2002 Arctic Cat

SERVICE MANUAL CD-ROM
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SECTION 1 — GENERAL INFORMATION
TABLE OF
CONTENTS
Snowmobile Identification ....................................... 1-2
Recommended Gasoline and Oil ........................... 1-2
Break-In Procedure ................................................ 1-3
Genuine Parts ........................................................ 1-3
High Altitude Operation .......................................... 1-4
Drive Chain Lubrication (120 cc) ............................ 1-4
Preparation For Storage ......................................... 1-4
Preparation After Storage ....................................... 1-6
After Break-In Checkup (100 Miles) ....................... 1-6
After Break-In Checkup Checklist .......................... 1-7
Torque Conversions ............................................... 1-8
Tightening Torque (General Bolts) ........................ 1-8
Fraction/Decimal Conversion Chart ....................... 1-9
Drill Bit Sizes (Number) Chart ................................ 1-9
MM/In. Conversion Chart ..................................... 1-10
Servicing Symbols ................................................ 1-11
1-1
RECOMMENDED GASOLINE
Snowmobile (EFI Models)
Identification The recommended gasoline to use in these snowmobiles
is 87 minimum octane regular unleaded, and the Fuel
Designation Connector at the ECU must be connected. In
The Arctic Cat Snowmobile has two important identifica- many areas, oxygenates (either ethanol or MTBE) are
tion numbers. The Vehicle Identification Number (VIN) added to the gasoline. Oxygenated gasolines containing
is stamped into the tunnel near the right-side footrest. The up to 10% ethanol or up to 15% MTBE are acceptable
Engine Serial Number (ESN) is stamped into the crank- gasolines; however, if oxygenated gasoline is used, the
case of the engine. Fuel Designation Connector at the ECU must be discon-
nected. Do not use gasolines containing methanol.
0726-383
734-482A
These numbers are required to complete warranty claims
properly. No warranty will be allowed by Arctic Cat Inc. ! CAUTION
if the engine serial number or VIN is removed or muti-
lated in any way. Do not use white gas or gasoline containing
methanol. Only Arctic Cat approved gasoline
additives should be used.
Recommended ! CAUTION
Gasoline and Oil If oxygenated gasoline is to be used, it is
extremely important that the Fuel Designation
Connector at the ECU is disconnected. If the
connector is not disconnected when using
RECOMMENDED GASOLINE oxygenated gasoline, severe engine damage
(Carbureted Models) may occur.
The recommended gasoline to use in these snowmo- NOTE: In order for the ECU to change modes, the
biles is 87 minimum octane regular unleaded. In many engine must be OFF when connecting or discon-
areas, oxygenates (either ethanol or MTBE) are added necting the Fuel Designation Connector.
to the gasoline. Oxygenated gasolines containing up to
10% ethanol or up to 15% MTBE are acceptable gaso- RECOMMENDED OIL
lines; however, whenever using oxygenated gasolines, (Oil-Injection System)
the carburetor main jet must be one size larger than the
main jet required for regular unleaded gasoline. For The recommended oil to use in the oil-injection system is
example, if a 400 main jet is recommended for regular Arctic Cat 50:1 Injection Oil (for standard models) or
unleaded gasoline, a 410 main jet must be installed if Arctic Cat Synthetic APV 2-Cycle Oil (for APV models).
using an oxygenated gasoline. The oil is specially formulated to be used either as an
injection oil or as a pre-mix oil (for carbureted model
When using ethanol blended gasoline, it is not necessary break-in) and meets all of the lubrication requirements of
to add a gasoline antifreeze since ethanol will prevent the the Arctic Cat snowmobile engine.
accumulation of moisture in the fuel system.
! CAUTION
Do not use white gas or gasolines containing
methanol. Only Arctic Cat approved gasoline
additives should be used.
1-2
RECOMMENDED OIL
(4-Stroke Model)
The recommended oil to use is a multi-grade oil cali-
! CAUTION
brated to the ambient temperature at which the engine is DO NOT exceed the one (1) tankful limitation of a
run. See the viscosity chart for details. 100:1 gas/oil break-in mixture. Continuous use of
a gas/oil mixture, unless consistently operating
in extremely cold conditions (-26°C/-15°F or
! CAUTION colder), could cause spark plug fouling and
Any oil used in place of the recommended oil excessive carbon buildup. A 100:1 gas/oil
may cause serious damage. mixture must be used in conjunction with the oil-
injection system to ensure adequate engine
lubrication in extremely cold conditions.
Multi-Grade
1
Break-In Procedure
(4-Stroke Model)
The Arctic Cat 4-stroke engine (when new or rebuilt)

requires a short break-in period before the engine is sub-
jected to heavy load conditions.
GEN-0048 This engine does not require any pre-mixed fuel during
the break-in period.
After the engine break-in period, the engine oil should be
changed every 3500 miles (on the 4-Stroke Touring and
Trail) and before prolonged storage. ! CAUTION
DO NOT use premixed fuel in the snowmobile gas
tank. Engine damage will occur.
Break-In Procedure To ensure trouble-free operation, careful adherence to the

following break-in guidelines will be beneficial.
(2-Stroke Models)
1/2 Throttle
The Arctic Cat 2-stroke engine (when new or rebuilt) 0-200 miles
(45 MPH-max)
requires a short break-in period before the engine is sub-
jected to heavy load conditions. Arctic Cat requires that 200-400 miles 1/2-3/4 Throttle
the first tankful of fuel be premixed at a 100:1 ratio in all
oil-injection models. 400-600 miles 1/2-3/4 Throttle *
During the break-in period, a maximum of 1/2 throttle is * With occasional full-throttle operation.
recommended; however, brief full-throttle accelerations
and variations in driving speeds contribute to good engine To ensure proper engine break-in, Arctic Cat recommends
break-in. that the engine oil and filter be changed after 600 miles or
after one month, whichever comes first. This service is at
the discretion and expense of the snowmobile owner.
Genuine Parts
When replacement of parts is necessary, use only genuine

Arctic Cat parts. They are precision-made to ensure high
quality and correct fit.
1-3
High Altitude Operation Preparation
For Storage
Operating a snowmobile at varying altitudes requires
changes in performance components. These changes Prior to storing the snowmobile, it must be properly ser-
affect drive train components (on all models) and carbure- viced to prevent corrosion and component deterioration.
tion components (on carbureted models). An authorized Arctic Cat Snowmobile dealer should per-
form this service; however, the owner/operator can per-
A high altitude information decal is located beneath the form this service if desired. To prepare the snowmobile
hood of the snowmobile. On carbureted models, the infor- for storage, Arctic Cat recommends the following proce-
mation is incorporated into the Main Jet Chart decal. dure:
! CAUTION 1. Clean the seat cushion with a damp cloth and

Arctic Cat Vinyl Protectant (p/n 0638-313).
On carbureted models, carefully follow the Main
Jet Chart recommendations for proper main jet 2. Clean the snowmobile thoroughly by hosing dirt,
selection for altitude, temperature, and gasoline oil, grass, and other foreign matter from the skid
being used. frame, tunnel, hood, and belly pan. Allow the
snowmobile to dry thoroughly. DO NOT get water
A number of Arctic Cat snowmobiles are initially set up into any part of the engine.
at the factory for operation between 5000-9000 feet. Con-
sult the appropriate specifications for this information. NOTE: Steps 3-7 are only for models with an oil-
injection system.
3. Place the rear of the snowmobile up on a shielded

safety stand.
Drive Chain
Lubrication NOTE: On some models, the air-intake silencer
(120 cc) is a one-piece unit, and the silencer boot(s) can be
removed to access the intake bore(s). Remove the
boots; then proceed to step 7.
The drive chain should be lubricated every 20 operating
hours with a dry, graphite-based chain lubricant. By using NOTE: On some models, the air-intake silencer
a dry, graphite-based chain lubricant, dirt buildup on the includes a cover/tool tray assembly and a baffle/
drive chain will be minimized. Before each lubrication, reso nato r, and the silencer bo ot can no t b e
inspect the drive chain for dirt accumulation. removed to access the intake bores. Proceed to
step 4.
To lubricate the drive chain, shut the engine off and wait
for all moving parts to stop, remove the drive chain guard 4. Open the air-intake silencer cover; then remove
and lubricate the drive chain. After lubricating the drive the three screws securing the cover/tool tray
chain, install the drive chain guard. assembly to the silencer.
If the drive chain is excessively dirty, it should be 5. Close the cover; then tip the cover/tool tray
removed and cleaned prior to being lubricated (see Drive assembly forward and out of its slots and remove
Chain and Sprockets in Section 8). the assembly.
NOTE: If a dry, graphite-based chain lubricant is 6. Using a large flat-blade screwdriver, remove the
not available, lubricate the drive chain with several baffle/resonator tabs from the air-intake silencer
drops of petroleum-based oil. If the snowmobile is
operated in the summer with the optional wheel slots and remove the baffle/resonator to access the
kit, the drive chain should be lubricated more fre- intake bores.
quently.
1-4
NOTE: The baffle/resonator can be removed 14. Clean and inspect the drive clutch and driven
more easily by removing the back tabs first. pulley.
7. Start the engine and allow to idle. With the engine 15. If applicable, remove the drive belt from the drive
idling, spray Arctic Cat Engine Storage Preserver clutch/driven pulley. Lay the belt on a flat surface
(p/n 0636-177) into the intake(s) until the engine or slide it into a cardboard sleeve to prevent
exhaust starts to smoke heavily or until the engine warping or distortion during storage; then clean
starts to drop in RPM. Turn engine off. and inspect the drive clutch and driven pulley.
NOTE: On some models, install the air-intake 16. Apply light oil to the upper steering post bushing,
silencer boot(s); on some models, install the baf- ski spindles and bolts, front and rear pivot
fle/resonator and the cover/tool tray assembly. bushings of the skid frame, and plungers of the
shock absorbers.
8. Plug the exhaust system outlet with a clean cloth.
! CAUTION
17. Lubricate all grease fittings (front and rear
suspension, spindles, speedometer drive adapter, 1
and the driven shaft support bearing) with a low-
Do not do step 9 on the 4-stroke model; severe temperature grease.
engine damage could result.
18. Tighten all nuts, bolts, and cap screws making sure
9. With the ignition switch in the OFF position: all calibrated nuts, bolts, and cap screws are
tightened to specifications. Make sure all rivets
A. Disconnect the high tension lead(s) from the holding the components together are tight.
spark plug(s); then remove the plug(s), connect Replace all loose rivets.
it/them to the lead(s), and ground it/them on the
cylinder head(s). 19. Clean and polish the hood, console, and chassis
with Arctic Cat Hood and Windshield Cleaner/
Polish (p/n 0636-174). DO NOT USE SOL-
! CAUTION VENTS OR SPRAY CLEANERS. THE PRO-
Never crank the engine over without grounding PELLENT WILL DAMAGE THE FINISH.
the spark plug(s). Damage to coils and/or CDI
unit may result. 20. On electric start models, disconnect the battery
cables making sure to disconnect the negative
B. Pour 29.5 ml (1 fl oz) of SAE #30 petroleum- cable first; then clean the battery posts and cables.
based oil into each spark plug hole and pull the
recoil starter handle slowly about 10 times. 21. If possible, store the snowmobile indoors. Raise
the track off the floor by blocking up the back end
C. Install the spark plug(s) and connect the high making sure the snowmobile is secure. Loosen the
tension lead(s). track adjusting bolts to reduce track tension. Cover
the snowmobile with a machine cover or a heavy
10. On the 4-stroke model, change the engine oil; then tarpaulin to protect it from dirt and dust.
clean the air filter.
22. If the snowmobile must be stored outdoors,
11. On carbureted models, drain the gas from each position the snowmobile out of direct sunlight;
carburetor float chamber. then block the entire snowmobile off the ground
making sure the snowmobile is secure. Loosen the
12. Fill the gas tank to its rated capacity; then add track adjusting bolts to reduce track tension. Cover
Arctic Cat Fuel Stabilizer (p/n 0638-165) to the with a machine cover or a heavy tarpaulin to
gas tank following directions on the container for protect it from dirt, dust, and rain.
the stabilizer/gasoline ratio. Tighten the gas tank
cap securely.
! CAUTION
13. If applicable, drain the chain-case lubricant by Avoid storing in direct sunlight and using a
removing the chain-case drain plug located on the plastic cover as moisture may collect on the
backside of the chain-case assembly. Remove the snowmobile causing corrosion.
chain-case cover and inspect chain, sprockets,
chain tensioner, and rollers for wear and the chain
for proper tension. Install the drain plug, chain-
case cover, and seal; then pour Arctic Cat
Transmission Lube (p/n 0636-817) into the filler
hole according to appropriate specifications.
1-5
10. Adjust the carburetor(s) and choke cable on
Preparation After carbureted models and throttle cable on all
models.
Storage
! WARNING
Taking the snowmobile out of storage and correctly pre-
paring it for another season will assure many miles and On VM-style carburetors, be sure to tighten the
hours of trouble-free snowmobiling. Arctic Cat recom- swivel adapter jam nuts securely. If a jam nut
mends the following procedure: isn’t tightened, the adjuster can rotate out of the
carburetor cap causing the piston valve not to
return to the full-closed position.
! CAUTION
On carbureted models if the gas in each 11. Tighten all nuts, bolts, and cap screws making sure
carburetor float chamber was not drained prior all calibrated nuts, bolts, and cap screws are
to storage, the carburetor(s) must be cleaned tightened to specifications.
before starting the engine.
12. Lubricate all grease fittings (rear suspension,
1. Clean the snowmobile thoroughly. Polish the spindles, speedometer drive adapter, and the
exterior of the snowmobile. driven shaft support bearing) with a low-
temperature grease.
2. Clean the engine. Remove the cloth from the
exhaust system. Check exhaust system and air- 13. On the 120 cc model, inspect the drive chain and
intake silencer/air filter for obstructions. drive chain tightener. Replace if necessary; then
lubricate the binding screw drum with WD-40 and
3. Inspect all control wires and cables for signs of the drive chain with a dry, graphite-based chain
wear or fraying. Replace if necessary. Use cable lubricant.
ties or tape to route wires and cables away from
hot or rotating parts. 14. On liquid cooled models, check the coolant level
and all coolant hoses and connections for
4. If applicable, inspect the drive belt for cracks and deterioration or cracks. Add properly mixed
tears. Check belt specifications. Replace if coolant as necessary.
damaged or worn. Install the drive belt.
15. On fan cooled models, clean the engine cooling
NOTE: If the old belt is worn but in reasonable fins and all vents.
condition, retain it with the snowmobile as a spare
in case of emergency. 16. On EFI models, place the rear of the snowmobile
on a shielded safety stand; then start the engine.
5. On carbureted models, inspect the in-line fuel Allow the engine to idle; then using a long stiff
filter and replace if necessary. wire with a hooked end, raise the oil-injection
pump control arm to the wide-open position until
6. Inspect all fuel hoses and oil hoses for the engine starts to smoke heavily. Release the
deterioration or cracks; replace if necessary. Make control arm and turn off the engine.
sure all connections are tight; then on 2-stroke
models, fill the oil-injection reservoir with the 17. On electric start models, charge the battery; then
recommended 50:1 injection oil. connect the battery cables making sure to connect
the positive cable first. Test the electric start
NOTE: On 2-stroke models after prolonged stor- system.
age, Arctic Cat recommends one tankful of 100:1
gas/oil mixture be used in conjunction with the oil-
injection system to ensure proper lubrication.
7. Inspect the entire brake system, all controls, After Break-In Checkup
headlight, taillight, brakelight, ski wear bars, and (100 Miles)
headlight aim; adjust or replace as necessary.
8. Inspect each spark plug. Replace, gap, or clean as The 100 mile checkup offered by some dealerships
necessary. reduces problems and warranty costs. A program of this
kind should be offered by all dealerships. Many dealer-
9. Adjust the track to the proper tension and ships have added the price of the checkup into the selling
alignment. Lock the jam nuts. price of the snowmobile, and others offer it as a bonus to
the customers who purchase snowmobiles from their
dealership.
There are three areas that require adjustment after the
break-in period in order to obtain peak performance.
These areas are the following.
1-6
A. Carburetor jetting TRACK TENSION AND ALIGNMENT — There is a
certain amount of stretch on all tracks during the first 500
B. Drive belt deflection miles. The track must be adjusted after the first 50 to 100
miles to the specifications given in the Setup and Pre-
C. Track tension and alignment delivery Manual and periodically thereafter. If these
adjustments aren’t performed, the track may “derail”
CARBURETOR JETTING (2-Stroke Carbureted which leads to track and slide rail damage.
Models)— Altitude, temperature, and the use of oxygen-
ated gasoline affect the carburetion needed for optimum Along with these three major areas, there are also other
engine performance. The carburetor main jets must be areas that should be checked and adjusted during the
changed in conjunction with changes in operating alti- “After Break-In Checkup.” A checklist to assist you with
tude, oxygenated gasoline usage, and temperature. this service follows. Not only will the customer be hap-
pier, but it also gets the customer back into your dealer-
DRIVE BELT DEFLECTION — Drive belt deflection ship, which in many cases will mean additional sales in
accessories, belts, oil, etc.
1
is very important to the snowmobile. Even if it is checked
and is correct when the snowmobile is set up, it does
change (more so during the break-in period). This is
because the rubber engine mounts and the rubber snubber
on the torque link will all take a “set” during the first 100
miles, which allows the distance between the drive clutch After Break-In
and driven pulley to shorten. When this happens, the
snowmobile will appear to have a too long drive belt. To
Checkup Checklist
add to this, the drive belt itself wears and stretches some-
what. This all leads to a low-end performance problem Below is a recommended list of items to check after
and, if not corrected, causes premature drive belt wear. the break-in period. By performing this inspection,
warranty cost can be reduced and customer satisfac-
After the break-in period, drive belt deflection should be
checked according to the instructions given in this man- tion can be increased.
ual. To correct for too much deflection, washer(s) from
between the driven pulley sheaves can be removed to The recommended mileage for this inspection is
“tighten the drive belt” and allow the belt to return to the between 100 and 300 miles. Please encourage the cus-
proper ratio for drive clutch engagement. tomers to have this important checkup done.
DRIVE BELT BREAK-IN — It is critical for maximum ❏ Jet carburetor(s) according to average
drive belt life to allow the belt to break in before subject- temperature, type of gasoline being used, and
ing it to hard use such as wide-open-throttle operation or altitude
hill climbing. ❏ Adjust drive belt deflection
The first 20 miles on the drive belt should be at 1/2 throt- ❏ Adjust track tension and alignment
tle or lower. This will allow the belt to cure totally before ❏ Adjust throttle cable tension
it is subjected to hard use.
❏ Check oil-injection pump adjustment
If this procedure isn’t followed, it is possible to destroy a ❏ Check engine idle
new drive belt in less than 50 miles. This should be
explained to customers at the time of drive belt sales. ❏ Check coolant level
❏ Check chain case lubricant level
To increase the life of a drive belt, it is very important that
the belt be warmed up before subjecting it to any type of ❏ Check lights (high/low beam, brakelight)
use. In cold temperature (0° or below), the engine should ❏ Check safety switch operation
be allowed to idle for a period of 8 to 10 minutes. This ❏ Check driveshaft area for any rubbing
will allow heat from the engine compartment to soften the components
drive belt. Not only will this procedure increase belt life
but will also help prevent engine damage from cold sei- ❏ Check steering hardware for tightness
zure. ❏ Check skid frame and A-arm mounting
hardware for tightness
! WARNING ❏ Check brake lever travel and adjustment
When following the above procedure, the operator ❏ Grease all lubrication points
must not leave the snowmobile unattended during
the warm-up period.
Each operator should be instructed to drive the snowmo-

bile for several minutes at a low throttle setting to warm
the belt up before using wide-open-throttle. This practice
should be followed on all models for maximum belt life.
1-7
kg-m x 7.235 = ft-lb
Torque Conversions ft-lb x 0.1383 = kg-m
ft-lb kg-m ft-lb kg-m ft-lb kg-m ft-lb kg-m ft-lb kg-m
1 0.1 21 2.9 41 5.7 61 8.4 81 11.2
2 0.3 22 3.0 42 5.8 62 8.6 82 11.3
3 0.4 23 3.2 43 5.8 63 8.7 83 11.5
4 0.6 24 3.3 44 6.1 64 8.9 84 11.6
5 0.7 25 3.5 45 6.2 65 9.0 85 11.8
6 0.8 26 3.6 46 6.4 66 9.1 86 11.9
7 1.0 27 3.7 47 6.5 67 9.3 87 12.0
8 1.1 28 3.9 48 6.6 68 9.4 88 12.2
9 1.2 29 4.0 49 6.8 69 9.5 89 12.3
10 1.4 30 4.2 50 6.9 70 9.7 90 12.5
11 1.5 31 4.3 51 7.1 71 9.8 91 12.6
12 1.7 32 4.4 52 7.2 72 10.0 92 12.8
13 1.8 33 4.6 53 7.3 73 10.1 93 12.9
14 1.9 34 4.7 54 7.5 74 10.2 94 13.0
15 2.1 35 4.8 55 7.6 75 10.4 95 13.1
16 2.2 36 5.0 56 7.7 76 10.5 96 13.3
17 2.4 37 5.1 57 7.9 77 10.7 97 13.4
18 2.5 38 5.3 58 8.0 78 10.8 98 13.6
19 2.6 39 5.4 59 8.2 79 10.9 99 13.7
20 2.8 40 5.5 60 8.3 80 11.1 100 13.8
Tightening Torque
(General Bolts)
Thread Tightening Torque

Type of Bolt Diameter
A (mm) kg-m ft-lb
5 0.2-0.4 1.5-3.0
(Conventional or 6 0.4-0.7 3.0-5.0
4 Marked Bolt) 8 1.0-1.6 7.0-11.5
10 2.2-3.5 16.0-25.5
5 0.3-0.6 2.0-4.5
6 0.8-1.2 6.0-8.5
(7 Marked Bolt)
8 1.8-2.8 13.0-20.0
10 4.0-6.0 29.0-43.5
1-8
Fraction/Decimal
Conversion Chart
8ths 16ths 32nds 64ths 64ths (cont)

1/8 = .125 1/16 = .0625 1/32 = .03125 1/64 = .015625 33/64 = .515625
1/4 = .250 3/16 = .1875 3/32 = .09375 3/64 = .046875 35/64 = .546875
3/8 = .375 5/16 = .3125 5/32 = .15625 5/64 = .078125 37/64 = .578125
1/2 = .500 7/16 = .4375 7/32 = .21875 7/64 = .109375 39/64 = .609375
5/8 = .625 9/16 = .5625 9/32 = .28125 9/64 = .140625 41/64 = .640625
3/4 = .750 11/16 = .6875 11/32 = .34375 11/64 = .171875 43/64 = .671875
7/8 = .875
—
13/16 = .8125
15/16 = .9375
13/32 = .40625
15/32 = .46875
13/64 = .203125
15/64 = .234370
45/64 = .703125
47/64 = .734375 1
— — 17/32 = .53125 17/64 = .265625 49/64 = .765625
— — 19/32 = .59375 19/64 = .296875 51/64 = .796875
— — 21/32 = .65625 21/64 = .328125 53/64 = .828125
— — 23/32 = .71875 23/64 = .359375 55/64 = .859375
— — 25/32 = .78125 25/64 = .390625 57/64 = .890625
— — 27/32 = .84375 27/64 = .421875 59/64 = .921875
— — 29/32 = .90625 29/64 = .453125 61/64 = .953125
— — 31/32 = .96875 31/64 = .484375 63/64 = .984375
Drill Bit Sizes

(Number) Chart
No. Size of Drill in No. Size of Drill in No. Size of Drill in No. Size of Drill in
Inches Inches Inches Inches
1 .2280 21 .1590 41 .0960 61 .0390
2 .2210 22 .1570 42 .0935 62 .0380
3 .2130 23 .1540 43 .0890 63 .0370
4 .2090 24 .1520 44 .0860 64 .0360
5 .2055 25 .1495 45 .0820 65 .0350
6 .2040 26 .1470 46 .0810 66 .0330
7 .2010 27 .1440 47 .0785 67 .0320
8 .1990 28 .1405 48 .0760 68 .0310
9 .1960 29 .1360 49 .0730 69 .0292
10 .1935 30 .1285 50 .0700 70 .0280
11 .1910 31 .1200 51 .0670 71 .0260
12 .1890 32 .1160 52 .0635 72 .0250
13 .1850 33 .1130 53 .0595 73 .0240
14 .1820 34 .1110 54 .0550 74 .0225
15 .1800 35 .1100 55 .0520 75 .0210
16 .1770 36 .1065 56 .0465 76 .0200
17 .1730 37 .1040 57 .0430 77 .0180
18 .1695 38 .1015 58 .0420 78 .0160
19 .1660 39 .0995 59 .0410 79 .0145
20 .1610 40 .0980 60 .0400 80 .0135
1-9
MM/IN. Conversion
Chart
mm in. mm in. mm in. mm in. mm in.

.01 .00039 .41 .01614 .81 .03189 21 .82677 61 2.40157
.02 .00079 .42 .01654 .82 .03228 22 .86614 62 2.44094
.03 .00118 .43 .01693 .83 .03268 23 .90551 63 2.48031
.04 .00157 .44 .01732 .84 .03307 24 .94488 64 2.51968
.05 .00197 .45 .01772 .85 .03346 25 .98425 65 2.55905
.06 .00236 .46 .01811 .86 .03386 26 1.02362 66 2.59842
.07 .00276 .47 .01850 .87 .03425 27 1.06299 67 2.63779
.08 .00315 .48 .01890 .88 .03465 28 1.10236 68 2.67716
.09 .00354 .49 .01929 .89 .03504 29 1.14173 69 2.71653
.10 .00394 .50 .01969 .90 .03543 30 1.18110 70 2.75590
.11 .00433 .51 .02008 .91 .03583 31 1.22047 71 2.79527
.12 .00472 .52 .02047 .92 .03622 32 1.25984 72 2.83464
.13 .00512 .53 .02087 .93 .03661 33 1.29921 73 2.87401
.14 .00551 .54 .02126 .94 .03701 34 1.33858 74 2.91338
.15 .00591 .55 .02165 .95 .03740 35 1.37795 75 2.95275
.16 .00630 .56 .02205 .96 .03780 36 1.41732 76 2.99212
.17 .00669 .57 .02244 .97 .03819 37 1.45669 77 3.03149
.18 .00709 .58 .02283 .98 .03858 38 1.49606 78 3.07086
.19 .00748 .59 .02323 .99 .03898 39 1.53543 79 3.11023
.20 .00787 .60 .02362 1.0 .03937 40 1.57480 80 3.14960
.21 .00827 .61 .02402 1 .03937 41 1.61417 81 3.18897
.22 .00866 .62 .02441 2 .07874 42 1.65354 82 3.22834
.23 .00906 .63 .02480 3 .11811 43 1.69291 83 3.26771
.24 .00945 .64 .02520 4 .15748 44 1.73228 84 3.30708
.25 .00984 .65 .02559 5 .19685 45 1.77165 85 3.34645
.26 .01024 .66 .02598 6 .23622 46 1.81102 86 3.38582
.27 .01063 .67 .02638 7 .27559 47 1.85039 87 3.42519
.28 .01102 .68 .02677 8 .31496 48 1.88976 88 3.46456
.29 .01142 .69 .02717 9 .35433 49 1.92913 89 3.50393
.30 .01181 .70 .02756 10 .39370 50 1.96850 90 3.54330
.31 .01220 .71 .02795 11 .43307 51 2.00787 91 3.58267
.32 .01260 .72 .02835 12 .47244 52 2.04724 92 3.62204
.33 .01299 .73 .02874 13 .51181 53 2.08661 93 3.66141
.34 .01339 .74 .02913 14 .55118 54 2.12598 94 3.70078
.35 .01378 .75 .02953 15 .59055 55 2.16535 95 3.74015
.36 .01417 .76 .02992 16 .62992 56 2.20472 96 3.77952
.37 .01457 .77 .03032 17 .66929 57 2.24409 97 3.81889
.38 .01496 .78 .03071 18 .70866 58 2.28346 98 3.85826
.39 .01535 .79 .03110 19 .74803 59 2.32283 99 3.89763
.40 .01575 .80 .03150 20 .78740 60 2.36220 100 3.93700
1-10
Servicing Symbols
Listed in the table below are symbols indicating special

instructions and other important information necessary
for proper servicing. Please note the definition for each
symbol. These symbols are used throughout this two-vol-
ume set.
1
SYMBOL DESCRIPTION
Torque control required
242 - apply blue Loctite #242 (p/n 1639-815)

270 - apply green Loctite #270 (p/n 1639-817)
271 - apply red Loctite #271 (p/n 1639-820)
Lubricate with Arctic Cat 50:1 Injection Oil (p/n 0636-286)

Lubricate with Arctic Cat Extreme 50:1 Injection Oil (p/n 0639-112)
Lubricate with Arctic Cat Low-Temp Grease (p/n 0636-593)
3B - Three Bond Sealant (p/n 0636-070)

HT - High-Temp Sealant (p/n 0636-069)
AS - Anti-Seize Thread Compound (p/n 0678-146)
1-11
NOTES
1-12
SECTION 2 — ENGINE
TABLE OF
CONTENTS
Engine ..................................................................... 2-2
Removing Engine (Table of Contents)..................... 2-2
Disassembling Engine (Table of Contents) ........... 2-12
Servicing Components (120 cc) ............................ 2-48
Cleaning and Inspecting Engine ........................... 2-58
Measuring Critical Components ............................ 2-62
2002 Arctic Cat Engine Specifications .................. 2-66
Assembling Engine (Table of Contents) ................ 2-67
Assembly Schematics (Table of Contents) .......... 2-114
Installing Engine (Table of Contents)................... 2-130
Troubleshooting Engine (120 cc)......................... 2-139
Troubleshooting Engine (Carbureted Models) ..... 2-140
Troubleshooting Engine (EFI Models) ................. 2-144
Engine Information (Table of Contents)............... 2-148
2-1
2. Remove the two cap screws securing the steering
Engine post to the steering post support. Account for two
bearing halves, two lock nuts, and a bearing
retainer.
This engine servicing section has been organized into
sub-sections which show a progression for the com-
plete servicing of the Arctic Cat engine. For consis-
tency purposes, this section shows a complete and
thorough progression; however, for efficiency it may
be preferable to remove the engine as a complete
assembly, to remove and disassemble only those com-
ponents which need to be addressed, and to service
only those components. Also, some components may
vary from model to model. The technician should use
discretion and sound judgment.
NOTE: Some illustrations and photographs used
in this section are used for clarity purposes only
A023A
and are not designed to depict actual conditions.
3. Pull the steering post up and back and then out of
the lower steering post bearing.
4. Remove the two lock nuts securing the tie rods to
Removing Engine 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
compartment.
120 cc Model........................................................... 2-2
Twin F/C Models...................................................... 2-3
500/600/800 cc Twin Models................................... 2-5
550 cc Models ......................................................... 2-7
Triple Models ........................................................... 2-9
Removing Engine
(120 cc Model)
NOTE: The drive chain must be removed in order

to remove the engine (see Drive Chain and Sprock- A024
ets sub-section in Section 8).
5. Cut the cable tie; then disconnect all wires (a total
1. Disconnect the choke and throttle cables from the of four) at the front of the engine. Route them out
carburetor; then on each cable, loosen the of the way.
adjustment jam nut closest to the carburetor and
remove the cables from the bracket. Route the
cables out of the way.
A047
6. Turn the gas tank shut-off valve to the CLOSED

A046A
position.
2-2
NOTE: The front center plug is to access the oil
drain plug.
! WARNING
Whenever any maintenance or inspection is made 13. Place the snowmobile in the upright position; then
on a fuel system when there may be fuel leakage, on the left-hand side of the engine, remove the
there should be no welding, smoking, open flames, three cap screws securing the engine and brake
etc., in the area. bracket to the front end.
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

cm (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. 2
10. At this point, scribe a line at the front of the engine A050A
and measure the distance between the crankshaft
and the driveshaft. Record the measurement for 14. Remove the engine from the engine compartment.
installing purposes.
Removing Engine
(Twin F/C Models)
NOTE: If equipped with electric start, disconnect

the battery.

position.
2. Open the belt guard.
A048
3. Remove the drive belt; then remove the plug from
11. Lay the snowmobile on its side. the belly pan.
NOTE: A piece of cardboard should be used to NOTE: Before installing the clutch puller, apply
protect the finish. oil to the threads of the puller and a small amount
of grease to the tip of the puller.
12. Using a flat-blade screwdriver, remove the four
belly pan plugs covering the engine mounting cap 4. Remove the bolt and lock washers securing the
screws; then remove the cap screws. Account for drive clutch to the crankshaft; then using the Drive
eight washers and four lock nuts. Clutch Puller (p/n 0644-207) and an impact
wrench or a breaker bar and Drive Clutch Spanner
Wrench (p/n 0644-136), tighten the puller. If the
drive clutch will not release, sharply strike the
head of the puller with a hammer. Repeat this
procedure until the clutch releases.
A049
2-3
AF472D AF473D
8. Remove the springs securing the expansion

chamber to the exhaust manifold and resonator;
then remove expansion chamber.
AF476D
5. Remove the clutch from the engine compartment.

