Table Of Contents - Arctic Cat Cougar Service Manual

Table of Contents

Table Of Contents2
Quick Reference Data5
General Information11
Chapter One11
Manual Organization12
Safety Information12
Notes, Cautions And Warnings12
Safety First12
Service Hints13
Gasket Remover14
Expendable Supplies14
Engine And Chassis Serial Numbers15
Engine Operation16
Fasteners17
Torque Specifications17
Index17
Screw Threads18
Precision Measuring Tools19
Self-Locking Fasteners20
Washers21
Cotter Pins21
Snap Rings (Circlips)21
Lubricants22
Engine Oil22
Threadlock23
Grease23
Applying Rtv Sealant23
Rtv Gasket Sealant23
Gasket Removal24
Basic Hand Tools24
Applying Threadlocks24
Special Tools33
Mechanic's Tips35
Removing Frozen Nuts And Screws35
Removing Broken Screws Or Bolts35
Remedying Stripped Threads36
Removing Broken Or Damaged Studs37
Ball Bearing Replacement38
Bearing Removal38
Bearing Installation39
Shrink Fit40
Seals41
Snowmobile Operation42
Prestart Inspection42
Tools And Spare Parts43
Emergency Starting43
Snowmobile Safety44
Proper Clothing44
Snowmobile Code Of Ethics44
Emergency Survival Techniques44
Model Listing45
General Dimensions46
Vehicle Weight50
Decimal And Metric Equivalents52
General Torque Specifications53
Technical Abbreviations53
Metrica Tap Drill Sizes54
Windchill Factors54
Troubleshooting55
Chapter Two55
Operating Requirements56
Troubleshooting Instruments56
Testing Electrical Components56
Engine Electrical System Troubleshooting57
Ignition Troubleshooting58
Switch Tests60
Ignition Testing61
Ignition Component Resistance Test61
Ignition High-Tension Coil61
Ignition Charge Coil62
Ignition Trigger Coil (Coil Under Flywheel)63
Ignition Trigger Coil (Coil Outside Flywheel)63
Lighting Coil63
Voltage Regulator64
Fuel System64
Identifying Fuel System Problems64
Engine Problems65
Preignition65
Detonation65
Electronic Fuel Injection65
Fuel System Troubleshooting66
Poor Idling68
Misfiring68
Flat Spots68
Power Loss68
Two-Stroke Pressure Testing69
Excessive Vibrations69
Low Engine Power70
Power Train Troubles71
Abnormal Engine Noise72
Glazed Drive Belt72
Uneven Drive Belt Wear72
Engine Idle Speed Too High72
Brake Not Holding Properly73
Excessive Chaincase Noise73
Leaking Chaincase73
Erratic Shifting73
Skis And Steering Troubles74
Track Assembly Troubles74
Electro Specialties Model 1L Settings75
Arctco Ignition Analyzer Peak Voltages75
Ignition High Tension Coil78
Ignition Trigger Coil (Sensor)80
Lubrication, Maintenance And Tune-Up82
Break-In Procedure82
Chapter Three82
Pre-Ride Checks82
Fluid Checks82
Maintenance Schedules83
Correct Fuel Mixing83
Lubrication84
Proper Fuel Selection84
Engine Oil Tank84
Chaincase Oil85
Steering Spindle Lubrication86
Slide Suspension Lubrication86
Air Cooling System87
Speedometer Drive Adaptor87
Checking/ Adjusting Fan Belt Tension87
Fan Belt Removal/Installation88
Liquid Cooling System89
Check/Fill Coolant90
Coolant Change91
Daily Maintenance92
Drive Belt Check92
Stop And Tether Switch Operation93
Headlight And Taillight Lens93
Headlight And Taillight Operation93
Steering Operation93
Steering Bolts Check94
Carburetor And Throttle Cable Inspection94
Battery94
Weekly Maintenance95
Shock Absorbers95
Ski And Ski Runner Check95
Ski Alignment96
Front Suspension Check97
Rear Suspension Rail Wear Strip Inspection97
Track Adjustment98
Monthly Maintenance100
Drive Belt100
Non-Scheduled Maintenance101
Brake Pad Wear Check101
Fuel Filter101
Brake Adjustment (Mechanical Brake)101
Motor Mount Plate Diagram102
Motor Mount Brackets (Powder Special) Diagram103
Motor Mount Brackets (Zrt 600) Diagram104
Hydraulic Brake Checking106
Drive Chain (Non-Reverse Gear)106
Throttle Cable Routing107
Oil Injection Pump Adjustment107
General Inspection And Maintenance108
Recoil Starter Check108
Body Fasteners Check108
Electrical Connectors Check109
Pulse Hose109
Engine Tune-Up110
Cylinder And Cylinder Head Nuts110
Cylinder Compression110
Correct Spark Plug Heat Rang111
Spark Plug Conditions112
Spark Plug Removal/Cleaning113
Gapping And Installing The Plug113
Reading Spark Plugs114
