LIMITED WARRANTY Arctic Cat Inc. (hereinafter referred to as Arctic Cat) extends a limited warranty on each new Arctic Cat Snowmobile it manufactures and on each part and accessory manufactured or sold by Arctic Cat. The warranty is extended to the original retail purchaser only on parts and accessories sold through an authorized Arctic Cat Snowmobile dealer.
Table of Contents Limited Warranty ..Inside Front Cover Removable/Adjustable Seat (F-Series/Z1 Models) ....25 Foreword ..........1 Arctic Power Valve (APV) System ..26 Declaration of Conformity....... 2 Exhaust Controlled Timing (ECT) Snowmobile Safety Rules ...... 3 System (600/800/1000 cc General Information ......4-27 Models) .........27 Snowmobile Identification....
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ACCESSORIES. Only genuine Arctic Cat parts, oil, and accessories are engi- neered to meet the standards and requirements of your Arctic Cat Snowmobile. For a complete list of accessories, refer to the current Arctic Cat Accessory Cat- alog. To aid in service and maintenance procedures on these snowmobiles, an Illustrated Parts Manual and a Service Manual are available through your local Arctic Cat Snowmobile dealer.
Always wear a helmet and eye protection. Drive with caution, observe all state and local regulations, and respect the rights of others. ISMA members like Arctic Cat do their part to improve trails, sponsor events, and generally support the sport of snowmobiling.
DECLARATION OF CONFORMITY Application of council directives: EMC Directive 89/336/EEC Issued by European Commission. EC Machinery Directive 98/37/EC Type of Equipment: Snowmobile Brand Name: Arctic Cat Model Numbers: S2009F5DFCUSG S2009TZNPKUSG S2009BCNWTUSL S2009F8HLXUSG S2009F5DFCOSG S2009TZNLXUSB S2009BCNWTOSL S2009F8HLEUSB S2009T5CTOUSG S2009TZNLXOSB S2009BCNWTUSB S2009F1LEPUSG...
(ESN) is stamped into the crank- properly. No warranty will be allowed case of the engine. by Arctic Cat Inc. if the engine serial number or VIN is removed or muti- lated in any way. Always provide the snowmobile name,...
The recommended oil to use in the oil- fuel system. injection system is Arctic Cat 50:1 Injection Oil (for standard models) or ! CAUTION Arctic Cat Synthetic APV 2-Cycle Oil (for APV models).
(2-Stroke Models) to the snowmobile gas tank near any open flames or with the engine The Arctic Cat engine (when new or running. DO NOT SMOKE while fill- rebuilt) requires a short break-in period ing the gas tank. Do not sit on the...
ENGINE BREAK-IN (1100 cc Models) The Arctic Cat engine (when new or rebuilt) requires a short break-in period before the engine is subjected to heavy load conditions. FZ003C A. Oil Pressure/Low Oil This engine does not require any pre- B.
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Hour-Meter/Clock error, take the snowmobile to an autho- NOTE: The clock is available on rized Arctic Cat Snowmobile dealer for service. If not under warranty, this ser- electric start models only. vice is at the discretion and expense of By pushing the right button, the read- the snowmobile owner.
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1. With the engine off, remove the rized Arctic Cat Snowmobile dealer for engine oil level stick and wipe it service. If not under warranty, this ser- clean.
RPM/MPH (kph) 4. If the warning light does not go out, shut the engine off immedi- By pushing the increment button once, ately and repeat step 2; then repeat the RPM and MPH will be displayed step 3. (one on the readout screen and one with the needle).
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At this point, the hours display will To reset the maximum altimeter read- begin to flash. Push the increment but- out with the maximum altimeter dis- ton to increase the hours; push the dec- played, push and hold the select button rement button to decrease the hours.
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1. With the engine off, remove the sible, take the snowmobile to an autho- engine oil level stick and wipe it rized Arctic Cat Snowmobile dealer for clean. Without screwing it in, set service. If not under warranty, this ser- the stick back in the oil tank.
Crossfire/F-Series/M- 2. Open the air bleed bolt located on the oil pump (beneath the coolant Series/T500 Models tank) to purge air from the oil Additional codes are displayed on the hose. readout screen. Refer to the following chart for diagnostic codes. Code Trouble Failure in injector(s).