6. Remove the cap screw and washer securing the AC067
driven pulley; then slide the pulley off the driven
shaft. Account for and note the position of any 9. Remove the cap screws and lock washers securing
alignment washers. the recoil starter; then remove the starter. Leave it
in the engine compartment.
NOTE: If the driven pulley will not slide off the
driven shaft, use the Driven Pulley Puller (p/n
0744-023) for removal.
AB082
10. Disconnect the four-prong main wiring harness

SC013D connector and the CDI unit wiring harness.
7. Remove the torque bumper. Account for any 11. Disconnect the impulse hose from the crankcase.
engine mount shims.
12. Disconnect the spark plug caps.
13. Loosen the carburetor flange clamp(s). Remove
the carburetor(s) from the intake flange(s) and
carburetor boot(s). Place the carburetor(s) to the
side in an upright position.
2-4
NOTE: If equipped with electric start, remove the
lock nuts and washers securing the starter motor
to the engine mounting bracket and remove the Removing Engine
starter motor. (500/600/800 cc Twin Models)
14. Disconnect the oil-injection cable from the oil- NOTE: Some engines are equipped with Arctic
injection pump. Account for the E-clip and Power Valves (APV). Closely observe the NOTE:
washer; then disconnect the oil supply hose from introducing this important information.
the pump and plug the hose to prevent leakage.
NOTE: If applicable, disconnect the battery
cables.

position.
2. Remove all springs securing the expansion
chamber(s) and remove the expansion chamber(s)
from the engine compartment.
3. Open the belt guard; then remove the drive belt. 2
4. Remove the plug from the belly pan. Using a ½-in.
12-point socket, remove the cap screw and lock
AB081 washer securing the drive clutch to the crankshaft;
then using Clutch Puller (p/n 0644-207) and an
NOTE: If equipped with electric start, remove the impact wrench or a breaker bar and Spanner
two lock nuts and washers securing the starter Wrench (p/n 0644-136), tighten the puller. If the
motor bracket; then remove the three remaining
cap screws, washers, and lock washers securing drive clutch will not release, sharply strike the
the starter motor bracket and ground cable. head of the puller. Repeat this step until the clutch
Remove the starter motor bracket. releases. Remove the drive clutch. If applicable,
account for the two sleeves.
15. Remove the cap screws securing the engine to the
front end. Account for washers, cap screws, and
lock nuts.
AN380D
5. Remove the cap screw and washer securing the

driven pulley; then slide the driven pulley off the
AL201D
driven shaft. Account for a key, stub shaft, and
16. Lift the engine out of the engine compartment. alignment washers.
17. Remove the cap screws, washers, and lock

washers securing the engine mounting brackets to
the engine; then remove the brackets.
AF120D
2-5
NOTE: If the driven pulley is tight on the driven
shaft, pull the driven pulley off using the Driven
Pulley Puller (p/n 0744-023).
NOTE: Steps 6 through 12 are for APV equipped

engines.
6. Remove the two cap screws securing the

servomotor cover.
AP118B
10. Remove the screw securing the servomotor

mounting plate to the air-intake silencer; then pull
the mounting plate forward and up to remove it
from the silencer. Lay the mounting plate aside out
of the way.
AP116A
7. Using a small screwdriver, pry off the cable

retaining cover.
AP127
11. Lift the silencer cover and remove the CDI unit;
then lay the unit aside out of the way.
12. Remove the two APV drain hoses and route them
out of the way.
AP117A
8. Rotate the servomotor actuator counterclockwise

to loosen the cable; then pull the cable housings
out of the holder.
AP128A
13. If applicable, remove the machine screw and

washer securing the mounting plate (for the
ignition coil and fuel pump) to the air-intake
AP118A silencer.
9. Pull the cable up and out of the cable housing 14. Remove the screws securing the air-intake
holder; then slide each cable drum to the left and silencer; then move the silencer forward and out of
out of the servomotor actuator. the engine compartment.
2-6
15. Disconnect the oil-injection cable/control rod from
the oil-injection pump; then disconnect the oil-
supply hose from the pump and plug the hose to
prevent oil drainage.
16. Loosen the flange clamps securing the throttle
body/carburetor to the flange; then remove the
throttle body/carburetor. Place them to one side in
an upright position.
17. On carbureted models, disconnect the impulse
hose from the crankcase.
AP126
24. Loosen the clamp securing the supply hose to the

coolant tank and remove the hose. Loosen the
clamp securing the hose to the thermostat cap;
then remove the hose from the cap.
NOTE: Inspect the engine to ensure all wires, 2
hoses, and cables have been removed.
25. Lift the engine with mounting brackets out of the

engine compartment.
AN385D 26. Remove the cap screws securing the engine

mounting brackets to the crankcase; then remove
18. Loosen the engine torque bumper and remove the the brackets.
left rear engine nut and washer.
27. Remove the exhaust manifold from the engine.
Account for nuts, washers, and gaskets.
28. Remove the clamp securing the coolant supply
hose to the water pump. Then remove the hose
from the pump.
Removing Engine
(550 cc Models)
1. Disconnect the battery cables making sure to

AN610D
disconnect the negative cable first.
19. Secure the hood with a tie-down strap; then
remove the hood cable. 2. Turn the gas tank shut-off valve to the CLOSED
position.
20. Disconnect all electrical wires from the engine.
3. Remove the cable tie and positive battery cable
21. Remove the recoil starter from the engine. Leave it from the starter motor.
in the engine compartment.
4. On the Wide Track, remove the two lock nuts
NOTE: If applicable, disconnect the solenoid-to- securing the starter motor to the engine mounting
starter motor cable from the starter motor. bracket; then place the starter motor and end cap
off to the side.
22. Loosen the cap screws/lock nuts securing the
engine mounting brackets to the front end. 5. Remove the springs securing the expansion
chamber to the exhaust manifold, front end, and
23. Remove the cap from the coolant drain hose and resonator. Remove the expansion chamber and
route the hose into a suitable container. Remove grafoil gasket.
the filler cap; then once the coolant stops draining,
install the drain hose cap.
2-7
6. Attach a long piece of fuel hose to the engine
coolant drain (located on the exhaust side of the
engine). Route the hose outside the engine
compartment and into a container. Open the drain
and remove the filler cap. Once the coolant stops
flowing, remove the hose and tighten the drain
valve.
AF459D

driven pulley; then slide the driven pulley off the
driven shaft. Account for a key and alignment
washers.
AP058
7. Open the belt guard: then remove the drive belt.

NOTE: On the Wide Track, remove the machine
screws securing the side panel to the belly pan;
then remove the side panel. On the Pantera 550
and ZL 550, remove the rubber plug from the belly
pan.
AF120D

10. Loosen the flange clamp securing each carburetor

to its flange; then remove the carburetors. Position
the carburetors to one side in an upright position.
AM115D
8. Using a ½-in. twelve-point socket, remove the bolt

and lock washer securing the drive clutch to the
crankshaft. Using the Clutch Puller (p/n 0644-207)
and an impact wrench or a breaker bar and the
Flywheel Pulley/Spanner Wrench (p/n 0144-310),
tighten the puller. If the drive clutch will not
release, sharply strike the head of the puller.
Repeat this step until the clutch releases. Remove
the drive clutch. If applicable, account for the two
sleeves.
AJ172
NOTE: On the Wide Track, remove the lock nut
securing the belly pan and bumper to the bumper 11. Disconnect the impulse hose from the crankcase.
support tube; then remove the rear plug from the
belly pan. 12. Remove the cable tie securing the engine and CDI
wiring harnesses to the engine; then disconnect the
main wiring harness from the engine and CDI
wiring harnesses.
2-8
13. Remove the spark plug caps and the cable tie
securing the temperature-gauge sender wire; then
disconnect the sender wire.
14. On the Wide Track, remove the ground wire from
the magneto housing.
15. Remove the E-clip and washer securing the oil-
injection cable; then disconnect the oil-injection
cable from the pump. Disconnect the oil-supply
hose from the pump and plug the hose to prevent
oil drainage.
AN013
20. Lift the engine with mounting brackets out of the

engine compartment.
! CAUTION
Do not use the starter motor shaft to lift the 2
engine. Damage may occur.
21. Remove the engine mounting brackets.
AN009
16. Loosen the clamp securing the supply hose to the Removing Engine
water pump housing; then remove the hose from (Triple Models)
the water pump. Loosen the clamp securing the
hose to the thermostat cap; then remove the hose
from the cap. NOTE: Some engines are equipped with Arctic
Power Valves (APV). Closely observe the NOTE:
17. Remove the four cap screws and lock washers introducing this important information.
securing the recoil starter; then remove the starter
from the engine. Leave it in the engine 1. Turn the gas tank shut-off valve to the CLOSED
compartment. position.
NOTE: On the Pantera 550, account for the

ground wire.
18. Support the hood; then remove the hood cable

from the exhaust manifold.
19. Remove the mounting hardware securing the
engine to the front end.
NOTE: On the Wide Track, account for shims and
note their position on the left rear engine mount
for assembly purposes.
AL658D
2. Secure the hood with a hold-down strap; then

remove the hood cable.
3. Remove the springs securing the expansion
chambers to the header pipes, the front end, and
the resonator. Remove the expansion chambers
and three grafoil gaskets.
NOTE: Number the expansion chambers before
removing to aid in assembly.
AR321
2-9
4. Remove the cap screws securing the resonator. NOTE: Steps 9 through 15 are for APV equipped
Account for and note the location of the engine engines.
ground cable with star washer, washers, bushings,
spacers, and retaining nuts. 9. Remove the two cap screws securing the
servomotor cover.
5. Attach a long piece of fuel hose to the engine
coolant drain. Route the hose outside the engine
compartment and into a container. Open the drain
valve; then remove the coolant filler cap to vent
the system. Once the coolant stops flowing,
remove the hose and tighten the drain valve.
AP116A
10. Using a small screwdriver, pry off the cable

retaining cover.
AQ123
6. Open the belt guard; then remove the drive belt.

7. Remove the plug from the belly pan; then using a
1/2 in. twelve-point socket, remove the bolt and
lock washer securing the drive clutch to the
crankshaft. Using the Drive Clutch Puller (p/n
0644-207) and an impact wrench or a breaker bar
and Spanner Wrench (p/n 0644-136), tighten the
puller. If the drive clutch will not release, sharply
strike the head of the puller. Repeat this step until
the clutch releases. Remove the drive clutch. If AP117A
applicable, account for the two sleeves.
11. Rotate the servomotor actuator counterclockwise
to loosen the cable; then pull the cable housings
out of the holder.
AF472D
8. Remove the cap screw securing the driven pulley;

then slide the driven pulley off the driven shaft. AP118A
Account for a stub shaft, the location of all
washers, and a key. 12. Pull the cable up and out of the cable housing
holder; then slide each cable drum to the left and
NOTE: If the driven pulley is tight on the shaft, out of the servomotor actuator.
pull the driven pulley off using the Driven Pulley
Puller (p/n 0744-023).
2-10
AP118B AN614D
13. Remove the screw securing the servomotor 17. Disconnect the impulse hose from the crankcase.
mounting plate to the air-intake silencer; then pull
the mounting plate forward and up to remove it 18. Loosen the engine torque bumper; then remove the
from the silencer. Lay the mounting plate aside out left-side rear engine nut and washer.
of the way.
2
AN610D
AP127
19. Disconnect the engine and timing sensor wiring
14. Lift the silencer cover and remove the CDI unit; harnesses from the main wiring harness. Remove
then lay the unit aside out of the way. the spark-plug caps from the spark plugs. Remove
the cap screw securing the two ground wires to the
15. Remove the two APV drain hoses and route them magneto housing cover.
out of the way.
20. Remove the E-clip and washer securing the oil-
injection cable; then disconnect the oil-injection
cable from the oil-injection pump. Disconnect the
oil-supply hose and the oil-output hose from the
pump and plug the hoses to prevent oil drainage.
AP128A
16. Label the carburetors. Loosen the flange clamp

securing each carburetor to its flange; then remove
the carburetors from the intake flanges. Position
the carburetors to one side in an upright position. AN392D
2-11
21. Loosen the clamp securing the coolant supply hose
to the water pump housing; then remove the hose
from the water pump. Loosen the clamp securing
Disassembling Engine
the hose to the thermostat cap; then remove the Table of Contents
hose from the cap.
22. Disconnect the temperature-gauge sender wire. 120 cc Model ......................................................... 2-12
370/440 cc Models ................................................ 2-17
550 cc Models ....................................................... 2-20
570 cc Models ....................................................... 2-23
500/600 cc Twin Models ........................................ 2-29
800 cc Models ....................................................... 2-34
600 cc Triple Model ............................................... 2-39
1000 cc Models ..................................................... 2-45
(120 cc Model)
AJ663
1. Remove the oil drain plug and drain the oil; then
23. Remove the cap screws securing the engine install the oil plug and tighten securely.
mounting brackets to the front end. Account for
mounting hardware.
24. Lift the MAG-side of the engine. Remove the four
cap screws and lock washers securing the recoil
starter; then remove the starter from the engine.
Leave it in the engine compartment.
NOTE: If applicable, disconnect the solenoid- to-
starter motor cable from the starter motor.
GM300D
2. Remove the wing nut securing the air cleaner end

cap to the air cleaner housing.
3. Remove the cap screw and flange nuts securing
the air cleaner housing to the carburetor and
engine.
AN012
25. Lift the engine with engine mounting brackets out

of the engine compartment.
26. Remove the mounting brackets from the
crankcase.
A002
2-12
GF314D GF208D
4. Remove the air breather hose from the air cleaner 6. Slide the carburetor off the mounting studs.
housing; then remove the air cleaner housing from Account for a gasket, insulator block, and a
the carburetor. Account for the gasket. gasket.
A001 GF318D
7. Remove the recoil starter/fan housing assembly.
GF316D
5. Mark the locations of the springs for assembly; GM201D

then disconnect the rod and spring from the
carburetor. 8. Remove the screws securing the recoil starter
pulley to the flywheel; then remove the nut
securing the flywheel to the crankshaft.
2-13
GM202D GE318D
12. Remove the cylinder head cover.
GM203D
9. Using a flywheel puller, remove the flywheel. GM205D
13. Remove the air breather body assembly from the

cylinder head cover. Account for a gasket.
GM110D
10. Remove the high tension lead from the spark plug
and two wire forms; then disconnect the ignition GM206D
coil wire.
14. Remove the screws securing the reed stopper to
11. Remove the cap screws securing the ignition coil the air breather body assembly.
to the crankcase housing.
2-14
GM207D GM210D
15. Remove the lock nuts and pivots securing the

rocker arms to the cylinder head.
GM211D
18. Remove the cap screws securing the crankcase

GM208D side cover to the crankcase. Account for dowel
pins and a gasket.
16. Remove the push rods.
GM212D
GM209D
17. Remove the cap screws securing the head to the

cylinder; then remove the head and account for a
gasket. Note the location of the dowel pins.
GM213D
2-15
19. Remove the washer from camshaft and note the 21. Rotate the crankshaft until the piston is at the top
location of the timing marks on the crankshaft and of the stroke; then using a chisel, loosen the
camshaft gears. connecting rod nut locking tabs.
GM214D GM119D
22. Note the direction of the arrow on the connecting

rod and mark the connecting rod and end cap for
reference during installation.
GM215D
20. Remove the camshaft; then remove the tappets.
GM121D
GM216D
GM120D
23. Remove the connecting rod end cap and account

for the splasher plate and lock tab.
GM217D
2-16
GM123D GM126D
24. Using two flat blade screwdrivers between the

connecting rod studs and the crankshaft web, push
upward on the piston.
(370/440 cc Models)
2
1. Remove the four nuts and lock washers securing
the exhaust manifold; then remove the exhaust
manifold. Account for two gaskets.
2. Noting the location of the longer cap screws for
assembly purposes, remove the 14 cap screws,
lock washers, and washers securing the top and
exhaust-side cooling shrouds.
3. Lift the top cooling shroud off the engine and slide
GM122D
the exhaust-side cooling shroud off the exhaust-
manifold studs. Account for two exhaust-manifold
25. Remove the crankshaft. shroud gaskets.
GM124D AB014
26. Remove the cap screws securing the oil level 4. Disconnect the two oil-injection hoses from their
sensor plate to the crankcase; then remove the fittings on the intake manifold (single carburetor)
plate. or on the adapter plates (twin carburetor).
5. A. On the 370 cc, remove the nuts securing the
intake manifold; then remove the manifold with
flange from the engine. Account for two
insulators. Discard the gaskets.
B. On the 440 cc, remove the nuts, lock washers,
and washers securing the intake flanges; then
remove the flanges from the engine. Remove
the screws securing the adapter plates; then
remove the adapter plates. Discard the gaskets.
2-17
6. Remove the intake-manifold cooling shroud from
the engine. Discard the two gaskets.
7. Using Flywheel Spanner Wrench (p/n 0144-007)
to secure the crankshaft, remove the three cap
screws and lock washers securing the starter
pulley to the flywheel. Remove the starter pulley;
then carefully pry the fan belt drive pulley from its
seated position on the flywheel and remove.
AB015
11. Install a protective cap onto the end of the

crankshaft.
NOTE: A suitable protective cap can be made by
welding a 3 mm (1/8 in.) plate on one side of a
spare flywheel nut.
AB020
8. Temporarily install the starter pulley on the

flywheel with three cap screws. Using the
flywheel spanner wrench to secure the crankshaft,
loosen and remove the flywheel nut and washers.
AB022
! CAUTION
To prevent damage to the crankshaft, thread a
protective cap onto the crankshaft. The puller
must bottom on the cap and not on the
crankshaft. Also, do not thread puller bolts more
than 12.7 mm (1/2 in.) into the flywheel. Damage
AB021
to the coils may result.
NOTE: If an impact wrench is being used, use of
a flywheel spanner wrench will not be necessary. 12. Using the Flywheel Puller/Spanner Wrench (p/n
0144-310) or suitable equivalent, remove the
9. Remove the cap screws securing the starter pulley flywheel from the crankshaft by tightening the
to the flywheel and remove the pulley. puller bolt, striking the head of the puller bolt with
a hammer, and tightening again. Repeat procedure
10. Remove the flange nuts securing the fan case to until the flywheel is free. Account for the key in
the crankcase; then remove the fan case. the end of the crankshaft.
NOTE: For further servicing of the axial fan com-

ponents, see section 3.
2-18
AB098 AB018
NOTE: To ensure the cleanliness of the flywheel 16. Remove the spark plugs.
magnets, place the flywheel (with the magnets fac-
ing upward) on a clean bench. 17. Remove the eight nuts, lock washers, and washers
securing the cylinder heads to the cylinders. Note
13. Scribe a reference line on the stator plate and
crankcase to aid in assembly; then remove the two
the position of the different-sized nuts. Remove
the heads and account for two gaskets and four 2
Allen-head cap screws, lock washers, and washers dowel pins.
securing the stator plate.
NOTE: The two stator plate Allen-head cap
screws had Loctite applied to the threads during
assembly. Before removing them, apply a sharp
blow to the head of each screw to break the Loctite
loose. If this isn’t done, the screws can be very dif-
ficult to remove.
B563
18. Using a rubber hammer, gently tap the cylinders

and remove from the crankcase by lifting them
straight up off their studs. Discard the two gaskets.
Account for two dowel pins.
! CAUTION
AB026
When removing a cylinder, make sure to support
14. Remove the stator plate from the engine. the pistons so they will not be damaged.
15. Remove the screws, lock washers, and washers 19. Using a felt-tipped marker, mark an M on the
securing the oil-injection pump to the crankcase; MAG-side head, cylinder, and piston and a P on
then remove the pump, retainer, shim, and gear. the PTO-side head, cylinder, and piston.
Account for two gaskets.
NOTE: For proper assembly, keep all MAG-side
components and all PTO-side components sepa-
rated. Assemble them on their proper sides.
20. Remove the PTO-side piston-pin circlip from the

PTO-side piston; remove the MAG-side piston-pin
circlip from the MAG-side piston.
2-19
23. Remove the cap screws securing the crankcase
halves. Note the position of the different-sized cap
screws.
A829
21. Using the Piston-Pin Puller (p/n 0644-328),

remove the piston pins from both pistons.
A831
24. Separate the crankcase halves by installing two

crankcase cap screws in diagonal corners leaving
the heads approximately 6 mm (1/4 in.) out. Using
a plastic hammer, tap on each cap screw head until
the halves separate. Remove the cap screws.
! CAUTION
DO NOT drive any tool between the crankcase
halves to separate the crankcase. Damage to the
sealing surfaces will result.
A830 25. Remove the rubber bands holding the connecting

rods; then separate the crankcase halves. Account
for the two dowel pins. Lift the crankshaft free
! CAUTION from the crankcase half and slide the two
DO NOT use any type of punch to drive the crankshaft seals off the crankshaft. Account for the
piston pin free of the piston; damage may result. C-ring and five bearing retaining pins.
Use a piston-pin puller only.
22. Lift the pistons clear of the connecting rods and

remove the small end connecting-rod bearings;
then remove the piston rings. Keep each piston Disassembling Engine
with its rings, piston pin, and bearing together as a (550 cc Models)
set.
NOTE: Place rubber bands over the connecting 1. Using the spanner wrench to secure the flywheel,
rods and around the cylinder studs. This will keep remove the flywheel nut, lock washer, and flat
the connecting rods from damaging the crank- washer; then remove the three starter pulley cap
case. screws and remove the pulley.
B160 AN015
2-20
2. Install the Crankshaft Protector Cap (p/n 0644- NOTE: The stator plate screws had Loctite
234) onto the end of the crankshaft. applied to the threads during assembly. Using an
impact driver, apply a sharp blow to the head of
NOTE: A suitable substitute protective cap can each screw to break the Loctite loose before
be made by welding a 3 mm (1/8 in.) plate on one removal.
side of a spare flywheel nut.
5. Remove the four nuts and lock washers securing
3. Using the Flywheel Puller/Spanner Wrench (p/n the exhaust manifold.
0144-310) or suitable substitute, remove the
flywheel from the crankshaft by tightening the 6. Remove the manifold and account for the two
puller bolt, striking the head of the puller bolt with exhaust gaskets.
a hammer, and tightening again. Repeat this
procedure until the flywheel is free. Account for 7. Remove the three cap screws securing the
the key. thermostat cap; then remove the cap, gasket, and
thermostat.
! CAUTION NOTE: The thermostat is of the lock-open type. If
To prevent damage to the crankshaft, the puller the thermostat is ever allowed to fully open, it will
must bottom on the cap and not on the remain open and replacement will be necessary.
8. Remove the four cap screws securing the
thermostat manifold to the cylinder heads.
2
Remove the manifold and discard the gaskets.
9. Remove the spark plugs.
10. Remove the six cap screws and O-rings securing
each head; then separate from the cylinder.
Account for two large O-rings beneath each head.
11. Remove the oil-injection hose from each cylinder
and the crankcase nozzle.
AN020
NOTE: To ensure the cleanliness of the flywheel

ing upward) on a clean bench.
4. Scribe a line on the stator plate and magneto case

to aid in assembly; then remove the two Allen-
head cap screws, lock washers, and washers
securing the stator plate. Remove the stator plate
from the engine. AN032
12. Remove the eight nuts, lock washers, and washers

securing the cylinders to the crankcase; then using
a rubber hammer, gently tap the cylinders and
remove from the crankcase by lifting them straight
up off their studs. Account for two gaskets.
! CAUTION
When removing a cylinder, be sure to support
the piston to prevent damage to the crankcase
and piston.
NOTE: The metal cylinder base gaskets may be

reused. When reusing gaskets, they must be
AN022 cleaned and sprayed with Copper Coat Gasket
Sealant (p/n 0636-092) on each side.
2-21
16. Remove the two screws, lock washers, and
washers securing the oil-injection pump to the
crankcase. Remove the pump, retainer, and O-ring.
17. Remove the water pump cover. Account for the O-
ring gasket.
18. Remove the cap screw securing the water pump
impeller; then slide the impeller free of the shaft.
19. Using an impact driver, remove the screws
securing the PTO-end plate to the crankcase; then
remove the plate.
AN033
20. Position the crankcase (with its bottom side up) on
NOTE: If servicing the intake flanges, remove two blocks of wood. Remove the fourteen cap
them at this time. screws securing the crankcase halves. Note the
position of the different-sized cap screws.
PTO-side piston; then remove the MAG-side 21. Separate the crankcase halves by installing two
piston-pin circlip from the MAG-side piston. crankcase cap screws in opposite corners leaving
the heads approximately 6 mm (1/4 in.) out. Using
14. Using the Piston Pin Puller (p/n 0644-328), a plastic-tipped hammer, tap on each cap screw
remove the piston pins from both pistons. head until the case halves separate. Remove the
cap screws.
! CAUTION
DO NOT drive any tool between halves to
separate the crankcase. Damage to the sealing
surfaces will result.
AN036
! CAUTION AN045
DO NOT use any type of punch to drive the
piston pin free of the piston; damage may result. 22. Lift the bottom half of the crankcase off the top
Use a piston-pin puller only. half.
15. Lift the pistons clear of the connecting rods and 23. Lift the crankshaft free from the top half of the
remove the small-end connecting-rod bearings; crankcase and slide the crankshaft oil seals off the
then remove the piston rings. Keep each piston crankshaft. Account for the C-ring. Remove the
with its rings; keep each piston pin and bearing two dowel pins and the four bearing retaining pins.
together as a set.
24. Remove the oil-injection pump driveshaft from the
NOTE: Place rubber bands over the connecting lower crankcase half. Account for the thrust
rods and around the cylinder studs. This will pre- washer on the outer end of the shaft.
vent the connecting rods from damaging the
crankcase.
2-22
28. Using a sharp, pointed tool, pry the seal ring from
the backside of the water pump impeller.
AN047
NOTE: Do not replace the inner seals unless the

water pump shows signs of leaking coolant out of AN051
the small bleed hole in the bottom half of the
crankcase. If a water pump seal is to be replaced,
use the Water Pump Bearing and Seal Kit (p/n
0644-084) and see Cleaning and Inspecting Engine 2
in this section. Disassembling Engine
(570 cc Models)
25. Place the crankcase on the bench with the water
pump side down. Using the long seal driver, drive
the water pump seal from the crankcase. 1. Remove the exhaust manifold. Account for the
gaskets.
2. Remove the nuts, lock washers, and washers
securing the intake flange assembly. Account for
the gaskets, insulators, and the heat deflector.
3. Remove eight cap screws securing the main fan
shroud; then remove the shroud with the recoil
starter assembly.
AN049
26. Remove the snap ring securing the inner seal in the
crankcase.
27. Using the hooked end of the tool, pull the inner
seal free of the crankcase.
MD0279
NOTE: Cap screws securing the front and rear

shrouds use special washers.
4. Remove the five cap screws securing the front

(exhaust-side) shroud to the cylinder head.
Account for the special washers.
AN050
2-23
6. Using Spanner Wrench (p/n 0144-007) to hold the
starter pulley, remove the cap screw securing the
flywheel to the crankshaft.
MD0276
NOTE: Keep the special mounting hardware with

the shrouds for assembling purposes.
MD0282

starter pulley, remove the three cap screws
securing the starter pulley and fan to the flywheel.
MD0065
5. Remove the spark plug grommets.
MD0000
! CAUTION
To prevent damage to the crankshaft, install a
protective insert into the end of the crankshaft.
The puller must bottom on the insert and not on
the crankshaft. Also, do not thread puller bolts
more than five threads into the flywheel. Damage
to the stator coils may result.
8. Install Flywheel Puller Insert (p/n 0644-179) into

MD0060 the end of the crankshaft. Using Flywheel Puller/
Spanner Wrench (p/n 0144-310) or suitable
substitute, remove the flywheel.
2-24
10. Remove the rubber insulator grommet from the
crankcase; then remove two Phillips-head cap
screws securing the ignition timing sensor and pull
the wires through the hole in the crankcase.
AN615

9. Remove the six cap screws securing the rear

(intake-side) shroud; then remove the shroud.
MD0075 2
Account for the special washers.
MD0074
MD0277
11. Remove the three Allen-head cap screws securing
the stator and remove it along with the stator
wiring.
MD0072
MD0067
2-25
MD0081

MD0076
12. Remove the four Allen-head cap screws securing

the stator plate. Remove the stator plate.
MD0083
15. Remove the eight cap screws, two nuts, and two
washers securing the cylinder head to the
MD0255 cylinders; then remove the cylinder head. Discard
the cylinder head gasket.
MD0078
13. Remove the four cap screws securing the seal MD0289
retainer plate on the PTO-side; then remove the
plate. 16. Remove the four 6 mm nuts and eight 10 mm nuts
securing the cylinders to the crankcase.
NOTE: Using a felt-tip marker, mark the cylinders
as to MAG-side and PTO-side for assembling.
Also, mark the pistons at this time.
2-26
MD0096
MD0087
18. Using an awl, remove the outside piston-pin
circlip and remove the piston pin using Piston Pin
Puller (p/n 0644-328) taking care not to drop the
piston-pin bearing washers into the crankcase.
2
MD0086
17. Remove the cylinders making sure to support the

pistons so they are not damaged. Account for four
dowel pins.
! CAUTION MD0094
When removing a cylinder, make sure to support NOTE: The open sides of the piston pin bearing
the piston so it will not be damaged. washers face inward.
MD0230
MD0251
2-27
MD0090
MD0208
NOTE: If the existing rings will not be replaced O-Ring

with new rings, note the location and top side of
each ring for proper installation. When replacing
with new rings, replace as a complete set only.
When replacing rings note notches in ring ends
which correspond with locating pins in ring
grooves on intake side of the piston. This prevents
the rings from turning on the piston when assem-
bled.
MD0092
20. Remove the oil-injection pump driveshaft retainer.

