2009 Arctic Cat M8 Sno Pro 153 Snowmobiles Service Repair Manual PDF

SECTION 1 -
GENERAL INFORMATION!
SPECIFICATIONS
TABLE OF
CONTENTS
General Specifications ............................................ 1-2 Engine Torque Patterns (1100 cc) ......................... 1-28
Snowmobile Identification ..................... .. ....... .. .. ..... 1-2 Arctic Power Valve (APV) System
Recommended Gasoline and Oil ............................ 1-2 Specifications (2-Stroke) .................................... 1-30
Break-In Procedure ................................. ....... .. .. ..... 1-3 Oil Consumption Specifications (2-Stroke) ............ 1-31
Genuine Parts ......................................................... 1-3 EFI Specifications ................................................. 1-31
High Altitude Operation ......................... .. ....... .. .. ..... 1-3 Throttle Valve Angle Specifications ....................... 1-31
Drive Chain Lubrication (120 cc) ............................. 1-6 Fuel Pump Specifications (570 cc) ........................ 1-31
Low Oil Pressure Warning Light (1100 cc) ...... .. ...... 1-6 Carburetor Specifications ..................... .. .. ...... .. ..... 1-31
Preparation For Storage .......................................... 1-6 Electrical Specifications ........................................ 1-32
Preparation After Storage ....................................... 1-7 Ignition Timing Specifications (2-Stroke) ........ .. .. ... 1-38
After Break-In Checkup (100 Miles - 2-Stroke/ Steering/Body Torque Specifications .................... 1-40
600 Miles - 4-Stroke) ............................................ 1-8 Drive System Specifications .................. .. ....... .. ..... 1-41
After Break-In Checkup Checklist ........................... 1-9 Drive Clutch/Driven Pulley-Related
Engine Specifications (2-Stroke) ........... .. .. ...... .. .... 1-10 Specifications ...................................... .. ...... .. ..... 1-41
Engine Specifications (4-Stroke) ........................... 1-11 Arctic Cat Drive Belt Dimensions .......................... 1-41
Cylinder Head Volume Specifications (2-Stroke) .. 1-12 Drive System Components ................... .. ....... .. ..... 1-41
Engine Piston Travel Versus Gear Case Performance Calibrations ................... 1-42
Crank Angle Chart (2-Stroke) ..................... .. .. ... 1-12 Drive System Torque Specifications ............... .. ..... 1-43
Crankshaft RunoutiRepair Specifications Rear Suspension Torque Specifications ............... 1-43
(2-Stroke) ...................................................... .. ... 1-12 Track Warranty Guidelines ............................... ..... 1-45
Fraction/Decimal Conversions .............................. 1-13 Track Specifications ............................................... 1-46
M M/I N. Conversions .............................. .. ....... ... .... 1-13 Front Suspension Specifications .......... .. .. ...... .. .. ... 1-46
Torque Conversions (ft-Ib/N-m) ............................. 1-14 Rear Suspension Specifications ........................... 1-46
Tightening Torque (General Bolts) ........................ 1-14 Shock Absorber Specifications ............. .. .. ...... .. .. ... 1-47
Assembly Schematics/Torque Specifications Idler Wheel Dimensions ........................................ 1-47
(Table of Contents) ............................................. 1-14
1-1
RECOMMENDED GASOLINE
General Specifications (Carbureted Models)
The recommended gasoline to use in these snowmo-
biles is 87 octane regular unleaded.
-NOTE: General specifications for each 2009 Arctic
Cat Snowmobile can be accessed from the Arctic Cat -NOTE: In many areas, oxygenates (either ethanol
Cat Tracker Dealer Communication System online. or MTBE) are added to the gasoline. Oxygenated
gasolines containing up to 10% ethanol or up to
15% MTBE are acceptable gasolines; however,
Snovvmobile whenever using oxygenated gasolines, the carbu-
Identification retor main jet must be one size larger than the
main jet required for regular unleaded gasoline.
For example, if a 220 main jet is recommended for
The Arctic Cat Snowmobile has two important identi- regular unleaded gasoline, a 230 main jet must be
fication numbers. The Vehicle Identification Number installed if using an oxygenated gasoline.
(VIN) is stamped into the tunnel near the right-side
footrest. The Engine Serial Number (ESN) is stamped When using ethanol blended gasoline, adding a gaso-
into the crankcase of the engine. line antifreeze is not necessary since ethanol will pre-
vent the accumulation of moisture in the fuel system.
VIN RECOMMENDED GASOLINE
(EFI Models)
The recommended gasoline to use in these snowmo-
biles is 87 octane regular unleaded. In many areas,
oxygenates (either ethanol or MTBE) are added to the
gasoline. Oxygenated gasolines containing up to 10%
ethanol or up to 15% MTBE are acceptable gasolines.
Do not use gasolines containing methanol.
-NOTE: For optimum performance, do not exceed
the recommended 87 octane gasoline. Using a
0726-383
higher octane gasoline will not increase overall
performance.
-NOTE: The VIN also appears on a decal beneath
the seat (CrossfireIM-Series) or attached to the -NOTE: The Z1 Turbo models will detect lower
right-side tunnel (remaining models). The decal octane gasoline and reduced engine performance will
also displays pertinent production information. result. 91 octane (minimum) gasoline should be used
in these models.
These numbers are required to complete warranty
claims properly. No warranty will be allowed by Arc- RECOMMENDED OIL (2-Stroke)
tic Cat Inc. if the engine serial number or VIN is
removed or mutilated in any way. The recommended oil to use in the oil-injection system
is Arctic Cat 50: 1 Injection Oil (for standard models)
or Arctic Cat Synthetic APV 2-Cycle Oil (for APV
models). The oil is specially formulated to be used
Recommended either as an injection oil or as a pre-mix oil (for carbu-
Gasoline and Oil reted model break-in) and meets all of the lubrication
requirements of the Arctic Cat snowmobile engine.
RECOMMENDED OIL (120 ee)
A CAUTION
Do not use white gas or gasolines containing metha- The recommended oil to use is a multi-grade oil cali-
nol. Only Arctic Cat approved gasoline additives brated to the ambient temperature at which the engine
should be used. is run. See the viscosity chart for details.
A CAUTION
Any oil used in place of the recommended oil may
cause serious damage.
1-2
2009 Arctic Cat Snowmobiles Factory Service Manual - all Models - www.ReadManuals.com
120 ee
Multi-Grade
The Arctic Cat engine requires a short break-in period
(approximately 10 operating hours) before being sub-
SAE # jected to heavy load conditions or full-throttle opera-
tion. Strict adherence to the break-in procedure will
ENGINE contribute to optimum performance and longevity of
OIL the engine.
~c -35 -29 -23 -18 "12 -7 1 " 10 15 21 21 32 During break-in, a maximum of 112 throttle is recom-
TEMP ~F -30 -.20 -10 0 10 20 30 40 SO 60 10 80 90 mended; however, brief full-throttle accelerations and
variations in driving speeds contribute to good engine
break-in. After the 10 hour break-in period, the snow-
mobile may be taken to an authorized Arctic Cat
GEN-0048 Snowmobile dealer for a checkup and oil change at the
RECOMMENDED OIL (1100 ee) discretion and expense of the snowmobile owner.
The recommended oil to use is Synthetic Turbo OW-40 1100 ee

Oil in all temperatures and conditions. The Arctic Cat engine (when new or rebuilt) requires a
short break-in period before the engine is subjected to
heavy load conditions.
Multi-Grade Engine Oil This engine does not require any pre-mixed fuel dur-
ing the break-in period.
ENGINE
& CAUTION
OIL DO NOT use premixed fuel in the snowmobile gas
tank. Engine damage will occur.
TEMP~OC ____-3_0_-_20_-_10__0__1_0__20__30__4_0~
-22 -4 14 32 50 68 86 104 To ensure trouble-free operation, careful adherence to
the following break-in guidelines will be beneficial.
0-200 miles 1/2 Throttle (45 MPH-max)

OILCHARTJ
200-400 miles 1/2-3/4 Throttle
After the engine break-in period, the engine oil should
be changed every 2500-3000 miles and before pro- 400-600 miles 1/2-3/4 Throttle *
longed storage.
* With occasional full-throttle operation.
To ensure proper engine break-in, Arctic Cat recom-
mends that the engine oil and filter be changed after
Break-In Procedure 600 miles or after one month, whichever comes first.
This service is at the discretion and expense of the
snowmobile owner.
2-STROKE
The Arctic Cat 2-stroke engine (when new or rebuilt)
requires a short break-in period before the engine is Genuine Parts
subjected to heavy load conditions. Arctic Cat requires
that the first tankful of fuel be premixed at a 100: 1
ratio in all oil-injection models. When replacement of parts is necessary, use only gen-
uine Arctic Cat parts. They are precision-made to
During the break-in period, a maximum of 112 throttle ensure high quality and correct fit.
is recommended; however, brief full-throttle accelera-
tions and variations in driving speeds contribute to
good engine break-in. High Altitude Operation
& CAUTION
DO NOT exceed the one (1) tankful limitation of a 100:1 Operating a snowmobile at varying altitudes requires
gaS/oil break-in mixture. Continuous use of a gaS/oil changes in performance components. These changes
mixture, unless consistently operating in extremely affect drive train components and carburetion compo-
cold conditions (-26°C/-15°F or colder), could cause nents (570 cc).
spark plug fouling and excessive carbon buildup. A
-NOTE: The 120 cc and 1100 cc turbo do not
100:1 gaS/oil mixture must be used in conjunction with
the oil-injection system to ensure adequate engine require calibration changes for varying altitudes.
lubrication in extremely cold conditions.
High altitude information decal(s) are located beneath ENGINE
the hood of the snowmobile.
A normally aspirated engine will generate more horse-
power at sea level than it does at higher altitudes.
A CAUTION Many reasons for this are possible, but the biggest rea-
On carbureted models, carefully follow the Main Jet son is that the higher you go, less oxygen is available
Chart recommendations for proper main jet selection for the engine to use during its combustion process.
for altitude, temperature, and gasoline being used. Less oxygen means it needs less fuel to obtain the cor-
rect air/fuel ratio to operate properly. This is why the
The M-Series snowmobiles are initially set up at the fuel ratio has to be recalibrated. High altitude engines
factory for operation between 6000-9000 feet. Consult operate as though they have a lower compression ratio.
the appropriate specifications for this information. This, along with less oxygen and less fuel, means that
the engine generates less horsepower.
Following are basic high altitude theories for clutch-
ing, engine, suspension, and track. The carbureted models will also have lower pressure
applied to the float chamber because of pressure
CLUTCHING changes in the atmosphere between high altitude and
As altitude changes, engine horsepower changes with sea level. All of these characteristics will become more
it. As you go up in altitude, the engine loses horse- evident the higher the altitude.
power. Because of this, the constant velocity transmis-
sion (CVT) system needs to be changed to compensate It will be necessary to make changes to the fuel sys-
for the horsepower loss. tems (carbureted models) and drive systems that sup-
port engine operation as altitude changes.
At altitudes above 5000 ft, clutch engagement RPM is
normally higher than the standard setting due to the TURBOCHARGING
horsepower loss at altitude as opposed to what would Turbocharging is one method of compensating for loss
be seen for horsepower at sea level. The engine will of air density that works extremely well when applied
lose peak horsepower but will also lose horsepower at to four-cycle internal combustion engines.
engagement speed. For this reason, higher engagement
speeds are usually needed at altitude in order to attain Exhaust gasses are directed through the turbocharger
acceptable acceleration. This higher engagement speed turbine wheel which is attached to the compressor
can be attained several ways. Some of the methods through a common shaft. As the exhaust gasses spin
will affect other characteristics of CVT operation, so the turbine, the compressor is spun at very high RPM.
you must be careful what you change. Drive clutch Inlet air is drawn into the compressor, compressed, and
springs are the most common way to increase engage- routed to the intake manifold of the engine. Intake
ment speed; however, by simply changing the cam pressure, therefore, is maintained at the optimum level
arms to a lighter weight from the heavier sea level cam as altitude or temperature increases.
arm, you will gain some engagement speed.
