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Arctic Cat Sno Pro 120 2011 Service Manual

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FOREWORD

This Arctic Cat Service Manual contains service and maintenance information for the Model Year 2011 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.

© 2010 Arctic Cat Inc.

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

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October 2010

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Summary of Contents for Arctic Cat Sno Pro 120 2011

Page 1 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.
Page 2: Steering And Body
Click on the blue text to go. TABLE OF CONTENTS Note: To navigate through this manual, use the PAGE UP/PAGE DOWN buttons on the keyboard, click on the Table of Contents bookmarks on the left side of the screen, or click the blue text below. To return to this page, click the Manual Table of Contents button at the bottom of each page.
Page 3 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 ............1-3 Drive Belt Break-In ..........1-3 Genuine Parts ............1-3 High Altitude Operation ........... 1-3 Low Oil Pressure Warning Light (4-Stroke) .....
Page 4 These numbers are required to complete warranty claims properly. No warranty will be allowed by Arctic Cat Inc. In many areas, oxygenates (either ethanol or MTBE) are if the engine serial number or VIN is removed or muti- added to the gasoline.
Page 5 Excessive revving of the engine could result in serious 2-STROKE engine damage and drive clutch failure. The Arctic Cat 2-stroke engine (when new or rebuilt) requires a short break-in period before the engine is sub- Genuine Parts jected to heavy load conditions. Arctic Cat requires that the first tankful of fuel be premixed at a 100:1 ratio in all oil-injection models.
Page 6 Other more complicated methods exist such as engage- The turbocharger output must be regulated to maintain the ment notches and changing the position of the cam arm optimum manifold pressure throughout the designed operat- center of gravity in relation to the roller. This is called ing range.
Page 7 M-Series/Crossfire TRACK As snow cover and riding conditions change, several dif- Carefully matching the riding requirements to the type of ferent adjustments can be made to change the ride and han- track will ensure the maximum use of all available engine dling characteristics for operator preference.
Page 8 3. On the 4-stroke models, change the engine oil. Arctic Cat Hood and Windshield Cleaner/ Polish. 4. Add Arctic Cat Fuel Stabilizer to the gas tank fol- DO NOT USE SOLVENTS OR SPRAY CLEAN- ERS. THE PROPELLENT WILL DAMAGE THE lowing directions on the container for the stabilizer/ FINISH.
Page 9 After the break-in period, drive belt deflection should be  NOTE: On the 2-stroke models after prolonged stor- checked according to the instructions given in Section 6 age, Arctic Cat recommends one tankful of 100:1 gas/ of this manual. oil mixture be used in conjunction with the oil-injec- DRIVE BELT BREAK-IN —...
Page 10  NOTE: Before starting the snowmobile in extremely After Break-In Checkup cold temperatures, the drive belt should be removed and warmed up to room temperature. Once the drive Checklist belt is at room temperature, install the drive belt. CAUTION Below is a recommended list of items to check after the break-in period.
Page 11 Engine Specifications 2-Stroke ITEM 500 cc 570 cc 600 cc 800 cc 1000 cc Engine Model Number AX50L9 AA56A9 AJ60L7 AB80L4 AB10L4 Displacement 499 cc 565 cc 599 cc 794 cc 999 cc No. of Cylinders Bore x Stroke 71 x 63 73.8 x 66 73.8 x 70 85 x 70...
Page 12 Cylinder Head Volume Runout D ± 0.015 Specifications (2-Stroke) Engine and F Point ± 0.006 ± 0.006 (except ± 0.002 570) 500 cc 4.515” 2.618” 4.465” 1.062” 0.196” 0.196”  NOTE: For cylinder head volume tests, see appro- 570 cc 4.70”...
Page 13 Crossfire/M-Series EFI Specifications (600 cc) Fuel Pressure (2-Stroke) 42.8-47.3 psi Fuel Pressure (1100 cc Non-Turbo) 43.5 psi Fuel Pressure (1100 cc Turbo) 36.0 psi - Idle 55.0 psi - Full Boost Throttle Valve Angle Specifications 739-715A ANALYZER TOOL Model TPS TOOL (DC VOLTS) CFR/Crossfire/M-Series (DC VOLTS) (800/1000 cc)
Page 14 Ignition Timing Specifications (2-Stroke) NOTE: Ignition timing shown with engine warm. Ignition timing is not adjustable. 500 cc 600 cc BTDC - 13° @ 2000 RPM - 0.040" BTDC - 15° @ 2000 RPM - 0.059" For timing verification, use a dial indicator and For timing verification, use a dial indicator and scribe a mark on the flywheel for 13°...
Page 15 1000 cc BTDC - 14° @ 1800 RPM - 0.057" 0744-034 Manual 1-13 Table of Contents...
Page 16 Electrical Specifications 570 cc NOTE: The ignition system is a Normally Open Ignition (NOI). Resistance Test Description + Test Connections - Test Value Ignition Coil Primary (External) 0.26-0.35 ohm orange black/white Secondary 6800-10,200 ohms high tension wire high tension wire Charge Coil (1) 12-18 ohms brown/white...
Page 17 Electrical Specifications 500/600 cc NOTE: The ignition system is a Normally Open Ignition (NOI). Resistance Test Description + Test Connections - Test Value Ignition Coil Primary 0.24-0.36 ohm orange/black orange/red Secondary 6800-10,200 ohms high tension wire high tension wire Charge Coil (1) 8.8-13.2 ohms black/red green/red...
Page 18 Electrical Specifications 800/1000 cc NOTE: The ignition system is a Normally Open Ignition (NOI). Resistance Test Description + Test Connections - Test Value Ignition Coil Primary 0.24-0.36 ohm black/white white/blue Secondary 5040-7560 ohms high tension wire high tension wire Charge Coil (1) 8.8-13.2 ohms black/red green/red...
Page 19 Electrical Specifications 1100 cc NOTE: The ignition system is a Normally Closed Ignition. Resistance Test Description + Test Connections - Test Value Magneto Coil (three tests) 0.2-0.4 ohm yellow yellow Coil (1) 1.4 ohms red/green gray/green Coil (2) 1.4 ohms red/green brown/green Crankshaft Position Sensor...
Page 20 Components Specifications A list of Arctic Drive Clutch and Driven Pulley compo- nents that are available through the Arctic Cat Service ALIGNMENT BAR Parts Department can be found in the Quick Reference Guide. This information will be useful when doing any...
Page 21 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 Manual 1-19...
Page 22 Model Diameter Length LB/Inch Coils Below is a list of shock absorbers used on the front and rear suspensions of Arctic Cat snowmobiles. If replacing F5/T570/F570 0.331” 11.25” 6.2*/8.2** NO a shock absorber, always select a shock absorber with the M6/M8 (STD) 0.331”...
Page 23 144" 1" 1.75-2" 2-2.25" F8 EXT/TZ1 Turbo/ 144" 1.25" 1.75-2" 2-2.25" Lubricate with Arctic Cat 50:1 Injection Z1 Turbo EXT Oil - Non-APV Engines Lubricate with Arctic Cat Synthetic APV F8 EXT Sno Pro/Z1 Turbo 144" 1.5" 1.75-2" 2-2.25" 2-Cycle Oil - APV Engines EXT Sno Pro ...
Page 24 570 cc Torque Specification Tolerances Torque (ft-lb) Tolerance 0-15 ±20% 16-39 ±15% ±10% 570-ENG10 1-22 Manual Table of Contents...
Page 25 570ENG09 Manual 1-23 Table of Contents...
Page 26 500 cc Torque Specification Tolerances Torque (ft-lb) Tolerance 0-15 ±20% 16-39 ±15% ±10% 500CC1A09 1-24 Manual Table of Contents...
Page 27 500CC2A_10 Manual 1-25 Table of Contents...
Page 28 600 cc Torque Specification Tolerances Torque (ft-lb) Tolerance 0-15 ±20% 16-39 ±15% ±10% 600CC1B_09 1-26 Manual Table of Contents...
Page 29 600CC2A_11 Manual 1-27 Table of Contents...
Page 30 800 cc Torque Specification Tolerances Torque (ft-lb) Tolerance 0-15 ±20% 16-39 ±15% ±10% 800_10_1 1-28 Manual Table of Contents...
Page 31 800_11_2 Manual 1-29 Table of Contents...
Page 32 1000 cc Torque Specification Tolerances Torque (ft-lb) Tolerance 0-15 ±20% 16-39 ±15% ±10% 1000_10_2 1-30 Manual Table of Contents...
Page 33 1000_10_1 Manual 1-31 Table of Contents...
Page 34 1100 cc Torque Specification Tolerances Torque (ft-lb) Tolerance 0-15 ±20% 16-39 ±15% ±10% 1100ccJAG11 1-32 Manual Table of Contents...
Page 35 1100ccZ1RV10 Manual 1-33 Table of Contents...
Page 36 Engine Torque Patterns (1100 cc) 1100TorquePattern 1-34 Manual Table of Contents...
Page 37: Steering Post (Cfr/Crossfire/M-Series)
Torque Specifications Bearcat/F-Series/T-Series/Z1 Torque Item Secured to ft-lb Spindle  NOTE: Torque specifications have the following tol- Suspension Mounting Bracket (Lower) Chassis 96 in.-lb erances: Suspension Mounting Bracket (Upper) Chassis Shock Mount Frame Suspension Mounting 96 in.-lb Torque (ft-lb) Tolerance Bracket 0-15 ±20%...
Page 38 REAR SUSPENSION M-Series Bearcat XT Torque Item Secured to ft-lb Torque Item Secured to ft-lb Wear Strip Rail 50 in.-lb Idler Wheel Axle Articulating Skid Frame End Cap Rail 80 in.-lb Wear Strip Rail 50 in.-lb Mounting Block Rail End Cap Rail 80 in.-lb Inner Idler Wheel...
Page 39 SECTION 2 — ENGINE TABLE OF CONTENTS Engine Removing/Installing - Bearcat 570/F 570/T570..2-2 Engine Removing/Installing - Crossfire/M-Series 600..2-8 Engine Removing/Installing - CFR/M-Series 800/ 1000 - Crossfire 800 ........2-15 Engine Removing/Installing - F-Series 500/600/800... 2-23 Engine Servicing - 570 cc........2-37 Engine Servicing - 500/600 cc.......
Page 40 Arctic Cat 570 cc (Bearcat 570/F 570/T570) engine. For 4. On the XT, remove the cap screws and lock nuts consistency purposes, this sub-section shows a complete securing the oil reservoir to the headlight support and thorough progression;...
Page 41 10. Remove the nuts and lock washers securing the exhaust manifold to the engine; then remove the manifold and account for the gaskets. 0743-921 14. Move the engine forward enough to remove the cap screws (C) securing the rear MAG-side engine mounting bracket to the engine;...
Page 42 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 43 8. Install the headlight support bracket and secure the bracket with the cap screws and lock nuts.  NOTE: The headlight support bracket must be installed before the engine is secured. 9. Install the rear MAG-side engine mounting bracket to the engine with the three cap screws (C). Tighten to 20 ft-lb;...
Page 44 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 45 24. Install the exhaust resonator and secure to the upper frame with the washer, cap screw, and lock nut. 25. Place gaskets on the resonator and exhaust manifold; then install the expansion chamber. Secure the cham- ber to manifold and resonator with the springs. ...
Page 46 This engine sub-section has been organized to show a breaker bar and Drive Clutch Spanner Wrench, tighten progression for the removing/installing of the Arctic Cat the puller. If the drive clutch will not release, sharply 600 cc (Crossfire/M-Series) engines. For consistency strike the head of the puller.
Page 47 8. Remove the three cap screws securing the heat shield to the oil tank and chassis. Account for the heat shield pad from the cap screw (A). CM028A 12. Loosen the clamps securing the coolant hoses con- nected to the cylinders beneath the exhaust ports and the PTO-side throttle body;...
Page 48 CM209A MS382D 16. Remove the front cap screws securing the side-plate brace to the chassis and remove the brace. CM034C  NOTE: Inspect the engine to ensure all electrical connectors, hoses, and cables have been removed or CM210A 17. Remove the cap screws (A) and lock nuts (B) secur- disconnected.
Page 49 2. Tip the engine forward, raise the PTO-side of the engine, and allow the chassis to support the engine in this position. Connect the coolant tank hose to the thermostat cap and secure with the hose clamp. CM028A 9. Connect the oil-supply hose to the oil-injection pump;...
Page 50 15. Install the side-plate brace onto the chassis and secure the front of the brace with the four cap screws (coated with blue Loctite #243). Tighten securely. 0742-854 11. Route the gasline hose to the throttle body assembly and secure the hose to the fuel rail. Tighten the clamp securely;...
Page 51 24. Check drive clutch/driven pulley alignment (see Sec- tion 6). IO003 20. Secure the cables to the servomotor with the cable holder. MS390 21. Check APV cable adjustment (see Arctic Power 25. Install the drive belt. Check belt deflection. Secure Valve (APV) System in Section 3).
Page 52 32. Start the engine and warm up to operating tempera- ture; then verify that all components are functioning properly and that coolant is circulating through the cooling system properly. CAUTION After running the engine to the proper operating temper- ature, shut the engine off; then open the hood and access panels and inspect for any signs of coolant, gas- oline, or oil leakage.
Page 53 Account for the heat shield pad from the cap screw (A). This engine sub-section has been organized to show a progression for the removing/installing of the Arctic Cat 800/1000 cc (CFR/Crossfire/M-Series) engines. For con- sistency purposes, this sub-section shows a complete and thorough progression;...
Page 54 CM127 CM027 8. Rotate the servomotor actuator counterclockwise to 13. Loosen the flange clamps securing the throttle body loosen the cable; then pull the cable housings down assembly to the flange; then move the throttle body and out of the servomotor. assembly forward to allow room to disconnect the oil-injection control rod from the oil-injection pump.
Page 55 CM131A CM134 19. Disconnect the lower coolant hose from the front  NOTE: On the 1000 cc, remove the coolant by-pass heat exchanger; then remove the remaining coolant hoses from the cylinders. hose from the thermostat outlet. 16. Move the throttle body assembly to one side out of the way to a secure position.
Page 56 Installing 1. Install the MAG-side engine mounting bracket to the engine with cap screws (coated with blue Loctite #243). Tighten to 30 ft-lb. CM133A 21. Remove the lock nuts (A) and (B) from the cap screws of the MAG-side engine mounting bracket and the front lower engine mounting bracket (do not remove the cap screws at this time).
Page 57 CM135A CM137 5. Raise the PTO-side of the engine and support the 11. Tighten the spark plugs to 19 ft-lb; then connect the engine in this position. Connect the coolant tank plug wires and on the 800 cc, the knock sensor plug-in. hose to the bottom left outlet on the engine and secure with the hose clamp.
Page 58 CM131B CM129B 16. Connect the two coolant hoses to the throttle body  NOTE: After securing the oil-supply hose to the oil assembly; then secure with the clamps. pump, remove the bleed screw to allow any air in the hose/pump to be released. CM131A 17.
Page 59 20. Rotate the servomotor clockwise to remove any slack from the cables; then install the servomotor retaining clip. CM132A TZ069A 21. Check APV cable adjustment. See Arctic Power Valve (APV) System in Section 3.  NOTE: Before installing the drive clutch, be sure to wipe both the crankshaft taper and clutch mounting taper clean using a clean towel.
Page 60 24. Check drive clutch/driven pulley alignment (see Sec- 29. With the heat shield pad in place, install the heat tion 6). Install the drive belt. Check belt deflection. shield and secure it to the chassis and oil tank with Secure the belt guard (see Section 6). the three cap screws;...
Page 61 This engine sub-section has been organized to show a  NOTE: On the LXR, disconnect the negative cable progression for the removing/installing of the Arctic Cat from the battery. 500/600/800 cc (F-Series) engines. For consistency pur- poses, this sub-section shows a complete and thorough 4.
Page 62  NOTE: To aid in accessing the cap screw, the ECU may be removed. 8. Remove the body screws and lock nuts (C) from each side securing the front bumper assembly to the chassis; then remove the two remaining self-tapping screws (B) from each side securing the front bumper assembly.
Page 63  NOTE: Remove the clamps from the intake flanges to avoid damage during engine removing. 19. On the 500/600 cc, loosen the clamps securing the coolant hoses connected to the cylinders beneath the exhaust port and the throttle body assembly; then remove the vent tube from the top of the cylinder head.
Page 64 800 cc 500/600 cc FS180 FS211A  NOTE: On the 800 cc, at the coolant filler neck 800 cc bracket, disconnect the knock sensor wiring connec- tor and slide the wiring out of the cable tie. FS210  NOTE: On the 500/600 cc LXR, remove the two set screws securing the flex-drive shaft to the starter motor;...
Page 65 500/600 cc FS214A 742-205B 25. Disconnect the front heat exchanger hose. 800 cc  NOTE: Prior to disconnecting the hose, place an absorbent towel beneath the hose to collect any cool- ant from the exchanger. 26. Remove the four cap screws securing the upper bear- ing bracket to the upper support plate (account for the two bracket plates);...
