 4). On this sub-section).
Page 241  NOTE: On the F/M/XF non-turbo, install the gas tank 2. Resistance must be 15.2-22.8 ohms. (see Section 4), seat (see Section 8), and hood. On Lighting Coil the F/M/XF turbo, install the lower console, upper 1. Disconnect the three wire connector from the mag- console, and hood.
Page 242 Ignition Coil (Primary) 3. If not within specifications, replace the injector. 1. Disconnect the double wire plug from the CDI unit Coolant Temperature Sensor to the ignition coil. 1. Disconnect the coolant temperature sensor wiring harness from the main harness. 2.
Page 243: Exhaust Temperature Sensor
Fuel Injector 1. Test between the two orange wires in the four-prong connector from the magneto. 1. Disconnect the fuel injector wiring harness; then set the meter to the OHMS position. 2. Resistance must be 1.52-2.28 ohms. Injection Coil 2. Test between the two injector terminals. Resistance must be 10-14 ohms.
Page 244 Crankshaft Position Sensor Voltage Regulator/CCU 1. Disconnect the sensor. Tests 2. Connect the red meter lead to the blue/white wire; then connect the black meter lead to the green/white wire.  NOTE: The following test should be made using MaxiClips and the Fluke Model 77 Multimeter set to 3.
Page 245: Testing Oil Level Sensor
Accessing CCU Codes 5. Test between the three yellow wires for a total of three tests. 1. Connect the appropriate harness from CCU Diagnos- tic Test Kit to the diagnostic port. 6. With the engine running at 2500-3000 RPM, all wire tests must be within 36-44 volts.
Page 246: Testing Fuel Gauge Sender
Emergency Stop Switch RESISTANCE 1. Remove the four torx-head cap screws securing the front/rear throttle control housing assembly to the handlebar. 2. Set the selector to the OHMS position. 3. Connect one tester lead to one pin; then connect the other tester lead to the other pin.
Page 247 Method #2 1. Using the multimeter set to the DC Voltage posi- tion, check the relay as follows. 2. Connect the red tester lead to the positive battery terminal; then connect the black tester lead to the starter cable connection on the starter relay. The meter must show battery voltage.
Page 248 ASSEMBLING PINION 3. Remove the positive lead from the starter motor; then remove the two cap screws securing the MAG- 1. Slide the pinion gear, spring retainer, pinion spring, side starter motor bracket to the engine. Remove the and snap-ring retainer (note end-for-end orientation) bracket and starter motor and account for the rubber onto the shaft in their original positions.
Page 249 INSTALLING (500 cc) 1. Install the starter motor to the lower starter mounting bracket and secure with new lock nuts. Tighten securely. 2. Place the upper starter motor bracket and washer on the starter motor; then install the starter motor cables to the starter motor.
Page 250 7. Inspect the brass commutator end of the armature for any discolored spots or damage. If the commutator is slightly discolored or damaged, the armature must be replaced. This is a molded commutator and no attempt to turn it down in a lathe should be attempted.
Page 251 0725-653 ZJ145 12. Inspect the ground brushes to make sure they are  NOTE: After completing step 2, ensure that the properly grounded. Use a multimeter and the follow- brushes are properly seated to the commutator. ing procedure. 3. Noting the alignment marks made in disassembling, A.
Page 252 5. Install the two long cap screws securing the starter motor together; then tighten the cap screws to 108 Troubleshooting Electric in.-lb. Start Problem: Hot or Smoking Wires Condition Remedy 1. System wired incor- 1. Check wiring against wir- rectly ing diagram Problem: Starter Does Not Turn Over Condition...
Page 253 4. Remove the three cap screws securing the oil tank to the chassis; then remove the clamps securing the oil return and oil supply hoses from the magneto cover. Disconnect the hoses (along with the breather hose located at the top of the tank) and remove the oil tank.
Page 254 ZJ148A ZJ151A 2. With the two dowel pins installed in the engine case, 4. Install the coolant hoses to the water pump, oil install the torque limiter (A) and spacer (B); then cooler, and separator tank; then secure the hoses with install the inner spacer (C), idler gear (D), and outer the clamps.
Page 255: Brakelight Switch
5. Using a small flat-blade screwdriver, compress the tabs of the switch; then push the switch toward the end of the handlebar and out of the control assembly. SNO-728 8. Install the resonator and secure using existing hard- ware.  NOTE: At this point, fill and bleed the oil and cool- CM108A ing systems (see Section 3).
Page 256 Testing Thumb Warmer Element  NOTE: Resistance will vary due to temperature; therefore, this test should be made at room tempera- ture of 20° C (68° F). 1. Remove the handlebar pad (if applicable); then dis- connect the thumb warmer three-wire connector. 2.
Page 257 5. With the thumb warmer toggle in the high position, 3. For the HI position, connect one ohmmeter lead to the connect one ohmmeter lead to pin (C) and the other green/blue wire from the element; then connect the ohmmeter lead to pin (A). The meter must read 1 other ohmmeter lead to the green wire from the ele- ohm or less resistance.
Page 258: Testing Shift Switch
Testing Speedometer Testing Gear Position Sensor Switch  NOTE: The following test should be made using 1. On the Bearcat/F-Series/T-Series, remove the six torx-head cap screws securing the left-side footrest to MaxiClips and the Fluke Model 77 Multimeter set to the chassis and remove the footrest;...
Page 259 4. Reverse the connections on the servo terminals: pos- Testing Shift Actuator itive lead to black/red and negative lead to red/black. The servomotor should rotate in the opposite direc- (500/1100 cc) tion. 5. Install the servomotor.  NOTE: On the Bearcat/F-Series/T-Series, the actua- ...
Page 260: Troubleshooting Servomotor
Troubleshooting Servomotor SERVO1A12 5-26...
Page 261 SERVO2rv 5-27...
Page 262 Voltage/Resistance Chart Voltage/Resistance Chart - Air Temperature - Coolant Temperature Temperature Volts Ohms Temperature Volts Ohms Temperature Volts Ohms Temperature Volts Ohms 100° C 212° F 0.113 28° C 82° F 1.230 8540 110° C 230° F 0.115 28° C 82°...
Page 263 NOTE: All magneto diagrams on p. 1, passenger seat harness on p. 22, and miscellaneous Groomer Special harnesses on p. 29. ©Arctic Cat Inc., 2011, Thief River Falls, MN 56701 ®™Trademarks of Arctic Cat Inc., P.O Box 810, Thief River Falls, MN 56701...
Page 264 Magneto 0746-255...
Page 265 Main Harness (p/n 1686-600) F570 (p/n 1686-601) Bearcat 570/T570 (p/n 1686-612) Bearcat 570 XT 0746-237...
Page 266 Main Harness (p/n 1686-603) F5 LXR 0746-249...
Page 267 Main Harness (p/n 1686-624) F 1100 Sno Pro M 1100/Sno Pro XF 1100 Sno Pro (p/n 1686-625) F 1100 LXR/LTD/Ann. M 1100 Sno Pro LTD/Ann. XF 1100 LXR/LTD/Ann. 0746-248...
Page 268 Main Harness (p/n 1686-621) F 1100 Turbo LXR/ Sno Pro LTD/Ann. M 1100 Turbo Sno Pro LTD/Ann. XF 1100 Turbo LXR XF 1100 Turbo Sno Pro LTD/Ann. (p/n 1686-623) F 1100 Turbo Sno Pro M 1100 Turbo Sno Pro HCR M 1100 Turbo 153/Sno Pro 162 XF 1100 Turbo High Country XF 1100 Turbo Sno Pro...