The turbocharger output must be regulated to maintain
Other more complicated methods exist such as the optimum manifold pressure throughout the
engagement notches and changing the position of the designed operating range. This is accomplished by
cam arm center of gravity in relation to the roller. This regulating the volume of exhaust gasses passing
is called "tucking the weight" and can be used, but, through the turbine by controlling a diverter valve
like the engagement notch, it can hurt belt life. (waste-gate) at the turbocharger turbine inlet. At lower
altitudes/temperatures, excessive exhaust gasses are
The driven clutch will also playa part in CVT tuning diverted past the turbine and into the exhaust down-
for high altitude operation. A steeper helix (torque stream of the turbocharger thus limiting the compres-
bracket) angle in the driven clutch will mean a quicker sor output to maintain correct manifold pressure.
up-shift. A shallower angle will mean a slower up-
shift. If the up-shift is too quick, due to a very steep As altitude increases, the manifold pressure is held
helix, RPM will be pulled down under the peak operat- constant by diverting less exhaust past the turbine, thus
ing RPM of the engine (where the horsepower is) and increasing compressor speed. This will continue until
performance will suffer. The engine may even bog. If the waste-gate is completely closed at which time
you have a helix that is too shallow, the engine may manifold pressure will start to decrease much the same
over-rev or have poor acceleration. Usually, angles as a normally aspirated engine.
shallower than the sea level calibrations work best. The waste-gate is controlled by a spring/diaphragm
The driven spring will also affect driven clutch tuning. mechanism that is connected to the intake manifold by
Tighten the spring, and RPM will increase. Loosen the an air line. A mechanical linkage connects the dia-
spring, and RPM will decrease. The spring should be phragm to the waste-gate control arm.
used to fine-tune and complement the helix selection.
Carburetor calibration changes for high altitude opera-
tion will have an effect on the CVT system and how it
operates. Understanding the basics of CVT operation
is important in order to make the correct high altitude
CVT calibration changes.
1-4
Air is heated by friction and compression through the Another adjustment that can be made on the rear sus-
turbocharger and air density is lost by heating the air; pension is the front arm shock spring tension. As trail
therefore, an after-cooler is installed between the tur- conditions change, the spring pre-load may be used to
bocharger compressor and the intake manifold. This is decrease the chance of the front end "bottoming out."
an air-to-air after-cooler that uses outside air directed With a stiffer spring pre-load, the ride of the snowmo-
through a radiator-type cooler to cool the compressed bile will improve on the trail but will affect the perfor-
air prior to entering the intake manifold. mance in the deep powder snow. In deep powder snow,
the stiffer spring pre-load will cause the front-end to
SUSPENSION "dig" and possibly take longer for it to plane off. Sev-
The different riding styles of the individual operator, eral different-rate springs are available for different
the varying snow conditions, and the type of terrain are riding styles and terrain conditions.
all factors that affect the suspension at high altitude. On the standard models, the front shock springs are
Trail riding versus powder snow riding versus combi- also individually adjustable for the terrain conditions
nation riding will all require different suspension set- and driving style of the operator. The spring adjuster
tings. has been set at the factory so the correct amount of
The normal setting for front ski suspension is as little threads are exposed between the spring adjuster and
spring pre-load tension as possible for powder snow the shock housing as an initial setting. Additional ski
riding allowing the skis to float across the snow with pressure can be obtained by tightening the spring ten-
the least amount of resistance. Trail riding will require sion; ski pressure can be decreased by relaxing spring
more spring tension to carry the varying load more tension. Springs with different spring rates are avail-
effectively. Many different settings and spring tensions able for operator choice and snow conditions. A limit
to consider exist when adjusting for riding style and exists as to how far you can pre-load the springs before
snow conditions. "coil bind" takes effect where the wire on the spring
actually runs into itself and causes binding. Equal
The rear suspension has a number of spring settings adjustments should be maintained on both sides of the
that produce different riding characteristics. snowmobile. On the Sno Pro models with air shocks,
they are individually adjustable for the terrain condi-
The front arm spring and shock will also affect the ride tions and driving style of the operator. The ski shocks
and handling when either on a trail or in powder snow. are preset at 4.6 kg/cm2 (65 psi) as an initial setting on
A strong spring setting on this shock will cause the the Crossfire Sno Pro models or at 4.2 kg/cm2 (60 psi)
snowmobile to tend to "dig" more when riding in the on the M-Series Sno Pro models. The rear arm shock is
powder snow rather than climbing up on top of the preset at 9.8 kg/cm2 (140 psi) on the Crossfire and M-
snow. But, it will work more effectively when riding Series Sno Pro models. The shocks can be "fine-
on a trail. A softer spring setting will allow the front of tuned" to match the operator's weight, riding style, and
the rear suspension to collapse much quicker and terrain conditions.
change the angle of the track to the snow. A more
gradual angle will tend to raise the snowmobile up on -NOTE: Care should be taken to have equal pres-
the snow rather than digging into it. sure in the ski shocks before operating the snow-
mobile.
Many possible variables and adjustments to the rear
suspension exist depending on snow conditions, riding Finally, track tension should be looked at to make sure
style, and type of terrain. These adjustments can be that it is within recommended specifications to affect
made to individualize the snowmobile to the riding the efficiency of the snowmobile. On models with the
style of the operator. torque sensing link, the track is actually tightening as
M-Series/Crossfire the suspension moves through its range of motion
causing the track to sag in the middle and rub on the
As snow cover and riding conditions change, several top part of the rear suspension arm.
different adjustments can be made to change the ride
and handling characteristics for operator preference. TRACK
Located on the front suspension arm are limiter straps. Carefully matching the riding requirements to the type
They limit the amount of "fallout" the front arm can of track will ensure the maximum use of all available
have. These straps may be adjusted in or out due to engine power. Lug height and track durometer are the
conditions and riding style. The more the straps are two main concerns when selecting a track for various
brought up, the more steering power the operator has riding styles.
due to the amount of ski pressure.
Tracks exist with lug heights from 0.750 in. up to 2.25
in. to accommodate various snow conditions. Gener-
ally, the deeper the snow, the taller the lug. It must be
noted that the installation of any deep-lug track may
reduce top end speed and promote premature wear
strip wear in marginal snow conditions.
2009 Arctic Cat Snowmobiles Factory Service Manual - all Models - www.ReadManuals.com 1-5
Durometer is a measurement of how hard a rubber is. 1. With the engine off, remove the engine oil level
The lugs on most tracks range between 60 and 80 stick and wipe it clean. Without screwing it in, set
durometer. On the durometer scale, the higher the the stick back in the oil tank. Remove it and
number, the harder the lugs. For riding in deep powder observe the oil level on the stick.
snow, a softer 60 durometer track works best. The
softer rubber allows the track to "give" a little and -NOTE: To ensure an accurate reading, the snow-
pack the snow creating lift rather than digging its way mobile should be on level ground.
straight down. When hill-climbing, the harder lug of
an 80 durometer track works the best due to penetrat- 2. If the oil level is at or below the ADD mark on the
ing the hard snow creating more bite. oil level stick, add only enough recommended oil
to raise the level to the NORMAL range. DO NOT
Some tracks come with a dual durometer rating, such overfill the reservoir with oil.
as a track with a 80/60 durometer rating. The lugs on
this track are 80% 80 durometer rubber, and the top 3. After adding oil if the engine starts, oil pressure
20% is made of the softer 60 durometer rubber. This should be normal.
track is designed to be a good all-around track for rid-
ing mostly in deep powder snow but can climb the
occasional hard snow hill. Preparation For Storage
Drive Chain Lubrication Prior to storing the snowmobile, it must be properly

(120 ee) serviced to prevent corrosion and component deterio-
ration. To prepare the snowmobile for storage, Arctic
Cat recommends the following procedure:
The drive chain should be lubricated every 20 operating
hours with a dry, graphite-based chain lubricant. By 1. Clean the seat cushion with a damp cloth and Arc-
using a dry, graphite-based chain lubricant, dirt buildup tic Cat Vinyl Protectant.
on the drive chain will be minimized. Before each lubri- 2. Clean the snowmobile thoroughly by hosing dirt,
cation, inspect the drive chain for dirt accumulation. oil, grass, and other foreign matter from the skid
To lubricate the drive chain, shut the engine off and frame, tunnel, hood, and belly pan. Allow the
wait for all moving parts to stop, remove the drive snowmobile to dry thoroughly. DO NOT get water
chain guard, and lubricate the drive chain. After lubri- into any part of the engine.
cating the drive chain, install the drive chain guard. 3. On the 4-stroke models, change the engine oil;
If the drive chain is excessively dirty, it should be then on the 120 cc and turbo models, clean the air
removed and cleaned prior to being lubricated (see filter (see Section 3).
Drive Chain and Sprockets (120 cc) in Section 6). 4. On the 2-stroke models, place the rear of the
-NOTE: If a dry, graphite-based chain lubricant is snowmobile up on a shielded safety stand.
not available, lubricate the drive chain with several 5. On the 500/600/800/1000 cc engine models, start
drops of petroleum-based oil. If the snowmobile is the engine and allow to idle. With the engine
operated in the summer with the optional wheel kit, idling, pry the intake boot forward; then spray an
the drive chain should be lubricated more frequently. Engine Storage Preserver into the intakes until the
engine exhaust starts to smoke heavily or until the
engine starts to drop in RPM. Tum engine off.
Lovv Oil Pressure Install the intake boot.
Warning Light 6. On the 570 cc engine models, carefully pry the
(1100 ee) intake boots partially over the carburetor inlets;
then start the engine and allow to idle. With the
engine idling, spray an Engine Storage Preserver
The Low Oil Pressure Warning Light indicates engine into the intakes until the engine exhaust starts to
oil pressure, not the oil level; however, if the oil level smoke heavily or until the engine starts to drop in
is low, it may affect oil pressure. The light should illu- RPM. Tum engine off. Install the intake boots.
minate each time the ignition switch is turned to RUN
or START, and it should go out when the engine starts. & CAUTION
If the light stays illuminated or it illuminates while the Do not run the engine without the belt guard in place
engine is running, oil pressure has been lost and the
and secured.
engine will automatically shut off.
-NOTE: The following oil check procedures are valid 7. Plug the exhaust system outlet with a clean cloth.
only if the oil pressure warning light has activated. 8. On the 2-stroke models with the ignition switch in
the OFF position:
If oil pressure is lost, use the following procedure:
1-6
A. Disconnect the high tension leads from the 17. On electric start models, disconnect the battery
spark plugs; then remove the plugs, connect cables making sure to disconnect the negative
them to the leads, and ground them on the cyl- cable first; then clean the battery posts and cables.
inder heads.
& CAUTION
& CAUTION Batteries require charging if left for extended non-start
Never crank the engine over without grounding the periods. Arctic Cat recommends trickle charging once
spark plugs. Damage to ignition system may result. a month. Follow the manufacturer's instructions and
cautions.
B. Pour 29.5 ml (1 fl oz) of SAE #30 petroleum-
based oil into each spark plug hole and pull the & CAUTION
recoil starter handle slowly about 10 times. On models with remote start, make sure to leave the
battery cables disconnected. Failure to disconnect the
C. Install the spark plugs and connect the high ten-
battery cables when storing the snowmobile for a pro-
sion leads.
longed period of time (six weeks or more) will result in
9. On carbureted models, drain the gas from each a discharged or damaged battery.
carburetor float chamber.
18. If possible, store the snowmobile indoors. Raise
10. Fill the gas tank to its rated capacity; then add Arc- the track off the floor by blocking up the back end
tic Cat Fuel Stabilizer to the gas tank following making sure the snowmobile is secure. Loosen the
directions on the container for the stabilizer/gaso- track adjusting bolts to reduce track tension. Cover
line ratio. Tighten the gas tank cap securely. the snowmobile with a machine cover or a heavy,
ventilated tarpaulin to protect it from dirt and dust.
