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: Contents
TABLE OF SHARE OUR PASSION. CONTENTS Click on the blue text to go. Foreword Section General Information/Specifications Engine Engine-Related Items Fuel Systems Electrical Systems Drive Train/Track/Brake Systems Rear Suspension Steering and Body Snowmobile Snowmobile Service Manual Service Manual...
Page 3: Table Of Contents
SECTION 1 — GENERAL INFORMATION/ SPECIFICATIONS TABLE OF CONTENTS General Specifications ..........1-2 Fuel Pump Specifications (570 cc)......1-15 Snowmobile Identification ........1-2 Carburetor Specifications (570 cc) ......1-15 Recommended Gasoline and Oil ......1-2 Electrical Specifications ........1-16 Engine Break-In ............1-3 Drive System Specifications........
Page 4: General Specifications
NOTE: General specifications for each 2010 Arctic biles is 87 octane regular unleaded. In many areas, Cat Snowmobile can be accessed from the Arctic Cat oxygenates (either ethanol or MTBE) are added to the Cat Tracker Dealer Communication System online.
Page 5: Engine Break-In
2-STROKE the drive belt (see Drive Belt sub-section in the Section 6 of this manual). The Arctic Cat 2-stroke engine (when new or rebuilt) requires a short break-in period before the engine is CAUTION subjected to heavy load conditions. Arctic Cat requires that the first tankful of fuel be premixed at a 100:1 Never run the engine with the drive belt removed.
Page 6: Engine
At altitudes above 5000 ft, clutch engagement RPM is It will be necessary to make changes to the fuel sys- normally higher than the standard setting due to the tems (carbureted models) and drive systems that sup- horsepower loss at altitude as opposed to what would port engine operation as altitude changes.
Page 7 The rear suspension has a number of spring settings A limit exists as to how far you can pre-load the that produce different riding characteristics. springs before “coil bind” takes effect where the wire on the spring actually runs into itself and causes bind- The front arm spring and shock will also affect the ride ing.
Page 8: Preparation For Storage
Some tracks come with a dual durometer rating, such 4. On the 2-stroke models, place the rear of the as a track with a 80/60 durometer rating. The lugs on snowmobile up on a shielded safety stand. this track are 80% 80 durometer rubber, and the top 5.
Page 9: Preparation After Storage
14. Tighten all nuts, bolts, and cap screws making sure preparing it for another season will assure many miles all calibrated nuts, bolts, and cap screws are tight- and hours of trouble-free snowmobiling. Arctic Cat ened to specifications. Make sure all rivets holding recommends the following procedure: the components together are tight.
Page 10: After Break-In Checkup (100 Miles - 2-Stroke 600 Miles - 4-Stroke)
8. Adjust the carburetors and choke cable on the 570 DRIVE BELT DEFLECTION — Drive belt deflec- tion is very important to the snowmobile. Even if it is cc and throttle cable on all models. checked and is correct when the snowmobile is set up, it does change (more so during the break-in period).
Page 11: After Break-In Checkup Checklist
After Break-In Checkup Checklist Below is a recommended list of items to check after the break-in period. The recommended mileage for this inspection is between 100 and 300 miles.  Jet carburetors according to average tempera- ture, type of gasoline being used, and altitude (570 cc) ...
Page 12: Engine Specifications (2-Stroke)
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 13: Cylinder Head Volume Specifications (2-Stroke)
NOTE: We have given the proper location for Cylinder Head Volume checking crankshaft runout as the very edge of the Specifications straight portion of the shaft where the oil seal makes contact. From the illustration, note that (2-Stroke) three check points are called out: at either end, out on the taper as shown, and also on the center bearing race.
Page 14: Ignition Timing Specifications (2-Stroke)
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 15 800 cc - CFR/Crossfire/M-Series 1000 cc BTDC - 15.5° @ 2000 RPM - 0.0634" BTDC - 14° @ 1800 RPM - 0.057" 0744-034 0744-783 Manual Section 1-13 Back Next Table of Contents Table of Contents...
Page 16: Arctic Power Valve (Apv) System Specifications (2-Stroke)
Crossfire/M-Series Arctic Power Valve (600 cc) (APV) System Specifications (2-Stroke) NOTE: The servo will activate once at APV cycle RPM. If the servo cycles three times, cable length adjustment or valve inspection is required. APV Position/RPM 739-715A ENGINE VALVE POSITION CYCLE RPM Crossfire/M-Series 600 cc...
Page 17: Oil Consumption Specifications (2-Stroke)
Oil Consumption Fuel Pump Specifications Specifications (2-Stroke) (570 cc) FULL-CLOSED KG/CM FULL-OPEN ENGINE (Idle) 2 Minutes 1000-2000 3.0-3.5 0.21-0.25 3 Minutes 3000-4000 4.5-5.5 0.32-0.39 500 cc 1833 1.0-2.5 cc 7.4-10.3 cc 5000-6000 6.0-7.0 0.42-0.49 570 cc 2000 1.4-2.2 cc 6.9-9.4 cc 600 cc 1833 1.3-3.2 cc...
Page 18: Electrical Specifications
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 black/red...
Page 19 Electrical Specifications (500 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) 7.2-10.8 ohms black/red green/red...
Page 20 Electrical Specifications (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) 7.2-10.8 ohms black/red green/red...
Page 21 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) 7.2-10.8 ohms black/red green/red...
Page 22 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 23: Drive System Specifications
Drive System Components A list of Arctic Drive Clutch and Driven Pulley com- ponents that are available through the Arctic Cat Ser- 0743-410 vice Parts Department can be found in the Quick NOTE: See Section 6 in this manual for alignment Reference Guide.
Page 24: Gear Case Performance Calibrations
Gear Case Performance Calibrations Engine RPM Drive Gear Ratio 6200 6400 6600 6800 7000 7200 7400 7600 7800 8000 8200 8400 8600 8800 9000 Sprocket Vehicle Speed (mph) 9 Tooth (2.52” pitch) 10 Tooth (2.52” pitch) 8 Tooth (3.0” pitch) Shaded rows indicate existing tooled gear ratios 1-22 Manual...
Page 25: Track Specifications
Track Specifications Rear Suspension Specifications Track Tension FRONT ARM SPRINGS After Model Length Setup Height Break-in Bearcat 570 151" 1.25" 1.75-2" 2-2.25" Model Free Length Rate LB/Inch Bearcat XT 156" 1.25" 1.5-1.75" 1.5-1.75" Bearcat XT 9.5” Crossfire 141" 1.25" 1.75-2" 2-2.25"...
Page 26: Shock Absorber Specifications
O.D. Bearing I.D. Below is a list of shock absorbers used on the front and Inside Rails 5.63" 0.787" rear suspensions of Arctic Cat snowmobiles. Specifi- Crossfire/M-Series/T- Idler Arm 7.12" 1.181" Series cations given for each shock absorber include col-...
Page 27: Torque Conversions (Ft-Lb/N-M)
271 - apply red Loctite #271 575 - apply white Loctite #575 Lubricate with Arctic Cat 50:1 Tightening Torque Injection Oil - Non-APV Engines Lubricate with Arctic Cat Synthetic APV (General Bolts) 2-Cycle Oil - APV Engines Thread Tightening Type of Bolt...
Page 28 570 cc 570-ENG10 1-26 Manual Section Back Next Table of Contents Table of Contents...
Page 29 570ENG09 Manual Section 1-27 Back Next Table of Contents Table of Contents...
Page 30 500 cc 500CC1A09 1-28 Manual Section Back Next Table of Contents Table of Contents...
Page 31 500CC2A_10 Manual Section 1-29 Back Next Table of Contents Table of Contents...
Page 32 600 cc 600CC1B_09 1-30 Manual Section Back Next Table of Contents Table of Contents...
Page 33 600CC2A_10 Manual Section 1-31 Back Next Table of Contents Table of Contents...
Page 34 800 cc 800_10_1 1-32 Manual Section Back Next Table of Contents Table of Contents...
Page 35 800_10_2 Manual Section 1-33 Back Next Table of Contents Table of Contents...
Page 36 1000 cc 1000_10_2 1-34 Manual Section Back Next Table of Contents Table of Contents...
Page 37 1000_10_1 Manual Section 1-35 Back Next Table of Contents Table of Contents...
Page 38 1100 cc 1100ccJAG10 1-36 Manual Section Back Next Table of Contents Table of Contents...
Page 39 1100ccZ1RV10 Manual Section 1-37 Back Next Table of Contents Table of Contents...
Page 40: Engine Torque Patterns (1100 Cc)
Engine Torque Patterns (1100 cc) Engine Case Oil Separator Plates 741-582A 741-737A Oil Pan Plate Oil Pan 741-738A 741-584A Cylinder Head 741-617A 1-38 Manual Section Back Next Table of Contents Table of Contents...
Page 41 Camshaft Cover Engine Cover 741-624A 741-580A Magneto Cover Exhaust Manifold 741-583A 744-003B Manual Section 1-39 Back Next Table of Contents Table of Contents...
Page 42: Steering Post (Cfr/Crossfire/M-Series)
Steering/Body Torque Bearcat/F-Series/T-Series/Z1 Torque Specifications Item Secured to ft-lb Spindle Suspension Mounting Bracket (Lower) Chassis 96 in.-lb NOTE: Torque specifications have the following Suspension Mounting Bracket (Upper) Chassis Shock Mount Frame Suspension Mounting 96 in.-lb tolerances: Bracket Shock Mount Frame Front Upper Frame 96 in.-lb Torque (ft-lb)
Page 43: Drive System Torque Specifications
Drive System Torque Rear Suspension Specifications Torque Specifications NOTE: Torque specifications have the following NOTE: Torque specifications have the following tolerances: tolerances: Torque (ft-lb) Tolerance Torque (ft-lb) Tolerance 0-15 ±20% 0-15 ±20% 16-39 ±15% 16-39 ±15% ±10% ±10% Torque Bearcat XT Item Secured to ft-lb...
Page 44 M-Series Bearcat 570/T-Series/Z1 EXT Torque Torque Item Secured to Item Secured to ft-lb ft-lb Wear Strip Rail 50 in.-lb Wear Strip Rail 50 in.-lb End Cap Rail 80 in.-lb End Cap Rail 80 in.-lb Mounting Block Rail Mounting Block Rail Inner Idler Wheel Mounting Block Idler Wheel...
Page 45 SECTION 2 — ENGINE TABLE OF CONTENTS Engine - Bearcat 570/F 570/T570 ......2-2 Engine Removing/Installing - Crossfire 600 - M-Series 600............2-27 Engine Removing/Installing - CFR 800/1000 - Crossfire 800 - M-Series 800/1000 ....2-34 Engine Removing/Installing - F-Series 500/600/800 ........2-42 Engine Servicing - 500/600 cc.......
Page 46 This engine servicing sub-section has been organized securing the console. to show a progression for the complete servicing of the Arctic Cat 570 cc (Bearcat 570/F 570/T570) engine. For consistency purposes, this sub-section shows a complete and thorough progression; however, for effi-...
Page 47 NOTE: It is advisable to apply a film of grease to the end of the puller to aid in removal of the drive clutch. 9. Remove the cap screw from the driven pulley and slide the driven pulley off the gear case input shaft. Account for alignment washers (if applicable).
Page 48 15. Remove the lock nuts and cap screws (D) securing the snubber bracket to the chassis; then remove the bracket. 16. Remove the cap screws and lock nuts securing the headlight support bracket to the front upper frame; then remove the bracket and account for the mounting hardware.
Page 49 20. Turn the steering all the way to the right; then rotate the engine allowing enough room to lift it up and out of the front of the chassis. MD0276 NOTE: Keep the special mounting hardware with the shrouds for assembling purposes. Cap screws securing the front and rear shrouds use special FZ013 washers.
Page 50 MD0282 MD0277 5. Using Flywheel Spanner Wrench to hold the starter pulley, remove the three cap screws secur- ing the starter pulley to the flywheel assembly. MD0067 8. Remove the rubber insulator grommet from the crankcase; then remove two Phillips-head cap screws securing the ignition timing sensor.
Page 51 9. Remove the three Allen-head cap screws securing 11. Remove the four cap screws securing the seal the stator and remove it along with the timing sen- retainer plate on the PTO-side; then remove the sor; then carefully pull the wires through the hole plate.
Page 52 MD0087 MD0096 16. Using an awl, remove the outside piston-pin cir- clip and remove the piston pin using Piston Pin Puller taking care not to drop the piston-pin bear- ing washers into the crankcase. MD0086 15. Remove the cylinders making sure to support the pistons so they are not damaged.
Page 53 MD0208 MD0090 NOTE: Never reuse rings. Always replace with new rings or a complete set. Note the identification on the tapered side of each ring for installation purposes. MD0092A 18. Remove the oil-injection pump driveshaft retainer. Account for an O-ring. 726-306A MD0100A 19.
Page 54 20. Place the crankcase (with its bottom side up) on Cleaning and Inspecting two blocks of wood. Remove the 12 cap screws securing the crankcase halves. Note the position of Engine the different-sized cap screws. 21. Separate the crankcase halves by installing two of the cap screws in opposite corners leaving the NOTE: Whenever a part is worn excessively, heads approximately 1/4 in.
Page 55 CAUTION Improper cleaning of the ring-grooves by the use of the wrong type of ring-groove cleaner will result in severe damage to the piston. 3. Inspect each piston for cracks in the piston pin and skirt areas. 4. Inspect each piston for seizure marks or scuffing. Repair with #400 grit wet-or-dry sandpaper and water or honing oil.
Page 56 NOTE: If any servicing of the connecting rods, center bearings, or oil-injection pump drive gear is necessary, Arctic Cat recommends that the crank- shaft be taken to a qualified machine shop for that service. 1. Wash the crankshaft with bearings in parts-clean- ing solvent.
Page 57 FC040 AN151A 4. Inspect the oil-injection pump drive gear for any 4. Inspect the crankshaft bearing area for wear. If any signs of worn or chipped teeth. If either condition wear is noted on either end, replace the crankshaft exists, replace the gear. end.
Page 58 2. Simultaneously insert two pieces of solder down through the spark plug hole and push them up against the inner cylinder bore towards the MAG- side and PTO-side of the cylinder. 3. Pull the recoil rope and crank the engine over sev- eral times while the solder is being held firmly in place.
Page 59 PISTON PIN AND PISTON-PIN BORE 1. Measure the piston pin diameter at each end and in the center. Acceptable piston pin measurement must be within 0.7085-0.7087 in. If any measure- ment varies by more than 0.001 in., the piston pin and bearing must be replaced as a set.
Page 60 NOTE: When the use of a lubricant is indicated, 0742-727 use Arctic Cat 50:1 Injection Oil. 1. Using the V Blocks, support the crankshaft on the surface plate. 1. Place the upper crankcase half (with its bottom side up) on two blocks of wood.
Page 61 MD0203 MD0088 6. Install crankcase lower half. Install eight 8 mm NOTE: Apply blue Loctite #243 on the machine and four 6 mm cap screws. Tighten the 8 mm cap screws when assembling; then tighten screws in two steps to 17 ft-lb and the 6 mm cap machine screws to 48 in.-lb.
Page 62 CAUTION Incorrect installation of the piston rings will result in engine damage. Always replace rings as a complete set. MD0293 NOTE: To aid in the circlip installation, install the circlip to the inside of the piston before installing the connecting rod. MD0271 8.
Page 63 MD0229 MS384 13. Secure each cylinder by installing the four 6 mm and eight 10 mm nuts. Tighten the 10 mm nuts in a crisscross pattern to 44 ft-lb and the 6 mm nuts to 96 in.-lb. MS384 MD0086 0738-291 15.
Page 64 MD0253 MD0076 MD0292 MD0274 17. Install the stator plate so the ignition wire cut-out 19. Place the ignition timing sensor wiring through the is in the upper left position. Lightly coat the four hole in the crankcase; then position the ignition Allen-head cap screws with blue Loctite #243;...
Page 65 20. Install the rubber insulator grommet into the crankcase. TZ067A 24. Using the six cap screws and the special washers, install the rear (intake-side) shroud. Tighten the MD0262 cap screws (coated with red Loctite #271) to 96 21. Place the starter pulley into position on the fly- in.-lb.
Page 66 MD0268 MD0294 26. Lubricate the oil-injection pump driveshaft; then NOTE: For assembling purposes, always use while rotating the driveshaft, install it and the new O-rings lubricated with oil on the oil-injection thrust washer into the lower crankcase half. pump and retainer. NOTE: When installing the oil-injection pump driveshaft, make sure the thrust washer is...
Page 67 NOTE: Place a cloth beneath the oil-injection pump to contain any oil spilled during the bleeding process. 7. With the throttle cable and fuel lines properly routed, install the flange clamps to the intake flanges; then install the carburetors and secure with the clamps.
Page 68 13. Install the PTO-side starter motor bracket to the 17. Place the recoil starter into position and secure the engine and secure with the two cap screws (B). starter with the cap screws (threads coated with Tighten to 20 ft-lb. blue Loctite #243).
Page 69 NOTE: On the Bearcat 570, make sure the ground wire is on the rear upper stud. After the shield is installed, secure with the wire with the lock nut. 20. Secure the wiring harness to the chassis with the wiring harness clamp, cap screw, and lock nut. Tighten securely.
Page 70 26. Place gaskets on the resonator and exhaust mani- 31. Secure the console to the steering support with the fold; then install the expansion chamber. Secure torx-head screws and tighten the screws securely; the chamber to manifold and resonator with the then close the left-side and right-side access panels springs.
Page 71 1. Remove the belt guard and disconnect the exhaust Engine Removing/ temperature sensor; then remove the cable ties securing the sensor harness to the chassis. Installing - Crossfire 600 - NOTE: For assembling purposes, note the loca- tion of the cable ties securing the harness to the M-Series 600 chassis.
Page 72 7. Slide each cable drum out of the slot of the servo- motor actuator. CM027 NOTE: At this point, drain the engine coolant (see Liquid Cooling System - Section 3). CM124A 8. Remove the three cap screws securing the heat 11.