Page 269 Main Harness (p/n 1686-588) F 800 M 800 XF 800 0746-242...
Page 270 Main Harness (p/n 1686-611) TZ1 Turbo LXR LTD 0746-253...
Page 271 Main Harness (p/n 1686-610) TZ1 LXR 0746-252...
Page 272 Main Harness (p/n 1686-613) Bearcat Z1 XT/GS (p/n 1686-615) Bearcat Z1 XT LTD 0746-511...
Page 273 Main Harness (p/n 1686-578) Sno Pro 120 0744-204...
Page 274 Ignition/Main Harness (p/n 1686-628) Sno Pro 500 0745-605...
Page 275 Ignition/Main Harness (p/n 1686-657) Sno Pro 600 0746-250...
Page 276 Console Harness (p/n 1686-631) TZ1 LXR TZ1 Turbo LXR LTD 0745-601...
Page 277 Hood Harness (p/n 1686-638) F 800 M 800 XF 800 0746-243...
Page 278 Console Harness (p/n 1686-633) Bearcat 570 F570 T570 0746-238...
Page 279 Console Harness (p/n 1686-634) F5 LXR 0746-240...
Page 280 Hood Harness (p/n 1686-639) F 1100/Turbo M 1100/Turbo/HCR XF 1100/Turbo 0746-246...
Page 281 Hood Harness (p/n 1686-658) Sno Pro 600 Cross Country (p/n 1686-664) Sno Pro 600 Sno Cross 0746-251...
Page 282 Console Harness (p/n 1686-547) Bearcat Z1 XT/GS (p/n 1686-549) Bearcat Z1 XT LTD 0746-254...
Page 283 Hood Harness (p/n 1686-587) Sno Pro 500 0744-201...
Page 284 Handlebar Harness (p/n 1686-652) TZ1/LXR/Turbo LXR LTD (p/n 1686-653) Bearcat Z1 XT/GS/LTD 0746-513...
Page 285 Passenger Seat Harness (p/n 1686-570) 0744-197...
Page 286 Handlebar Harness (p/n 1686-636) F 800 M 800 XF 800 (p/n 1686-654) M 800 HCR 0746-244...
Page 287 Handlebar Harness (p/n 1686-537) Bearcat 570 F570 T570 0746-239...
Page 288 Handlebar Harness (p/n 1686-574) F5 LXR 0744-189...
Page 289 Handlebar Harness (p/n 1686-637) F 1100/Turbo M 1100/Turbo XF 1100/Turbo 0746-247...
Page 290 Handlebar Harness (p/n 1686-590) Sno Pro 500 0744-200...
Page 291 Handlebar Harness (p/n 1686-656) M 1100 Turbo Sno Pro HCR 0746-510...
Page 292 Misc. Groomer Special (p/n 1686-645) (p/n 1686-646) (p/n 1686-647) (p/n 1686-648) 0746-241...
Page 293: Drive Train/Track/Brake Systems
SECTION 6 — DRIVE TRAIN/TRACK/ BRAKE SYSTEMS TABLE OF CONTENTS Drive Train/Track/Brake Systems........6-2 Drive Belt ................6-2 Drive Clutch ...............6-3 Driven Pulley (Bearcat/F-Series/T-Series)......6-4 Driven Pulley (F/M/XF) ............6-9 Drive Clutch/Driven Pulley..........6-12 Drive Train (Bearcat/F-Series/T-Series)......6-13 Drive Train (F/M/XF 800) ..........6-25 Drive Train (F/M/XF 1100) ..........6-29 Drive Sprockets ...............6-37 Track Tension..............6-40 Track Alignment ...............6-41...
Page 294: Rear Suspension
 NOTE: A stiff belt causes a HP loss to the track. As Drive Train/Track/Brake a belt warms up, it gets more flexible and transmits Systems power with less HP loss.  NOTE: When installing a new drive belt, see After Break-In Checkup - Drive Belt Break-In in Section 1.
Page 295: Drive Clutch
1. Loosen the machine screws securing the cover. Remove every other cap screw and lock washer from ! WARNING the cover; then while firmly holding the cover, Never operate the snowmobile without the belt guard/ remove the three remaining screws and lock washers equally.
Page 296 Cleaning And Inspecting 1. Using parts-cleaning solvent, wash grease, dirt, and foreign matter off all components; dry with com- pressed air. ! WARNING Always wear safety glasses when using compressed air to dry components. 2. Remove any drive belt dust accumulation from the stationary sheave, movable sheave, and bushings using parts-cleaning solvent only.
Page 297 2. Using a 9/16-in. socket and extension, remove the 4. Release the compression of the spring by removing cap screw securing the driven pulley to the input the wing nut; then remove the movable sheave. shaft. Account for the torque bracket retainer. 3.
Page 298 CM064 FS122 CLEANING AND INSPECTING 1. Using parts-cleaning solvent, wash grease, drive belt dust, and foreign matter off all components. CAUTION Do not use steel wool or a wire brush to clean driven pul- ley components. A wire brush or steel wool will cause the sheaves to be gouged (thus, the drive belt may not slide properly between sheaves).
Page 299 4. Tap the spring pin back into place. CM065 CAUTION CM068A Care must be taken not to damage the driven pulley shaft. ASSEMBLING  NOTE: Once the roller pin is exposed, it may be nec- 1. Place the torque bracket onto the Driven Pulley essary to use a pair of vise-grips to remove the pin.
Page 300 CM062 CM069 3. Place the spacer (retainer) into position on the sta- 6. Install the torx-head cap screws securing the movable tionary sheave with the holes properly aligned. sheave. Tighten in a crisscross pattern to 72 in.-lb. FS094 CM061 4. Noting the alignment marks made during disassem- 7.
Page 301 Driven Pulley (F/M/XF) REMOVING 1. With the engine off, remove the drive belt (see Drive Belt in this section). 2. Slide the driven pulley off the shaft.  NOTE: Account for in any alignment washers. These washers must be in place during installation. DISASSEMBLING PC127 1.
Page 302 CLEANING AND INSPECTING 1. Using parts-cleaning solvent, wash grease, drive belt dust, and foreign matter off all components. 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).
Page 303 PC120 PC124  NOTE: Premature wear will result if the spring seat is not installed. 2. Place the stationary sheave spring seat onto the spring (flat side toward the spring); then noting the alignment marks made during disassembling, place the stationary sheave onto the torque bracket. PC121 ASSEMBLING 1.
Page 304 4. With the bar against the outside edge of the driven pulley stationary sheave at points A and B, the bar should just clear the inside edge of the stationary sheave of the drive clutch and rest on the stationary shaft at point C.
Page 305: Drive Belt Deflection
DRIVE BELT DEFLECTION Drive belt length, condition, and deflection are all impor- tant for peak performance. To check and adjust drive belt deflection, use the following procedure.  NOTE: Make sure the drive belt is sitting at the top of the driven pulley sheaves. 1.
Page 306 2. Engage the brake lever lock; then remove the cap screw securing the driven pulley to the input shaft. Remove the pulley from the shaft. 742-020A  NOTE: If the gear case is being removed, do not remove the 5/8-in. cap screw. If only the track drive- shaft is being removed, remove the cap screw and ZJ182A proceed to step 10.
Page 307  NOTE: If the gear case is difficult to remove, it may 15. With the gear case and skid frame removed, pull the driveshaft toward the gear case side of the tunnel be necessary to loosen the track tension. until it clears the brake caliper housing; then remove the driveshaft.