11. Flush the gear case and change the lubricant (see
Section 6). 19. If the snowmobile must be stored outdoors, posi-
tion the snowmobile out of direct sunlight; then
12. Remove the drive belt from the drive clutch/driven block the entire snowmobile off the ground mak-
pulley. Lay the belt on a flat surface or slide it into ing sure the snowmobile is secure. Loosen the
a cardboard sleeve to prevent warping or distortion track adjusting bolts to reduce track tension. Cover
during storage; then clean and inspect the drive with a machine cover or a heavy, ventilated tar-
clutch and driven pulley. paulin to protect it from dirt, dust, and rain.
-NOTE: For removing drive belt, see Removing! & CAUTION
Installing Drive Belt in Section 6 of this manual.
Avoid storing in direct sunlight and using a plastic
cover as moisture may collect on the snowmobile
13. Clean and inspect the drive clutch and driven pul-
ley. causing corrosion.
14. Apply light oil to the shafts of the shock absorbers;

then lubricate all grease fittings (front and rear Preparation After
suspension, spindles, and upper steering shafts on
the CrossfirelM -Series or steering arms on the
Storage
Bearcat/F-Series/ZliT-Series) with a low-tempera-
ture grease. Taking the snowmobile out of storage and correctly
15. 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. Replace all
loose rivets. & CAUTION
On carbureted models if the gas in each carburetor
16. Clean and polish the hood, console, and chassis float chamber was not drained prior to storage, the
with Arctic Cat Hood and Windshield Cleaner/ carburetors must be cleaned before starting the
Polish. DO NOT USE SOLVENTS OR SPRAY engine.
CLEANERS. THE PROPELLENT WILL DAM-
AGE THE FINISH. 1. Clean the snowmobile thoroughly. Polish the exte-
rior of the snowmobile.
2. Clean the engine. Remove the cloth from the
exhaust system. Check exhaust system and air
silencer for obstructions.
3. Inspect all control wires and cables for signs of 13. On fan cooled models, clean the engine cooling
wear or fraying. Replace if necessary. Use cable fins and all shrouding.
ties or tape to route wires and cables away from
hot or rotating parts. 14. On electric start models, charge the battery; then
connect the battery cables making sure to connect
4. Remove and inspect the drive belt for cracks and the positive cable first. Test the electric start sys-
tears. Check belt specifications. Replace if dam- tem.
aged or worn. Install the drive belt.
15. Inspect the entire brake system, all controls, head-
-NOTE: For installing drive belt, see Removing! light, taillight, brakelight, ski wear bars, and head-
Installing Drive Belt in Section 6 of this manual. light aim; adjust or replace as necessary.
-NOTE: If the old belt is worn but in reasonable 16. Adjust the track to the proper tension and align-
condition, retain it with the snowmobile as a spare ment. Lock the jam nuts.
in case of emergency.
5. On carbureted models, inspect the in-line fuel fil- After Break-In Checkup
ter and replace if necessary. (100 Miles - 2-Strokel
600 Miles - 4-Stroke)
6. Inspect all fuel hoses and oil hoses for deteriora-
tion or cracks; replace if necessary. Make sure all
connections are tight; then on the 2-stroke models, Certain areas require adjustment after the break-in
fill the oil-injection reservoir with the recom- period in order to obtain peak performance. These
mended injection oil. areas are the following.
-NOTE: On the 2-stroke models after prolonged CARBURETOR JETTING (Carbureted Models)
storage, Arctic Cat recommends one tankful of - Altitude, temperature, and the use of oxygenated
100:1 gaS/oil mixture be used in conjunction with gasoline affect the carburetion needed for optimum
the oil-injection system to ensure proper lubrica- engine performance. The carburetor main jets must be
tion. changed in conjunction with changes in operating alti-
tude, oxygenated gasoline usage, and temperature.
7. On the 2-stroke models, inspect each spark plug.
Replace, gap, or clean as necessary. DRIVE BELT DEFLECTION - Drive belt deflec-
tion is very important to the snowmobile. Even if it is
8. Adjust the carburetor(s) and choke cable on carbu- checked and is correct when the snowmobile is set up,
reted models and throttle cable on all models. it does change (more so during the break-in period).
This is because the rubber engine mounts and the rub-
ber snubber on the torque link will all take a "set" dur-
& WARNING ing the first 100 miles allowing the distance between
On carbureted models, be sure to tighten the swivel the drive clutch and driven pulley to shorten. When
adapter jam nuts securely. If a jam nut isn't tightened, this happens, the snowmobile will appear to have a too
the adjuster can rotate out of the carburetor cap caus- long drive belt. To add to this, the drive belt itself
ing the piston valve not to return to the full-closed wears and stretches somewhat leading to a low-end
position. performance problem and, if not corrected, causes pre-
mature drive belt wear.
9. Tighten all nuts, bolts, and cap screws making sure
all calibrated nuts, bolts, and cap screws are tight- After the break-in period, drive belt deflection should
ened to specifications. be checked according to the instructions given in Sec-
tion 6 of this manual.
10. On the 120 cc, inspect the drive chain and drive
chain tightener. Replace if necessary; then lubri- DRIVE BELT BREAK-IN - For maximum drive
cate the binding screw drum with WD-40 and the belt life, allow the belt to break in before subjecting it
drive chain with a dry, graphite-based chain lubri- to hard use such as wide-open-throttle operation or hill
cant. climbing.
11. If not done during preparation for storage, lubricate The first 20 miles on the drive belt should be at 112
all grease fittings (front and rear suspension, spin- throttle or lower allowing the belt to gain its optimum
dles, and upper steering shafts on the Crossfire/M- flexibility and will extend belt life. Do not exceed 50
Series or steering arms on the BearcatlF -Series/Z 11 MPH during the first 20 miles.
T-Series) with a low-temperature grease.
If this procedure isn't followed, a new drive belt can
12. On liquid cooled models, check the coolant level be destroyed in less than 50 miles.
and all coolant hoses and connections for deterio-
ration or cracks. Add properly mixed coolant as
necessary.
1-8
To increase the life of a drive belt, the belt must be
warmed up before subjecting it to any type of use. In After Break-In Checkup
cold temperature (0° or below), the engine should be
allowed to idle for a period of 8 to 10 minutes allowing Checklist
heat from the engine compartment to soften the drive
belt. Not only will this procedure increase belt life but
will also help prevent engine damage from cold sei- Below is a recommended list of items to check after
zure. the break-in period. The recommended mileage for
this inspection is between 100 and 300 miles.
& WARNING o Jet carburetors according to average tempera-
When following this procedure, the operator must not ture, type of gasoline being used, and altitude
leave the snowmobile unattended during the warm-up (570 cc)
period.
o Check drive belt deflection - drive clutch/driven
Each operator should be instructed to drive the snow- pulley alignment and parallelism (800/1000/
mobile for several minutes at a low throttle setting to 1100cc)
warm the belt up before using wide-open-throttle. This
practice should be followed on all models for maxi- o Adjust track tension and alignment
mum belt life. o Check throttle cable tension
DRIVE CLUTCHIDRIVEN PULLEY o Check oil-injection pump adjustment (2-stroke)
ALIGNMENT - The parallelism and the offset
between the drive clutch and driven pulley are set at
o Check engine idle
the factory. Normally, no adjustment is necessary; o Check coolant level
however, if premature drive belt wear or poor perfor-
mance is experienced, the drive clutch/driven pulley o Check gear case lubricant level
alignment must be checked. o Check engine oil (4-stroke)
TRACK TENSION AND ALIGNMENT - A cer- o Check lights (high/low beam, brakelight)
tain amount of stretch occurs on all tracks during the
first 500 miles. The track must be adjusted after the
o Check safety switch operation
first 50 to 100 miles to the specifications given in the o Check engine compartment for any rubbing
Setup and Pre-Delivery Manual and periodically there- components
after. If these adjustments aren't performed, the track
may "derail" which leads to track and slide rail dam- o Check steering hardware for tightness
age. o Check skid frame and A-arm mounting hard-
ware for tightness
Along with these three major areas, other areas should
be checked and adjusted during the "After Break-In o Check brake lever travel and adjustment
Checkup." A checklist to assist you with this service
follows.
o Grease all lubrication points
Engine Specifications
(2-Stroke)
ITEM 500 cc 570 cc 600 cc 800 cc 1000 cc

Engine Model Number AX50L7 AA56A8 AJ60L6 AB80L3 AB10L3
Displacement 499 cc 565 cc 599 cc 794 cc 999 cc
No. of Cylinders 2 2 2 2 2
Bore x Stroke 71 x 63 73.8 x 66 73.8 x 70 85 x 70 90.3 x 78
Compression Ratio 6.38:1 6.41 :1 6.46:1 6.39:1 6.41 :1
Cooling System Liquid Fan Liquid Liquid Liquid
Fuel Mixture
Ignition Timing (Engine Warm)
Oil Injection
12° @ 2000 RPM
0.034 in.
Oil Injection
20° @ 2000 RPM
0.099 in.
Oil Injection
15° @ 2000 RPM
0.059 in.
Oil Injection
25° @ 3250 RPM
0.162 in.
Oil Injection
20° @ 3750
RPM*
0.113 in.
ro
@ 1800
RPM**
0.057 in.
Spark Plug (NGK) BR9EYA BR9EYA BR9EYA BR9EYA BR9EYA
Spark Plug Gap 0.028-0.031 in. 0.028-0.031 in. 0.028-0.031 in. 0.028-0.031 in. 0.028-0.031 in.
Piston Skirt/Cylinder Clearance 0.0030-0.0041 in. 0.0033-0.0045 in. 0.0030-0.0041 in. 0.0030-0.0041 in. 0.0030-0.0041 in.
Piston Ring End Gap 0.008-0.016 in. 0.012-0.0196 in. 0.012-0.0196 in. 0.012-0.0196 in. 0.012-0.0196 in.
Cylinder Trueness Limit 0.004 in. 0.004 in. 0.004 in. 0.004 in. 0.004 in.
Piston Pin Diameter 0.8659-0.8661 in. 0.7085-0.7087 in. 0.8659-0.8661 in. 0.8659-0.8661 in. 0.9447-0.9449 in.
Piston Pin Bore Diameter 0.8661-0.8665 in. 0.7087-0.7091 in. 0.8661-0.8665 in. 0.8661-0.8665 in. 0.9450-0.9453 in.
Connecting Rod Small End Bore 1.0631-1.0634 in. 0.9056-0.9059 in. 1.0631-1.0634 in. 1.0631-1.0634 in. 1.1418-1.1422 in.
Connecting Rod Radial Play 0.0001-0.0008 in. 0.0001-0.0008 in. 0.0001-0.0008 in. 0.0001-0.0008 in. 0.0001-0.0008 in.
Crankshaft Runout (t.i.r.) 0.002 in. 0.002 in. 0.002 in. 0.002 in. 0.002 in.
Crankshaft End Play 0.002-0.004 in. 0.002-0.004 in. 0.002-0.004 in. 0.002-0.004 in. 0.002-0.004 in.
Reed Stopper Height 0.315 in. 0.236 in. 0.433 in. 0.433 in. 0.512 in.
* F-Series
** Crossfire/M-Series
1-10
Engine Specifications Engine Specifications
(120 ee) (1100 ee)
ITEM 120 cc
ITEM 1100 cc
Engine Model Number AA12A2
Engine Model Number AA11L1
Displacement 119 cc
Displacement 1056 cc
No. of Cylinders 1
No. of Cylinders 2
Bore x Stroke 60 x 42
Bore x Stroke 98 x 70
Cooling System Air
Cooling System Liquid
Spark Plug (NGK) BPR6ES
Spark Plug (NGK) - Non-Turbo CR8EIB-9
Spark Plug Gap 0.028-0.031 in.
Spark Plug (NGK) - Turbo MR8AI-9
Piston SkirtiCylinder Clearance 0.0008-0.0047 in.
Spark Plug Gap - Non-Turbo 0.031-0.035 in.
Piston Pin Diameter 0.5898-0.5904 in.
Spark Plug Gap - Turbo 0.035 in.
Piston Pin Bore Diameter 0.5908-0.5917 in.
Piston SkirtiCylinder Clearance (Non-Turbo) 0.0011-0.0016 in.