Page 73 CM029A 742-238A 14. Remove the recoil starter and secure it up and out 18. Loosen the cap screw/lock nut (C) securing the of the way in the engine compartment. MAG-side engine mounting bracket to the front end. 15. Remove the cap screws securing the left side of the steering support to the chassis;...
Page 74 23. Remove the exhaust manifold from the engine. 3. Connect all electrical wiring making sure all wir- Account for flange nuts and gaskets. ing and coolant hoses are routed properly (as noted in removing); then place the engine into the 24.
Page 75 9. Connect the oil-supply hose to the oil-injection 11. Route the gasline hose to the throttle body assem- pump; then remove the oil bleed plug from the oil- bly and secure the hose to the fuel rail. Tighten the injection pump. When oil flows from pump free of clamp securely;...
Page 76 CM210A IO003 20. Secure the cables to the servomotor with the cable NOTE: Install the two front lower cap screws first holder. to properly align the remaining cap screws. 21. Check APV cable adjustment (see Arctic Power 16. After securing the front of the brace, secure the Valve (APV) System in Section 3).
Page 77 24. Check drive clutch/driven pulley alignment (see Section 6). CM038 30. Install the resonator and secure with three springs; then place the expansion chamber and grafoil gas- MS390 kets into position and secure to the exhaust mani- 25. Install the drive belt. Check belt deflection. Secure fold and resonator with the springs.
Page 78 1. Remove the belt guard and disconnect the exhaust Engine Removing/ temperature sensor; then remove the cable ties securing the sensor harness to the chassis. Installing - CFR 800/1000 - NOTE: For assembling purposes, note the loca- tion of the cable ties securing the harness to the Crossfire 800 - chassis.
Page 79 7. Using a small needle-nose pliers, remove the ser- vomotor retaining clip and the cable holder. CM026A 12. Pull the air silencer boot forward enough to gain access to the throttle body assembly. TZ069A CM127 CM027 8. Rotate the servomotor actuator counterclockwise 13.
Page 80 CM130A CM137 15. Loosen the clamps securing the coolant hoses con- 18. Remove the wiring harness wrap; then disconnect nected to the throttle bodies; then remove the vent the ignition/main harness connectors and the tem- tube from the top of the cylinder head. perature sensor connector.
Page 81 20. Remove the cap screws and lock nuts securing the 26. Remove the exhaust manifold and engine mount- steering support and the side-plate brace to the ing brackets from the engine. Account for nuts and chassis. gaskets. 27. Remove the clamp securing the coolant supply hose from the cylinder head to the water pump.
Page 82 3. Place the engine in position in the chassis; then 7. From step 6, tighten the PTO-side mounting install the cap screw and lock nut (A) and (B) bracket-to-engine cap screws (D) (coated with securing the MAG-side engine mounting bracket blue Loctite #243) to 24 ft-lb;...
Page 83 14. Place the throttle bodies into position and secure with the flange clamps; then connect the gasline hose to the throttle body assembly and tighten the clamp securely. CAUTION When installing the throttle bodies, make sure the gasline hose is properly routed to avoid premature wear and/or contact with exhaust components.
Page 84 CM026A CM133B 18. Install the side-plate brace onto the chassis and 19. Slide the APV cable drums into the servomotor secure the brace and the steering support with the actuator; then place the cable housings into posi- cap screws (coated with blue Loctite #243). tion in the servomotor.
Page 85 NOTE: To aid in proper tightening of the drive 27. Install and secure the access panels; then place the hood into position on the front end and secure with clutch cap screw, apply oil to the threads of the the two pins and the cables. cap screw prior to installing.
Page 86 Engine Removing/ Installing - F-Series 500/600/800 This engine sub-section has been organized to show a progression for the removing/installing of the Arctic Cat 500/600/800 cc (F-Series) engines. For consis- tency purposes, this sub-section shows a complete and thorough progression; however, for efficiency it may be preferable to remove only those components need- ing to be addressed.
Page 87 NOTE: If the driven pulley is tight on the driven shaft, pull the driven pulley off using the Driven Pulley Puller. NOTE: Steps 12-14 are for the 600/800 cc. For the 500 cc engine, proceed to step 16. 12. Using a small needle-nose pliers, remove the sero- motor retaining clip and cable holder.
Page 88 B. Loosen the two set screws securing the flex- NOTE: Note the routing and securing locations of drive shaft to the pinion driveshaft. the hose for assembling purposes. 18. Loosen the flange clamps securing the throttle body assembly to the flange; then move the throt- tle body assembly forward and disconnect the oil- injection cable/control rod from the oil-injection pump.
Page 89 500/600 cc FS179A FS177A 23. Remove the spark plug wires from the plugs; then 800 cc disconnect the two-wire plug-in for the coolant temperature sensor (located below the ignition coil). 500/600 cc FS213A 22. Remove the cap screws securing the recoil starter; then secure the recoil starter up and out of the way.
Page 90 FS212A FS182A 24. Remove the harness wrap and disconnect all igni- tion/main harness connectors; then remove the cable tie (if applicable) securing the harness to the coolant tank/heat exchanger hose and secure the harness out of the way. FS183A 27. Remove the exhaust manifold from the engine. Account for the flange nuts and gaskets.
Page 91 29. Remove the four cap screws (C) securing the 500/600 cc PTO-side bracket to the engine; then remove the bracket. Account for the torque bumper. 30. On the 500/600 cc, remove the two cap screws (D) securing the front engine plate to the chassis; then remove the cap screw (E) securing the MAG-side engine mounting bracket to the chassis.
Page 92 500/600 cc 500/600 cc FS187A 742-205B 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) the pinion bracket assembly to the engine with two (coated with blue Loctite #243).
Page 93 800 cc FS217A FS195A 9. Using the illustration following step 2, install the NOTE: At this point on the 500/600 cc LXR, insert cap screw and lock nut (A) and the lower cap the flex-drive shaft into the pinion drive and secure screw (B) securing the PTO-side bracket to the with the two set screws.
Page 94 NOTE: Prior to connecting the harness, clean all plug-ins with contact cleaner and compressed air. ! WARNING Always wear safety glasses when drying components with compressed air. 12. Secure the ignition harness to the coolant hose with a cable tie in the position as noted in remov- ing;...
Page 95 500 cc CM184B 0742-853 NOTE: On the 500 cc when the cable adjusting NOTE: Place a cloth beneath the oil-injection nut is adjusted correctly, the throttle lever will pump to contain any oil spilled during the bleeding move approximately 1/8 in. before the oil-injection process.
Page 96 21. Route the gasline hose to the throttle body assem- bly and secure the hose to the fuel rail. Tighten the clamp securely; then on the 500/600 cc using a cable tie, secure the hose to the MAG-side engine mounting bracket. CAUTION When installing the throttle bodies, make sure the gasline hose is properly routed to avoid premature...
Page 97 FS176 FS192 CAUTION Do not apply Loctite to the cap screw or damage to the gear case will occur. 28. Check drive clutch/driven pulley alignment (see Section 6). Install the drive belt. Check belt deflec- tion. Secure the belt guard (see Section 6). 29.
Page 98 NOTE: To aid in installing the air silencer, it can NOTE: If the ECU was removed to gain access to be helpful to remove the air silencer cover and the air-intake duct cap screw, install the ECU using work the intake boot over the throttle body from the two lock nuts.
Page 99 39. Install the exhaust resonator and secure to the 44. Allow the engine to cool; then check the coolant upper frame with the tab washer and the hairpin level and add coolant as necessary. clip. 45. Verify the tightening torque of the drive clutch. 40.
Page 100 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 101 CM013 FC019 NOTE: To ensure the cleanliness of the flywheel magnets, place the flywheel (with the magnets fac- ing upward) on a clean bench. 4. Remove the ignition timing sensor. RS020A 7. Remove the stator plate from the engine. FC022 5.
Page 102 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 gaskets are directional for assembling purposes. FC026 NOTE: When removing the cylinders, place the engine on its intake flanges on a drain tray to allow residual coolant to drain from the cylinder/crank-...
Page 103 FC027 CM151 14. Remove the PTO-side piston-pin circlip from the CAUTION PTO-side piston; then remove the MAG-side pis- On the 500 cc, place rubber bands over the connect- ton-pin circlip from the MAG-side piston. ing rods and around the cylinder studs to prevent the connecting rods from damaging the crankcase.
Page 104 21. Remove either lower union cap screw securing the 25. Lift the bottom half of the crankcase off the top lower check valve assembly; then remove the two half. screws securing the oil-injection pump to the crankcase. Remove the pump, retainer, and O-ring. CAUTION Care must be taken to not allow the connecting rods to drop onto the sealing surface of the bottom case...
Page 105 30. Using the hooked end of the tool, pull the inner seal free of the crankcase. 31. Using the hooked end of the tool, pry the seal ring from the backside of the water pump impeller. CM211A AN327D Servicing Top-Side Components (Crossfire/M-Series) Many services can be performed without removing the...
Page 106 A. Using Vacuum Test Pump or a suitable substi- tute, rig the pump to 3/16 in. outside diameter hose. CM214A 6. Disconnect the APV cables from the servomotor; then remove the APV’s from the cylinder. NOTE: Note that the APV exhaust valves and the FC058 B.
Page 107 CM218 726-306A CAUTION NOTE: The piston pins must be removed from the PTO-side of the piston. Incorrect installation of the piston rings will result in engine damage. NOTE: For proper assembly, keep all MAG-side 2. Apply oil to the connecting-rod small end bear- components and all PTO-side components sepa- ings;...
Page 108 CM217 CM194A 6. Secure the cylinders by tightening the cylinder CAUTION base nuts and cap screws to 44 ft-lb in three steps using the pattern shown. Make sure the circlips are firmly seated and the open end is directed either up or down before continuing with assembly.
Page 109 13. Secure the steering support to the chassis. Tighten CAUTION to 20 ft-lb. The long side of the exhaust valve must be facing NOTE: At this point if no additional engine ser- toward the cylinder head or severe engine damage vice work is necessary, proceed to Engine Install- may occur.
Page 110 2. Snap an old piston ring into two pieces; then grind the end of the old ring to a 45° angle and to a sharp edge. Using the sharpened ring as a tool, clean car- bon from the ring-grooves. Be sure to position the ring with its tapered side up.
Page 111 CRANKSHAFT NOTE: If any servicing of the connecting rods, center bearings, or oil-injection pump drive gear is necessary, Arctic Cat recommends that the crank- shaft be taken to a qualified machine shop for that service. 1. Wash the crankshaft with bearings in parts-clean- ing solvent.
Page 112 NOTE: Install the bearings by sliding each bear- 4. Inspect the reed-to-seat clearance. Using a feeler gauge, measure the clearance. Clearance must be ing onto the crankshaft making sure the dowel-pin less than 0.008 in. If clearance is not within speci- hole in the outer race is properly positioned and fications, replace the reed valve.
Page 113 6. Pull the recoil rope and crank the engine over sev- 2. Measure the corresponding piston skirt diameter at eral times. Remove both pieces of solder from the a point 1 cm above the piston skirt at a right angle cylinder and measure the opposite squeezed ends to the piston-pin bore.
Page 114 CRANKSHAFT RUNOUT IO012 2. Insert a snap gauge into each piston-pin bore; then 0742-727 remove the gauge and measure it with a microme- 1. Using the V Blocks, support the crankshaft on the ter. The diameter measurement must be within surface plate.
Page 115 NOTE: When the use of a lubricant is indicated, MS988 use Arctic Cat Synthetic APV 2-Cycle Oil. 1. Apply a thin coat of grease to the inner seal lips of the water pump seal. 2. Using the seal driver, position the inner water pump shaft seal onto the seal driver and gently tap the seal down into position.
Page 116 FC071 NOTE: Use only Arctic Cat High-Temp Sealant to seal the crankcase halves. 10. Assemble the crankcase halves making sure that the crankshaft gear and oil-injection pump driveshaft CM045A gears mesh.
Page 117 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; then place the Oil Seal Protector Tool at the end of the shaft.
Page 118 FC072B IO050A 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 119 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 bear- ings;...
Page 120 FC079A FC076 28. Install the new circlips so the open end is directed 31. On the 500 cc, secure each cylinder by installing either up or down. the 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 121 600 cc FC077 0738-205 NOTE: Lubricating the O-ring with a light coat of NOTE: Lubricating the O-ring with a light coat of grease will help keep the O-ring in place. grease will help keep them seated in the grooves of the cylinder. 36.
Page 122 39. Secure the stator plate to the crankcase with the Allen-head cap screws (coated with blue Loctite #243) and tighten to 96 in.-lb. FC018 42. Install the key in the crankshaft. 43. Thread two puller bolts into the flywheel; then slide the flywheel onto the crankshaft making sure FC021 40.
Page 123 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 124 3. Using Flywheel Puller or suitable substitute, remove the flywheel from the crankshaft by tight- ening the puller bolt, striking the head of the puller bolt with a hammer, and tightening again. Repeat this procedure until the flywheel is free. Account for the key.
Page 125 CM143A CM146A 7. Remove the cap screws securing the stator plate to the engine; then remove the plate. CM147 9. Remove the spark plugs. NOTE: On the 800 cc at this point, remove the CM145D knock sensor and lock plate from the cylinder NOTE: For assembling purposes, note that the head by bending the lock plate tabs down and indentation (A) of the stator plate is aligned with...
Page 126 CM148 CM151 12. Remove the PTO-side piston-pin circlip from the NOTE: Place a suitable length of rubber hose PTO-side piston; then remove the MAG-side pis- around the connecting rods to prevent the con- ton-pin circlip from the MAG-side piston. necting rods from damaging the crankcase. 15.
Page 127 IO015A CM156A 17. Remove the four cap screws securing the thermo- 19. Remove the cap screw securing the water pump stat cap; then remove the cap, gasket, and thermo- impeller; then slide the impeller free of the shaft. stat. Account for the cap screw washer and gasket. IO017A IO018A 20.
Page 128 800 cc 742-197B IO023A 21. Turn the engine upside down on support blocks, 1000 cc cut the cable tie, and remove the coolant tempera- ture sensor switch. 22. With its bottom side up on two support blocks, remove the cap screws securing the crankcase halves.
Page 129 REMOVING TOP-SIDE COMPONENTS To access top-side components, use the following pro- cedure: 1. Disconnect the exhaust temperature sensor; then cut the cable tie securing the sensor harness to the APV cable. 2. Remove the expansion chamber and resonator and account for the springs, hairpin clip, and the tab washer;...
Page 130 5. Remove the cap screws securing the APV assem- blies to the cylinders; then remove the APV assemblies and set them aside. NOTE: For installing purposes, note that the APV exhaust valves and gaskets are directional. CM190 7. Carefully lift and turn the cylinder head to gain access to the hose clamp securing the coolant hose to the cylinder head;...
Page 131 NOTE: After the cylinders have been removed, NOTE: Place a suitable length of rubber hose cover the crankcase to avoid components falling around the connecting rods to prevent the con- into the crankcase. necting rods from damaging the crankcase. 9. Remove the PTO-side piston-pin circlip from the NOTE: For servicing procedures, see Cleaning PTO-side piston;...
Page 132 6. Rotate each piston ring until the ring ends are properly positioned on either side of the ring keeper; then apply oil to the piston assemblies and cylinder bores. Remove the rubber hoses from the connecting rods. 7. 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;...
Page 133 10. Apply a thin coat of high-temperature silicone sealant to the mating surfaces of the exhaust mani- fold; then install the exhaust manifold and secure with eight nuts. Tighten the nuts using the pattern shown to 17 ft-lb. CM199A 13. Install the coolant hose and secure the hose onto the cylinder head;...
Page 134 15. Place new O-rings onto each of the head cap NOTE: On the 800 cc, connect the knock sensor screws. Place four of these cap screws (from oppo- plug-in. site end of each other) into the cylinder head. NOTE: If the knock sensor was removed or Thread the spark plugs in part way;...
Page 135 CYLINDER HEAD 4. Place the head surface of each cylinder on the sur- face plate covered with #400 grit wet-or-dry sand- 1. Using a non-metallic carbon removal tool, remove paper. Using light pressure, move each cylinder in any carbon buildup from the combustion chambers a figure eight motion.
Page 136 CRANKSHAFT NOTE: If any servicing of the connecting rods, center bearings, or oil-injection pump drive gear is necessary, Arctic Cat recommends that the crank- shaft be taken to a qualified machine shop for that service. Manual...
Page 137 3. Inspect the reed stopper height. Using a caliper, measure the distance from the seat to the bottom outer tip edge of the stopper. Measurement must not exceed specifications. If measurement is not within specifications, either bend or replace the reed stopper.
Page 138 2. Simultaneously insert two pieces of solder down through the spark plug hole and push them up against the inner cylinder bore towards the MAG- side and PTO-side of the cylinder. 3. Pull the recoil rope and crank the engine over sev- eral times while the solder is being held firmly in place.
Page 139 PISTON PIN AND PISTON-PIN BORE 1. Measure the piston pin diameter at each end and in the center. Acceptable piston pin measurement must be within 0.8659-0.8661 in. for the 800 cc or 0.9447-0.9449 in. for the 1000 cc. If any measure- ment varies by more than 0.001 in., the piston pin and bearing must be replaced as a set.
Page 140 Always wear safety glasses when drying components with compressed air. NOTE: When the use of a lubricant is indicated, use Arctic Cat Synthetic APV 2-Cycle Oil. 1. Apply a thin coat of grease to the inner seal lips of the water pump seal.
Page 141 Be sure the alignment hole in each bearing is posi- tioned over its respective retaining pin in the crankcase; then seat the crankshaft. CM166 NOTE: Use only Arctic Cat High-Temp Sealant to seal the crankcase halves. Manual Section 2-97...
Page 142 10. Assemble the crankcase halves making sure that the crankshaft gear and oil-injection pump drive- shaft gears mesh. Rotate the crankshaft one full turn to align the crankshaft gear and pump drive- shaft. 11. Install the crankcase cap screws securing the crankcase halves.