Page 66 800 cc FS184A FS216A 34. Carefully remove the engine out the MAG-side of 36. Remove the two cap screws (F) securing the MAG- the chassis. side engine mounting bracket to the engine. 37. Remove the four cap screws (G) securing the front engine plate to the engine.
Page 67 800 cc 800 cc FS216A 742-201A 3. On the 500/600 cc, install the front lower engine  NOTE: At this point on the 500/600 cc LXR, install plate to the engine with four cap screws (G) (coated the pinion bracket assembly to the engine with two with blue Loctite #243).
Page 68 FS177A FS196A 5. On the 500/600 cc, position the engine to the chassis 11. Route the ignition harness and the coolant tempera- mounts; then in order, install cap screws (D) securing ture sensor two-wire connector between the coolant the engine plate to the front chassis mounts; then tank and the chassis;...
Page 69 A. Place the flex-drive shaft into position on the pin- 500/600 cc ion driveshaft so the set screws are aligned with the flat-side of the pinion driveshaft; then tighten the set screws (coated with blue Loctite #243) securely. FS180 800 cc FS204 B.
Page 70 600 cc CM028A 0742-854 800 cc FS198A 0744-528 17. On the 500/600 cc, install the two coolant hoses to  NOTE: Verify the mark on the control arm is aligned the MAG-side and PTO-side of the crankcase (below with alignment mark on the oil-injection pump boss the exhaust ports);...
Page 71 FS198A FS212A 19. Apply a thin coat of high-temperature silicone seal-  NOTE: At this point, secure the coolant hose, ant to each exhaust port; then install the exhaust gas- gasline hose, and on the LXR, the battery cables kets. together.
Page 72 29. Secure the bearing bracket/steering post assembly to the upper support plate with the bracket plates and cap screws (coated with blue Loctite #243). Tighten the cap screws to 96 in.-lb. TZ069A 25. Check APV cable adjustment. See Arctic Power Valve (APV) System in Section 3.
Page 73 CAUTION Do not tighten the machine screw against the seat sup- port. The screw must be loose enough to be effective as a seat “stop.” 37. Fill the cooling system (see Liquid Cooling System in Section 3). 38. Place the rubber exhaust bumper into position on the chassis.
Page 74 45. Verify the tightening torque of the drive clutch. CAUTION 46. Secure the console to the steering support with the torx-head screws (from step 41) and tighten the If the engine had a major overhaul or if any major com- screws securely;...
Page 75 This engine sub-section has been organized to show a progression for servicing of the Arctic Cat 570 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 76 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 77 MD0076 MD0083 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 78 MD0086 MD0094 15. Remove the cylinders making sure to support the pis-  NOTE: The shoulder sides of the piston pin bearing tons so they are not damaged. Account for four washers must seat to the bearing. dowel pins. CAUTION When removing a cylinder, make sure to support the piston so it will not be damaged.
Page 79 19. Remove the oil-injection pump driveshaft. Account for a thrust washer. MD0271 17. Remove the two Allen-head cap screws securing the oil-injection pump; then remove the pump. Account MD0101 for an O-ring. 20. Place the crankcase (with its bottom side up) on two blocks of wood.
Page 80 4. Place the cylinder head on a Surface Plate covered CAUTION with #400 grit wet-or-dry sandpaper. Using light pressure, move each cylinder head in a figure eight To prevent damage to the crankshaft, crankshaft bear- motion. Inspect the sealing surface for any indication ings, or seals, be sure to always lift the crankshaft from of high spots.
Page 81 PISTON ASSEMBLY 6. Inspect the sealing surfaces of the crankcase halves for trueness by placing each crankcase half on the 1. Using a non-metallic carbon removal tool, remove surface plate covered with #400 grit wet-or-dry sand- the carbon buildup from the dome of each piston. paper.
Page 82 Account for any shim(s). Note the position of the ter bearings, or oil-injection pump drive gear is nec- dowel pin hole. essary, Arctic Cat recommends the crankshaft be taken to a qualified machine shop for that service. 1. Wash the crankshaft with bearings in parts-cleaning solvent.
Page 83 2. Heat the bearing either by placing the entire bearing 5. To assemble, place the reed valves on the cage with in a pan of oil on a hot plate or by squirting oil into its angled corner positioned to the lower right hand the bearing and using a propane torch to heat the corner of the cage.
Page 84  NOTE: Measure from PTO to MAG-side of the piston to accurately measure the squish gap. Never mea- sure across piston, exhaust to carburetor side, as the piston will rock and the reading won’t be accurate. Readings may vary from side to side. ...
Page 85 Always wear safety glasses when drying components with compressed air.  NOTE: When the use of a lubricant is indicated, use Arctic Cat 50:1 Injection Oil. 1. Place the upper crankcase half (with its bottom side up) on two blocks of wood.
Page 86 2. Lightly grease the inner lips of the crankshaft seals; then slide them onto the crankshaft. 3. Apply oil to the crankshaft bearings; then install the crankshaft into the upper crankcase half. Be sure the alignment hole in each bearing is positioned over its respective dowel pin in the crankcase;...
Page 87 TZ068 MD0248 9. Install piston pin bearing washers on each side of the CAUTION bearing with the shoulder side facing the bearings. Make sure the new circlips are firmly seated in their  NOTE: The shoulder side of the piston pin bearing grooves and the open ends are pointed up or down washers must face the bearing.
Page 88 MD0086 0738-291 15. Install the spark plugs; then tighten to 19 ft-lb. Pres- sure test the engine (see Section 3). MD0087 14. Install a new cylinder head gasket and the cylinder head; then install the eight cap screws and two flange MS385 nuts.
Page 89 17. Install the stator plate so the ignition wire cut-out is in the upper left position. Lightly coat the four Allen- head cap screws with blue Loctite #243; then install and tighten them to 96 in.-lb. MD0074 MD0255 18. Place the stator wiring through the hole in the crank- case;...
Page 90 25. Using the five 6 mm cap screws and the special washers, install the front (exhaust-side) cooling shroud and tighten to 96 in.-lb. Install the rubber spark plug grommets; then tighten the cap screws securely. MD0264 MD0269 MD0278 23. Using Flywheel Spanner Wrench to hold the starter cup, tighten the three cap screws (from step 21) to 28 ft-lb.
Page 91  NOTE: For assembling purposes, always use new O-rings lubricated with oil on the oil-injection pump and retainer. MD0273 28. With a new O-ring 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 92 Engine Servicing - 500/600 cc This engine sub-section has been organized to show a progression for servicing of the Arctic Cat 500/600 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 93 CM013 FC019  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. RS020A 7. Remove the stator plate from the engine. FC022 5.
Page 94 8. On the 600 cc, remove the cap screws securing the APV assemblies to the cylinders; then remove the APV assemblies and set them aside.  NOTE: Note that the APV exhaust valves and gas- kets are directional for assembling purposes. FC026 ...
Page 95 14. Remove the PTO-side piston-pin circlip from the CAUTION PTO-side piston; then remove the MAG-side piston- pin circlip from the MAG-side piston. On the 500 cc, place rubber bands over the connecting rods and around the cylinder studs to prevent the con- necting rods from damaging the crankcase.
Page 96 22. Turn the engine upside down on support blocks and 27. Remove the oil-injection pump/water pump drive- remove the coolant temperature sensor (if neces- shaft from the lower crankcase half. Account for the sary). thrust washer on the outer end of the shaft. FC033 CM159A 23.
Page 97 Servicing Top-Side Components (Crossfire/M-Series) Many services can be performed without removing the engine. Some components may vary from model to model. The technician should use discretion and sound judgment when removing and installing components.  NOTE: Prior to starting the removing procedure, disconnect the hood harness and the air intake con- nector from the air silencer;...
Page 98 CM216 CM217  NOTE: At this point, remove all loose hardware to  NOTE: If servicing the MAG-side only, the PTO-side avoid any falling down into the chassis. cylinder must be removed. 8. Remove the residual coolant from the cylinder/ ...
Page 99  NOTE: Prior to installing the pistons, make sure to install the MAG-side piston pin circlips first. 3. Place each piston over the connecting rod so the indi- cator dot on each piston will point toward the intake/ exhaust ports; then install an oiled piston pin and secure the pin with the remaining circlips.
Page 100 CM217 CM219 6. Secure the cylinders by tightening the cylinder base nuts and cap screws to 44 ft-lb in three steps using the pattern shown. CM220 9. Connect the two coolant hoses on the cylinders beneath the exhaust ports; then install the coolant hose and breather hose onto the cylinder head.
Page 101 CAUTION Cleaning and Inspecting Water or parts-cleaning solvent must be used in con- junction with the wet-or-dry sandpaper or damage to  NOTE: Whenever a part is worn excessively, cracked, the sealing surface may result. or damaged in any way, replacement is necessary. CYLINDERS CYLINDER HEAD 1.
Page 102  NOTE: If any servicing of the connecting rods, cen- ter bearings, or oil-injection pump drive gear is nec-  NOTE: The coolant temperature sensor must be essary, Arctic Cat recommends the crankshaft be removed for this procedure. taken to a qualified machine shop for that service.
Page 103 REED VALVE ASSEMBLY 1. Inspect the reed valves, stoppers, and valve blocks for cracks or any deterioration. FC040 4. Inspect the oil-injection pump drive gear for any signs of worn or chipped teeth. If either condition exists, replace the gear. CM162 ...
Page 104 Measuring Critical Components  NOTE: Critical engine specifications charts 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. FC044 1.
Page 105 CONNECTING-ROD SMALL END 2. Using a feeler gauge, measure each piston-ring end gap. Acceptable ring end gap must be within 0.008- BORE 0.016 in. for the 500 cc or 0.0120-0.0196 in. for the 1. Insert a snap gauge into each connecting-rod small 600 cc.
Page 106 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. 1. Apply a thin coat of grease to the inner seal lips of 6.
Page 107 FC071  NOTE: Use only Arctic Cat High-Temp Sealant to seal the crankcase halves. 10. Assemble the crankcase halves making sure the crankshaft gear and oil-injection pump driveshaft gears mesh.
Page 108  NOTE: On the 500 cc, secure the connecting rods with rubber bands on the cylinder studs. On the 600 cc, secure the connecting rods with rubber hoses. 13. Apply a thin coat of grease to the sealing surface of the oil-injection pump/water pump driveshaft;...
Page 109 IO050A FC072B 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 110 0742-304 726-306A 22. Noting the alignment dots, install the thermostat CAUTION housing with thermostat. Secure the housing with Incorrect installation of the piston rings will result in cap screws and tighten to 96 in.-lb. engine damage. 26. Apply oil to the connecting-rod small end bearings; then install the small-end bearings.
Page 111 FC079A FC076 28. Install the new circlips so the open end is directed 31. On the 500 cc, secure each cylinder by installing the either up or down. eight nuts. DO NOT TIGHTEN AT THIS TIME. 32. On the 600 cc, secure each cylinder by installing the four nuts and four cap screws.
Page 112  NOTE: Lubricating the O-ring with a light coat of grease will help keep them seated in the grooves of the cylinder.  NOTE: At this point, pressure test the engine (see Section 3). 38. On the 600 cc with the APV gaskets properly posi- tioned as noted during disassembling, slide the APV assemblies into position in the cylinders;...
Page 113 40. On the 600 cc, install the magneto case on the crank- 42. Install the key in the crankshaft. case accounting for the different-sized cap screws 43. Thread two puller bolts into the flywheel; then slide and the alignment pins. Tighten cap screws to 40 ft- the flywheel onto the crankshaft making sure the keyways match.
Page 114 Engine Servicing - 800/1000 cc This engine sub-section has been organized to show a progression for servicing of the Arctic Cat 800/1000 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 115 3. Using Flywheel Puller or suitable substitute, remove 5. Remove the Allen-head cap screw (A) securing the the flywheel from the crankshaft by tightening the stator lead wire plate to the crankcase; then remove puller bolt, striking the head of the puller bolt with a the Allen-head cap screws (B) securing the timing hammer, and tightening again.
Page 116 CM145D CM147 9. Remove the spark plugs.  NOTE: For assembling purposes, note the indenta- tion (A) of the stator plate is aligned with the harness  NOTE: On the 800 cc at this point, remove the knock opening (B) in the crankcase. sensor and lock plate from the cylinder head by bend- ing the lock plate tabs down and unthreading the sen- sor.
Page 117 15. Disconnect the intake flange oil lines from the oil pump; then remove the cap screws securing the intake flanges. Remove the intake flanges and reed valve assemblies. CM149 13. Using Piston Pin Puller and medium Extractor Nut, remove the piston pins from both pistons. ...
Page 118 IO017A IO018A 20. Prior to turning the engine upside down on the 800  NOTE: For assembling purposes, note that the posi- cc, remove the two crankcase cap screws (A) from tioning of the bypass/check valve is directed up. the water pump side of the engine; then remove the two cap screws (B) from the magneto housing.
Page 119 26. Remove the oil-injection pump/water pump drive- CAUTION shaft from the lower crankcase half. Account for the thrust washer on the outer end of the shaft. DO NOT drive any tool between halves to separate the crankcase. Damage to the sealing surfaces will result. CM159A ...
Page 120 Servicing Top-Side Components (Crossfire/M-Series) Many services can be performed without removing the engine. Some components may vary from model to model. The technician should use discretion and sound judgment when removing and installing components.  NOTE: Prior to starting the removing procedure, disconnect the hood harness and the air intake con- CM133A nector from the air silencer;...
Page 121 CM188B CM191A 6. Remove the cap screws securing the cylinder head;  NOTE: On the 1000 cc, remove the coolant bypass then lift the front of the head and remove the O-rings. hoses from the cylinders. 8. Remove the cap screws and nuts securing the cylin- ders to the crankcase;...
Page 122 2. Install the piston rings on each piston so the letter on the top (inclined surface) of each ring faces the dome of the piston. CM193  NOTE: The piston pins must be removed from the PTO-side of the piston. 726-306A CAUTION CAUTION...
Page 123  NOTE: The indicator dot (A) is found on the piston dome. CM192 8. Secure each cylinder by installing the four nuts and four cap screws. DO NOT TIGHTEN AT THIS TIME. CM194A 5. Install the new circlips so the open end is directed ...
Page 124 11. Secure the cylinders (from step 8) by tightening the cylinder base nuts and cap screws to 44 ft-lb in three steps using the appropriate pattern shown. 800 cc CM191 14. Lubricate the O-rings with a light coat of grease; then install the two cylinder O-rings on the top of each cylinder making sure they are correctly posi- 0738-206...
Page 125 16. Start the remaining cap screws being very careful not 19. Install the side-plate brace; then secure with the cap to move the cylinder head. ONLY FINGER- screws (coated with blue Loctite #243). TIGHTEN AT THIS TIME; then tighten the cap ...
Page 126 4. Place the cylinder heads on a Surface Plate covered 4. Inspect each piston for seizure marks or scuffing. with #400 grit wet-or-dry sandpaper. Using light Repair with #400 grit wet-or-dry sandpaper and pressure, move each cylinder head in a figure eight water or honing oil.
Page 127  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 128: Reed Valve Assembly
REED VALVE ASSEMBLY Measuring Critical 1. Inspect the reed valves, stoppers, and valve blocks Components for cracks or any deterioration.  NOTE: Critical engine specifications charts 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 129 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 FC045 PISTON PIN AND PISTON-PIN BORE...
Page 130  NOTE: When the use of a lubricant is indicated, use 0742-727 Arctic Cat Synthetic APV 2-Cycle Oil. 1. Using the V Blocks, support the crankshaft on the surface plate. 1. Apply a thin coat of grease to the inner seal lips of the water pump seal.
Page 131  NOTE: The seal must be installed with its spring 1000 cc side towards the crankshaft. 3. Install the snap ring securing the inner seal in the crankcase. CM165C 6. Place the crankshaft end bearings into position mak- ing sure the bearing retaining pin hole is positioned inward.
Page 132 CM166 Be very careful not to damage the seals when installing  NOTE: Use only Arctic Cat High-Temp Sealant to the oil pump driveshaft. Be certain to use the seal pro- tector tool. Twist the driveshaft clockwise as it enters seal the crankcase halves.
Page 133 16. Rotate the oil-injection pump/water pump driveshaft while carefully pushing it through the oil and water CAUTION pump seals until the driveshaft and crankshaft gears Be sure the oil-injection pump/water pump driveshaft is engage; then remove the oil seal protector tool (A) from the end of the shaft.
Page 134 IO022A IO050A 21. Install the coolant temperature sensor (threads coated CAUTION with white Loctite #575) and tighten to 18 ft-lb; then secure the sensor wire to the sensor with a cable tie. When installing the ceramic/rubber seal into the impel- ler, never touch the ceramic part of the seal.
Page 135 CM171B CM155A 26. Apply a thin film of low-temp grease to the water 28. Install the dowel pins into the crankcase; then place pump cover O-ring; then position the O-ring into the the cylinder base gasket into position on the crank- water pump cover.