Piston Pin/Connecting Rod Small End Clearance 0.0002-0.0020 in.
Piston SkirtiCylinder Clearance (Turbo) 0.0006-0.0010 in.
Piston Ring End Gap (1 stl2nd) 0.0079-0.0280 in.
Piston Pin Diameter (Non-Turbo) 0.8658-0.8661 in.
Piston Ring/Groove Clearance (1 stl2nd) 0.0012-0.0039 in.
Piston Pin Diameter (Turbo) 0.9447-0.9449 in.
Piston Ring Thickness 0.058-0.059 in.
Piston Pin Bore Diameter (Non-Turbo) 0.8662-0.8664 in.
Piston Diameter (10 mm from skirt edge) 2.3575-2.3618 in.
Piston Pin Bore Diameter (Turbo) 0.9449-0.9451 in.
Cylinder/Head Distortion (max) 0.0012 in.
Piston Pin/Connecting Rod Small End Clearance 0.0004-0.0010 in.
Connecting Rod Small End Bore Inside Diameter 0.5908-0.5917 in. (Non-Turbo)
Connecting Rod Big End Inside Diameter 1.0242-1.0246 in. Piston Pin/Connecting Rod Small End Clearance 0.0004-0.0009 in.
0.0079-0.0472 in. (Turbo)
Connecting Rod Big End Side Clearance
Piston Ring End Gap (1st) 0.0059-0.0138 in.
Cam Lobe Height (min) 1.189 in. (2nd) 0.0118-0.0177 in.
Crank Pin Diameter 1.0232-1.0236 in. (Oil) 0.0078-0.0275 in.
Crank Pin/Connecting Rod Clearance 0.0006-0.0028 in. Piston Ring/Groove Clearance (1st - Top) 0.0059-0.0074 in.
(1st - Bottom) 0.0008-0.0035 in.
Crankshaft Rod Journal (Out-of-Round/Taper) 0.004 in. (2nd) 0.0008-0.0024 in.
Crankshaft Runout (t.i.r.) 0.004 in. (Oil) 0.0024-0.0059 in.
Valve Guide Inside Diameter 0.2165-0.2170 in. Piston Diameter (10 mm from skirt edge) 3.8568-3.8574 in.
(Non-Turbo)
Valve Guide/Stem Clearance (max) (Int) 0.0032 in.
(Exh) 0.0039 in. Piston Diameter (10 mm from skirt edge) (Turbo) 3.8574-3.8580 in.
Valve Guide Bore Diameter 0.4409-0.4416 in. Cylinder/Head Distortion (max) 0.002 in.
Valve Face Width 0.032-0.039 in. Connecting Rod Small End Bore Inside Diameter 0.866-0.867 in.
(Non-Turbo)
Valve Face Runout (max) 0.0012 in.
Connecting Rod Small End Bore Inside Diameter 0.945-0.946 in.
Valve Clearance - Cold (59°_77° F) (IntlExh) 0.030-0.070 in. (Turbo)
Valve Seat Contact Width (IntlExh) 0.032-0.039 in. Cam Lobe Height (Non-Turbo) (Int) 1.487-1.489 in.
Valve Stem Diameter (IntlExh) 0.2150-0.2156 in. Cam Lobe Height (Turbo) (Int) 1.436-1.437 in.
Valve Stem Runout (max) 0.002 in. Cam Lobe Height (Non-Turbo) (Exh) 1.432-1.433 in.
Valve Spring Free Length (max) 1.22 in. Cam Lobe Height (Turbo) (Exh) 1.417-1.418 in.
Camshaft Journal Outside Diameter 0.8650-0.8658 in.
Camshaft Journal Bore Diameter 0.8666-0.8670 in.
Camshaft Journal Clearance 0.0007-0.0020 in.
Crank Pin Diameter 1.7707-1.7720 in.
Crankshaft Runout 0.002 in.
Crankshaft Main Bearing Clearance 0.0006-0.0016 in.
Crankshaft Thrust Runout (max) 0.0043 in.
Crankshaft Main/Rod Journals (Bearing Surfaces) 0.0012 in.
Valve Guide Inside Diameter 0.2165-0.2170 in.
Valve Guide/Stem Clearance (max) (Int) 0.0015 in.
(Exh) 0.0022 in.
Valve Face Width 0.0197 in.
Valve Clearance - Cold (59°_77° F) (Int) 0.0039-0.0078 in.
(Exh - Non-Turbo) 0.0078-0.0118 in.
(Exh - Turbo) 0.0118-0.0157 in.
Valve Seat Contact Width (IntlExh) 0.0354-0.0433 in.
Valve Stem Diameter (Int) 0.2155-0.2161 in.
(Exh) 0.2147-0.2153 in.
-NOTE: We have given the proper location for
Cylinder Head Volume checking crankshaft runout as the very edge of the
straight portion of the shaft where the oil seal
Specifications 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
-NOTE: For cylinder head volume tests, see bearing race. The crankshaft is still supported on
appropriate Measuring Critical Components sub- the outer bearings using V blocks.
section in Section 2.
ENGINE TYPE SQUISH - GAP --A-I

500 cc
570 cc
0.059 in.
0.066 in.
iB-1 ------
600 cc 0.059 in.
800 cc 0.059 in.
1000 cc 0.058 in.
A CAUTION
These specifications are not intended to be used for
engine modification. Reducing the head volume to a
smaller specification could cause piston detonation
problems which is not a warranty situation.
728-144A
Engine Piston Travel

Versus Crank Angle
(2-Stroke)
570 cc in.
-NOTE: When using the chart below, first know 73.8 x 66
the engine stroke and timing in degrees; then read 600 cc in.
73.8 x 70
across from the degree figure to find timing. 800 cc in.
85 x 70
500 cc 6001800 cc 570 cc 1000 cc 1000 cc in.
90.3 x 78
63mm 70mm 66mm 78mm
stroke stroke stroke stroke
-NOTE: Measure in from the shaft end the speci-
Degrees
BTDC
BTDC BTDC BTDC BTDC fied amount when checking runout at points D and
12 0.034 in. 0.038 in. 0.036 in. 0.042 in. F. When checking runout in the center, place indi-
15 0.053 in. 0.059 in. 0.056 in. 0.065 in. cator on center of bearing as shown at point E.
18 0.076 in. 0.085 in. 0.081 in. 0.093 in. Maximum runout at any of the three measuring
20 0.094 in. 0.105 in. 0.099 in. 0.113 in. points is ± 0.002 in.
Crankshaft Runoutl
Repair Specifications
(2-Stroke)
For those who have crankshaft work sent out to

another shop, provide them with this information.
To use the specifications, first refer to the drawing;
then find the letter which indicates the specification
and refer to the chart below the illustration. Be sure to
note the proper engine row.
1-12
Fraction/Decimal MM/IN. Conversions
Conversions
8ths 16ths 32nds 64ths 64ths

1/8 = 1/16 = .0625 1/32 = .03125 1/64 = .015625 33/64 = .515625
.125
1/4 = 3/16 = .1875 3/32 = .09375 3/64 = .046875 35/64 = .546875
.250
3/8 = 5/16 = .3125 5/32 = .15625 5/64 = .078125 37/64 = .578125
.375
1/2 = 7/16 = .4375 7/32 = .21875 7/64= .109375 39/64 = .609375
.500
5/8 = 9/16 = .5625 9/32 = .28125 9/64 = .140625 41 /64 = .640625
.625
3/4 = 11/16 = .6875 11/32 = 11/64 = 43/64 = .671875
.750 .34375 .171875
7/8 = 13/16 = .8125 13/32 = 13/64 = 45/64 = .703125
.875 .40625 .203125
- 15/16 = .9375 15/32 = 15/64 = 47/64 = .734375
.46875 .234370
- - 17/32 = 17/64 = 49/64 = .765625
.53125 .265625
- - 19/32 = 19/64 = 51/64 = .796875
.59375 .296875
- - 21/32 = 21/64 = 53/64 = .828125
.65625 .328125
- - 23/32 = 23/64 = 55/64 = .859375
.71875 .359375
- - 25/32 = 25/64 = 57/64 = .890625
.78125 .390625
- - 27/32 = 27/64 = 59/64 = .921875
.84375 .421875
- - 29/32 = 29/64 = 61/64 = .953125
.90625 .453125
- - 31/32 = 31/64= 63/64 = .984375
.96875 .484375
Torque Conversions Assembly Schematicsl
(ft-lb/N-m) Torque Specifications
(Table of Contents)
Servicing Symbols .... .. ...... ..... ...... .. ....... ... ....... ... .... 1-14
120 cc .................................................................... 1-15
570 cc .................................................................... 1-16
500 cc .................................................................... 1-18
OOO~ .................................................................... 1~0
800 cc .................................................................... 1-22
1000 cc .................................................................. 1-24
1100 cc .................................................................. 1-26
Servicing Symbols
Listed in the table below are symbols indicating spe-

cial instructions and other important information nec-
essary for proper servicing. Please note the definition
for each symbol.
-NOTE: Before engine assembly, ensure all
threaded areas are clean to assure an accurate
torque value is achieved.
& CAUTION
Torque values have a range of + or - 20%.
SYMBOL DESCRIPTION
Torque control required
~_ID'
243 - apply blue Loctite #243
271 - apply red Loctite #271
Tightening Torque Lubricate with Arctic Cat 50:1

Injection Oil - Non-APV Engines
(General Bolts) Lubricate with Arctic Cat Synthetic APV
2-Cycle Oil - APV Engines
Thread
Type of Bolt Diameter A Tightening
Torque
(mm)
(Conventional or 4 Marked Bolt) 5 12-36 in.-Ib
Lubricate with Arctic Cat
® ~~ 6 36-60 in.-Ib
','1"1 , '
T · ' I.I., - .qj 8 7-11 ft-Ib
Low-Temp Grease
10 16-25 ft-Ib
(7 Marked Bolt) 5 24-48 in.-Ib
3B - Three Bond Sealant
wmmtll« (j 6
8
6-8 ft-Ib
13-20 ft-Ib
HT - High-Temp Sealant
AS - Anti-Seize Thread Compound
10 29-43 ft-Ib
1-14
120 cc
. t e
~
96 in.-Ib
~ : . / 20 ft-Ib
.~ ' P @@~
""\~20 ft-Ib
~
I 96 in.-Ib
18 ft-Ib
~
15 ft-Ib
120-ENG09
2009 Arctic Cat Snowmobiles Factory Service Manual - all Models - www.ReadManuals.com1-15
570 cc
~
96 in.-Ib
@ ®
~ ©
(i)
@
IJJ
~y c€
7
® ® Q) 0
11 4 210
570-ENG09
1-16
~
28 ft-Ib
~
48 in.-Ib
~
15 ft-Ib
fJIJ-~~-·
48 in.-Ib ~ 96 in.-Ib
..... . .-
570ENG09
2009 Arctic Cat Sn owmobiles Factory S ervlce

. Manual - all Mod es-
I wwwR
. eadManuals.com 1-17
500 cc
<D 0
-~<D
\
< ~
96in.·lb
108 in.·lb
500CC1A09
1-18
~
96 in.-Ib
(C) 6 mm 96 in .-Ib
(D) Coolant Temperature Sensor 18 ft-Ib •
~ 20ft-lb ~ (A)
, f;!i!J~ 15ft.O._:
(A)
.
crossfire..:
/ 4fC <lll- "
'-
"~ (A)
~
22 ft-Ib (B)
""-------~'," ~- 5
G @.