Page 143 20. With new gaskets, install the reed valve assem- blies and intake flanges using the pattern shown. Tighten to 96 in.-lb; then secure the intake flange oil hoses to the oil pump and secure with the clamps. CM167A NOTE: For assembling purposes, always use a new O-ring lubricated with oil on the oil-injection pump.
Page 144 CM171A CM168 23. Using a suitable tool, press the seal into position NOTE: Sealant is only required on the crankcase making sure its marked side is positioned towards seam. the rubber seal cup; then apply a thin coat of grease to the seal outer surface. CM171B 26.
Page 145 CM157A TZ068 NOTE: The shoulder side of the washer must seat to the needle bearing. CM155A 28. Install the dowel pins into the crankcase; then place the cylinder base gasket into position on the crankcase. CM172A 31. Place each piston over the connecting rod so the 29.
Page 146 800 cc CM174 0738-206 CAUTION 1000 cc Make sure the circlips are firmly seated and the open end is directed either up or down before continuing with assembly. 33. Rotate each piston ring until the ring ends are properly positioned on either side of the ring keeper;...
Page 147 39. With the raised edge of the valve aligned with the channel of the cylinder, slide the APV assemblies into position in the cylinders; then secure with cap screws. Tighten to 96 in.-lb. CM175 NOTE: On the 800 cc to install the remaining cap screws, the spark plugs must be removed.
Page 148 43. Secure the lower ignition timing sensor with two cap screws (A) (coated with blue Loctite #243). Tighten to 48 in.-lb; then install the grommet. With the stator harness properly positioned, install the plate and cap screw (B) (coated with blue Loc- tite #243).
Page 149 51. Apply a thin coat of high-temperature silicone sealant to the mating surfaces of the exhaust mani- fold; then install the exhaust manifold and secure with the eight nuts. Tighten the nuts using the pat- tern shown to 17 ft-lb. CM181 NOTE: At this time if the coolant temperature sensor was removed, install the sensor (threads...
Page 150 This engine section has been organized into sub-sec- tions 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 effi-...
Page 151 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 cap screw securing the driven pulley to the input oil cooler; then clamp off the coolant hose. With a shaft.
Page 152 TZ072A TZ077A NOTE: On the non-turbo models, remove the MAP sensor from the left-side upper frame. 14. Remove the two cap screws and lock nuts (A) securing 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.
Page 153 ZJ024A ZJ018A 18. On the turbo models, remove the coolant hoses NOTE: On the turbo models after removing the from the throttle body; then on all models, discon- five cap screws and lock nuts, account for the clip nect and remove the coolant hoses from the ther- from the cap screw (A) securing the two gasline mostat housing.
Page 154 TZ079A TZ084A 21. On the turbo models, use a suitable clamping CAUTION device to close off the coolant return hose and Anytime hoses are removed from the turbocharger, remove it from the turbocharger. always close-off the inlets and outlets of the turbo to avoid dirt or foreign objects from entering the turbo- charger.
Page 155 TZ078A TZ099A 24. With the cover removed, move the steering post 27. Disconnect the throttle position sensor, air temper- assembly to the right side of the engine compart- ature sensor, boost sensor, and cam position sen- ment. sor. NOTE: Steps 25-30 are for the turbo models only. 25.
Page 156 TZ090A ZJ021A 31. Remove the positive cable from the starter motor. NOTE: The oil reservoir will be removed with the engine. 32. On the non-turbo models, disconnect the harness plug-ins from the ignition coils (A) and camshaft 35. Remove the two lock nuts (A) from under the timing sensor (B).
Page 157 743-993A ZJ048A 4. Remove the banjo bolts securing the oil feed pipe NOTE: Lift the engine at an angle (with the PTO- to the turbocharger and engine. Discard the crush side upward) to allow clearance for the oil reser- washers. voir to be removed from the chassis with the engine.
Page 158 ZJ028B 8. On the non-turbo models, remove the cap screws securing the two intake flanges to the cylinder head; then remove the flanges. 743-780C 6. Remove the lock nuts and washers securing the exhaust manifold to the cylinder head; then care- fully remove the turbocharger and exhaust mani- fold assembly.
Page 159 ZJ030A ZJ032A NOTE: Note the position of the thermostat NOTE: Care must be taken when removing the bypass/check valve for assembling purposes. magneto cover not to tip the cover downward. Tip- ping the cover downward will allow the starter torque limiter/idler gear assembly to slide out of the cover.
Page 160 ZJ036A ZJ037A 15. On the non-turbo models, remove the cap screws 17. Obtain top-dead-center by rotating the crankshaft securing the two cylinder ignition coils to the cyl- until the arrows on the intake camshaft face (A) inder head cover and remove the coils. are 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 161 ZJ039A 741-617B 20. Using a magnet, carefully remove the tappets from NOTE: If removing the oil cooler for cleaning pur- the cylinder head. poses, remove the union bolt securing the cooler to the engine; then remove the oil cooler and account for a washer and an O-ring.
Page 162 741-584B ZJ068A 24. Tip the engine upside down; then remove the 28 27. Remove the front and rear crank balancers from cap screws securing the upper and lower crankcase the engine and account for the two end seals. halves. Using a soft hammer, gently tap around the bottom half until it separates.
Page 163 ZJ044 ZJ046A 31. Remove the oil separator plates for the lower NOTE: Because the connecting rods and con- crankcase half and account for the eight Allen- necting rod caps are unique, note the I.D. marks head cap screws. and keep all associated parts together for assem- bling purposes.
Page 164 NOTE: For assembling purposes, ensure that the 2. Remove each ring by working it toward the dome of the piston while rotating it out of the groove. orifices in the piston cooling jets are cleared of any dirt and/or debris. NOTE: If the existing rings will not be replaced with new ones, note the location of each ring for proper installation.
Page 165 1st – Top Ring 0.0059-0.0074 in. 1st – Bottom Ring 0.0008-0.0035 in. 2nd Ring 0.0008-0.0024 in. Oil Ring 0.0024-0.0059 in. ATV-1069 Measuring Piston Pin Diameter Measure the piston pin diameter at each end and in the center. Measurement must be within 0.8658-0.8661 in. 0738-532 for the non-turbo and 0.9447-0.9449 for the turbo.
Page 166 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 167 ZJ058A 0738-540 2. Rotate the crankshaft slowly. MAIN BEARINGS 3. The reading must be 0.002 in. or crankshaft repair- Check the main bearings for signs of pitting, scratches, ing/replacing will be necessary. wear, or damage. If any of these conditions are found, the bearings must be replaced.
Page 168 Assembling Engine shaft and clearance, use the following procedure. 1. Install the main bearing upper half inserts in the NOTE: Arctic Cat recommends that new gaskets, crankcase; then place the crankshaft into position. seals, and O-rings be installed whenever assem- 2.
Page 169 NOTE: For assembling purposes, use oil-dissolv- able molybdenum disulfide grease as engine- assembly grease. 1. Install one piston pin circlip into one of the pistons making sure the open end is directed either up or down. Place the connecting rod in position making sure the identification number on the rod cap (A) is aligned with the intake side of the piston (B).
Page 170 ZJ055A ZJ053 7. With the proper bearings selected, install the half- 9. Lubricate the thrust bearings with engine oil; then bearings into the upper engine case; then lubricate with the grooved side of the bearings (A) facing the bearing faces liberally with engine-assembling outward towards the crankshaft counterweights, grease taking care not to get any grease between install the first bearing and roll it into place.
Page 171 ZJ075 741-596A 16. With the crankshaft at bottom-dead-center, install NOTE: Rotate the crankshaft one revolution to the front counterbalancer with the single dot (B) verify free movement. on the face of the crankshaft and balancer gears directly in line with each other at the sealing sur- 13.
Page 172 NOTE: Cap screws 25-28 have only the one torque value. NOTE: After the tightening sequence, rotate the crankshaft one revolution to verify free movement. 25. With a new O-ring, install the oil cooler, washer, and the union bolt; then tighten to 52 ft-lb. 741-737A 19.
Page 173 NOTE: Rotate the engine to the upright position; then, if applicable, remove the cap screw and washer securing the pistons in the cylinder. 27. Install the cam chain onto the sprocket on the crankshaft and route the chain up through the engine case;...
Page 174 35. With the timing marks (A) on the face of the cam- shaft gear properly aligned, place the camshaft into position on the cylinder head. 741-617A 33. With a light film of engine-assembly grease applied to the tappets, install the correct shim (A) and tappet (B) to each valve of the cylinder head as noted during disassembling.
Page 175 ZJ085A ZJ036A 39. Install the tensioner and secure with two Allen- 42. Install the flywheel with the cap screw and washer. head cap screws; then tighten to 84 in.-lb. Install Using the flywheel holder wrench from Flywheel the ball, spring, and tensioner bolt and tighten to Puller, tighten the cap screw to 88 ft-lb.
Page 176 742-002A ZJ031B 45. Install the two alignment pins in the engine for the 47. Install a new thermostat; then install the cover and magneto cover; then with a new gasket, install the secure with the two cap screws. Tighten to 84 in.- cover and with the pattern shown, tighten the 18 cap screws to 84 in.-lb.
Page 177 ZJ093 741-586A NOTE: On the turbo models, install the intake NOTE: At this point, assembly of the non-turbo flange assembly; then tighten the cap screws engine is complete. The remaining steps are for evenly to 96 in.-lb. the turbo models only. NOTE: If removed, install the mounting bracket to the turbocharger;...
Page 178 54. Install the three lock nuts securing the turbo- NOTE: Make sure when installing the oil feed charger mounting bracket to the engine and tighten pipe that the correct banjo bolt is securing the to 30 ft-lb. pipe to the engine and turbo charger (as noted in disassembling).
Page 179 ZJ090B NOTE: Steps 7-10 are for the non-turbo models only. 7. Install the throttle bodies and secure with clamps; 741-540A then install the throttle cable to the throttle bodies. A. Rear mount lock nuts: 37 ft-lb. B. Through-bolt: 30 ft-lb. C.
Page 180 ZJ024A TZ085B NOTE: Prior to securing the left-side upper frame to the steering support, make sure that the ECU harness is directed below the upper frame. 10. Install the ECU to the left-side upper frame and secure with the hold-down strap; then install the MAP sensor to the bracket.
Page 181 NOTE: At this time, make sure the coolant hoses from the coolant tank to the throttle body assem- blies and throttle bodies to the left-side cylinder head are secured and properly routed. On the turbo models, make sure the throttle body coolant return hose is secured.
Page 182 19. On the non-turbo models, install the air silencer 23. Place the resonator into position in the chassis and (see Section 3); then on all models, install the gas install the two springs securing the resonator to the tank (see Section 8). chassis;...
Page 183 CAUTION When installing the drive clutch, do not tighten the clutch cap screw with any kind of impact tool. Tighten cap screw using a hand torque wrench only. Failure to do so could result in stationary sheave damage. NOTE: Apply a coat of Anti-Seize Thread Com- pound to the splines of the input shaft.
Page 184 35. Install the battery; then secure with the hold-down C. Without starting the engine, place the handlebar plate. Connect the positive cable and then the neg- emergency stop switch to the RUN position and ative cable. the ignition switch to the ON position. The Oil Pressure Warning Light should illuminate.
Page 185 39. Start the engine and allow it to run for five min- utes. Inspect for any signs of coolant leaks in the engine compartment; then shut the engine off and allow it to cool. 40. Repeat steps 38-39 at least two more two times (more if necessary) until no air is in the cooling system.
Page 186 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 187 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. Carburetors adjusted incorrectly — jetted incorrectly 3. Troubleshoot — clean carburetors — jet correctly —...
Page 188 Problem: Engine Stops Suddenly Condition Remedy 1. In-line fuel filter obstructed — damaged 1. Remove obstruction — replace in-line fuel filter 2. Fuel hose obstructed — broken — pinched 2. Remove obstruction — repair — replace fuel hose 3. CDI unit faulty 3.
Page 189 Problem: Engine Does Not Start (No Fuel at Cylinders) Condition Remedy 1. Gas tank empty 1. Fill tank 2. Injector dropping resistor faulty 2. Replace dropping resistor 3. Fuel pressure regulator faulty 3. Replace regulator — hose 4. Check valve faulty 4.
Page 190 Problem: Engine Backfires Condition Remedy 1. ECU/CCU LED trouble code 1. Service — replace problem component 2. Throttle/ignition monitor switch adjusted incorrectly 2. Adjust throttle cable tension — service spring 3. Spark plugs fouled — damaged 3. Clean — replace spark plugs 4.
Page 191 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 192 Troubleshooting Engine (4-Stroke) 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. Wiring harness shorting — disconnected 2. Repair — replace — connect wiring harness 3.
Page 193 Problem: Engine Loses Power Condition Remedy 1. Sensor faulty 1. Check engine light for trouble code — repair — replace problem circuit or sensor 2. Spark plug fouled 2. Replace spark plugs 3. External coil faulty 3. Service — replace coil 4.
Page 194: Engine-Related Items
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 195 1. Remove the cap screws securing the water pump Engine-Related Items cover; then remove the cover and account for the O-ring seal. NOTE: Critical torque specifications can be found in Section 1 of this manual. NOTE: Some illustrations and photographs used in this section are used for clarity purposes only and are not designed to depict actual conditions.
Page 196 FC124 FC121 8. Using the hooked end of the long seal driver, pull 5. Remove the oil-injection pump retainer and shaft the inner seal free of the crankcase. from the opposite side of the crankcase. Account for the thrust washer located between the retainer ASSEMBLING and shaft flange.
Page 197 FC127 FS233A 4. Using a pair of snap ring pliers, install the snap 7. Position the shim on the oil pump end of the shaft; ring securing the inner seal in the crankcase. then with the O-ring installed on the retainer, install the oil-injection pump retainer.
Page 198 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. FS235A 10.
Page 199 FS219A FS220A NOTE: When servicing the water pump, use NOTE: Leave the two upper check valves secured Water Pump Bearing and Seal Tool Kit and Oil Seal to the pump. Protector Tool. 1. Loosen the clamps securing the coolant hose to the water pump and cylinder head;...
Page 200 FS225 FS227 8. Using a pair of snap ring pliers, remove the snap NOTE: If the impeller will not slide off the shaft, ring 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 impel- ler.
Page 201 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 202 FS220A FC133A 11. Position the O-ring into the water pump cover; NOTE: When installing the lower check valve, then install the cover. Install the cap screws; then assure that the gaskets are installed on each side using the pattern shown, tighten to 96 in.-lb. of the valve.
Page 203 3. Remove the separator tank breather hose to gain NOTE: Apply heat to the housing to aid in remov- access to the water pump; then remove the water ing 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 204 5. Install the impeller shaft into the inner housing and C. Connect the tester pump to an impulse fitting secure with the E-clip (B); then with a new O-ring on the crankcase; then plug any remaining properly positioned in the outer housing, place the impulse fittings and pressurize the crankcase to water pump halves together.
Page 205 Valve clearance must be within specifications. If valves, valve guides, or valve seats require servic- ing or replacement, Arctic Cat recommends the com- ponents be taken to a qualified machine shop for Valve Clearance (Cold) servicing.
Page 206 NOTE: When measuring valve/tappet clearance NOTE: Do not remove the tensioner adjuster bolt on the exhaust valves, rotate the engine until the until the tensioner assembly is removed from the decompression pin of the valve/tappet is acti- cylinder head to avoid internal components from vated;...
Page 207 10. To select the correct replacement shim for an out- of-specification clearance, note the three-digit number on the surface of the existing shim; then refer to the appropriate Tappet Shim Selection Table (Exhaust or Intake) and use this procedure: A. Find the Measured Tappet Clearance (from step 5) in the left-side vertical column of the table.
Page 208 SNO2152 Manual Section 3-15 Back Next Table of Contents Table of Contents...
Page 209 SNO2153 Manual Section 3-16 Back Next Table of Contents Table of Contents...
Page 210 11. With a light film of engine oil applied to the tap- pets, 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 211 ZJ106A IO051A 17. With the camshafts in position and properly timed, install the camshaft covers along with cam chain tensioner 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 clear- ance, install the timing inspection plug to the mag- neto case and tighten to 22 ft-lb.
Page 212 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 the air silencer, make sure the gasline hose is wiring harness plug-ins to the coils (A) and the routed over the air silencer.
Page 213 NOTE: At this point, remove the strainer from the 14. Shut the engine off and pour the remaining amount (0.9 l or 1 U.S. qt) of recommended oil into the oil oil reservoir to allow the oil to drain completely. reservoir;...
Page 214 DRAINING COOLING SYSTEM Oil Flow Chart (Crossfire/M-Series) (1100 cc) 1. Using a piece of cardboard to protect the hood and belly pan, tip the snowmobile on its PTO-side. 2. From beneath the front end, remove the self-tap- Non-Turbo ping screws securing the skid plate to the chassis. 3.
Page 215 2. Lift the rear of the console and disconnect the con- NOTE: If coolant is required, mix coolant for a sole/main harness plug-in; then remove the con- temperature of -36°C (-34°F). Follow mixing recom- sole. mendations of the manufacturer of the coolant. 3.
Page 216 3. Remove the hose clamp from the coolant hose (A) 3. On the non-turbo models, remove the headlight connecting the water pump to the right side of the support bracket/heat shield. oil cooler. Clamp off the coolant hose; then with a 4.
Page 217 INSPECTING THERMOSTAT 10. On the non-turbo models, install the headlight sup- port bracket/heat shield. 1. Inspect the thermostat for corrosion, wear, or spring damage. 11. On the turbo models, place the heat shield into position and secure with the cap screws. Tighten 2.
Page 218 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 219 F-Series 2-Stroke 0742-314 CFR/Crossfire/M-Series 738-067A Manual Section 3-26 Back Next Table of Contents Table of Contents...
Page 220 5. Remove the pawl (F); then remove the return Recoil Starter spring (G). (500/600 cc) 6. Carefully lift the roller free of the case making sure the main spring (H) does not disengage from the case. ! WARNING Care must be taken when lifting the roller free of the case.