Page 136 34. In turn on each cylinder, place a piston holder (or suitable substitute) beneath the piston skirt and square the piston in respect to the crankcase; then using a ring compressor or the fingers, compress the rings and slide the cylinder over the piston. Remove the piston holder and seat the cylinder firmly onto the crankcase.
Page 137 1000 cc FC077 0742-199  NOTE: Lubricating the cylinder O-rings with a light  NOTE: At this point on the 800 cc, install the spark coat of grease will help keep them seated in the plugs and on both models, tighten the spark plugs to grooves of the cylinder.
Page 138 42. Secure the upper ignition timing sensor (white dot/ 46. Apply red Loctite #271 to the threads of the flywheel connector) with cap screws (coated with blue Loctite cap screw; then finger-tighten with a large flat #243). Tighten to 48 in.-lb; then install the wiring washer.
Page 139 51. Apply a thin coat of high-temperature silicone seal- ant to the mating surfaces of the exhaust manifold; then install the exhaust manifold and secure with the eight nuts. Tighten the nuts using the pattern shown to 17 ft-lb. CM181 ...
Page 140 This engine section has been organized into sub-sections showing a progression for the complete servicing of the Arctic Cat 1100 cc (Bearcat Z1 XT/TZ1/Z1) engine. For consistency purposes, this section shows a complete and thorough progression; however, for efficiency it may be...
Page 141 7. Remove the hose clamp from the coolant hose (A) 10. Using a 9/16-in. socket and extension, remove the connecting the water pump to the right side of the oil cap screw securing the driven pulley to the input cooler; then clamp off the coolant hose. With a drain shaft.
Page 142 14. Remove the two cap screws and lock nuts (A) secur- ing the left-side upper frame to the front end. Remove the one remaining cap screw and lock nut (B) securing the upper frame to the left-side skid plate. ZJ090A ...
Page 143 743-995A TZ075A 16. Disconnect the harness plug-in (A) from the regula- 19. On the turbo models and the non-turbo TZ1, remove tor/rectifier; then remove the air pressure sensor (B) the two cap screws and lock nuts securing the cool- from the bracket on the right-side upper frame. ant separator tank assembly;...
Page 144 TZ086A TZ060A 23. Remove the two cap screws (A) securing the close- 22. On the turbo models, loosen the clamps securing the off cover to the front end; then remove the cover and intercooler hoses from the intake pipe and the turbo- on the non-turbo models, account for the exhaust charger;...
Page 145 28. From the opposite side of the throttle body, discon- nect the idle speed control and the throttle cable. TZ085A 26. Remove the two cap screws securing the intake pipe to the cylinder head cover; then remove the remain- 0743-992 ing cap screw securing the pipe to the left side of the 29.
Page 146 36. Using an appropriate engine hoist, lift the engine (from the proper lift points) with oil reservoir from the chassis. ZJ022  NOTE: Close off the intake ports of the cylinder head to avoid any foreign objects or components from falling into the engine. 741-658A 34.
Page 147 2. Remove the remaining coolant hoses; then remove 5. Remove the three lock nuts and washers (A) securing the clamps and hoses connecting the oil reservoir to the bracket of the turbocharger to the engine; then the engine. loosen the lock nuts (B) securing the bracket to the turbocharger.
Page 148 ZJ028B ZJ030A 8. On the non-turbo models, remove the cap screws  NOTE: Note the position of the thermostat bypass/ securing the two intake flanges to the cylinder head; check valve for assembling purposes. then remove the flanges. ZJ091A ZJ029A 9.
Page 149 ZJ032A ZJ036A 15. On the non-turbo models, remove the cap screws  NOTE: Care must be taken when removing the mag- securing the two cylinder ignition coils to the cylin- neto cover not to tip the cover downward. Tipping the der head cover and remove the coils.
Page 150 ZJ037A ZJ039A 17. Obtain top-dead-center by rotating the crankshaft 20. Using a magnet, carefully remove the tappets from until the arrows on the intake camshaft face (A) are the cylinder head. in the 12 o’clock and 9 o’clock positions and the arrows on the exhaust camshaft face (B) are in the 12 o’clock and 3 o’clock positions.
Page 151 741-617B 741-584B 24. Tip the engine upside down; then remove the 28 cap  NOTE: If removing the oil cooler for cleaning pur- screws securing the upper and lower crankcase poses, remove the union bolt securing the cooler to halves. Using a soft hammer, gently tap around the the engine;...
Page 152 ZJ068A ZJ044 27. Remove the front and rear crank balancers from the  NOTE: Because the connecting rods and connect- engine and account for the two end seals. ing rod caps are unique, note the I.D. marks and keep all associated parts together for assembling pur- poses.
Page 153  NOTE: For assembling purposes, ensure the ori- fices in the piston cooling jets are cleared of any dirt and/or debris. ZJ046A 31. Remove the oil separator plates for the lower crank- case half and account for the eight Allen-head cap screws.
Page 154  NOTE: If the existing rings will not be replaced with new ones, note the location of each ring for proper installation. When installing new rings, install as a complete set only. Cleaning/Inspecting Piston Rings Using a ring-groove cleaning tool, clean carbon from the ring-grooves.
Page 155 4. Rotate the rings until the ring end gaps are no less than 90° from one another. CAUTION Incorrect installation of the piston rings will result in engine damage. MEASURING CONNECTING ROD SMALL END BORE INSIDE DIAMETER 1. Using a small bore gauge, measure the connecting rod small end bore inside diameter.
Page 156 4. Inspect the cylinder bore for minor scoring or scuff- 2. If any journal is badly damaged or has wear that is ing. If marks are found, repair the surface using the not within specifications, the crankshaft must be appropriate hone and honing oil. replaced.
Page 157 Bearing Selection Charts Balancer Shaft Bearing Selection To select the correct main or balancer shaft bearing Crankcase Mark Balancer Mark insert, read the letter stamped for the bearing location on the crankcase; then read the letter stamped on the crank- Green Black shaft or balancer shaft corresponding to the same bearing...
Page 158  NOTE: Arctic Cat recommends that new gaskets, seals, and O-rings be installed whenever assembling the engine.  NOTE: For assembling purposes, use oil-dissolv- able molybdenum disulfide grease as engine-assem- bly grease.
Page 159 8. Lubricate the lips of the crankshaft seal with grease and install the crankshaft seal over the PTO end of the crankshaft with the spring side of the seal directed toward the crankshaft; then install the crank- shaft.  NOTE: Position the crankshaft at bottom-dead-cen- ter for assembling purposes.
Page 160 16. With the crankshaft at bottom-dead-center, install the front counterbalancer with the single dot (B) on the face of the crankshaft and balancer gears directly in line with each other at the sealing surface of the engine case. 17. Place the oil-passage O-rings (A) into place in the upper engine case;...
Page 161 21. Install the lower crankcase half to the upper engine case; then verify the cases are properly seated together. 22. Install the 10 mm, 8 mm, and 6 mm cap screws into the proper locations in the crankcase; then with the torque pattern shown as numbered on the case, tighten the cap screws only until snug.
Page 162 28. Install the cam chain tensioner; then install the wash- 32. Install the flange nuts and cap screws (cap screws 1- ers between the engine case and guide/tensioner and 6 threads coated with oil); then using the pattern secure with two Allen-head cap screws. Tighten to shown, tighten in the following sequence: 84 in.-lb.
Page 163 ZJ084 741-624A 35. With the timing marks (A) on the face of the cam- 38. Install the cam chain tensioner adjuster by first com- shaft gear properly aligned, place the camshaft into pressing the locking clip; then by pushing in the ten- position on the cylinder head.
Page 164 741-580A 0742-125 44. With the two pins installed in the engine case, first  NOTE: At this point, install the spark plugs and install the starter torque limiter (A) and spacer (B); tighten to 96 in.-lb. then install the inner spacer (C), idler gear (D), and outer spacer (E).
Page 165 ZJ090A ZJ092 46. Install the coolant hose inlet fitting and secure with 48. On the non-turbo models, install the two intake the two cap screws. Tighten to 84 in.-lb. flanges; then secure with the four cap screws. Tighten to 60 in.-lb. ZJ031B 47.
Page 166 53. 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. ZJ028C 50. Install the coolant hoses onto the proper inlets/outlets of the engine;...
Page 167 2. Pry the front engine mount forward until the engine and mount are in proper alignment; then lower the engine completely into the chassis. 3. Secure the engine to the chassis with lock nut (C) and long through-bolt (B) on the front engine mount; then install the two lock nuts (A) to the rear engine mounts.
Page 168 ZJ090B ZJ024A  NOTE: Steps 7-10 are for the non-turbo models  NOTE: Prior to securing the left-side upper frame to only. the steering support, make sure the ECU harness is directed below the upper frame. 7. Install the throttle bodies and secure with clamps; then install the throttle cable to the throttle bodies.
Page 169 TZ099A 743-995A 15. Install the four remaining cap screws securing the  NOTE: Place the upper frame into position and upper frame/support gusset to the steering support. install the clip securing the wire harness to the steer- ing support gusset. 16.
Page 170 22. Install the close-off cover to the front end with the two cap screws (A) noting the mounting tab (non- turbo only) (B) is installed with the right-side cap screw. Tighten cap screws securely. TZ075A 17. Connect the harness plug-ins to the ignition coils (A) and camshaft sensor (B);...
Page 171 TZ060A TZ072A  NOTE: To aid in coolant bleeding procedure, do not  NOTE: Before installing the drive clutch, be sure to secure the upper heat shield to the manifold at this wipe both the crankshaft taper and clutch mounting point.
Page 172 FZ021 744-032A 37. If the engine oil was drained, remove the filler cap CAUTION from the oil reservoir and add the recommended Do not allow the driven pulley to “float” on the input amount of oil using the following procedure. If the shaft.
Page 173 G. Shut the engine off; then remove the oil level stick 40. Repeat steps 38-39 at least two more two times from the oil reservoir. Wipe the stick clean. (more if necessary) until no air is in the cooling sys- tem.
Page 174 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 175 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 176 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 177 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 178 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 179 Problem: Engine Does Not Idle Condition Remedy 1. ECU trouble code 1. Service — replace problem component 2. Throttle cable too tight 2. Adjust throttle cable to specifications* 3. Injector(s) faulty 3. Replace injector(s) 4. Fuel pressure regulator faulty 4. Replace regulator — hose 5.
Page 180 SECTION 3 — ENGINE-RELATED ITEMS TABLE OF CONTENTS Engine-Related Items..........3-2 Water Pump (500/600 cc) ........3-2 Water Pump (800/1000 cc) ........3-5 Water Pump (1100 cc) ..........3-9 Pressure Testing Engine (2-Stroke) ...... 3-11 Removing Spark Plugs (1100 cc)......3-11 Checking Compression (1100 cc) ......
Page 181: Water Pump
Engine-Related Items  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. SPECIAL TOOLS A number of special tools must be available to the techni- cian when servicing the engine-related items.
Page 182 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 183 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 184  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 185 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 186 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 187 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 on the oil pump end of the shaft; then with the O-ring installed on the retainer, install the oil-injection pump retainer.
Page 188 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 189 3. Remove the separator tank breather hose to gain  NOTE: Apply heat to the housing to aid in removing access to the water pump; then remove the water the seals. inlet hose from the water pump. CAUTION Care should be taken not to apply too much heat to the housing or the bushing next to the bearing may be damaged.
Page 190  NOTE: Apply a light coat of grease on the O-ring to aid in keeping it properly positioned. 6. Secure the housings with the two Phillips-head screws (A); then tighten the screws with an impact driver. CAUTION Care should be taken not to over-tighten the screws with the impact driver or damage to the housings may occur.
Page 191 Valve clearance tive cable from the battery. must be within specifications. If valves, valve guides, or valve seats require servicing or replacement, Arctic Cat recommends the components be Valve Clearance (Cold) taken to a qualified machine shop for servicing. 15°-25° C Intake: 0.0039-0.0078 in.
Page 192  NOTE: After removing the throttle bodies, close off the intake ports of the cylinder head to avoid any foreign objects or components from falling into the engine. 8. Remove the cap screws securing the camshaft covers to the cylinder head; then remove the covers. Remove both camshafts.
Page 193 10. To select the correct replacement shim for an out-of- B. Find the Present Shim Size (three-digit-number) specification clearance, note the three-digit number at the top-side horizontal column of the table. on the surface of the existing shim; then refer to the C.
Page 194 SNO2152 Manual 3-15 Table of Contents...
Page 195 SNO2153 Manual 3-16 Table of Contents...
Page 196 11. With a light film of engine oil applied to the tappets, install the correct shim (A) and tappet (B) to each valve being adjusted. 0741-801 14. With the cam chain properly seated to the gears of the crankshaft and exhaust camshaft, install the intake camshaft noting that the timing marks (B) are properly aligned.
Page 197 ZJ106A IO051A 17. With the camshafts in position and properly timed, install the camshaft covers along with cam chain ten- sioner guide number two; then using the pattern shown, tighten the twelve cap screws to 84 in.-lb. IO052B 20. After rechecking for proper valve/tappet clearance, install the timing inspection plug to the magneto case and tighten to 22 ft-lb.
Page 198 ZJ127A ZJ094C 22. On the non-turbo models, install the ignition coils  NOTE: On the non-turbo models before installing and secure with the cap screws; then install the wir- the air silencer, make sure the gasline hose is routed ing harness plug-ins to the coils (A) and the crank- over the air silencer.
Page 199 5. After the oil has drained completely, install the oil strainer, drain plugs, and washers and tighten to 15 Testing Oil Pressure ft-lb. (1100 cc)  NOTE: Always install a new crankcase drain plug washer and a new reservoir washer when changing 1.
Page 200 DRAINING COOLING SYSTEM Oil Flow Chart (1100 cc) (Crossfire/M-Series) 1. Using a piece of cardboard to protect the hood and belly pan, tip the snowmobile on its PTO-side. Non-Turbo 2. From beneath the front end, remove the self-tapping screws securing the skid plate to the chassis. 3.
Page 201  NOTE: At this point, secure the console with the torx-head screws. INSPECTING COOLANT HOSES AND CLAMPS All coolant hoses and connections should be checked annually for deterioration, cracks, and wear. All coolant hoses and clamps should be replaced every four years.
Page 202 CAUTION Make sure the washers are free from the heat shield cap screws or damage to the heat shield will occur. 5. Loosen the bleed screw and add coolant into the filler neck until coolant is visible at the bleed screw; then tighten the bleed screw and add coolant to the coolant reservoir Full-Cold line.
Page 203 All coolant hoses and clamps should be replaced every four years. INSPECTING THERMOSTAT 1. Inspect the thermostat for corrosion, wear, or spring damage. 2. Using the following procedure, inspect the thermo- stat for proper operation. A. Suspend the thermostat in a container filled with water.
Page 204 Cooling System Schematics The following schematics are representative of the different 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 205 F-Series 2-Stroke 0742-314 CFR/Crossfire/M-Series 738-067A Manual 3-26 Table of Contents...
Page 206 6. Carefully lift the roller free of the case making sure Recoil Starter the main spring (H) does not disengage from the case. (500/600 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.
Page 207 6. Install the return spring making sure the end is prop- 800/1000 cc erly installed in the hole in the roller; then install the pawl making sure the return spring is properly pre- loaded. 7. Slide the end of the rope through the rope guide of the case;...
Page 208 8. Slide the end of the rope through the rope guide of the case; then tie a slip-knot in the rope. ! WARNING 9. Apply a low-temperature grease to the friction plate. Care must be taken when lifting the roller free of the Place the pawl activator into position on the friction case.
Page 209 Air Intake Assembly (CFR/Crossfire/M-Series) REMOVING 1. Remove the connector clamp securing the intake connector (hose) to the hood screen (right-side). SC077A 3. Remove the screen and air silencer from the front bumper. FC248 2. With the hood closed, loosen the headlight adjust- ment knobs.
Page 210 7. Remove the cap screw located directly above the ECU securing the air-silencer duct to the front upper panel; then disconnect the air temperature sensor and remove the duct.  NOTE: To aid in accessing the cap screw, the ECU may be removed.
Page 211 742-207A FS203A 3. Install the body screws and lock nuts (C) from each 9. Place gaskets on the resonator and exhaust manifold; side and the self-tapping screws (B) from each side then install the expansion chamber. Secure the cham- securing the front bumper assembly to the chassis. ber to manifold and upper frame with the springs.
Page 212 ZJ100A ZJ009A 2. Remove the two torx-head cap screws (A) securing 7. Remove the six torx-head screws securing the seat the console to the chassis; then lift up the rearward support assembly to the tunnel; then slide the support end of the console and disconnect the console har- back out of the way.
Page 213 IO053A ZJ015A 13. Inspect the throttle valve thoroughly for carbon resi- CAUTION due buildup. If signs of carbon buildup exist, the The gasoline supply hose may be under pressure. throttle body should be cleaned (see Fuel System Place an absorbent towel around the connection to (EFI) - Throttle Body Assembly in Section 4).