Account for an O-ring.
O-Ring
MD0272
MD0100
21. Remove the oil-injection pump driveshaft.

Account for a thrust washer.
MD0271
19. Remove the two Allen-head cap screws securing

the oil-injection pump; then remove the pump.
Account for an O-ring.
MD0101
2-28
22. Place the crankcase (with its bottom side up) on
two blocks of wood. Remove the 12 cap screws
securing the crankcase halves. Note the position of
the different-sized cap screws.
23. Separate the crankcase halves by installing two of
the cap screws in opposite corners leaving the
heads approximately 6 mm (1/4 in.) out. Using a
plastic mallet, tap on each cap screw until the
crankcase halves separate. Account for four dowel
pins.
MD0246
(500/600 cc Twin Models)
2
NOTE: Some engines are equipped with Arctic
MD0283
introducing this important information.
1. Using the spanner wrench to secure the flywheel,

remove the flywheel nut, lock washer, and flat
washer; then remove the three starter pulley cap
screws and remove the pulley.
MD0204
24. Remove the two cap screws; then remove the

crankshaft assembly from the upper crankcase half
making sure to hold both ends of the crankshaft to AN015
keep the bearings and seals from falling off.

Account for bearings and a C-ring.
! CAUTION
To prevent damage to the crankshaft, crankshaft
bearings, or seals, be sure to always lift the
crankshaft from both ends.
AN407D
2. Install the Crankshaft Protector Cap (p/n 0644-

234) onto the end of the crankshaft.
2-29
AN018 AN410D

4. Remove the Allen-head cap screws securing the

stator to the stator plate.
AN408D
NOTE: A suitable substitute protective cap can

be made by welding a 3 mm (1/8 in.) plate on one
side of a spare flywheel nut.
3. Using the Flywheel Puller/Spanner Wrench (p/n

0144-310) or suitable substitute, remove the AP132
flywheel from the crankshaft by tightening the
puller bolt, striking the head of the puller bolt with 5. Remove the Allen-head cap screws securing the
a hammer, and tightening again. Repeat this stator plate.
procedure until the flywheel is free. Account for
the key.
! CAUTION
To prevent damage to the crankshaft, the puller
must bottom on the cap and not on the
AR106
6. Remove the stator plate from the engine.
AR105
2-30
AN414D AP134
NOTE: The stator plate screws had Loctite 10. Remove the cap screws securing the valves to the
applied to the threads during assembly. Using an cylinders; then remove the APV assemblies and
impact driver, apply a sharp blow to the head of set them aside.
each screw to break the Loctite loose before
removal. NOTE: The following illustrations are the 500 cc.
Other models may vary slightly. 2
7. Remove the ignition timing sensor.
AP120
AR107
AP121
AN415D
8. Remove the three cap screws securing the
thermostat cap; then remove the cap, gasket, and 12. Remove the cap screws with O-rings securing the
thermostat. cylinder head(s); then separate from the cylinders.
Account for the O-rings.
9. Remove the nuts securing the APV covers to the
cylinders; then slide the covers back to expose the 13. Remove the oil-injection hose from each cylinder
valves. and the crankcase nozzle.
2-31
AN420D AN316D
14. Remove the eight nuts (with lock washers and

washers) securing the cylinders to the crankcase; ! CAUTION
then using a rubber hammer, gently tap the DO NOT use any type of punch to drive the
cylinders and remove from the crankcase by lifting piston pin free of the piston; damage may result.
them straight up off their studs. Account for Use a piston-pin puller only.
gasket(s) and any alignment bushings.
! CAUTION remove the small-end connecting-rod bearings
(account for two washers); then remove the piston
When removing a cylinder, be sure to support rings. Keep each piston with its rings; keep each
the piston to prevent damage to the crankcase piston pin and bearing together as a set.
and piston.

PTO-side piston; then remove the MAG-side
piston-pin circlip from the MAG-side piston.
AN317D
NOTE: Place rubber bands over the connecting

rods and around the cylinder studs. This will pre-
vent the connecting rods from damaging the
AN315D crankcase.
16. Using the Piston Pin Puller (p/n 0644-328), 18. Remove the intake flanges and reed valve
remove the piston pins from both pistons. assemblies.
AN433D
2-32
19. Remove either lower union cap screw securing the
lower check valve assembly; then remove the two
screws, lock washers, and washers securing the
oil-injection pump to the crankcase. Remove the
pump, retainer, and O-ring.
20. Remove the five screws securing the water pump
cover to the crankcase and remove the cover.
Account for the O-ring gasket.
21. Remove the cap screw securing the water pump
impeller; then slide the impeller free of the shaft.
22. Remove the cap screws securing the PTO-end AN324D
plate to the crankcase; then remove the plate.
NOTE: Do not replace the inner seals unless the
23. Position the crankcase, with its bottom side up, on water pump shows signs of leaking coolant out of
two blocks of wood. Remove the cap screws the small bleed hole in the bottom half of the
securing the crankcase halves. crankcase. If a water pump seal is to be replaced,
24. Separate the crankcase halves by installing two

0644-084). 2
crankcase cap screws in opposite corners leaving
the heads approximately 6 mm (1/4 in.) out. Using 28. Place the crankcase on the bench with the water
a plastic-tipped hammer, tap on each cap screw pump side down. Using the long seal driver, drive
head until the case halves separate. Remove the the mechanical water pump seal from the
cap screws. crankcase.
! CAUTION
AN325D
29. Using a pair of snap ring pliers, remove the snap

ring securing the inner seal in the crankcase.
AN045
25. Lift the bottom half of the crankcase off the top
half.
! CAUTION
Care must be taken to not allow the connecting
rods to drop onto the sealing surface of the
bottom case half.
26. Lift the crankshaft free from the top half of the
crankcase and slide the crankshaft oil seals off the
crankshaft. Account for the C-ring. Remove the
bearing retaining pins and account for the
crankcase dowel pins. AN326D
27. Remove the oil-injection pump/water pump 31. Using the hooked end of the tool, pry the seal ring
driveshaft from the lower crankcase half. Account from the backside of the water pump impeller.
for the thrust washer on the outer end of the shaft.
2-33
AN327D AP130
! CAUTION
Disassembling Engine To prevent damage to the crankshaft, place a
(800 cc Models) puller insert into the crankshaft. The puller must
bottom on the insert and not on the crankshaft.
Also, do not thread puller bolts more then
1. Using a spanner wrench to secure the flywheel, 12.7 mm (1/2 in.) into the flywheel. Damage to the
remove the flywheel cap screw, lock washer, and coils may result.
flat washer.
4. Using Flywheel Puller (p/n 0144-310), remove the
flywheel from the crankshaft by tightening the
puller bolt, striking the head of the puller bolt with
a brass hammer, and tightening again. Repeat
procedure until the flywheel is free. Account for
the key in the crankshaft keyway.
! CAUTION
When installing Flywheel Puller (p/n 0144-310), it
must be installed with its welded side facing
outward or the puller will be damaged.
AJ012
2. Using a spanner wrench to secure the crankshaft,

remove the three cap screws from the starter
pulley. Remove the starter pulley.
AJ015
! CAUTION
Before applying excessive pressure to the center
flywheel puller bolt, check to make sure puller
bolt is pulling straight. If it is pulling to one side,
AJ013 the crankshaft will be damaged. Square the
puller using the three bolts that attach the puller
3. Install the Flywheel Puller Insert (p/n 0644-179) to the flywheel.
into the end of the crankshaft.
2-34
5. Remove the two screws securing the timing 9. Remove the nuts securing the APV covers to the
sensor; then loosen the screws securing the wiring cylinders; then slide the covers back to expose the
harness retainer tab. Remove the timing sensor valves.
from the crankcase.
AP134
2
AP131
10. Remove the cap screws securing the valves to the
6. Remove the cap screws securing the stator. cylinders; then remove the APV assemblies and
set them aside.
AP132
AP120
7. Remove the rubber grommet from the stator
wiring harness. Slide the stator free of the
crankshaft and remove.
8. Remove the cap screws securing the stator backing
plate. Remove the plate from the crankcase.
AP121
11. Remove the three cap screws securing the

thermostat cap; then remove cap, rubber gasket,
and thermostat.
AP133 12. Remove the cap screws securing the thermostat

manifold to the cylinder heads. Remove the
manifold and discard the gaskets.
2-35
16. Slowly lift each cylinder straight up and free of the
studs. Grasp the connecting rod and piston as the
cylinder clears the piston to prevent the rod from
dropping against the crankcase. Remove and save
the cylinder base gaskets.
AP135

14. Remove the cap screws and O-rings securing each
head; then separate each head from each cylinder.
Account for two O-rings beneath each head. AP138
NOTE: Mark each cylinder head, cylinder, and 17. Remove the PTO-side piston-pin circlip from the
piston and keep together as an assembly. Mark the PTO-side piston; remove the MAG-side piston-pin
MAG cylinder components #1 and the PTO cylinder circlip from the MAG-side piston.
components #2.
AP140
AP136
18. Using the Piston Pin Puller (p/n 0644-328),
NOTE: If servicing the intake flanges, remove remove the piston pins from both pistons.
them at this time.
15. Remove the four cylinder base nuts and four

flange cap screws securing the cylinders to the
crankcase. Account for four flat washers and lock
washers. Using a rubber hammer, gently tap on the
side of each cylinder to free it from the crankcase.
AP141

AP137
2-36
! CAUTION
DO NOT use any type of punch to drive the pin
free of the piston; damage may result. Use a
piston-pin puller only.

account for two washers. Remove the small-end
connecting-rod bearings; then remove the piston
rings. Keep each piston with its rings; keep each
piston, pin, and bearing together as a set.
AP143
23. Remove the six cap screws securing the water

pump cover to the crankcase. Remove the cover
and O-ring seal. Account for two dowel pins.
AQ059
20. Remove the four cap screws securing the PTO-end

plate to the crankcase; then remove the plate.
AP145
NOTE: Do not remove the water pump impeller

or the impeller shaft unless necessary. Only
remove impeller and shaft if there are signs of
coolant leakage from the small hole located in the
bottom of the crankcase directly behind the water
pump housing.
24. Lay the engine on its side and remove the cap
screws securing the crankcase halves. Note the
position of the different-sizes cap screws for
AP142
assembling.
21. Remove the intake manifold and reed block

assemblies.
22. Remove either lower union bolt securing the lower
check valve assembly; then remove the two cap
screws securing the oil-injection pump to the
crankcase. Remove the pump, retainer, and two O-
rings.
AP146
NOTE: On EFI models, the magneto case must

be removed prior to separating the crankcase
halves.
2-37
25. Separate the crankcase halves by installing two B. While holding the retainer tight against the
crankcase cap screws in opposite corners leaving crankcase, rotate the shaft. Bearing rotation
the heads approximately 6 mm (1/4 in.) out. Using must feel smooth.
a plastic tipped hammer, tap on each cap screw
head until the case halves separate; then remove
the two cap screws. Lift the top half of the
crankcase off the bottom half. Grasp the
connecting rods as the top half of the crankcase is
removed. Do not allow them to drop onto the
sealing surface of the bottom case half.
! CAUTION
26. Lift the crankshaft free from the crankcase half AJ044
and slide the crankshaft oil seals off the ends of the
crankshaft. Account for the C-ring. Slide the C. If any roughness is felt, remove the retainer and
bearings off the crankshaft. Remove and account inspect its bearing by turning it several
for the four bearing retaining pins and the two revolutions. If it is smooth, the shaft must then
crankcase dowel pins from the crankcase. be removed and the inner bearing inspected.
Turn inner bearing by hand. If any roughness is
felt, replace the inner bearing.
D. Check the bottom of the water pump housing
for any signs of coolant leakage. The small
hole, located on the bottom of the crankcase
directly behind the water pump housing, will
show coolant stains if the seal has any leakage
problems. If stains or any signs of leakage are
present, remove impeller and shaft and replace
seals.
AP148A
! CAUTION
DO NOT remove the water pump impeller or shaft
unless necessary. The shaft and impeller should AJ045
only be removed from the lower crankcase half
when there is a coolant leakage problem or a NOTE: For instructions on bearing and seal
rough inner bearing. To inspect for either replacement, see the appropriate Assembling
condition, follow steps A through D. Engine sub-section of this manual. Complete
steps 27-32 only if there is a bad seal or shaft bear-
A. Remove the O-ring from the oil-injection pump ing.
retainer. Slide the retainer into position on the
shaft in the lower half of the crankcase. 27. Remove the cap screw securing the impeller to the
shaft.
2-38
AJ046
28. Remove the oil-injection pump/water pump

driveshaft from the lower crankcase half. Account AN326D
for the thrust washer on the outer end of the shaft.
32. Using the hooked end of the tool, pry the seal ring
from the backside of the water pump impeller.
2
AN324D
NOTE: Do not replace the inner seals unless the AN327D

water pump shows signs of leaking coolant out of
the small bleed hole in the bottom half of the
crankcase. If a water pump seal is to be replaced,
0644-084). Disassembling Engine
(600 cc Triple Model)
the mechanical water pump seal from the NOTE: If servicing the exhaust manifolds,
crankcase. remove them at this time.
1. Using an impact driver or a 6-mm hex wrench,

remove the four cap screws securing the magneto
case to the crankcase.
remove the cap screw, lock washer, and large flat
washer securing the flywheel.
3. Remove the three cap screws securing the starter
pulley to the flywheel.
4. To prevent damaging the crankshaft threads during
the flywheel removal procedure, install a
AN325D Crankshaft Protector Cap (p/n 0644-234) onto the
end of the crankshaft.
2-39
9. Remove the two Allen-head cap screws securing
the stator backing plate to the crankcase.
AN162
5. Attach the flywheel puller to the flywheel using

three 8-mm cap screws approximately 2 3/4 in. AN158
long. Thread each of the three cap screws evenly
into the flywheel 1/2 in. 10. Remove the two screws securing the timing
sensor; then loosen the screw securing the wiring
6. Tighten the center puller bolt against the harness retainer tab. Remove the timing sensor
crankshaft protector on the end of the crankshaft. from the crankcase.
Continue to tighten the puller bolt until the
flywheel snaps free of the crankshaft taper.
Remove the puller from the flywheel and place the
flywheel, open side up, on a clean work bench.
Account for the flywheel key.
AN157
11. Remove the nuts securing the APV covers to the

cylinders; then slide the covers back to expose the
valves.
AN161

the stator to the stator plate.
8. Remove the rubber grommet from the crankcase
and slide the stator free of the crankshaft.
AP134
12. Remove the cap screws securing the valves to the

cylinders; then remove the APV assemblies and
set them aside.
AN160
2-40
AP153 AN209
15. Remove the four nuts securing each cylinder to the

crankcase; then carefully lift each cylinder straight
up and free of the piston. Support the piston as the
cylinder clears the piston to prevent the connecting
rod from dropping against the crankcase and
causing damage to the crankcase sealing surface. 2
Account for two alignment dowel pins per
cylinder.
AP154
13. Remove the thermostat cover; then remove the

thermostat from the water manifold. Remove the
water manifold assembly.
NOTE: The thermostat is designed to open at
50°C (122°F). It should be checked for proper oper-
ation before installing (see Section 3).
AN207
16. For assembly purposes, number the dome of each

piston starting from the MAG-side; then remove
the MAG-side circlip from each piston.
AN156
14. Remove each cylinder head; then account for the

two O-rings under each head. For assembly
purposes, number the three heads and cylinders
using a marker. Start from the MAG-side. AN242
17. Using Piston Pin Puller (p/n 0644-328), remove

the piston pin from each piston. Remove the
piston, piston pin bearing, and the two shim
washers. Keep each piston, piston pin, and bearing
together as a set.
2-41
AN241 AN237
18. Remove the cylinder base gaskets from the 21. Remove each intake flange and reed valve
crankcase. Note that the cylinder base gaskets are assembly. Be very careful not to damage the reed
aligned with the same dowel pins which align the valve stops. Place the assembly on its flat side.
cylinders on the crankcase. Remove and discard and reed valve assembly
gasket.
NOTE: If the cylinder base gaskets are not dam-
aged, they can be reused.
AN236
AN239 22. Using an impact driver, remove the five screws

securing the water pump cover to the crankcase
19. Remove the two screws securing the oil-injection and remove the cover. Account for the O-ring
pump to the crankcase. Slide the pump free of the gasket.
crankcase. Account for the O-ring located around
the pump inner flange.
AN234
AQ130D 23. Loosen the cap screw securing the water pump
impeller until there is a 1/4-in. space between the
20. Remove the six cap screws securing the intake cap screw flange and impeller.
flanges and reed valve assemblies to the
crankcase.
2-42
AN233 AN230
24. Using a plastic hammer, gently tap on the head of 27. Remove the 14 cap screws securing the two
the cap screw until the impeller is free of the shaft. crankcase halves together.
Remove the cap screw and impeller.
AN229
AN232
28. To separate the crankcase halves, start two of the
25. From the opposite side of the crankcase, remove crankcase cap screws into the crankcase at
the oil pump retainer and shaft. Account for the opposite corners. Thread the cap screws into the
shaft thrust washer located between the retainer crankcase until a 6.4 mm (1/4 in.) space remains
and shaft flange. between the cap screw flange and the crankcase
surface.
29. Set the crankcase on its side with the flat reed
surfaces resting on the work bench. Using a
hammer, strike the heads of the two cap screws
alternately driving the two case halves apart.
AN231
26. Using an impact driver, remove the four screws

securing the seal protector plate to the end of the
crankcase; then slide the plate free of the
crankshaft.
AN227
30. Once there is a 6.4 mm (1/4 in.) space between the

two case halves, set the crankcase down on the
work bench with its bottom side up. Remove the
cap screws; then lift the bottom of the crankcase
free of the engine.
2-43
the water pump seal from the crankcase.
AN221
31. Grasp the crankshaft at either end and carefully lift

it from the crankcase. Have a clean area ready to
lay the crankshaft on once it has been removed. AN226
Account for the two crankcase dowel pins.
35. Using the hooked end of the seal driver, pull the
inner seal free of the crankcase.
AN222
32. With the crankshaft removed from the top half of

the crankcase, remove the seven bearing retaining
pins and the C-ring.
AN224
36. Using a sharp-pointed tool, pry the seal ring from

the backside of the water pump impeller.
AN223
NOTE: Do not replace the inner oil seal or

mechanical seal unless the water pump shows
signs of leaking coolant out of the small bleed hole AN051
in the bottom half of the crankcase. If a water
pump seal is to be replaced, use the Water Pump
Bearing and Seal Kit (p/n 0644-084).
2-44
(1000 cc Models)
NOTE: If servicing the exhaust manifolds,

remove them at this time.
1. Using an impact driver or a 6-mm hex wrench,

remove the four cap screws securing the magneto
case to the crankcase. Account for the dowel pins.
2. Using an impact driver, remove the five screws
AQ008
securing the water pump cover. Remove the cover
and account for the O-ring seal and two dowel 6. Remove the remaining water pump center and
pins. back section from the counterbalance shaft.
7. Inspect the front mechanical seal and rear seal
surface for any rough areas. If the seals need
replacement, see the appropriate Repairing Water 2
Pump in Section 3.
AQ005
3. Secure the crankshaft using a spanner wrench;

then remove the cap screw securing the water
pump impeller.
AQ010

remove the cap screw, lock washer, and large flat
washer securing the flywheel.
9. Remove the three cap screws securing the starter
pulley to the flywheel.
10. To prevent damaging the crankshaft threads during
the flywheel removal procedure, use the Puller
Insert (p/n 0644-179) on the end of the crankshaft.
AQ006
4. Remove the water pump impeller from the

counterbalance shaft.
5. With the impeller removed, check the condition of
the seal on the back side. It must be free of any
cracks, chips, or rough areas.
NOTE: If any rough areas are found, the seal ring
can be removed using a small screwdriver. Simply
pry the seal ring upward; then remove the rubber
cup from beneath the seal ring.
AQ019
2-45
11. Attach the flywheel puller to the flywheel using
three 8-mm cap screws approximately 2 3/4 in.
long. Thread each of the three cap screws evenly
into the flywheel 1/2 in.
12. Tighten the center puller bolt against the insert on
the crankshaft. Continue to tighten the puller bolt
until the flywheel snaps free of the crankshaft
taper. Remove the puller from the flywheel and
place the flywheel, open side up, on a clean work
bench. Account for the flywheel key.
AQ026
20. Remove the four nuts, lock washers, and flat

washers securing each cylinder to the crankcase;
then carefully lift each cylinder straight up and
free of the piston. Support the piston as the
cylinder clears the piston to prevent the connecting
rod from dropping against the crankcase and
causing damage to the crankcase sealing surface.
AQ020
13. Remove the Allen-head cap screws securing the

stator to the stator plate.
14. Remove the rubber grommet from the crankcase
and slide the stator free of the crankshaft.
AQ027
21. For assembly purposes, number the dome of each

piston starting from the MAG-side; then remove
the MAG-side circlip from each piston.
AQ021

the stator plate to the crankcase.
16. Remove the thermostat cover; then remove the
thermostat from the water manifold.
NOTE: The thermostat is designed to open at
50°C (122°F). It should be checked for proper oper-
AQ028
ation before installing (see Section 3).
22. Using Piston Pin Puller (p/n 0644-328), remove
17. Remove the water manifold assembly. the piston pin from each piston. Remove the
piston, piston pin bearing, and the two shim
18. Remove the heads from the cylinders. Account for washers. Keep each piston, piston pin, and bearing
the two O-rings under each head. together as a set.
19. For assembly purposes, number the three heads
and cylinders. Start from the MAG-side.
2-46
27. Remove each intake flange and reed valve
assembly. Be very careful not to damage the reed
valve stops. Place the assembly on its flat side.
Remove and discard the reed valve assembly
gasket.
AQ029
23. Before lifting the cylinder base gasket from the

crankcase, note how it is installed. The smaller of
the three water passage holes must be positioned
to the MAG-side of the crankcase when installing.
Lift the gasket free of the crankcase. AN236
2
NOTE: If the cylinder base gasket is not dam- 28. Using an impact driver, remove the four screws
aged, it can be reused. securing the PTO-end plate to the end of the
crankcase; then slide the plate free of the
crankshaft.
AQ030
24. Remove the two screws securing the oil-injection AQ034

pump to the crankcase. Slide the pump free of the
crankcase. Account for the O-ring located around 29. Remove the twenty cap screws securing the two
the pump inner flange. crankcase halves together.
25. Remove the pump retainer and shaft. Account for

the shaft thrust washer.
AQ035
30. To separate the crankcase halves, start two of the

AQ119 crankcase cap screws into the crankcase at
opposite corners. Thread the cap screws into the
26. Remove the six cap screws securing the intake crankcase until a 6.4 mm (1/4 in.) space remains
flanges and reed valve assembly to the crankcase. between the cap screw flange and the crankcase
surface.
2-47
34. Remove the balancer shaft end seals from the
crankcase.
35. Grasp the crankshaft at either end and carefully lift
it from the crankcase. Have a clean area ready to
lay the crankshaft on once it has been removed.
AQ036
31. Set the crankcase on its side with the flat reed
surfaces resting on the work bench. Using a plastic
hammer, strike the heads of the two cap screws
alternately driving the two case halves apart.
32. Once there is a 6.4 mm (1/4 in.) space between the AQ039
two case halves, set the crankcase down on the
work bench with its bottom side up. Remove the 36. With the crankshaft removed from the top half of
cap screws; then lift the bottom of the crankcase the crankcase, remove the seven bearing retaining
free of the engine. Account for the two dowel pins. pins and the two C-rings.
AQ037 AQ040
33. Remove the balancer shaft from the crankcase.

Notice that it has a timing mark located on the side
of the drive gear. This timing mark must be
aligned with the crankshaft gear during assembly. Servicing Components
(120 cc)
Thoroughly clean all non-electrical components in

parts-cleaning solvent; then remove any carbon
buildup from the cylinder head, piston dome, valves,
and valve seats.
Visually inspect all engine components for wear or
damage.
NOTE: Whenever a part is worn excessively,
cracked, or damaged in any way, replacement is
necessary.
AQ038
2-48
CYLINDER HEAD/VALVE ASSEMBLY
NOTE: Remove the valves by pressing down on

the spring retainer and removing the valve keeper.
Account for valve springs, spring retainers, and
valve keepers.
When servicing valve assembly, inspect valve seats,

valve stems, valve faces, and valve stem ends for pits,
burn marks, or other signs of abnormal wear.
NOTE: Discard any valve that fails the listed
inspections. Do not grind the valves. If a valve is
damaged, it must be replaced.
ATV-1004
Measuring Cylinder Head Distortion 2. Acceptable valve face width must be within a
1. Using a non-metallic carbon removal tool, remove range of 0.8-1.0 mm (0.032-0.039 in.).
any carbon buildup from the combustion chambers Measuring Valve Face Runout
being careful not to nick, scrape, or damage the
combustion chambers or the sealing surfaces. 1. Mount a dial indicator on a surface plate; then
place the valve stem on a set of V blocks.
2
2. Inspect the spark-plug holes for any damaged
threads. Repair damaged threads using a heli-coil 2. Position the dial indicator contact point on the
insert. outside edge of the valve face; then zero the
indicator.
3. Inspect the cylinder head for flatness using a
straightedge and a feeler gauge. Acceptable
distortion must not exceed 0.03 mm (0.0012 in.).
NOTE: If the distortion exceeds specification,
replace the cylinder head.
Measuring Valve Stem Runout

1. Support each valve stem end with V Blocks (p/n
0644-022); then check the valve stem runout using
a dial indicator.
ATV1082A
3. Rotate the valve in the V blocks.