Page 221 5. Align the hook in the end of the main spring with Recoil Starter the notch in the roller; then carefully slide the roller over the hub and engage the spring with the (570/800/1000 cc) roller. 6. Install the return spring making sure the end is properly installed in the hole in the roller;...
Page 222 ASSEMBLING 2. Rotate the roller (B) counterclockwise until the notch of the roller is near the rope guide in the 1. Hook the end of the main spring around the case. Guide the rope into the notch and slowly mounting lug in the case. allow the roller to retract until all recoil spring ten- sion is released.
Page 223 2. On the 570 cc, secure the starter with cap screws 3. Carefully push the headlight lenses rearward far (coated with blue Loctite #243). Tighten to 60 in.- enough to remove the torx-head screws securing lb. On the 800 cc/1000 cc, secure the starter with the air silencer plenum to the hood.
Page 224 3. Remove the springs securing the expansion cham- ber; then remove the expansion chamber from the engine compartment. Account for the two exhaust gaskets. 4. With the seat adjusted to its lowest position, remove the self-tapping screw from the right-side seat adjustment track;...
Page 225 CLEANING AND INSPECTING NOTE: To aid in installing the duct, it can be help- ful to apply a thin film of WD-40 to the air silencer 1. Check for holes or cracks in the silencer. seal and to work the duct back and forth until the 2.
Page 226 10. Secure the console to the steering support with the torx-head screws and tighten the screws securely; then close the left-side and right-side access panels and close the hood. 741-744A 3. Remove the torx-head cap screws securing the upper front/rear panels (C) and the handlebar close-off panel (B) along with the body screws securing the knee-pads to the steering support.
Page 227 10. Remove the two torx-head cap screws securing the air silencer to the chassis; then loosen the screws on the clamps securing intake boot to the throttle bodies. ZJ010A 8. Disconnect the fuel pump four-wire connector; then slide the gas tank rearward enough to gain access to the gasline hose connector.
Page 228 NOTE: Install the air silencer at an angle posi- tioning it to the PTO-side throttle body first and tightening its clamp; then working it back and forth and with an angle tool, slide the mag-side air silencer boot onto the throttle body and tighten its clamp.
Page 229 IO054A ZJ097A 8. Connect the fuel pump four-wire connector; then CAUTION secure the knee-pads to the steering support with Make sure the gasline hose is properly locked to the the two body screws. gas tank before continuing installing. 9. Install the upper body panels and secure with the 5.
Page 230 REMOVING/INSPECTING CAUTION Remove the air cleaner cover; then remove the air filter. Do not store the turbo vertically as oil will be lost from the bearing cavity and bearing damage on start-up 1. Inspect the filter for tears or dirt and replace if nec- could occur.
Page 231 9. Loosen the hose clamp and remove the waste gate control valve hose from the elbow fitting of the turbocharger. TZ058A 7. Using a suitable clamping device, clamp off the coolant return hose; then remove the clamp secur- ing the coolant return hose to the return line of the turbocharger.
Page 232 TZ091A 16. Remove the four lock nuts securing the turbo to the exhaust manifold. Account for the gasket and flat washers. 743-780C 13. Remove the lock nuts and washers securing the exhaust manifold to the engine cylinder head; then carefully remove the turbocharger and exhaust manifold assembly.
Page 233 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. TZ093A 2. Inspect the air bypass linkage for signs of wear or damage.
Page 234 TZ092A TZ061 9. Connect the coolant feed hose and oil return hose 13. Connect the coolant return hose to the turbo and to the turbo, release the clamps, and secure the secure with the hose clamp. hoses with the hose clamps. TZ060A 14.
Page 235 THEORY Two-cycle engines and their exhaust systems are designed to produce maximum horsepower in a given RPM range. This RPM range will change according to how high (or low) the exhaust port is in relation to the cylinder. Engines designed for racing have a “high port”...
Page 236 Voltage Regulator/Rectifier Servomotor Cycles Three Times (570/800/1000/1100 cc) In this situation the ECU computer has been pro- grammed with a voltage range (low and high) that the The AC current from the power coil first enters the servomotor must operate within. If the servomotor is regulator/rectifier changing from AC current to DC put under too much load, its resistance goes up and current.
Page 237 The cables should be checked every 1000-2000 miles and adjusted as necessary. To ensure maximum performance and minimize maintenance requirements, Arctic Cat recommends using Arctic Cat Synthetic APV 2-Cycle Oil. Using oils other than the recommended oil may increase the frequency of required cleaning due to increased buildup of carbon deposits.
Page 238 NOTE: The measurements must be within the 600 cc specifications from the chart. If the measurements are within specifications, no adjustment is neces- sary (proceed to step 8). If they are not within specifications, proceed to step 6. 6. Loosen the jam nut on the cable to be adjusted; then using the adjusting nuts, lengthen or shorten the housing as needed.
Page 239 Cleaning and Inspecting 1. Slide the return spring over the end of the actuat- ing cable. 1. Remove all carbon deposits with solvent and a soft abrasive such as a Scotch-Brite pad. 2. Inspect all parts for nicks, burrs, or other signs of unusual wear.
Page 240 600 cc FC115 FC023 6. Perform steps 5-8 in Cable Adjustment in this sub- CAUTION section. On the 600 cc, the long side of the exhaust valve must TROUBLESHOOTING be facing toward the cylinder head or severe engine damage may occur. The APV system has a self-testing mode built in.
Page 241 Exhaust Controlled Timing (ECT) System (2-Stroke) The APV models are equipped with the Exhaust Con- trolled Timing (ECT) system utilizing an exhaust pipe temperature sensor. This system automatically adjusts the ignition timing to provide maximum performance through a variety of operating conditions. The ECU receives input on engine RPM (demand) and exhaust temperature (engine condition) and adjusts the ignition 0737-314...
Page 242: Fuel Systems
SECTION 4 — FUEL SYSTEMS TABLE OF CONTENTS Fuel Systems ............4-2 Fuel System (Carbureted) ........4-2 Fuel System (EFI) ..........4-15 Fuel System (Related Items)......... 4-32 Manual Table of Contents...
Page 243 Description 728-272B 3. Check the hoses to ensure that all are correctly 2256-974 Arctic Cat Diagnostic System Manual connected; then check for cracks. If any cracks are 0644-364 Fuel Pump Socket Wrench evident in the hoses, replace them making sure...
Page 244 4. Install the drain plug and O-ring; then tighten securely. CAUTION When installing the throttle bodies/carburetors, make sure the gasline hoses are properly routed to avoid premature wear and/or contact with exhaust compo- nents. TZ103A 0728-054 5. Install and secure each carburetor. Carburetor TZ104A (570 cc)
Page 245 NOTE: Unless a problem with the safety switches exists, do not loosen or remove the screws secur- ing the switch to the carburetor. 1. Remove the four screws and lock washers secur- ing the float chamber; then remove the float cham- ber and gasket.
Page 246 CM050A CM052 4. Remove the needle valve and the seat. Account for 7. While counting the rotations for installing purposes, a washer from the seat. rotate the pilot air screw clockwise until lightly seated; then remove the pilot air screw and spring. CM051 5.
Page 247 5. Blow compressed air through all hoses to remove any obstructions. ! WARNING Always wear safety glasses when drying components with compressed air. CAUTION DO NOT use wire or small drill bits to clean carburetor orifices, holes, or channels. Distorted or damaged ori- fices, holes, or channels can result in poor carburetor operation.
Page 248 CM053B AH084 2. Install the pilot air screw and spring. Rotate clock- 5. In order, place a washer and inlet seat into position wise until lightly seated; then turn counterclock- and secure. Install the inlet needle valve. wise the same number of turns as noted in disassembling for an initial setting.
Page 249 AH046 725-266C 8. Place the O-ring and drain plug into position and 11. Place the cable retainer into the piston valve and secure; then place the floats into position making secure with the Phillips-head screw. Guide the sure the word UP is properly positioned. Press the cable end down into the cable retainer slot and caps onto the float towers.
Page 250: Electrical Systems
CM056A TZ104A 6. Connect the safety switch harness connectors to NOTE: Prior to threading the mixing body top the main wiring harness. onto the carburetor, assure the rubber washer is positioned correctly on the body top. 7. Adjust the carburetors to the initial setting (see ADJUSTING in this sub-section).
Page 251 Piston Valves Synchronizing Piston Valves NOTE: The console can be removed for this pro- NOTE: Arctic Cat recommends using a suitable cedure. carburetor synchronizer. If a carburetor synchro- NOTE: The air silencer is a one-piece unit, and nizer is not available, use the following procedure.
Page 252 ! WARNING Be sure to tighten the swivel adapter jam nuts securely. If a swivel adapter jam nut is not tightened, the adjuster can rotate out of the carburetor cap causing the piston valve not to return to the full-closed position. 6.
Page 253 3. Remove the throttle cables from the piston valves. Choke Cable 4. Remove the throttle cables from the mixing body (570 cc) tops. 5. Remove the handlebar pad and console. REMOVING 6. Remove the throttle cable end from the throttle lever.
Page 254 2. Route the choke cable from the console to each 5. Thread each brass choke cable housing into each carburetor; avoid any sharp bends or moving parts. carburetor and tighten. Bend the lock tab up to secure the brass housing. Adjust the choke cable 3.
Page 255 Problem: Carburetor Too Lean (1/4-3/4 Opening) Condition Remedy 1. Pilot air screw too far out — damaged 1. Adjust — replace pilot air screw 2. Needle jet obstructed 2. Remove obstruction 3. Pilot jet — outlet — main jet obstructed 3.
Page 256 If the engine should become flooded, set the brake lever lock, compress the throttle lever to the full-open The Arctic Cat EFI System operates off a series of position, and crank the engine over until it starts and coils located on the stator and is made up of the fol- clears itself.
Page 257 These components are grouped into the fuel handling If the ECU is not receiving current from one of the system. They work together along with electrical sen- output coils on the stator, that circuit will not operate. sors (following list) and the ECU to provide the engine Coils on the stator are the charge coils operating the with a precise fuel mixture for combustion.
Page 258 IGNITION TIMING SENSOR On the 600/800/1000 cc, the injectors are coded with symbols ( ) and are color-coded yellow and (2-Stroke)    green. When replacement of a fuel injector is neces- This sensor is located inside the magneto case next to sary, the injector must be replaced with an injector of the flywheel, and the recoil starter and the flywheel the same code symbol and color.
Page 259 CAMSHAFT POSITION SENSOR NOTE: To aid in testing the 500/600 cc EFI sys- (1100 cc) tem, refer to the EFI Analyzer Usage Manual with EFI Analyzer. This sensor tells the ECU which stroke the engine is on. Because the 4-stroke engine operates on a 720° INTRODUCTION cycle, the piston is at TDC twice per cycle - once on the exhaust stroke and once on the compression stroke.
Page 260 TROUBLESHOOTING INDIVIDUAL COMPONENTS 3. Test between the two yellow leads. NOTE: With the Arctic Cat EFI System, the ECU 4. The meter must show 0.08-0.12 ohm. must receive the proper current output from four coils (two charge coils, an injector coil, and a fuel NOTE: If reading is out of tolerance, recheck to...
Page 261 2. Set the meter selector to the OHMS scale. Memory Problem Diagnosis Test 3. Test between the two injector terminals. Test spec- 6. Press the analyzer TEST button. If all sensors are ification is 2.1-2.9 ohms (600/800 cc), 10-14 ohms good, SENSORS ALL O.K.
Page 262 3. Place the injector hold-down plate into position on 3. Connect the positive lead of a 12-volt power sup- top of the injectors and secure with two screws. ply to the red wire and the negative lead of the 12- volt power supply to the black wire.
Page 263 3. Compare the resistance reading to the Voltage/ 2. Connect the wiring harness to the air temperature Resistance Chart - Coolant Temperature in this sensor. Secure the sensor leads with cable ties so sub-section. If resistance is not within the specifi- they do not rub on any other components.
Page 264 729-325A ZJ289A 6. Connect the wiring harness to each injector and 2. Loosen the throttle cable jam nut; then remove the throttle position sensor. throttle cable from the bracket and the throttle valve cam. NOTE: Install the air silencer and the expansion chamber (see Section 3).
Page 265 ZJ290 ZJ132A ASSEMBLING/INSTALLING NOTE: For assembling purposes, note from (1100 cc Non-Turbo) which side the fuel injectors were removed. 1. Place the throttle sensor in position on the throttle 6. Remove the two screws securing the ISC valve; body assembly; then secure with the screw. then remove the valve from the throttle body assembly.
Page 266 ZJ255 ZJ291A 6. Install the throttle cable to the bracket on the throt- tle body assembly and to the throttle valve cam; then secure the cable with the jam nut. NOTE: Assure proper free-play exists in the throt- tle cable when securing the jam nut. ZJ290 NOTE: Always use new O-rings on the injectors before installing.
Page 267 2. Remove the two screws securing the handlebar close-off panel (B); then remove the three screws (C) securing the left-side rear spar panel to the seat support tube. Remove the screws (D) securing the left-front spar panel to the front bumper; then remove the spar panel.
Page 268 NOTE: With the injectors removed, inspect the O- rings and gaskets for damage. AO252 CAUTION Never place the throttle body in cleaning solvent with TZ113A the TPS secured to the throttle body or the sensor 13. If necessary, remove the cap screws securing the must be replaced.
Page 269 TZ117 TZ109A 6. Install the hose connecting the intake pipe to the NOTE: Always use new gaskets when installing throttle body and secure with the hose clamps. the injectors. 7. Install the coolant hoses (B) to the throttle body and secure with the clamps; then install the har- ness connector to the throttle position sensor (A).
Page 270 4. On the 500 cc, loosen the oil-injection cable jam nuts. 5. On the other models, remove the handlebar pad and the console (if applicable). 6. Remove the cable ties securing the throttle cable. 7. Remove the throttle cable ends from the throttle lever and from the throttle control housing.
Page 271 CAUTION Compress the throttle control lever to ensure free movement. If the throttle cable sticks or binds, correct the problem before starting the engine. 10. Synchronize the oil-injection pump. Manual Section 4-30 Back Next Table of Contents Table of Contents...
Page 272 Voltage/Resistance Voltage/Resistance Chart - Air Temperature Chart - Coolant Temperature Temperature Volts Ohms Temperature Volts Ohms 100° C 212° F 0.113 28° C 82° F 1.230 8540 Temperature Volts Ohms Temperature Volts Ohms 98° C 208° F 0.121 26° C 79°...
Page 273 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 274 9. Check the oil-injection system synchronization 800/1000 cc (see Synchronizing Oil-Injection Pump in this sub- section). Tighten the jam nuts securely. NOTE: On EFI models to install the exhaust sys- tem and the air silencer, see Section 3. 10. Install the carburetors/throttle bodies. Synchronizing Oil-Injection Pump 0744-528...
Page 275 9. If the oil-injection pump output does not meet the the oil pump; then using Oil Injection Usage Tool, specifications, see Testing Oil-Injection Check fill the hose with Arctic Cat Synthetic APV 2- Valves in this sub-section. Cycle Oil. 10. Disconnect the oil usage tool, remove the plug NOTE: Use clear hose when performing this test...
Page 276 REMOVING/INSPECTING 1. Open the left-side access panel; then remove the 1. Gasket 2. Check Valve fuel filter from the bracket. 3. Gasket 4. Union 731-551A 2. Attach the vacuum test pump hose to the check valve. 3. Squeeze the vacuum pump handle and watch the ZJ135B pump gauge.
Page 277 INSTALLING Fuel Pump 1. Install the gasline hose to the inlet of the fuel (CFR/Crossfire/M-Series) pump and secure with a new hose clamp; then install new grommets (C) on the mounting stud and the fuel outlet of the fuel pump. 2.
Page 278 INSTALLING TESTING VACUUM 1. Install a new seal (B) on the fuel pump; then with a NOTE: Make sure adequate fuel is in the carbure- new hose clamp, secure the gasline hose with the tor for this test. smart valves to the inlet of the fuel pump. 1.
Page 279 SECTION 5 — ELECTRICAL SYSTEMS TABLE OF CONTENTS Testing Fuel Gauge Sender (4-Stroke)....5-19 Testing Electric Fuel Pump (2-Stroke)....5-19 Testing Electric Fuel Pump (4-Stroke)....5-20 Testing Ignition Key Switch (4-Stroke)....5-20 Electrical Systems........... 5-2 Testing Ignition Components (4-Stroke) ....5-20 Testing Components ..........
Page 280 If spark is now present, adjust the throttle stroke EFI electrical system components, refer to the cable tension. Arctic Cat Diagnostic System Manual or to the Laptop NOTE: There must be 0.030-0.060 in. free-play Diagnostic Tool. between the throttle lever and the control housing.
Page 281 Main Wiring And Safety Switches 4. With the throttle lever in the idle position and the emergency stop knob in the down (STOP) posi- 1. Check the wiring connections coming from the tion, the meter must read resistance (closed). If the ignition key and emergency stop switches.
Page 282 2. Disconnect the three-wire connector. Using an ohmmeter, connect one meter lead to the black wire and the other meter lead to the black/red wire in the connector. 3. With the emergency stop knob, located on top of the throttle control, in the ON (pulled up) position and the throttle lever compressed, the meter must read resistance (closed).
Page 283 Synchronizing Carburetor Safety Switches Before synchronizing the carburetor safety switches, check to make certain the carburetor idle speed screws are adjusted equally and the piston valves are synchro- nized. The carburetor safety switches affect ignition spark at idle only. If ignition spark problems are observed at partial or full-throttle positions, the prob- lem is not with the carburetor safety switches.
Page 284 CHECKING TPS 9. Repeat steps 6-8 several times. If ignition shut- down always occurs at or slightly after clutch NOTE: If the snowmobile is in warranty, breaking engagement, the carburetor safety switches are the seal on the idle screw jam nut or the Phillips- synchronized.