Page 214 INSTALLING 1. Join the air silencer halves and secure with the seven machine screws; then install the dual intake boot and secure with retaining clips. 2. Install the air temperature sensor.  NOTE: Before installing the air silencer, make sure the gasline hose is routed over the air silencer.
Page 215 CAUTION Do not tighten machine screw against the seat sup- port. The screw must be loose enough to be effective as a seat “stop.” Air Silencer (1100 cc Turbo)  NOTE: Air silencer should be inspected weekly and seasonally. ZJ009A 7.
Page 216 6. Remove the cap screw (A) securing the air silencer CAUTION to the right-side upper frame; then loosen the hose clamp (B) and disconnect the air silencer from the Do not carry the turbocharger by the hoses or by the turbo inlet.
Page 217 9. Loosen the hose clamp and remove the waste gate control valve hose from the elbow fitting of the tur- bocharger. 743-780C 13. Remove the lock nuts and washers securing the TZ086B exhaust manifold to the engine cylinder head; then 10.
Page 218 TZ091A TZ093A 16. Remove the four lock nuts securing the turbo to the 2. Inspect the air bypass linkage for signs of wear or exhaust manifold. Account for the gasket and flat damage. washers. INSTALLING 1. With the turbocharger secured in a suitable vise and the gasket in place, secure the turbo outlet to the tur- bocharger with the washers and lock nuts.
Page 219 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. TZ092A 9. Connect the coolant feed hose and oil return hose to the turbo, release the clamps, and secure the hoses with the hose clamps.
Page 220 TZ061 TZ086B 13. Connect the coolant return hose to the turbo and 16. Connect the air silencer hose to the turbo and secure secure with the hose clamp. with the clamp; then secure the air silencer to the right-side upper frame with the cap screw. TZ060A 14.
Page 221 THEORY Voltage Regulator/Rectifier (570/800/1000/1100 cc) Two-cycle engines and their exhaust systems are designed to produce maximum horsepower in a given The AC current from the power coil first enters the regulator/ RPM range. This RPM range will change according to rectifier changing from AC current to DC current.
Page 222 Arctic Cat recommends using Arctic Cat Synthetic APV 2-Cycle Oil. Using oils other than the rec- 3. Slide each cable drum out of the slot of the servomo- ommended oil may increase the frequency of required tor actuator.
Page 223 MS401A CM124A CAUTION  NOTE: Before proceeding with the cable adjust- ment, ensure that the exhaust valves are free to Never attempt to remove or install the servo pulley jam move. nut with the pulley unsecured or damage to the servo- motor will occur.
Page 224 CM147 FC116 2. Remove the retaining screw securing the exhaust 2. Install the new seal using an appropriate-sized seal valve to the valve stopper. driving tool. FC112 FC117 3. Hold the valve stopper securely and pull the cable ASSEMBLING/INSTALLING back and up until it clears the top of the stopper; then slowly release the cable and remove it from the valve stopper.
Page 225 600 cc FC114 FC115 CAUTION  NOTE: Make sure that the small cable end spring stays in place at the end of the cable. On the 600 cc, the long side of the exhaust valve must be facing toward the cylinder head or severe engine 2.
Page 226 6. Perform steps 5-8 in Cable Adjustment in this sub- Exhaust Controlled section. Timing (ECT) System TROUBLESHOOTING (2-Stroke) The APV system has a self-testing mode built in. Every time that the engine is started, the servo will cycle once. The ECU monitors the voltages at the servo during this The APV models are equipped with the Exhaust Con- cycle to assure they are within operational tolerances.
Page 227 SECTION 4 — FUEL SYSTEMS TABLE OF CONTENTS Fuel Systems ............4-2 Fuel System (Carbureted) ........4-2 Fuel System (EFI) ..........4-14 Fuel System (Related Items)......... 4-30 Manual Table of Contents...
Page 228 Description 2256-974 4. Check the impulse hose for cracks or any possible air Arctic Cat Diagnostic System Manual leaks. The hose must fit tightly at both ends. If loose 0644-364 Fuel Pump Socket Wrench or cracked, replace the hose.
Page 229 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 230 CM047 AH144  NOTE: The floats should be removed only if DISASSEMBLING replacement is necessary or the float chamber requires cleaning with carburetor cleaner. VM-34 2. Remove the caps from the float towers; then remove the floats. Remove the drain screw and O-ring. 1.
Page 231 CM051 CM053A 5. Remove the main jet and baffle ring; then remove the 8. Remove the idle speed screw and spring. main jet extender guide from the needle jet. Push the needle jet out through the top of the carburetor. CM053B 9.
Page 232  NOTE: Note the position of the E-clip on the jet nee- 6. When applicable, inspect the tips of the idle speed screw, jet needle, pilot air screw, needle valve, and dle for assembly purposes. fuel mixture screw for wear, damage, or distortion. CAUTION ...
Page 233 CM052 CM050A 4. Insert the needle jet into position from the top of the 7. Check the float arm height. Using a calipers, mea- carburetor making sure the groove in the needle jet is sure the distance from the gasket surface to the top of aligned with the pin in the mixing body;...
Page 234 12. Thread the plunger cap onto the choke cable. Place the spring over the cable end and compress. Position the cable end into the starter plunger and release the spring. INSTALLING 1. Place the piston valve into position making sure the full-length groove in the piston valve is aligned with the pin in the mixing chamber bore;...
Page 235 4. With free-play removed from the lever, slowly rotate 5. Thread the brass choke-cable housing into the carbu- the choke cable adjuster once again clockwise while retor making sure the washer is properly positioned checking the choke cable lever for free-play. Adjust and tighten securely.
Page 236 1 for an initial setting. Synchronizing Piston Valves 3. Synchronize the oil-injection pump (see Related  NOTE: Arctic Cat recommends using a suitable car- Items in this section). buretor synchronizer. If a carburetor synchronizer is Engine Idle Speed not available, use the following procedure.
Page 237 INSTALLING 4. Rotate the PTO-side carburetor idle speed screw clockwise until the tachometer reads slightly above 1. Route the throttle cable from the throttle switch 1500 RPM; then rotate the idle speed screw counter- assembly to the carburetors and oil-injection pump; clockwise to achieve exact 1500 RPM reading.
Page 238 4. Remove the screws securing the console. 7. Cut any cable ties used to secure the choke cable and remove the choke cable from the engine compartment. 5. Position the choke lever in the middle-choke posi- INSTALLING tion; then remove the knurled nut securing the choke lever housing to the console.
Page 239 Problem: Carburetor Too Lean (0-1/4 Opening) Condition Remedy 1. Choke plunger remains seated 1. Adjust — service choke cable — plunger assembly 2. Pilot air screw too far out — damaged 2. Adjust — replace pilot air screw 3. Piston valve sticks open — damaged — worn 3.
Page 240 6. Engine RPM more stable in every condition. FUEL SYSTEM The Arctic Cat EFI System operates off a series of coils The EFI fuel system consists of the following compo- located on the stator and is made up of the following nents.
Page 241 COOLANT TEMPERATURE SENSOR 4. Throttle Position Sensor This sensor is very sensitive to temperature change. The 5. Barometric Pressure Sensor (2-stroke) ECU measures the current flow through the sensor to 6. Knock Sensor (800/1100 cc turbo) ground. From this measurement, the ECU can determine the engine coolant temperature and calculate the correct The fuel is first drawn into the electric fuel pump through fuel/air mixture ratio.
Page 242: Crankshaft Position Sensor
On the 500 cc, the injectors are coded with letters (A-B- C. Fuel pump - see fuel pump test procedure. C). When replacement of a fuel injector is necessary, the D. Wiring harness and connectors - clean the con- injector must be replaced with an injector of the same nectors and test the harness.
Page 243 TROUBLESHOOTING INDIVIDUAL COMPONENTS FZ003B  NOTE: With the Arctic Cat EFI System, the ECU must receive the proper current output from four coils (two charge coils, an injector coil, and a fuel pump coil) to function as designed. If a problem exists, these coils should be checked using the fol- lowing procedures.
Page 244 Injector Coil Resistance Test 2. Connect the analyzer test harness red and black leads to a 12-volt battery. The injector coil located on the stator powers the two injectors. 3. Turn the analyzer switch ON. 1. Disconnect the double-wire plug with two blue/white 4.
Page 245 THROTTLE POSITION SENSOR Installing If the sensor should malfunction, see appropriate Throttle 1. Apply a light coat of oil to all O-rings; then install Position Sensor in Section 5. the upper and lower O-rings onto each injector. FUEL INJECTORS 2. Install the injectors into the throttle body assembly. Testing Resistance 3.
Page 246: Exhaust Temperature Sensor
2. Disconnect the fuel pump from the main wiring har-  NOTE: A coolant temperature sensor voltage test ness. can be made using the EFI Analyzer. 3. Connect the positive lead of a 12-volt power supply  NOTE: On the 2-stroke models, the coolant temper- to the red wire and the negative lead of the 12-volt ature sensor is located at the lower half of the crank- power supply to the black wire.
Page 247 2. Suspend the sensor (only up to the threads) in a 3. Where applicable, connect the oil pump control rod. container filled with automatic transmission oil;  NOTE: The coolant hoses must be connected first; then slowly heat the oil on a hot plate. then the throttle body assembly must be installed.
Page 248 ZJ018A ZJ094D 4. Loosen the clamps securing the throttle bodies to the intake boots; then remove the throttle body assembly. 5. Remove the retaining clips securing the fuel rail to the injectors; then remove the two screws securing the fuel rail to the throttle body assembly. Remove the fuel rail and injectors from the throttle body assembly.
Page 249 ZJ134A ZJ131A 7. Remove the screw securing the throttle sensor; then 3. Install the fuel injectors onto the throttle body assem- remove the sensor from the throttle body assembly. bly; then secure the fuel rail and injectors to the throttle body assembly with the two screws and the retaining clips.
Page 250 REMOVING/DISASSEMBLING (1100 cc Turbo) 1. Remove the two torx-head cap screws (A) securing the console to the chassis; then lift up the rearward end of the console and disconnect the console har- ness plug-in. Remove the console. ZJ094D  NOTE: At this point the throttle position sensor must be adjusted to specification.
Page 251 TZ075B TZ110A  NOTE: If the snowmobile is in warranty, breaking  NOTE: Remove the throttle body ISC valve before the seal on the idle screw jam nut or the Phillips-head using any type of cleaner to clean the throttle body. screws on the TPS will void warranty.
Page 252  NOTE: After removing the fuel rail, account for the four injector gaskets. 12. Remove the four harness connectors from the injec- tors; then carefully remove the injectors from the fuel rail. TZ116A 3. Install new injector gaskets into the intake flange and install the fuel rail/injectors.
Page 253 TZ110A TZ108A  NOTE: Never reuse a throttle body gasket.  NOTE: At the time, make sure the throttle lever free- play is within a range of 0.030-0.060 in. 5. With a new throttle body gasket, secure the throttle body with the cable support bracket to the intake ple- 9.
Page 254: Throttle Cable
3. Secure all wires and hoses with cable ties. 4. Attach the throttle cable to the pulley on the throttle body shaft. Throttle Cable 5. On the 500 cc, install the oil-injection cable adjuster on the oil-injection pump; secure with the jam nuts. 6.
Page 255 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 256 Troubleshooting Fuel System Problem: Too Rich Condition Remedy 1. Diagnostic trouble code activated 1. Replace problem sensor 2. Fuel pressure too high 2. Replace regulator 3. Fuel return hose obstructed 3. Service — replace hose — remove obstruction 4. Injectors leaking 4.
Page 257 10. Install the carburetors/throttle bodies. 800/1000 cc Synchronizing Oil- Injection Pump  NOTE: On certain models, the oil pump cable adjuster is located at the juncture of the throttle cable. CAUTION Use a 100:1 fuel mixture for the following procedure. 0744-528 INSPECTING/ADJUSTING/ 570 cc...
Page 258  NOTE: On all engines, use Arctic Cat Synthetic APV engine lubrication. Failure to use the 100:1 mixture to the oil-injection system will result in severe engine damage.
Page 259 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” are not within specifications, replace the check valve. 4. Record the “release” and “reset” readings for the valve;...
Page 260 3. Remove the extension neck from the gas tank; then 2. Remove the six self-tapping screws (A) securing the holding on to the fuel pump inside the gas tank, retaining plate; then remove the fuel pump and remove the fuel pump outlet fitting (A) and the mount- account for the seal (B).
Page 261 2. With snowmobile on a safety stand, start the engine and accelerate to 2000-3000 RPM for a period of 30 Gas Tank/Seat Assembly seconds. Note maximum reading of gauge. Reading must be within the range listed.  NOTE: To service the gas tank/seat assembly, see 3.
Page 262 SECTION 5 — ELECTRICAL SYSTEMS Testing Fuel Gauge Sender ........5-17 TABLE OF CONTENTS Testing Electric Fuel Pump (2-Stroke)....5-17 Testing Electric Fuel Pump (4-Stroke)....5-17 Testing Ignition Components (4-Stroke) ....5-18 Electrical Systems........... 5-2 Emergency Stop Switch ........5-19 Ignition System (4-Stroke)........
Page 263: Electrical Systems
Electrical Systems For testing procedures for specific 4-stroke EFI electrical system components, refer to the Arctic Cat Diagnostic Sys- tem Manual or to the Laptop Diagnostic Tool. All tests of the electrical components should be made using the digital Fluke Model 77 Multimeter. Replace any component that does not have a test value within specifications.
Page 264 TESTING 3. With the throttle lever in the idle position and the emergency stop knob in the down (STOP) position, Main Wiring And Safety Switches the meter must read resistance (closed). If the meter reads no resistance (open), replace the switch. With 1.
Page 265 2. Crank the engine over and check for spark. If no 5. If the meter reads resistance (closed) but the engine spark is present, check to make sure the throttle cable will not start, with the ohmmeter leads still connected, is properly tensioned.
Page 266 2. To determine which switch needs adjusting, discon- nect both carburetor safety switches from the main wiring harness connector. 3. Connect a digital ohmmeter to one carburetor safety switch connector; then compress the throttle lever while observing the meter reading and measure the gap between the throttle lever and control housing at the moment the meter reading changes from open to closed.
Page 267 VERIFYING TPS ADJUSTMENT TOOL ADJUSTING TPS Before using the TPS adjustment tool, verify its battery  NOTE: Adjusting the TPS is for out of warranty condition. The battery used in the tool is a 9-volt battery. snowmobiles only. To check battery condition, use a digital volt/ohmmeter set on DC volt scale.
Page 268 TPS TOOL ANALYZER TOOL Model (DC VOLTS) (DC VOLTS) 500 cc Full-Closed 0.412-0.414 Idle 0.710-0.818 0.710-0.818 Full-Open 3.472-4.048 3.470-4.046 600 cc Full-Closed 0.412-0.414 Idle 0.646-0.754 0.646-0.754 Full-Open 3.472-4.485 3.470-4.485 DIAGNOSTIC TOOL 800 cc Full-Closed 0.412-0.414 Idle 0.646-0.754 3.99° -6.66° Full-Open 3.472-4.485 74.97°-89.37°...
Page 269 1. Using Throttle Position Sensor (TPS) Adjustment 5. Gently snap the throttle open and closed several Tool Kit, connect its wiring harness to the TPS. Con- times to check the TPS voltage. If it has changed nect the red tester lead to the white adjustment tool from the idle voltage specification, loosen the jack;...
Page 270 FUEL PUMP COIL 1. Test between the two orange wires in the four-prong connector from the stator. 2. Meter reading must be 1.52-2.28 ohms. INJECTION COIL 1. Test between the two blue/white leads in the connec- tor harness from the stator plate. 2.
Page 271 IGNITION SWITCH 2. Set the selector in the OHMS position.  NOTE: On the F5/F6, the console must be removed 3. Connect the two meter leads to each of the yellow leads in the connector from the engine. to access the ignition switch. 4.
Page 272 IGNITION COIL (Primary) Testing Electrical 1. Disconnect the double wire plug from the main har- Resistances (800/1000 cc) ness to the ignition coil. 2. Set the selector in the OHMS position.  NOTE: Resistance tests of the engine electrical 3. Connect the red meter lead to the black/white lead; components should be made using the Fluke Multim- then connect the black meter lead to the white/blue eter only.
Page 273 This test should be made at the three-pin connector of the This test should be made at the three-pin connector of the regulator/rectifier. regulator/rectifier. ! WARNING ! WARNING Most voltages generated by the ignition system are Most voltages generated by the ignition system are sufficient to interrupt pacemakers! All technicians, sufficient to interrupt pacemakers! All technicians, especially those using pacemakers, must avoid con-...
Page 274 SERVICE ICON CCU Diagnostic Codes The Service Icon is controlled by the CCU/ECU and may Code Trouble Cause illuminate for a number of reasons. The icon should illu- CCU 32 High power DC Headlight and Hand Warmer (Red/ minate each time the engine is started, and it should go output over current.