Code Trouble Failure in crankshaft position sen- sor. Failure in speed sensor. Failure in coil (#1). Failure in coil (#2). Failure in ISC valve. Failure in oxygen sensor. 0743-467 Failure in camshaft position sen- 2. Adjust the handlebar up or down sor.
“flip” the ! CAUTION cam lever up. If at any time the lock pin will not engage into the locked position, do NOT operate the snowmobile. Take the snowmobile to an authorized Arctic Cat dealer for service. 0741-427 GENERAL INFORMATION...
AIR-INTAKE SILENCER ! WARNING Used in conjunction with the fuel Care must be taken to securely intake system is a specially designed lock the handlebar cam lever to air-intake silencer. The purpose of the prevent unexpected “movement” silencer is to quiet the intake of fresh of the handlebar during operation air.
Some snowmobiles are equipped with a drive clutch and/or the driven pulley. closed liquid cooling system for engine See an authorized Arctic Cat Snowmo- cooling. The cooling system should be bile dealer for further information. inspected daily for leakage and damage.
Some models are equipped with a deep- deteriorating), take the snowmobile lug track which is specially designed for to an authorized Arctic Cat Snow- use in powder snow riding conditions. mobile dealer for shock absorber When the deep-lug track is operated in evaluation and/or servicing.
(p/n 4639-968) for Crossfire mod- operating on hard-packed snow condi- els, or (p/n 5639-143) for the Bearcat tions is NOT covered under Arctic Cat Z1 XT model must be installed. Inc. warranty policy. For proper installation, use the follow-...
Cat recommends taking the snowmo- the skis deeper into the snow. Before bile to an authorized Arctic Cat Snow- starting the snowmobile, be sure the mobile dealer for this service. If not...
REVERSE ! WARNING TRANSMISSION (Switch Button Style Use caution and minimal speed Models) when operating the snowmobile in reverse. Be sure the button is in The reverse transmission offers the the desired position. operator the convenience of being able to back up the snowmobile rather than ...
To move the backrest, push the adjuster To install the rear seat, use the follow- down, pull the backrest up and out of ing procedure: the slots, slide the backrest into the 1. Place the seat into position on the desired position, and raise the adjuster mount making sure the four pin to lock the backrest in place.
1. Slide the front of the seat into position on the tunnel; then lower the rear of the seat onto the lock- ing pins. 2. Press down on the rear of the seat until the retaining clips snap into place on the locking pins; then rotate the latch cover until it snaps into place on the right-side locking pin.
1. With the seat adjuster lever pulled 5. Install the rear seat. out, slide the front of the seat into ! WARNING position on the chassis; then with seat position selected, lower the Make sure the seats are securely rear of the seat onto the rear stor- locked in place or personal injury age compartment.
ARCTIC POWER VALVE (APV) SYSTEM ! CAUTION The correct engine oil to use is Arctic Cat Synthetic APV 2-Cycle Oil (p/n 4639-348). Any substitute may cause an APV malfunction. 741-718A 2. Press in on the left-end of the seat...
EXHAUST CONTROLLED TIMING (ECT) SYSTEM (600/ 800/1000 cc Models) This system automatically adjusts the ignition timing to provide maximum performance through a variety of oper- ating conditions. The ECU receives input on engine RPM (demand) and 739-152G exhaust pipe temperature (engine con- At high RPM, the exhaust valves are dition) and adjusts the ignition timing raised.
OPERATING INSTRUCTIONS STARTING AND 2. Check the fluid level in the reser- STOPPING ENGINE voir. The brake fluid level must be visible in the sight glass. Add Arc- It is imperative that the brake system tic Cat approved brake fluid as be checked for wear and proper opera- necessary.
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NOTE: On large-displacement 6. On carbureted models for a cold engine, move the choke lever to engines in extremely cold weather, the full-choke position. If the pull the recoil handle slowly two to engine is warm, choking is nor- three times to begin the starting mally not necessary.
! CAUTION spark plugs must be replaced, take the snowmobile to an authorized It is extremely important that the Arctic Cat Snowmobile dealer for engine is properly warmed up inspection and service. This ser- before subjecting the engine to vice is at the discretion and high speed operation or heavy expense of the snowmobile owner.