Page 285 3. Disconnect the TPS wiring harness from the TPS; NOTE: It is important that the throttle shaft is in then using Throttle Position Sensor (TPS) Adjust- the completely closed position for this procedure. ment Tool, connect the appropriate wiring harness to the TPS.
Page 286 NOTE: Before installing the TPS harness connec- Engine Idle Full-Open tor, apply dielectric grease to the connector pins. 1100 cc Non-Turbo 1.10-1.14 4.30-4.50 1100 cc Turbo 0.69-1.11 4.00-4.20 Throttle Position 4. Compress the throttle lever slowly to the full-open position. The meter reading should show a smooth Sensor rise in voltage all the way to the full-open throttle (4-Stroke)
Page 287 NOTE: If, after adjusting the Throttle Position 3. Install the screw(s), flat washer(s), and lock washer(s) securing the sensor to the throttle body. Sensor to the IDLE specification, the FULL-OPEN Do not tighten at this time. is less than 4.30 volts, recheck the IDLE setting. If the IDLE setting is correct, replace the sensor.
Page 288 IGNITION COIL (Secondary) 2. Set the selector in the OHMS position. 1. Remove the spark-plug caps from the high tension 3. Connect the red meter lead to the black/red wire in wires. the plug; then connect the black meter lead to the green/red wire in the plug.
Page 289 3. Connect the two meter leads to each of the yellow leads in the connector from the engine. 4. Lighting coil resistance must be 0.15 ohm ± 20%. IGNITION COIL (Primary) 1. Disconnect the double wire plug from the CDI unit to the ignition coil.
Page 290 FUEL PUMP COIL Testing Electrical 1. Test between the two orange wires in the four- Resistances prong connector from the magneto. (800/1000 cc) 2. Meter reading must be 1.9 ohms ± 20%. INJECTOR COIL NOTE: Resistance tests of the engine electrical components should be made using the Fluke Mul- 1.
Page 291 4. Spark-plug cap resistance must be between 4000- ! WARNING 6000 ohms. Most voltages generated by the ignition system are IGNITION SWITCH sufficient to interrupt pacemakers! All technicians, NOTE: On the F8, the console must be removed especially those using pacemakers, must avoid con- tact with all electrical connections after the engine has to access the ignition switch.
Page 292 The CCU has two DC outputs used for lighting cir- Standard Gauge cuits. Both outputs have a circuit breaker (self reset- ting devices) protecting components from over-current and short circuit situations. If a system stops working, a short has likely occurred and the system has shut itself off much like a fuse will blow if a circuit is shorted to ground.
Page 293 3. Press and hold the shift button for 5 seconds. 2. Contact the red/black servo terminal with the bat- tery positive lead; then contact the black/red servo NOTE: Two quick flashes of the service icon indi- terminal with the battery negative lead. cate the codes have been cleared.
Page 294 2. Pull the recoil starter rope briskly. Meter reading Peak Voltage Output must be within specification. Tests CHARGE COIL (1) (500/600 cc) 1. Test between the black/red and green/red wires in the triple-plug connector from the magneto. NOTE: The following tests should be made using 2.
Page 295 IGNITION TIMING SENSOR NOTE: Peak Voltage Tests were made with connec- tors plugged in, spark plugs removed and grounded, 1. Test between the green/white and brown/green and by pulling the recoil starter rope briskly. wires in the connector from the sensor. ! WARNING 2.
Page 296 INJECTOR COIL Testing Low-Oil 1. Test between the two blue/white leads in the four- Light Sensor prong connector harness from the magneto. 2. Pull the recoil starter rope briskly. Meter reading must be within specification. The low-oil light sensor is a magnetic switch. Its oper- ation is based on a magnet located around the inside CHARGE COIL (1) diameter of a 1/2-in.
Page 297 2. Connect an ohmmeter between the sensor terminal Testing Fuel and any convenient chassis ground (or any brown wire). The ohmmeter must read less than 20 ohms of Gauge Sender resistance with the coolant temperature more than (2-Stroke) +230°F. The ohmmeter must read no resistance with the coolant temperature less than +190°F.
Page 298 3. Connect the positive lead of a 12-volt power sup- 3. With the switch in the ON position, the meter must ply to the red wire and the negative lead of the 12- read OL (infinite resistance). volt power supply to the black wire. Testing Ignition 4.
Page 299 2. Test between the three yellow wires for a total of 4. The meter reading must be at least 5.0 DC volts three tests. for both coils. 3. The meter reading must be less than 1 ohm. Emergency Stop Switch CRANKSHAFT POSITION SENSOR Resistance RESISTANCE...
Page 300 2. A loud, audible “click” should be heard as the solenoid internal contacts make connection. 3. Disconnect the battery from the solenoid. 4. A loud, audible “click” should be heard as the solenoid internal contacts release. NOTE: An in-line ampmeter would measure between 2 and 4 amps of solenoid coil current flow with the battery connected.
Page 301 DISASSEMBLING 1. With the ignition switch plugged in, place the emergency stop switch to the OFF position. NOTE: For assembly purposes, scribe a refer- 2. Connect the red tester lead to the black/yellow ence line on the end plate/drive cap, commutator wire;...
Page 302 ! WARNING When using compressed air to dry components, always wear safety glasses. AI028 6. Lift all brushes from the brush holder and account for the four brush springs. 7. Using a 5/16-in. socket, remove the two cap screws securing the ground brushes to the commu- AI029 tator cap.
Page 303 AI031 AI033 6. Inspect the end plate/drive cap bushing for wear. NOTE: After cleaning any buildup from the com- Using a calipers, measure the inner diameter of the mutator, use compressed air to clean. cap bushing. If found to be 0.523 in. or larger, replace the cap.
Page 304 CAUTION Check the stud to make sure insulator is between stud and cap on backside. 2. In order from disassembling, place the washers on the stud. Apply a small amount of red Loctite #271 to the stud threads and secure with the nut. Tighten to 60 in.-lb.
Page 305 8. Apply a thin coat of grease to the armature shaft NOTE: The starter shouldn’t be picked up until and slide the drive gear and spring washer onto the the two through-bolts have been secured. Spring shaft. Secure with a snap ring. pressure from the brush springs will push the commutator cap off the case.
Page 306 TESTING STARTER MOTOR 2. Place the flex-drive shaft into position on the pinion driveshaft so the set screws are aligned with the flat- NOTE: Before installing the starter motor, per- side of the pinion driveshaft; then tighten the set form test to ensure proper operation using the fol- screws (coated with blue Loctite #243) securely.
Page 307 5. Connect the battery cables (positive cable first) to the battery. 6. Install and secure the resonator and the expansion chamber. NOTE: To finalize the installing procedure, the air silencer must be installed. Proceed to the appro- priate Air Silencer sub-section in Section 3. Starter Motor (4-Stroke) ZJ152A...
Page 308 10. Inspect the commutator for shorting using a multi- meter and the following procedure. CAUTION A. Set the selector to the OHMS position. Do not wash the armature and brushes in any kind of solvent. Use only compressed air and clean dry, lint- B.
Page 309 4. With a suitable driving tool, install new seal into the bearing housing; then install the bearing housing. NOTE: Prior to installing the bearing housing, position the locking plate with the tabs (A) of the locking plate aligned with the cap screw ears (B) of the starter motor.
Page 310 2. Install the positive cable (A) to the starter motor and tighten securely. Secure the positive and nega- tive cables with cable ties as noted during disas- sembling. NOTE: To finalize this procedure, the air silencer must be installed. Proceed to appropriate Air Silencer sub-section in Section 3.
Page 311 ZJ150A 0742-002 3. Install the two alignment pins in the engine for the INSTALLING magneto cover; then with a new gasket, install the cover and with the pattern shown, tighten the 18 1. Place the magneto into position on the cover; then cap screws to 84-in.-lb.
Page 312 CHECKING NOTE: Assure that the O-rings are properly seated in the supply/return oil hose fittings. 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. Gradually increase the engine speed to the speci- fied RPM;...
Page 313 2. Install the brake lever and secure with the pin and Testing Handlebar snap ring. Warmer Elements 3. Connect the switch harness to the main wiring har- ness. Position the wires so they will not be either pinched or come in contact with any moving com- ponents.
Page 314 INSTALLING NOTE: If either test is not within specification, replace the thumb warmer element. 1. Connect the handlebar/thumb warmer harness to the switch; then place the control assembly on the 6. Connect the leads; then install and secure the han- handlebar.
Page 315 NOTE: If this voltage test does not read within Testing Seat Heater specification, troubleshoot the main harness, F-2 Harness/Switches fuse, K-2 relay, or the F-7 main fuse. Testing NOTE: The seat heater elements cannot be Speedometer Sensor tested. OPERATOR HEATER SWITCH - Resistance NOTE: The following test should be made using MaxiClips and the Fluke Model 77 Multimeter set to...
Page 316 2. Connect one ohmmeter lead to the black wire; then connect the other ohmmeter lead to the white/violet wire. 3. With the reverse button pressed in, the meter must read less than 1 ohm of resistance. With the reverse button released, the meter must read OL (open).
Page 317 Troubleshooting Servomotor SERVO1A Manual Section 5-40 Back Next Table of Contents Table of Contents...
Page 318 SERVO2 Manual Section 5-41 Back Next Table of Contents Table of Contents...
Page 319 * Passanger Seat Harness on p. 21. „NOTE: All Magneto Diagrams on p. 1. © Arctic Cat Inc., 2009, Thief River Falls, MN 56701®™Trademarks of Arctic Cat Inc., P.O Box 810, Thief River Falls, MN 56701 p/n 2258-677 Manual Section...
Page 320 Magneto Manual Section Wiring Diagram 0744-205 Table of Contents Table of Contents Table of Contents...
Page 321 Main Harness (p/n 1686-527) F 570 (p/n 1686-528) T570 (p/n 1686-534) Bearcat 570 XT (p/n 1686-535) Bearcat 570 Manual Section Wiring Diagram 0744-182 Table of Contents Table of Contents Table of Contents...
Page 322 Main Harness (p/n 1686-553) F5 LXR Manual Section Wiring Diagram 0744-188 Table of Contents Table of Contents Table of Contents...
Page 323 Main Harness (p/n 1686-554) Crossfire 600 Manual Section Wiring Diagram 0744-181 Table of Contents Table of Contents Table of Contents...
Page 324 Main Harness (p/n 1686-551) F6 Sno Pro Manual Section Wiring Diagram 0744-187 Table of Contents Table of Contents Table of Contents...
Page 325 Main Harness (p/n 1686-539) F8 LXR Manual Section Wiring Diagram 0744-185 Table of Contents Table of Contents Table of Contents...
Page 326 Main Harness (p/n 1686-538) F8/Sno Pro Manual Section Wiring Diagram 0744-186 Table of Contents Table of Contents Table of Contents...
Page 327 Main Harness (p/n 1686-533) CFR/Crossfire/M-Series - 800/1000 cc Manual Section Wiring Diagram 0744-178 Table of Contents Table of Contents Table of Contents...
Page 328 Main Harness (p/n 1686-522) Bearcat Z1 XT (p/n 1686-581) TZ1/TZ1 LXR (p/n 1686-575) (p/n 1686-518) Z1 LXR Manual Section Wiring Diagram 0744-192 Table of Contents Table of Contents Table of Contents...
Page 329 Main Harness (p/n 1686-516) TZ1 Turbo LXR/Z1 Turbo Sno Pro (p/n 1686-520) Z1 Turbo LXR (p/n 1686-519) Z1 Turbo/Z1 Turbo EXT Manual Section Wiring Diagram 0744-203 Table of Contents Table of Contents Table of Contents...
Page 330 Console Harness (p/n 1686-547) Bearcat Z1 XT Z1 Turbo/EXT Z1 Turbo Sno Pro (p/n 1686-549) TZ1/Z1 LXR/Z1 Turbo LXR Manual Section Wiring Diagram 0744-194 Table of Contents Table of Contents Table of Contents...
Page 331 Console Harness (p/n 1686-548) TZ1 LXR TZ1 Turbo LXR Manual Section Wiring Diagram 0744-193 Table of Contents Table of Contents Table of Contents...
Page 332 Hood Harness (p/n 1686-565) CFR/Crossfire/M-Series Manual Section Wiring Diagram 0744-179 Table of Contents Table of Contents Table of Contents...
Page 333 Console Harness (p/n 1686-576) Bearcat 570 (p/n 1686-567) Bearcat 570 XT F 570 T570 Manual Section Wiring Diagram 0744-184 Table of Contents Table of Contents Table of Contents...
Page 334 Console Harness (p/n 1686-573) F5 LXR F8 LXR Manual Section Wiring Diagram 0744-190 Table of Contents Table of Contents Table of Contents...
Page 335 Console Harness (p/n 1686-572) F6 Sno Pro F8/Sno Pro Manual Section Wiring Diagram 0744-191 Table of Contents Table of Contents Table of Contents...
Page 336 Handlebar Harness (p/n 1686-566) Crossfire/M-Series (p/n 1686-575) Manual Section Wiring Diagram 0744-180 Table of Contents Table of Contents Table of Contents...
Page 337 Handlebar Harness (p/n 1686-574) F-Series Manual Section Wiring Diagram 0744-189 Table of Contents Table of Contents Table of Contents...
Page 338 Handlebar Harness (p/n 1686-537) Bearcat 570/570 XT F 570 T570 Manual Section Wiring Diagram 0744-183 Table of Contents Table of Contents Table of Contents...
Page 339 Handlebar Harness (p/n 1686-568) TZ1/TZ1 LXR/TZ1 Turbo LXR/ Z1/Z1 LXR/Z1 Turbo LXR/ Z1 Turbo EXT/Z1 Turbo Sno Pro (p/n 1686-577) Bearcat Z1 XT Manual Section Wiring Diagram 0744-195 Table of Contents Table of Contents Table of Contents...
Page 340 Passenger Seat Harness (p/n 1686-570) TZ1 Models Manual Section Wiring Diagram 0744-197 Table of Contents Table of Contents Table of Contents...
Page 341: Drive Train/Track/Brake Systems
SECTION 6 — DRIVE TRAIN/TRACK/ BRAKE SYSTEMS TABLE OF CONTENTS Drive Train/Track/Brake Systems......6-2 Drive Belt..............6-2 Drive Clutch............. 6-3 Driven Pulley ............6-5 Drive Clutch/Driven Pulley........6-10 Drive Train/Brake Disc ........... 6-12 Drive Sprockets ............. 6-30 Track Tension ............6-33 Track Alignment.............
Page 342: Rear Suspension
NOTE: Critical torque specifications are located amount of power that will be transmitted through the in Section 1 of this manual. system. ONLY ARCTIC CAT DRIVE BELTS SHOULD BE USED. Different brands of belts may SPECIAL TOOLS not have the same construction causing either more...
Page 343 5. Remove the cap screw (w/lock washer and 2. Using the Drive Clutch Puller and a breaker bar washer) from the adjuster, remove the washer and and the Drive Clutch Spanner Wrench, tighten the lock washer from the cap screw, turn the adjuster puller.
Page 344 3. Remove the cam arm pin lock nuts; then using a 4. Inspect the cam arm pins for wear or bends. small torch, apply heat to the cam arm set screws 5. Inspect the spring for proper compression rate to loosen the Loctite used in assembly. qualities (see Drive System Components in Sec- tion 1 of this manual).
Page 345 NOTE: For installing drive belt, see Drive Belt in this section. ! WARNING Never operate the engine without the belt guard/side panel secured. 4. Either test drive the snowmobile or run the engine for five minutes; then verify the drive clutch cap screw torque specification.
Page 346 FS090 FS094 3. Remove the torx-head cap screws securing the 5. Remove the stationary sheave; then remove the movable sheave to the torque bracket. plastic washer (spring seat) and the spacer. CM061 CM062 NOTE: To loosen the torx-head cap screws, it 6.
Page 347 NOTE: Premature wear will result if the plastic washer is not installed during assembling. CLEANING AND INSPECTING NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. 1. Using parts-cleaning solvent, wash grease, drive belt dust, and foreign matter off all components.
Page 348 CM065 CM067A 4. Tap the spring pin back into place. CAUTION Care must be taken not to damage the driven pulley shaft. NOTE: Once the roller pin is exposed, it may be necessary to use a pair of vise-grips to remove the pin.
Page 349 CM063 FS093 5. With the pulley in place on the compressor, install NOTE: Premature wear will result if the plastic the compressor flange spacer and wing nut; then washer is not installed. compress the driven pulley spring. 2. Noting the alignment marks made during disas- sembling and with the spring seat and spacer on the stationary sheave shaft, place the stationary sheave onto the torque bracket.
Page 350 CM125A 733-912C CAUTION CORRECTING OFFSET Do not apply Loctite to the cap screw or damage to the 1. To correct offset, the driven pulley must be moved gear case will occur. laterally on the input shaft. Remove the cap screw and washers securing the driven pulley.
Page 351 2. Using a 2x4 block of wood tapered at each end, drive the block between crankshaft and the input shaft until the engine has visibly moved forward (see illustration). 0744-609 3. If parallelism is not within specifications, the par- allelism must be corrected by first loosening all the engine mounting bolts (left side, front, and right top rear).
Page 352 5. To correct drive belt deflection, remove the sheave 3. On the F-Series/T-Series/Z1, remove the torx-head adjuster from the pulley, remove or add shim cap screws securing the toe shield and hook washers to the adjuster, and install the adjuster. bracket to the chassis and remove the shield and bracket;...
Page 353 5. Loosen the 16 mm cap screw (from the brake disc side of the inner driveshaft) securing the driveshaft to the gear case. ZJ308A 7. Place the snowmobile in the upright position; then using a 16 mm socket, long extension, and a ham- mer, tap against the driveshaft cap screw until the 742-020A gear case is free from the studs of the mounting...
Page 354 NOTE: Steps 1-8 are for installing the track drive- shaft. If only installing the gear case, proceed to step 9. NOTE: Prior to installing the driveshaft, apply a coat of Anti-Seize Thread Compound to the inter- nal splines of the driveshaft. ZJ211 12.