Page 308 ZJ214A ZJ237  NOTE: Prior to installing the driveshaft, ensure the  NOTE: After the retaining nut is tightened to specifi- driveshaft sleeves are centered to the inner bore of cations, peen the nut at the flat spot of the driveshaft. the brake caliper housing.
Page 309 10. Secure the gear case by installing the lock nuts; then using the pattern shown, evenly tighten all the nuts to 20 ft-lb. ZJ183A 14. Install the toe shield and toe hook bracket; then install the torx-head cap screws. Tighten securely. 742-195B 11.
Page 310 4. Remove the shift fork assembly; then remove the retaining ring securing the shift fork arm to the shaft and remove the arm. Account for the retaining rings, O-ring, and slider blocks. ZJ250A 18. Install the drive belt (see Drive Belt in this section). 19.
Page 311 7. Using a suitable bearing press and fixture, press the input shaft bearing out of the gear case cover. Account for a bearing and a seal. ZJ193 10. Remove the output gear assembly from the slider housing. ZJ191 ZJ194 MS331 11.
Page 312  NOTE: The output shaft bearing is a non-service- able component. If any damage or binding is noted, the output shaft assembly must be replaced. 7. Apply a light film of Arctic Cat Synthetic ACT Drive Fluid to the unsealed bearings prior to assem- bling.
Page 313 3. Using a suitable bearing press, install the bearing onto the ring gear. ZJ303A ZJ199 4. In order, install the thrust washer and then the thrust bearing onto the transfer gear shaft. ZJ304  NOTE: Always install the seal with the wide, raised edge of the seal facing against the seal surface of the gear case.
Page 314 6. Install the output gear assembly into the slider assembly until the inner bearing is properly seated. ZJ202 ZJ194 7. With the alignment notches of the slider and gear case properly positioned, install the slider/output gear assembly into the gear case. ZJ204 10.
Page 315 ZJ186A  NOTE: Make sure to install the slider blocks with 16. Pour 12 fl oz of Arctic Cat Synthetic ACT Drive the rounded end up and the raised edges facing to Fluid into the drain/fill hole; then install the plug.
Page 316 20. Pour the exact amount (see appropriate specification 7. When the lubricant has completely drained form the sheet) of Arctic Cat Synthetic ACT Gear Case Fluid gear case, tip the snowmobile back to the upright into the check/fill hole; then install the plug. Tighten position, remove the drain adapter, and install and to 12 ft-lb.
Page 317 Drive Train (F/M/XF 800) REMOVING CHAIN CASE/DRIVEN SHAFT/DRIVESHAFT/TRACK 1. Remove the left- and right-side panels, hood; then loosen the retaining pin securing the lower console to the skid panels and secure out of the way. 2. Remove the resonator; then remove the right-side footrest.
Page 318 PC251A PC148A 19. Pull the driveshaft out to the left; then drop out of tunnel right side first. PC164 14. With the socket on the ring nut, lightly tap the socket to disengage the adapter sleeve. PC14  NOTE: If the caliper does not remove from the drive- shaft easily, proceed to step 20.
Page 319 3. Clean all interior chain case surfaces and compo- nents in cleaning solvent and dry using compressed air. ! WARNING Always wear safety glasses when using compressed air. ASSEMBLING/INSTALLING CHAIN CASE/DRIVEN SHAFT/DRIVESHAFT/ TRACK If the driveshaft and driven shaft were not removed, pro- ceed to step 12.
Page 320 PC 150 PC182 5. Making sure the seal is correctly installed in the 9. Secure the PTO-side engine mounting plate to the outer brake caliper, install on the inner caliper and crankcase with four cap screws (coated with blue secure with two cap screws. Tighten to 25 ft-lb. Loctite #243).
Page 321 144 in.-lb. sprocket to the driven shaft with a spring washer and cap screw (coated with blue Loctite #243). Tighten 15. Fill the chain case with 12 oz of Arctic Cat Trans- to 25 ft-lb. mission Lube (p/n 4639-364).  NOTE: Make sure washer is cupped toward the 16.
Page 322 4. Disconnect the speed sensor connector (A), gear indicator switch connector (B), and reverse actuator connector (C). PC073A 9. Remove the reverse gear (A), reverse fork (B), reverse shift shaft (C), and the reverse shift arm (D) as an assembly. PC067A 5.
Page 323 PC242A PC086 10. Remove the retaining ring from the driveshaft; then  NOTE: If the driven shaft and driveshaft are going to remove the reverse chain and sprockets. Account for serviced, proceed to Cleaning and Inspecting Chain a thrust washer. Case.
Page 324 PC162B PC177 17. Lift and support the engine at the rear to allow the 19. Bend down the locking tab on the driven shaft chain engine mount to clear chassis. case bearing adapter sleeve assembly; then using the Socket (p/n 0644-516), loosen the adapter sleeve ...
Page 325 21. Remove the inner retaining ring; then from the left  NOTE: Place an absorbent towel under the caliper side, carefully remove the driven shaft assembly to absorb slight amount of brake fluid. Do not com- keeping the bearing 90° to the shaft. press the brake lever.
Page 326 ASSEMBLING/INSTALLING CHAIN CASE/DRIVEN SHAFT/DRIVESHAFT/ TRACK If the driveshaft and driven shaft were not removed, pro- ceed to step 16. 1. Install chain case assembly onto chassis and secure with six self-tapping screws and four machine screws with lock nuts. Tighten the self-tapping screws to 144 in.-lb.
Page 327 PC 150 PC177 5. Making sure the seal is correctly installed in the 9. Install the cap screws (using blue Loctite #243) outer brake caliper, install on the inner caliper and securing the PTO-side engine mount to the engine. secure with two cap screws. Tighten to 25 ft-lb. Tighten the upper cap screw to 40 ft-lb and the lower to 50 ft-lb.
Page 328  NOTE: Make sure there is approximately 4.5 mm gap between the retaining ring and the adapter sleeve. This ensures the driven shaft is installed cor- rectly. PC082A 18. Install a thrust washer on the idler shaft; then install the reverse sprockets and chain. PC247A ...
Page 329: Drive Sprockets
144 in.-lb.  NOTE: The drive sprockets must be removed from the gear case end of the driveshaft (Bearcat/F-Series/ 22. Fill the chain case with 12 oz of Arctic Cat Trans- T-Series) or the brake side (F/M/XF). mission Lube (p/n 4639-364).
Page 330 6. Inspect the brake disc for wear or cracks. 7. Inspect the track drive sprockets for wear or damage. INSTALLING  NOTE: The drive sprockets must be installed on the gear case end of the driveshaft (Bearcat/F-Series/T- Series) or the brake side (F/M/XF). MS357A 2.
Page 331 MS361A 740-043A 3. Slide the remaining sprocket onto the driveshaft 4. Using a calipers, measure distances between the making sure the timing arrow/lines (from removing) sprockets and from the sprockets to each end of the are aligned; then using the press/fixture, press the driveshaft for proper location (see appropriate illus- sprocket to the remaining alignment line.
Page 332: Track Tension
ADJUSTING (Bearcat/F-Series/T- Series) 1. If the measurement is not as specified, loosen the jam nuts of the adjusting bolts. 0746-508 M/XF 739-636B  NOTE: On the Bearcat XT, the rear axle cap screws must also be loosened. 0746-509 Track Tension CHECKING ! WARNING DO NOT attempt to check or adjust track tension with...