Page 275 HIGH POWER 5. Continue the pulley rotation, and the ohms should appear at a very low value but will again increase to 1. Connect the red maxiclip and meter lead to the red/ 4700-5000 ohms. This is normal operation. black lead; then connect the black maxiclip and meter lead to the black lead.
Page 276 CHARGE COIL (1) LIGHTING COIL 1. Test between the black/red and green/red wires in the 1. Connect the red meter lead to one yellow wire; then triple-plug connector from the magneto. connect the black meter lead to the ground wire. 2.
Page 277 2. Pull the recoil starter rope briskly. Meter reading must be 19.2-23.5V. Testing Low-Oil Light Sensor INJECTION COIL 1. Test between the two blue/white leads in the four- prong connector harness from the magneto. The low-oil light sensor is a magnetic switch. Its opera- tion is based on a magnet located around the inside diam- 2.
Page 278  NOTE: If the sensor has been removed from the 3. Disconnect the fuel gauge sender unit from the main wiring harness. engine for testing purposes, immerse the sensor body (only up to the threads) in automatic transmission fluid  NOTE: On the CFR/Crossfire/M-Series, test from the and slowly heat the fluid.
Page 279  NOTE: Note that the plug-in terminals are desig- Resistance nated A, B, C, and D for testing purposes. CAUTION 2. Connect the positive lead of a 12-volt power supply Always disconnect the battery when performing resis- to the red wire (A) and the negative lead of the 12- tance tests to avoid damaging the multimeter.
Page 280 Method #2 2. On coil #1, connect the red tester lead to the red/green wire; then connect the black tester lead to the gray/ 1. Connect the battery to the solenoid coil terminals green wire. On coil #2, connect the red tester lead to (brown wire and red/white wire).
Page 281 3. The ohmmeter must read less than 1 ohm of resis-  NOTE: If the ignition switch tests good, verify bat- tance. tery voltage to the harness side of the switch plug-in. If there is no voltage, troubleshoot the battery, switch fuse, or starter relay.
Page 282 4. Remove the snap-ring retainer (note end-for-end ori-  NOTE: Starter motor must instantly spin at a high entation), pinion spring, spring retainer, and pinion RPM. The pinion must snap out against the stopper. If gear. Retain all components. the motor does not spin, remove the red cable imme- diately.
Page 283 DISASSEMBLING 4. Place the positive and negative cables on the starter motor; then secure with the lock nuts. Tighten 1. Secure the starter motor in a suitable clamping securely. device; then remove the two long cap screws from the starter motor. FS205A 5.
Page 284 9. Using a caliper, measure the undercut. Maximum undercut groove must be 0.008 in. ZJ142A CLEANING AND INSPECTING SNO2171  NOTE: Whenever a part is worn excessively, CAUTION cracked, or damaged in any way, replacement is nec- essary. Buildup in the grooves must be removed to prevent any chance of an electrical arc between individual sec- 1.
Page 285  NOTE: If no resistance is indicated, check the ground connection for tightness and for cleanliness. If there is still no meter indication, replace the brush assembly. ASSEMBLING 1. With the brush assembly secured in a vise, compress each brush all the way into the housing; then care- fully push the brush wire over and down to secure the brush in the fully compressed position.
Page 286 4. Remove the eighteen cap screws securing the mag- neto cover to the engine; then remove the cover and account for the dowel pins, the oil pump seal, and the gasket. ZJ139A 2. Install the positive cable (A) to the starter motor and tighten securely.
Page 287 ZJ150A 0742-002 3. Install the two alignment pins in the engine for the INSTALLING magneto cover; then with a new gasket, install the 1. Place the magneto into position on the cover; then cover and with the pattern shown, tighten the 18 cap install and tighten the three cap screws to 84 in.-lb.
Page 288 CHECKING 1. Connect a timing light to the MAG-side spark plug lead. 2. Using a shielded safety stand, raise the rear of the snowmobile off the floor and start the engine. Gradu- ally increase the engine speed to the specified RPM; the pointer should align with the proper timing mark on the flywheel.
Page 289 3. Connect the switch harness to the main wiring har-  NOTE: To access the element connectors, the han- ness. Position the wires so they will not be either dlebar control assembly for the side being tested pinched or come in contact with any moving compo- must be removed.
Page 290 2. Remove the four screws securing the left-side han- 3. With the switch in the MED position, connect one dlebar control assembly; then remove the control ohmmeter lead to the green/red wire at the connec- assembly from the handlebar. tor; then connect the other ohmmeter lead to the brown wire at the connector.
Page 291  NOTE: If this resistance test does not read within specification, troubleshoot the switch connector located below the steering support. If the switch con- nector tests good, replace the switch. PASSENGER HEATER SWITCH - Resistance 1. Disconnect the main harness/element connector. 2.
Page 292 4. With the reverse button pressed in, the meter must read less than 1 ohm of resistance. With the reverse Testing Shift Actuator button released, the meter must read OL (open). (500/600/1100 cc)  NOTE: If the meter does not read as specified in either test, the switch is defective and must be ...
Page 293 Troubleshooting Servomotor SERVO1Arv Manual 5-32 Table of Contents...
Page 294 SERVO2rv Manual 5-33 Table of Contents...
Page 295 * Passanger Seat Harness on p. 22. „NOTE: All Magneto Diagrams on ©Arctic Cat Inc., 2010, Thief River Falls, MN 56701 ®™Trademarks of Arctic Cat Inc., P.O Box 810, Thief River Falls, MN 56701 p/n 2258-813 Manual Table of Contents...
Page 296 Magneto Diagram Manual 0744-205 Table of Contents Table of Contents...
Page 297 Main Harness (p/n 1686-600) F570 (p/n 1686-612) Bearcat 570 XT (p/n 1686-601) Bearcat 570/LTD T570 Diagram Manual 0745-594 Table of Contents Table of Contents...
Page 298 Main Harness (p/n 1686-603) F5 LXR Diagram Manual 0745-595 Table of Contents Table of Contents...
Page 299 Main Harness (p/n 1686-598) Crossfire 6 Diagram Manual 0745-596 Table of Contents Table of Contents...
Page 300 Main Harness (p/n 1686-604) F6 Sno Pro Diagram Manual 0745-597 Table of Contents Table of Contents...
Page 301 Main Harness (p/n 1686-606) F8 EXT F8 LXR Diagram Manual 0745-603 Table of Contents Table of Contents...
Page 302 Main Harness (p/n 1686-605) F8 Sno Pro/LTD Diagram Manual 0745-604 Table of Contents Table of Contents...
Page 303 Main Harness (p/n 1686-597) CFR 800 CFR 1000 Crossfire 800/Sno Pro/LTD M8/HCR/Sno Pro/LTD M1000 Sno Pro Diagram Manual 0745-598 Table of Contents Table of Contents...
Page 304 Main Harness (p/n 1686-613) Bearcat Z1 XT (p/n 1686-615) Bearcat Z1 XT LTD Diagram Manual 0745-607 Table of Contents Table of Contents...
Page 305 Main Harness (p/n 1686-611) TZ1 Turbo LXR LTD (p/n 1686-609) Z1 Turbo EXT/LXR (p/n 1686-599) Z1 Turbo Sno Pro Diagram Manual 0745-600 Table of Contents Table of Contents...
Page 306 Main Harness (p/n 1686-610) TZ1/LXR LTD (p/n 1686-608) Z1 LXR (p/n 1686-607) Z1 Sno Pro Diagram Manual 0745-599 Table of Contents Table of Contents...
Page 307 Console Harness (p/n 1686-547) Bearcat Z1 XT Z1 Sno Pro/Z1 Turbo Sno Pro (p/n 1686-549) Bearcat Z1 XT LTD Z1 LXR/Z1 Turbo EXT/LXR Diagram Manual 0744-194 Table of Contents Table of Contents...
Page 308 Console Harness (p/n 1686-631) TZ1 LXR LTD TZ1 Turbo LXR LTD Diagram Manual 0745-601 Table of Contents Table of Contents...
Page 309 Hood Harness (p/n 1686-614) CFR/Crossfire/M-Series Diagram Manual 0744-179 Table of Contents Table of Contents...
Page 310 Console Harness (p/n 1686-567) Bearcat 570/LTD Bearcat 570 XT F570 T570 Diagram Manual 0745-602 Table of Contents Table of Contents...
Page 311 Console Harness (p/n 1686-573) F5 LXR F8 EXT F8 LXR Diagram Manual 0744-190 Table of Contents Table of Contents...
Page 312 Console Harness (p/n 1686-572) F6 Sno Pro F8 Sno Pro/LTD Diagram Manual 0744-191 Table of Contents Table of Contents...
Page 313 Handlebar Harness (p/n 1686-566) Crossfire/M-Series (p/n 1686-575) Diagram Manual 0744-180 Table of Contents Table of Contents...
Page 314 Handlebar Harness (p/n 1686-574) F5 LXR F6 Sno Pro F8 EXT F8 LXR F8 Sno Pro/LTD Diagram Manual 0744-189 Table of Contents Table of Contents...
Page 315 Handlebar Harness (p/n 1686-537) Bearcat 570/LTD/570 XT F570 T570 Diagram Manual 0744-183 Table of Contents Table of Contents...
Page 316 Handlebar Harness (p/n 1686-568) TZ1/TZ1 LXR LTD/TZ1 Turbo LXR LTD Z1 LXR/Sno Pro Z1 Turbo EXT/LXR/Sno Pro (p/n 1686-577) Bearcat Z1 XT/LTD Diagram Manual 0744-195 Table of Contents Table of Contents...
Page 317 Passenger Seat Harness (p/n 1686-570) TZ1 Models Diagram Manual 0744-197 Table of Contents Table of Contents...
Page 318 Ignition/Main Harness (p/n 1686-628) Sno Pro 500 Diagram Manual 0745-605 Table of Contents Table of Contents...
Page 319 Hood Harness (p/n 1686-587) Sno Pro 500 Diagram Manual 0744-201 Table of Contents Table of Contents...
Page 320 Ignition/Main Harness (p/n 1686-629) Sno Pro 600 Diagram Manual 0745-606 Table of Contents Table of Contents...
Page 321 Hood Harness (p/n 1686-596) Sno Pro 600 C.C. (p/n 1686-595) Sno Pro 600 Sno Cross Diagram Manual 0744-202 Table of Contents Table of Contents...
Page 322 Handlebar Harness (p/n 1686-590) Sno Pro 500 Diagram Manual 0744-200 Table of Contents Table of Contents...
Page 323 Main Harness (p/n 1686-578) Sno Pro 120 Diagram Manual 0744-204 Table of Contents Table of Contents...
Page 324 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 ............6-5 Drive Clutch/Driven Pulley........6-9 Drive Train/Brake Disc ........... 6-12 Drive Sprockets ............. 6-29 Track Tension ............6-31 Track Alignment.............
Page 325: Drive Belt
 NOTE: Some illustrations and photographs used in tem. ONLY ARCTIC CAT DRIVE BELTS SHOULD BE this section are used for clarity purposes only and USED. Different brands of belts may not have the same are not designed to depict actual conditions.
Page 326 0744-551 ZJ293 6. Install the sheave adjuster and cap screw onto the 3. Remove the drive clutch and drive belt from the driven pulley; then tighten the cap screw until the engine compartment. movable sheave opens far enough to allow the belt to be removed.
Page 327 Assembling 1. With the head of each cam arm pin positioned towards the direction of the drive clutch rotation, install the cam arms.  NOTE: The drive clutch rotates counterclockwise. 2. With the cam arm pin properly positioned, apply green Loctite #620 to the set screw holes in the cam arm, install the new set screws (pre-coated with Loc- tite), and tighten to 19 in.-lb.
Page 328 2. Using a 9/16-in. socket and extension, remove the cap screw securing the driven pulley to the input shaft. 3. Slide the driven pulley off the shaft.  NOTE: Account for and remove any alignment washers. These washers must be used during install- ing.
Page 329  NOTE: To loosen the torx-head cap screws, it may be necessary to insert a torx-bit and strike each screw with a hammer. 4. Release the compression of the spring by removing the wing nut; then remove the movable sheave. Account for the torque bracket retainer.
Page 330 7. Inspect the cover and movable sheave bearings for 3. Install the new bearing; then secure with the snap wear. For each respective bearing, measure the out- ring. side diameter of the shaft and the inside diameter of REPLACING ROLLERS the bearing.
Page 331 CM066 CM063  NOTE: Premature wear will result if the plastic washer is not installed. 2. Noting the alignment marks made during disassem- bling and with the spring seat and spacer on the sta- tionary sheave shaft, place the stationary sheave onto the torque bracket.
Page 332 FS093 CM125A 5. With the pulley in place on the compressor, install CAUTION the compressor flange spacer and wing nut; then Do not apply Loctite to the cap screw or damage to the compress the driven pulley spring. gear case will occur. 3.
Page 333 0744-549 0744-609 3. If parallelism is not within specifications, the paral- CORRECTING OFFSET lelism must be corrected by first loosening all the 1. To correct offset, the driven pulley must be moved engine mounting bolts (left side, front, and right top laterally on the input shaft.
Page 334 6. Once the drive clutch offset is corrected. Tighten cap screw to 25 ft-lb from step 5. 7. Install drive belt, drive belt guard, right- and left-side access panels, and the hood. DRIVE BELT DEFLECTION Drive belt length, condition, and deflection are all impor- tant for peak performance.
Page 335 Drive Train/Brake Disc Removing Gear Case/Track Driveshaft ....6-12 Installing Track Driveshaft/Gear Case ....6-14 Disassembling Gear Case (w/Reverse) ....6-17 Cleaning and Inspecting Gear Case (w/Reverse)............6-19 Assembling Gear Case (w/Reverse) ..... 6-20 Disassembling Gear Case (w/o Reverse) ..... 6-23 Cleaning and Inspecting Gear Case (w/o Reverse).............
Page 336 742-020A ZJ308A 7. Place the snowmobile in the upright position; then  NOTE: If the gear case is being removed, do not using a 5/8-in. socket, long extension, and a hammer, remove the 5/8-in. cap screw. If only the track drive- tap against the driveshaft cap screw until the gear shaft is being removed, remove the cap screw and case is free from the studs of the mounting plate.
Page 337  NOTE: Prior to installing the driveshaft, apply a coat of Anti-Seize Thread Compound to the internal splines of the driveshaft. ZJ211 12. Using the Rear Suspension Spring Tool, remove the spring from the adjusting cam. ! WARNING ZJ213A 1. If the brake disc was removed, place the track/drive- Care must be taken when removing the spring or dam- shaft assembly into the bearing of the brake housing age or injury could result.
Page 338 7. Place the resonator into position and secure with the springs and hairpin clip. 8. Install the skid frame (see Section 7).  NOTE: At this point if the gear case is installed, pro- ceed to step 22 to finish installing the track drive- shaft.
Page 339 MS299A ZJ183A 14. Install the toe shield and toe hook bracket; then install the torx-head cap screws. Tighten securely. ZJ309A  NOTE: Use of a quality silicone spray will aid in installing the torque bumper. 0742-089 15. On the 600 cc Crossfire/M-Series, connect shift actu- 12.
Page 340 2. Remove the torx-head cap screws securing the gear case cover to the gear case assembly; then insert two flat-blade screwdrivers into the slots on the gear case. Working back and forth, pry the cover up and off the gear case. Discard the gasket. 0742-020 17.
Page 341 5. Secure the gear case cover in a suitable clamping device; then using two flat-blade screwdrivers from opposite sides of the cover bearing, evenly pry the input shaft bearing up and off the shaft. MS331 8. Secure the gear case in a suitable clamping device; then using the procedure from step 5, remove the outer bearing from the transfer gear.
Page 342 ZJ194 ZJ197 11. Using a suitable bearing puller, remove the inner 13. Remove the retaining ring and thrust washer secur- bearing from the transfer gear assembly. Account for ing the slider housing assembly to the output shaft a spacer washer. assembly.
Page 343 If any damage or binding is noted, ing with the thrust washer and retaining ring. 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 344 7. With the alignment notches of the slider and gear case properly positioned, install the slider/output gear assembly into the gear case. ZJ196 ZJ201 8. Using a suitable bearing press, install the outer bear- ing onto the transfer gear shaft. ZJ197 5.
Page 345 ZJ204 ZJ205 10. Using a suitable press, install the input shaft to the  NOTE: Make sure to install the slider blocks with gear case cover. the rounded end up and the raised edges facing to the outside of each other. MS349 11.
Page 346 ZJ186A 16. Pour 12 fl oz of Arctic Cat Synthetic ACT Drive MS329 Fluid into the drain/fill hole; then install the plug. 4. Using a suitable bearing press and fixture, press the Tighten to 12 ft-lb.