Page 355 2. With the brake lever lock engaged and the brake disc correctly positioned in the brake housing assembly, properly align the splines of the drive- shaft with the brake disc; then push the driveshaft the rest of the way into the brake housing until properly seated.
Page 356 742-195B ZJ308A 13. On the 500/600/1100 cc F-Series, connect shift NOTE: When tightening the nuts to the proper actuator harness (A) and gear indicator switch har- torque factor, begin tightening the nuts located on ness (B). the bottom of the gear case and working upward until all nuts are tightened to the proper torque factor.
Page 357 DISASSEMBLING GEAR CASE (w/Reverse) 1. On electronic reverse models, remove the three torx-head cap screws securing the shift actuator to the gear case and remove the actuator; then remove the gear indicator switch. FS268A 16. Install the 16 mm cap screw (coated with blue Loctite #243) securing the driveshaft to the gear case output shaft;...
Page 358 ZJ300 ZJ191 NOTE: For assembling purposes, note the posi- tion of the slider blocks on the shift fork arm. CAUTION If the input shaft bearing is removed, always replace it with a new one or severe component damage may occur. 5.
Page 359 ZJ196 ZJ193 10. Remove the output gear assembly from the slider NOTE: For assembling purposes, note that the housing. thrust bearing is positioned between the thrust washer and the gear assembly. ZJ194 11. Using a suitable bearing puller, remove the inner ZJ197 bearing from the transfer gear assembly.
Page 360 2. Place the output shaft assembly into position in the replaced. slider housing; then secure the assembly to the housing with the thrust washer and retaining ring. 8. Apply a light film of Arctic Cat Synthetic ACT Drive Fluid to the unsealed bearings prior to assembling. ASSEMBLING GEAR CASE (w/Reverse) 1.
Page 361 5. Position the planetary gear assembly onto the transfer gear shaft; then install the spacer washer. Using a suitable press, install the inner bearing onto the transfer gear shaft. ZJ200 3. Using a suitable bearing press, install the bearing onto the ring gear. ZJ208 6.
Page 362 ZJ199 MS349 9. Using a suitable bearing press and fixture, install 11. Install the first retaining ring onto the shift fork the input shaft bearing to the gear case; then install shaft; then install a new oil seal. the oil seal. NOTE: Apply a film of grease to the oil seal prior NOTE: A light coat of grease must be applied to to installing.
Page 363 ZJ207 CAUTION ZJ186A 17. Pour 12 fl oz of Arctic Cat Synthetic ACT Drive Care must be taken not to allow silicone sealant into the Fluid into the drain/fill hole; then install the plug. cap screw holes and dowel pin holes or damage to the Tighten to 12 ft-lb.
Page 364 744-133A MS330 744-134A MS331 3. Drain the gear case fluid into a suitable container. 6. Remove the transfer gear assembly from the gear case. 4. With a cap screw threaded into the input shaft and using a soft hammer, drive the input shaft out of the gear case cover.
Page 365 MS520 MS515 12. Noting the position of the gap, remove the retain- 9. Remove the retaining ring securing the planetary ing ring using a flat-blade screwdriver. gear assembly to the gear case. MS518A MS513 13. With a suitable bearing press and fixture, remove 10.
Page 366 If any abnormal condition is noted, replace the bearing. 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. ASSEMBLING GEAR CASE (w/o Reverse) MS523 3.
Page 367 MS517 MS518A 4. With the proper orientation as noted during disas- 6. Using a suitable bearing press, install the outer sembling, install the gear assembly into the plane- bearing (A) to the transfer gear assembly; then tary gear and secure with the retaining ring. install the spacer (B) and press the inner bearing (C) to the assembly.
Page 368 MS526 MS349 9. Using a suitable bearing press and fixture, install 11. Apply a film of High-Temp Silicone Sealant to the the input shaft bearing to the gear case; then install sealing surfaces of the gear case. the oil seal. NOTE: Grease must be applied to the inner seal prior to installing.
Page 369 744-134C 741-636A 13. Pour 15 fl oz of Arctic Cat Synthetic ACT Gear NOTE: To aid in draining the lubricant, it is advis- Case Fluid into the drain/fill hole; then install the able to fashion a drain adapter by using the Gear plug.
Page 370 Cat Synthetic ACT Gear Case Fluid. Any substitute may cause serious damage to the drive system. 20. Pour the exact amount (see appropriate specifica- tion sheet) of Arctic Cat Synthetic ACT Gear Case MS357A Fluid into the check/fill hole; then install the plug.
Page 371 CAUTION Always press against the tension-collar of the drive sprockets or damage to the components will occur. MS362 1. Properly align the scribed line on the driveshaft (from removing) with the timing arrow on the drive sprocket; then slide the sprocket onto the driveshaft as far as it will go.
Page 372 MS364 MS359A NOTE: The drive sprockets must be installed on the brake disc end of the driveshaft. 744-059B MS313C NOTE: When pressing new sprockets on the driveshaft, align the sprocket alignment marks or the sprockets won’t be timed correctly. 742-367A 740-043A 4.
Page 373 744-060B 0742-921 3. If the measurement obtained in step 2 is more than specified, tighten the adjusting bolts. If the mea- surement obtained is less than specified, loosen the adjusting bolts. When the measurement is within specification range, lock the adjustment by bottoming the jam nuts against the axle housings.
Page 374 2. Start the engine and accelerate slightly. Use only 2. Measure the distance between the brake lever and enough throttle to rotate the track several revolu- the handlebar. The distance must be greater than tions. SHUT THE ENGINE OFF. 1 in. NOTE: Allow the track to coast to a stop.
Page 375 ! WARNING 2. Slide a piece of flexible tubing over the ball of the Use only Arctic Cat approved brake fluid. Any substi- bleeder valve and direct the other end into a con- tute may result in a loss of brakes.
Page 376 1. Remove the brake fluid reservoir cover; then remove most of the brake fluid from the reservoir. Replace the cover. NOTE: The above procedure will allow room for the fluid from the caliper when the pistons are pushed into the caliper for installing new brake pads.
Page 377 3. Remove the two torx-head cap screws securing the 8. Disengage the brake lever lock and remove the speedometer sensor mounting bracket to the cali- hairpin clip and pin securing the brake pads; then per assembly; then disconnect the harness plug-in. remove both pads.
Page 378 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. ZJ226 CAUTION Use care not to bind the bearing in the caliper hous- ing when removing or damage to the housing may occur.
Page 379 ZJ230 AF230 3. Inspect the piston bore of the inner and outer brake calipers for gouges, cracks, pitting, scuffing, or corrosion. If any of these conditions exist, replace the caliper. 4. Clean the caliper inner wall surface using a soft lint-free cloth and clean brake fluid.
Page 380 0739-269 ZJ230 6. Inspect the brake hose for cracks and deterioration NOTE: To aid in installing the piston, make sure and check the condition of the threaded connectors. the piston O-ring is properly seated in the groove Assembling/Installing of the caliper housing. 1.
Page 381 ZJ241 ZJ244 CAUTION CAUTION When installing a bearing, always press on the outer When installing a bearing, always press on the outer race of the bearing. 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, spacer, and outer bearing to maintain proper align- ment of the spacer for driveshaft installation.
Page 382 NOTE: Always use a new O-ring and make sure the O-ring is properly seated in the outer brake housing. ZJ232 MS320A ZJ233 8. With the brake disc splines and driveshaft splines aligned, use a soft hammer and tap the caliper from side to side until the caliper is properly seated to the tunnel.
Page 383 14. Install the speedometer sensor mounting bracket to the caliper housing with the two remaining torx- head cap screws; then tighten to 17 ft-lb. 739-269B 2. Place an absorbent towel around the connection to absorb brake fluid. Remove the banjo-fitting bolt (A) securing the brake fluid hose (B) to the master ZJ210A cylinder.
Page 384 2. Install the brake fluid hose (B) to the master cylin- 4. Install the brake lever; then secure with pin (D) der with the banjo-fitting bolt (A) and two new and snap ring (C). crush washers. Tighten securely. 5. Place the reservoir cover onto the master cylinder reservoir;...
Page 385: Troubleshooting
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 386 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 387 Problem: Drive Clutch Jerks—Shifts Erratically Condition Remedy 1. Drive clutch dirty 1. Clean — drive clutch components 2. Rollers worn 2. Replace rollers 3. Cam arms rough 3. Polish — replace cam arms 4. Spider buttons worn 4. Replace buttons 5.
Page 388 SECTION 7 — REAR SUSPENSION TABLE OF CONTENTS Rear Suspension............. 7-2 Understanding the Suspension ....... 7-2 Suspension Setup Basics ........7-2 Chassis and Skid Frame Mounting Locations ..7-6 Servicing Rear Suspension Bearcat XT ............7-10 CFR/Crossfire ............ 7-34 M-Series............. 7-61 F-Series/Z1 ............
Page 389 Assume that the front arm functions as a stationary Rear Suspension pivot point between the rear axle center and the ski saddle center. Also assume that the ski saddle center is the same height off the ground as the rear axle center. This produces the standard position arrangement.
Page 390 Heavier Or Stiffer Springs If the spring tension is adjusted too stiff, the track angle at the front of the skid frame is steep. This steep 1. These will require shocks with more rebound con- angle prevents the snowmobile from getting up on trol, or the front end will become like a pogo stick.
Page 391 NOTE: As the pump is being attached to the NOTE: When making any changes to the front or shock, the hose will fill with air resulting in a lower rear suspension, the change should be made at both ends to keep the suspension balanced. For gauge pressure 0.14-3.52 kg/cm (2-5 psi).
Page 392 If additional coupler action is desired, the coupler blocks can be set to the number 2 or 3 position. Each of the coupler blocks has three positions numbered on the inside surface of the block. When changing the block position, change both to the same number. To make the coupler adjustment, follow the procedure below.
Page 393 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 394 Bearcat 570 0744-126 Crossfire (Standard) 0744-837 Manual Section Back Next Table of Contents Table of Contents...
Page 395 0744-128 M-Series 0744-835 Manual Section Back Next Table of Contents Table of Contents...
Page 396 Bearcat XT 0744-841 Z1 Turbo EXT 0744-842 Manual Section Back Next Table of Contents Table of Contents...
Page 397 5. Remove the support stand; then tip the snow- Servicing mobile onto one side using a suitable handlebar support stand. Remove the skid frame. Rear Suspension NOTE: At this point if servicing the articulating (Bearcat XT) skid frame only, proceed to Articulating Skid Frame in this sub-section.
Page 398 739-884A 739-884A 2. Secure with a machine screw and lock nut. Tighten CLEANING AND INSPECTING to 50 in.-lb. NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is End Caps necessary. 1. Clean the slide rail using parts-cleaning solvent NOTE: The skid frame does not have to be and compressed air.
Page 399 1. Using a 3/16-in. drill bit, drill out the rivets secur- ing each front and rear shock pad to the slide rail. Account for the retaining brackets. MS017A 2. Inspect the end cap for any signs of cracking or wear. AG476D 2.
Page 400 REMOVING 1. Remove the cap screws and lock nuts securing the front outer idler wheel and the idler wheel mount- ing block. Account for flat washers and two shim washers (if applicable). MS005 CLEANING AND INSPECTING NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary.
Page 401 MS007A MS009A E. Install the insert (if applicable). 2. Place the two shim washers (if applicable), idler wheel, and axle against the mounting block mak- ing sure a flat washer is on the outside of the idler wheel. MS008 INSTALLING 1.
Page 402 MS208 SC014B 3. Loosen the cap screws securing the pivot arm to the idler arm; then remove the pivot arm assembly. Rear Upper Idler Account for two pivot arm spacers. Wheels/Rear Springs NOTE: The skid frame must be removed for this procedure (see Removing Skid Frame in this sub- section).
Page 403 NOTE: Use the same procedure for the other side. CLEANING AND INSPECTING NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. 1. Clean the bearing with a clean cloth. 2. Inspect each idler wheel and plastic hub for cracks or damage.
Page 404 SC017 MS064 5. Place the flared bushings with a thin flat washer through the back 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 405 DISASSEMBLING 1. Remove the rear upper idler wheels and springs (see Rear Upper Idler Wheels/Rear Springs in this sub-section). MS076 3. Remove the cap screw and lock nut securing the upper shock links to the idler arm. Account for a lock nut, spacer, and axle links.
Page 406 ASSEMBLING 1. Install the rear arm onto the idler arm with an alu- minum axle, bushing assemblies, and two cap screws (coated with blue Loctite #243). Tighten only until snug. MS028 5. Remove the cap screw and lock nut securing the rear arm to the idler arm.
Page 407 NOTE: Install the rear arm springs onto the adjuster blocks after the skid frame has been installed. Front Arm/Front Shock Absorber/Front Inner Idler Wheels NOTE: The skid frame must be removed for this procedure (see Removing Skid Frame in this sub- MS031 section), and the rear springs must be removed from the adjusting cams.
Page 408 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 bearing, account for the flared spacers. SC025A SC028 7. Remove the cap screw and lock nut securing the shock absorber to the bracket.
Page 409 MS086A SC026A 4. Position the front arm into the slide rail. Secure NOTE: Do not over-tighten the shock absorber with cap screws and lock nuts. Tighten to 40 ft-lb. cap screw as the shock eyelet must be free to pivot. 2.
Page 410 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 411 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 upward and out from between the rails. NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary.
Page 412 ASSEMBLING NOTE: If the idler wheel has a non-removable bearing, install the flared spacers with the flared 1. Secure the shock rod links (with axles) and the side of the spacer directed towards the pivot lower end of the shock absorber to the idler wheel/ bracket.
Page 413 3. Using a suitable driving tool, drive the wear strip off the rail. MS100 NOTE: Do not over-tighten the shock absorber cap screw as the shock eyelet must be free to AG510D pivot. NOTE: If binding of the wear strip occurs, use a pipe wrench, start from either end, and hook the edge 7.
Page 414 7. Remove the lock nuts and cap screws securing the 9. Remove the cap screw and flat washer securing articulating skid frame to the mounting location of the spring slide and overload spring to the rail. the slide rails. Account for a spacer, the slide block, overload spring, retainer clips, bushing, one small washer, and two large washers.
Page 415 MS116A SC042A 12. Remove the cap screw from the rear arm stop. INSPECTING NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. 1. Inspect the slide rail for cracks (A), elongated holes (B), or unusual bends. SC042A 13.
Page 416 3. Install the rear arm limiter and secure with cap screw (coated with blue Loctite #243) and tighten to 40 ft-lb. 0743-189 INSTALLING 1. Install the front and rear shock pads and retaining SC042A brackets; then secure with rivets. 4. Secure the two front rail supports with cap screws (coated with blue Loctite #243).
Page 417 MS122 SC046A 8. Install the overload spring tension block with a cap 11. Secure the end cap onto the slide rail using a cap screw and lock nut. Tighten securely. screw, flat washers, and a lock nut. Tighten to 80 in.-lb.
Page 418 MS289 SC038A 14. Install the skid frame (see Installing Skid Frame in this sub-section). NOTE: Install the rear arm springs onto the adjuster blocks after the skid frame has been installed. 15. Adjust track tension deflection (see Track Tension in Section 6) and track alignment (see Track Alignment in Section 6).
Page 419 744-166A INSPECTING 2. Slide the rear axle through one side of the swing arm and through a washer (K) and an idler wheel NOTE: Whenever a part is worn excessively, spacer (J); then in order on the rear axle (I), install cracked, or damaged in any way, replacement is the center idler wheel, the remaining spacer (J), necessary.
Page 420 ADJUSTING 1. Place the skid frame assembly on a flat work sur- face. 2. Preload the articulating suspension by equally adjusting the lock nuts on the spring brackets until both rear idler wheels are 1 in. off the work sur- face.
Page 421 5. Remove the support stand; then tip the snow- Servicing mobile onto one side using a suitable handlebar support stand. Remove the skid frame. Rear Suspension (CFR/Crossfire) Wear Strips This Rear Suspension sub-section has been organized so each procedure can be completed individually and REMOVING efficiently.
Page 422 CLEANING AND INSPECTING 2. Secure with a machine screw and lock nut. Tighten to 50 in.-lb. NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is End Caps necessary. 1. Clean the slide rail using parts-cleaning solvent and compressed air.
Page 423 INSTALLING 1. Place the rear pads into position on the slide rail. 2. Secure the rear pads with new push nuts. 3. Place the front pads and retaining brackets into position on the slide rail. 4. Secure the front pads with rivets. Idler Wheels/ Mounting Blocks MS290A...
Page 424 3. Rotate the idler wheel bearing (by hand) and inspect for binding or roughness. 4. If a bearing must be replaced, use this procedure. CAUTION Do not remove the bearing unless absolutely neces- sary. The bearing will be damaged during removal. A.
Page 425 Rear Upper Idler Wheels/Rear Springs NOTE: The skid frame must be removed for this procedure (see Removing Skid Frame in this sub- section). REMOVING 1. On the CFR and Crossfire standard using the Rear Suspension Spring Tool, remove the spring from the adjusting cam.
Page 426 CAUTION Do not remove the bearing unless absolutely neces- sary. The bearing will be damaged during removal. 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 NOTE: Steps 1 and 2 are for the CFR and Cross- fire standard.
Page 427 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. SC051A 6. Align the marks on the idler arm to the centerline of the pivot arm assembly.
Page 428 CM239 CM239 10. Grease the idler arm and rear arm grease fittings NOTE: Steps 7-9 for the Crossfire models only. with a low-temperature grease. 7. Install the inner carriage axle to the idler arm; then install a wave washer and idler wheel. Secure with Rear Axle and the snap ring.
Page 429 1. In order from the right-hand side, slide the axle through the slide rail axle slot; then place a bush- ing (E), inner idler wheel (D), rear idler wheel spacer (C), inner idler wheel (D), and bushing (E) on the axle. Slide the axle through the opposite slide rail axle slot.
Page 430 MS153 FZ040A NOTE: On the standard Sno Pro, remove the NOTE: Mark the hole that the upper shock links snap ring securing the rear arm idler wheels to the are mounted in for assembly purposes. inner carriage axle and account for the wave wash- ers;...