/~ .-
•~
24 ft-Ib
~
F5/T500 /
0
~
50 ft-Ib
/ 3~~
~
~ -~ ~ ." ~
:,,;r:::: 25ft-lb
23ft-lb " ;~/ ",
<lll-,
~
15 ft-Ib
600 cc
@
®
(Do(D
ill
ill
~----1
0 0
@ CD (!) @
(J) ill
--
1>--
48 in.·lb >--/
\ >-- 48 in.·lb
96 in.·lb
>--
96 in.·lb
1-20
. Manual - all Models - www. ReadManuals.com
2009 Arctic Cat Snowmobiles Factory Service
~
96 in.·lb
(A) 10 mm Step 1: 13 ft-Ib

Step 2 : 31 It-Ib
(8) 6 mm 96In .·lb (8) (A) (8) (A)(C) (8)
(A) 1· i..'1"- -o'k '©J lk-
;.1..1 Vl II
I ~/o ~ j _II
(A)
(A) ~ -~I"-:''-@I
81J8 ~I
'l:Jttt:J ~'~
(A) (A) (A)
(C)Coolant Temperature Sensor 18 I t . l b .
~
20ft·lb
16ft·lb
F-Series
~ ~,.-
50 ft . Ib \ \ 25f!
.lb ; ' ~ 15ft·lb
~
.~~'~~.v~
~ "'<:J
23 ft· lb '- ~..., '.
j~
@:j~
~
25 ft·lb ,
~~
@
~
' ... 48 in.·lb
800 cc
*
9 513
I
I
®
@ <D ill 0 ®
@ 0 ill @ 0 @
ill ®
* Accessible from Top Side
:J ·
(A) 10 mm Step 1: 13 ft-Ib
Step 2: 31 ft·lb :J • :J
19ft·lb 17 ft·lb
(8) 8 mm 25 ft-Ib (Knock Sensor)
(C) 6 mm 96 in.-Ib
(D) Coolant Temperature Sensor 18 ft·lb . .
:J ·
/ 96in.·lb
800 09 1
1-22
:J
96 in.-Ib
30 ft-Ib
F-Series
:J. :J.
50 ft-Ib \ 25 ft-~
Ib :J 17ft-lb
--~ _\
f'J Ai .,~~
23 ft-Ib
"
-
19 ft·lb
96 in.-Ib
800 09 2
1000 cc
® ill <D @
0 0
@
0
ill ill 0
@
/~ ill @ ® ill
'"
~ *
14
18 ft·lb I
:J -
(8 )
(8 ) 6 mm 96 in.·lb
(A) * Accessible from Top Side
~
19 ft·lb
~~
~
96 in.·lb
~
____ J
0:>
-~ ~ / ~ 48in.·lb
c(;<::e /
..
( ,.'~' . t?
. ' .
. '-'" 'J..'
.. ~
48 in.·lb
~~~~U
~~
il~ /
~
50ft.lb
1000 09 2
1-24
~ F-Series
96 in.-Ib - -~/6' 9Yo'
" 0J
~
,~
501t-lb ,
. (
~
501t.lb ~ QP
/
.'
~ (!PeP
iCa
25 It-Ib
~
50 It-Ib
•
~
108 in.-Ib
2009 Arctic Cat S nowmobiles Facto ry Service Ma nual - all Models - www.ReadManuals.com 1-25
1100 cc
Engine Case Torque Va lue

15 ft-Ib
Qty 4 - 96 in.-Ib
• 6 mm Cap Screw S 1 120 in -Ib
at 18 - Step
.. 8 mm Cap Screw y
tep
2 19 ft-Ib
.
... 10 mm Cap Screw Oty

6 - Step 1 13 ft -Ib
Step 2 33 ft-Ib
1100ccJAG09
1-26
- Manual - all Models - www.ReadManuals.com
2009 Arctic Cat Snowmobiles Factory Service
84 in.-Ib
60 in.-Ib
60 in.-Ib , '~
84 in.-Ib
30 ft-Ib
1100ccZ1RV09
2009 Arctic Cat Snowmobiles Facto ry Service

. Manual - all Models - www.ReadManuals.com 1-27
Engine Torque Patterns
(1100 ee)
Engine Case Oil Separator Plates
741-582A 741-737A
Oil Pan Plate Oil Pan
741-738A 741-584A
Cylinder Head
741-617A
1-28
Camshaft Cover Engine Cover
741-624A 741-580A
Magneto Cover Exhaust Manifold
741-583A 744-0038
Crossfire/M-Series
Arctic Povver Valve (800/1000 ee)
(APV) System Servomotor
/
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
742-209A
ENGINE VALVE POSITION CYCLE RPM
600 cc Full-Open 73-7400 (Low/High All) APV CABLE LENGTH
800 cc Mid-Open 60-6500 (Low/High All) ENGINE CENTER ± 0.039 in.
Full-Open 78-8100 (Low/High All) 600 cc 1.417 in.
1000 cc Mid-Open 6300 (Low/High All) 800 cc 1.377 in.
Full-Open 6500 (Low/High All)
1000 cc 1.319 in.
-NOTE: The 800 cc and 1000 cc have a three-stage

exhaust valve system. The stages are closed, mid-
open, and full-open. Each model has a designated
RPM at which the system is synchronized and
checked by the ECU for proper operation occuring
once each time the engine is started. The 800 cc
system is checked at 4800 RPM and the 1000 cc
system is checked at 6100 RPM (CrossfirelF-
Series) or at 6270 RPM (M-Series).
F-Series
• 0735-516
Servomotor
741-635A
Crossfire/M-Series
(600 ee)
Support Tube -"...
Steering Post
739-715A
1-30
Oil Consumption Fuel Pump
Specifications Specifications
(2-Stroke) (570 ee)
FULL-CLOSED RPM PSI KG/CM 2

FULL-OPEN
ENGINE RPM (Idle)
2 Minutes 1000-2000 3.0-3.5 0.21-0.25
3 Minutes
500 cc 1833 1.0-2.5 cc 7.4-10.3 cc 3000-4000 4.5-5.5 0.32-0.39
570 cc 2000 1.4-2.2 cc 6.9-9.4 cc
600 cc 1833 1.3-3.2 cc 10.9-15.2 cc
800 cc 1833 1.32-3.48 cc 8.74-10.8 cc
1000 cc 1833 1.96-3.57 cc 8.96-10.72 cc
Carburetor
EFI Specifications Specifications
Fuel Pressure (2-Stroke) 42.8-47.3 psi
Fuel Pressure (1100 cc Non-Turbo) 43.5 psi
Fuel Pressure (1100 cc Turbo) 36.0 psi - Idle
55.0 psi - Full Boost
PILOT AIR FLOAT HEIGHT MAIN PILOT THROTTLE

SCREW SETTING
Throttle Valve Angle (TURNS OUT) (mm) AIR JET OUTLET VALVE
Specifications
1 1/2 22-24
-NOTE: The above specifications are production

TPSTOOL ANALYZER TOOL
(DC VOLTS) (DC VOLTS) settings. For high altitude jetting and settings,
500 cc Idle 0.710-0.818 0.710-0.818 refer to the jet chart beneath the snowmobile
Full-Open 3.472-4.048 3.470-4.046 hood. For optional tuning components, see the
600 cc Idle 0.646-0.754 0.646-0.754 Quick Reference Guide.
Full-Open 3.472-4.485 3.470-4.046
DIAGNOSTIC TOOL
800 cc Idle 0.646-0.754 3.99° -6.66°
Full-Open 3.472-4.485 74.97"-89.37"
1000 cc Idle 0.591-0.699 4.75°-7.55°
Full-Open 3.477-4.054 77.39°-91.66°
1100 cc Idle 1.100-1.140 8.5°
Non-Turbo
Full-Open 4.300-4.500 90°
1100 cc Turbo Idle 0.690-1.110 10°
Full-Open 4.000-4.200 90°
-NOTE: Breaking the seal on the idle screw jam

nut or the screws on the TPS will void warranty.
Electrical
Specifications
(570 ee)
-NOTE: The ignition system is a Normally Open Ignition (NOI).
Resistance Test
Description
Test Value
+ Test Connections -
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 green/red
Charge Coil (2) 12-18 ohms brown/white green/red
Ignition Timing Sensor 148-222 ohms green/white brown
Lighting Coil 0.12-0.18 ohm yellow yellow
Spark-Plug Cap 4000-6000 ohms cap end cap end
Description Test Value + Test Connections -
Voltage Regulator/Rectifier 11-14 AC volts yellow brown
Low Oil-Light Sending Unit Less than 1 ohm (float end down) terminal terminal
Ignition Switch Less than 1 ohm (key in OFF posi- terminal terminal
tion)
Description Peak Voltage Test + Test Connections -
Primary Coil (External) 254-266V orange black/white
Charge Coil (1) 13.7-15.4V black/red green/red
Charge Coil (2) 14.5-15.7V brown/white green/red
Ignition Timing Sensor 4.8-6.4V green/white brown
Lighting Coil 6.5-7.0V yellow yellow
Peak Voltage Tests were made with the Fluke Model 73 Multimeter (pin 0644-191) set to the DC Volt scale and the
Peak Voltage Reading Adapter (pin 0644-307) with the main harness connectors plugged in (except on the primary
coil/CCU tests), spark plugs removed and grounded, and by pulling the recoil starter rope briskly.
-NOTE: Lighting coil output is unregulated voltage.
A WARNING
Most voltages generated by the ignition system are sufficient to interrupt pacemakers! All technicians, especially
those using pacemakers, must avoid contact with all electrical connections when pulling the recoil starter rope or
after the engine has been started.
1-32
Electrical
Specifications
(500 ee)
Resistance Test
Description
Test Value
Ignition Coil
Primary 0.24-0.36 ohm orange/black orange/red
Charge Coil (1) 7.2-10.8 ohms black/red green/red
Charge Coil (2) 7.2-10.8 ohms brown/white green/red
Ignition Timing Sensor 80.8-121 ohms green/white brown/green
Injection Coil 15.2-22.8 ohms blue/white blue/white
Fuel Pump Coil 1.52-2.28 ohms orange orange
Chassis Control Unit* 10-15 DC Volts red/blue (low power) black (low power)
(Crossfire/F-Series) red/black (high power) black (high power)
Voltage Regulator/Rectifier 10-15 DC Volts red/blue black
(T500) 11-14 AC Volts yellow black
Ignition Switch Less than 1 ohm (key in OFF position) terminal terminal
Primary Coil* 104V orange/black orange/red
Lighting Coil 8.3V yellow yellow
Ignition Timing Sensor 4.8V green/white brown/green
Injection Coil 13.2V blue/white blue/white
Fuel Pump Coil 12.8V orange orange
Lighting Coil 14.8-22.2V (@ 2000 RPM) yellow brown
* Harness plugged III
-NOTE: To test the coolant temperature sensor, see Section 5.
Peak Voltage Tests were made at room temperature with the MaxiClips (pin 0744-041), Fluke Model 73 Multime-
ter (pin 0644-191) set to the DC Volt scale, and the Peak Voltage Reading Adapter (pin 0644-307). Also, the main
harness connectors must be unplugged (except on the primary coil/CCU tests), the spark plugs removed and
grounded, and by pulling the recoil starter rope briskly.
A WARNING
Electrical
Specifications
(600 ee)
Resistance Test
Description
Test Value
Ignition Coil
Primary 0.24-0.36 ohm orange/black orange/red
Ignition Timing Sensor 80.8-121 ohms green/white brown/green
Chassis Control Unit* 10-15 DC Volts red/blue (low power) black (low power)
red/black (high power) black (high power)
Servomotor 12 DC Volts red/black (counterclockwise) black/red (counterclockwise)
black/red (clockwise) red/black (clockwise)
Primary Coil* 104V orange/black orange/red
Lighting Coil 8.3V yellow yellow
Ignition Timing Sensor 4.8V green/white brown/green
Injection Coil 13.2V blue/white blue/white
* Harness plugged III
Peak Voltage Tests were made at room temperature with the MaxiClips (pin 0744-041), Fluke Model 73 Multime-
ter (pin 0644-191) set to the DC Volt scale, and the Peak Voltage Reading Adapter (pin 0644-307). Also, the main
harness connectors must be unplugged (except on the primary coil/CCU tests), the spark plugs removed and
grounded, and by pulling the recoil starter rope briskly.