Page 347 MS512 MS516A 6. Secure the transfer gear in a suitable clamping  NOTE: Note the orientation of the planetary gear device; then using two flat-blade screwdrivers from assembly for assembling purposes. opposite sides of the cover bearing, evenly pry the input shaft bearing up and off the shaft.
Page 348 6. Inspect the planetary and ring gears for wear, cracks, or chipped teeth. 7. Apply a light film of Arctic Cat ACT Drive Fluid to the unsealed bearings prior to assembling. Manual 6-25...
Page 349 MS517 MS518A 4. With the proper orientation as noted during disas- 6. Using a suitable bearing press, install the outer bear- sembling, install the gear assembly into the planetary ing (A) to the transfer gear assembly; then install the gear and secure with the retaining ring. spacer (B) and press the inner bearing (C) to the assembly.
Page 350 744-133C MS347 744-134C 12. Pour 15 fl oz of Arctic Cat Synthetic ACT Gear Case Fluid into the drain/fill hole; then install the plug. MS351 Tighten securely. 10. Using a suitable press, install the input shaft to the gear case cover.
Page 351 2. Remove the drive belt (see Drive Belt in this sec- 8. Pour the recommended amount of Arctic Cat ACT tion); then remove the driven pulley. Drive Flush Fluid into the check/fill hole; then install the plug. Tighten securely. 3. Tip the snowmobile onto its right side and use a suit-...
Page 352 CAUTION Do not add more or less than the recommended amount of lubricant to the gear case or damage to the gear case will occur. Oil level should be at the Oil Fill Level on the gear case cover. 21. Install the driven pulley; then install the drive belt (see Drive Belt sub-section) and the belt guard.
Page 353 ZJ216A MS361A 3. Slide the remaining sprocket onto the driveshaft  NOTE: Prior to installing the sprockets onto the making sure the timing arrow/lines (from removing) driveshaft, lightly chamfer the inside edge of the are aligned; then using the press/fixture, press the sprocket to avoid binding.
Page 354 740-043A 744-061A 4. Using a calipers, measure distances between the sprockets and from the sprockets to each end of the driveshaft for proper location (see appropriate illus- tration). 744-060B MS364 742-366A Track Tension 744-059B ! WARNING Deactivate all switches. CHECKING DEFLECTION 1.
Page 355: Track Alignment
ADJUSTING DEFLECTION ! WARNING 1. Place the snowmobile up on a shielded safety stand. Check to make sure the track is 2-3 in. off the floor. The tips of the skis must be positioned against a wall or similar object for safety. Keep hands, feet, and 2.
Page 356 (see Checking and Replacing Brake Pads in this sub-section). ! WARNING Use only Arctic Cat approved brake fluid. Any substi- ! WARNING tute may result in a loss of brakes. Do not operate the snowmobile if the distance 1.
Page 357 5. Proceed to bleed the brake system (see Bleeding 1. Remove the brake fluid reservoir cover; then remove Brake System in this sub-section). most of the brake fluid from the reservoir. Replace the cover. BLEEDING BRAKE SYSTEM  NOTE: The above procedure will allow room for the If the brake lever feels spongy when applied, the brake fluid from the caliper when the pistons are pushed system may need to be bled.
Page 358 ZJ210A ZJ224 4. Engage the brake lever lock; then using Brake Disc 5. Using a flat-blade tool, slowly and carefully push the Socket Wrench, remove the retaining nut from the piston into the caliper. driveshaft. 6. Position the new brake pads into the caliper. 7.
Page 359  NOTE: If servicing the brake disc only, remove the two remaining torx-head cap screws securing the cal- iper housings together; then remove the outside housing. Account for the O-ring. ZJ226 CAUTION Use care not to bind the bearing in the caliper hous- ing when removing or damage to the housing may occur.
Page 360 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 361 AF230 0739-269 3. Inspect the piston bore of the inner and outer brake 6. Inspect the brake hose for cracks and deterioration calipers for gouges, cracks, pitting, scuffing, or cor- and check the condition of the threaded connectors. rosion. If any of these conditions exist, replace the Assembling/Installing caliper.
Page 362 ZJ230 ZJ241 CAUTION  NOTE: To aid in installing the piston, make sure the piston O-ring is properly seated in the groove of the When installing a bearing, always press on the outer caliper housing. race of the bearing. 3. Place the small O-ring into position; then assemble the two caliper halves.
Page 363 ZJ244 ZJ232 CAUTION When installing a bearing, always press on the outer race of the bearing.  NOTE: For aid in installing the outer bearing, insert a length of shaft (the same diameter as the bearing inner bore) through the inner bearing, drive- shaft sleeves, and outer bearing to maintain proper alignment of the driveshaft sleeves for driveshaft installation.
Page 364 MS320A ZJ210A 15. Connect the harness connector to the speedometer sensor plug-in. 16. Install the toe shield and toe hook bracket; then install the torx-head cap screws. Tighten securely. 17. Place the expansion chamber and resonator into posi- tion and secure with the springs and the hairpin clip. 18.
Page 365 1. Inspect the snap ring and pin securing the brake lever for wear or damage; then inspect the brake lever for cracks or damage. 2. Inspect the master cylinder reservoir and cover for cracks and leakage.  NOTE: The master cylinder is a non-serviceable component.
Page 366 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 367 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 368 Troubleshooting Drive Belt Problem: Drive Belt Glazed Condition Remedy 1. Drive belt does not meet measurement specifications 1. Replace drive belt 2. Drive clutch spring tension inadequate 2. Replace drive clutch spring 3. Drive clutch components dirty — damaged 3. Clean — replace drive clutch 4.
Page 369 SECTION 7 — REAR SUSPENSION TABLE OF CONTENTS Rear Suspension............. 7-2 Suspension Setup Basics ........7-2 Chassis and Skid Frame Mounting Locations ..7-5 Servicing Rear Suspension Bearcat XT ............7-9 CFR..............7-32 Crossfire/M-Series ..........7-54 F-Series/Z1 ............7-70 Bearcat 570/T-Series/EXT Models ..... 7-89 Servicing ACT Shock ..........
Page 370: Rear Suspension
Rear Suspension SPECIAL TOOLS A number of special tools must be available to the techni- cian when servicing the rear suspension. Description Shock Absorber Air Pump 2603-614 Floating Piston Installation/Location Tool Kit 0644-402 Idler Wheel Puller Kit 0644-122 Idler Wheel Puller Kit 0644-400 0728-180 Floating Piston Removal Tool...
Page 371 When riding in sticky snow (springtime or warm days) or 2. With stiffer springs, the front end will become more hill climbing on hard snow, it may be desirable to stiffen aggressive in the corners as more weight will be the front arm spring tension.
Page 372 4. To increase air pressure in the shock, pump until desired pressure is attained. 5. Remove the pump valve from the shock air valve.  NOTE: As the pump valve is being removed from the shock, the sound of air loss is from the pump hose, not from the shock.
Page 373 Chassis and Skid Frame Mounting Locations The suspensions have several possible mounting loca- CAUTION tions in the slide rails and tunnel. However, Arctic Cat recommends that when disassembling and assembling All stock mounting locations must be used. If any the suspension, all stock mounting locations be used as alterations to the skid frame are made, shock absorber shown in the following illustrations.
Page 374 Bearcat 570 0744-126 Crossfire Models 0745-585 Manual Table of Contents...
Page 375 0744-128 M-Series 0745-584 Manual Table of Contents...
Page 376 Bearcat XT 0744-841 EXT Models 0744-842 Manual Table of Contents...
Page 377  NOTE: At this point if servicing the articulating skid Servicing Rear Suspension frame only, proceed to Articulating Skid Frame in this (Bearcat XT) sub-section. Wear Strips This Rear Suspension sub-section has been organized so each procedure can be completed individually and efficiently.
Page 378 REMOVING 1. Clean the slide rail using parts-cleaning solvent and compressed air. 1. Remove the lock nut, washers, and cap screw secur- ing the end cap. ! WARNING Always wear an approved pair of safety glasses when using compressed air. 2.
Page 379 4. Inspect the cap screw for cracked, stretched, or dam- aged threads. Use a new lock nut when assembling. Idler Wheels/Mounting Blocks INSTALLING 1. Position the end cap on the slide rail; then align the hole in the end cap with the hole in the slide rail. ...
Page 380 MS005 MS007A E. Install the insert (if applicable). CLEANING AND INSPECTING  NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is nec- essary. 1. Clean the bearing with a clean cloth. 2. Inspect each idler wheel and each plastic hub for cracks or damage.
Page 381 MS009A MS208 2. Place the two shim washers (if applicable), idler wheel, and axle against the mounting block making Rear Upper Idler Wheels/ sure a flat washer is on the outside of the idler wheel. Rear Springs  NOTE: The skid frame must be removed for this pro- cedure (see Removing Skid Frame in this sub-sec- tion).
Page 382 3. Loosen the cap screws securing the pivot arm to the idler arm; then remove the pivot arm assembly. Account for two pivot arm spacers. SC016A SC014A  NOTE: Unless the pivot arm is being replaced, the cap screws and lock nuts do not need to be removed to remove the pivot arm.
Page 383 5. Inspect the spring, spring slide, sleeve, washers, slide block insert, and shaft area for wear. 6. Inspect the adjusting cams and arms for cracks. INSTALLING 1. Slide the sleeve and spring onto the idler arm. SC018 CAUTION When driving the idler wheel onto the idler arm, use a tool to contact the inside race of the bearing or dam- age to the wheel or bearing may occur.
Page 384 7. Install the skid frame (see Installing Skid Frame in  NOTE: Mark the hole that the upper shock links are this sub-section). mounted in for assembly purposes.  NOTE: Install the rear arm springs onto the adjuster blocks after the skid frame has been installed. Idler Arm/Rear Arm ...
Page 385 7. If an idler wheel bearing must be replaced, see Idler Wheels/Mounting Blocks - Cleaning and Inspecting in this sub-section. ASSEMBLING 1. Install the rear arm onto the idler arm with an alumi- num axle, bushing assemblies, and two cap screws (coated with blue Loctite #243).
Page 386 4. Position the shock links in the appropriate holes of 8. Install the skid frame (see Installing Skid Frame in the idler arm brackets (see Chassis and Skid Frame this sub-section). Mounting Locations in this section). Place a spacer  NOTE: Install the rear arm springs onto the adjuster between the center of the brackets.
Page 387 6. Remove the outer spacers and idler wheels; then slide the axle out of the shock bracket.  NOTE: On idler wheels with a non-removable bear- ing, account for the flared spacers. SC025A SC028 7. Remove the cap screw and lock nut securing the shock absorber to the bracket.
Page 388 MS086A SC026A 4. Position the front arm into the slide rail. Secure with  NOTE: Do not over-tighten the shock absorber cap cap screws and lock nuts. Tighten to 40 ft-lb. screw as the shock eyelet must be free to pivot. 2.
Page 389 SC024A MS089A  NOTE: Do not over-tighten the shock absorber cap screw as the shock eyelet must be free to pivot. 6. Secure the limiter straps to the rail supports with cap screws, washers, and lock nuts. Tighten to 72 in.-lb. 7.
Page 390 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  NOTE: Whenever a part is worn excessively, upward and out from between the rails. cracked, or damaged in any way, replacement is nec- essary.
Page 391 MS096A SC033  NOTE: Do not over-tighten the shock absorber cap screw as the shock eyelet must be free to pivot. 2. Apply a thin coat of low-temperature grease to the axle and slide the axle and center spacer into the shock pivot bracket.
Page 392 MS100 AG510D  NOTE: Do not over-tighten the shock absorber cap  NOTE: If binding of the wear strip occurs, use a pipe screw as the shock eyelet must be free to pivot. wrench, start from either end, and hook the edge of the wear strip with the pipe wrench jaw and twist the 7.
Page 393 SC037A SC040A  NOTE: Depending on the slide rail being replaced, the rear idler wheel from the opposite side may need to be removed to remove the cap screws securing the articulating skid frame being removed. MS108 10. Remove the cap screw and lock nut securing the overload spring tension block to the slide rail.
Page 394 SC042A AG530D 13. Remove the cap screw and lock nut securing the rear arm to the rail. 0743-189 INSTALLING SC043A 1. Place the slide rail into position; then install the cap screws and new lock nuts securing the components  NOTE: At this point, the slide rail should be free of to the slide rails in the following order and tighten the skid frame components and can be removed.
Page 395 SC043B MS119A 6. Place the spring into the spring slide; then with the  NOTE: Take care that all the shim washers and overload spring in position, place the spring slide spacers are in place on the center components of the and slide block assembly into position on the slide slide rail.
Page 396 MS121A MS288 9. Secure the outer idler wheel to the mounting block 11. From the back, start the wear strip onto the rail; then with a cap screw, flat washers, idler wheel, and a using a soft hammer, drive the wear strip forward lock nut.
Page 397 5. From one side, slide the rear axle (I) out from between the swing arm and account for the two idler wheel spacers (J) and two washers (K). 6. Remove the two cap screws and lock nuts (L) secur- ing the adjuster blocks (M) to the swing arm. INSPECTING ...
Page 398 744-166A ADJUSTING CAUTION 1. Place the skid frame assembly on a flat work surface. When installing the skid frame, make sure the rear arm 2. Preload the articulating suspension by equally shock mounting location on the pivot/axle is posi- adjusting the lock nuts on the spring brackets until tioned correctly above the axle or component damage both rear idler wheels are 1 in.
Page 399 6. Tip the snowmobile onto the other side; then align  NOTE: At this point, tighten all remaining skid the rear arm assembly with the appropriate hole in frame mounting hardware to 40 ft-lb. the tunnel. Secure the pivot arm assembly with a cap screw, lock washer, and flat washer.
Page 400 Servicing Rear Suspension Wear Strips (CFR)  NOTE: The skid frame does not have to be removed for this procedure; however, if wear strip binding or This Rear Suspension sub-section has been organized slide rail damage has occurred, the skid frame so each procedure can be completed individually and efficiently.
Page 401 REMOVING 1. Clean the slide rail using parts-cleaning solvent and compressed air. 1. Remove the lock nut, washers, and cap screw secur- ing the end cap. ! WARNING Always wear an approved pair of safety glasses when using compressed air. 2.
Page 402 4. Inspect the cap screw for cracked, stretched, or dam- aged threads. Use a new lock nut when assembling. INSTALLING 1. Position the end cap on the slide rail; then align the hole in the end cap with the hole in the slide rail. 2.
Page 403 MS009A MS006A 2. Place the idler wheel to the mounting block; then D. Install the snap ring making sure the “sharp side” secure the idler wheel assembly with a cap screw, is directed away from the bearing. flat washer, and a lock nut. Tighten to 20 ft-lb. MS007A E.
Page 404 2. Mark the pivot arm and the idler arm for assembly purposes; then remove the cap screws securing the pivot arm assembly to the idler arm. Remove the pivot arm assembly. SC049B MS142 MS014 6. Remove the spring and sleeve from the idler arm. MS064 ...
Page 405  NOTE: If the idler wheel has no snap ring securing CAUTION the bearing, the idler wheel is not serviceable. When driving the idler wheel onto the idler arm, use a 5. Inspect the spring, spring slide, sleeve, washers, slide block insert, and shaft area for wear.
Page 406 DISASSEMBLING 1. Remove the cap screw and large flat washer securing the outer rear idler wheel. Remove the outer idler wheel from the shaft. SC051A 6. Align the marks on the idler arm to the centerline of the pivot arm assembly. Secure the pivot arm to the idler arm with cap screws and lock nuts.
Page 407 3. Inspect the outer rubber portion of the idler wheels for cracks and poor bonding. 4. Inspect the plastic insert of each idler wheel for cracks. 5. Inspect the shaft for wear and damaged threads. 6. Inspect all idler wheel bearings. Turn each bearing (by hand) and if any roughness or binding is noted, replace the bearing.
Page 408 4. Remove the cap screw and lock nut securing the rear arm to the slide rail. Account for the serrated axles and axle tube. FZ040A  NOTE: Mark the hole that the upper shock links are mounted in for assembly purposes. FZ042A MS155 MS028...
Page 409 CLEANING AND INSPECTING 3. Position the shock links in the appropriate holes of the idler arm brackets (see Chassis and Skid Frame  NOTE: Whenever a part is worn excessively, Mounting Locations in this section). Place a spacer cracked, or damaged in any way, replacement is nec- between the center of the brackets;...
Page 410 739-992A MS162A 3. Remove the cap screw and lock nut securing the  NOTE: Install the rear arm springs onto the adjuster front arm to the slide rail. blocks after the skid frame has been installed. 5. Install the rear upper idler wheels, rear springs, and pivot arm (see Rear Upper Idler Wheels/Rear Springs in this sub-section).
Page 411 MS164 FZ052 5. Remove the cap screws securing the front inner idler wheels to the idler wheel mounting block. Account for lock nuts, cap screws, shim washers (if applica- ble), and flat washers. MS167 7. Remove the lock nut and cap screw securing the rear shock pivot/inner idler wheel assembly to the slide rail.