Page 333: Track Alignment
ADJUSTING (F/M/XF) CHECKING/ADJUSTING  NOTE: To ensure proper track tension adjustment, ! WARNING perform all adjustments on both sides of the snow- Make sure the ignition key is in the OFF position and mobile. the track is not rotating before checking or adjusting track alignment.
Page 334 ! WARNING If jam nuts are not locked, the adjusting bolts could loosen causing the track to ratchet, derail, or lock. 9. On the F/M/XF after proper track tension and align- ment are obtained, tighten the idler wheel axle cap screw to 34 ft-lb;...
Page 335 741-328D 739-269B 0745-817 2. If the brake fluid level is low, add Arctic Cat approved brake fluid until the fluid is at the recommended level. Install and secure the reservoir cover. DO NOT allow moisture to contaminate the brake system.
Page 336 CHECKING AND REPLACING BRAKE 1. With the handlebar in the highest position, remove the reservoir cover and fill the reservoir with PADS (Bearcat/F-Series/T-Series) approved brake fluid. 1. Remove the brake fluid reservoir cover; then remove most of the brake fluid from the reservoir. Replace the cover. CAUTION ...
Page 337 3. Remove the two torx-head cap screws securing the speedometer sensor mounting bracket to the caliper assembly; then disconnect the harness plug-in. Remove the sensor and bracket. ZJ224 5. Using a flat-blade tool, slowly and carefully push the piston into the caliper. 6.
Page 338 8. Disengage the brake lever lock and remove the hair- pin clip and pin securing the brake pads; then remove both pads.  NOTE: If servicing the brake disc only, remove the two remaining torx-head cap screws securing the cal- iper housings together;...
Page 339 13. Position a piece of wood between the pistons. Using low-pressure compressed air, blow into the caliper brake hose fitting to remove the brake pistons. ! WARNING Always wear safety glasses when using compressed air. ZJ230 ZJ228A  NOTE: Remove the two remaining torx-head cap screws securing the caliper halves.
Page 340 Assembling/Installing 3. Inspect the piston bore of the inner and outer brake calipers for gouges, cracks, pitting, scuffing, or cor- 1. Apply approved brake fluid to the new O-ring; then rosion. If any of these conditions exist, replace the install the O-ring into the groove of each caliper half. caliper.
Page 341 ZJ231A ZJ239A 5. Install the snap ring securing the inner bearing in the  NOTE: Always use a new O-ring and make sure the caliper housing. O-ring is properly seated in the outer brake housing. ZJ245 MS320A 6. Install the bearing spacer; then press a new outer 4.
Page 342 8. With the brake disc splines and driveshaft splines aligned, use a soft hammer and tap the caliper from side to side until the caliper is properly seated to the tunnel. 9. Install the Phillips-head cap screw and lock nut (B); then install the four lock nuts (A).
Page 343 13. Engage the brake lever lock; then using Brake Disc Socket Wrench, tighten the brake disc retaining nut (from step 10) to 120 ft-lb.  NOTE: The brake lever lock must be engaged for this procedure. PC195 2. Remove one brake pad and measure the thickness. MS323 ...
Page 344 CAUTION Brake fluid is highly corrosive. Do not spill brake fluid on any surface of the snowmobile. 4. Open the bleeder valve and compress the brake lever several times to drain the reservoir of fluid. 5. Remove the brake hose from the caliper. Use an absorbent towel to collect any remaining brake fluid.
Page 345 PC174 PC221A 10. Remove the two screws securing the caliper halves. Discard the seal. PC148A 8. If the bearing will be replaced, remove the retaining ring; then using a suitable press, remove the bearing PC219A from the housing. PC173 11. Remove the pistons (A) and O-rings (B); then dis- PC200 card the O-rings.
Page 346 Cleaning and Inspecting 1. Inspect the brake pistons for gouges, cracks, pitting, scuffing, or corrosion. If any of these conditions exist, replace the piston.  NOTE: The inner and outer caliper housings are not serviceable components. If either or both are defec- tive or damaged, the complete caliper assembly must be replaced.
Page 347 7. Install a new seal in the outer caliper fluid passage; Bearcat/F-Series/T-Series them install the outer caliper and secure with the cap screws. Tighten to 25 ft-lb. 739-269B F/M/XF PC173A 8. Install new brake pads in the caliper and secure with the retainer pin.
Page 348: Troubleshooting Track
 NOTE: The master cylinder is a non-serviceable F/M/XF component. If any wear or damage is detected, the master cylinder must be replaced. 3. Inspect the brake fluid hose for cracks, deterioration, and the condition of the fittings (threaded and com- pression).
Page 349: Brake System
Troubleshooting Hydraulic Brake System Problem: Caliper Leaks Condition Remedy 1. Caliper O-ring deteriorated — severed 1. Replace O-ring 2. Piston — O-ring damaged 2. Repair piston — replace piston — O-ring Problem: Lever Spongy — Bottoms Out Condition Remedy 1. Brake system air bubbles present 1.
Page 350 Troubleshooting Drive Clutch/Driven Pulley Problem: Midrange Shift-Up (Too Quickly - Lowers RPM) Condition Remedy 1. Drive clutch spring weak 1. Replace drive clutch spring 2. Driven pulley spring weak 2. Replace driven pulley spring 3. Driven pulley spring preload tension inadequate 3.
Page 351 SECTION 7 — SUSPENSION TABLE OF CONTENTS Suspension................7-2 Suspension Setup Basics..........7-2 Servicing Suspension (Bearcat XT) ........7-5 Servicing Suspension (F/M/XF)........7-25 Servicing Suspension (Bearcat 570/T-Series)....7-39 Servicing Suspension (F-Series)........7-57 Rebuilding/Recharging Fox Air Shocks ......7-74 Servicing Fox Zero Pro Shock Absorbers .......7-79 Pressurizing Rebuildable Shocks ........7-84...
Page 352 Suspension  NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is nec- essary. SPECIAL TOOLS A number of special tools must be available to the techni- cian when servicing the rear suspension. Description 0728-180 Shock Absorber Air Pump 2603-614 Under acceleration when the center of gravity is trans-...
Page 353 2. With stiffer springs, the front end will become more 3. To increase air pressure in the shock, pump until aggressive in the corners as more weight will be desired pressure is attained. transferred to the skis when decelerating. Also, more 4.
Page 354 FRONT ARM LIMITER STRAPS  NOTE: When making any changes to the front or rear suspension, the change should be made at both Under no circumstances should the front arm limiter ends to keep the suspension balanced. For example, strap be lengthened. If lengthened, it may cause shock installing stiffer springs in front may require install- absorber travel problems.
Page 355 End Caps Servicing Suspension (Bearcat XT) REMOVING This sub-section has been organized so each procedure 1. Remove the lock nut, washers, and cap screw secur- can be completed individually and efficiently. ing the end cap.  NOTE: Some components may vary from model to model.
Page 356 INSTALLING  NOTE: Use a file to remove any sharp edges on the lower portion of the rail. 1. 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 wood and a hammer, drive the wear strip forward into position.
Page 357 Idler Wheels/Mounting Blocks REMOVING Remove the cap screws and lock nuts securing the front outer idler wheel and mounting block. Account for the washer. MS006A D. Install the snap ring making sure the “sharp side” is directed away from the bearing. MS208 MS007A INSTALLING...
Page 358 MS208 SC025A Front Arm/Front Shock Absorber/Front Inner Idler Wheels REMOVING 1. With skid frame removed and the rear springs removed from the adjusting cams, remove the lower cap screws and lock nuts securing the limiter straps to the rail support. Account for flat washers. MS036A 4.