A WARNING
1-34
Electrical
Specifications
(800 ee)
Resistance Test
Description
Test Value
Ignition Coil
Primary 0.24-0.36 ohm black/white white/blue
Secondary 5040-7560 ohms high tension wire high tension wire
Ignition Timing Sensor (1) 148-222 ohms blue/white brown/green
Ignition Timing Sensor (2) 148-222 ohms green/white brown/green
Voltage Regulator/Rectifier* 10-15 DC Volts red/violet black
(F-Series)
Voltage Regulator/Rectifier* 10-15 DC Volts red/blue black
(Crossfire/M-Series) 11-14 AC Volts yellow black
Servomotor 12 DC Volts red/black (counter- black/red (counter-
clockwise) clockwise)
MAG Primary Coil (Harness Sider 125-137V orange/red orange/black
PTa Primary Coil (Harness Sider 126-139V white/red white/black
Ignition Timing Sensor (1) 4.3V blue/white brown/green
Ignition Timing Sensor (2) 4.4V green/white brown/green
Injection Coil 6.8-7.3V blue/white blue/white
* Malll harness plugged III
Peak Voltage Tests were made at room temperature with the MaxiClips (p/n 0744-041), Fluke Model 73 Multime-
ter (p/n 0644-191) set to the DC Volt scale, and the Peak Voltage Reading Adapter (p/n 0644-307). Also, the main
harness connectors must be unplugged (except on the primary coil and voltage regulator/rectifier tests), the spark
plugs removed and grounded, and by pulling the recoil starter rope briskly.
A WARNING
Electrical
Specifications
(1000 ee)
Resistance Test
Description
Test Value
Ignition Coil
Primary 0.24-0.36 ohm black/white white/blue
Secondary 5040-7560 ohms high tension wire high tension wire
Ignition Timing Sensor (1) 148-222 ohms blue/white brown/green
Ignition Timing Sensor (2) 148-222 ohms green/white brown/green
Voltage Regulator/Rectifier* 10-15 DC Volts red/violet black
(F-Series)
Voltage Regulator/Rectifier* 10-15 DC Volts red/blue black
(Crossfire/M-Series) 11-14 AC Volts yellow black
Servomotor 12 DC Volts red/black (counter- black/red (counter-
clockwise) clockwise)
MAG Primary Coil (Harness Sider 125-137V orange/red orange/black
PTa Primary Coil (Harness Sider 126-139V white/red white/black
Ignition Timing Sensor (1) 4.3V blue/white brown/green
Ignition Timing Sensor (2) 4.4V green/white brown/green
Injection Coil 6.8-7.3V blue/white blue/white
* Malll harness plugged III
Peak Voltage Tests were made at room temperature with the MaxiClips (p/n 0744-041), Fluke Model 73 Multime-
ter (p/n 0644-191) set to the DC Volt scale, and the Peak Voltage Reading Adapter (p/n 0644-307). Also, the main
harness connectors must be unplugged (except on the primary coil and voltage regulator/rectifier tests), the spark
plugs removed and grounded, and by pulling the recoil starter rope briskly.
A WARNING
1-36
Electrical
Specifications
(1100 ee)
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 173-211 ohms green blue
Coolant Temperature Sensor 2.3k-2.6k ohms yellow/black ground
Injection Coil Starter Relay 3.6 ohms black/yellow black
These tests were made at room temperature with the MaxiClips (pin 0744-041), Fluke Model 73 Multimeter (pin
0644-191), and the Peak Voltage Reading Adapter (pin 0644-307). For ignition coil peak voltage test, the battery
must be fully charged. Also, the main harness connectors must be unplugged (except on the voltage regulator/recti-
fier test).
& WARNING
600 cc
Ignition Timing
Ignition Timing - Engine Warm
Specifications BTDC - 15°/2000 RPM - 0.059 in.
(2-Stroke)
Not Adjustable
500 cc
BTDC - 12°/2000 RPM - 0.034 in.
Not Adjustable
ROTATING DIRECTION
I~~:::~i, i!!~~
~_j-C_BT_DC_2_40 _ _ _---,
740-130A
800 cc
-NOTE: For timing verification, use a dial indicator
•
Rotating Direction and scribe a mark on the flywheel for 25° BTDC.
0742-218 Ignition Timing - Engine Warm

BTDC - 25°/3250 RPM - 0.162 in.
570 cc Not Adjustable
BTDC - 20°/2000 RPM - 0.099 in. ~
Not Adjustable 'Y~
BlDC 18°
/.' J BlDC
:::;I~~_ I::~
BlOC
BlDC 16°
14" 21l"
BlDC 2T
BlDC IT ! - BlDC 24°
Q,'"lrl/"
II
~3J(-
~/I
~ •
Rotating Direction
0742-217
0744-033
1-38
1000 cc 1000 cc (F-Series)
(Crossfire/M-Series)
Ignition Timing - Engine Warm BTDC - 20°/3750 RPM - 0.113 in.
BTDC - 14°/1800 RPM - 0.057 in. Not Adjustable
Not Adjustable
:
BTDC 15" i
BlDC 16"
BTDCIII"
BTDC 20"
:::~~ ifI
i~::~
BTDC 14" i BTDC 22"
BlDC 8"~_Ir=BlDC211"
I
•
Rotating Direction
0744-035
0744-034
BearcatIF-SerieslT-SerieslZ1
Steering/Body Torque Item
Torque
ft-Ib
Specifications Ski 26
Spindle Arm/Spindle** 30
Suspension Arm/Spindle 32
120 Sno Pro
Front Suspension Arm (Upper) 32
Torque
Item Front Suspension Arm (Lower) 32
ft-Ib
Tie Rod End (Spindle)* 15 Steering Arm/Spindle* 40
Inner Tie Rod End/Steering* 20 Steering Arm/Suspension Mounting Bracket 20
Ski Shock/Shock Mount 20 Sway Bar Mounting Bracket/Suspension Mounting Bracket 120 in.-Ib
A-Arm/Spindle 30 Tie Rod Jam Nut** 13
A-Arm/Chassis 30 Spindle Arm and Steering ArmlTie Rod* 30
Ski/Spindle 20 Steering Post/Chassis* 35
CrossfirelM-Series Steering Post/Steering Tie Rod* 35
Ski 35 Steering Tie Rod/Steering Arm 30
Handlebar Adjuster Block/Post (Standard) 120 in.-Ib Drag Link/Steering and Spindle Tie Rods* 35
Handlebar Adjuster (Sno Pro) 20 Steering Post/Suspension Mounting Bracket* 35
Steering Post Mounting Block 96 in.-Ib Drag Link/Steering Arm (Bearcat/F-SerieslT-Series)** 12
Steering Post/Stop* 30 Drag Link/Steering Arm (Z1)** 120 in.-Ib
Steering Tie Rod/Shaft Arm* 30 Shock Absorber/Shock Mounting Frame 32
(Bearcat/F-SerieslT-Series)
Steering ArmlTie Rod 30
Shock Absorber/Shock Mounting Frame (Z1) 32
Steering PostlTie Rod* 30
Bearing Cap/Spindle** 13
Steering Link/Steering Arm 20
Upper Bearing Bracket/Support Plate** 96 in.-Ib
Spindle ArmlTie Rod 30
Shock Absorber/Spindle 32
Suspension Arm/Spindle (Upper) 30
Suspension Mounting Bracket/Chassis (Lower) 96 in.-Ib
Suspension Arm/Spindle (Lower) (Crossfire) 40
Suspension Mounting Bracket/Chassis (Upper) 20
Suspension Arm/Spindle (Lower) (M-Series) 30
Steering Support Plate/Steering Support 96 in.-Ib
Sway Bar Link/Front Arm (Crossfire) 96 in.-Ib
Shock Mount Frame/Suspension Mounting Bracket 96 in.-Ib
Shock Absorber/Spindle 20
Shock Mount Frame/Front Upper Frame 20
Front Suspension Arm/Chassis* (Upper) 30
Spindle Retainer/Spindle** 13
Front Suspension Arm/Chassis* (Lower) 30
Front Bumper (Bearcat) 32
Steering Post/Chassis* 30
Rear Bumper/Heat Exchanger** 25
Steering Support/Chassis** 20 (Bearcat/F-SerieslT-Series)
Center Steering Link/Steering Arm* 20 Rear Bumper/Heat Exchanger** (Upper) (Z1) 25
Gas Tank/Steering Support 96 in.-Ib Rear Bumper/Heat Exchanger** (Lower) (Z1) 20
Rear RacklTunnel (Bearcat XT) 20
* w/Green Loctite #609 * w/Green Loctlte #609
** w/Blue Loctite #243 ** w/Blue Loctite #243
1-40
Drive System
Specifications
Drive Clutch/Driven Arctic Cat Drive Belt

Pulley-Related Dimensions
Specifications
BELT PIN LENGTH WIDTH
ALIGNMENT BAR *0627-046 46 ± 3/16 inch 1 29/64 inch
MODEL OFFSET CENTER- *0627-047 4317/32 ± 3/16 inch 1 29/64 inch
PIN TO-CENTER OFFSET FLOAT
**0627-060 46 ± 3/16 inch 1 29/64 inch
Crossfire/M-Series 0644-427 11.50" 1.655" None
**0627-066 43 17/32 ± 3/16 inch 1 29/64 inch
Z1ITZ1 /Bearcat Z1 XT 0644-727 10.20" 1.655" None
**0627-067 45 13/32 ± 3/16 inch 1 13/32 inch
Bearcat 570/F-Series/ 0644-496 11.50" 1.507" None
T-Series
*Double-Cog High Performance Belt w/Hard Compound
& CAUTION **Double-Cog High Performance Belt w/High COF Compound
Do not allow the driven pulley to "float" on the output -NOTE: The difference between Drive Belt (pIn
shaft or damage to the driven pulley will occur. 0627-046) and Drive Belt (pIn 0627-060) is the hard-
ness. The Drive Belt (pIn 0627-060) is more flexi-
Parallelism ble, and if used in place of Drive Belt (pIn 0627-
800 eel 1 000 ee/11 00 ee 046), the engine will run at a lower RPM.
Drive System
---'---~--- = Components
;9
C J
--r- C
~
0.060 in.
0.040 in.
~
A list of Arctic Drive Clutch and Driven Pulley com-

ponents that are available through the Arctic Cat Ser-
vice Parts Department can be found in the Quick
Reference Guide. This information will be useful
0743-410
when doing any fine-tuning on the drive system.
-NOTE: See Section 6 in this manual for alignment
and parallelism procedures.