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(by high the snowmobile to an authorized speed stops or repetitive use) or if Arctic Cat Snowmobile dealer for moisture is allowed to enter the service. If not under warranty, this system, it must be changed. Never...
THROTTLE/IGNITION and stops when the throttle lever is MONITOR SWITCH released, take the snowmobile to an authorized Arctic Cat Snowmo- The throttle control is equipped with a bile dealer for service. If not under monitor switch for safety purposes warranty, this service is at the dis-...
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Take netic carburetor switch may be the the snowmobile to an authorized problem. Take the snowmobile to Arctic Cat Snowmobile dealer for an authorized Arctic Cat Snowmo- service. If not under warranty, this bile dealer for service. If not under...
If the owner does not feel NOTE: Just as important as cali- qualified, take the snowmobile to brating the snowmobile for higher an authorized Arctic Cat Snowmo- altitudes is recalibrating the snow- bile dealer for this service. This mobile when going to lower alti- service is at the discretion and tudes.
5. Tip the snowmobile back to the are noticed, take the snowmobile upright position; then place a drain to an authorized Arctic Cat Snow- pan on the floor next to the drain mobile dealer for service. If not hose and tip the snowmobile...
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Belt sub-section); then remove the driven pulley. 8. Pour the recommended amount of Arctic Cat ACT Drive Flush Fluid 15. Tip the snowmobile onto its right (p/n 4639-333) into the check/fill side and place a piece of cardboard hole;...
! CAUTION and bottom of the spindle. Wipe excess grease from the spindle. The correct lubricant to use in the gear case is Arctic Cat Synthetic Crossfire/M-Series Models ACT Gear Case Fluid (p/n 4639-628). Any substitute may cause serious damage to the drive system.
MAINTENANCE PERIODIC MAINTENANCE CHECKLIST ITEM INTERVAL PAGE REMARKS Brake System (Hydraulic) Daily Check for binding, leakage, and proper opera- tion; lever firmness, travel, caliper, disc, and pads Cooling System - Liquid Daily 18,44 Check for leakage, damage, obstructions, cool- ant level Oil System Daily 42-44 Check for leakage, damage, and injection/engine...
DO NOT OPERATE occur. THE SNOWMOBILE. Take the snow- ! CAUTION mobile to an authorized Arctic Cat Snowmobile dealer for inspection and A torn air filter can cause damage adjustment or repair. If not under war- to the turbocharger/engine. Con-...
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In-Line Fuel Filter ! WARNING (Carbureted Models) The fuel hoses must fit tightly on Arctic Cat recommends that the in-line the fuel filter. If the fuel hose length fuel filter be checked weekly. The in- doesn’t permit this procedure, line fuel filter is located just in front of replace the fuel hose.
NORMAL cleaner for EFI models is recom- range on the stick. mended especially in the last tank of gasoline before storage. Arctic Cat Fuel Stabilizer (p/n 0436-907) should also be added to the last tank of gaso- line before storage.
CHANGING ENGINE NOTE: Always install a new Oil OIL/FILTER Pan Drain Plug Gasket (p/n 3402- (1100 cc Models) 011) and a new Reservoir Drain Plug O-Ring (p/n 1670-926) when ! WARNING changing the oil. 6. Install a new belly pan plug. Care must be taken if a hot drain plug is removed by hand.
1. Remove the two torx-head screws securing the console to the chassis; not illuminate, take the snowmo- then lift up the rearward end of the bile to an authorized Arctic Cat console and disconnect the console Snowmobile dealer for service. If harness plug-in.
3. Slowly rotate one choke cable engine performance, Arctic Cat recom- adjuster counterclockwise while mends that all changes in internal car- checking the choke lever for free- buretor calibration and piston valve play. As soon as all free-play has...
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NOTE: If a carburetor choke 6. With the piston valves synchro- nized, tighten the swivel adapter cable is adjusted too tight, the jam nuts securely. Slide the rubber engine will only operate on one throttle cable caps down over the cylinder at idle.
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NOTE: If cable free-play gap is NOTE: Make engine idle adjust- not correct, rotate each swivel ment only after the engine has adapter an equal amount until rec- reached running temperature. ommended free-play is achieved. Since the idle speed screws have Each piston valve must be resting not been fine-tuned, slight throttle against the tip of its idle speed...