Page 359 6. Remove the outer spacers and idler wheels; then slide the axle out of the shock bracket. 7. Remove the cap screw and lock nut securing the shock absorber to the bracket. SC027 3. Place the idler wheel/shock bracket assembly into position on the skid frame making sure the axle is aligned with the hole in the slide rail.
Page 360 SC030 MS063 5. Secure the upper shock eyelet and serrated axle in 2. Mark the offset arm and the idler arm for assembly the mounting hole of the front arm. Secure with a cap purposes. Note the flared side of the upper bushing is screw and lock nut.
Page 361 MS064 MS069 4. Using the appropriate Idler Wheel Puller Kit, remove  NOTE: Use the same procedure for the other side. the wheel. CLEANING AND INSPECTING 1. Clean the bearing with a clean cloth. 2. Inspect each idler wheel and plastic hub for cracks or damage.
Page 362 MS068 MS064 5. Place the flared bushings with a thin flat washer  NOTE: Make sure the spring is located above the through the back side of the offset arm assembly. spring slide mounting cap screw.  NOTE: If the flared bushing in the offset arm is loose, it must be cleaned and green Loctite #609 must be applied to it prior to installation.
Page 363 3. Remove the cap screw and lock nut securing the upper shock links to the idler arm. Account for a lock nut, spacer, and axle links. MS074 2. Remove the cap screw and lock nut securing the upper shock eyelet to the idler arm. Account for a spacer, lock nut, and bushings.
Page 364 5. Remove the cap screw and lock nut securing the rear arm to the idler arm. Account for the aluminum axle and bushing assemblies. SC021A 3. Place a support beneath the rear arm; then tighten the cap screws (from step 1) to 40 ft-lb. SC022A CLEANING AND INSPECTING 1.
Page 365 5. Place the upper shock eyelet with bushings between the idler arm brackets making sure the spacer is properly positioned between the brackets. Secure with a cap screw and lock nut. Tighten securely. MS089A SC019A  NOTE: Do not over-tighten the shock absorber cap screw as the shock eyelet must be free to pivot.
Page 366 SC032 SC036 4. Tap the idler wheel/pivot assembly forward and up CLEANING AND INSPECTING until it clears the slide rails; then lift the assembly 1. Clean shock pivot and idler wheel axle in part-clean- upward and out from between the rails. ing solvent.
Page 367 MS096A SC032 2. Apply a thin coat of low-temperature grease to the 5. Position the shock links in the appropriate holes of axle and slide the axle and center spacer into the the idler arm brackets (as marked during disassem- shock pivot bracket.
Page 368 Slide Rails REMOVING  NOTE: When replacing one or both slide rails is neces- sary, remove one slide rail at a time. The remaining slide rail will then hold the rail supports, axles, and brackets in their correct assembly order. Always mark the mount- ing hole locations during disassembly to speed up the assembly process and to prevent any damage.
Page 369 8. Remove the cap screw and lock nut (A) securing the shock bracket/wheel assembly to the slide rail; then remove the lock nut and cap screw (B) securing the front arm to the slide rails. SC041A 11. Remove the cap screw and lock nut securing the rear arm shock pivot assembly to the slide rail.
Page 370  NOTE: At this point, the slide rail should be free of the skid frame components and can be removed.  NOTE: If the shock pad must be replaced, refer to Shock Pads at the beginning of this procedure. INSPECTING 1.
Page 371 MS122 SC046A 7. Install the overload spring tension block with a cap 10. Secure the end cap onto the slide rail using a cap screw and lock nut. Tighten securely. screw, flat washers, and a lock nut. Tighten to 80 in.-lb.
Page 372 13. Install the skid frame (see Installing Skid Frame in this sub-section); then install the rear arm springs onto the adjuster blocks. Articulating Skid Frame  NOTE: For the following procedure, refer to illustra- tion 744-166A on the following page. DISASSEMBLING 1.
Page 373 744-166A 4. Install the adjuster rods (D) into the swing arm; then Installing Skid Frame install the adjuster springs (F) and lock nuts (E). Tighten only until snug. 5. Slide the adjuster rod axle (C) into the adjuster rods; 1. Using an appropriate handlebar/steering post support then install the swing arm axle into the swing arm.
Page 374 5. Align the rear arm assembly with the appropriate hole in the tunnel. Secure the rear arm assembly with a cap screw. TIGHTEN ONLY UNTIL SNUG. 6. Tip the snowmobile onto the other side; then align the rear arm assembly with the appropriate hole in the tunnel.
Page 375 Servicing Suspension (F/M/XF) This sub-section has been organized so each procedure can be completed individually and efficiently.  NOTE: Some components may vary from model to model. Some illustrations and photographs used in this sub-section are used for clarity purposes only and are not designed to depict actual conditions.
Page 376 2. Remove the rear shock pads. INSPECTING 1. Inspect the pads for damage or wear. 2. Inspect the rivet holes in the slide rail for damage or elongation. INSTALLING 1. Place the pads brackets into position on the slide rail. 2.
Page 377  NOTE: If the idler wheel has no snap ring securing 2. Place the idler wheel to the mounting block; then secure the idler wheel assembly with a cap screw, the bearing, the idler wheel is not serviceable. flat washer, and a lock nut. Tighten to 20 ft-lb. A.
Page 378 INSPECTING 1. Inspect all front arm weldments for cracks or unusual bends; then inspect the front arm mounting brackets for cracks and for elongated holes. 2. Closely inspect all tubing for cracks or unusual bends. 3. Inspect the bearings, bushings, and front arm spacers for wear or damage.
Page 379 FZ037 FZ034 5. Remove the cap screw, flat washer, and lock nut 3. Loosen the cap screws and lock nuts securing the securing the spring slide to the slide rail. Account for offset arm assembly to the idler arm; then remove the the spring slide and all mounting hardware.
Page 380 FZ101A FZ103A 10. Remove the cap screw and lock nut securing the rear 2. Install the rear arm onto the idler arm with an alumi- arm to the slide rail. Account for the serrated axles num axle and two cap screws. Tighten to 40 ft-lb. and axle tube.
Page 381 FZ047 0742-877 9. Place the flared bushing with a thin flat washer 4. With the sleeves installed, install the shock absorber through the notched side of the offset arm assembly. link to the lower mounting hole of the idler arm along with the cap screw and lock nut;...
Page 382  NOTE: With the rear arm shock and shock link removed, account for the four sleeves. 4. Remove the cap screw and lock nut securing the rear arm to the idler arm. Account for the aluminum axle and flared bushings. XM001A XM006A ...
Page 383 ASSEMBLING 1. Place the rear arm assembly into position between the slide rails. Secure with existing cap screws. Tighten to 20 ft-lb. XM003A 5. Install the inner carriage axle to the idler arm; then install a wave washer and idler wheel. Secure with the snap ring.
Page 384 ASSEMBLING REAR AXLE XM001A 8. Grease the idler arm and rear arm grease fittings with SNO-2239A an all-temperature grease. 1. If the rear idler wheels were separated, install both wheels onto the axle and secure using the existing Rear Axle/Idler Wheels cap screws (B) and nuts (A).
Page 385 2. Remove the end cap from the slide rail. Account for 7. On the F, remove the lock nut, cap screw, and flat a cap screw, lock nut, and two flat washers. washer securing the spring slide to the rail. Account for a spacer and the slide block.