Page 431 MS031 CM233A NOTE: On the Sno Pro, remove the cap screw NOTE: To remove the rear arm, it may be neces- and lock nut securing the upper shock eyelet to sary to loosen the rear arm limiter. the idler arm; then remove the cap screw and lock nut securing the rear shock link to the idler arms.
Page 432 NOTE: If the rear arm limiter was loosened, treat the threads of the cap screw with blue Loctite #243 and tighten to 40 ft-lb. MS030 CLEANING AND INSPECTING NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is FZ042C 2.
Page 433 MS026 CM232 CAUTION NOTE: On the Sno Pro with the sleeves installed, position the shock link and shock absorber in the On the standard and CFR, make certain that the shock appropriate holes of the idler arm brackets; then pivot assembly is properly positioned prior to secur- insert the cap screw through the eyelets.
Page 434 7. Install the remaining idler wheel along with the snap ring onto the axle; then using a suitable driv- ing tool, carefully drive the snap ring into the idler wheel until properly seated in the groove of the axle. CM233A 2.
Page 435 SC054A FZ094A 4. Remove the front arm and account for the two front arm spacers. FZ052 MS164 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 applicable), and flat washers.
Page 436 8. On the CFR, move the assembly rearward far 2. Move the rear shock pivot/inner idler wheel assem- enough to gain access to the front arm mounting bly to the appropriate mounting location. Secure bracket lock nuts; then remove the cap screws and with cap screws and lock nuts tightened to 40 ft-lb.
Page 437 FZ094A CM233A 5. Secure the front arm to the slide rail with two cap 7. Secure the limiter straps with cap screws, washers, screws and tighten to 40 ft-lb. and lock nuts. Tighten to 120 in.-lb. NOTE: On the CFR, position the front arm with spacers into the mounting brackets.
Page 438 Rear Shock Absorber and Shock Links/ Idler Wheel/ Pivot Assembly (Standard and CFR) NOTE: Before removing the skid frame by using the Rear Suspension Spring Tool, remove the spring from the adjusting cam. MS176A ! WARNING NOTE: Mark the hole that the upper shock links Care must be taken when removing the spring from are mounted in for assembling purposes.
Page 439 2. Clean the idler wheel bearings with a clean cloth. 3. Closely inspect the torque link arm and axles for wear, bends, or damaged splines at either end. 4. Inspect the idler wheels for signs of cracking, wear, or outer rubber separation from plastic wheel. 5.
Page 440 2. Apply a thin coat of low-temperature grease to the axle and slide the axle into the shock pivot bracket. Have equal amounts of the axle exposed on either side of the bracket tube; then install an idler wheel and spacer to each side of the pivot bracket.
Page 441 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 disassembly to speed up the assembly pro- cess and to prevent any damage.
Page 442 NOTE: If removing the axle cap screws is neces- sary for replacing the slide rail, install the cap screw from the opposite side into the assembly to secure components and aid in replacing the slide rail. 6. Remove the cap screw and flat washer securing the spring slide to the rail.
Page 443 FZ064 MS220A 2. Inspect the wear strip for wear. The wear strip NOTE: The adjusting bolt may have to be loos- must be 0.42 in. thick or thicker. If the wear strip ened to remove the adjuster bushing. measurement is less than specified, replacement of both wear strips is necessary.
Page 444 CM261A MS197 6. Install the cap screw (if removed) and lock nut NOTE: Care must be taken that the adjuster securing the front inner idler wheel assembly to bushing slot with the hole is aligned properly with the slide rails. Tighten only until snug. the adjuster bolt.
Page 445 SC055B FZ073A 8. Install the cap screws securing the rear rail sup- 12. Secure the idler wheels to the mounting blocks ports to the slide rail. Tighten to 20 ft-lb. with existing hardware. Tighten to 20 ft-lb. MS191A SC056C 9. Return to steps 4-7 and tighten cap screws and 13.
Page 446 MS206A MS016B 16. After the skid frame has been installed, adjust NOTE: Apply a light coat of grease to the slide track tension deflection (see Track Tension in Sec- rail surface to aid in installing a new wear strip. tion 6) and track alignment (see Track Alignment Use a file to remove any sharp edges on the lower in Section 6).
Page 447 5. Align the rear arm assembly with the appropriate 6. At this time, tighten the two rear arm assembly cap hole in the tunnel. Secure the rear arm assembly screws to 40 ft-lb; then tighten the front arm cap with a cap screw (coated with red Loctite #271), screws and lock nuts to 40 ft-lb.
Page 448 4. Remove the front lock nuts and cap screws secur- Servicing ing the skid frame to the tunnel. Account for a flat washer and axles. Rear Suspension 5. Remove the support stand; then tip the snow- (M-Series) mobile onto one side using a suitable handlebar support stand.
Page 449 CLEANING AND INSPECTING End Caps NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. NOTE: The skid frame does not have to be removed for this procedure. 1. Clean the slide rail using parts-cleaning solvent and compressed air.
Page 450 INSTALLING 1. Place the front pads into position on the slide rail. 2. Secure the front pads with new push-nuts. 3. Place the rear pads into position on the slide rail. 4. Secure the rear pads with the torx-head screws and lock nuts.
Page 451 2. Inspect all idler wheel inserts (inner and outer) for any cracks. 3. Inspect the idler wheels for cracks, damage, or poor bonding of the outer rubber portion. 4. Inspect the shaft for wear and damaged threads. 5. Inspect all idler wheel bearings. Turn each bearing (by hand) and if any roughness or binding is noted, replace the bearing.
Page 452 CM225 CM225 3. Carefully slide the shaft out from the slide rails and inner idler wheels. Account for the rear idler wheel spacer and adjuster bushings. CM224A NOTE: Make sure the hole in the bushing is directed to the adjusted bolt. CM230 ASSEMBLING CM261A...
Page 453 DISASSEMBLING 1. Remove the snap ring securing the rear arm idler wheels to the inner carriage axle and account for the wave washers; then remove the axle from the idler arm. CM232 NOTE: With the rear arm shock and shock link removed, account for the four sleeves.
Page 454 2. Install the idler arm onto the rear arm with an alu- minum axle, bushing assemblies, and two cap screws. Tighten to 34 ft-lb. CM235B CLEANING AND INSPECTING NOTE: Whenever a part is worn excessively, CM237 cracked, or damaged in any way, replacement is NOTE: If the rear arm limiter and rail support necessary.
Page 455 4. With the sleeves installed, position the shock link in the appropriate holes of the idler arm brackets and shock absorber; then insert the cap screw through the eyelets. Secure with the cap screws and lock nuts. Tighten securely. CM239 8.
Page 456 3. Remove the cap screw and lock nut securing the shock absorber to the front arm. Pull the shock eyelet free of the bracket. Account for a serrated axle. CM243A 7. Remove the cap screw, washer, and lock nut from the front shock axle;...
Page 457 3. Inspect the bearings, bushings, and front arm spac- 4. Position the front arm with aluminum axle to the ers for wear or damage. mounting location in the slide rail. Secure with cap screws. Tighten to 40 ft-lb. 4. Inspect the shock absorber for any signs of oil leakage especially at the point where the shock shaft enters the shock body.
Page 458 CM240A CM222B NOTE: If binding of the wear strip occurs, it may be Slide Rails necessary to use a pipe wrench, start from either end, and hook the edge of the wear strip with the pipe wrench jaw and twist the wear strip off the slide NOTE: The skid frame must be removed for this rail.
Page 459 CM249B CM253 5. Remove the cap screws and lock nuts securing the NOTE: The adjusting bolt may have to be loos- slide rail idler wheels and the idler wheel mount- ened to remove the adjuster bushing. ing blocks. Account for flat washers. 7.
Page 460 INSPECTING NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. 1. Inspect the slide rail for cracks (A), elongated holes (B), or unusual bends. CM257A 10. Remove the cap screw, washers, and lock nut securing the front shock axle.
Page 461 2. Place the slide rail into position. With the spacers and washers in place, install the front arm shock axle; then secure with the cap screw, washers, and the lock nut. Tighten only until snug. 3. Install the rear arm cap screw and lock nut; then install the rear arm limiter cap screw.
Page 462 7. Install the adjuster bushing and rear idler wheel. 9. Place the idler wheels onto the mounting blocks; Install a cap screw and flat washer. Tighten only then install the cap screw and lock nut securing the until snug. idler wheels to the mounting blocks. Tighten to 20 ft-lb.
Page 463 CAUTION When installing the skid frame, make sure the rear arm shock mounting location on the pivot/axle is posi- tioned correctly above the axle or component damage will occur. CM265 739-992A NOTE: To aid in centering the front arm with the hole in the tunnel, position the skid frame and track at a 45°...
Page 464 4. Remove the support stand; then using a suitable Servicing handlebar support stand, tip the snowmobile onto one side. Rear Suspension 5. Slide the skid frame rearward far enough to drop (F-Series/Z1) the front arm out of the slider axle; then remove the skid frame.
Page 465 CLEANING AND INSPECTING End Caps NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. NOTE: The skid frame does not have to be removed for this procedure. 1. Clean the slide rail using parts-cleaning solvent and compressed air.
Page 466 Idler Wheels/ Mounting Blocks REMOVING NOTE: The skid frame does not have to be removed for this procedure. 1. Remove the cap screw and lock nut securing the idler wheel to the idler wheel mounting block; then remove the cap screw and lock nut securing the mounting block to the slide rail.
Page 467 A. Remove the bearing snap ring. 2. Place the idler wheel to the mounting block; then secure the idler wheel assembly with a cap screw, B. Using a suitable press or suitable driving tool, flat washer, and a lock nut. Tighten to 20 ft-lb. remove the bearing from the inside of the wheel.
Page 468 FZ037 FZ034 5. Remove the cap screw, flat washer, and lock nut 3. Loosen the cap screws and lock nuts securing the securing the spring slide to the slide rail. Account pivot arm assembly to the idler arm; then remove for the spring slide and all mounting hardware.
Page 469 NOTE: Use the same procedure for the other side. 7. Remove the cap screw (A) and lock nut securing the upper shock eyelet to the idler arm; then remove the cap screw (B) and lock nut securing the upper shock link to the idler arm. Account for the cap screws, lock nuts, and sleeves.
Page 470 FZ044 FZ040C 3. With the sleeves installed, install the shock NOTE: Do not over-tighten the shock absorber absorber link to the lower mounting hole of the rear shock pivot; then install the shock absorber cap screw as the shock eyelet must be free to with cap screws (A) and (B) and lock nuts.
Page 471 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 assem- bly. 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 472 ASSEMBLING REAR AXLE Rear Axle/Idler Wheels DISASSEMBLING REAR AXLE NOTE: The skid frame must be removed for this procedure (see Removing Skid Frame in this sub- section). 1. Remove the cap screw and large flat washer secur- ing the outer rear idler wheel. Remove the outer idler wheel from the shaft.
Page 473 Front Arm Assembly NOTE: The skid frame must be removed for this procedure (see Removing Skid Frame in this sub- section), and the rear springs must be removed from the adjusting cams. REMOVING 1. Remove the cap screws and lock nuts securing the limiter straps to the front arm.
Page 474 8. Remove the cap screws, washer, and lock nut from the front shock axle; then from one side, tap the assembly forward far enough for the axle assem- bly to clear the slide rails. Account for an axle, two spacers, and two shim washers. CM246A 2.
Page 475 FZ056 ZJ271A 5. Install the axle into the front arm; then position the NOTE: Do not over-tighten the shock absorber front arm to the mounting location of the slide rail. cap screw as the shock eyelet must be free to Secure with cap screws and lock nuts.
Page 476 FZ026B FZ080A 2. Remove the end cap from the slide rail. Account 5. Remove the cap screws and lock nuts securing the for a cap screw, lock nut, and two flat washers. front outer idler wheel and the idler wheel mount- ing block.
Page 477 NOTE: If removing the cap screws from the front shock axle is necessary to replace the slide rail, install the cap screw from the opposite side into the assembly to secure components and aid in replacing the slide rail. 7. Remove the lock nut, cap screw, and flat washer securing the spring slide to the rail.
Page 478 FZ064 MS220A 2. Inspect the wear strip for wear. The wear strip NOTE: The adjusting bolt may have to be loos- must be 0.42 in. thick or thicker. If the wear strip ened to remove the adjuster bushing. measurement is less than specified, replacement of 13.
Page 479 INSTALLING 1. Install the shock pads and retaining brackets and secure with rivets. FZ084B 5. Secure the front arm to the slide rail with the cap screws and lock nuts. Tighten to 40 ft-lb. AG531D 2. Secure the track adjuster bracket with the cap screws and lock nuts.
Page 480 CM261A FZ074 10. Install the inner idler wheel mounting block and NOTE: Tighten the rear idler wheel axle only until secure with cap screw and lock nut. Tighten to 20 snug until the skid frame has been installed and ft-lb. track tension has been adjusted;...
Page 481 ZJ288 FZ078A 14. Secure the end cap onto the slide rail using a cap NOTE: To obtain proper alignment for the idler screw, flat washers, and a lock nut. Tighten to 80 wheel cap screw, place the cap screw in the top in.-lb.
Page 482 MS207 0742-187 NOTE: To aid in centering the front arm with the hole in the tunnel, position the skid frame and track at a 45° angle to the bottom of the tunnel. 4. Push the rear of the skid frame and the track into the tunnel.
Page 483 4. Remove the support stand; then using a suitable Servicing handlebar support stand, tip the snowmobile onto one side. Rear Suspension 5. Slide the skid frame rearward far enough to drop (Bearcat 570/T-Series/Z1 EXT) the front arm out of the slider axle; then remove the skid frame.
Page 484 CLEANING AND INSPECTING End Caps NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. NOTE: The skid frame does not have to be removed for this procedure. 1. Clean the slide rail using parts-cleaning solvent and compressed air.
Page 485 2. Remove the torx-head screws and lock nuts secur- ing the rear shock pads to the slide rail. FZ028A 3. Clean both the slide rail area and the end cap. Using compressed air, clean the areas of dirt and gravel. MS117A 3.
Page 486 CLEANING AND INSPECTING NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. 1. Clean the bearing with a clean cloth. 2. Inspect each idler wheel for cracks or damage. 3. Rotate the idler wheel bearing (by hand) and inspect for binding or roughness.
Page 487 NOTE: For proper alignment, install an idler wheel cap screw into the top mounting block hole prior to tightening. TZ002A 2. Mark the pivot arm and the idler arm for assembly purposes. TZ025 2. Place the idler wheel to the mounting block; then secure the idler wheel assembly with a cap screw, flat washer, and a lock nut.
Page 488 4. Remove the idler wheel. NOTE: Use the appropriate Idler Wheel Puller Kit to remove the wheel. TZ008 6. Remove the spring and sleeve from the idler arm. TZ005 5. Remove the cap screw, flat washers, and lock nut securing the spring slide and overload spring to the slide rail.
Page 489 TZ011A TZ014 10. Remove the cap screws securing the idler arm to NOTE: For assembling purposes, note the the rear arm. Account for the aluminum axle. mounting location of the shock links to the idler arm. 8. Remove the cap screw and lock nut securing the rear shock pivot/idler wheel assembly to the slide rails;...
Page 490 5. Inspect the two adjusting cams for damage. 6. Rotate the idler wheel bearings (by hand) and check for binding or roughness. 7. If a bearing must be replaced, see Idler Wheels/ Mounting Blocks - Cleaning and Inspecting in this sub-section.
Page 491 TZ008 TZ010B NOTE: Install the rear arm springs onto the NOTE: Do not over-tighten the shock absorber adjuster blocks after the skid frame has been cap screw as the shock eyelet must be free to installed. pivot. TZ021 TZ020A 9. With a suitable driving tool, install the rear upper NOTE: Be sure that the spacer is installed idler wheel on the idler arm.
Page 492 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 DISASSEMBLING REAR AXLE NOTE: The skid frame must be removed for this procedure (see Removing Skid Frame in this sub- section).
Page 493 ASSEMBLING REAR AXLE NOTE: Tighten the rear idler wheel axle only until snug until the skid frame has been installed and track tension has been adjusted; then the axle assembly must be tightened to 20 ft-lb. 3. Install the skid frame (see Installing Skid Frame in this sub-section).
Page 494 TZ028A TZ030 4. Remove the front arm and account for the front INSPECTING arm axle. NOTE: Whenever a part is worn excessively, 5. Remove the front outer idler wheel and mounting cracked, or damaged in any way, replacement is block from the side of the slide rail in which the necessary.
Page 495 2. Place the front arm shock axle assembly into posi- 5. Install the axle into the front arm; then position the tion on the skid frame making sure the spacers and front arm to the mounting location of the slide rail. washers are properly positioned.
Page 496 Slide Rails NOTE: The skid frame must be removed for this procedure (see Removing Skid Frame in this sub- section). 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 FZ079A 3.
Page 497 TZ033A TZ036 NOTE: If not already done, remove the short spring leg from the adjusting cam. 7. Remove the cap screws and lock nuts securing the inner idler wheel and mounting block. TZ034A 6. Remove the lock nut from the cap screw securing the front shock axle assembly to the slide rail.
Page 498 TZ039A TZ041 12. Remove the cap screw and lock nut securing the NOTE: If removing the cap screw is necessary to overload spring tension block to the slide rail. replace the slide rail, install the cap screw from the opposite side into the assembly to secure the components and aid in replacing the slide rail.
Page 499 NOTE: The adjusting bolt may have to be loos- ened to remove the adjuster bushing. 14. Remove the cap screw securing the rear arm cou- pler block to the slide rail. Account for the block, bushing, cap screw, and lock nut. TZ049 NOTE: If the shock pad must be replaced, refer to Shock Pads at the beginning of this procedure.
Page 500 0743-189 TZ050 3. Inspect the front arm slider bumpers for cracks or NOTE: At this point, return to step 1 and tighten wear. the rear arm and front arm cap screws and lock nuts to 40 ft-lb; then tighten the rear arm pivot/idler wheel assembly to 20 ft-lb.