Ignition Timing (Liquid-Cooled Engines)114
Static Timing Check115
Dynamic Timing Check116
Setting Ignition Timing118
Ignition Timing (Air-Cooled Engines)120
Carburetur Adjustment123
Idle Speed124
Idle Mixture124
Maintenance Schedule125
Recommended Lubricants And Fuel125
Approximate Refill Capacity126
Track Tension129
Maintenance Tightening Torques129
Spark Plugs131
Ignition Timing131
Ignition Timing Type132
Carburetor Pilot Air Screw And Idle Speed133
Adjustments For Special Use135
Carburetor Tuning135
Chapter Four135
Carburetor Adjustment136
Carburetor Circuit Guide136
High-Altitude Clutch Tuning143
Gearing143
Spring Suspension Adjustment143
Front Suspension Spring Preload144
Rear Suspension Adjustment145
Slide Rails Adjustment146
Carburetor Specifications147
Driven Pulley Torque Bracket And Spring Application148
Cam Arm Specifications150
Sprocket Specifications155
Shock Absorber Spring Settings157
Engine Number Identification159
Chapter Five159
Engine Lubrication160
Engine Service Precautions160
Servicing Engine In Frame161
Engine Removal161
Engine Mounts Removal/Installation164
Engine Installation166
Engine Mounting Brackets Diagram166
Engine Top End168
Cylinder Head Removal/Installation169
Top End Diagram170
Cylinder Head Inspection174
Cylinder Removal176
Cylinder Inspection177
Cylinder Stud Replacement178
Threaded Holes And Screws179
Cylinder Installation179
Piston, Piston Pin, And Piston Rings180
Piston And Piston Ring Removal181
Piston (Wrist) Pin And Needle Bearing Inspection182
Connecting Rod Inspection184
Piston And Ring Inspection185
Piston/Cylinder Clearance187
Cylinder Honing188
Piston Installation189
Reed Valve Assembly (1990-1991 El Tigre)190
Reed Valve Assembly (437.4, 497, 594 And 599 Cc Engines)192
Crankcase And Crankshaft194
Crankcase Disassembly195
Crankcase And Crankshaft Cleaning196
Crankcase Inspection197
Crankshaft Inspection198
Crankshaft Bearing Replacement200
Crankshaft Installation203
Crankcase Assembly206
Driveshaft For Coolant Pump And Oil Injection Pump208
Shaft Removal208
Engine Identification Table212
Engine Technical Data215
Engine Tightening Torques218
Fuel System - Carbureted Models221
Air Silencer221
Carburetor Operation221
Chapter Six221
Float Mechanism222
Idle, Intermediate And Main Fuel Systems222
Starting Enrichment223
Carburetor Removal/Installation223
Carburetor To Engine Boots224
Carburetor Application224
Carburetor Disassembly225
Carburetor Assembly227
Carburetor Cleaning/Inspection228
Float Heigh Check And Adjustment229
Jet Needleffhrottle Valve Removal/Installation229
Fuel Pump Removal/Installation230
Altitude Compensator230
Fuel Tank Removal/Installation231
Throttle Cable Replacement232
Fuel Tank Cleaning/Inspection232
Carburetor Application Table233
Carburetor Pilot Air Screw Adjustment235
Fuel System - Fuel Injected Models237
Chapter Seven237
Fuel Injection System Components239
Air Flow System240
Electronic Control System240
Fuel Flow System240
Fuel Injection System Testing And Troubleshooting242
(Efi Powered By Battery)242
Testing And Troubleshooting (Efi System Magneto-Powered)252
Fuel Tank Service256
Component Service256
Throttle Cable Service257
Console Switches View257
Fuel Rail, Pressure Regulator And Injectors Service258
Throttle Body Assembly Service261
Purge The Fuel System262
Fuel Pump Service262
Electronic Control Unit (Ecu) Service263
Changing The Eprom Chip263
Idle Speed And Throttle Synchronization Adjustment264
Throttle Position Sensor (Tps) Removal/Installation264
Tps Setting Adjustment265
Idle Speed Stop265
Electronic Fuel Injection Error Codes266
Engine Coolant Temperature Sensor Specifications267
Exhaust System Removal/Installation272
Chapter Eight272
Exhaust System Cleaning273
Exhaust System Repair276
Small Dents (Exhaust System)276
Large Dents (Exhaust System)277
Electrical System278
Chapter Nine278
Ignition System Diagram279
Flywheel Removal/Installation280
Stator Plate Removal/Installation290
Ignition Generating Coil Replacement291
Lighting Coil Replacement291
Ignition Coil Removal/Installation292
Cdi Unit Removal/Installation293