NOTE: If spark plugs must be Arctic Cat Snowmobile dealer for replaced, take the snowmobile to this service. This service is at the an authorized Arctic Cat Snowmo-...
SPARK PLUGS (2-Stroke Models) NOTE: Always use the recom- mended spark plugs in the engine. See the appropriate specifications chart for correct spark plug gap. Varying terrain conditions and operat- ing usage may require spark plugs of a different heat range. For example, sus- 0743-428 2.
(heat range too hot). NOTE: Take the snowmobile to C. BLACK insulator indicates an authorized Arctic Cat Snowmo- bile dealer for inspection and ser- fuel in the combustion chamber vice. This service is not burning completely. This...
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NOTE: Battery maintenance may 2. Thoroughly wash the battery with soap and water. be done by the snowmobile owner if qualified to do so. If the owner NOTE: If battery posts or cable does not feel qualified, take the ends have a build-up of white/ snowmobile to an authorized Arc- green powder residue, apply water...
B. When using a constant-current 7. After charging the battery for the battery charger, use the follow- specified time, remove the battery ing Battery Charging Chart. charger and allow the battery to sit for 1-2 hours. ! CAUTION 8. Connect the multimeter and test the battery voltage.
4-stroke models, remove continues to blow, take the snowmobile the fuse panel cover (the fuse to an authorized Arctic Cat Snowmo- panel is located behind the bat- bile dealer for service. If not under tery). On 2-stroke models, discon- warranty, this service is at the discre- nect the fuse connector harness.
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2. If the brake fluid is not visible in 2. Measure the distance between the the sight glass, remove the reser- brake lever and the handlebar. The voir cover and add Arctic Cat distance must be greater than 2.54 approved brake fluid until the fluid cm (1 in.).
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The condition of the brake pads must 1. Remove the reservoir cover and be checked daily and changed if worn fill the reservoir with Arctic Cat or damaged. To check and change the approved brake fluid. brake pads, use the following proce-...
DRIVE BELT 3. Remove the brake fluid reservoir cover; then remove most of the The drive belt transfers power from the brake fluid from the reservoir. drive clutch to the driven pulley. If the Install the cover. belt is worn, cracked, or stretched, maximum power will not be transmit- ...
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20 miles at 1/2 throttle deflection. Available shim washers or less. This will allow the drive belt to from Arctic Cat are p/n 0648-714 (0.090 in.) - one included in the tool gain its optimum flexibility and will kit, p/n 0648-715 (0.030 in.), and p/n...
“lock.” Arctic Cat recommends NOTE: Before installing the drive that the track tension be checked daily...
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Checking Track Tension After Setup Model Break-In Tension Tension ! WARNING Bearcat 570/ 44-51 mm 51-57 mm DO NOT attempt to check or adjust T-Series/TZ1 (1 3/4-2 in.) (2-2 1/4 in.) Models @ 20 lb track tension with engine running. Turn ignition key to the OFF posi- Bearcat XT 38-44 mm...
Checking Track 3. If the distance between the bottom of the wear strip and the inside sur- Alignment face of the track is less than speci- ! WARNING fied, loosen the adjusting bolts to increase the slack in the track. Make sure the ignition key is in the 4.
3. After proper track alignment is obtained, tighten the adjusting bolt jam nut against the axle housing. ! WARNING If a jam nut is not tightened prop- erly, adjusting bolt could loosen causing track become dangerously loose. 0727-729 4. Field test the track under actual conditions.
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Adjusting Shocks The front shock springs are individu- ally adjustable for the terrain condi- (Fox Air Shocks) tions and driving style of the operator. NOTE: It is recommended to The spring adjuster has been set at the monitor the air pressure in the air factory so the correct amount of shocks once every month.
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The skid frame front arm shock spring NOTE: Adding air pressure will and limiter straps are adjustable. How- increase the air spring force; ever, Arctic Cat recommends that the reducing pressure will shock spring be maintained at the fac- decrease air spring force.
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2-up, the overload springs should be engaged by rotating the spring tension blocks to the UP position. The spring tension blocks lock in an over-center position when engaged. NOTE: Arctic Cat recommends that overload springs 741-450A engaged whenever a load on the snowmobile (operator/passenger/ cargo) exceeds 136 kg (300 lb).