Page 412 MS169A MS171 3. Install the axle into the lower shock eyelet bushing INSPECTING assembly; then install the two spacers and the two  NOTE: Whenever a part is worn excessively, shim washers. cracked, or damaged in any way, replacement is nec- essary.
Page 413 SC054A SC056A 6. Secure the upper shock eyelet and serrated axle in the appropriate mounting hole of the front arm (stan- Rear Shock Absorber and dard arm mounting position). Secure with a cap Shock Links/Idler Wheel/ screw and lock nut. Tighten securely. Pivot Assembly ...
Page 414 AG665D MS178 2. Remove the cap screw and lock nut securing the 4. Remove the axle from the shock pivot. Account for shock rod links to the idler arm. Account for a spacer an axle, three spacers, and four washers. and two axle links.
Page 415 MS181 MS180 CLEANING AND INSPECTING  NOTE: Do not over-tighten the shock absorber cap screw as the shock eyelet must be free to pivot.  NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is nec- 2.
Page 416 REMOVING  NOTE: When replacing one or both slide rails is necessary, remove one slide rail at a time. The remaining slide rail will then hold the crossbraces, axles, and brackets in their correct assembly order. Always mark the mounting hole locations during dis- assembly to speed up the assembly process and to prevent any damage.
Page 417 FZ095A SC049B 7. Remove the cap screws securing the front arm  NOTE: If removing the axle cap screws is necessary mounting bracket. Account for lock nuts. for replacing the slide rail, install the cap screw from the opposite side into the assembly to secure compo- nents and aid in replacing the slide rail.
Page 418 2. Inspect the wear strip for wear. The wear strip must be 0.42 in. thick or thicker. If the wear strip measure- ment is less than specified, replacement of both wear strips is necessary. FZ064  NOTE: The adjusting bolt may have to be loosened to remove the adjuster bushing.
Page 419 3. Secure the front arm mounting bracket with the cap screws and lock nuts. Tighten to 20 ft-lb. MS198A 6. Secure the front arm shock axle to the rail with the cap screw (if removed), washers, and the lock nut. MS188A Tighten only until snug.
Page 420 CM228A MS206A  NOTE: To obtain proper alignment for the idler wheel  NOTE: Apply a light coat of grease to the slide rail cap screw, place the cap screw in the top hole through surface to aid in installing a new wear strip. Use a file the rail and mounting block prior to tightening.
Page 421 MS016B 739-992A 14. Install the skid frame (see Installing Skid Frame in  NOTE: To aid in centering the front arm with the this sub-section). hole in the tunnel, position the skid frame and track at a 45° angle to the bottom of the tunnel. Installing Skid Frame 4.
Page 422 Servicing Rear Suspension Wear Strips (Crossfire/M-Series)  NOTE: The skid frame does not have to be removed for this procedure; however, if wear strip binding or This Rear Suspension sub-section has been organized slide rail damage has occurred, the skid frame so each procedure can be completed individually and efficiently.
Page 423 REMOVING ! WARNING 1. Remove the lock nut, washers, and cap screw secur- Always wear an approved pair of safety glasses when ing the end cap. using compressed air. 2. Inspect the slide rail for cracks. If any cracks are found, replace the slide rail.
Page 424 4. Inspect the cap screw for cracked, stretched, or dam- aged threads. Use a new lock nut when assembling. INSTALLING 1. Position the end cap on the slide rail; then align the hole in the end cap with the hole in the slide rail. 2.
Page 425 MS006A CM229 D. Install the snap ring making sure the “sharp side” is directed away from the bearing. Rear Axle  NOTE: The skid frame must be removed for this pro- cedure. DISASSEMBLING 1. Remove the cap screw and large flat washer securing the outer rear idler wheel.
Page 426 CM230 CM224A ASSEMBLING  NOTE: Make sure the hole in the bushing is directed to the adjusted bolt. 742-863A 1. In order from the right-hand side, slide the axle CM261A through the slide rail axle slot; then place a bushing ...
Page 427  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. CM231 CM235C ...
Page 428 CLEANING AND INSPECTING  NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is nec- essary. 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.
Page 429 REMOVING 1. Remove the cap screws and lock nuts securing the rear arm shock absorber and shock link to the front arm pivot and account for the sleeves. CM232 6. Turn the slide rail onto the side the idler wheel was installed in (from step 5);...
Page 430 CM242A CM244 5. Remove the front arm and account for the two front arm spacers. CM245 INSPECTING MS164  NOTE: Whenever a part is worn excessively, 6. To access the front shock axle cap screws, remove cracked, or damaged in any way, replacement is nec- the cap screw securing the front outer idler wheel to essary.
Page 431 CM246A CM241 2. Place the front arm shock axle assembly into position  NOTE: Do not over-tighten the shock absorber cap on the skid frame making sure the spacers and wash- screw as the shock eyelet must be free to pivot. ers are properly positioned.
Page 432 REMOVING  NOTE: When replacing one or both slide rails is necessary, remove one slide rail at a time. The remaining slide rail will then hold the crossbraces, axles, and brackets in their correct assembly order. Always mark the mounting hole locations during dis- assembly to speed up the assembly process and to prevent any damage.
Page 433 CM251A CM254A 8. Remove the cap screws, washers, and lock nut from the rear arm. CM252A 6. Remove the idler wheel cap; then remove the cap screw and flat washer securing the rear idler wheel. CM255A Remove the idler wheel; then remove the adjuster bushing.
Page 434 CM256A 0743-189 INSTALLING  NOTE: If removing the front shock axle cap screw is necessary to replace the slide rail, install the cap 1. Place the slide rail into position. With the spacers screw from the opposite side into the assembly to and washers in place, install the front arm shock secure the axle and aid in replacing the slide rail.
Page 435 CM249B CM260 5. Secure the track adjuster bracket with the cap screws  NOTE: Make sure the spacers are installed to the and lock nuts. Tighten to 120 in.-lb. front rail support before installing.  NOTE: At this time, tighten the cap screws and lock nuts from steps 2 and 3 to 40 ft-lb.
Page 436 10. Secure the end cap onto the slide rail using a cap screw, flat washers, and a lock nut. Tighten to 80 in.- CM261A  NOTE: Tighten the rear idler wheel axle only until snug until the skid frame has been installed and track tension has been adjusted;...
Page 437 CM222A 739-992A 12. Install the skid frame (see Installing Skid Frame in  NOTE: To aid in centering the front arm with the this sub-section). hole in the tunnel, position the skid frame and track at a 45° angle to the bottom of the tunnel. Installing Skid Frame 4.
Page 438 Servicing Rear Suspension Wear Strips (F-Series/Z1)  NOTE: The skid frame does not have to be removed for this procedure; however, if wear strip binding or This Rear Suspension sub-section has been organized slide rail damage has occurred, the skid frame so each procedure can be completed individually and efficiently.
Page 439 REMOVING 1. Clean the slide rail using parts-cleaning solvent and compressed air. 1. Remove the lock nut and cap screw securing the end cap. ! WARNING Always wear an approved pair of safety glasses when using compressed air. 2. Inspect the slide rail for cracks. If any cracks are found, replace the slide rail.
Page 440 4. Inspect the cap screw for cracked, stretched, or dam- aged threads. Use a new lock nut when assembling. INSTALLING 1. Position the end cap on the slide rail; then align the hole in the end cap with the hole in the slide rail. 2.
Page 441 FZ032 MS006A D. Install the snap ring making sure the “sharp side” is directed away from the bearing. Rear Arm Assembly  NOTE: The skid frame must be removed for this pro- cedure (see Removing Skid Frame in this sub-section). REMOVING 1.
Page 442 3. Loosen the cap screws and lock nuts securing the pivot arm assembly to the idler arm; then remove the pivot arm assembly. Account for a flanged axle, idler spacer, and washer. FZ038A FZ035A MS014 6. Remove the spring and sleeve from the idler arm. FZ036 4.
Page 443 FZ040C FZ042A 8. Remove the cap screw (A) and lock nut securing the CLEANING AND INSPECTING rear arm shock absorber to the rear shock pivot; then remove the cap screw (B) and lock nut securing the  NOTE: Whenever a part is worn excessively, shock absorber link to the pivot and account for the cracked, or damaged in any way, replacement is nec- cap screws, lock nuts, and sleeves.
Page 444 FZ044 FZ040C 3. With the sleeves installed, install the shock absorber  NOTE: Do not over-tighten the shock absorber cap link to the lower mounting hole of the rear shock pivot; then install the shock absorber with cap screws screw as the shock eyelet must be free to pivot. (A) and (B) and lock nuts.
Page 445 FZ045 FZ047 7. With a suitable driving tool, install the rear upper 9. Place the flared bushing with a thin flat washer idler wheel on the idler arm. through the notched side of the pivot arm assembly.  NOTE: If the flared bushing in the pivot arm is loose, it must be cleaned and green Loctite #609 must be applied to it prior to installation.
Page 446 ASSEMBLING REAR AXLE Rear Axle/Idler Wheels DISASSEMBLING REAR AXLE  NOTE: The skid frame must be removed for this pro- cedure (see Removing Skid Frame in this sub-sec- tion). 1. Remove the cap screw and large flat washer securing the outer rear idler wheel. Remove the outer idler wheel from the shaft.
Page 447 4. Remove the cap screw and lock nut securing the Front Arm Assembly front arm to the front arm mounting bracket.  NOTE: The skid frame must be removed for this pro- cedure (see Removing Skid Frame in this sub-sec- tion), and the rear springs must be removed from the adjusting cams.
Page 448 FZ052 FZ053 3. On the side that the idler wheel and mounting block INSPECTING were removed from, secure the mounting block on  NOTE: Whenever a part is worn excessively, the slide rail with a cap screw and lock nut. Tighten to 20 ft-lb.
Page 449 FZ054 ZJ270 6. Secure the rear shock pivot to the front arm with cap screw and lock nut. Tighten to 20 ft-lb. Slide Rails  NOTE: The skid frame must be removed for this pro- cedure (see Removing Skid Frame in this sub-sec- tion).
Page 450 FZ079A FZ081A  NOTE: If binding of the wear strip occurs, use a pipe wrench, start from either end, and hook the edge of the wear strip with the pipe wrench jaw and twist the wear strip off the slide rail. Move the pipe wrench 3 in.
Page 451 FZ059A FZ062A 11. Remove the cap screw securing the rear arm coupler  NOTE: If not already done, remove the short spring block to the slide rail. Account for the block, bush- leg from the adjusting cam. ing, cap screw, and lock nut. 8.
Page 452 FZ067A AG530D 14. Remove the cap screw and lock nut securing the rear arm assembly to the slide rail. 0743-189 3. Inspect the front arm slider bumpers for cracks or wear. FZ065A  NOTE: At this point, the slide rail should be free of the skid frame components and can be removed.
Page 453 2. With the slide rail assembly on its side, place the rail that was removed or replaced into position; then push the rear arm cap screw and the pivot shock axle cap screw through the mounting holes in the rail. 3.
Page 454 FZ073A FZ075 8. Place the spring into the spring slide; then place the  NOTE: On the Sno Pro models, install the rear inner spring slide and slide block assembly into position idler wheel mounting block and idler wheel. on the slide rail. Secure with a cap screw and washer. Tighten to 20 ft-lb.
Page 455 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 456 3. Position the front of the skid frame into the tunnel 6. Tip the snowmobile onto the other side; then align and engage the front arm with the slider axle in the the pivot arm assembly with the appropriate hole in tunnel.
Page 457 Servicing Rear Suspension Wear Strips (Bearcat 570/T-Series/ EXT Models)  NOTE: The skid frame does not have to be removed for this procedure; however, if wear strip binding or slide rail damage has occurred, the skid frame This Rear Suspension sub-section has been organized should be removed for this procedure (see Removing so each procedure can be completed individually and Skid Frame in this sub-section).
Page 458 REMOVING ! WARNING 1. Remove the lock nut and cap screw securing the end Always wear an approved pair of safety glasses when cap. using compressed air. 2. Inspect the slide rail for cracks. If any cracks are found, replace the slide rail. 3.
Page 459 4. Inspect the cap screw for cracked, stretched, or dam- aged threads. Use a new lock nut when assembling. INSTALLING 1. Position the end cap on the slide rail; then align the hole in the end cap with the hole in the slide rail. 2.
Page 460 TZ026 MS006A D. Install the snap ring making sure the “sharp side” is directed away from the bearing. Rear Arm/Rear Shock Pivot Assembly  NOTE: The skid frame must be removed for this pro- cedure (see Removing Skid Frame in this sub-sec- tion).
Page 461 3. Loosen the cap screws and lock nuts securing the pivot arm assembly to the idler arm; then remove the pivot arm assembly. Account for a flanged axle, idler spacer, and washer. TZ007A  NOTE: On the Bearcat and T-Series if the overload spring is being removed, use a punch to drive the bushing out from the back side of the slide rail and TZ004A...
Page 462  NOTE: Use the same procedure for the other side. 7. Remove the cap screw and lock nut securing the upper shock eyelet to the idler arm; then remove the cap screw and lock nut securing the upper shock links to the idler arm. Account for the cap screws, lock nuts, and sleeves.
Page 463 CLEANING AND INSPECTING  NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is nec- essary. 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.
Page 464 TZ008 TZ010B  NOTE: Install the rear arm springs onto the adjuster  NOTE: Do not over-tighten the shock absorber cap blocks after the skid frame has been installed. screw as the shock eyelet must be free to pivot. TZ021 TZ020A 9.
Page 465 MS072A TZ004C 10. Install the idler spacer collar onto the idler arm. 13. Grease the idler arm and rear arm grease fittings with a low-temperature grease. Rear Axle and Slide Rail Idler Wheels  NOTE: The skid frame must be removed for this pro- cedure (see Removing Skid Frame in this sub-section).
Page 466 ASSEMBLING REAR AXLE 3. Install the skid frame (see Installing Skid Frame in this sub-section). 4. Adjust track tension and alignment (see Track Align- ment in Section 6). Front Arm Assembly  NOTE: The skid frame must be removed for this pro- cedure (see Removing Skid Frame in this sub-sec- tion), and the rear springs must be removed from the adjusting cams.
Page 467 TZ028A TZ030 4. Remove the front arm and account for the front arm INSPECTING axle.  NOTE: Whenever a part is worn excessively, cracked, 5. Remove the front outer idler wheel and mounting or damaged in any way, replacement is necessary. block from the side of the slide rail in which the front arm shock axle cap screw was installed.
Page 468 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 469 REMOVING  NOTE: When replacing one or both slide rails is necessary, 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 mounting hole locations during dis- assembly to speed up the assembly process and to prevent any damage.
Page 470 6. Remove the lock nut from the cap screw securing the front shock axle assembly to the slide rail. TZ038A 9. Remove the lock nut from the cap screw securing the rear arm pivot/idler wheel assembly to the slide rail. TZ035A ...
Page 471 TZ040A TZ045  NOTE: The adjusting bolt may have to be loosened to remove the adjuster bushing. 14. Remove the cap screw securing the rear arm coupler block to the slide rail. Account for the block, bush- ing, cap screw, and lock nut. TZ041 12.
Page 472 TZ048A AG530D  NOTE: At this point, the slide rail should be free of the skid frame components and can be removed. 0743-189 3. Inspect the front arm slider bumpers for cracks or wear. TZ049  NOTE: If the shock pad must be replaced, refer to Shock Pads at the beginning of this procedure.
Page 473 TZ049 TZ045A 2. Secure the track adjuster bracket with the cap screws  NOTE: Tighten the rear idler wheel axle only until and lock nuts. Tighten to 120 in.-lb. snug until the skid frame is installed and track ten- 3. Secure the front arm to the slide rail with the cap sion is adjusted;...
Page 474 TZ006A TZ055 9. Place the spring into the spring slide; then place the  NOTE: To obtain proper alignment for the idler wheel spring slide and slide block assembly into position cap screw, place the cap screw in the top hole through on the slide rail.
Page 475 FZ079A FZ026B 16. Install the skid frame (see Installing Skid Frame in  NOTE: Apply a light coat of grease to the slide rail this sub-section). surface to aid in installing a new wear strip. Use a file to remove any sharp edges on the lower portion of ...
Page 476 4. Install the rear of the skid frame and the track into  NOTE: At this point, tighten all remaining skid position in the tunnel. frame mounting hardware to 40 ft-lb. 5. Align the rear arm assembly with the appropriate 8.
Page 477 Servicing ACT Shock ! WARNING Before any service is performed on the gas shock absorber, first discharge all pressure from the shock remote reservoir. Remove the valve screw from the pressure valve and insert the Inflation Needle. Open valve until all pressure is released. Failure to do this may cause personal injury.
Page 478 6. Items to inspect: A. Shock shaft for straightness, nicks, or burrs. B. Shaft bearing end cap — clean, inspect, or replace. C. Inside of shock body for scratches, burrs, or excessive wear. D. Piston strap for cuts, chipped or nicked edges, or excessive wear.