4. Maximum runout is 0.03 mm (0.0012 in.).
Replacing Valve Guide
NOTE: If a valve guide is worn or damaged, it

must be replaced.
1. If a valve guide needs replacing, before removing

ATV-1082 the existing guide, measure the distance from the
top of the valve seat to the top of the valve guide
2. Maximum runout is 0.05 mm (0.002 in.) for both (B) for a reference depth when installing the new
valves. guide.
Measuring Valve Face Width
1. Using a micrometer, measure the width of the
valve face.
2-49
NOTE: Install the valve guide so the stepped part
on the guide wall faces the head of the valve.
GEN-0021
2. To replace a valve guide, use a valve guide

remover from the top side of the cylinder to gently GEN-0019
pull the valve guide out of the cylinder.
GEN-0020
GEN-0017
6. After installing the guide, measure the inside
3. Using a valve guide reamer, remove any burrs or diameter of the guide. The measurement must be
tight areas from the valve guide journals. within a range of 5.500-5.512 mm (0.2165-
0.2170 in.). If the measurement does not fall
within the specification or the valve does not move
freely in the guide, use a standard valve guide
reamer and handle to remove all burrs and tight
areas that may remain in each valve guide.
GEN-0018
4. Valve guide hole diameter (after reaming) intake

and exhaust must be within a range of 11.200-
11.218 mm (0.4409-0.4416 in.).
GEN-0022
5. To install an oversized valve guide at room
temperature, use a valve guide installer and gently
drive a valve guide into the bore from the top side
until the guide is set to the distance noted before
removal.
2-50
GEN-0023
ATV-0107
Measuring Valve Guide/Valve Stem GEN-0024

Clearance
NOTE: Do not grind the valves. If a valve is dam-
1. Using a micrometer and small bore gauge, take aged, it must be replaced.
diameter readings on the valve stems and inside
the guides. 3. Lubricate each valve stem with lightweight oil;
then apply a small amount of valve lapping
2. Determine the stem clearance inside the guide. compound to the entire seating face of each valve.
NOTE: Be sure to take readings at more than one 4. Attach the suction cup of a valve lapping tool to
place along the length of each stem and guide. the head of the valve.
ITEM SPECIFICATION 5. Rotate the valve until the valve and seat are evenly
polished.
Intake 0.080 mm
Valve Guide/Valve (max) (0.0031 in.) 6. Clean all compound residue from the valve and
Stem Clearance Exhaust 0.100 mm seat.
(max) (0.0039 in.)
Valve Seat Repair
Lapping Valves NOTE: If the valve seat is beyond servicing, the
cylinder must be replaced.
NOTE: Ensure that all carbon has been removed
from the valves.
1. Using a valve lapper, produce a contact pattern on

each valve face by applying a uniform coat of
valve lapping compound to the valve seat and by
rotating and tapping the valve head.
2. Acceptable width of valve seat contact width
(measurement A) is within a range of 0.8-1.0 mm
(0.032-0.039 in.).
GEN-0025
2-51
A valve seat not producing a uniform contact with its
valve or showing a seating contact width that is not
within the specified range must be repaired by cutting.
1. Insert the expandable pilot shaft into a valve
guide; then install a 45° cutter onto the pilot shaft.
Grind the valve seat by turning the cutter 1-2 turns
using a T-handle.
2. Remove the pilot shaft and cutter; then coat the
valve seat with a blueing compound and insert the
valve into the valve guide. Rotate the valve while
tapping the valve head; then remove the valve and
inspect the valve seat and valve face for proper GEN-0027
width.
6. After reconditioning the valve seat, the valve seat
3. The pattern produced on the seating surface of the could be narrow. In this case, recondition the valve
valve and valve seat must be a continuous ring seat using the 45° cutter. After reconditioning,
without any break and the width of the pattern thoroughly remove any burrs which may be
must be within specifications. Grind the valve seat caused by grinding. The valve seat surface should
width to 0.8-1.0 mm (0.032-0.039 in.). be smooth but not too glossy. Repeat the valve seat
repair procedure on the remaining valve.
4. Inspect for dents or burning on the valve seat and,
if necessary, rotate the 45° cutter another turn to NOTE: After reconditioning all valve seats, thor-
smooth out the valve seat. oughly clean the seat and its vicinity.
! CAUTION ! CAUTION
Do not over-grind the valve seats. Grind the Avoid using a lapping compound after this
seats only as necessary to ensure a continuous procedure.
contact with the valve seating surface.
Valve Springs
5. If the position of the valve face width is low, grind
the valve seat using a 75° cutter to raise the 1. When the valve springs are weak, the valve and
position of the valve seat. If the position of the valve seat fail to form a good seal, thus allowing
valve face width is high, grind the valve seat using gas to leak past the valve seat causing a loss of
a 15° cutter to lower the position of the valve seat. power. Whether or not a valve spring is weak can
be determined by its free length.
GEN-0026
GM128D
2. Minimum valve spring free length is 31.0 mm

(1.22 in.).
NOTE: With the crankshaft at top dead center on
the compression stroke, install the valve springs
and spring retainers; then compress the valve
springs and install the valve keepers.
PISTON ASSEMBLY
NOTE: Oversized pistons are available allowing

the cylinder to be bored oversized.
2-52
NOTE: Whenever a piston, rings, or pins are out Measuring Piston-Ring End Gap
of tolerance, they must be replaced. (Installed)
Cleaning/Inspecting Piston 1. Place each piston ring in the wear portion of the
cylinder. Use the piston to position each ring
1. Using a non-metallic carbon removal tool, remove squarely in the cylinder.
any carbon buildup from the dome of the piston.
NOTE: When measuring a piston ring, it should
2. Inspect the piston for cracks in the piston pin, be placed into the area of the cylinder where wear
dome, and skirt areas. is least (the area is about 3 mm (0.12 in.) from the
upper or lower edge of the cylinder).
3. Inspect the piston for seizure marks or scuffing.
Repair with #400 grit wet-or-dry sandpaper and 2. Using a feeler gauge, measure each piston-ring
water or honing oil. end gap. Acceptable ring end gap must be within
specifications.
AN135
GEN-0043
NOTE: If scuffing or seizure marks are too deep
to correct with the sandpaper, replace the piston. PISTON RING END GAP
1st & 2nd
4. Inspect the perimeter of each piston for signs of Range
0.20-0.70 mm (0.0079-0.0280 in.)
excessive “blowby.” Excessive “blowby” indicates
worn piston rings or an out-of-round cylinder. Piston Ring/Groove Clearance
Removing Piston Rings 1. Using a thickness gauge, measure the side
1. Starting with the top ring, slide one end of the ring clearances of the 1st and 2nd rings.
out of the ring-groove. 2. If any of the clearances exceeds the limit, replace
2. Remove each ring by working it toward the dome both piston and piston rings.
of the piston while rotating it out of the groove.
PISTON RING GROOVE WIDTH
NOTE: If the existing rings will not be replaced 1st & 2nd
with new ones, note the location of each ring for 1.52-1.54 mm (0.060-0.061 in.)
Range
proper installation. When installing new rings,
install as a complete set only. Oil Range 2.51-2.53 mm (0.098-0.099 in.)
PISTON RING THICKNESS
Cleaning/Inspecting Piston Rings
1st & 2nd
1.47-1.49 mm (0.058-0.059 in.)
NOTE: If replacing the rings, make a ring-groove Range
cleaning tool by taking an old piston ring and PISTON RING/GROOVE CLEARANCE
snapping it into two pieces; then grind the end of
the old ring to a 45° angle and to a sharp edge. 1st & 2nd
0.03-0.10 mm (0.0012-0.0039 in.)
Range
1. Using a ring-groove cleaning tool, clean carbon
from the ring-grooves. Be sure to position the ring Measuring Piston Pin Bore Diameter
with its tapered side up.
1. Insert an inside dial indicator into the piston-pin
bore. The diameter must be within specifications.
! CAUTION Take two measurements to ensure accuracy.
Improper cleaning of the ring-grooves by the use
of the wrong type of ring-groove cleaner will 2. Piston pin bore must be within a range of 15.006-
result in severe damage to the piston. 15.030 mm (0.5908-0.5917 in.).
2-53
3. Piston skirt to cylinder clearance must be within a
range of 0.020-0.120 mm (0.0008-0.0047 in.).
4. If the piston/cylinder clearance exceeds the limit,
bore the cylinder and use an oversized piston or
replace both cylinder and piston.
Installing Piston Rings
1. Install the rings in the appropriate grooves.
Stagger the gaps of the rings.
ATV-1069
! CAUTION
Measuring Piston Skirt/ Incorrect installation of the piston rings will
Cylinder Clearance result in engine damage.
1. Measure the cylinder front to back in six places
using a cylinder bore gauge. The amount of wear Measuring Piston Pin Diameter
is the difference between the largest and smallest
readings. If the determined wear exceeds the limit 1. Measure the piston pin diameter at each end and in
indicated, bore to the next oversize by using a the center. If measurement is less than minimum
boring machine or replace the cylinder. specifications, the piston pin must be replaced.
2. Piston pin diameter must be within a range of
14.980-14.995 mm (0.5898-0.5904 in.).
GEN-0032
2. Measure the corresponding piston diameter at a ATV-1070

point 14 mm (0.551 in.) above the piston skirt at a
right angle to the piston-pin bore. Piston diameter CYLINDER/CYLINDER HEAD
must be within a range of 59.880-59.990 mm
(2.3575-2.3618 in.). NOTE: If the cylinder/cylinder head assembly
cannot be trued, they must be replaced.
Cleaning/Inspecting Cylinder Head

1. Using a non-metallic carbon removal tool, remove
any carbon buildup from the combustion chamber
combustion chamber or the sealing surface.
2. Inspect the spark plug hole for any damaged
threads. Repair damaged threads using a “heli-
coil” insert.
GEN-0033
2-54
3. Place the cylinder head on a surface plate covered
with #400 grit wet-or-dry sandpaper. Using light
pressure, move the cylinder head in a figure eight
motion. Inspect the sealing surface for any
indication of high spots. A high spot can be noted
by a bright metallic finish. Correct any high spots
before assembly by continuing to move the
cylinder head in a figure eight motion until a
uniform bright metallic finish is attained.
! CAUTION
Water or parts-cleaning solvent must be used in
conjunction with the wet-or-dry sandpaper or GEN-0030
damage to the sealing surface may result.
4. Inspect the cylinder for pitting, scoring, scuffing,
Measuring Cylinder Head Distortion warpage, and corrosion. If marks are found, repair
the surface using the Cylinder Hone Set (p/n 0644-
1. Remove any carbon buildup in the combustion 041) (see Honing Cylinder in this sub-section).
chamber.
2. Lay a straightedge across the cylinder head; then
5. Place the cylinder on the surface plate covered 2
with #400 grit wet-or-dry sandpaper. Using light
using a feeler gauge, check the distortion factor pressure, move the cylinder in a figure eight
between the head and the straightedge. motion. Inspect the sealing surface for any
indication of high spots. A high spot can be noted
3. Maximum distortion is 0.03 mm (0.0012 in.). by a bright metallic finish. Correct any high spots
before assembly by continuing to move the
cylinder in a figure eight motion until a uniform
bright metallic finish is attained.
! CAUTION
conjunction with the wet-or-dry sandpaper or
Honing Cylinder
1. Wash the cylinder in parts-cleaning solvent.
GM130D 2. Inspect the cylinder for pitting, scoring, scuffing,

and corrosion. If marks are found, repair the
Cleaning/Inspecting/Measuring surface using the cylinder hone.
Cylinder
NOTE: To produce the proper 60° cross-hatch
1. Wash the cylinder in parts-cleaning solvent. pattern, use a low RPM drill (600 RPM) at the rate
of 30 strokes per minute. If honing oil is not avail-
2. Check the gasket surface of the cylinder for able, use a lightweight petroleum-based oil. Thor-
distortion with a straightedge and thickness gauge oughly clean cylinder after honing using soap and
taking a clearance reading at several places. If the hot water. Dry with compressed air; then immedi-
largest reading at any position of the straightedge ately apply oil to the cylinder bore. If the bore is
exceeds the limit, replace the cylinder. severely damaged or gouged, replace the cylinder.
3. Maximum cylinder distortion limit is 0.03 mm 3. If any measurement exceeds the limit, hone the
(0.0012 in.). cylinder and install an oversized piston or replace
the cylinder.
NOTE: Oversized piston and rings are available.
The oversized piston and rings are marked for
identification purposes.
2-55
ATV-1068 GEN-0034
CAM LOBE WEAR 3. If the difference between the connecting rod small
end bore inside diameter and the piston pin outside
Worn cam lobes result in reduced power output. The diameter exceeds the limit, replace both
limit of cam lobe wear is specified for both intake and connecting rod and piston pin. The measurement
exhaust lobes in terms of cam height which is to be must be within a range of 0.006-0.050 mm
measured with a micrometer. Replace the camshaft if (0.0002-0.0020 in.).
found to be worn below specifications.
Measurement must be within a range of 30.20-
30.56 mm (1.189-1.203 in.).
GEN-0035
CRANKSHAFT RUNOUT
GEN0028B 1. Support the crankshaft using a set of V blocks; use

a dial indicator to read crankshaft runout.
NOTE: The contact point of the dial indicator
should be on the seal area of the crankshaft.
2. Total indicator reading on the dial must be

0.10 mm (0.004 in.) or less.
GEN-0029
MEASURING CONNECTING ROD

SMALL END BORE INSIDE DIAMETER
1. Using a small bore gauge, measure the connecting
rod small end bore inside diameter.
2. Measurement must be within a range of 15.006- GEN-0031
15.030 mm (0.5908-0.5917 in.). 3. If not within specification, either straighten the

crankshaft or replace it.
2-56
MEASURING CONNECTING ROD BIG
END SIDE CLEARANCE
1. Check the connecting rod side clearance by using
a thickness gauge. If the clearance exceeds the
limit, replace the connecting rod or crankshaft.
2. Clearance measurement must be within a range of
0.20-1.20 mm (0.0079-0.0472 in.).
GEN-0038
5. Measure the crank pin/connecting rod clearance.

6. Measurement must be within a range of 0.015-
0.070 mm (0.0006-0.0028 in.).
2
GEN-0036
MEASURING CRANK PIN/

CONNECTING ROD CLEARANCE
1. Measure the crank pin diameter.
26.000 mm (1.0232-1.0236 in.).
GEN-0039
CARBURETOR INSULATOR PLATE

1. Inspect for cracks, scoring, pitting, imperfections,
or warping.
2. Inspect the sealing surfaces for trueness by placing
each on the surface plate covered with #400 grit
wet-or-dry sandpaper. Using light pressure, move
both sides in a figure eight motion. Inspect the
sealing surfaces for any indication of high spots or
warping. Correct highs spots by continuing to
GEN-0037 move each side in a figure eight motion. Warped
3. Measure the connecting rod big end inside components must be replaced.
diameter.
26.025 mm (1.0242-1.0246 in.).
A932
2-57
CYLINDER HEAD (500/600 cc)
! CAUTION 1. Using a non-metallic carbon removal tool, remove
Water or parts-cleaning solvent must be used in any carbon buildup from the combustion chambers
conjunction with the wet-or-dry sandpaper or being careful not to nick, scrape, or damage the
damage to the sealing surfaces may result. combustion chambers or the sealing surfaces.
threads. Repair damaged threads using a heli-coil
insert.
Cleaning and Inspecting
3. Inspect the cylinder head for flatness using a
Engine straightedge and a feeler gauge. Acceptable
warpage must not exceed 0.05 mm (0.002 in.).
NOTE: Whenever a part is worn excessively, NOTE: If the warpage exceeds specification,
cracked, or damaged in any way, replacement is resurface the cylinder head using procedures
necessary. identified in step 6 in the Crankcase sub-section of
Cleaning and Inspecting Engine.
CYLINDER HEADS
any carbon buildup from the combustion chambers
combustion chambers or the sealing surfaces.
threads. Repair damaged threads using a heli-coil
insert.
3. Place the cylinder heads on a Surface Plate (p/n
0644-016) covered with #400 grit wet-or-dry
sandpaper. Using light pressure, move each
cylinder head in a figure eight motion. Inspect the
sealing surface for any indication of high spots. A AN426D
high spot can be noted by a bright metallic finish.
Correct any high spots before assembly by ! CAUTION
continuing to move the cylinder head in a figure
eight motion until a uniform bright metallic finish conjunction with the wet-or-dry sandpaper or
is attained. damage to the sealing surface may result.
CYLINDERS
carbon buildup from the exhaust ports.
2. Wash the cylinders in parts-cleaning solvent.
3. Inspect the cylinders for pitting, scoring, scuffing,
and corrosion. If marks are found, repair the
surface with Ball Hone (p/n 0644-036) for the 600
cc or (p/n 0644-037) for the 800 cc or with #500
grit stones and honing oil.
AQ132D
! CAUTION
2-58
4. Inspect each piston for seizure marks or scuffing.
Repair with #400 grit wet-or-dry sandpaper and
water or honing oil.
AN053
NOTE: To produce the proper 60° crosshatch

pattern, use a low RPM drill (600 RPM) at the rate
of 30 strokes per minute. If honing oil is not avail- AN135
able, use a lightweight, petroleum-based oil. Thor-
oughly clean the cylinders after honing using
detergent soap and hot water and dry with com-
pressed air; then immediately apply oil to the cyl-
NOTE: If scuffing or seizure marks are too deep
to correct with the sandpaper, it will be necessary 2
to replace the piston.
inder bores. If a bore is severely damaged or
gouged, the cylinder will have to be replaced.
5. Inspect the perimeter of each piston for signs of
excessive “blowby.” Excessive “blowby” indicates
4. Place the head surface of each cylinder on the worn piston rings or an out-of-round cylinder.
surface plate covered with #400 grit wet-or-dry
sandpaper. Using light pressure, move each CRANKCASE
cylinder in a figure eight motion. Inspect the
surface for any indication of high spots. A high 1. Wash the crankcase halves in parts-cleaning
spot can be noted by a bright metallic finish. solvent.
Correct any high spots before assembly by
continuing to move the cylinder in a figure eight NOTE: Before washing the crankcase halves,
motion until a uniform bright metallic finish is make sure the four bearing dowel pins have been
attained. removed and accounted for.
2. Inspect the crankcase halves for scoring, pitting,

! CAUTION scuffing, or any imperfections in the casting.
conjunction with the wet-or-dry sandpaper or 3. Inspect all threaded areas for damaged or stripped
damage to the sealing surface may result. threads.
PISTON ASSEMBLY 4. Inspect the bearing areas for cracks or excessive
bearing movement. If evidence of excessive
1. Using a non-metallic carbon removal tool, remove bearing movement is noted, repair by peening the
the carbon buildup from the dome of each piston. bearing area in a pinking (sawtooth) pattern.
2. Take an old piston ring and snap it into two pieces; 5. Inspect the bearing dowel pins for wear.
then grind the end of the old ring to a 45° angle
and to a sharp edge. Using the sharpened ring as a 6. Inspect the sealing surfaces of the crankcase
tool, clean carbon from the ring-grooves. Be sure halves for trueness by placing each crankcase half
to position the ring with its tapered side up. on the surface plate covered with #400 grit wet-or-
dry sandpaper. Using light pressure, move each
! CAUTION half in a figure eight motion. Inspect the sealing
surfaces for any indication of high spots. A high
Improper cleaning of the ring-grooves by the use spot can be noted by a bright metallic finish.
of the wrong type of ring-groove cleaner will Correct any high spots by continuing to move the
result in severe damage to the piston. half in a figure eight motion until a uniform bright
metallic finish is attained.
3. Inspect each piston for cracks in the piston pin and
skirt areas. NOTE: Care must be taken not to remove an
excessive amount of aluminum, or the crankcase
will have to be replaced. If excessive aluminum is
removed, too much pre-load will be exerted on the
crankshaft bearings when assembled.
2-59
CRANKSHAFT
1. Wash the crankshaft with bearings in parts-
cleaning solvent.
2. Inspect the bearings for wear, scoring, scuffing,
damage, or discoloration. Rotate the bearings.
Bearings must rotate freely and must not bind or
feel rough. If any abnormal condition is noted,
replace the bearing.
AN060
! CAUTION
INTAKE MANIFOLD
INSULATORS (Single Carburetor)/
ADAPTER PLATES (Twin Carburetors)
AN218
NOTE: For fan cooled models only.
3. Inspect the connecting-rod bearings by rotating
1. Inspect for cracks, scoring, pitting, imperfections, them. The bearings must rotate freely and must not
or warping. bind or feel rough. If a connecting-rod bearing
must be replaced, the connecting rod and crank pin
2. Inspect the sealing surfaces for trueness by placing must also be replaced.
each on the surface plate covered with #400 grit
wet-or-dry sandpaper. Using light pressure, move
both sides in a figure eight motion. Inspect the
sealing surface for any indication of high spots or
warping. Correct high spots by continuing to move
each side in a figure eight motion. Warped
components must be replaced.
NOTE: On the twin carburetor model in order to
inspect adapter plate trueness, it will be necessary
to remove the studs.
! CAUTION
Water or parts-cleaning solvent must be used in AN217
damage to the sealing surfaces may result. 4. Inspect the oil-injection pump drive gear for any
signs of worn or chipped teeth. If either condition
exists, replace the gear.
A932
AQ043
2-60
NOTE: Lubricate bearings thoroughly prior to 5. Inspect the crankshaft bearing area for wear. If any
assembly. wear is noted on either end, replace the crankshaft
end.
REMOVING OUTER
CRANKSHAFT BEARINGS INSTALLING OUTER
CRANKSHAFT BEARINGS
! WARNING NOTE: Steps 1-3 are for installing the MAG-side
Safety glasses must be worn when spreading bear- bearing.
ings.
1. Wrap a thick towel around the crankshaft; then
NOTE: Steps 1-3 are for removing the MAG-side secure the crankshaft vertically in a vise.
bearing.
2. Heat the bearing either by placing the entire
1. Place a bearing support (block of wood, etc.) bearing in a pan of oil on a hot plate or by
beneath the MAG-side bearing. squirting oil into the bearing and using a propane
torch to heat the inner race of the bearing until a
slight smoke is noted coming from the bearing.
! CAUTION
A bearing support must be positioned beneath
the bearing that is being removed to prevent
! CAUTION
DO NOT overheat the bearing.
2
crankshaft damage.
2. Drive a chisel or bearing splitter between the 3. Place any shims removed during disassembly onto
bearing race and crankshaft counterweight until the crankshaft; then slide the bearing onto the
the bearing is spread far enough to install the jaws crankshaft making sure the dowel-pin hole in the
of the crankshaft bearing remover. outer race is properly positioned and will align
with its hole and pin in the crankcase.
3. Place the protective cap on the crankshaft end;
then using the Crankshaft Bearing Remover (p/n 4. Slide the PTO-side bearing onto the PTO end
0144-302), remove the bearing from the end of the making sure the dowel-pin hole will align with the
crankshaft. Account for any shim(s). Note the hole and pin in the crankcase.
position of the dowel pin hole.
AN151A
AQ045
BALANCER SHAFT
4. The PTO-side bearing may be removed simply by (1000 cc)
sliding the bearing off the PTO end.
1. Inspect the balancer shaft bearings by rotating
them by hand. The bearings must rotate freely
without binding or feeling rough. If either
condition exists, replace the bearing.
2. Inspect the balancer gear very closely for any
chipped teeth or signs of wear. If either condition
exists, replace the gear.
AN151A
2-61
4. Inspect the reed-to-seat clearance. Using a feeler
gauge, measure the clearance. Clearance must be
less than 0.20 mm (0.008 in.). If clearance is not
within specifications, replace the reed valve.
5. To assemble, place the reed valves on the cage
with its clipped corner positioned to the lower
right hand corner of the cage. Place the reed
stopper assembly into position and secure with the
three screws coated with red Loctite #271.
AQ044
REED ASSEMBLY
1. Inspect the reed valves, stoppers, and valve blocks
for cracks or any deterioration.
AQ047
Measuring Critical
Components
AQ046
NOTE: Critical engine component specifications
2. Wash the reed valves, stopper, and cage assembly are on page 66 of this sub-section.
in parts-cleaning solvent and blow dry.
CYLINDER TRUENESS
3. Inspect the reed stopper height. Using a caliper,
measure the distance from the seat to the bottom 1. Measure each cylinder in the three locations from
outer tip edge of the stopper. Measurement must front to back and side to side for a total of six
not exceed specifications. If measurement is not readings.
within specifications, either bend or replace the
reed stopper.
AN302
2. The trueness (out-of-roundness) is the difference

AJ156 between the highest and lowest reading.
Maximum trueness (out-of-roundness) must not
exceed specifications.
2-62
0725-586 AN057
CYLINDER TRUENESS LIMIT (max) PISTON PIN AND PISTON-PIN BORE

mm in. 1. Measure the piston pin diameter at each end and in
0.10 0.004 the center. Acceptable piston pin measurement
PISTON SKIRT/CYLINDER CLEARANCE

must be within specifications. If any measurement
varies by more than 0.02 mm (0.001 in.), the 2
piston pin and bearing must be replaced as a set.
1. Measure each cylinder front to back about 2.5 cm
(1 in.) from the bottom of each cylinder.
2. Measure the corresponding piston skirt diameter at
a point 1 cm (0.394 in.) above the piston skirt at a
right angle to the piston-pin bore. Subtract this
measurement from the measurement in step 1. The
difference (clearance) must be within
specifications.
AN056
2. Insert a snap gauge into each piston-pin bore; then

remove the gauge and measure it with a
micrometer. The diameter measurement must be
within specifications. Take two measurements to
ensure accuracy.
AC091
PISTON-RING END GAP

1. Place each piston ring in the wear portion above
the exhaust port of its respective cylinder. Use the
piston to position each ring squarely in each
cylinder.
2. Using a feeler gauge, measure each piston-ring
end gap. Acceptable ring end gap must be within
specifications.
AC092
CONNECTING-ROD SMALL END BORE

1. Insert a snap gauge into each connecting-rod small
end bore; then remove the gauge and measure it
with a micrometer.
2-63
AN061 AQ042
2. The diameter measurement must be within 4. Position the indicator contact point against the
specifications. crankshaft at point E (center). Zero the indicator
and rotate the crankshaft slowly. Note the amount
CRANKSHAFT RUNOUT of crankshaft runout (total indicator reading).
1. Using the V Blocks (p/n 0644-022), support the
crankshaft on the surface plate. CRANKSHAFT RUNOUT (max)
(total indicator reading)
NOTE: The V blocks should support the crank- mm in.
shaft on the outer bearings. 0.05 0.002
2. Mount a dial indicator and base on the surface 5. If runout exceeds specifications at any of the
plate. Position the indicator contact point against checkpoints, the crankshaft must be either
the crankshaft distance F (PTO-end) from the straightened or replaced.
crankshaft end. Zero the indicator and rotate the
crankshaft slowly. Note the amount of crankshaft
runout (total indicator reading).
NOTE: For runout distance specifications, see
Engine Information sub-section.
3. Position the indicator contact point against the

crankshaft distance D (MAG-end) from the
crankshaft end. Zero the indicator and rotate the
crankshaft slowly. Note the amount of crankshaft
runout (total indicator reading).
2-64
NOTES
2-65
2002 Arctic Cat Engine Specifications
2-66
ITEM 120 cc 370 cc 440 cc 500 cc 550 cc 570 cc 600 cc EFI 600 cc 600 cc 800 cc Carb 800 cc EFI 1000 cc
Carb (Triple) Carb (Twin)
Engine Model Number AA12A1 AA37A4 AS44A5 AU50L6 ACB55L3 AA56A1 AD60L6 AG60L8 AF60L6 AA78L2 AB78L2 AA10L5
Displacement- cc cu. in. 119 367 431 497 550 565 599 594 599 785 785 999
7.3 22.41 26.3 30.3 33.56 34.5 36.54 36.24 36.54 47.9 47.9 60.96
No. of Cylinders 1 2 2 2 2 2 2 3 2 2 2 3
Bore · mm 60 60 65 71 73.4 73.8 78 66.5 78 81 81 81
· in. 2.4 2.362 2.559 2.800 2.890 2.910 3.071 2.618 3.071 3.188 3.188 3.19
Stroke · mm 42 65 65 62.7 65 66 62.7 57 62.7 76 76 64.6
· in. 1.7 2.559 2.559 2.469 2.559 2.598 2.469 2.240 2.469 2.992 2.992 2.54
Compression Ratio 8.2:1 6.3:1 6.5:1 6.74:1 6.6:1 6.4:1 6.55:1 6.4:1 6.55:1 6.29:1 6.29:1 6.4:1
Cooling System Fan Cooled Fan Cooled Fan Cooled Liquid Cooled Liquid Cooled Fan Cooled Liquid Cooled Liquid Cooled Liquid Cooled Liquid Cooled Liquid Cooled Liquid Cooled
Gasoline Octane (min) 87 87 87 87 87 87 87 87 87 87 87 87
Fuel Mixture N/A Oil Injection Oil Injection Oil Injection Oil Injection Oil Injection Oil Injection Oil Injection Oil Injection Oil Injection Oil Injection Oil Injection
Ignition Timing degrees Fixed 18i* 18i* 25i 33i* 18i* 24f 18i 24i 14i 26k 16e
· mm 2.012 2.012 3.671 6.556 2.049 3.390 2.012 3.390 1.417 4.796 1.556
· in. 0.079 0.079 0.145 0.258 0.081 0.133 0.079 0.133 0.056 0.189 0.061
Spark Plug (NGK) BPR6ES BR9EYA BR9EYA BR9EYA BR9EYA BR9EYA BR9EYA BR9EYA BR9EYA BR9EYA BR9EYA BR9EYA
Spark Plug Gap · mm 0.7-0.8 0.7-0.8 0. 0.7-0.8 0.7-0.8 0.7-0.8 0.7-0.8 0.7-0.8 0.7-0.8 0.7-0.8 0.7-0.8 0.7 -0.8 0.7-0.8
· in. 0.028-0.031 028-0.031 0.028-0.031 0.028-0.031 0.028-0.031 0.028-0.031 0.028-0.031 0.028-0.031 0.028-0.031 0.028-0.031 0.028-0.031 0.028-0.031
Lighting Coil Output 12V/55W 12V/185W 12V/185W 12V/210W 12V/180W 12V/210W 12V/175W 12V/210W 12V/210W 12V/210W 12V/190W 12V/185W
Ignition Type Transistorized CDI/NOI CDI/NOI CDI/NOI CDI/NOI CDI/NOI CDI/NOI CDI/NOI CDI/NOI CDI/NOI CDI/NOI CDI/NOI
Piston Skirt/Cylinder · mm 0.020-0.120 0.060-0.150 0.080-0.150 0.083-0.150 0.095-0.150 0.095-0.150 0.083-0.150 0.085-0.150 0.083-0.150 0.083-0.150 0.083-0.150 0.095-0.150
Clearance Range · in. 0.0008-0.0047 0.0024-0.0059 0.0031-0.0059 0.0033-0.0059 0.0037-0.0059 0.0037-0.0059 0.0033-0.0059 0.0034-0.0059 0.0033-0.0059 0.0033-0.0059 0.0033-0.0059 0.0037-0.0059
Piston Ring End · mm 0.20-0.70 0.15-0.80 0.15-0.83 0.20-0.83 0.20-0.83 0.20-0.83 0.20-0.83 0.20-0.83 0.20-0.83 0.30-0.50 0.30-0.50 0.20-0.83
Gap Range · in. 0.0079-0.0280 0.006-0.031 0.006-0.033 0.008-0.033 0.008-0.033 0.008-0.033 0.008-0.033 0.008-0.033 0.008-0.033 0.012-0.020 0.012-0.020 0.008-0.033
Cylinder Trueness · mm 0.03 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1
Limit (max) · in. 0.0012 0.004 0.004 0.004 0.004 0.004 0.004 0.004 0.004 0.004 0.004 0.004
Piston Pin · mm 14.980-14.995 17.995-18.000 15.995-16.000 19.995-20.000 19.995-20.000 17.995-18.000 19.995-20.000 17.995-18.000 19.995-20.000 23.995-24.000 23.995-24.000 19.995-20.000
Diameter Range · in. 0.5898-0.5904 0.7085-0.7087 0.6297-0.6299 0.7872-0.7874 0.7872-0.7874 0.7085-0.7087 0.7872-0.7874 0.7085-0.7087 0.7872-0.7874 0.9447-0.9449 0.9447-0.9449 0.7872-0.7874
Piston Pin Bore · mm 15.006-15.030 17.998-18.006 15.996-16.004 20.002-20.010 20.002-20.010 17.998-18.006 20.002-20.010 18.002-18.008 20.002-20.010 24.002-24.010 24.002-24.010 20.002-20.010
Connecting Rod · mm 15.006-15.030 23.003-23.011 21.003-21.011 26.003-26.011 26.003-26.011 23.003-23.011 26.003-26.011 23.003-23.011 26.003-26.011 29.003-29.011 29.003-29.011 26.003-26.011
Small End Bore · in. 0.5908-0.5917 0.9056-0.9059 0.8269-0.8272 1.0237-1.0241 1.0237-1.0241 0.9056-0.9059 1.0237-1.0241 0.9056-0.9059 1.0237-1.0241 1.1410-1.1420 1.1410-1.1420 1.0237-1.0241
Diameter Range
Radial Play Range · in. 0.0006-0.0028 0.0008-0.0012 0.0008-0.0012 0.0008-0.0012 0.0008-0.0012 0.0008-0.0012 0.0008-0.0012 0.0008-0.0012 0.0008-0.0012 0.0001-0.0008 0.0001-0.0008 0.0008-0.0012
Crankshaft Runout · mm 0.10 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05
(t.i.r.) · in. 0.004 0.002 0.002 0.002 0.002 0.002 0.002 0.002 0.002 0.002 0.002 0.002
Crankshaft End · mm 0.05-0.10 0.05-0.10 0.05-0.10 0.05-0.10 0.05-0.10 0.05-0.10 0.05-0.10 0.05-0.10 0.05-0.10 0.05-0.10 0.05-0.10 0.05-0.10
Play Range · in. 0.002-0.004 0.002-0.004 0.002-0.004 0.002-0.004 0.002-0.004 0.002-0.004 0.002-0.004 0.002-0.004 0.002-0.004 0.002-0.004 0.002-0.004 0.002-0.004
Reed Stopper · mm N/A N/A N/A 9.4 - 9.8 N/A 6.0 9.4 - 9.8 9.3 - 9.9 9.4 - 9.8 8.0 8.0 9.3 - 9.9
Height · in. 0.370 - 0.385 0.236 0.370 - 0.385 0.366 - 0.389 0.370 - 0.385 0.315 0.315 0.366 - 0.389
c @ 6000 RPM f @ 3500 RPM i @ 2000 RPM