Page 386 3. Secure the front arm to the slide rail with the cap screw. FZ103B 11. Remove the idler wheel cap screw; then remove the adjuster bushing. FZ107  NOTE: The adjusting bolt may have to be loosened  NOTE: At this point, return to steps 2 and 3 and to remove the adjuster bushing.
Page 387 7. On the F, place the spring into the spring slide; then place the spring slide and slide block assembly into position on the slide rail. Secure with a cap screw and washer. Tighten to 20 ft-lb. FZ096B  NOTE: Use a file to remove any sharp edges on the lower portion of the rail.
Page 388 2. Pull the track away from the tunnel and spread open; 6. Align the rear arm assembly with the appropriate then place the skid frame into the track. hole in the tunnel. Secure the rear arm assembly with a cap screw, lock washer, and flat washer. AT THIS 3.
Page 389 End Caps Servicing Suspension (Bearcat 570/T-Series) REMOVING This sub-section has been organized so each procedure 1. Remove the lock nut and cap screw securing the end can be completed individually and efficiently. cap.  NOTE: Some components may vary from model to model.
Page 390 INSTALLING  NOTE: Use a file to remove any sharp edges on the lower portion of the rail. 1. 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 wood and a hammer, drive the wear strip forward into position.
Page 391 INSTALLING 1. Secure the mounting block on the slide rail with a cap screw and lock nut. Tighten to 20 ft-lb.  NOTE: For proper alignment, install an idler wheel cap screw into the top mounting block hole prior to tightening.
Page 392 2. Remove the cap screw and lock nut securing the upper front shock absorber eyelet to the front arm. Pull the shock eyelet free of the bracket. Account for a sleeve. TZ029 ZJ271A 3. Remove the cap screw and lock nut securing the front arm to the slide rail.
Page 393 TZ031 TZ028A 3. On the side that the idler wheel and mounting block 6. Secure the upper shock eyelet and axle in the mount- were removed from, secure the mounting block on ing hole of the front arm. Secure with a cap screw the slide rail with a cap screw and lock nut.
Page 394 Rear Arm/Rear Shock Pivot Assembly REMOVING 1. With the skid frame removed using the Rear Suspension Spring Tool, remove the spring from the adjusting cam. ! WARNING Care must be taken when removing the spring or dam- age or injury could result. FZ036 4.
Page 395 TZ006A TZ010A TZ008 TZ011A 6. Remove the spring and sleeve from the idler arm.  NOTE: For assembling purposes, note the mount- ing location of the shock links to the idler arm. 8. Remove the cap screw and lock nut securing the rear shock pivot/idler wheel assembly to the slide rails;...
Page 396 CLEANING AND INSPECTING 1. 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 rear arm/idler arm for cracks or unusual bends.
Page 397 TZ017A TZ010B 4. Assemble the rear shock pivot idler wheel assembly  NOTE: Do not over-tighten the shock absorber cap with the axle (A), axle tube (B), axle spacers (C), and screw as the shock eyelet must be free to pivot. shim washers (if applicable).
Page 398 TZ008 MS072A 10. Install the idler spacer collar onto the idler arm.  NOTE: Install the rear arm springs onto the adjuster blocks after the skid frame has been installed. TZ023 11. Install the axle with a thin flat washer through the TZ021 back side of the flared bushing of the offset arm.
Page 399 TZ004C MS058A 13. Grease the idler arm and rear arm grease fittings with an all-temperature grease. Rear Axle and Slide Rail Idler Wheels DISASSEMBLING REAR AXLE 1. With the skid frame removed, remove the cap screw and large flat washer securing the outer rear idler wheel.
Page 400 5. Remove the cap screws and lock nuts securing the front outer idler wheel and the idler wheel mounting block. FZ026B 2. Remove the end cap from the slide rail. Account for a cap screw, lock nut, and two flat washers. TZ033A FZ079A 3.
Page 401 TZ036 TZ039A  NOTE: If not already done, remove the short spring  NOTE: If removing the cap screw is necessary to leg from the adjusting cam. replace the slide rail, install the cap screw from the opposite side into the assembly to secure the compo- 7.
Page 402 TZ042A TZ046A 12. Remove the cap screws from the rear arm limiter 14. Remove the lock nut from the cap screw securing the (A); then remove the cap screw and flat washer rear arm assembly to the slide rail. securing the rear idler wheel. Remove the idler wheel;...
Page 403 TZ049 TZ050  NOTE: If the shock pad must be replaced, refer to  NOTE: At this point, return to step 1 and tighten the Shock Pads at the beginning of this procedure. rear arm and front arm cap screws and lock nuts to 40 ft-lb;...
Page 404 6. Install the rear arm limiter and secure with the cap screw. Tighten the cap screw (coated with blue Loc- tite #243) to 50 ft-lb. TZ053A 10. Install the inner idler wheel mounting block and secure with cap screws and lock nuts. Tighten to 20 ft-lb.
Page 405 FZ077 TZ056 13. With the spacer on the front rail support centered 15. From the back, start the wear strip onto the rail; then between the limiter straps, secure the straps to the using a soft hammer, drive the wear strip forward rail support with the cap screw, washers, and lock into position.
Page 406 6. Tip the snowmobile onto the other side; then align the rear arm assembly with the appropriate hole in the tunnel. Secure the offset arm assembly with a cap screw, lock washer, and flat washer. TIGHTEN ONLY UNTIL SNUG.  NOTE: Do not install the short legs of the rear springs onto the adjusting cams at this time.
Page 407 Servicing Suspension End Caps (F-Series) REMOVING This sub-section has been organized so each procedure 1. Remove the lock nut and cap screw securing the end can be completed individually and efficiently. cap.  NOTE: Some components may vary from model to model.
Page 408 INSTALLING  NOTE: Use a file to remove any sharp edges on the lower portion of the rail. 1. 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 wood and a hammer, drive the wear strip forward into position.
Page 409 INSTALLING 1. Secure the mounting block on the slide rail with a cap screw and lock nut. Tighten to 20 ft-lb.  NOTE: For proper alignment, install an idler wheel cap screw into the top mounting block hole prior to tightening.
Page 410 2. Remove the cap screw and lock nut securing the upper front shock absorber eyelet to the front arm. Pull the shock eyelet free of the bracket. Account for a sleeve. FZ029A 7. Remove the cap screw and lock nut securing the idler wheel mounting block to the slide rail.
Page 411 3. Inspect the bearings, bushings, and front arm spacers for wear or damage. 4. Inspect the shock absorber for damage and 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 separation, or for unthread- ing.
Page 412 FZ049 FZ033A 7. Secure the upper shock eyelet and axle in the mount- 2. Mark the offset arm and the idler arm for assembly ing hole of the front arm. Secure with a cap screw purposes. and lock nut. Tighten securely. FZ034 ZJ271A 3.
Page 413 4. Remove the idler wheel using Idler Wheel Puller Kit.  NOTE: Use the same procedure for the other side. 7. Remove the cap screw (A) and lock nut securing the upper shock eyelet to the idler arm; then remove the cap screw (B) and lock nut securing the upper shock link to the idler arm.
Page 414 FZ042A FZ044 3. With the sleeves installed, install the shock absorber CLEANING AND INSPECTING link to the lower mounting hole of the rear shock 1. Clean the bearings with a clean cloth. pivot; then install the shock absorber with cap screws (A) and (B) and lock nuts.
Page 415 FZ045 FZ040C 7. With a suitable driving tool, install the rear upper  NOTE: Do not over-tighten the shock absorber cap idler wheel on the idler arm. screw as the shock eyelet must be free to pivot.  NOTE: Install the rear arm springs onto the adjuster blocks after the skid frame has been installed.