Page 479 FS258 FS251 10. Install the valve screw (with O-ring) into the pres-  NOTE: Tapping the eyelet will allow air to escape sure valve assembly. from the valve stack/piston assembly. 7. While holding up on the eyelet, thread the bearing assembly into the body.
Page 480 4. Remove the air chamber from the bottom of the Rebuilding/Recharging Fox shock body. Air Shocks ! WARNING Always wear latex or rubber gloves when servicing a shock absorber with shock oil. DISASSEMBLING 1. Remove the valve cap; then bleed the air from the air chamber.
Page 481 11. Remove the shock rod/piston assembly from the shock body. FS147 8. Using a 5/64-in. Allen-wrench, remove the set screw from the bearing cap. FS151 12. Drain the oil from the shock body into a suitable con- tainer. 13. Using Floating Piston Removal Tool, remove the floating piston.
Page 482 FS154 FS157 2. Carefully install the floating piston into the shock 5. Lubricate the O-ring on the underside of the end cap body until it is below the threads. with shock oil. FS155 FS158 3. Using Floating Piston Installation/Location Tool, 6.
Page 483 8. Using Spanner Wrench, tighten the bearing cap. 10. Charge the shock with nitrogen to 200 psi. FS161 FS164 11. Using a 3/16-in. Allen-wrench, tighten the  NOTE: When tightening the bearing cap, note air nitrogen bladder. and excess oil being bled from the hole in the cap. FS165 FS150A 12.
Page 484 18. Thread the air chamber into the end cap until hand- tight. FS167 15. Lubricate the seal on the air chamber with Fox Float Fluid. FS171  NOTE: Prior to installing the air chamber, make sure the end cap O-ring is properly positioned in the chamber.
Page 485 FS174 FS040 5. Insert the needle squarely into center of the nitrogen valve to release the pressure. Servicing Fox Zero Pro Shock Absorbers This procedure shows the proper methods for disassem- bling, rebuilding, and assembling the pro shock absorbers with no external damping adjustments. ! WARNING Before starting, read through all of these instructions first to become familiar with the procedure.
Page 486 15. Clean the body tube, reservoir tube, and the IFP with solvent. Dry with compressed air in a well ventilated area. 16. Set body assembly aside on a clean, lint-free towel. 17. Clamp the shaft eyelet securely in vise with the pis- ton end up.
Page 487  NOTE: To aid in proper seating of the O-ring, it may be advisable to use a soft, blunt object (non-writing end of a pen, etc.) to push it in. 6. Install the new, well lubricated O-rings into the bear- ing housing making sure the shaft O-ring is in the groove next to the DU bushing and that the O-rings are properly seated and not twisted.
Page 488 9. Fill the body tube with oil to the bottom of the bear- ing threads. Wrap the new piston band around the piston making sure the rounded edges face out. Insert the shaft assembly into the body tube. Slowly push shaft into body until piston assembly is approxi- mately 0.5 in.
Page 489  NOTE: At this point, DO NOT attempt to pull the shaft up out of the body. 17. If there is any interference while pushing the shaft into the body, the IFP is in the wrong location. ! WARNING If there is interference, unthread the bearing assembly from the body and repeat steps 4-16 of Assembling.
Page 490 ! WARNING Always rotate the regulator T-handle to its loose posi- tion each time when finished using the system. Each time before the nitrogen tank valve is opened, check to make sure the regulator T-handle is turned out. When opening the nitrogen tank valve, never stand in front of the regulator in case there should be a problem.
Page 491: Table Of Contents
SECTION 8 — STEERING AND BODY TABLE OF CONTENTS Front Bumper/Belly Pan Assembly Steering and Body ..........8-2 (CFR/Crossfire/M-Series) ........8-32 Steering Post (CFR/Crossfire/M-Series) ....8-2 Gas Tank/Seat Assembly Steering Post (Bearcat/F-Series/T-Series/Z1)..8-5 (CFR/Crossfire/M-Series)..........8-35 Ski ................8-8 Gas Tank/Seat Assembly Ski Wear Bar ............
Page 492 5. On the standard models, remove four lock nuts, cap Steering and Body screws, and adjuster block caps securing the handle- bar to the adjuster block. Secure the handlebar out of the way. This section has been organized into sub-sections for ser- vicing steering and body components;...
Page 493 9. Remove the ignition switch and the torx-head cap screws and lock nuts securing the console to the gas tank; then lay the console aside. 10. Remove the cap screw and lock nut securing the steering tie rod to the steering post. Discard the lock nut.
Page 494 SC085A 0744-927 5. Place the steering tie rod into position on the steering 10. With the lock rod (B) and springs (C) in place, thread post. Secure with the cap screw (threads coated with the cam lever into the lock rod far enough to hold the green Loctite #609) and new lock nut.
Page 495 3. On the standard models, remove the four cap screws, ! WARNING lock nuts, and adjuster block caps securing the han- dlebar/riser assembly to the steering post; then lay Care must be taken to securely lock the handlebar the handlebar/riser assembly aside. Account for the cam lever to prevent unexpected “movement”...
Page 496 11. Remove and discard the lock nut and washer secur- ing the steering post to the chassis; then carefully guide the steering post out of the chassis. FS203A  NOTE: On the turbo models, loosen the intercooler hose clamps at the intake pipe and the turbocharger; then carefully work the intercooler upward until it ZJ157A releases from the rubber grommets.
Page 497 ZJ157A FS200A 2. Install the steering tie rod to the steering post and 4. On the Bearcat 570/F-Series/T-Series, place the rub- secure with new lock nut. Tighten to 35 ft-lb. ber exhaust bumper into position on the air silencer. ZJ156A FS203A 3.
Page 498: Ski
 NOTE: On the turbo models, position the inter- 13. After the handlebar is “locked” in position, release the cam lever and rotate it one turn clockwise; then cooler into the grommets of the mounting bracket; press down on the cam lever until it “locks” in place. then connect the intercooler hoses to the turbo and to the intake plenum.
Page 499: Ski Wear Bar
REMOVING procedure. on terrain where the snow cover is minimal, the ski wear bar will wear faster. Arctic Cat recommends that the ski 1. On the Z1, remove the hood and disconnect the oxy- wear bars be checked once a week and replaced if worn gen temperature sensor;...
Page 500 0741-924 ZJ162 INSPECTING  NOTE: To aid in removing the tie rod cap screws from the drag link, position the drag link so the cap  NOTE: Whenever a part is worn excessively, screw is aligned with the opening between the skid cracked, or damaged in any way, replacement is nec- plate and the suspension mounting bracket.
Page 501: Tie Rods/Steering Link (Cfr/Crossfire/M-Series)
3. Place the steering arms/drag link assembly into posi- Tie Rods/Steering Link tion in the chassis; then secure the arms (D) with axles (F) to the chassis with cap screws and new lock (CFR/Crossfire/M-Series) nuts (C). Tighten the lock nuts to 20 ft-lb. 4.
Page 502: Tie Rods (Bearcat/F-Series/T-Series/Z1)
CM268A CM266A 3. Place the tie rod into position on the spindle arm.  NOTE: At this point, repeat this procedure for the Secure with the cap screw and new lock nut. Tighten opposite side. to 30 ft-lb. CLEANING AND INSPECTING ...
Page 503: Spindle (Cfr/Crossfire/M-Series)
 NOTE: Note whether the inner tie rod is installed on 4. Adjust ski alignment (see Ski Alignment in this sec- tion). the top side or on the bottom side of the spindle arm for installing purposes. 5. Tighten the jam nuts (coated with blue Loctite #243) against the tie rod to 13 ft-lb.
Page 504 INSTALLING 1. Insert the spindle shaft into the spindle making sure the two washers are correctly positioned. 2. Place the upper and lower suspension arm ends with bushings in position into the spindle. Secure with cap screws and new lock nuts. Tighten the upper lock nuts to 30 ft-lb and lower lock nuts to 30 ft-lb (M- Series) or 40 ft-lb (Crossfire).
Page 505: Spindle (Bearcat/F-Series/T-Series/Z1)
CM269A ZJ177 5. Install the ski.  NOTE: The cap screw must be removed to remove the spindle from the spindle housing. 6. Remove the safety stand from beneath the front end. 5. Using a soft hammer and a suitable driving tool, drive the spindle out of the spindle housing.
Page 506 1. Inspect the spindle for excessive wear, cracks, bends, or imperfections. 2. Inspect all welds for cracking. 3. Inspect the suspension arm bushings and axle area for wear. 4. Secure the spindle in a vise. Rotate the spindle clock- wise and counterclockwise. The movement should be smooth and free.
Page 507: Steering Tie Rod (Cfr/Crossfire/M-Series)
9. Place the steering tie-rod ball joint into position on the steering arm as noted during removing and secure with a lock nut. Tighten to 30 ft-lb; then install the tie rod cap. 10. Install the ski and tighten to 26 ft-lb. 11.
Page 508: Steering Tie Rod (Bearcat/F-Series/T-Series/Z1)
1. Place the steering tie rod into position on the upper 2. On the Z1, remove the hood; then remove the arm of the steering shaft. Secure with the cap screw exhaust springs securing the exhaust pipe to the (coated with green Loctite #609), washer, and new mounting tab and exhaust manifold.
Page 509: Ski Alignment
 NOTE: There must be an approximate equal number of threads exposed on each ball joint. 2. Place the tie-rod assembly into position; then rotate the steering tie rod until the holes in the ball joints align with the holes in the steering post and the drag link.
Page 510  NOTE: The straightedge should be long enough to 1. Secure the idler tie rod in the centered position. extend from the back of the track to the front of the 2. Loosen both spindle tie rod jam nuts on the same ski.
Page 511: Front Suspension Arms (Cfr/Crossfire/M-Series)
0734-408 SC080A 5. Remove the cap screws and lock nuts securing the ! WARNING spindle to the front suspension arms. Account for all The measurement taken in front of the spindle must mounting hardware. never be less than the measurement taken behind the spindle or poor handling will be experienced.
Page 512 SC077A SC083A 8. Remove the 15 torx-head screws securing the center INSPECTING belly pan to the frame; then remove the belly pan.  NOTE: Whenever a part is worn excessively, Note the location of the different-length screws for installing purposes. cracked, or damaged in any way, replacement is nec- essary.
Page 513 2. On the Crossfire, secure the sway bar link to the front arm with the cap screw and lock nut. Tighten the lock nut to 96 in.-lb. SC077A 5. Secure the arms to the spindle with existing hard- ware. Tighten the upper arm lock nut and cap screw to 30 ft-lb and the lower arm lock nut and cap screw SC078A to 30 ft-lb (M-Series) or 40 ft-lb (CFR/Crossfire).
Page 514 1. Inspect the arm welded areas for cracks or any signs of deterioration. 2. Inspect the bearings and axles for wear or damage. 3. Inspect the arm tubing for signs of twisting or bend- ing. INSTALLING UPPER ARMS 1. With the axles properly installed as noted during removing, install the front and rear upper arms to the chassis;...
Page 515 INSPECTING 4. Remove the cap screw and lock nut securing the shock absorber to the spindle; then remove the shock  NOTE: Whenever a part is worn excessively, from the spindle and account for the shock sleeve. cracked, or damaged in any way, replacement is nec- 5.
Page 516: Front Suspension (Ski) Shock Absorber
Front Suspension (Ski) Shock Absorber REMOVING 1. Position the front of the snowmobile up onto a safety stand taking all pressure off the skis. 2. Remove the cap screws securing the shock absorber to the front end assembly and spindle; then remove the shock absorber.
Page 517: Sway Bar (F-Series/T-Series/Z1)
2. Remove the lock nuts and cap screws securing the sway bar arms to the sway bar; then remove the arms. Pull the sway bar out and account for two bear- ings. INSPECTING  NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is nec- essary.
Page 518 0744-930 Manual 8-28 Table of Contents...
Page 519 ZJ166B TZ078A 3. Remove the two body screws and lock nuts securing 6. Remove the lock nut (A) securing the steering post to the bottom of the bumper assembly to the suspension the suspension mounting bracket. mounting bracket. 7. Remove the cap screw and lock nut (B) securing the steering tie rod and inner tie rod to the drag link.
Page 520 15. Remove the four upper (K) and four lower (L) cap 6. At this time, position the drag link and steering arms screws and lock nuts securing the suspension mount- into the suspension mounting bracket; then with ing bracket to the chassis; then remove the bracket axles in place, install the right-side upper A-arms noting the number of washers between the steering and lower A-arm with all cap screws and lock nuts...
Page 521: Console (Cfr/Crossfire/M-Series)
16. Secure the sway bar to the suspension mounting bracket with the sway bar mounting brackets and lock nuts (C). Tighten securely.  NOTE: Steps 17-20 are for the Z1 only. 17. Install the close-off cover; then with the exhaust pipe mounting tab (B) installed to the right-side cap screw, secure the cover with the two torx-head cap screws (A).
Page 522: Console (Bearcat/F-Series/T-Series/Z1)
2. Remove the console. INSTALLING 1. Place the console into position on the headlight sup- port bracket; then connect the console harness con- nector. 2. Secure the console to the chassis with the two torx- head screws. Front Bumper/Belly Pan Assembly (CFR/Crossfire/M-Series) FC227...
Page 523 SC069A SC073A 11. In the left- and right-side ski well, remove the two torx-head cap screws securing the front bumper to the left- and right-side belly pan; then remove the three torx-head cap screws securing the belly pan to the chassis. SC070A 7.
Page 524  NOTE: Make sure to install the longer and stub- nose torx-head cap screws to the proper locations as noted during removing. 3. Place the front bumper into position; then secure with the eight torx-head screws. SC075A 13. Remove the remaining torx-head cap screws secur- ing the center, left-, and right-side belly pans to the chassis.
Page 525: Gas Tank/Seat Assembly (Cfr/Crossfire/M-Series)
SC077A SC067A 6. Install the torx-head cap screws and lock nuts secur-  NOTE: If removed, install the clutch guard. ing the top of the front bumper to the belly pan. 10. Install the air intake connector to the air silencer and secure with new cable ties.
Page 526 2. Connect the fuel hose and the fuel pump two-wire  NOTE: On the LXR/Sno Pro/Z1/TZ1 LXR models, connector; then install the two remaining lock nuts adjust the seat to the lowest position; then while lift- securing the gas tank to the tunnel. ing on the top forward part of the seat, remove the machine screw (E) from the right side of the seat sup- 3.
Page 527: Seat Cushion
IO053 FS261A 5. Install the screws (D) and the body screws securing CAUTION the knee pads to the gas tank and the steering sup- The gasline supply hose may be under pressure. port; then secure the rear side panels (spars) with the Place an absorbent towel around the connection to three torx-head cap screws (C) for each side.
Page 528: Taillight/Brakelight Assembly
5. 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 529 Windshield (CFR/Crossfire/M-Series) REMOVING 1. Rivet 2. Windshield 3. O-Ring 0744-462 1. Disconnect the taillight harness connector. 2. Remove the two self-tapping screws securing the taillight to the snowflap. 3. Secure the taillight to the snowflap with the two self- tapping screws; then connect the taillight connector. 742-422A 4.
Page 530 INSTALLING 2. Secure the windshield to the console with the torx- head screws. 1. Place the windshield into position on the console. 3. Using a new plastic rivet, secure the windshield to 2. Secure the windshield using the torx-head screws the windshield bracket.
Page 531: (Bearcat 570/T-Series)
REMOVING BUMPER/SNOWFLAP Tunnel/Chassis/Rear  NOTE: The snowflap can be removed without Bumper/Snowflap removing the bumper by removing the four torx-head (CFR/Crossfire/M-Series) cap screws and lock nuts. 1. Remove the four torx-head cap screws and lock nuts securing the bumper assembly to the running board; REMOVING/REPLACING TUNNEL then remove the four lock nuts from under the tun- To remove and/or replace a tunnel on a particular snow-...
Page 532: (F-Series/Z1)
Tunnel/Chassis/Rear CAUTION Bumper/Snowflap Use caution when drilling the rivets from the rear bum- (F-Series/Z1) per and snowflap not to damage the heat exchangers. 2. Remove the bumper. REMOVING/REPLACING TUNNEL 3. Place the bumper into position on the tunnel; then install the four machine screws and rivets securing To remove and/or replace a tunnel on a particular snow- the bumper to the tunnel.
Page 533 Headlight Assembly (CFR/Crossfire/M-Series) REMOVING HEADLIGHT BULB/ HEADLIGHT  NOTE: The bulb portion of the headlight is fragile. HANDLE WITH CARE. When replacing the headlight bulb, the bulb assembly must first be removed from the housing. Do not touch the glass portion of the bulb.
Page 534: Adjusting Headlight Aim
6. Check headlight aim (see Adjusting Headlight Aim 4. Make a vertical mark intersecting the horizontal in this sub-section). mark on the aiming surface directly in front of the headlight. ! WARNING 5. Start the engine. Select the headlight dimmer switch HIGH beam position.
Page 535 Printed in U.S.A. Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701 p/n 2258-805 ®™...