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)
66 54 91 94 97 100 103 106 109 112 114 117 120 123 126 129 132
65 55 88 91 94 96 99 102 105 108 111 113 116 119 122 125 128
64 56 85 88 91 93 96 99 102 104 107 110 112 115 118 121 123
63 57 82 85 88 90 93 96 98 101 103 106 109 111 114 117 119
62 58 80 82 85 87 90 92 95 98 100 103 105 108 110 113 115
61 59 77 79 82 84 87 89 92 94 97 99 102 104 107 109 112
9 Tooth 60 60 74 77 79 82 84 86 89 91 94 96 98 101 103 106 108
(2.52" pitch)
59 61 72 74 77 79 81 84 86 88 91 93 95 98 100 102 104
58 62 70 72 74 76 79 81 83 85 88 90 92 94 97 99 101
57 63 67 70 72 74 76 78 80 83 85 87 89 91 93 96 98
56 64 65 67 69 71 74 76 78 80 82 84 86 88 90 92 95
55 65 63 65 67 69 71 73 75 77 79 81 83 85 87 89 91
54 66 61 63 65 67 69 71 73 75 77 79 81 83 84 86 88
66 54 101 104 108 111 114 117 121 124 127 130 134 137 140 143 147
65 55 98 101 104 107 110 113 117 120 123 126 129 132 136 139 142
64 56 95 98 101 104 107 110 113 116 119 122 125 128 131 134 137
63 57 91 94 97 100 103 106 109 112 115 118 121 124 127 130 133
62 58 88 91 94 97 100 103 106 108 111 114 117 120 123 125 128
61 59 85 88 91 94 97 99 102 105 108 110 113 116 119 121 124
10 Tooth 60 60 83 85 88 91 93 96 99 101 104 107 109 112 115 117 120
(2.52" pitch)
59 61 80 83 85 88 90 93 95 98 101 103 106 108 111 114 116
58 62 77 80 82 85 87 90 92 95 97 100 102 105 107 110 112
57 63 75 77 80 82 84 87 89 92 94 97 99 101 104 106 109
56 64 72 75 77 79 82 84 86 89 91 93 96 98 100 103 105
55 65 70 72 74 77 79 81 84 86 88 90 93 95 97 99 102
54 66 68 70 72 74 76 79 81 83 85 87 89 92 94 96 98
66 54 96 99 102 106 109 112 115 118 121 124 127 130 134 137 140
65 55 93 96 99 102 105 108 111 114 117 120 123 126 129 132 135
64 56 90 93 96 99 102 105 107 110 113 116 119 122 125 128 131
63 57 87 90 93 95 98 101 104 107 110 112 115 118 121 124 126
62 58 84 87 90 92 95 98 100 103 106 109 111 114 117 119 122
61 59 81 84 87 89 92 95 97 100 102 105 108 110 113 116 118
8 Tooth 60 60 79 81 84 86 89 91 94 97 99 102 104 107 109 112 114
(3.0" pitch)
59 61 76 79 81 84 86 88 91 93 96 98 101 103 106 108 111
58 62 74 76 78 81 83 86 88 90 93 95 97 100 102 105 107
57 63 71 74 76 78 80 83 85 87 90 92 94 97 99 101 103
56 64 69 71 73 76 78 80 82 84 87 89 91 93 96 98 100
55 65 67 69 71 73 75 77 80 82 84 86 88 90 92 95 97
54 66 64 67 69 71 73 75 77 79 81 83 85 87 89 91 94
Shaded rows indicate existing tooled gear ratios
1-42
Drive System Torque Bearcat XT
Item
Torque
ft-Ib
Specifications Wear Strip/Rail 50 in.-Ib
End Cap/Rail 80 in.-Ib
Mounting Block/Rail 20
120 Sno Pro
Idler Wheel/Mounting Block 20
Item Torque Slide Block/Rail 20
ft-Ib
Pivot Arm/Idler Arm 20
Centrifugal Clutch** 20
Rear Arm/Rail 40
Secondary Sprocket** 20
Rear Arm/Idler Arm 40
Drive Sprocket Bearing/Chassis 20
Front Arm/Rail 40
BearcatIF-SerieslM-SerieslCrossfireIT-SeriesIZ1
Idler Wheel/Shock Bracket - Rail 40
Drive Clutch 55 Idler Wheel/Pivot Assembly - Rail 40
Spider* 250 Rear Arm Shock Pivot Axle/Rail 40
Spider Retainer Nut* 85 Front Arm Shock Bracket Axle/Rail 40
Drive Clutch Cover** 120 in.-Ib Rear Arm Limiter/Rail* 40
Cam Arm Pin Lock Nut 11 Front Rail Support/Rail* 20
Cam Arm Set Screw* 19 in.-Ib Limiter Strap/Rail Support 120 in.-Ib
Drive Clutch/Ring Gear* 22 Spring Slide Block/Rail 20
Driven Pulley 32 Outer Idler Wheel Mounting Block/Rail 20
Driven Shaft Jam Nut 40 Articulating Skid Frame/Rail 20
Torque Bracket 66 in.-Ib RaillTunnel 40
Brakeline Fitting/Caliper 10.5 Crossfire/Crossfire R
Brakeline/Master Cylinder 21 Wear Strip/Rail 50 in.-Ib
Torque Bracket Cover 72 in.-Ib End Cap/Rail 80 in.-Ib
72 in.-Ib Mounting Block/Rail 20

Movable Sheave
Idler Wheel/Mounting Block 20
Speedometer Sensor Bracket 17
Spring Slide/Slide Block - Rail (Standard) 40
Gear Case/Chassis 20
Spring Slide/Slide Block - Rail (R) 34
Brake Caliper Housing/Chassis 20
Pivot Arm/Idler Arm (R) 20
Outside Caliper Housing/Inside Caliper Housing 17
Idler Wheel Axle/Rail 40
Gear Case Cover 12.5
Rear Arm/Rail 40
Gear Case Drain Plug 12 Rear Arm Limiter/Rail* 40
Driveshaft/Output Shaft Cap Screw** 70 Front Arm Mounting Bracket/Rail (R) 20
Driveshaft/Brake Disc Retaining Nut 120 Rear Shock Pivot/Inner Idler Wheel - Rail 40
Shift Actuator/Gear Case 41 in.-Ib Front Arm Shock Axle/Rail 40
Front Rail Support/Rail* (Standard/Sno Pro) 20
*w/Green Loctite #620
Front Rail Support/Rail* (R) 30
**w/Blue Loctite #243
Front Arm/Rail (Standard/Sno Pro) 40
Front Arm/Mounting Bracket (R) 40
Rear Suspension Limiter Strap/Rail Support

Pivot Assembly/Rail
120 in.-Ib
40
Torque Specifications Track Adjuster Bracket/Rail 120 in.-Ib
Rear Rail Support/Rail 20
Inner Idler Wheel/Rail 40
120 Sno Pro RaillTunnel 40
Item Torque M-Series
ft-Ib
Wear Strip/Rail 50 in.-Ib
Axle Housing/Rail 20 Mounting Block/Rail 20
Rear Arm/Bracket* 20 Inner Idler Wheel/Mounting Block 20
Rear Wheel Axle* 20 Idler Wheel Axle/Rail 40
Cross-Brace Axle/Rail* 20 Rear Arm/Rail 40
Idler AxlelTunnel* 20 Idler Arm/Rear Arm 34
Rear Arm Limiter/Rail Support 20
* w/Blue Loctite #243 Front Arm Shock Axle/Rail 40
Front Rail Support/Rail 20
Outer Idler Wheel/Mounting Block 20
Front Arm/Rail 40
Limiter Strap/Rail Support 120 in.-Ib
Track Adjuster Bracket/Rail 120 in.-Ib
RaillTunnel 40
* w/Blue Loctite #243
F-SerieslZ1 Bearcat 5701T-Series
Torque Torque
Item Item
ft-Ib ft-Ib
Wear Strip/Rail 50 in.-Ib Wear Strip/Rail 50 in.-Ib
End Cap/Rail 80 in.-Ib End Cap 80 in.-Ib
Mounting Block/Rail 20 Mounting Block/Rail 20
Idler Wheel/Mounting Block 20 Idler Wheel/Mounting Block 20
Rear Arm/Rail 40 Rear Arm/Rail 40
Rear Arm/Idler Arm 40 Rear Arm/Idler Arm 40
Spring Slide/Slide Block - Rail 20 Shock Pivot/Idler Wheel - Rail 20
Pivot Arm/Idler Arm 20 Spring Slide Block/Rail 20
Idler Wheel Axle/Rail 20 Pivot Arm/Idler Arm 20
Front Arm Shock Axle/Rail 40 Idler Wheel Axle/Rail 20
Front Arm/Rail 40 Front Arm Shock Axle/Rail 40
Rear Shock Pivot/Front Arm 20 Front Arm/Rail 40
Limiter Strap/Rail Support 120 in.-Ib Limiter Strap/Front Arm 120 in.-Ib
Rear Shock Pivot/Rail 40 Track Adjuster Bracket/Rail 120 in.-Ib
Rear Arm Limiter/Rail 50 Rear Arm Limiter/Rail* 50
Rail Support/Rail 20 Rail Support/Rail 20
RaillTunnel 40 Limiter Strap/Rail Support 120 in.-Ib
RaillTunnel 40
* w/Blue Loctlte #243
1-44
Track Warranty Guidelines
Failure Mode Description Cause Warranty
Delamination (A) Condition in which the track fabric cleanly sepa- Result of poor adhesion between fabric and rubber material Covered
rates or spreads apart from the rubber.
Tread/External Condition in which the lugs are torn, cracked, Most often a result of riding/spinning on rugged terrain ... Not Covered
Lug Damage (B) worn, or separated. -rocks,
-jagged ice,
-metal objects,
-gravel roads.
High speed running with poor lubrication may produce gummy
external track lugs leading to separation.
Edge Tearing (C) A track failure that occurs along the side of the Rods out of center. If a rod is positioned off-center during track Covered
track in which tearing occurs either parallel or manufacturing, tearing along the side of the track may occur ± 1/2
perpendicular to the track edge. in. from the edge.
Traction Product Cutting that occurs where a stud or pick is Often the result of contact having been made with a solid or jag- Not Covered
and Clip Damage attached to the track including tearing due to stud ged object (e.g. rocks, ice, metal, gravel, etc.).
pull-through as well as track clips that are torn off.
Internal Lug Condition in which internal lugs are torn, worn, or Result of contact being made with a foreign object. Not Covered
Damage cracked.
Track derailment can also cause this damage.
Broken Rods/ Condition in which tracks are found to have bro- Typically, results from track impacts and overheating. Not Covered
Missing Clip (D) ken rods. Gummy tread sometimes accompanies
broken rods. Overheating of the rod can result from friction buildup due to poor
lubrication or riding at high continuous speeds for long periods of
Wear clip and rod section broken out and miss- time in minimal snow conditions.
ing.
Gummy tread and brown or dark brown rod color at the center
sometimes accompanies this failure.
Signs of wear strip material melted and sticking to the edges of

the wear clip. Also, wear clips that have started to turn blue in
color from overheating are all signs of operating the snowmobile
on minimal snow.
Large Deformities Condition in which a track has large deformities Manufacturing flaw. Covered
of the Track or Air which may include air bubbles/pockets/voids
Bubbles within the track.
Lugs Torn Off Condition normally found on deep lug tracks. Typically, the result of operating a deep lug track on minimal snow Not Covered
Outer Belt (B) at high rates of speed. This track is designed for deep snow
mountainous areas only.
A c
734-522C
B D
Lug/
Tread Damag@
Broken Rod/Miss ing Clip

LugfTread Damage
734-5228 734-522D
Track Specifications Rear Suspension
Specifications
Below is a listing of drive tracks for Arctic Cat snow-
mobiles with its specifications. FRONT ARM SPRINGS
Model Free Length Rate LBllnch
Bearcat 570 9.5" 110
Bearcat XT 9.5" 140
F 570 9.5" 90
F5fT500fT570lZ1 fTZ1 7.75" 110
Crossfire/M-Series 7.75" 135
Crossfire R 8.0" 190
F8 8.25" 90/250
F-Series Sno ProlZ1 Turbo Sno Pro 8.25" 100/250
REAR ARM SPRINGS
-NOTE: On the M-Series, measurement is from the

bottom of the wear strip at the point of the shock
pad on the slide rail. All tracks are 15 in. wide
except for 120 Sno Pro (11 in.), Crossfire R (14 in.),
and Bearcat XT (20 in.). All models at 20 Ib except
M-Series (10 Ib).
Front Suspension
Specifications
0730-218
SWAVBARS
SKI SHOCK SPRINGS

-NOTE: All springs have a 0.331" wire diameter
except 120 Sno Pro (0.235") and Z1m1 (0.343").
Model Free Rate LBI # of Coils Tab

Length Inch
F5fT500fT570 11.25" 90 6.2* 18 .2** NO * Square wire
M6/M8/M1000 (STO) 12.50" 120 12.75 YES -NOTE: The wire diameter and length of the spring
F 570 9.36" 90 8.5 NO have a large influence over the valving of the
Bearcat 5701 10.10" 110 8.4 NO shocks. A longer spring in areas (0) and (E) can be
Bearcat 570 XT
selected if cut off to match the original spring.
F8 (STO) 12.50" 95 14 YES
Replacement springs must match the original
Crossfire (STO) 13.50" 120 12 NO
spring in areas (0) and (E).