Page 416 Rear Axle/Idler Wheels DISASSEMBLING REAR AXLE 1. With the skid frame removed, remove the cap screw and large flat washer securing the outer rear idler wheel. Remove the outer idler wheel from the shaft. FZ047 9. Place the flared bushing with a thin flat washer through the notched side of the offset arm assembly.
Page 417 2. Place the plastic adjuster bushings on the axle (on the outside of each axle slot); then install the outer idler wheels on the axle and secure with two cap screws (coated with blue Loctite #243) and large flat wash- ers.
Page 418 5. Remove the cap screws and lock nuts securing the front outer idler wheel and the idler wheel mounting block. FZ059A  NOTE: If not already done, remove the short spring leg from the adjusting cam. FZ081A 8. Note the mounting location for installing purposes; then remove the cap screws and lock nuts securing the inner idler wheel and mounting block.
Page 419 FZ063A FZ065A 12. Remove the idler wheel cap; then remove the cap  NOTE: At this point, the slide rail should be free of screw and flat washer securing the rear idler wheel. the skid frame components and can be removed. Remove the idler wheel;...
Page 420 FZ066 FZ083B  NOTE: Care must be taken that the adjuster bushing slot with the hole is aligned properly with the adjuster bolt. FZ084B 4. Secure the front arm to the slide rail with the cap screws and lock nuts. Tighten to 40 ft-lb. CM261A ...
Page 421 FZ073A FZ075 10. Secure the outer idler wheel mounting block with the 8. Place the spring into the spring slide; then place the cap screw and lock nut. Tighten to 20 ft-lb; then spring slide and slide block assembly into position secure the outer and inner idler wheels to the mount- on the slide rail.
Page 422 FZ077 MS288 12. With the spacer on the front rail support centered 14. From the back, start the wear strip onto the rail; then between the limiter straps, secure the straps to the using a soft hammer, drive the wear strip forward rail support with the cap screw, washers, and lock into position.
Page 423 6. Tip the snowmobile onto the other side; then align the offset arm assembly with the appropriate hole in the tunnel. Secure the rear arm assembly with a cap screw, lock washer, and flat washer. AT THIS TIME, TIGHTEN ONLY UNTIL SNUG. ...
Page 424 Rebuilding/Recharging Fox Air Shocks ! WARNING Before starting, read through all of these instructions first to become familiar with the procedure. Make sure the work area is clean and all of the necessary tools are available. These shocks contain high pressure nitrogen gas.
Page 425 5. Using a pick, remove the air valve ball from the nitrogen bladder. PC244 9. Using a magnet, remove the bleed ball. FS145A 6. Using an Allen-wrench, loosen the nitrogen bladder half turn. PC245 10. Using Spanner Wrench, loosen the bearing cap. FS146 7.
Page 426 12. Drain the oil from the shock body into a suitable con- tainer. 13. Using an appropriate piston removal tool, remove the floating piston. FS155 3. Using Floating Piston Location Gauge, install the floating piston while using the inflation needle to vent the shock body.
Page 427  NOTE: When tightening the bearing cap, note air and excess oil being bled from the hole in the cap. 9. Install the bleed ball and set screw into the bearing cap. FS158 6. Lower the shock rod into the shock body until the piston is submerged in oil.
Page 428 FS165 FS170 12. Install the air valve ball by gently tapping it with a 18. Thread the air chamber into the end cap until hand- rubber hammer. tight.  NOTE: Prior to installing the air chamber, make sure the end cap O-ring is properly positioned in the chamber.
Page 429: Shock Absorbers
Servicing Fox Zero Pro Shock Absorbers ! WARNING Before starting, read through all of these instructions first to become familiar with the procedure. Make sure the work area is clean and all of the necessary tools are available. These shocks contain high pressure nitrogen gas.
Page 430 12. Loosen and remove the nitrogen valve from the body. FS016 ! WARNING Point the nitrogen valve away from face and body to FS014 13. Remove the shock body from the vise; then invert avoid injury when discharging or charging the shock. the shock body and place it on a folded shop towel 6.
Page 431 19. Hold the tip of a screwdriver against the end of shaft; then hold the piston assembly under the top-out plate and lift upwards. FS011 CAUTION Care must be taken when using a scribe to remove a FS009 seal. Always spear the seal with the point of the scribe.
Page 432 FS015 FS007 7. Using Floating Piston Location Gauge, install the 10. Install the new, well greased O-ring onto the IFP. floating piston while using the inflation needle to 11. Replace the bearing bleed screw O-ring. vent the shock body. ASSEMBLING ...
Page 433 13. As the bearing assembly is being threaded down, it 21. Insert the needle squarely into the center of the nitro- will contact the damping piston assembly and pull it gen valve (taking care that the valve is directed away down into the shock body with it.
Page 434 Pressurizing Rebuildable Shocks To pressurize the gas shock absorber, a regulator system and a nitrogen tank will be needed. ! 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 lb of pressure and personal injury may result.
Page 435: Steering And Body
SECTION 8 — STEERING AND BODY TABLE OF CONTENTS Steering and Body ..............8-2 Steering Post (F/M/XF) ............8-2 Steering Post (Bearcat/F-Series/T-Series) ......8-5 Ski ..................8-8 Ski Wear Bar ................8-9 Drag Link (Bearcat/F-Series/T-Series) ........8-9 Tie Rods (Bearcat/F-Series/T-Series) ........8-11 Spindle (Bearcat/F-Series/T-Series)........
Page 436 1100 cc Non-Turbo Steering and Body This section has been organized into sub-sections for ser- vicing steering and body components; however, some components may vary from model to model. The techni- cian should use discretion and sound judgment when removing and installing components. ...
Page 437 SNO-691A 6. Remove the nut (A) securing the bottom of the SNO-2226B 9. Carefully remove the steering post from the snow- existing steering post to the steering stop bracket; mobile. then remove the nut (B) securing the steering tie rod assembly to the steering post. Discard both 10.
Page 438 1. Insert the adjustable steering post into the steering support along with two bushings; then secure the steering post using the existing retaining ring.  NOTE: Verify the bushings are properly oriented (the seam should be centered front to back). 2.
Page 439 12. Secure the hood with the six torx-head screws and tighten securely.  NOTE: Before installing the hood, make sure the mounting screw clips are in position.  NOTE: On the 1100 cc non-turbo models, make sure the foam seal is in place on the air intake. ...
Page 440 8. On the non-turbo TZ1, remove the two cap screws (A) securing the front end close-off cover to the chassis. 0744-927 5. On the LXR/Sno Pro models, unlock the cam lever and unthread the lever from the lock rod (B); then remove the lock rod and account for the two bottom ZJ020A cap springs (C).
Page 441 ZJ156B FS182A INSPECTING  NOTE: When installing the bracket plates, the wider end of the plate must be directed up. 1. Inspect all welded areas for cracks or deterioration. 2. Inspect the steering post and steering-post brackets for cracks, bends, or wear. 3.
Page 442 CAUTION Do not rotate the handlebar to position allowing air to enter the brake system. 11. Test the handlebar to ensure it does not rotate within the riser block. If it does rotate, release the cam lever and rotate the cam lever clockwise; then press down on the cam lever until the lock pin is properly posi- tioned and locked.
Page 443: Ski Wear Bar
3. Inspect the wear bar for wear. the snow cover is minimal, the ski wear bar will wear faster. Arctic Cat recommends that the ski wear bars be 4. Inspect all hardware and the spindle bushings for replaced if worn to 1/2 of original diameter.