Page 501 6. Install the rear arm limiter and secure with the cap screw. Tighten the cap screw (coated with blue Loctite #243) to 50 ft-lb. TZ053A 10. Install the inner idler wheel mounting block and secure with cap screws and lock nuts. Tighten to 20 ft-lb.
Page 502 FZ077 TZ056 13. With the spacer on the front rail support centered 15. From the back, start the wear strip onto the rail; between the limiter straps, secure the straps to the then using a soft hammer, drive the wear strip for- rail support with the cap screw, washers, and lock ward into position.
Page 503 5. Align the rear arm assembly with the appropriate Installing Skid Frame hole in the tunnel. Secure the rear arm assembly with a cap screw. TIGHTEN ONLY UNTIL SNUG. 1. Using a suitable handlebar support stand, tip the 6. Tip the snowmobile onto the other side; then align snowmobile onto one side.
Page 504 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 505 2. Lubricate the O-ring and Teflon strap on floating piston; then press the floating piston into shock until flush with the top of the body. FS254 6. Items to inspect: A. Shock shaft for straightness, nicks, or burrs. FS063 B. Shaft bearing end cap — clean, inspect, or replace.
Page 506 FS257A FS252 6. With the bearing assembly positioned at the top of 9. Pressurize the shock with nitrogen to 200 psi (see the shock rod, install the shock rod/piston assem- Pressurizing Rebuildable Shocks sub-section). bly into body; then with the top of the shock body and rod covered with a shop towel, tap the top of the rod eyelet with a soft hammer.
Page 507 FS080 FS142 INSTALLING NOTE: The air chamber should only be hand- tight. 1. Place the shock into position on the snowmobile. 3. Drain the oil from the air chamber. 2. Secure with existing hardware. Tighten securely. Rebuilding/Recharging Fox Air Shocks ! WARNING Always wear latex or rubber gloves when servicing a shock absorber with shock oil.
Page 508 FS145A FS148 6. Using an Allen-wrench, loosen the nitrogen blad- 9. Using a magnet on an Allen-wrench, remove the der ½ turn. bleed ball. FS146 FS149 7. Using Inflation Needle, remove all the nitrogen 10. Using Spanner Wrench, loosen the bearing cap. from the shock.
Page 509 12. Drain the oil from the shock body into a suitable container. 13. Using Floating Piston Removal Tool, remove the floating piston. FS155 3. Using Floating Piston Installation/Location Tool, install the floating piston while using the inflation needle to vent the shock body. NOTE: Refer to the Rebuildable Shock Specifica- FS152 tions sub-section in Section 1.
Page 510 NOTE: When tightening the bearing cap, note air and excess oil being bled from the hole in the cap. FS158 6. Lower the shock rod into the shock body until the piston is submerged in oil. FS150A 9. Install the bleed ball and set screw into the bearing cap.
Page 511 11. Using a 3/16-in. Allen-wrench, tighten the nitrogen bladder. FS168 16. Slide the air chamber onto the shock body. FS165 12. Install the air valve ball by gently tapping it with a plastic mallet. FS169 17. Add 1 cc of Fox Float Fluid into the chamber. FS166 13.
Page 512 NOTE: Prior to installing the air chamber, make Servicing Fox Zero Pro sure the end cap O-ring is properly positioned in the chamber. Shock Absorbers 19. Invert the shock and secure by the end cap to assure the air chamber is tight. This procedure shows the proper methods for disas- sembling, rebuilding, and assembling the pro shock absorbers with no external damping adjustments.
Page 513 5. Insert the needle squarely into center of the nitro- 10. Remove the shock from the vise and pour shock gen valve to release the pressure. oil from body tube into a proper disposal con- tainer. DO NOT REUSE OLD SHOCK OIL. 11.
Page 514 22. Remove the bleed screw from the bearing and set them both on a clean, lint-free towel. REBUILDING 1. Using a pair of snap ring pliers, remove the snap ring from the bearing housing. Using fingers, remove the FIST scraper from the housing. Using a scribe, remove the O-ring from the inside of the FIST scraper by “spearing”...
Page 515 9. Using a pair of snap ring pliers, install the snap ring into the bearing housing. Check for proper orientation of the snap ring. The flat side of the snap ring should be visible. Check to make sure the snap ring is properly seated. FS015 7.
Page 516 13. As the bearing assembly is being threaded down, it 21. Insert the needle squarely into the center of the will contact the damping piston assembly and pull it nitrogen valve (taking care that the valve is down into the shock body with it. As the bearing is directed away from face and body) and pressurize being threaded in from this point, be sure the damp- the reservoir to 200 psi.
Page 517 ! WARNING Never have a nitrogen bottle in the area without having it chained or secured. If the bottle should tip over and the regulator break off, the gas inside it is under 1800 lb of pressure and personal injury may result. ! WARNING Always rotate the regulator T-handle to its loose posi- tion each time when finished using the system.
Page 518 SECTION 8 — STEERING AND BODY TABLE OF CONTENTS Front Bumper/Belly Pan Assembly Steering and Body ..........8-2 (Crossfire/M-Series)........... 8-33 Steering Post (CFR/Crossfire/M-Series) ....8-2 Gas Tank/Seat Assembly (Crossfire/M-Series) ..8-36 Steering Post (Bearcat/F-Series/T-Series/Z1)..8-5 Gas Tank/Seat Assembly Ski ................8-8 (Bearcat/F-Series/T-Series/Z1) ......
Page 519 NOTE: Remove the routing clips securing the Steering and Body brake hose and wiring to the steering support. 5. On the standard models, remove four lock nuts, cap screws, and adjuster block caps securing the han- This section has been organized into sub-sections for dlebar to the adjuster block.
Page 520 8. Unlock the cam lever and unthread the lever from the lock rod (B); then remove the lock rod and account for the two bottom cap springs (C). CAUTION Do not rotate the handlebar to a position allowing air to enter the brake system. 9.
Page 521 8. On the Sno Pro and HCR models, install the adjust- ing block cover and position the handlebar into the mounting block; then install the handlebar clamp and tighten the four cap screws to 20 ft-lb. CM005 3. Tighten the lock nuts to 96 in.-lb; then install the close-out panel and secure with torx-head cap screws.
Page 522 CAUTION Steering Post Do not rotate the handlebar to position allowing air to (Bearcat/F-Series/T-Series/Z1) enter the brake system. 12. Test the handlebar to ensure it does not rotate REMOVING within the riser block. If it does rotate, release the cam lever and rotate the cam lever clockwise; then 1.
Page 523 NOTE: For installing purposes, note the location of the exhaust pipe mounting tab (B). 10. Remove and discard the lock nut securing the steering tie rod to the steering post. FS182A 7. On the Bearcat 570/F-Series/T-Series, remove the springs securing the expansion chamber; then remove the expansion chamber from the engine compartment.
Page 524 2. Inspect the steering post and steering-post brackets NOTE: When installing the bracket plates, the for cracks, bends, or wear. wider end of the plate must be directed up. 3. Inspect the bearing halves, bearing caps, and bear- ing housings for cracks or wear. INSTALLING 1.
Page 525: Ski
NOTE: On the turbo models, position the intercooler 12. Test the handlebar to ensure it does not rotate within the riser block. If it does rotate, release the into the grommets of the mounting bracket; then con- cam lever and rotate the cam lever clockwise; then nect the intercooler hoses to the turbo and to the press down on the cam lever until the lock pin is intake plenum.
Page 526: Ski Wear Bar
(Bearcat/F-Series/T-Series/Z1) operated on terrain where the snow cover is minimal, the ski wear bar will wear faster. Arctic Cat recom- mends that the ski wear bars be checked once a week REMOVING and replaced if worn to 1/2 of original diameter.
Page 527 ZJ020A ZJ161A 3. Remove the cap screw and lock nut (A) from the 6. If replacing using a suitable punch, drive the two drag link end of the inner tie rod; then remove the bearings out of the drag link. cap screw and lock nut (B) securing the left-side inner tie rod and steering tie rod to the drag link.
Page 528 2. Secure the steering arms to the drag link with the drag link axles, cap screws (E) (threads coated with blue Loctite #243), and new lock nuts (E). Tighten to 12 ft-lb (Bearcat/F-Series/T-Series) or 120 in.-lb (Z1). ZJ165A NOTE: On the liquid-cooled F-Series to finalize the installing of the drag link, proceed to Air Silencer (Liq- uid Cooled F-Series 2-Stroke) sub-section in Section 3 and follow the INSTALLING procedure.
Page 529 3. Remove the cap screw and lock nuts securing the tie rod to the right-side spindle arm. Discard the lock nuts. CM268A 2. Place the rod ends into position on the steering arm. Secure with the Allen-head cap screw coated with green Loctite #609.
Page 530 1. Inspect the ball joints and tie rods for damaged threads or wear. 2. Inspect the ball joints and tie rods for cracks or unusual bends. 3. Wash the ball joint in parts-cleaning solvent. Dry with compressed air. Inspect the ball joint pivot area for wear.
Page 531 INSPECTING NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. 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.
Page 532 Spindle (Bearcat/F-Series/T-Series/Z1) REMOVING 1. Position the front of the snowmobile up on a safety stand. 2. Remove the ski. 3. Remove the tie rod cap and lock nut securing the tie-rod ball joint to the spindle; then remove the ball joint from the spindle. CM269C 3.
Page 533 6. Inspect the tie-rod ball joint in place. If damage, wear, or unusual bends are noted, loosen the jam nut; then remove the ball joint from the tie rod. NOTE: Replacing the ski bolt bushings is diffi- cult. The existing bushings will be damaged during removal.
Page 534 ZJ173A ZJ295A 5. At this point, tighten the lock nut (from step 1) to 7. Install the cap screw (threads coated with green 32 ft-lb. Loctite #609) securing the steering arm to the spin- dle; then tighten to 40 ft-lb. ZJ173B 6.
Page 535: Steering Tie Rod
Steering Tie Rod (Crossfire/M-Series) REMOVING 1. Remove the cap screw and lock nut securing the steering tie rod to the steering post. Discard the lock nut. FC206 2. Place the steering tie rod into position on the steer- ing post. Secure with the cap screw coated with green Loctite #609 and new lock nut.
Page 536 2. On the Z1, remove the hood; then remove the NOTE: There must be an approximate equal num- exhaust springs securing the exhaust pipe to the ber of threads exposed on each ball joint. mounting tab and exhaust manifold. Move the exhaust pipe out of the way to gain access to the 2.
Page 537: Ski Alignment
NOTE: The straightedge should be long enough to extend from the back of the track to the front of the ski. 5. Measure the distance from the straightedge to the left-side ski wear bar bolts in two places: approxi- mately 7-8 in. in front of the spindle and 7-8 in. behind the spindle.
Page 538: Front Suspension Arms
1. Secure the idler tie rod in the centered position. 2. Loosen both spindle tie rod jam nuts on the same side as the ski to be aligned. 3. Using a wrench on the spindle tie rod “flats,” rotate the spindle tie rod until recommended specification is attained.
Page 539 SC080A SC077A 5. Remove the cap screws and lock nuts securing the 8. Remove the 15 torx-head screws securing the cen- spindle to the front suspension arms. Account for ter belly pan to the frame; then remove the belly all mounting hardware. pan.
Page 540 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. SC083A INSPECTING NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is SC078A 3.
Page 541 SC077A SC079A 5. Secure the arms to the spindle with existing hard- 8. Install the ski with existing hardware and tighten to ware. Tighten the upper arm lock nut and cap screw 35 ft-lb. to 30 ft-lb and the lower arm lock nut and cap screw 9.
Page 542 1. Inspect the arm welded areas for cracks or any 4. Remove the cap screw and lock nut securing the signs of deterioration. shock absorber to the spindle; then remove the shock from the spindle and account for the shock 2.
Page 543 NOTE: The split bearings cannot be reused; they must be replaced with new ones. INSPECTING NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. 1. Inspect the arm welded areas for cracks or any signs of deterioration.
Page 544: Front Suspension (Ski) Shock Absorber
Front Suspension (Ski) Sway Bar Shock Absorber (CFR/Crossfire) REMOVING REMOVING 1. Remove the lock nuts and cap screws securing the 1. Position the front of the snowmobile up onto a sway bar arm to the links and remove. safety stand taking all pressure off the skis. 2.
Page 545: (Bearcat/F-Series/T-Series/Z1)
Sway Bar Front Suspension Mounting Bracket (F-Series/T-Series/Z1) (Bearcat/F-Series/T-Series/Z1) REMOVING NOTE: On the liquid-cooled F-Series to remove 1. Remove the two lock nuts securing the sway bar mounting brackets to the chassis; then using a soft the front suspension mounting bracket, it will be hammer, tap the sway bar in either direction until necessary to remove the air silencer.
Page 546 0744-930 Manual Section 8-29 Back Next Table of Contents Table of Contents...
Page 547 NOTE: On the turbo models, loosen the inter- NOTE: At this point, remove all cap screws and cooler hose clamps at the intake pipe and the tur- lock nuts corresponding to (E) securing the right- bocharger; then carefully work the intercooler side upper A-arms and lower A-arm to the suspen- upward until it releases from the rubber grommets.
Page 548 7. Install the right-side steering arm with cap screw and lock nut (H). 8. To install the left-side steering components, first place the sway bar into the sway bar link on the right-side A-arm; then move the sway bar to the mounting position.
Page 549: (Crossfire/M-Series)
20. Secure the bottom of the assembly to the suspen- sion mounting bracket with the two body screws and lock nuts. Tighten securely; then install the hood. ZJ020A NOTE: On the Bearcat Z1 XT, remove the four cap screws securing the close-off panel and account for the exhaust pipe mounting tab (A) from the left front cap screw.
Page 550 Front Bumper/ Belly Pan Assembly (Crossfire/M-Series) REMOVING 1. Remove the hairpin clip and torx-head cap screws securing the side panels; then remove the panels. 2. Remove the cable tie and remove the air intake connector from the air silencer. FC227 3.
Page 551 SC070A SC074A 7. Remove the torx-head screw securing the air silencer hold-down tab to the front bumper; then remove the two torx-head screws securing the cen- ter belly pan screen. 8. Remove the center belly pan. SC076A 12. Tip the snowmobile onto its side using a suitable support stand under the handlebar;...
Page 552 INSPECTING 1. Inspect for gouges, cuts, and tears. 2. Inspect all belly pan threaded bosses and ensure they are in good shape. INSTALLING NOTE: Steps 1-2 should be used for each side belly pan. 1. Install the left- or right-side belly pan and secure within the ski well and below the running boards with the torx-head cap screws.
Page 553: Gas Tank/Seat Assembly
11. Install the side panels and secure with the torx- head cap screws and hairpin clip. Gas Tank/ Seat Assembly (Crossfire/M-Series) REMOVING 1. On the CFR/Crossfire, trip the seat latches inside the storage compartment and remove the seat. SC073A 2. On the M-Series, remove the two lock nuts and 7.
Page 554: (Bearcat/F-Series/T-Series/Z1)
Gas Tank/ Seat Assembly (Bearcat/F-Series/T-Series/Z1) ZJ010A 8. Disconnect the fuel pump four-wire connector; then slide the gas tank rearward enough to gain access to the gasline hose connector. 0741-965 REMOVING 1. Remove the hood and open the right-side and left- side access panels.
Page 555: Seat Cushion
NOTE: On the LXR/Sno Pro/Z1/TZ1 LXR models, install the seat; then install the machine screw (E) (threads coated with blue Loctite #243) to the right side of the seat support. CAUTION Do not tighten the machine screw (E) against the seat support.
Page 556: Taillight/Brakelight Assembly
NOTE: Note the cushion fit. If any wrinkles are 5. Remove the two self-tapping screws securing the taillight to the bumper; then route the harness out noted, remove by pulling the cushion material in the of the bumper and remove the taillight. appropriate direction before securing with staples.
Page 557: Windshield
2. Secure the windshield to the hood with the rein- stallable rivets. Windshield (Bearcat/F-Series/T570/ TZ1/Z1 — Non-Turbo) REMOVING 1. Remove the plastic rivet securing the front of the windshield to the windshield bracket. 742-467A 2. Remove the two torx-head screws securing the 2.
Page 558: (Bearcat Xt)
2. In turn on each side, remove the two cap screws (inside the tunnel) securing the backrest assembly to the tunnel. Account for the washers. 3. If applicable, disconnect the passenger hand- warmer wiring harness. 4. Remove the backrest assembly from the tunnel. Account for the two spacers.
Page 559: (Bearcat 570/T-Series)
INSTALLING BUMPER/SNOWFLAP REMOVING BUMPER/SNOWFLAP 1. Secure the snowflap to the tunnel with the cap 1. Drill out the rivets securing the snowflap to the screws, washers, and lock nuts taking care to place tunnel end cap; then disconnect the taillight har- the washers next to the underside of the snowflap.
Page 560: Headlight Assembly
BUMPER/SNOWFLAP To access the headlight bulbs, use the following proce- dure: NOTE: The snowflap can be removed without 1. Remove the two torx-head screws located to the removing the bumper by removing the five rivets outside of the headlight adjustment knobs; then securing the snowflap to the heat exchanger and remove the single torx-head cap screw from compressing the two flanged tabs located on the...
Page 561: Adjusting Headlight Aim
743-439A 0740-462 4. Position the console onto the air silencer; then secure INSTALLING HEADLIGHT BULB with the single torx-head cap screw beneath the con- sole (located between the headlights). CAUTION 5. Install the two torx-head screws located to the out- Do not touch the glass portion of the bulb.
Page 562 4. Make a vertical mark intersecting the horizontal mark on the aiming surface directly in front of the headlight. 5. Start the engine. Select the headlight dimmer switch HIGH beam position. DO NOT USE LOW BEAM. 6. Observe the headlight beam aim. Proper aim is when the most intense beam is centered on the ver- tical mark 5 cm (2 in.) below the horizontal mark on the aiming surface.

Arctic Cat 120 Sno Pro 2010 Service Manual

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