Z1fTZ1 10.50" 110 9.0 YES
120 Sno Pro 6.97" 85 9.0 NO
Crossfire R 13.00" 125 11.5 NO
Bearcat Z1 XT 10.10" 90 9.6 NO
* Active Coils
** Total Coils
1-46
REAR ARM SHOCK
Shock Absorber Model
Collapsed Extended
Stroke
Piston
Length Length Depth
Specifications Bearcat 570fT-Series 10.91" 16.69" 5.78" N/A
Crossfire 500 9.89" 14.50" 4.61" N/A
F5 10.00" 15.00" 4.61" N/A
Below is a list of shock absorbers used on the front and
rear suspensions of Arctic Cat snowmobiles. Specifi- F 570 9.92" 15.00" 5.08" N/A
cations given for each shock absorber include col- Bearcat XT 10.89" 16.67" 5.78" N/A
lapsed and extended length, stroke, and piston depth Z1 9.87" 14.51" 4.61" N/A
(if applicable). If replacing a shock absorber, always Crossfire (STO)I 9.88" 14.37" 4.48" 0.90"
Crossfire R
select a shock absorber with the same length, both col-
Crossfire Sno Pro/M- 11.10" 16.00" 4.90" 5.77"
lapsed and extended. Series
F8 (STO)/F8 LXR 9.89" 14.53" 4.64" 5.80"
SKI SHOCK
F-Series Sno ProlZ1 10.13" 14.53" 4.40" 5.70"
Collapsed Extended Piston Turbo Sno Pro
Model Stroke
Length Length Depth
Bearcat 570/F5/F 5701 11.55" 17.50" 5.95" N/A
T500fT570
Idler Wheel Dimensions
Crossfire 500 12.55" 18.75" 6.20" N/A
120 Sno Pro 7.78" 9.49" 1.71" N/A
Bearcat XT 10.67" 16.00" 5.33" N/A Model Location 0.0. Bearing 1.0.
Z1 fTZ1 fTZ1 Turbo 11.55" 17.50" 5.90" N/A All Inside Rails 5.63 in. 0.787 in.
Crossfire 600/800/1 000 12.13" 18.72" 6.59" 1.40" All Idler Arm 7.12 in. 1.181 in.
(STO)/Crossfire R
AII** Inside Rear Axle 7.12 in. 0.787 in.
Crossfire Sno Pro 12.60" 18.80" 6.20" 6.97"
F-Seriesl Outside Front 5.63 in. 0.787 in.
F8 (STO)/F8 LXR 11.47" 16.70" 5.21" 6.50" T-Series/Z1
F-Series Sno Prol 12.30" 16.75" 4.45" 7.00" F-Seriesl Outside Rear Axle 7.12 in. 0.787 in.
Z1 Turbo Sno Pro T-Series/Z1
M-Series (STO) 11.56" 17.55" 5.99" 1.25" M-Series* Inside Rear Axle 8.00 in. 0.787 in.
M-Series Sno Pro 12.00" 17.55" 5.55" 6.68" M-Series* Outside Rear Axle 8.00 in. 0.787 in.
Bearcat XT Rear Axle 6.38 in. 0.787 in.
FRONT ARM SHOCK
Model
Collapsed Extended
Stroke
Piston * 8.00 in. idler wheel cannot be used with standard slide rails.
Length Length Depth ** Except M-Series
Bearcat XT 8.42" 12.49" 4.07" N/A
F5/F 570lZ1 8.43" 12.53" 4.10" N/A
Bearcat 5701 8.09" 11.78" 3.69" N/A
Crossfire 500fT-Series
Crossfire R 8.17" 11.76" 3.59" 0.58"
F8 (STO)/F8 LXR 8.55" 12.49" 3.94" 4.85"
Crossfire 600/800/1 000 8.54" 12.51" 3.97" 0.62"
(STO)I
F-Series Sno Pro/Z1
Turbo Sno Pro
M-Series 8.11" 11.25" 3.14" 0.58"
SECTION 2 - ENGINE
TABLE OF
CONTENTS
Engine - 120 Sno Pro .............................................. 2-2

Engine - Bearcat 570/F 5701T570 ......................... 2-22
Engine - Crossfire 500/600 - M-Series 600 ........... 2-47
Engine - Crossfire 800/1000 -
M-Series 800/1 000 ............................................. 2-76
Engine - F-Series 500/600 - T-Series 500 ........... 2-109
Engine - F-Series 800/1000 ................................ 2-137
Engine - Bearcat Z1 XTITZ1/Z1 .......................... 2-167
Troubleshooting Engine (2-Stroke
Carbureted Models) ......................................... 2-203
Troubleshooting Engine (2-Stroke EFI Models) ... 2-205
Troubleshooting Engine (4-Stroke) ...................... 2-209
Engine - 1 20 Sno Pro
This engine section has been organized into sub-sec-

tions showing a progression for the complete servicing
of the Arctic Cat 120 cc (120 Sno Pro) engine. For
consistency purposes, this section shows a complete
and thorough progression; however, for efficiency it
may be preferable to remove and disassemble only
those components needing to be addressed and to ser-
vice only those components. Also, some components
may vary from model to model. The technician should
use discretion and sound judgment. For engine-related A046A
servicing procedures, see Section 3 of this manual. 2. Remove the two cap screws securing the steering
post to the steering post support. Account for two
-NOTE: Some illustrations and photographs used bearing halves, two lock nuts, and a bearing
in this section are used for clarity purposes only retainer.
and are not designed to depict actual conditions.
-NOTE: Critical torque specifications are located

in Section 1 of this manual.
SPECIAL TOOLS
A number of special tools must be available to the

technician when servicing the engine.
Description pIn
V Blocks 0644-022
Surface Plate 0644-016
Ball Hone 0644-290 A023A
-NOTE: Special tools are available from the Arctic 3. Pull the steering post up and back and then out of
the lower steering post bearing.
Cat Service Parts Department.
4. Remove the two lock nuts securing the tie rods to
the steering post; then remove the tie rods from the
Table of Contents steering post. Place the steering post out of the
way on the right-hand side of the engine compart-
ment.
Removing ..... ........... .... .. ... .... ... .. ..... .. .. ..... .. .... .... .. ... . 2-2
Disassembling ......................................................... 2-3
Servicing Components .... ... .. ... .. .. ... .. .. ... ... .. .. ... ....... . 2-8
Assembling ............................................................ 2-16
Installing ....... .... ... .. ..... .. .... .... .. ... .... .. ... ..... .. .... ........ 2-21
Removing Engine
-NOTE: The drive chain must be removed in order

to remove the engine (see Drive Chain and Sprock-
ets sub-section in Section 6).
A024
1. Disconnect the choke and throttle cables from the
carburetor; then on each cable, loosen the adjust- 5. Cut the cable tie; then disconnect all wires (a total
ment jam nut closest to the carburetor and remove of four) at the front of the engine. Route them out
the cables from the bracket. Route the cables out of the way.
of the way.
2-2 2009 Arctic Cat Snowmobiles Factory Service Manual - all Models - www.ReadManuals.com
A049
6. Turn the gas tank shut-off valve to the CLOSED -NOTE: The front center plug is to access the oil
position. drain plug.
& WARNING 13. Place the snowmobile in the upright position; then
Whenever any maintenance or inspection is made on on the left-hand side of the engine, remove the
a fuel system when there may be fuel leakage, there three cap screws securing the engine and brake
should be no welding, smoking, open flames, etc., in bracket to the front end.
the area.
7. Disconnect the fuel hose from the carburetor.

-NOTE: Be prepared to wipe up any fuel spillage.
8. Pull the recoil starter rope out approximately 60

em (24 in.); then tie a slip-knot in the starter rope
below the console and allow the rope to slowly
retract against the starter case.
9. Remove the knot at the handle and remove the
handle; then thread the rope through the bushing in
the console.
10. At this point, scribe a line at the front of the engine
and measure the distance between the crankshaft 14. Remove the engine from the engine compartment.
and the driveshaft. Record the measurement for
installing purposes.
Disassembling Engine
1. Remove the oil drain plug and drain the oil; then
install the oil plug and tighten securely.
11. Lay the snowmobile on its side.

-NOTE: A piece of cardboard should be used to
protect the finish.
GM300D
12. Using a flat-blade screwdriver, remove the four 2. Remove the wing nut securing the air cleaner end
belly pan plugs covering the engine mounting cap cap to the air cleaner housing.
screws; then remove the cap screws. Account for
eight washers and four lock nuts.
3. Remove the cap screw and flange nuts securing 5. Mark the locations of the springs for assembly;
the air cleaner housing to the carburetor and then disconnect the rod and spring from the carbu-
engine. retor.
GF208D
6. Slide the carburetor off the mounting studs.

Account for a gasket, insulator block, and a gas-
ket.
GF314D
4. Remove the air breather hose from the air cleaner

housing; then remove the air cleaner housing from
the carburetor. Account for the gasket.
7. Remove the recoil starter/fan housing assembly.
A001
GM201E
8. Remove the screws securing the recoil starter pul-

ley to the flywheel; then remove the nut securing
the flywheel to the crankshaft.
GF316D
2-4 2009 Arctic Cat Snowmobiles Factory Service Manual - all Models - www.ReadManuals.com
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SECTION 1 -

The recommended oil to use is Synthetic Turbo OW-40 1100 ee

0-200 miles 1/2 Throttle (45 MPH-max)

Drive Chain Lubrication Prior to storing the snowmobile, it must be properly

14. Apply light oil to the shafts of the shock absorbers;

ITEM 500 cc 570 cc 600 cc 800 cc 1000 cc

ENGINE TYPE SQUISH - GAP --A-I

Engine Piston Travel

For those who have crankshaft work sent out to

8ths 16ths 32nds 64ths 64ths

Listed in the table below are symbols indicating spe-

Tightening Torque Lubricate with Arctic Cat 50:1

2009 Arctic Cat Sn owmobiles Factory S ervlce

(D) Coolant Temperature Sensor 18 ft-Ib •

/ 4fC <lll- "

(A) 10 mm Step 1: 13 ft-Ib

(A) 1· i..'1"- -o'k '©J lk-

(C)Coolant Temperature Sensor 18 I t . l b .

* Accessible from Top Side

(D) Coolant Temperature Sensor 18 ft·lb . .

(A) * Accessible from Top Side

Engine Case Torque Va lue

... 10 mm Cap Screw Oty

2009 Arctic Cat Snowmobiles Facto ry Service

Engine Case Oil Separator Plates

Oil Pan Plate Oil Pan

Magneto Cover Exhaust Manifold

-NOTE: The servo will activate once at APV cycle

-NOTE: The 800 cc and 1000 cc have a three-stage

FULL-CLOSED RPM PSI KG/CM 2

PILOT AIR FLOAT HEIGHT MAIN PILOT THROTTLE

-NOTE: The above specifications are production

-NOTE: Breaking the seal on the idle screw jam

-NOTE: The ignition system is a Normally Open Ignition (NOI).

-NOTE: The ignition system is a Normally Open Ignition (NOI).

-NOTE: The ignition system is a Normally Open Ignition (NOI).

-NOTE: The ignition system is a Normally Open Ignition (NOI).

-NOTE: The ignition system is a Normally Open Ignition (NOI).

-NOTE: The ignition system is a Normally Open Ignition (NOI).

-NOTE: To test the coolant temperature sensor, see Section 5.

0742-218 Ignition Timing - Engine Warm

Drive Clutch/Driven Arctic Cat Drive Belt

A list of Arctic Drive Clutch and Driven Pulley com-

Torque Bracket Cover 72 in.-Ib End Cap/Rail 80 in.-Ib

72 in.-Ib Mounting Block/Rail 20

Rear Suspension Limiter Strap/Rail Support

* w/Blue Loctite #243

Signs of wear strip material melted and sticking to the edges of

Broken Rod/Miss ing Clip

REAR ARM SPRINGS

-NOTE: On the M-Series, measurement is from the

SKI SHOCK SPRINGS

Model Free Rate LBI # of Coils Tab

Engine - 120 Sno Pro .............................................. 2-2

This engine section has been organized into sub-sec-

-NOTE: Critical torque specifications are located

A number of special tools must be available to the

-NOTE: The drive chain must be removed in order

7. Disconnect the fuel hose from the carburetor.