d @ 4000 RPM g @ 5000 RPM j @ 3000 RPM *Engine Warm
e @ 3250 RPM h @ 1800 RPM k @ 2500 RPM
3. Note the direction of the arrow on the connecting
Assembling Engine rod and the marks on the connecting rod and end
cap made during disassembly.
Table of Contents
120 cc Model......................................................... 2-67
370/440 cc Models ................................................ 2-71
550 cc Models ....................................................... 2-75
570 cc Models ....................................................... 2-81
500/600 cc Twin Models........................................ 2-88
800 cc Models ....................................................... 2-94
600 cc Triple Model ............................................. 2-100
1000 cc Models ................................................... 2-107
GM121D
Assembling Engine
(120 cc Model) 2
NOTE: The use of new gaskets and seals is rec-
ommended when assembling the engine.
NOTE: When the use of a lubrication is indi-

cated, use a lightweight engine oil.
1. Secure the oil level sensor plate to the crankcase

with the cap screws.
GM120D
4. Coat the cylinder wall, connecting rod bearing

surface, and the crankshaft with lightweight oil;
then compress the piston rings and install the
piston and connecting rod assembly taking care
not to damage the crankshaft with the connecting
rod studs.
! CAUTION
The arrow on the connecting rod must face out.
GM126D
NOTE: When installing the piston, rotate the
2. Install the crankshaft with the connecting rod crankshaft until the piston is at the bottom of the
journal facing down. stroke.
5. Install the connecting rod end cap with the

splasher plate, lock tab, and nuts. Tighten the nuts
to 1.1-1.4 kg-m (8-10 ft-lb).
GM124D
2-67
7. Install the washer onto the camshaft.
GM123D
6. Apply lightweight oil to the tappets and camshaft; GM214D

then install the tappets and camshaft.
8. Place the dowel pins and a gasket into position.
GM217D
GM213D
9. Secure the crankcase side cover to the crankcase

with the cap screws. Tighten to 0.9-1.2 kg-m (6.5-
9 ft-lb).
GM216D
NOTE: Make sure the timing marks are aligned.
GM212D
10. Install the dowel pins and a new gasket; then

secure the head to the cylinder with the cap
screws. Tighten to 2.8 kg-m (20 ft-lb).
GM215D
2-68
13. Secure the reed stopper to the air breather body
assembly with the screws.
GM210D
11. Apply lightweight oil to the ends of the push rods;

then install the rods. GM207D
14. Place the air breather body assembly with gasket

onto the cylinder head cover.
2
GM209D
12. Loosely secure the rocker arms to the cylinder

head with the pivots and lock nuts; then place the GM206D
piston to the top of the compression stroke, set the
valve clearance to the recommended setting with a 15. Install the valve cover with gasket. Tighten to
feeler gauge, and while holding the adjustment 1.1 kg-m (8 ft-lb).
nut, tighten the rocker arm lock nuts securely.
Verify valve clearance.
VALVE CLEARANCE RANGE (Cold)

0.030-0.070 mm (0.0012-0.0028 in.)
GM205D
16. Secure the ignition coil to the crankcase housing

with the cap screws.
GM208D
2-69
GE318D GM201D
17. Connect the ignition coil wire.

! WARNING
NOTE: The spark plug should be removed and When performing service work on the fuel system,
cleaned or replaced. Adjust gap to specification do not smoke or allow open flames near the snow-
and tighten the plug to 2.5-2.8 kg-m (18-20 ft-lb). mobile.
18. Connect the high tension lead to the spark plug 22. Install the carburetor (with a gasket, insulator
and secure with the two wire forms. block, and a gasket) onto the mounting studs.
19. Install the flywheel and secure with the nut.
Tighten to 6-7 kg-m (43.5-50.5 ft-lb).
GF318D
23. Noting the locations of the springs from

GM203D disassembly, install the rod and spring onto the
carburetor.
NOTE: The ignition coil to flywheel air gap must
have a clearance of 0.5 mm (0.020 in.).
20. Secure the recoil starter pulley to the flywheel

with the screws.
GF208D
24. Install the gasket onto the mounting studs; then

install the air cleaner housing onto the carburetor.
Install the air breather hose onto the air cleaner
GM202D housing.
21. Install the recoil starter/fan housing assembly.
2-70
26. Secure the air cleaner end cap to the air cleaner
housing with the wing nut.
Assembling Engine
(370/440 cc Models)

GF316D
NOTE: When the use of a lubricant is indicated,
use Arctic Cat 50:1 Injection Oil.
1. Install the C-ring and the five bearing retaining

pins into the lower crankcase half.
2. Lubricate the inner lips of the crankshaft oil seals
with grease; then slide the seals onto the 2
crankshaft making sure the spring side of each seal
faces the center of the crankshaft.
A001
25. Secure the air cleaner housing to the carburetor

and engine with the cap screw and flanged nuts.
AC087
3. Apply oil to the crankshaft bearings; then install

the dowel pins, C-ring, and crankshaft into the
lower crankcase half. Be sure the alignment hole
in each bearing is positioned over its respective
bearing retaining pin in the crankcase; then seat
the crankshaft.
GF314D
AB091
A002 NOTE: Make sure the crankshaft center seal is

properly positioned in the groove of the lower
crankcase half.
2-71
NOTE: To check the bearing for proper position,
place the point of a sharp tool into the dimple
found in the bearing race. Strike the tool with the
palm of the hand in either direction. If the bearing
moves, it isn't positioned correctly and must be
rotated until it drops onto the dowel pin.
! CAUTION
If the bearings are not properly seated during
assembly, the crankcase halves will not seal
tightly and engine damage will result.
4. Apply a thin coat of Three Bond Sealant (p/n

B160
0636-070) to the crankcase sealing surfaces.
7. Install the piston rings on each piston so the letter
5. Assemble the crankcase halves making sure the on the top (inclined surface) of each ring faces the
crankcase dowel pins are properly positioned and dome of the piston.
the end seal tab will not block the oil transfer port
in the upper crankcase half.
726-306A
AB092
6. Install the crankcase cap screws making sure the

cap screws are in the corresponding-sized holes.
Tighten in three steps the 8 mm cap screws to 1.8-
2.8 kg-m (13-20 ft-lb) and the 6 mm cap screws to
0.8-1.2 kg-m (6-9 ft-lb) using the pattern shown.
AC088
! CAUTION
Incorrect installation of the piston rings will
result in engine damage.
8. Apply oil to the connecting-rod small-end

0726-412 bearings; then install the small-end bearings into
the connecting rods.
NOTE: Secure the connecting rods with rubber
bands on the cylinder studs. NOTE: Apply oil to the piston pin before install-
ing.
9. Place each piston over the connecting rod so the

arrow on the piston dome points toward the
exhaust port; then secure with a piston pin.
2-72
NOTE: The arrow is found either up inside the NOTE: Inspect the cylinder-base gasket to
piston or on the dome top. ensure proper positioning.
10. Install the new circlips so the open end is directed 13. For each piston, place a piston holder (or suitable
either down or up. substitute) beneath the piston skirt and square the
piston in respect to the crankcase; then using a ring
compressor or the fingers, compress the rings and
slide the cylinder over the piston. Remove the
piston holder and seat the cylinder firmly onto the
crankcase.
B324D
2
! CAUTION
Make sure circlips are firmly seated and the open A828
end is directed either down or up before
continuing with assembly. 14. Place each cylinder head with dowel pins and
gasket into position and install the eight nuts. DO
11. Install the cylinder base gaskets onto the crankcase NOT TIGHTEN AT THIS TIME.
making sure each gasket aligns with crankcase
transfer passages. 15. Temporarily install the exhaust manifold and
secure with four nuts and lock washers to square
12. Rotate each piston ring until the ring ends are the cylinders. Tighten the manifold nuts to 1.8-
properly positioned on each side of the ring 2.2 kg-m (13-16 ft-lb).
keeper; then apply oil to the piston assemblies and
cylinder bores. Remove the rubber bands from the 16. With the exhaust manifold in place, tighten the
connecting rods. cylinder head nuts in three steps to 1.8-2.8 kg-m
(13-20 ft-lb) using the pattern shown.
726-306B
0725-318
NOTE: Apply a generous amount of oil to the
surfaces of the pistons, rings, and cylinder bores. 17. In order, install the gear, shim, gasket, retainer,
gasket, and oil-injection pump. Secure with two
screws, lock washers, and washers. Tighten to
0.7 kg-m (5 ft-lb).
2-73
22. On the 440 cc, apply a thin coat of High-Temp
Sealant (p/n 0636-069) to both sides of the intake
gaskets and the front side of each adapter plate;
then in order, install a gasket (one on each port),
shroud, gasket (one on each port), and adapter
plate (one on each port). Secure with screws
coated with red Loctite #271.
23. Place the intake flanges into position and secure
with nuts (threads coated with red Loctite #271),
lock washers, and washers. Tighten to 1.8-2.2 kg-
m (13-16 ft-lb).
AB078 24. Remove the exhaust manifold.

25. Install spark plugs and tighten to 2.5-2.8 kg-m
! CAUTION (18-20 ft-lb).
Be sure the gear is properly aligned with the slot
of the oil-injection pump shaft. The injection 26. Attach the oil-injection hoses to their fittings.
pump will be damaged if these two components Secure with clamps.
are not aligned.
27. Test the engine for air leaks (see Section 3).
NOTE: If removed, secure the ignition coil to the
fan case. 28. Temporarily secure the starter pulley on the
flywheel with three cap screws. Install the
18. Align the reference marks made during flywheel washer, lock washer, and nut. Apply red
disassembly; then secure the stator plate with two Loctite #271 to the crankshaft threads before
Allen-head cap screws (coated with red Loctite installing the flywheel nut. Using a spanner
#271), lock washers, and washers. wrench to secure the crankshaft, tighten the
flywheel nut to 7-9 kg-m (50.5-65 ft-lb).
NOTE: Before installing the flywheel, wipe the
crankshaft and flywheel taper clean using a clean
cloth.
19. Install the key in the crankshaft and slide the

flywheel onto the crankshaft making sure the
keyways match.
20. Place the fan case into position and secure with
four nuts. Tighten the nuts to 1.8-2.2 kg-m (13-
16 ft-lb).
AB024
29. Remove the starter pulley. Position the fan belt

drive pulley into the belt. Align the starter pulley
holes with those in the belt pulley. Start one of the
cap screws into the flywheel; then rotate the belt
pulley and starter pulley in a counterclockwise
direction.
30. When the pulley pivots on the cap screw, rock the
pulleys backward or forward until the remaining
A814 cap screw holes align. Install the remaining two
cap screws and tighten evenly to 0.8-1.2 kg-m (6-
21. On the 370 cc, apply a thin coat of High-Temp 9 ft-lb).
Sealant (p/n 0636-069) to both sides of the intake
gaskets; then in order, install a gasket (one on each NOTE: Apply red Loctite #271 to the threads of
port), shroud, gasket (one on each port), insulator the cap screws before installing.
(one on each port), gasket (one on each port), and
intake manifold with flange. Secure with nuts
(threads coated with red Loctite #271). Tighten
nuts in three steps to 0.8-1.2 kg-m (6-9 ft-lb).
2-74
NOTE: Apply grease to the lips of the inner seal
before installation.
AB040
31. Place an exhaust manifold gasket on each exhaust

port making sure the metal side of the gasket faces AN070
the cylinder. Slide the exhaust-side cooling shroud
onto the exhaust port studs; then place the upper NOTE: The seal must be installed with its spring
cooling shroud into position and secure the
shrouds with 14 cap screws noting the location of
side towards the crankshaft.
2
the longer cap screws from disassembling. Tighten 2. Using a small screwdriver, apply a thin coat of
to 0.4-0.7 kg-m (3-5 ft-lb). Connect the spark-plug grease to the inner seal lips.
caps.
3. Using a pair of snap ring pliers, install the snap
4. Using the seal driver, carefully install the outer
water pump seal. Gently tap the seal down into
position until it seats itself against its flange.
AB012
32. Apply a thin coat of High-Temp Sealant (p/n

0636-069) to the exhaust-manifold gasket; then
place a gasket on each exhaust port making sure
the metal side of each gasket faces away from the
cylinder. Install the exhaust manifold, lock AN072
washers, and nuts and tighten to 1.8-2.2 kg-m (13-
16 ft-lb). 5. Apply a thin coat of grease to the sealing surface
of the oil-injection pump driveshaft; then place the
Oil Seal Installation Tool (p/n 0644-219) at the
end of the shaft. Twist the driveshaft clockwise as
it is pushed through the oil and water pump seals;
Assembling Engine then remove the tool. Position the shim on the oil-
(550 cc Models) injection pump end of the driveshaft.
NOTE: The use of new gaskets and seals is rec- ! CAUTION

ommended when assembling the engine. Be very careful not to damage the seals when
installing the oil pump driveshaft. Be certain to
NOTE: When the use of a lubricant is indicated, use the seal installation tool. Twist the driveshaft
use Arctic Cat 50:1 Injection Oil. clockwise as it enters the seal area and while it is
being pushed through the seals.
1. Using the water pump bearing and seal driver,
position the inner water pump shaft seal onto the 6. Position the upper crankcase half upside-down on
seal driver and gently tap the seal down into two wooden blocks; then install the C-ring, the
position. four bearing retaining pins, and two crankcase
dowel pins.
2-75
7. Place the PTO-side crankshaft bearing into
position making sure the bearing retaining pin hole
is positioned inward.
NOTE: The bearing retaining pin hole is the hole
that doesn't go entirely through the bearing case.
AN083

0636-069) to the entire bottom half of the
crankcase sealing surface.
AN078

with grease; then slide the seals onto the
NOTE: There is a MAG-side seal and a PTO-side
seal.

the crankshaft into the upper crankcase half. Be
sure the alignment hole in each bearing is AQ127
positioned over its respective dowel pin in the
crankcase; then seat the crankshaft. NOTE: Use only High-Temp Sealant (p/n 0636-
069) to seal the crankcase halves.
place the point of a sharp tool into the dimple 12. Assemble the crankcase halves making sure that
found in the bearing race. Strike the tool with the the crankshaft gear and oil-injection pump
palm of the hand in either direction. If the bearing driveshaft gears mesh. Rotate the crankshaft one
moves, it isn't positioned correctly and must be full turn to align the crankshaft gear and pump
rotated until it drops onto the retaining pin.
driveshaft.
! CAUTION 13. Install the 14 crankcase cap screws securing the

crankcase halves making sure the cap screws are
If the bearings are not properly seated during in the proper-sized holes. Tighten in three steps the
tightly and engine damage will result.
8 mm cap screws to 1.8-2.8 kg-m (13-20 ft-lb) and
the 6 mm cap screws to 0.8-1.2 kg-m (6-9 ft-lb)
using the pattern shown.
10. Position the two center seal rings with their end
gaps 180° apart (up on one and down on the
other).
0728-137
2-76
bands on the cylinder studs.
14. Install the oil-injection pump retainer O-ring and

retainer.
AN094
20. Apply sealant to the crankcase seam; then install

the alignment pins into the crankcase.
AN088
2
15. Install the O-ring/gasket and the oil-injection
pump making sure the pump shaft and pump align.
Secure with two screws and washers. Tighten the
two screws to 0.7 kg-m (5 ft-lb).
! CAUTION
Be sure the driveshaft is properly aligned with
the slot of the oil-injection pump. The pump will
be damaged if these two components are not
aligned.
AN095
16. Position the rubber seal retainer and seal into the NOTE: Sealant is only required on the crankcase
back side of the water pump impeller. seam.
NOTE: The lined or marked side of the porcelain 21. Position the O-ring into the water pump cover;
seal must face the rubber retainer. then install the cover. Secure with five screws.
Tighten securely.
17. Using both thumbs, press the seal into position
making sure its marked side is positioned towards 22. Place the cylinder base gaskets into position on the
the rubber seal cup. crankcase.
18. Apply a thin coat of grease to the seal outer NOTE: Be sure to spray a thin coat of Copper
surface. Coat Gasket Sealant (p/n 0636-092) onto the gas-
ket if it is being reused.
19. Place the impeller into position and secure with a
cap screw and washer. Be sure the rubber side of 23. Install the piston rings on each piston so the letter
the washer is directed toward the impeller. Apply on the top (inclined surface) of each ring faces the
blue Loctite #242 to the threads of the cap screw dome of the piston.
and tighten to 0.8-1.2 kg-m (6-9 ft-lb).
! CAUTION
The rubber side of the washer (which secures
the impeller) must be positioned toward the
impeller. If installed incorrectly, a coolant leak
will result.
2-77
726-306A AN102
! CAUTION ! CAUTION
Incorrect installation of the piston rings will Make sure the circlips are firmly seated and the
result in engine damage. open end is directed either up or down before
continuing with assembly.
24. Apply oil to the connecting-rod small end
bearings; then install the small-end bearings. 27. Rotate each piston ring until the ring ends are
Install a washer on each side of the connecting properly positioned on either side of the ring
rod. keeper; then apply oil to the piston assemblies and
cylinder bores. Remove the rubber bands from the
25. Place each piston over the connecting rod so the connecting rods.
arrow on each piston will point toward the exhaust
port; then secure with an oiled piston pin. NOTE: If the intake flanges were removed from
the cylinders, install them prior to installing the
NOTE: The arrow is found either up inside the cylinders. Tighten the nuts to 1.8-2.2 kg-m (13-16
piston or on the dome top. ft-lb).
28. In turn on each cylinder, place a piston holder (or

suitable substitute) beneath the piston skirt and
square the piston in respect to the crankcase; then
using a ring compressor or the fingers, compress
the rings and slide the cylinder over the piston.
Remove the piston holder and seat the cylinder
firmly onto the crankcase.
NOTE: The cylinders should slide on easily. DO
NOT force the cylinders on.
AN101
26. Install the circlips so the open end is directed

either up or down.
AN105
29. Secure each cylinder by installing the four nuts,

washers, and lock washers. DO NOT TIGHTEN
AT THIS TIME.
0636-069) to each exhaust port; then install the
two exhaust gaskets with the metal sides facing
out.
2-78
AN106 AN111
31. Install the exhaust manifold and secure with four 34. Install the two cylinder O-rings on the top of each
nuts and lock washers. Tighten the four nuts to cylinder making sure they are correctly positioned
1.8-2.2 kg-m (13-16 ft-lb). in the grooves.
AN107 AN110
32. With the exhaust manifold tightened, secure the 35. Place new O-rings onto each of the twelve head
cylinders by tightening the cylinder base nuts to 4- cap screws. Place four of these cap screws into one
6 kg-m (29-43.5 ft-lb). Tighten the nuts in three of the cylinder heads. Thread the spark plug in part
steps using the pattern shown. way; then while holding the head above the
cylinder, carefully start all four cap screws while
observing the cylinder O-rings to make sure they
remain in position. Slowly place the head into
position on top of the O-rings. Start the remaining
two cap screws being very careful not to move the
cylinder head. Repeat the same procedure on the
remaining head. ONLY FINGER-TIGHTEN AT
THIS TIME.
36. Apply a thin coat of sealant to the two thermostat
housing gaskets. Place the gaskets and housing
into position and secure with four cap screws and
washers. Tighten the four cap screws in a
crisscross pattern to 0.7-1 kg-m (5-7 ft-lb).
725-318B
NOTE: The thermostat housing cap screws must
33. Install the two oil-injection hoses and secure with be tightened before tightening the cap screws
the clamps. securing the head. This will allow the gasket sur-
faces of the head to align with the housing and
prevent any coolant leakage.
2-79
AN113 AN118
37. Tighten the cap screws securing the head in three NOTE: Before installing the flywheel, be sure to
steps to 1.8-2.8 kg-m (13-20 ft-lb) using the wipe the crankshaft and flywheel tapers clean
pattern shown. Pressure test the engine (see using a clean towel.
Section 3).
keyways match; then finger-tighten the flywheel
nut with large flat washer and lock washer. Apply
red Loctite #271 to the threads of the flywheel nut.
44. Install the starter pulley; then secure the starter
pulley with three cap screws and lock washers.
Secure the pulley while using the spanner wrench
and tighten the three cap screws evenly to 0.7-
1 kg-m (5-7 ft-lb).
0728-138
38. Place the thermostat, gasket, and cap into position.

Secure the cap with three cap screws tightened to
0.7-1 kg-m (5-7 ft-lb).
39. Place the PTO-end plate into position on the
crankcase; then apply blue Loctite #242 to the
screws and tighten securely.
40. Place the stator plate into position over the
crankshaft end. AN121
41. Install the lock washers and washers on the Allen- 45. Using the spanner wrench, tighten the flywheel
head cap screws; then apply blue Loctite #242 to nut to 7-9 kg-m (50.5-65 ft-lb).
the threads of the stator plate Allen-head cap
screws and install. DO NOT TIGHTEN AT THIS
TIME.
42. Align the stator plate with the alignment mark
made during disassembly. Tighten both stator plate
screws securely.
AN122
46. Install the spark plugs and tighten to 2.5-2.8 kg-m

(18-20 ft-lb). Connect the spark plug caps.
2-80
47. Place the engine mounting brackets into position
on the crankcase and secure with the cap screws.
Tighten to 2.8-3.5 kg-m (20-25 ft-lb).
Assembling Engine
(570 cc Models)

NOTE: When the use of a lubricant is indicated, MD0203
use Arctic Cat 50:1 Injection Oil. 6. Install crankcase lower half. Install eight 8 mm
and four 6 mm cap screws. Tighten in three steps
1. Place the upper crankcase half (with its bottom the 8 mm cap screws to 1.8-2.8 kg-m (13-20 ft-lb)
side up) on two blocks of wood. and the 6 mm cap screws to 0.8-1.2 kg-m (6-9 ft-
lb) using the pattern shown. 2
! CAUTION
To prevent damage to the crankshaft, crankshaft
bearings, or seals, make sure to always lift the
crankshaft from both ends.
2. Lightly grease the inner lips of the crankshaft

seals; then slide them onto the crankshaft.
sure the alignment hole in each bearing is
positioned over its respective dowel pin in the
crankcase; then seat the crankshaft.
NOTE: To check the bearing for proper position, 737-027A
moves, it isn’t positioned correctly and must be
rotated until it drops onto the dowel pin.
NOTE: Make sure the crankshaft center C-ring

(integral with the center seal) is properly posi-
tioned in the groove of the upper crankcase half.
! CAUTION
If the bearings are not properly seated during
MD0212
tightly and severe engine damage will result.
NOTE: Check the reed valve on each cylinder for
4. Install the four crankcase dowel pins. cracking or fraying around the edges. Make sure
they are closing completely.
5. Evenly apply a thin coat of Three Bond Sealant (p/n
0636-070) to the entire bottom half crankcase NOTE: To inspect a reed valve assembly, remove
sealing surface. the two Phillips-head screws securing the reed
valve and reed valve stopper to the block; then
NOTE: Use only Three Bond Sealant (p/n 0636- remove the reed valve and stopper.
070) to seal the crankcase halves.
2-81
726-306A
MD0088
NOTE: Apply blue Loctite #242 on the Phillips- ! CAUTION

head screws when assembling. Incorrect installation of the piston rings will
NOTE: Make sure the angled corner on the reed
valve align with the angled corner on the reed NOTE: If the existing rings will not be replaced
valve stopper. with new rings, note the location and top side of
each ring for proper installation. When replacing
with new rings, replace as a complete set only.
When replacing rings note notches in ring ends
which correspond with locating pins in ring
grooves on intake side of the piston. This prevents
the rings from turning on the piston when assem-
bled.
MD0213
! CAUTION
Do not over-tighten the Phillips-head screws
when installing the reed valves and reed valve
stoppers.
MD0208
on the top (inclined surface) of each ring faces the
dome of the piston.
MD0272
2-82
MD0248
MD0271
11. Place the cylinder base gasket into position on the
8. Lubricate the piston pin bearings and install them crankcase making sure the gasket is properly
into the connecting rods. oriented so the dowel pins will fit through the
2
holes easily.
9. Install a piston pin bearing washer on each side of
the bearings with the open sides facing the NOTE: Be sure to spray a thin coat of Copper
bearings. Coat Gasket Sealant (p/n 0636-092) onto the gas-
ket if it is being reused.
NOTE: The open sides of the piston pin bearing
washers must face the bearing.
! CAUTION
Make sure the circlips are firmly seated in their
grooves and the open ends are pointed up or
down before continuing with assembly.
12. Rotate each piston ring until the ring ends are
properly positioned with the pins in the ring
grooves; then apply oil to the piston assemblies
and cylinder bores. Using a ring compressor or the
fingers, compress the rings and slide the cylinder
over the piston. Seat the cylinder firmly onto the
crankcase.
NOTE: The cylinders should slide on easily. DO
NOT force them on.
MD0251
10. Place pistons over the connecting rods with the

arrow (or indicator dot) pointing toward the
exhaust port; then secure with an oiled piston pin.
Install piston pin circlips with the open ends up or
down.
MD0229
13. Secure each cylinder by installing the four 6 mm

and eight 8 mm nuts. Tighten the 8 mm nuts to 4-6
kg-m (29-43.5 ft-lb) and the 6 mm nuts to 0.7-1
kg-m (5-7 ft-lb).
MD0293
2-83
MD0086
MD0233
MD0087
14. Install a new cylinder head gasket and the cylinder

head; then install the eight cap screws and two
nuts with washers. Tighten in three steps to 1.8-2.8
kg-m (13-20 ft-lb) using the pattern shown. MD0234
MD0232
MD0259A
15. Install the spark plugs; then tighten to 2.5-2.8 kg-m

(18-20 ft-lb).
2-84
MD0235
16. Position the seal retainer plate on the PTO-side; MD0255
then install the four cap screws. Tighten the cap 18. Place the stator wiring through the hole in the
screws to 0.8-1.2 kg-m (6-9 ft-lb). crankcase; then install the stator. Lightly coat the
three Allen-head cap screws with red Loctite
#271; then tighten them to 0.8-1.2 kg-m (6-9 ft-
lb).
2
MD0253
MD0076
MD0292
17. Install the stator plate and secure with four Allen-
head cap screws. Install the stator plate so the
ignition wire cut-out is in the upper left position.
MD0274
Lightly coat the four Allen-head cap screws with
red Loctite #271; then tighten them to 0.8-1.2 kg- 19. Place the ignition timing sensor wiring through the
m (6-9 ft-lb). hole in the crankcase; then position the ignition
timing sensor and install two Phillips-head cap
screws (coated with red Loctite #271). Tighten the
cap screws securely.
2-85
MD0074
MD0264
22. Place the fan and starter pulley into position on the
flywheel. Using Spanner Wrench (p/n 0144-007)
to hold the starter cup, tighten the three cap screws
(coated with green Loctite #609 and Loctite
Primer #7471) to 1.8-2.8 kg-m (13-20 ft-lb).
! CAUTION
Do not use green Loctite #609 without also using
Loctite Primer #7471.
! CAUTION
When installing the fan, make sure that the
locating pins on the flywheel align with the
indentations in the fan.
MD0273
20. Install the rubber insulator grommet into the

crankcase.
MD0280
MD0262
21. Install the key; then install the flywheel and cap starter cup, tighten the flywheel cap screw (threads
screw. Tighten the cap screw only until snug. coated with red Loctite #271) to 8.0-8.7 kg-m (58-
63 ft-lb).
NOTE: Do not tighten the flywheel cap screw at
this point.
2-86
MD0278 MD0268
24. Using the six cap screws and the special washers, 26. Install the main fan shroud and recoil starter
2
install the rear (intake-side) shroud. Tighten the assembly. Tighten the eight cap screws to 1.1 kg-m
cap screws to 0.4-0.7 kg-m (3-5 ft-lb). (8 ft-lb).
MD0279
MD0277
25. Using the five 6 mm cap screws and the special

washers, install the front (exhaust-side) cooling
shroud and tighten to 0.4-0.7 kg-m (3-5 ft-lb).
Install the rubber spark plug grommets; then
tighten the cap screws securely.
MD0291
27. Lubricate the oil-injection pump driveshaft; then

while rotating the driveshaft, install it and the
thrust washer into the lower crankcase half.
MD0269
NOTE: Make sure the thrust washer is installed
on the oil injection pump driveshaft when it is
installed.
2-87
MD0090
MD0252
30. Install the intake flange assembly using washers,
28. Install the oil injection pump driveshaft retainer lock washers, and nuts. Note the placement of
and O-ring. gaskets, heat deflector, gaskets, insulators, and
flanges. Tighten the nuts (threads coated with red
NOTE: Make sure the O-ring is installed on the Loctite #271) to 1.8-2.2 kg-m (13-16 ft-lb).
oil injection pump driveshaft retainer when it is
installed.
31. Install the exhaust manifold and gaskets using lock
washers and nuts. Tighten the nuts to 1.8-2.2 kg-m
(13-16 ft-lb).
Assembling Engine
(500/600 cc Twin Models)


MD0273 use Arctic Cat 50:1 Injection Oil.
29. Install the oil injection pump aligning the slot on 1. Apply a thin coat of grease to the inner seal lips of
the oil pump with the flat on the end of the oil the water pump seal.
injection pump driveshaft. Tighten the Allen-head
cap screws to 0.8-1.2 kg-m (6-9 ft-lb). 2. Using the seal driver, position the inner water
pump shaft seal onto the seal driver and gently tap
the seal down into position.
NOTE: Grease must be applied to the lips of the
inner seal before installation.
MD0294
AN070D
NOTE: The seal must be installed with its spring

2-88
3. Install the snap ring securing the inner seal in the NOTE: The bearing retaining pin hole is the hole
crankcase. that doesn't go entirely through the bearing case.