Lighting System294
Headlight Replacement294
Instrument Assembly295
Headlight Adjustment295
Taillight Bulb Replacement295
Warning Lamps296
High Beam Indicator Lamp296
Switches297
Safety Stop Switches297
Tether Switch Removal/Installation297
Emergency Kill (Stop) Switch298
Headlight Dimmer Switch298
Brake Light Switch298
Ignition Switch298
Fuel Level Sensor299
Oil Level Gauge299
Electric Starting Motor299
Electric Starting Motor Disassembly300
Electric Starting Motor Inspection301
Electric Starting Motor Assembly302
Battery State Of Charge303
Wiring Diagrams303
Electrical System Tightening Torques304
0Il Injection System305
Oil Pump Service305
Oil Pump Bleeding305
System Components305
Oil Tank Removal/Installation306
Component Replacement306
Oil Pump Removal, Inspection, Installation307
Cooling Systems310
Fan Belt Removal And Installation310
Chapter Eleven310
Fan-Cooled Models310
Cooling Fan Assembly311
Fan Cooling System Diagram311
Cowling312
Liquid-Cooled Models313
Thermostat Removal314
Thermostat Testing315
Coolant Pump316
Heat Exchangers319
Hoses319
Coolant Check Valve And Filter323
Recoil Starter324
Chapter Twelve324
Starter Pulley Removal/Installation325
Starter Housing Disassembly327
Starter Housing Inspection329
Starter Housing Assembly330
Drive System334
Drive Unit334
Chapter Thirteen334
Drive Pulley Assembly335
Fixed And Sliding Pulley Halves336
Drive Pulley Spring337
Centrifugal Weight Levers337
Driven Pulley338
Drive Belt Removal/Installation340
Drive Belt Inspection341
Drive Belt Deflection342
Drive Belt Alignment342
Drive Pulley Service344
Cam Arm Removal344
Driven Pulley Service355
Drive Belt Specifications365
Drive System Specifications367
Engine Speeds368
Drive Pulley Clutch Spring Application370
Drive Pulley Spring Specifications371
Driven Pulley Torque Bracket (Cam) And Spring Application372
Drive System Tightening Torques379
Brake, Driven Shaft, Dropcase And Driveshaft380
Chapter Fourteen380
Drive Chain And Sprockets (Models Without Reverse)380
Drive/Dropcase Assembly Diagram381
Drive Chain And Sprockets (Models With Reverse)384
External Chain Tensioner Diagram388
External Chain Tensioner Service390
Driven Shaft391
Driven Shaft Inspection393
Brake Disc Inspection393
Driven Shaft Installation393
Driveshaft Service394
Drive Sprockets And Idler Wheel Replacement396
Mechanical Brake System Service397
Hydraulic Brake System Service403
Brake Pads Service404
Caliper Assembly405
Master Cylinder406
Brake Specifications410
Front Suspension And Steering411
Chapter Fifteen411
Skis411
Front Suspension416
Spindle Removal416
Spindle Inspection417
Spindle Installation418
Lower Suspension Arm Removal/Installation419
Lower Suspension Arm Inspection420
Upper Suspension Arm Removal/Installation420
Upper Suspension Arm Inspection421
Sway (Stabilizer) Bar Removal/Installation422
Sway Bar Diagram422
Sway Bar Linkage Adjustment423
Shock Absorber Removal/Installation423
Spring Removal/Installation424
Shock Inspection425
Rebuildable Shock Absorbers Disassembly/ Assembly/Charging425
Steering Assembly432
Throttle Lever/Switch Assembly Diagram432
Handlebar Removal/Installation433
Brake Lever/Switch Assembly Diagram433
Handlebar Grips Removal/Installation434
Steering Post Removal/Installation434
Steering Assembly Diagram435
Steering Post Inspection437
Drag Link And Tie Rods Removal/Installation437
Tie Rod Inspection437
Steering Adjustment438
Handlebar Alignment438
Shock Absorber Specifications440
Track And Rear Suspension442
Rear Suspension Removal442
Chapter Sixteen442
Rear Suspension Inspection443
Rear Suspension Installation443
Wear Strips Inspection/Replacement444
End Caps445
Front Shock Removal/Installation445
Rear Shock Absorber Removal/Installation447
Front Arm Spring Removal/Installation467
Rear Spring467
Front Arm Removal/Installation469
Rear Arm And Lower Arm Removal/Installation470
Idler Wheels Inspection471
Rear Axle Removal/Installation471
Wheel Bearing Replacement471
Track Removal/Installation472
Track Inspection472
Cleat Replacement474
Chapter Seventeen Off-Season Storage477