Removing and ! CAUTION Installing Taillight/ Brakelight (Bearcat XT There are weight limitations for Models) these snowmobiles. If additional cargo is being added, maximum These models are equipped with an weight on the snowmobile (opera- LED taillight/brakelight. If the LED tor/passenger/cargo) should not fails, it must be replaced.
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5. Remove the two self-tapping screws securing the taillight to the bumper; then route the harness out of the bumper and remove the tail- light. 6. Route the taillight harness through the bumper; then secure the tail- light to the bumper with the two self-tapping screws.
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To access the headlight bulbs, use the following procedure: 1. With the hood closed, loosen the headlight adjustment knobs. 2. Carefully push the headlight lenses rearward far enough to remove the torx-head screws securing the air silencer plenum to the hood. 742-467A 3.
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4. Carefully push the headlight lenses 2. Remove the cap screw and lock rearward far enough to install the nut securing the front of the head- torx-head screws. Tighten the light assembly to the air-intake screws securely. silencer. 5. Tighten the headlight adjustment 3.
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3. Using the measurement obtained in step 2, make a horizontal mark on the aiming surface. 4. Make a vertical mark which inter- sects the horizontal mark on the aiming surface directly in front of the headlight. 5. Engage the brake lever lock and start the engine.
To main- Installing Ski Wear tain positive steering characteristics, Bars Arctic Cat recommends that the ski 1. Move the wear bar into position on wear bars be checked before each use the bottom of the ski.
RAIL WEAR STRIPS snow cover is minimal. Loose snow is required to cool and lubri- Arctic Cat recommends that the wear cate the wear strips and prevent strips be checked weekly and replaced accelerated wear.
2-stroke EFI engine models for opti- will increase belt deflection. Available mum performance, do not exceed the shim washers from Arctic Cat are p/n recommended 87 octane gasoline. 0648-714 (0.090 in.) - one included in Using a higher octane gasoline will not the tool kit, p/n 0648-715 (0.030 in.),...
An authorized Arctic Cat Snowmobile then start the engine and allow to dealer should perform this service; idle. With the engine idling, spray...
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9. Fill the gas tank to its rated capac- and cables. Charge the battery. ity; then add Arctic Cat Fuel Stabi- lizer (p/n 0436-907) to the gas ! CAUTION tank following directions on the...
PREPARATION AFTER STORAGE Taking the snowmobile out of storage NOTE: After prolonged storage and correctly preparing it for another of 2-stroke models, Arctic Cat rec- season will assure many miles and ommends one tankful of 100:1 gas/ hours of trouble-free snowmobiling.
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13. On electric start models, charge 14. Inspect the entire brake system, all the battery until fully charged (see controls, headlight, taillight, Battery sub-section in the Mainte- brakelight, ski wear bars, and nance section); then connect the headlight aim; adjust or replace as battery cables making sure to con- necessary.
(U.S. Only) STATEMENT/WARRANTY Arctic Cat warrants to the original retail purchaser, and each subsequent purchaser, that all U.S. EPA- certified Arctic Cat snowmobiles are designed, built, and equipped to conform to all U.S. EPA Emission Control Regulations. Please read the following information completely.
CHANGE OF ADDRESS, OWNERSHIP, OR WARRANTY TRANSFER Arctic Cat Inc. keeps on file the current name and address of the owner of this snowmobile. This will allow Arctic Cat to reach the current owner with any important safety information which may be necessary to protect customers from personal injury or property damage.
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Fold Back Once Place Stamp Here CHANGE OF ADDRESS/OWNERSHIP ARCTIC CAT INC. PRODUCT SERVICE AND WARRANTY DEPT. P.O. BOX 810 THIEF RIVER FALLS, MN 56701...
At the time of sale, an Owner Registration form is to be completed by the sell- ing dealer and consumer. The receipt of the registration form by Arctic Cat is a condition precedent to warranty coverage. It is the selling dealer’s responsibil- ity to retain and/or submit the appropriate copies of the form to the appropriate place(s) to initiate warranty coverage.
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ARCTIC CAT ® ®TM Printed in U.S.A. Trademarks of Arctic Cat Inc. Thief River Falls, MN 56701 p/n 2258-236 Phone: (218) 681-9851 - U.S./(204) 982-1772 - Canada...
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