AN330D
AN072D
crankshaft making sure the spring side of each seal 2
5. Apply a thin coat of grease to the sealing surface
of the oil-injection pump/water pump driveshaft; NOTE: There is a MAG-side seal and a PTO-side
then place the Oil Seal Installation Tool (p/n 0644- seal.
219) at the end of the shaft. Twist the driveshaft
clockwise as it is pushed through the oil and water 9. Apply oil to the crankshaft bearings; then install
pump seals; then remove the tool. Position the the crankshaft into the upper crankcase half. Be
shim on the oil-injection pump end of the sure the alignment hole in each bearing is
driveshaft. positioned over its respective dowel pin in the
! CAUTION
Be very careful not to damage the seals when
use the seal installation tool. Twist the driveshaft
clockwise as it enters the seal area and while it is
being pushed through the seals.
AN331D

moves, it isn’t positioned correctly and must be
AN074 rotated until it drops onto the dowel pin.
6. Position the upper crankcase half upside-down on

two wooden blocks; then install the C-ring, the ! CAUTION
four bearing retaining pins, and the two crankcase If the bearings are not properly seated during
dowel pins. assembly, the crankcase halves will not seal
position making sure the bearing retaining pin hole 10. Position the two center seal rings with their end
is positioned inward. gaps 180° apart (up on one and down on the
other).
2-89
bands on the cylinder studs.

retainer.
AN083D

0636-069) to the entire bottom half of the
crankcase sealing surface.
AN088D
16. Install the O-ring and the oil-injection pump

making sure the pump shaft slot and pump driven
gear shaft align. Secure with two screws (coated
with blue Loctite #242) and washers. Tighten the
! CAUTION
Be sure the oil-injection pump/water pump
driveshaft is properly aligned with the slot of the
oil-injection pump. The pump will be damaged if
these two components are not aligned.
AQ127
NOTE: Use only Arctic Cat High-Temp Sealant 17. Position the rubber seal retainer and seal into the
(p/n 0636-069) to seal the crankcase halves. back side of the water pump impeller.
12. Assemble the crankcase halves making sure that 18. Using both thumbs, press the seal into position
the crankshaft gear and oil-injection pump making sure its marked side is positioned towards
driveshaft gears mesh. Rotate the crankshaft one the rubber seal cup; then apply a thin coat of
full turn to align the crankshaft gear and pump grease to the seal outer surface.
driveshaft.
13. Install the crankcase cap screws (coated with blue cap screw and washer. Be sure the rubber side of
Loctite #242) securing the crankcase halves. the washer is directed toward the impeller. Apply
blue Loctite #242 to the threads of the cap screw
14. Tighten the 8 mm cap screws to 1.8-2.8 kg-m (13- and tighten to 0.8-1.2 kg-m (6-9 ft-lb).
20 ft-lb) and the 10 mm cap screws to 4-6 kg-m
(29-43.5 ft-lb) using the pattern shown. ! CAUTION
The rubber side of the washer, which secures the
500/600 cc impeller, must be positioned toward the impeller.
If installed incorrectly, a coolant leak will result.
20. Apply high-temperature sealant to the crankcase/

water pump cover seam; then install the dowel
pins into the crankcase.
735-670A
2-90
AN095 AN100
NOTE: Sealant is only required on the crankcase

seam.
21. Position the O-ring into the water pump cover;

then install the cover. Secure with five screws.
Tighten to 1.1 kg-m (8 ft-lb). 2
22. Secure the intake flanges, reed valve assemblies,
and gaskets with cap screws. Tighten to 0.8-
1.2 kg-m (6-9 ft-lb).
23. Place the cylinder base gasket into position on the
crankcase.
AQ059
on the top (inclined surface) of each ring faces the 26. Place each piston over the connecting rod so the
dome of the piston. arrow (or indicator dot) on each piston will point
toward the exhaust port; then secure with an oiled
piston pin.
NOTE: The arrow (or indicator dot) is found
either up inside the piston or on the dome top.
726-306A
! CAUTION
result in engine damage. AN101
25. Apply oil to the connecting-rod small end 27. Install the new circlips so the open end is directed
bearings; then install the small-end bearings. either up or down.
Install a washer on each side of the connecting
rod.
2-91
31. Install the oil-injection hoses and secure with the
clamps; then place the lower check-valve
assembly into position and secure with the gaskets
and union cap screw. Tighten securely.
32. Install the two cylinder O-rings on the top of each
cylinder making sure they are correctly positioned
in the grooves.
B324D
! CAUTION
Make sure the circlips are firmly seated and the
open end is directed either up or down before
28. Rotate each piston ring until the ring ends are
properly positioned on either side of the ring AN110D
keeper; then apply oil to the piston assemblies and
cylinder bores. Remove the rubber bands from the 33. Place new O-rings onto each of the head cap
connecting rods. screws. Place four of these cap screws into the
cylinder head. Thread the spark plugs in part way;
29. In turn on each cylinder, place a piston holder (or then while holding the head above the cylinder,
suitable substitute) beneath the piston skirt and carefully start all four cap screws while observing
square the piston in respect to the crankcase; then the cylinder O-rings to make sure they remain in
using a ring compressor or the fingers, compress position. Slowly place the head into position on
the rings and slide the cylinder over the piston. top of the O-rings. Start the remaining cap screws
Remove the piston holder and seat the cylinder being very careful not to move the cylinder head.
firmly onto the crankcase. ONLY FINGER-TIGHTEN AT THIS TIME.
NOTE: The cylinders should slide on easily. DO 34. Tighten the cap screws securing the head in three
NOT force the cylinders on. steps to 1.8-2.8 kg-m (13-20 ft-lb) using the
pattern shown.
500/600 cc
AN105D
0733-524
30. Secure each cylinder by installing the four nuts,
washers, and lock washers. DO NOT TIGHTEN 35. Place the thermostat, gasket, and cap into position.
AT THIS TIME.
36. Secure the cap with three cap screws tightened to
NOTE: The cylinders will be tightened at the 0.7-1 kg-m (5-7 ft-lb).
same time as the exhaust manifold is installed to
assure proper cylinder to exhaust manifold align- 37. Apply a thin coat of high-temperature silicone
ment. sealant to each exhaust port; then install the
exhaust gaskets with the metal sides facing out.
38. Install the exhaust manifold and secure with four
nuts and lock washers. Tighten the four nuts to
1.8-2.2 kg-m (13-16 ft-lb).
2-92
39. Tighten the spark plugs to 2.5-2.8 kg-m (18- 45. Apply red Loctite #271 to the threads of the
20 ft-lb); then secure the cylinders by tightening flywheel nut; then finger-tighten with a large flat
the cylinder base nuts to 4-6 kg-m (29-43.5 ft-lb) washer, lock washer, and the nut. DO NOT
in three steps using the pattern shown. Pressure TIGHTEN AT THIS TIME.
test the engine (see Section 3).
2
AN120D
725-318B
46. Place the starter pulley in position; then loosely
40. Secure the ignition timing sensor with screws secure the starter pulley with three cap screws
coated with blue Loctite #242. (coated with red Loctite #271) and lock washers.
Secure the pulley while using the spanner wrench
41. Place the PTO-end plate into position on the and tighten the three cap screws evenly to 0.7-
crankcase; then apply blue Loctite #242 to the four 1 kg-m (5-7 ft-lb).
screws and tighten to 1.1 kg-m (8 ft-lb).
42. Secure the stator to the stator plate with the Allen-
head cap screws coated with blue Loctite #242 and
tightened to 1.1 kg-m (8 ft-lb); then install the
stator wires with a grommet into the crankcase.
AN121D
47. Using the spanner wrench, tighten the flywheel

nut to 7-9 kg-m (50.5-65 ft-lb).
48. Place the engine mounting brackets into position
AN413D on the crankcase and secure with the cap screws.
Tighten to 2.4 kg-m (17 ft-lb).
43. Install the key in the crankshaft.
49. Slide the APV assemblies into position in the
44. Slide the flywheel onto the crankshaft making sure cylinders making sure that on the 500 cc, the
the keyways match. grooved sides are down; then slide the valve
keepers into position and secure with cap screws
NOTE: Before installing the flywheel, be sure to (coated with blue Loctite #242). Tighten to 0.9-
wipe the crankshaft and flywheel tapers clean 1.3 kg-m (6.5-9.5 ft-lb) on the 500 cc and to
using a clean towel. 1.1 kg-m (8 ft-lb) on the 600 cc.
NOTE: The following illustrations are the 500 cc.
Other models may vary slightly.
2-93
AP149 AN070D
NOTE: The seal must be installed with its spring

3. Install the snap ring securing the inner seal in the

crankcase.
AP120
50. Slide the valve covers into position and secure

with existing nuts. Tighten to 0.9-1.3 kg-m (6.5-
9.5 ft-lb).
Assembling Engine
(800 cc Models) AN072D
5. Apply a thin coat of grease to the sealing surface

NOTE: The use of new gaskets and seals is rec- of the oil-injection pump/water pump driveshaft;
ommended when assembling the engine. then place the Oil Seal Installation Tool (p/n 0644-
219) at the end of the shaft. Twist the driveshaft
NOTE: When the use of a lubricant is indicated, clockwise as it is pushed through the oil and water
use Arctic Cat 50:1 Injection Oil. pump seals; then remove the tool. Position the
shim on the oil-injection pump end of the
NOTE: Do steps 1-5 only if the water pump has driveshaft.
been disassembled.
1. Apply a thin coat of grease to the inner seal lips of ! CAUTION

the water pump seal. Be very careful not to damage the seals when
2. Using the seal driver, position the inner water use the seal installation tool. Twist the driveshaft
pump shaft seal onto the seal driver and gently tap clockwise as it enters the seal area and while it is
the seal down into position. being pushed through the seals.
NOTE: Grease must be applied to the lips of the

inner seal before installation.
2-94
faces the center of the crankcase.
NOTE: There is a MAG-side seal and a PTO-side
seal.
10. Apply Arctic Cat 50:1 Injection Oil to all of the

crankshaft bearings; then install the crankshaft
into the upper crankcase half. Be sure the retaining
pin hole in each bearing is positioned over its
respective dowel pin in the crankcase.
AN074
NOTE: Check all bearings by trying to rotate
6. Set the top half of the crankcase upside down on them to make sure they are being held in position
the work bench with a 4 in. block of wood under by the retaining pin. Each bearing must drop onto
each end. the retaining pin.
7. Install the C-ring in the upper crankcase half.

Install the four bearing retaining pins in the
! CAUTION 2
crankcase bearing areas. If the bearings are not properly seated during
AJ095
8. Using Arctic Cat 50:1 Injection Oil, lubricate the AJ097

crankshaft bearings and slide them onto the
crankshaft. 11. Rotate the crankshaft center seal rings so the end
gaps of the two large rings are 180° apart, one end
! CAUTION gap being positioned downward and the other
upward; then seat the crankshaft.
The retaining pin holes on both bearings must be
positioned toward the center of the crankshaft.
AP151
AP150B
0636-069) to the lower crankcase sealing surface.
2-95
NOTE: On EFI models after assembling the
crankcase halves, install the magneto case .

retainer.
AQ127
! CAUTION
Check to make sure the two crankcase half
dowel pins are in position at opposite corners of
the lower case half.
AN088D
13. Assemble the crankcase halves.
16. Install the O-ring and the oil-injection pump
14. Install the crankcase cap screws securing the making sure the pump shaft slot and pump driven
crankcase halves making sure the proper-sized cap gear shaft align. Secure with two screws (coated
screws (on carbureted models) are in the proper with blue Loctite #242) and washers. Tighten the
holes. Tighten in three steps the 10 mm cap screws two screws to 1-1.4 kg-m (7-10 ft-lb).
to 4.8-5.4 kg-m (35-39 ft-lb), the 8 mm cap screws
to 1.8-2.8 kg-m (13-20 ft-lb), and the 6 mm cap
screws to 0.9-1.3 kg-m (6.5-9.5 ft-lb) using the
pattern shown.
AP143
! CAUTION
AJ101
Be sure the oil-injection pump/water pump
driveshaft is properly aligned with the slot of the
oil-injection pump. The pump will be damaged if
these two components are not aligned.
17. Place the lower check valve assembly into position

and secure with the gaskets and the union bolt.
18. Position the rubber seal retainer and seal into the
back side of the water pump impeller.
making sure its marked side is positioned towards
the rubber seal cup; then apply a thin coat of
grease to the seal outer surface.
736-280A
2-96
cap screw and washer. Be sure the rubber side of
the washer is directed toward the impeller. Apply
! CAUTION
The rubber side of the washer, which secures the
impeller, must be positioned toward the impeller.
If installed incorrectly, a coolant leak will result.
21. Place the end plate into position on the crankcase;

then apply blue Loctite #242 to the four cap AQ059
screws and tighten securely.
24. Place each piston over the connecting rod so the
arrow on each piston will point toward the exhaust
port and secure with a piston pin; then install the
new circlips so the open end is directed either
down or up.
2
AP142

on the top or inclined surface of each ring faces the
dome of the piston.
AJ110
! CAUTION
Make sure circlips are firmly seated and the open
end is directed either down or up before
25. Apply a thin coat of Copper Coat Gasket Sealant

(p/n 0636-092) to both sides of each cylinder-base
gasket if the gaskets are being reused. If using new
gaskets, it isn't necessary to apply copper coat.
Install the gasket with the raised portion of the
gasket positioned upward.
726-306A
! CAUTION
23. Apply oil to the connecting-rod small end

bearings; then install the small-end bearings and
thrust washers.
AJ111
2-97
26. Rotate each piston ring until the ring ends are NOTE: If reusing O-rings and they are slightly
properly positioned on either side of the ring stretched, shrink the O-rings by cooling them (in a
keeper; then apply oil to the piston assemblies and refrigerator for example) for a short period of time.
cylinder bores.
30. Check sealing surface to make sure the surface is
clean; then set the cylinder heads in position.
0636-069) to the two thermostat manifold gaskets.
Place the gaskets and housing into position and
secure with four cap screws and washers. Tighten
the four cap screws in a crisscross pattern to 0.9-
1.3 kg-m (6.5-9.5 ft-lb).
NOTE: The thermostat manifold cap screws
must be tightened before tightening the head cap
screws. This will allow the gasket surfaces of the
head to align with the housing and prevent any
coolant leakage.
726-306B
27. In turn on each cylinder, place a piston holder (or 32. Tighten the head cap screws in three steps to 2.4-
suitable substitute) beneath the piston skirt and 3.2 kg-m (17-23 ft-lb) using the pattern shown;
square the piston in respect to the crankcase; then then install the spark plugs and tighten to 2.5-2.8
using a ring compressor or the fingers, compress kg-m (18-20 ft-lb).
the rings and slide the cylinder over the piston.
Remove the piston holder and seat the cylinder
firmly onto the crankcase.
0728-138
33. If removed in turn for each cylinder, install the

gasket, reed valve assembly, and carburetor flange
AP138
to the crankcase; then secure with six cap screws.
28. Secure each cylinder with four flange cap screws Tighten to 0.8-1.2 kg-m (6-9 ft-lb).
and four nuts with flat and lock washers. Using a
crisscross pattern, tighten the nuts to 4.6-6.8 kg-m
(33-49 ft-lb) and the cap screws to 4.8-7.2 kg-m
(35-52 ft-lb).
29. Place the O-rings into position on the top of each
cylinder.
AN213
34. Test the engine for air leaks (see Section 3).
35. Place the thermostat with gasket and cap into
position. Secure with three cap screws. Tighten to
0.9-1.3 kg-m (6.5-9.5 ft-lb).
AJ118
2-98
39. Set the timing sensor into position in the magneto
housing. Apply blue Loctite #242 to the threads of
the two screws and secure the timing sensor to the
housing.
40. Route the stator wiring harness through the rubber
grommet; then place the stator into position and
secure with three screws coated with blue Loctite
#242. Tighten securely.
41. Secure the stator wiring harness to the magneto
housing using the tab plate and screw.
AP152
36. Apply a thin coat of silicone sealant to the keyways align.
crankcase water pump housing sealing surface.
NOTE: Sealant is required only on the crankcase
seam.
2
AJ128
43. Apply blue Loctite #242 to the threads of the cap

screw; then install the flat washer, lock washer,
AN095
and cap screw securing the flywheel. Tighten the
cap screw finger-tight.
0636-069) to the water pump cover seal and 44. Place the starter pulley into position on the
position the O-ring into the cover. Carefully place flywheel and secure with three cap screws coated
the cover over the impeller and onto the crankcase. with blue Loctite #242. Tighten the three cap
Secure with six cap screws. Tighten cap screws screws evenly to 0.9-1.3 kg-m (6.5-9.5 ft-lb).
evenly to 0.9-1.3 kg-m (6.5-9.5 ft-lb).
38. Install the stator backing plate and secure with
four cap screws. Apply blue Loctite #242 to the
threads of each cap screw before installation.
Tighten securely.
AJ130
45. Using a spanner wrench, tighten the flywheel bolt

to 7.95-8.65 kg-m (57.5-62.5 ft-lb).
AP133
2-99
59. Position the coolant supply hose on the water
pump and secure with a clamp.
Assembling Engine

AJ131
use Arctic Cat 50:1 Injection Oil.
46. Place the exhaust manifold into position on the
cylinders; then secure with flange nuts. Tighten to 1. Using the Water Pump Bearing and Seal Kit (p/n
1.8-2.2 kg-m (13-16 ft-lb). 0644-084), position the inner water pump shaft
seal onto the special seal driver and gently tap the
47. Place the engine mounting brackets into position seal down into position.
on the engine; then secure with cap screws (coated
with blue Loctite #242), lock washers, and flat NOTE: The seal must be installed with its spring
washers. Tighten to 2.4 kg-m (17 ft-lb). side towards the crankshaft.
48. Slide the APV assemblies into position in the 2. Apply a thin coat of grease to the inner seal lips.
cylinders making sure the grooved sides are down;
then slide the valve keepers into position and 3. Using a pair of snap ring pliers, install the snap
secure with two cap screws (coated with blue ring securing the inner seal in the crankcase.
Loctite #242). Tighten to 0.9-1.3 kg-m (6.5-
9.5 ft-lb). 4. Using the seal driver, carefully install the outer
AP149
AN072
5. Apply a light coat of grease to the sealing surface

of the oil-injection pump driveshaft; then install
the Oil Seal Installation Tool (p/n 0644-219) at the
end of the shaft. Twist the shaft clockwise as it is
pushed through the oil-injection and water pump
seals; then remove the tool. Position the shim on
the oil-injection pump end of the driveshaft.
! CAUTION
Be very careful not to damage the seals when
AP120
installing the pump driveshaft. Be certain to use
Oil Seal Installation Tool (p/n 0644-219).
49. Slide the APV covers into position and secure with
existing nuts. Tighten to 0.9-1.3 kg-m (6.5-
9.5 ft-lb).
2-100
AN205 AN203
6. Position the upper crankcase half upside-down on

two wooden blocks; then install the C-ring and the ! CAUTION
six bearing retaining pins. If the bearings are not properly seated during
position making sure the bearing retaining pin hole
2
is positioned inward. 10. The sealing rings must be located so none of the
end gaps align. Rotate the rings to “stagger” the
NOTE: The bearing retaining pin hole is the hole end gaps.
that doesn't go entirely through the bearing case.
AN083
AN152
11. Apply a light coat of High-Temp Sealant (p/n
8. Lubricate the inner lips of the crankshaft end seals 0636-069) to the entire sealing surface of the
with grease; then slide the seals onto the bottom half of the crankcase. Install the two dowel
crankshaft making sure the spring side of each seal pins into the corners of the crankcase.
faces the bearing on the crankshaft.
NOTE: There is a MAG-side seal and a PTO-side ! CAUTION
seal. When installing the crankcase dowel pins, use
the two long dowel pins. The six shorter pins
9. Apply oil to the crankshaft bearings; then install must be used to align the cylinders.
sure the alignment hole in each bearing is
positioned over its respective retaining pin in the
AN201
2-101
12. Place the bottom crankcase half into position and 15. Place the piston over the connecting rod so the
install the 14 crankcase cap screws (threads coated arrow on the piston dome will point towards the
with blue Loctite #242). Tighten the cap screws exhaust port of the cylinder; then apply a light coat
evenly by hand starting in the center; then tighten of oil to the piston pin and install.
the cap screws in three steps to 1.8-2.8 kg-m (13-
20 ft-lb). Follow the pattern shown.
AN193
0731-342 16. Install the piston rings on the piston with their
tapered side “up.”
13. Set the engine upright. On the appropriate
crankcase cylinder mounting studs, position two 17. Secure the piston pin by installing new piston pin
dowel pins per cylinder. Install the cylinder base circlips. Install the circlip with the open end up.
gaskets.
18. Apply oil to the piston rings and pistons; then
rotate the rings to correctly position them on either
side of the locating pin in the ring groove. Place a
short piece of wear strip under the piston to keep it
square; then compress the piston rings with one
hand and slide the cylinder down onto the piston.
AN197
NOTE: The cylinder base gaskets can be reused

if not damaged. When reusing a gasket, coat each
side with Copper Coat Gasket Sealant (p/n 0636-
092).
AN190
14. Pre-oil the piston pin bearings and place into
position in the connecting rods; then place a thrust 19. Align the cylinder exhaust ports using a straight
washer on each end of the bearing. The flat side of edge; then secure each cylinder base with four
each washer must face outward. flanged nuts. In three steps, tighten the nuts to 1.8-
2.8 kg-m (13-20 ft-lb).
AN194
2-102
0729-585 AN187
NOTE: If removed, install the exhaust manifolds. 23. Tighten the cylinder head cap screws in three steps
Tighten to 1.8-2.2 kg-m (13-16 ft-lb). using the pattern shown to 2-2.5 kg-m (14.5-
18 ft-lb).
20. Place the cylinder head O-rings into position on
each cylinder.
2
NOTE: If reusing O-rings and they are slightly
stretched, shrink the O-rings by cooling them (in a
refrigerator for example) for a period of time.
21. Being very careful not to move the two O-ring

seals, hold the cylinder head above the cylinder
approximately 1/4 in. and start the cap screws into
the cylinder; then check the O-rings for proper
position and set the head carefully down onto the
cylinder. Finger-tighten the cap screws at this
time.
0729-587
24. In turn for each cylinder, install the gasket, reed

valve assembly, and intake flange to the
crankcase; then secure with six cap screws.
AN188
! CAUTION
Be very careful not to move the cylinder heads
once they are placed on top of the O-rings.
AN213
0636-069) to the three water manifold gaskets. 25. Place the thrust washer on the outward end of the
Place the gaskets and manifold into position and oil-injection pump driveshaft.
secure with six cap screws. Using a crisscross
pattern, tighten to 0.7-1 kg-m (5-7 ft-lb). 26. Apply a light coat of oil to the shaft adapter; then
install the O-ring and slide the adapter into
position on the pump driveshaft.
2-103
making sure its marked side is positioned towards
the rubber retainer.
30. Apply a light coat of grease to the seal outer
surface.
cap screw and washer. Be sure the rubber side of
the washer is directed toward the impeller.
screw and tighten to 0.8-1.2 kg-m (6-9 ft-lb).
AN184
! CAUTION
27. Being careful to align the slot of the oil-injection
pump shaft with the flat end of the oil-injection The rubber side of the washer which secures the
pump driveshaft, install the pump on the crankcase impeller must be positioned toward the impeller.
and secure with two screws. If installed incorrectly, a coolant leak will result.
AN183 AN181
33. Apply sealant to the crankcase seam; then install

! CAUTION the dowel pins into the crankcase.
When installing the oil-injection pump, the pump
driveshaft must align with the pump shaft or
serious damage will result.
28. Position the rubber seal retainer and seal into the
back side of the water pump impeller.
NOTE: The lined or marked side of the porcelain
seal must face the rubber retainer.
AN179
NOTE: Sealant is only required on the crankcase

seam.
34. Position the O-ring into the water pump cover;

then install the cover. Secure with five screws.
Tighten securely.
AN091
35. Place the seal protector plate into position on the
crankcase; then apply blue Loctite #242 to the four
screws and secure.
2-104
AJ103 AN172
36. Install the stator plate with the large notch for the 39. Secure the timing sensor wiring harness to the
wiring harness in the 10 o’clock position; then magneto housing using the tab plate and screw.
secure with two cap screws (threads coated with Apply blue Loctite #242 to the screw threads and
blue Loctite #242). tighten securely.
2
AN170 AN173
37. Install the stator; then route the wiring harness NOTE: Wipe the flywheel and crankshaft taper
through the crankcase housing and install the with a clean cloth to remove any foreign material.
rubber grommet. Apply blue Loctite #242 to the
threads of the three Allen-head cap screws and 40. Install the flywheel key in the crankshaft; then
secure the stator to the stator plate. slide the flywheel onto the crankshaft making sure
the keyways align. Install, but do not tighten, the
flat washer, lock washer, and flywheel nut.
AN171
38. Set the timing sensor into position in the magneto AN174
housing. Apply blue Loctite #242 to the threads of
the two screws and secure the timing sensor to the 41. Install the starter pulley and secure with three cap
housing. screws. Tighten to 0.8-1.2 kg-m (6-9 ft-lb).
2-105
AN175 AQ079
42. Tighten the flywheel nut to 7-9 kg-m (50.5- 45. Slide the valve assembly into the proper cylinder.
65 ft-lb).
AP154
AN176
46. Secure the valve assembly to the cylinder with
43. Install the magneto case; then apply blue Loctite three Allen-head cap screws (coated with blue
#242 to the four Allen-head cap screws and Loctite #242). Tighten to 1.1 kg-m (8 ft-lb).
secure. Tighten to 1.8-2.2 kg-m (13-16 ft-lb).
AP153
AN165
47. Slide the valve cover onto the studs on the engine.
44. Install the thermostat with its rubber seal and Secure with four nuts. Tighten securely.
thermostat cover. Secure with three cap screws.
Tighten to 0.7-1 kg-m (5-7 ft-lb).
2-106
AP119 AQ049
48. Install and tighten the spark plugs to 2.5-2.8 kg-m 3. Apply bearing grease to the lips of the end seals.
(18-20 ft-lb); then pressure test the engine (see
Section 3).
2
Assembling Engine
(1000 cc Models)


use Arctic Cat Extreme 50:1 Injection Oil. AQ050
1.Set the top half of the crankcase on the work bench 4. Install the two end seals onto the crankshaft with
with a wooden block under each end; then install the spring side facing the bearing.
the seven bearing retaining pins and two dowel
pins into the crankcase.
AQ051
AQ048
5. Set the crankshaft into the crankcase. Rotate each
bearing until its hole in the outer race drops onto
2. Install the two C-clips into the crankcase. the retaining pin. Check each bearing to make sure
it is properly positioned.
found in the bearing race. Strike the tool with palm
of the hand in either direction. If the bearing
2-107
8. Locate the timing mark on the balancer shaft gear;
then set the shaft into position aligning its timing
mark with the timing mark of the crankshaft gear.
AQ052
! CAUTION
If the bearings are not properly seated during AQ055
tightly and severe engine damage will result. 9. Set the balancer shaft seal into position against the
bearing.
6. The sealing rings must be located so none of the
end gaps align. Rotate the rings to “stagger” the NOTE: Using Arctic Extreme 50:1 Injection Oil,
end gaps. pre-oil the crankshaft and balancer shaft bearings
at this time.
AQ053
AQ056
7. Rotate the crankshaft while observing the timing
mark on the side of the gear. Align the timing 10. Apply a light coat of High-Temp Sealant (p/n
mark with the parting surface of the crankcase. 0636-069) to the sealing surface of the bottom half
of the crankcase. Make sure the entire surface is
NOTE: Before installing the balancer shaft, pack coated evenly.
the bearings with grease. It is recommended that
Arctic Cat Low-Temp Grease (p/n 0636-593) be
used for this purpose.
AQ057
11. Place the bottom crankcase half into position and

AQ054 install the twenty crankcase cap screws. Tighten
the cap screws evenly by hand starting in the
center. Tighten the cap screws in three steps to 4-
6 kg-m (29-43.5 ft-lb). Follow the pattern shown.
2-108
0729-590 AQ060
12. Set the engine upright. Install the cylinder base 15. Install the piston rings on the piston with their
gasket making sure the small water passage hole is tapered side “up.”
positioned to the MAG-side.
16. Secure the piston pin by installing new piston pin
NOTE: The cylinder base gasket can be reused if
not damaged. When reusing a gasket, coat each
circlips. Install the circlip with the open end up.
2
side with Copper Coat Gasket Sealant (p/n 0636-
092).
! CAUTION
The cylinder base gasket must be installed with
the small water passage hole located to the
MAG-side of the crankcase or engine damage
will result.
AQ080
17. Apply oil to the piston rings; then rotate the rings
to correctly position them on either side of the
locating pin in the ring groove. Place a short piece
of wear strip under the piston to keep it square;
then compress the piston rings with one hand and
AQ030A
slide the cylinder down onto the piston.
13. Pre-oil the piston pin bearings and place into
position in the connecting rods; then place a thrust
washer on each end of the bearing. The flat side of
each washer must face outward.
AQ061
18. Align the cylinder exhaust ports using a straight

edge; then secure each cylinder base with four
washers, lock washers, and nuts. In three steps
AQ059
tighten the nuts to 4-6 kg-m (29-43.5 ft-lb). Use
14. Place the piston over the connecting rod so the the pattern shown.
arrow on the piston dome will point towards the
exhaust port of the cylinder; then apply a light coat
of oil to the piston pin and install.
2-109
0729-585 AQ064
NOTE: If removed, install the exhaust manifolds.