Page 444 ZJ020A ZJ161A 3. Remove the cap screw and lock nut (A) from the 6. If replacing using a suitable punch, drive the two drag link end of the inner tie rod; then remove the bearings out of the drag link. cap screw and lock nut (B) securing the left-side inner tie rod and steering tie rod to the drag link.
Page 445 0741-924 ZJ165A 3. Place the steering arms/drag link assembly into posi-  NOTE: On the F5 LXR to finalize the installing of the tion in the chassis; then secure the arms (D) with drag link, proceed to Air Silencer (Liquid Cooled F 2- axles (F) to the chassis with cap screws and new lock Stroke) sub-section in Section 3 and follow the nuts (C).
Page 446 3. Wash the ball joint in parts-cleaning solvent. Dry with compressed air. Inspect the ball joint pivot area for wear. Apply an all-temperature grease to the ball joint. ! WARNING Always wear safety glasses when using compressed air. ASSEMBLING AND INSTALLING 1.
Page 447 ZJ174A ZJ175A 8. Remove the cap screw and lock nut securing the  NOTE: The split bearings cannot be reused; they spindle to the upper A-arm. Account for all mount- must be replaced with new ones. ing hardware. 3. Position the spindle into the lower A-arm; then INSPECTING install the retainer and secure the cap to the spindle 1.
Page 448 ZJ173B ZJ176A 6. Install the spindle into the spindle housing; then with 8. Install the snap ring and spindle cap. the correct number of thrust washers (as noted in removing) and with the space (A) in the splines of the spindle aligned with the slot (B) in the steering arm, install the steering arm.
Page 449  NOTE: Replacing the ski bolt bushings is difficult. The existing bushings will be damaged during removal. Be careful, however, not to damage the spin- dle when removing the bushings. Press the new bushings into the spindle. INSTALLING 1. Place the shock absorber into position on the spindle. Secure with the cap screw and nyloc nut.
Page 450 PC088A PC088A 4. Install the ski (see Ski in this section). 3. Slide the steering tie rod out of the steering boot and out of the snowmobile. 5. Turn the handlebar fully to the right and then to the left to verify the steering moves freely. 4.
Page 451 SNO-225A PC099A 4. Slide the steering tie rod through the steering boot INSPECTING and into the snowmobile; then place the steering tie 1. Inspect the ball joints for damaged threads or wear. rod into the spindle arm with the washer. Secure with a new nyloc nut.
Page 452: Ski Alignment
5. Place the rubber exhaust bumper into position on the air silencer. FS203A 2. Remove and discard the lock nut securing the steer- ing tie rod to the steering post; then remove the cap FS203A screw and lock nut securing the left-side inner tie rod 6.
Page 453 5. Measure the distance from the straightedge to the 2. Loosen both spindle tie rod jam nuts on the same left-side ski wear bar bolts in two places: approxi- side as the ski to be aligned. mately 7-8 in. in front of the spindle and 7-8 in. 3.
Page 454 4. Remove the ski shock absorber (see Ski Shock Absorber in this section). 5. Remove the two lock nuts securing the spindle to the A-arms; then using a rubber mallet, remove the arms from the spindle. Discard the nuts. 0734-408 ! WARNING The measurement taken in front of the spindle must never be less than the measurement taken behind the spindle or...
Page 455  NOTE: On the turbo models, install the front left fas- cia using the existing torx-head screws. 2. Slide the lower arm into the boot; then place the arm into position on the chassis. Secure with the cap screws and new nyloc nuts and tighten to 55 ft-lb (front) and 45 ft-lb (rear).
Page 456 1. Elevate the front of the snowmobile with a suitable A-Arms (Bearcat/F-Series/ safety stand or lift. T-Series) 2. Remove the cap screw and lock nut securing the shock absorber to the spindle; then remove the shock from the spindle and account for the shock sleeve. REMOVING UPPER ARMS 3.
Page 457: Ski Shock Absorber
 NOTE: The split bearings cannot be reused; they must be replaced with new ones. INSPECTING  NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. 1. Inspect the arm welded areas for cracks or any signs of deterioration.
Page 458 3. Install the bushings, sleeves, and spacers into each shock end; then place the shock absorber into posi- Sway Bar (F-Series/T- tion and secure with the cap screws and lock nuts. Series) Tighten the lock nuts to 20 ft-lb (Bearcat/F-Series/T- Series) or 32 ft-lb (F/M/XF).
Page 459 ZJ166B TZ078A 3. Remove the two body screws and lock nuts securing  NOTE: For the following, refer to the illustration on the bottom of the bumper assembly to the suspension the following page. mounting bracket. 6. Remove the lock nut (A) securing the steering post to the suspension mounting bracket.
Page 460 0744-930 8-26...
Page 461 INSTALLING  NOTE: For the following procedure, refer to illustra- tion on the previous page. 1. Install the steering post with the proper number of washers as noted during removing to the suspension mounting bracket with the lock nut (threads coated with green Loctite #609) (A).
Page 462 17. Install the close-off cover; then with the exhaust pipe 20. Secure the bottom of the assembly to the suspension mounting tab (B) installed to the right-side cap mounting bracket with the two body screws and lock screw, secure the cover with the two torx-head cap nuts.
Page 463 4. Remove the two screws (D) securing the knee pads to the gas tank; then remove the remaining body screws securing the knee pads to the steering support. 5. On the standard models, push down on both seat retainer brackets (located in the rear storage com- partment) and remove the seat.
Page 464 4. From beneath the seat foam, remove the seat wire from the two elastic loops; then remove the cover from the seat base and seat foam. INSTALLING 1. Position the cover over the seat foam and seat base; then pull the two elastic loops through the slots in the seat foam and secure with the seat wire.
Page 465 3. If applicable, disconnect the passenger handwarmer wiring harness. 4. Remove the backrest assembly from the tunnel. Account for the two spacers. INSTALLING 1. Place the backrest assembly and spacers (located on the rear hole on each side) into position and align holes with tunnel mounting holes.
Page 466 2. Remove the right- and left-side rear fenders; then carefully drill out the rivets from the back side of the tunnel. CAUTION Use caution when drilling the rivets from the rear bum- per and snowflap not to damage the heat exchangers. INSTALLING BUMPER SNOWFLAP (Bearcat 570/T-Series) 1.
Page 467 2. Insert the bulb into the headlight housing. Headlight Assembly 3. Lift the front of the console enough to allow the (Bearcat/F-Series/T-Series) headlight housing to be installed; then install the housing making sure the forks of the housing go into the grommets on top of the air silencer.
Page 468 INSTALLING WINDSHIELD (Bearcat/F-Series/T570/TZ1) 0743-777 2. Remove the console. INSTALLING CONSOLE 741-637A 1. Place the console into position on the headlight sup- 1. Place the windshield into position on the console. port bracket; then connect the console harness plug- 2. Secure the windshield to the console with the two torx-head screws.
Page 469 5. Connect the gauge; then connect the electrical acces- sory wires and the ignition switch. 6. With the windshield in position, secure the wind- shield to the frame using the four screws. Tighten securely. 7. Connect the console harness; then install the hood assembly and secure with the screws.
Page 470  NOTE: There should be an “average” operating load 7. Adjust the headlight using the adjusting screw on the backside of the headlight housing until correct aim is on the snowmobile when adjusting headlight aim. obtained. Shut the engine off; then disengage the brake lever lock.

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