Tighten to 1.8-2.2 kg-m (13-16 ft-lb). ! CAUTION
Be very careful not to move the cylinder heads
19. Place the cylinder head O-rings into position on once they are placed on top of the O-rings.
each cylinder.
NOTE: If reusing O-rings and they are slightly 0636-069) to the three water manifold gaskets.
stretched, shrink the O-rings by cooling them (in a Place the gaskets and manifold into position and
refrigerator for example) for a period of time. secure with six cap screws. Using a crisscross
pattern, tighten to 0.7-1 kg-m (5-7 ft-lb).
AQ063
AQ065
20. Being very careful not to move the two O-ring
seals, hold the cylinder head above the cylinder 22. Tighten the cylinder head cap screws in three steps
approximately 1/4 in. and start the cap screws into using the pattern shown to 2-2.5 kg-m (14.5-
the cylinder; then check the O-rings for proper 18 ft-lb).
position and set the head carefully down onto the
cylinder. Finger-tighten the cap screws at this
time.
0729-587
23. In turn for each cylinder, install the gasket, reed

assembly, and intake flange to the crankcase; then
secure with six cap screws. Tighten to 0.8-
1.2 kg-m (6-9 ft-lb).
2-110
AQ066 AQ069
24. Place the thrust washer on the outward end of the 30. Install the alignment pins in the water pump cover
oil-injection pump driveshaft. Lubricate the shaft and apply a low-temperature grease to the cover
and install into the crankcase. O-ring seal.
25. Apply a light coat of oil to the shaft adapter; then
install the O-ring and slide the adapter into 2
position on the oil-injection pump driveshaft.
26. Being careful to align the slot of the oil-injection
pump shaft with the flat end of the oil-injection
pump driveshaft, install the pump on the crankcase
and secure with two screws.
! CAUTION
When installing the oil-injection pump, the pump
driveshaft must align with the pump shaft or
serious damage will result.
AQ070
27. Place the PTO-end plate into position on the 31. Place the water pump cover into position and
crankcase; then apply blue Loctite #242 to the four secure.
screws and secure.
32. Install the stator plate with the notch for the wiring
28. Place the water pump housing into position on the harness in the 10 o’clock position; then secure.
crankcase. Make sure the two O-ring seals on the
backside are in their proper position. 33. Install the stator; then route the wiring harness
through the stator plate and crankcase housing and
install the rubber grommet.
34. Apply blue Loctite #242 to the threads of the three
Allen-head cap screws and secure the stator to the
stator plate.
AQ068
29. Install the water pump impeller. Apply blue

Loctite #242 to the threads of the impeller cap
screw; then install the washer and cap screw.
AQ073
NOTE: The rubber side of the washer must be
toward the impeller. NOTE: Wipe the flywheel and crankshaft taper
with a clean cloth to remove any foreign material.
2-111
35. Install the flywheel key in the crankshaft; then
slide the flywheel onto the crankshaft making sure
the keyways align. Install, but do not tighten, the
flywheel cap screw.
AQ076
39. Install the thermostat with its rubber seal and

thermostat cover. Secure with three cap screws.
Tighten to 0.7-1 kg-m (5-7 ft-lb).
AQ074
36. Install the starter pulley and secure with three cap
screws. Tighten to 0.8-1.2 kg-m (6-9 ft-lb).
37. Tighten the flywheel cap screw to 4-6 kg-m (29-
43.5 ft-lb).
38. Install the magneto case; then apply blue Loctite
#242 to the four Allen-head cap screws and
secure. Tighten to 1.8-2.2 kg-m (13-16 ft-lb).
AQ079
40. Cap the MAG-side impulse fitting. Secure with a

clamp.
41. Install the spark plugs. Tighten to 2.5-2.8 kg-m
(18-20 ft-lb); then pressure test the engine (see
Section 3).
2-112
NOTES
2-113
Listed in the table below are symbols indicating spe-
Assembly Schematics cial instructions and other important information nec-
essary for proper servicing. Please note the definition
Table of Contents for each symbol. These symbols are used throughout
this two-volume set.
120 cc ................................................................. 2-115

370/440 cc .......................................................... 2-116
500/600 cc Twin .................................................. 2-118
550 cc ................................................................. 2-120
570 cc ................................................................. 2-122
800 cc ................................................................. 2-124
600 cc Triple ........................................................ 2-126
1000 cc ............................................................... 2-128
SYMBOL DESCRIPTION
Torque control required

271 - apply red Loctite #271 (p/n 1639-820)
Lubricate with Arctic Cat 50:1 Injection Oil (p/n 0636-286)

Lubricate with Arctic Cat Extreme 50:1 Injection Oil (p/n 0639-112)
Lubricate with Arctic Cat Low-Temp Grease (p/n 0636-593)
3B - Three Bond Sealant (p/n 0636-070)

HT - High-Temp Sealant (p/n 0636-069)
AS - Anti-Seize Thread Compound (p/n 0678-146)
KEY-TSKA
2-114
120 cc
6-7 kg-m
(43.5-50.5 ft-lb)
243
2
243
1.1-1.4 kg-m
(8-10 ft-lb)
243
2.5-2.8 kg-m
0.9-1.2 kg-m 1.1 kg-m
(18-20 ft-lb)
(6.5-9 ft-lb) (8 ft-lb)
2.8 kg-m
(20 ft-lb)
120-ENG
2-115
370/440 cc
2.5-2.8
2.5-2.8kg-m
kg-m
(18-20
(18-20ft-lb)
ft-lb)
1.8-2.8
1.8-2.8kg-m
kg-m
(13-20
(13-20ft-lb)
ft-lb)
3B
3B
1.1
1.1kg-m 2.5-4
kg-m 2.5-4kg-m
kg-m
(8(8ft-lb) (18-29
ft-lb) (18-29ft-lb)
ft-lb)
1.8-2.2
1.8-2.2kg-m
kg-m
(13-16
(13-16ft-lb)
ft-lb)
0.4-0.7
0.4-0.7kg-m
kg-m
2.8
2.8kg-m
kg-m (3-5
(3-5ft-lb)
ft-lb)
(20
(20ft-lb)
ft-lb)
2.8-3.5
2.8-3.5kg-m
kg-m
(20-25
(20-25ft-lb)
ft-lb)
2.8
2.8kg-m
kg-m
(20
(20ft-lb)
ft-lb)
6.9-7.6
6.9-7.6kg-m
kg-m
(50-55
(50-55ft-lb)
ft-lb)
2.8-3.5
2.8-3.5kg-m
kg-m
(20-25
(20-25ft-lb)
ft-lb) 0.4-0.7
0.4-0.7kg-m
kg-m
(3-5
(3-5ft-lb)
ft-lb)
3744-ENG
2-116
0.8-1.2 kg-m
(6-9 ft-lb)
271
1.1 kg-m
(8 ft-lb)
7-9 kg-m
(50.5-65 ft-lb)
271
2.6-3.3 kg-m
271 (19-24 ft-lb)
2
HT 1.8-2.2 kg-m 6 mm 0.8-1.2 kg-m
(13-16 ft-lb) (6-9 ft-lb)
8 mm 1.8-2.8 kg-m
HT (13-20 ft-lb)
1.8-2.2 kg-m
(13-16 ft-lb)
271
HT 1.8-2.2 kg-m
(13-16 ft-lb)
1.8-2.2 kg-m
(13-16 ft-lb) HT
271 0.7 kg-m
(5 ft-lb)
271
3744ENG2
2-117
500/600 cc Twin
242
242
242
HT
1.1 kg-m
(8 ft-lb)
8 mm 1.8-2.8 kg-m
(13-20 ft-lb)
10 mm 4-6 kg-m
(29-43.5 ft-lb)
2.8-3.5 kg-m
(20-25 ft-lb)
2.4 kg-m
(17 ft-lb)
242
0.7 kg-m
(5 ft-lb)
2.4 kg-m
(17 ft-lb)
2.4 kg-m 2.8-3.5 kg-m 6.9-7.6 kg-m

(17 ft-lb) (20-25 ft-lb) (50-55 ft-lb)
5&6-ENG
2-118
1.8-2.8 kg-m 271
(13-20 ft-lb)
2.5-2.8 kg-m
0.7-1 kg-m
(18-20 ft-lb)
(5-7 ft-lb)
HT
1 kg-m
4-6 kg-m
(7 ft-lb)
(29-43.5 ft-lb)
1.8-2.2 kg-m
(13-16 ft-lb) 2
242
271
242
1.1 kg-m
(8 ft-lb) 7-9 kg-m
(50.5-65 ft-lb)
0.8-1.2 kg-m
(6-9 ft-lb)
0.7-1 kg-m
(5-7 ft-lb)
2.6-3.3 kg-m
(19-24 ft-lb)
242
0.8-1.2 kg-m
(6-9 ft-lb)
1.1 kg-m
(8 ft-lb)
5&6ENG2
2-119
550 cc
HT
8 mm 242
1.8-2.8 kg-m
(13-20 ft-lb)
6 mm
0.8-1.2 kg-m
(6-9 ft-lb)
2.4 kg-m
(17 ft-lb)
2.8-3.5 kg-m
(20-25 ft-lb)
1.4 kg-m
(10 ft-lb)
6.9-7.6 kg-m
(50-55 ft-lb)
2.8-3.5 kg-m
2.8-3.5 kg-m (20-25 ft-lb)
2.4 kg-m
(20-25 ft-lb)
(17 ft-lb)
7.6 kg-m
(55 ft-lb)
(Pantera/ZL)
6.9-7.6 kg-m
(50-55 ft-lb)
2.8-3.5 kg-m
(20-25 ft-lb) (Bearcat)
550-ENG
2-120
1.8-2.8 kg-m
(13-20 ft-lb)
2.5-2.8 kg-m
(18-20 ft-lb)
0.7-1 kg-m
(5-7 ft-lb)
4-6 kg-m 1 kg-m

(29-43.5 ft-lb) (7 ft-lb)
1.8-2.2 kg-m
2
(13-16 ft-lb)
HT
242
271
7-9 kg-m
(50.5-65 ft-lb)
0.8-1.2 kg-m 0.7-1 kg-m

(6-9 ft-lb) (5-7 ft-lb)
2.6-3.3 kg-m
(19-24 ft-lb)
242
HT
550ENG2
2-121
570 cc
0.4-0.7 kg-m
0.4-0.7
(3-5kg-m
ft-lb)
(3-5 ft-lb)
1.8-2.8 kg-m
1.8-2.8
(13-20kg-m
ft-lb)
(13-20 ft-lb)
2.5-2.8 kg-m
2.5-2.8
(18-20kg-m
ft-lb)
(18-20 ft-lb)
0.7-1 kg-m 4-6 kg-m

(5-7 ft-lb) (29-43.5 ft-lb)
6 mm 0.8-1.2 kg-m (6-9 ft-lb)

6 mm 0.8-1.2 kg-m (6-9 ft-lb)
0.8-1.2 kg-m 8 mm 1.8-2.8 kg-m (13-20 ft-lb)
8 mm 1.8-2.8 kg-m (13-20 ft-lb)
(6-9 ft-lb)
2.8-3.5
2.8-3.5 kg-mkg-m
(20-25
(20-25 ft-lb)
ft-lb)
3B3B
2.8-3.5
2.8-3.5 kg-m
kg-m
(20-25
(20-25 ft-lb)
ft-lb)
6.9-7.6
6.9-7.6 kg-mkg-m
2.82.8
kg-mkg-m (50-55
(50-55 ft-lb)
ft-lb)
(20(20 ft-lb)
ft-lb)
570-ENG
2-122
0.8-1.2 kg-m 1.1 kg-m
0.7ft-lb)
(6-9 kg-m 1.1ft-lb)
(8 kg-m
(5 ft-lb) (8 ft-lb)
0.8-2.1 kg-m
0.8-2.1 kg-m
(6-9 ft-lb)
(6-9 ft-lb)
609*
609*
1.8-2.8 kg-m
1.8-2.8 kg-m
(13-20 ft-lb)
(13-20 ft-lb)
2
*Must be used in conjunction
HT with Loctite Primer #7471.
HT
1.8-2.2
1.8-2.2 kg-m
kg-m
(13-16
(13-16 ft-lb)
ft-lb)
HTHT
4.6
4.6kg-m
kg-m
(29-43.5
(29-43.5ft-lb)
ft-lb)
271
271
271
0.7-1.0
0.7-1.0kg-mkg-m
(5-7
(5-7ft-lb)
ft-lb) 0.8-1.2 kg-m
1.8-2.2 kg-m
1.8-2.2 kg-m (6-9 ft-lb)
(13-16
(13-16 ft-lb)
ft-lb)
271
271
8.0-8.7
8-8.7 kg-m
kg-m
(58-63
(58-63ft-lb)
ft-lb)
0.8-1.2 kg-m
(6-9 ft-lb)
271
271
570ENG2
2-123
800 cc
HT
242
10 mm 4.8-5.4 kg-m
(35-39 ft-lb)
8 mm 1.8-2.8 kg-m
(13-20 ft-lb)
6 mm 0.9-1.3 kg-m
(6.5-9.5 ft-lb)
2.8-3.5 kg-m
(20-25 ft-lb)
242
2.4 kg-m
(17 ft-lb)
2.8-3.5 kg-m
(20-25 ft-lb)
242
6.9-7.6 kg-m
2.4 kg-m
(50-55 ft-lb)
(17 ft-lb)
800-ENG
2-124
2.5-2.8 kg-m
(18-20 ft-lb)
2.4-3.2 kg-m
(17-23 ft-lb)
2.6-3.3 kg-m
4.6-6.8 kg-m
0.9-1.3 kg-m (19-24 ft-lb)
(33-49 ft-lb)
(6.5-9.5 ft-lb)
242
0.9-1.3 kg-m
4.8-7.2 kg-m
2
(6.5-9.5 ft-lb)
(35-52 ft-lb)
242
0.9-1.3 kg-m
(6.5-9.5 ft-lb)
242
1 kg-m
(7 ft-lb)
242
7.95-8.65 kg-m
(57.5-62.5 ft-lb)
242
1-1.4 kg-m
(7-10 ft-lb)
0.9-1.3 kg-m
(6.5-9.5 ft-lb)
242
0.8-1.2 kg-m
(6-9 ft-lb)
0.9-1.3 kg-m HT
(6.5-9.5 ft-lb)
800ENG2
2-125
600 cc Triple
242
HT
1.8-2.2 kg-m
1.8-2.8 kg-m
(13-16 ft-lb)
(13-20 ft-lb)
242
2.4 kg-m
(17 ft-lb)
2.8-3.5 kg-m
(20-25 ft-lb)
1.4 kg-m
(10 ft-lb)
2.4 kg-m
(17 ft-lb)
6.9-7.6 kg-m
(50-55 ft-lb)
6003-ENG
2-126
2.5-2.8 kg-m
(18-20 ft-lb)
2-2.5 kg-m
(14.5-18 ft-lb)
2.6-3.3 kg-m
(19-24 ft-lb)
1.8-2.8 kg-m
(13-20 ft-lb)
2
0.8-1.2 kg-m
(6-9 ft-lb)
0.7 kg-m
(5 ft-lb)
0.8-1.2 kg-m
(6-9 ft-lb)
242
0.7-1 kg-m
(5-7 ft-lb)
HT
0.7-1 kg-m 7-9 kg-m

(5-7 ft-lb) (50.5-65 ft-lb)
242
242
242
0.8-1.2 kg-m
(6-9 ft-lb)
6003ENG2
2-127
1000 cc
242
HT
4-6 kg-m 242

(29-43.5 ft-lb)
1.8-2.2 kg-m
(13-16 ft-lb)
2.8-3.5 kg-m 2.4 kg-m

(20-25 ft-lb) (17 ft-lb)
2.8-3.5 kg-m
(20-25 ft-lb)
1.4 kg-m
(10 ft-lb)
2.4 kg-m
(17 ft-lb)
6.9-7.6 kg-m
(50-55 ft-lb)
1000-ENG
2-128
2-2.5 kg-m
(14.5-18 ft-lb)
2.5-2.8 kg-m
(18-20 ft-lb)
2.6-3.3 kg-m
(19-24 ft-lb)
4-6 kg-m
(29-43.5 ft-lb)
0.8-1.2 kg-m
(6-9 ft-lb) 2
0.7 kg-m 0.8-1.2 kg-m

(5 ft-lb) (6-9 ft-lb)
0.7-1 kg-m
(5-7 ft-lb)
4-6 kg-m
HT (29-43.5 ft-lb)
0.7-1 kg-m
(5-7 ft-lb)
242
242
0.8-1.2 kg-m
(6-9 ft-lb)
1000ENG2
2-129
10. Connect the engine wiring harness to the main
Installing Engine wiring harness; then secure the wiring harnesses
with a cable tie.
Table of Contents
11. Install the tie rods on the steering post; then secure
with lock nuts (threads coated with blue Loctite
120 cc Model....................................................... 2-130 #243) and washers. Tighten to 2.5-2.8 kg-m (18-
Twin F/C Models.................................................. 2-131 20 ft-lb).
Twin L/C Models.................................................. 2-132
Triple Models ....................................................... 2-136 12. Place the steering post in position in the lower
steering post bearing and on the steering post
support.
Installing Engine
(120 cc Model)
1. Place the engine assembly into position in the

engine compartment.
2. On the left-hand side of the engine, install the
three cap screws (coated with blue Loctite #243)
securing the engine and brake bracket to the front
end. DO NOT TIGHTEN AT THIS TIME.
A025
13. Place the upper steering post bearing into position

on the steering post and support; then secure with
the bearing retainer, cap screws, and lock nuts.
A050A
3. Align the engine with the scribed line made during

removing; then measure the distance between the
crankshaft and the driveshaft. Adjust the engine
position as necessary.
4. Tighten the three left-hand side mounting cap A023A
screws (from step 2) to 2.4-2.6 kg-m (17-19 ft-lb). 14. Position the choke and throttle cables in the
bracket; then connect them to the carburetor.
5. Lay the snowmobile on its side and install the four
lower engine mounting cap screws with washers
and lock nuts. Tighten to 2.4-2.6 kg-m (17-19 ft-lb).
6. Install the four mounting cap screw plugs in the
belly pan; then place the snowmobile in the
upright position.
7. Thread the recoil starter rope through the bushing
in the console and the handle; then tie a knot at the
end of the rope and pull the handle up and onto the
knot.
8. Untie the slip-knot at the starter case and allow it
to slowly rewind into the case.
A046A
9. Connect the fuel hose to the carburetor; then turn 15. Tighten the adjustment jam nuts securely.
the gas tank shut-off valve to the OPEN position.
2-130
NOTE: At this point, install the drive chain (see 3. Connect the oil-supply hose to the oil-injection
D r i v e C h a i n a n d S p ro ck e t s s u b - s e c t i o n i n pump; then bleed the system (see Section 4).
Section 8).
NOTE: If equipped with electric start, place the
starter motor bracket on the crankcase and install
the front two and lower rear cap screws, lock
washers, and washers. Place the starter motor into
Installing Engine position and secure with two washers and lock
(Twin F/C Models) nuts.
4. Connect the oil-injection cable to the oil-injection

1. Place each engine mounting bracket onto the pump control arm and secure the cable mounting
engine. Secure with cap screws, washers, and lock pin with a nylon washer and E-clip.
washers. Tighten to 2.8 kg-m (20 ft-lb).
5. Place the carburetor(s) into position making sure
2. Place the engine assembly into position in the the boot(s) are properly positioned and secure with
engine compartment. Secure the engine to the the flange clamp(s).
front end with the cap screws, washers, and lock
nuts. Tighten to 2.8-3.5 kg-m (20-25 ft-lb).
AH283D
AL201D NOTE: At this point, check oil-injection system

synchronization (see Section 4).
6. Connect the impulse hose to the crankcase, the

main wiring harness, the CDI unit wiring harness,
and the spark plug caps.
7. Place the recoil starter into position and secure
with four cap screws and lock washers. Tighten to
1.1 kg-m (8 ft-lb).
NOTE: If equipped with electric start, secure the
battery ground cable with the rear cap screw.
AL200D
AB073
8. Place the expansion chamber and grafoil gasket

AL199D into position and secure with springs.
2-131
12. Install the drive belt and secure the belt guard.
Install the plug in the belly pan.
NOTE: If equipped with electric start, connect
the battery.
13. Turn the gas tank shut-off valve to the OPEN

position.
14. Check the ignition timing.
15. Place the rear of the snowmobile up on a safety
stand. Start engine and allow to warm up. Adjust
AB105D
engine idle to 1500 RPM and check all safety
switches for proper operation.
9. Place the engine mount shims into position
between the torque bumper and engine mounting 16. Test drive the snowmobile; then tighten the clutch
bracket; then tighten the torque bumper jam nut. bolt to 7.6 kg-m (55 ft-lb).
10. Place the drive clutch into position on the

crankshaft; then install the lock washer and bolt.
Tighten the clutch bolt to 6.9-7.6 kg-m (50-
55 ft-lb).
AF477D
! CAUTION
If the engine had a major overhaul or if any major
AF477D
part was replaced, proper engine break-in
procedures must be followed.
NOTE: Apply a coat of Anti-Seize Thread Com-
pound (p/n 0678-146) to the keyway end of the
driven shaft.
11. Install the driven pulley and alignment washers. Installing Engine
Secure with a cap screw and washer tightened to (Twin L/C Models)
2.6-3.3 kg-m (19-24 ft-lb).
NOTE: Some engines are equipped with Arctic
introducing this important information.
1. Place the engine into the engine compartment;

then place the coolant supply hose on the water
pump (coolant tank on the 800 cc) and secure with
the clamp.
NOTE: On the Wide Track, place the shims in
their proper position on the left rear engine mount
(as noted during removal).
2. On all models except the Wide Track, secure the

SC013D
right-side front and rear and left-side front engine
NOTE: At this point, check drive clutch/driven mounts to the front end making sure the mounts
pulley alignment (see Section 8). are properly positioned. Tighten the cap screws
and nut to 2.8-3.5 kg-m (20-25 ft-lb).
2-132
NOTE: On the Wide Track tighten the engine
mount cap screws to 7.6 kg-m (55 ft-lb).
3. On all models except the Wide Track, adjust the

torque bumper to allow a clearance between the
engine and the torque bumper of 1.78 mm (0.070
in.); then secure the adjustment by tightening the
jam nuts.
AN392D
11. On carbureted models, connect the impulse hose

to the crankcase.
2
AN610D
4. On the 500/600 cc, secure the hood cable and

ground wire to the magneto case with the machine
screw tightened to 1.1 kg-m (8 ft-lb).
5. On the 550 cc, attach the hood cable to the exhaust
manifold and the ground wires to the magneto
case.
AN385D
6. Secure the rear ground wires to the magneto case
with the machine screw tightened to 1.1 kg-m 12. Place the carburetors/throttle bodies into position
(8 ft-lb). and secure with the flange clamps. Synchronize
the oil-injection system (see Section 4).
7. Place the coolant return hose into position on the
thermostat housing and secure with the clamp. NOTE: On the 800 cc, install the air-intake
silencer; then place the CDI unit into position and
8. Place the recoil starter into position and secure the close the cover.
starter with four cap screws and lock washers.
Tighten to 1 kg-m (7 ft-lb). NOTE: On the Wide Track, place the starter
motor and end cap into position and secure with
9. Connect all electrical wires. the lock nuts. Tighten securely.
NOTE: Use cable ties to secure the wiring har- 13. Place the expansion chamber and grafoil gaskets
nesses as necessary. into position and secure to the exhaust manifold,
front end, and resonator with the springs.
10. Connect the oil-injection cable/control rod to the
oil-injection pump and secure; then connect the
oil-supply hose to the pump and secure with the
clamp. Bleed the oil-injection system (see
Section 4).
AN378D
2-133
NOTE: When installing the three exhaust mani-
fold springs, the long hook portion of the spring
must be attached to the exhaust manifold or pre-
mature spring failure will result.
NOTE: Before installing the drive clutch, be sure

to wipe both the crankshaft taper and clutch
mounting taper clean using a clean towel.
14. Place the drive clutch into position on the

crankshaft and secure with the cap screw and lock
washer. Tighten to 6.9-7.6 kg-m (50-55 ft-lb).
SC013D
16. Check drive clutch/driven pulley alignment (see

Section 8).
17. Install the drive belt. Check belt deflection. Secure
the belt guard.
AN381D
NOTE: On the Wide Track, secure the side panel

to the belly pan with the existing machine screws.

driven shaft.
AN379D
15. Install the driven pulley, key, stub shaft, and
alignment washers. Secure with a cap screw and NOTE: On the Wide Track, secure the belly pan
washer. Tighten to 2.6-3.3 kg-m (19-24 ft-lb). and bumper to the bumper support tube with a
lock nut; then install the rear belly pan plug.
18. Fill the cooling system (see Section 3).

19. On models equipped w/electric start, connect the
positive cable to the starter motor; then secure
with the washers and nut making sure the cable is
directed toward the PTO-side of the engine. Secure
the positive cable with a long cable tie.
20. On models equipped w/electric start, connect the
cables to the battery making sure to connect the
positive cable first.
AF120D NOTE: Steps 21 through 25 are for APV equipped

engines.
21. Slide the cable drums into the servomotor

actuator; then place the cable housings into
position in the servomotor. Secure the cable
housings with the holder.
2-134
AP118C AP116A
24. Check APV cable adjustment. See Arctic Power

Valve (APV) System in Section 3.
25. Connect the two APV drain hoses making sure
they are not in contact with hot or moving parts.
2
AP117
22. Position the tab (on the bottom of the servomotor

mounting plate) into the slot in the air-intake
silencer; then secure the mounting plate to the
silencer with a screw.
AP128A

position.
27. Start engine and verify ignition timing.
28. Test drive or run the snowmobile and recheck the
coolant level after 5-6 minutes. Tighten the drive
clutch cap screw to 7.6 kg-m (55 ft-lb).
! CAUTION
component was replaced, proper engine break-in
AP127
procedures must be followed. If the proper
engine break-in procedures are not followed,
23. Place the servomotor with cover into position on severe engine damage may result.
the mounting plate; then secure with two cap
screws.
2-135
Installing Engine
(Triple Models)
1. Secure the four engine mounting brackets to the

crankcase. Tighten the cap screws securing the
front and right-side rear brackets to 2.4 kg-m
(17 ft-lb). Tighten the rear PTO-side bracket to
1.4 kg-m (10 ft-lb).
2. Place the engine assembly in the engine
compartment. Place the recoil starter into position
and secure with four cap screws and lock washers. AN009
7. Connect the impulse hose to the crankcase.
8. Secure the right-side front and rear and left-side
front engine mounts to the front end making sure
the mounts are properly positioned. Tighten the
cap screws and nut to 2.8-3.5 kg-m (20-25 ft-lb).
AN150
3. Place the resonator into position; then secure with

the cap screws, washers, bushings, spacers, and
retainer nuts.
NOTE: On models equipped with electric start, AN611D
make sure the battery ground cable and star
washer are properly positioned. 9. Adjust the torque bumper to allow a clearance
between the engine and the torque bumper of
4. Connect the temperature-gauge sender wire. 1.78 mm (0.070 in.) on the 1000 cc or 1.5 mm
(0.060 in.) on the 600 cc; then secure the adjust-
ment by tightening the jam nuts.
10. Place the carburetors into position and secure with
the flange clamps. Synchronize the oil-injection
pump (see Fuel System (Related Items) in Section
4).
AJ159
5. Place the coolant hoses into position and secure

with the clamps.
6. Connect the cable to the oil-injection pump and
secure with the nylon washer and E-clip; then
connect the oil-supply and oil-output hoses and AN614D
secure with the clamp. Bleed the oil-injection
system (see Fuel System - Related Items in
Section 4).
2-136
11. Connect the main wiring harness, ignition timing
sensor wiring harness, and the spark-plug caps.
Secure the two brown ground wires to the magneto
housing with a cap screw.
SC013D

Section 8).
17. Install the drive belt. Check belt deflection (see
2
AQ125
Section 8). Secure the belt guard.
12. In order, place the expansion chambers and grafoil
gaskets into position. Secure the expansion 18. Fill the cooling system (see Section 3); then install
chambers to the header pipes and resonator with the coolant filler cap.
the springs. Secure the expansion chambers to the
front end with the long spring. 19. Bleed the oil-injection system (see Fuel System -
Related Items in Section 4).
13. Connect the hood cable to the cable hook; then
secure the hook. NOTE: Steps 20 through 24 are for APV equipped
engines.
NOTE: Before installing the drive clutch, be sure
to wipe both the crankshaft taper and clutch 20. Slide the cable drums into the servomotor
mounting taper clean using a clean towel. actuator; then place the cable housings into
position in the servomotor. Secure the cable
14. Place the drive clutch into position on the housings with the holder.
crankshaft making sure the two sleeves are
properly positioned (see Section 8) and secure
with the clutch bolt and lock washer. Tighten to
6.9-7.6 kg-m (50-55 ft-lb). Install the belly pan
plug.
AP118C
AF477D

driven shaft.
15. Install the driven pulley, stub shaft, key, and

washers (see Section 8). Secure with a cap screw.
AP117
2-137
21. Position the tab (on the bottom of the servomotor 23. Check APV cable adjustment. See Arctic Cat
mounting plate) into the slot in the air-intake Power Valve (APV) System in Section 3.
silencer; then secure the mounting plate to the
silencer with a screw. 24. Connect the two APV drain hoses making sure
they are not in contact with hot or moving pats.
AP127
AP128A
22. Place the servomotor with cover into position on
the mounting plate; then secure with two cap 25. Turn the shut-off valve to the OPEN position.
screws.
26. Check ignition timing.
27. Test drive the snowmobile and recheck the coolant
level after 5-10 minutes. Retighten the drive clutch
to 7.6 kg-m (55 ft-lb).
! CAUTION
component was replaced, proper engine break-in
procedures must be followed. If the proper
engine break-in procedures are not followed,
severe engine damage may result.
AP116A
2-138
Troubleshooting Engine
(120 cc)
Problem: Engine Will Not Start or is Hard to Start (Compression too Low)
Condition Remedy
1. Valve clearance out of adjustment 1. Adjust clearance
2. Valve guides worn — seated poorly 2. Repair — replace guides
3. Piston rings worn excessively 3. Replace rings
4. Cylinder bore worn 4. Replace — rebore cylinder
5. Spark plug seating poorly 5. Tighten plug
Problem: Engine Will Not Start or is Hard to Start (No Spark)
Condition Remedy
1. Spark plug fouled 1. Clean — replace plug
2. Spark plug wet
3. Magneto defective
2. Clean — dry plug
3. Replace magneto
2
4. Ignition coil assembly defective 4. Replace ignition coil assembly
5. Spark plug cap shorted 5. Replace spark plug cap
Problem: Engine Will Not Start or is Hard to Start (No Fuel Reaching the Carburetor)
Condition Remedy
1. Gas tank vent obstructed 1. Clean vent completely on
2. Gas tank shut-off valve obstructed — not 2. Clean — turn on valve
turned completely on
3. Carburetor inlet needle defective 3. Replace inlet needle
4. Fuel hose obstructed 4. Clean hose
5. Fuel filter obstructed 5. Clean — replace fuel filter
Problem: Engine Stalls Easily
Condition Remedy
1. Spark plug fouled 1. Clean plug
2. Magneto defective 2. Replace magneto
3. Transistorized ignition module defective 3. Replace ignition coil assembly
4. Carburetor jets obstructed 4. Clean jets
5. Valve clearance out of adjustment 5. Adjust clearance
6. Exhaust plugged 6. Unplug — replace muffler
7. Air cleaner plugged 7. Clean — replace air filter
8. Gasoline contaminated 8. Drain and replace gasoline
Problem: Engine Noisy (Excessive Valve Chatter)
Condition Remedy
1. Valve clearance too large 1. Adjust clearance
2. Valve spring(s) weak — broken 2. Replace spring(s)
3. Camshaft worn 3. Replace camshaft
4. Rocker arm — rocker arm shaft worn 4. Replace arm — shaft
Problem: Engine Noisy (Noise Appears to Come from Piston)
Condition Remedy
1. Piston — cylinder worn 1. Replace — service piston — cylinder
2. Combustion chamber carbon buildup 2. Clean chamber
excessive
3. Piston pin — piston pin bore worn 3. Replace — service pin — bore
4. Piston rings — ring groove(s) worn 4. Replace rings — piston
2-139
Troubleshooting Engine
(Carbureted Models)
Problem: Engine Does Not Start (No Spark at Spark Plugs)

Condition Remedy
1. Ignition switch malfunctioning — not in RUN 1. Replace ignition switch — turn switch to RUN
position position
2. Wiring harness shorting 2. Repair — replace wiring harness
3. Emergency stop switch knob in DOWN 3. Move knob to UP position — replace throttle
position — malfunctioning switch
4. Throttle/ignition monitor switch (TM-style) 4. Adjust (tighten) throttle cable — replace throttle
adjusted too loose — malfunctioning switch
5. Throttle/ignition monitor switch (VM-style) 5. Adjust (loosen) throttle cable — replace throttle
adjusted too tight — malfunctioning switch
6. Carburetor safety switches (VM-style) 6. Adjust — replace carburetor safety switches
adjusted incorrectly — malfunctioning
7. Spark plugs fouled — damaged 7. Clean — gap — replace spark plugs
8. Spark-plug caps damaged — leaking — 8. Replace spark-plug caps
shorting
9. High tension wires/coil loose — grounded — 9. Service — replace high tension wires/coil
faulty
10. CDI unit faulty 10. Replace CDI unit
11. Charge coil (1) faulty 11. Replace coil
13. Flywheel magnets weak 13. Replace flywheel
14. Flywheel key sheared 14. Replace key
Problem: Engine Does Not Start (No Fuel at Cylinders)
Condition Remedy
1. Gas tank empty 1. Fill tank
2. Shut-off valve closed 2. Open shut-off valve
3. Fuel hose broken — pinched 3. Replace — service hose
4. Gas-tank vent — hose obstructed 4. Remove obstruction — replace vent — hose
5. In-line fuel filter obstructed — damaged 5. Remove obstruction — replace in-line fuel filter
6. Fuel pump malfunctioning — faulty 6. Replace — repair — clean fuel pump
7. Impulse hose cracked — broken — pinched — 7. Replace — connect impulse hose
disconnected
8. Carburetors adjusted incorrectly — dirty — 8. Troubleshoot — clean — replace carburetors
damaged
9. Primary compression (crankcase) absent 9. Repair — replace damaged — worn engine
components
2-140
Problem: Engine Does Not Start ( Fuel Does Not Ignite)
Condition Remedy
1. Carburetor-to-cylinder air leak 1. Replace — service gaskets — intake flanges —
connect oil delivery hose — service intake ports
2. Carburetors adjusted incorrectly — dirty — 2. Troubleshoot — clean — replace carburetors
damaged
3. Gasoline contaminated 3. Clean tank — entire fuel system
4. Engine flooded 4. Troubleshoot carburetors — clean — replace
air-intake silencer — clear engine by pulling
recoil several times — install new spark plugs —
try restarting engine
5. Secondary compression (cylinder) low 5. Repair — replace damaged — worn engine
components
6. Choke cable(s) adjusted improperly 6. Check and adjust choke cable(s)
Problem: Engine Does Not Idle
Condition
1. Carburetors adjusted incorrectly — dirty —
Remedy
1. Troubleshoot — clean — replace carburetors
2
damaged
2. Fuel pump malfunctioning — faulty 2. Replace — repair — clean fuel pump
3. Impulse hose cracked — broken 3. Replace impulse hose
4. Air-intake silencer obstructed — damaged 4. Remove obstruction — replace air-intake
silencer
Problem: Engine Loses Power
Condition Remedy
2. Fuel hose cracked — broken — pinched 2. Replace — service fuel hose
4. Carburetors adjusted incorrectly — dirty — 4. Troubleshoot — tighten — clean — replace
damaged — loose carburetors
5. Muffler obstructed — disconnected — 5. Remove obstruction — connect — replace
damaged muffler
6. Air-intake silencer obstructed — disconnected 6. Remove obstruction — connect — replace air-
— damaged intake silencer
7. Exhaust ports carboned 7. Clean exhaust ports
9. High tension wires/coil loose — faulty 9. Service — replace high tension wires/coil
10. Spark-plug caps leaking — shorting 10. Replace spark-plug caps
11. Ignition timing adjusted incorrectly 11. Time ignition
12. Primary and secondary compression low 12. Repair — replace damaged — worn engine
components
16. Oil-injection pump malfunctioning — adjusted 16. Replace — bleed — adjust oil-injection pump
incorrectly
2-141
Problem: Engine Overheats
Condition Remedy
1. Spark plug heat range too hot 1. Install lower heat-range spark plugs
2. Coolant low — absent 2. Add coolant
3. Carburetors adjusted incorrectly — jetted 3. Troubleshoot — clean carburetors — jet
incorrectly — dirty correctly
4. Carburetor-to-cylinder air leak 4. Replace — repair gaskets — intake flanges —
service intake ports
5. Heat exchangers no snow for cooling 5. Select new trail — install ice studs to chew up
hard packed snow and ice
6. Rings/grooves carboned 6. Clean — replace rings — pistons
7. Exhaust ports obstructed 7. Remove obstruction
8. Muffler obstructed 8. Remove obstruction
9. Gas/air mixture incorrect 9. Replace jets — adjust jet needle E-clip position
incorrectly
11. Primary compression (crankcase) low — 11. Repair — replace damaged — worn engine
absent components
12. Ignition timing adjusted incorrectly 12. Time ignition
13. Gasoline octane too low 13. Use 87 minimum octane gasoline
14. Water pump — thermostat damaged — faulty 14. Replace — rebuild water pump — replace
thermostat
Problem: Engine Backfires
Condition Remedy
1. Throttle/ignition monitor switch adjusted 1. Adjust throttle cable free-play — service spring
incorrectly
4. High tension wires/coil shorting 4. Service — replace high tension wires/coil
5. Carburetor-to-cylinder air leak 5. Repair — replace gaskets — intake flanges
service intake ports
6. Carburetors adjusted incorrectly — dirty — 6. Troubleshoot — tighten carburetors
damaged — loose
7. Gas/air mixture incorrect — too lean 7. Adjust jetting
incorrectly
Problem: Engine Four-Cycles (Floods Excessively)
Condition Remedy
1. Carburetors adjusted incorrectly — dirty — 1. Troubleshoot — clean carburetors
damaged
2. Gas/air mixture incorrect 2. Adjust jetting
incorrectly
4. Air-intake silencer obstructed 4. Remove obstruction
2-142
Problem: Engine Stops Gradually
Condition Remedy
2. Fuel hose obstructed — broken — pinched 2. Remove obstruction — replace — repair fuel
hose
3. Head gasket(s) burned out 3. Replace head gasket(s) — service cylinders —
head
4. Cylinder head loosening 4. Tighten cylinder head cap screws
5. Spark plugs loose 5. Tighten spark plugs
6. Impulse hose cracked 6. Replace impulse hose
7. High tension wires/coil faulty 7. Service — replace high tension wires/coil
8. Float bowl vent hose (TM-style) obstructed — 8. Service — replace float bowl vent hose
kinked — damaged
Problem: Engine Stops Suddenly
Condition Remedy
1. In-line fuel filter obstructed — damaged
2. Fuel hose obstructed — broken — pinched
1. Remove obstruction — replace in-line fuel filter
2. Remove obstruction — repair — replace fuel
2
hose
4. Ignition coil faulty 4. Replace ignition coil
7. Gas-tank vent — hose obstructed — damaged 7. Remove obstruction — replace vent — hose
8. Engine seized 8. Overhaul engine
9. Throttle/ignition monitor switch faulty — 9. Replace throttle control — adjust throttle cable
throttle cable adjusted incorrectly free-play — adjust — connect — replace
carburetor safety switches (VM-style)
Problem: Engine Fails to Stop (Continues to Run, Even with All Switches Off)
Condition Remedy
1. CDI unit shorted to ground 1. Replace CDI unit
2. Main wiring harness four-prong connector 2. Connect four-prong connector
disconnected
2-143
Troubleshooting
Engine
(EFI Models)
Problem: Engine Does Not Start (No Spark at Spark Plugs)

Condition Remedy
1. Ground connections dirty — loose 1. Check all ground connections — clean and tight
2. Throttle/ignition monitor switch 2. Replace faulty switch — turn switch on
malfunctioning — ignition switch not on
3. Wiring harness shorting — disconnected 3. Repair — replace — connect wiring harness
4. Emergency stop switch in DOWN position — 4. Move switch to UP position — replace throttle
malfunctioning control
5. Throttle/ignition monitor switch 5. Adjust throttle cable tension — replace throttle
malfunctioning body assembly
6. Spark plugs fouled — damaged 6. Clean — replace spark plugs
7. Spark-plug caps damaged — leaking — 7. Replace spark-plug caps
shorting
8. High tension leads/coil loose — grounded — 8. Service — replace high tension leads/coil
faulty
9. CDI unit faulty 9. Replace ECU
10. Ignition timing sensor faulty 10. Replace sensor
11. ECU faulty 11. Replace ECU
Problem: Engine Does Not Start (No Fuel at Cylinders)
Condition Remedy
2. Injector dropping resistor faulty 2. Replace dropping resistor
3. Fuel pressure regulator faulty 3. Replace regulator — hose
4. Gasoline contaminated 4. Replace gasoline
5. Fuel pump faulty 5. Service — replace fuel pump — connections —
wires
6. Fuel hose broken — pinched 6. Replace — service hose
8. Pick-up valve(s) obstructed — damaged 8. Remove obstruction — replace pick-up valve(s)
9. Primary compression absent 9. Repair — replace damaged — worn engine
components
2-144
Problem: Engine Does Not Start (Fuel Does Not Ignite)
Condition Remedy
1. ECU LED trouble code 1. Service — replace problem component
2. Spark absent 2. Check for spark — see No Spark at Spark Plugs
sub-section
3. Primary compression low 3. Service engine
4. Secondary compression low 4. Service engine
5. Engine flooded 5. Clear engine (hold throttle full-open)
6. Gasoline contaminated 6. Clean tank and entire fuel system
Problem: Engine Does Not Idle
Condition Remedy
1. ECU LED trouble code 1. Service — replace problem component
2. Throttle position sensor idle adjustment 2. Adjust idle RPM to specifications
incorrect
3. Injector(s) faulty 3. Replace injector(s)
4. Fuel pressure regulator faulty
5. Air-intake silencer obstructed
4. Replace regulator — hose
5. Clean air-intake silencer
2
Problem: Engine Loses Power or Runs on One Cylinder
Condition Remedy
1. Sensor faulty 1. Check LED for trouble code — repair — replace
problem circuit or sensor
2. Spark plug fouled 2. Replace spark plugs
3. External coil faulty 3. Service — replace coil
4. Gas tank vent — hose obstructed 4. Service — replace vent hose
5. Secondary compression low 5. Service engine
7. Fuel pressure regulator faulty 7. Replace regulator
8. Pick-up valve(s) obstructed — out of position 8. Replace — relocate pick-up valve(s)
incorrectly
10. Throttle bodies out of synchronization 10. Replace throttle bodies from a similar engine —
if problem is corrected, replace the original
assembly
11. Injector faulty 11. Replace injector
12. Dropping resistor faulty 12. Test resistor — replace as necessary
2-145
Problem: Engine Overheats
Condition Remedy
2. Coolant low — absent 2. Add coolant
3. Heat exchanger obstructed 3. Remove obstruction
4. Intake flange to cylinder air leak 4. Replace — seal intake flange(s)
5. Drive system (drive clutch — driven pulley — 5. Troubleshoot — adjust drive system
track — drive belt) adjusted incorrectly — worn
— damaged
6. Rings/grooves carboned 6. Clean — replace rings — pistons
7. Exhaust ports obstructed 7. Remove obstruction
8. Expansion chamber obstructed 8. Remove obstruction
incorrectly
10. Primary compression low — absent 10. Repair — replace damaged — worn engine
components
11. Gasoline octane too low 11. Use 87 minimum octane gasoline
12. Water pump — thermostat damaged — faulty 12. Replace water pump — thermostat
Problem: Engine Backfires
Condition Remedy
1. LED trouble code 1. Service — replace problem component
2. Throttle/ignition monitor switch adjusted 2. Adjust throttle cable tension — service spring
incorrectly
3. Spark plugs fouled — damaged 3. Clean — replace spark plugs
4. High tension leads/coil shorting 4. Service — replace high tension leads/coil
5. CDI unit faulty — damaged 5. Replace ECU
6. Fuel mixture lean 6. Repair fuel regulator — injector(s)
incorrectly
Problem: Engine Four-Cycles (Floods Excessively)
Condition Remedy
2. Fuel pressure too high 2. Replace regulator — hose
3. Injector faulty 3. Replace injector
4. Throttle position sensor faulty 4. Replace throttle body assembly
5. Air-intake silencer obstructed 5. Remove obstruction
2-146
Problem: Engine Stops Suddenly
Condition Remedy
2. Spark absent 2. See No Spark at Spark Plugs sub-section
4. CDI relay faulty 4. Replace CDI relay
5. Fuel filter(s) obstructed 5. Replace filter(s)
6. Fuel pressure low 6. Replace regulator — hose
7. Fuel pump faulty 7. Service — replace fuel pump
8. Fuel pump relay faulty 8. Replace relay
9. Gas tank vent hose obstructed 9. Service vent hose
11. Fuel hose obstructed — broken — pinched 11. Remove obstruction — repair — replace fuel
hose
13. Ignition coil faulty 13. Replace ignition coil 2
14. Engine seized 14. Overhaul engine
15. Throttle/ignition monitor switch — throttle15. Replace throttle control — adjust throttle cable
cable tension faulty — adjusted incorrectly
Problem: Engine Fails to Stop (Continues to Run, Even with All Switches Off)
Condition Remedy
1. CDI unit shorted to ground 1. Replace ECU
2. Engine wiring harness connections wet 2. Clean — dry connections
2-147
Engine Information
Table of Contents
2002 Arctic Cat Engine Specifications ................ 2-149

2002 Arctic Cat Engine Torque Specifications .... 2-150
Torque Conversions ............................................ 2-150
2002 Engine Torque Patterns.............................. 2-151
Piston Replacement Guide (1976-2000)............. 2-152
Piston Replacement Guide (2001/2002) ............. 2-153
Engine Piston Travel Versus Crank Angle Chart . 2-154
Cylinder Head Volume Tests ............................... 2-155
Cylinder Head Volume Specifications ................. 2-156
Crankshaft Runout Specifications ....................... 2-157
Crankshaft Repair ............................................... 2-158
Exhaust Pipe Temperature.................................. 2-159
Exhaust Pipe Temperature Probe Location......... 2-160
2-148
2002 Arctic Cat Engine Specifications
ITEM 120 cc 370 cc 440 cc 500 cc 550 cc 570 cc 600 cc EFI 600 cc 600 cc 800 cc Carb 800 cc EFI 1000 cc
Carb (Triple) Carb (Twin)
Engine Model Number AA12A1 AA37A4 AS44A5 AU50L6 ACB55L3 AA56A1 AD60L6 AG60L8 AF60L6 AA78L2 AB78L2 AA10L5
Displacement- cc cu. in. 119 367 431 497 550 565 599 594 599 785 785 999
7.3 22.41 26.3 30.3 33.56 34.5 36.54 36.24 36.54 47.9 47.9 60.96
No. of Cylinders 1 2 2 2 2 2 2 3 2 2 2 3
Bore · mm 60 60 65 71 73.4 73.8 78 66.5 78 81 81 81
· in. 2.4 2.362 2.559 2.800 2.890 2.910 3.071 2.618 3.071 3.188 3.188 3.19
Stroke · mm 42 65 65 62.7 65 66 62.7 57 62.7 76 76 64.6
· in. 1.7 2.559 2.559 2.469 2.559 2.598 2.469 2.240 2.469 2.992 2.992 2.54
Compression Ratio 8.2:1 6.3:1 6.5:1 6.74:1 6.6:1 6.4:1 6.55:1 6.4:1 6.55:1 6.29:1 6.29:1 6.4:1
Cooling System Fan Cooled Fan Cooled Fan Cooled Liquid Cooled Liquid Cooled Fan Cooled Liquid Cooled Liquid Cooled Liquid Cooled Liquid Cooled Liquid Cooled Liquid Cooled
Gasoline Octane (min) 87 87 87 87 87 87 87 87 87 87 87 87
Fuel Mixture N/A Oil Injection Oil Injection Oil Injection Oil Injection Oil Injection Oil Injection Oil Injection Oil Injection Oil Injection Oil Injection Oil Injection
Ignition Timing degrees Fixed 18i* 18i* 25i 33i* 18i* 24f 18i 24i 14i 26k 16e
· mm 2.012 2.012 3.671 6.556 2.049 3.390 2.012 3.390 1.417 4.796 1.556
· in. 0.079 0.079 0.145 0.258 0.081 0.133 0.079 0.133 0.056 0.189 0.061
Spark Plug (NGK) BPR6ES BR9EYA BR9EYA BR9EYA BR9EYA BR9EYA BR9EYA BR9EYA BR9EYA BR9EYA BR9EYA BR9EYA
Spark Plug Gap · mm 0.7-0.8 0.7-0.8 0. 0.7-0.8 0.7-0.8 0.7-0.8 0.7-0.8 0.7-0.8 0.7-0.8 0.7-0.8 0.7-0.8 0.7 -0.8 0.7-0.8
· in. 0.028-0.031 028-0.031 0.028-0.031 0.028-0.031 0.028-0.031 0.028-0.031 0.028-0.031 0.028-0.031 0.028-0.031 0.028-0.031 0.028-0.031 0.028-0.031
Lighting Coil Output 12V/55W 12V/185W 12V/185W 12V/210W 12V/180W 12V/210W 12V/175W 12V/210W 12V/210W 12V/210W 12V/190W 12V/185W
Ignition Type Transistorized CDI/NOI CDI/NOI CDI/NOI CDI/NOI CDI/NOI CDI/NOI CDI/NOI CDI/NOI CDI/NOI CDI/NOI CDI/NOI
Piston Skirt/Cylinder · mm 0.020-0.120 0.060-0.150 0.080-0.150 0.083-0.150 0.095-0.150 0.095-0.150 0.083-0.150 0.085-0.150 0.083-0.150 0.083-0.150 0.083-0.150 0.095-0.150
Clearance Range · in. 0.0008-0.0047 0.0024-0.0059 0.0031-0.0059 0.0033-0.0059 0.0037-0.0059 0.0037-0.0059 0.0033-0.0059 0.0034-0.0059 0.0033-0.0059 0.0033-0.0059 0.0033-0.0059 0.0037-0.0059
Piston Ring End · mm 0.20-0.70 0.15-0.80 0.15-0.83 0.20-0.83 0.20-0.83 0.20-0.83 0.20-0.83 0.20-0.83 0.20-0.83 0.30-0.50 0.30-0.50 0.20-0.83
Gap Range · in. 0.0079-0.0280 0.006-0.031 0.006-0.033 0.008-0.033 0.008-0.033 0.008-0.033 0.008-0.033 0.008-0.033 0.008-0.033 0.012-0.020 0.012-0.020 0.008-0.033
Cylinder Trueness · mm 0.03 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1
Limit (max) · in. 0.0012 0.004 0.004 0.004 0.004 0.004 0.004 0.004 0.004 0.004 0.004 0.004
Piston Pin · mm 14.980-14.995 17.995-18.000 15.995-16.000 19.995-20.000 19.995-20.000 17.995-18.000 19.995-20.000 17.995-18.000 19.995-20.000 23.995-24.000 23.995-24.000 19.995-20.000
Piston Pin Bore · mm 15.006-15.030 17.998-18.006 15.996-16.004 20.002-20.010 20.002-20.010 17.998-18.006 20.002-20.010 18.002-18.008 20.002-20.010 24.002-24.010 24.002-24.010 20.002-20.010
Small End Bore · in. 0.5908-0.5917 0.9056-0.9059 0.8269-0.8272 1.0237-1.0241 1.0237-1.0241 0.9056-0.9059 1.0237-1.0241 0.9056-0.9059 1.0237-1.0241 1.1410-1.1420 1.1410-1.1420 1.0237-1.0241
Diameter Range
Radial Play Range · in. 0.0006-0.0028 0.0008-0.0012 0.0008-0.0012 0.0008-0.0012 0.0008-0.0012 0.0008-0.0012 0.0008-0.0012 0.0008-0.0012 0.0008-0.0012 0.0001-0.0008 0.0001-0.0008 0.0008-0.0012
Crankshaft Runout · mm 0.10 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05
(t.i.r.) · in. 0.004 0.002 0.002 0.002 0.002 0.002 0.002 0.002 0.002 0.002 0.002 0.002
Crankshaft End · mm 0.05-0.10 0.05-0.10 0.05-0.10 0.05-0.10 0.05-0.10 0.05-0.10 0.05-0.10 0.05-0.10 0.05-0.10 0.05-0.10 0.05-0.10 0.05-0.10
Play Range · in. 0.002-0.004 0.002-0.004 0.002-0.004 0.002-0.004 0.002-0.004 0.002-0.004 0.002-0.004 0.002-0.004 0.002-0.004 0.002-0.004 0.002-0.004 0.002-0.004
Reed Stopper · mm N/A N/A N/A 9.4 - 9.8 N/A 6.0 9.4 - 9.8 9.3 - 9.9 9.4 - 9.8 8.0 8.0 9.3 - 9.9
Height · in. 0.370 - 0.385 0.236 0.370 - 0.385 0.366 - 0.389 0.370 - 0.385 0.315 0.315 0.366 - 0.389
c @ 6000 RPM f @ 3500 RPM i @ 2000 RPM

d @ 4000 RPM g @ 5000 RPM j @ 3000 RPM *Engine Warm
e @ 3250 RPM h @ 1800 RPM k @ 2500 RPM
2-149
2
2002 Arctic Cat Engine Torque Specifications
2-150
Model 120 cc 370 cc/440 cc 550 cc 570 cc 500 cc 600 cc (Twin) 600 cc (Triple) 800 cc 1000 cc
Cylinder Head ft-lb 20 13-20 13-20 13-20 13-20 13-20 14.5-18 17-23 14.5-18
kg-m 2.8 1.8-2.8 1.8-2.8 1.8-2.8 1.8-2.8 1.8-2.8 2.0-2.5 2.4-3.2 2.0-2.5
Cylinder Base ft-lb N/A N/A N/A N/A N/A N/A N/A 35-52 N/A
(Cap Screws) kg-m 4.8-7.2
Cylinder Base ft-lb N/A N/A 29-43.5 29-43.5 / 5-7 29-43.5 29-43.5 13-20 33-49 29-43.5
(Nuts) kg-m 4.0-6.0 4.0-6.0 / 0.7-1.0 4.0-6.0 4.0-6.0 1.8-2.8 4.6-6.8 4.0-6.0
Flywheel ft-lb 43.5-50.5 50.5-65 50.5-65 58-63 50.5-65 50.5-65 50.5-65 57.5-62.5 29-43.5
kg-m 6-7 7.0-9.0 7.0-9.0 8.0-8.7 7.0-9.0 7.0-9.0 7.0-9.0 7.95-8.65 4.0-6.0
Intake Flange ft-lb N/A 13-16 13-16 13-16 N/A N/A N/A N/A N/A
kg-m 1.8-2.2 (440) 1.8-2.2 1.8-2.2
Intake Flange/ ft-lb N/A N/A N/A N/A 6-9 6-9 6-9 6-9 6-9
Reed Valve kg-m 0.8-1.2 0.8-1.2 0.8-1.2 0.8-1.2 0.8-1.2
Intake Manifold ft-lb N/A 6-9 N/A N/A N/A N/A N/A N/A N/A
kg-m 0.8-1.2 (370)
Exhaust Manifold ft-lb N/A 13-16 13-16 13-16 13-16 13-16 13-16 13-16 13-16
kg-m 1.8-2.2 1.8-2.2 1.8-2.2 1.8-2.2 1.8-2.2 1.8-2.2 1.8-2.2 1.8-2.2
Magneto Case/ ft-lb N/A 13-16 N/A 13-16 N/A N/A 13-16 13-16 13-16
Fan Case kg-m 1.8-2.2 1.8-2.2 1.8-2.2 1.8-2.2 1.8-2.2
Crankcase 6 mm ft-lb 6.5-9 6-9 6-9 6-9 N/A N/A N/A 6.5-9.5 N/A
kg-m 0.9-1.2 0.8-1.2 0.8-1.2 0.8-1.2 0.9-1.3
8 mm ft-lb N/A 13-20 13-20 13-20 13-20 13-20 13-20 13-20 N/A
kg-m 1.8-2.8 1.8-2.8 1.8-2.8 1.8-2.8 1.8-2.8 1.8-2.8 1.8-2.8
10 mm ft-lb N/A N/A N/A N/A 29-43.5 29-43.5 N/A 35-39 29-43.5
kg-m 4.0-6.0 4.0-6.0 4.8-5.4 4.0-6.0
Spark Plug ft-lb 18-20 18-20 18-20 18-20 18-20 18-20 18-20 18-20 18-20
kg-m 2.5-2.8 2.5-2.8 2.5-2.8 2.5-2.8 2.5-2.8 2.5-2.8 2.5-2.8 2.5-2.8 2.5-2.8
Drive Clutch ft-lb 15-16.5 50-55 50-55 50-55 50-55 50-55 50-55 50-55 50-55
kg-m 2.1-2.3 6.9-7.6 6.9-7.6 6.9-7.6 6.9-7.6 6.9-7.6 6.9-7.6 6.9-7.6 6.9-7.6
TORQUE CONVERSIONS
ft-lb kg-m ft-lb kg-m ft-lb kg-m ft-lb kg-m ft-lb kg-m ft-lb kg-m ft-lb kg-m ft-lb kg-m ft-lb kg-m ft-lb kg-m
1 0.1 11 1.5 21 2.9 31 4.3 41 5.7 51 7.1 61 8.4 71 9.8 81 11.2 91 12.6
2 0.3 12 1.7 22 3.0 32 4.4 42 5.8 52 7.2 62 8.6 72 10.0 82 11.3 92 12.8
3 0.4 13 1.8 23 3.2 33 4.6 43 5.8 53 7.3 63 8.7 73 10.1 83 11.5 92 12.9
4 0.6 14 1.9 24 3.3 34 4.7 44 6.1 54 7.5 64 8.9 74 10.2 84 11.6 94 13.0
5 0.7 15 2.1 25 3.5 35 4.8 45 6.2 55 7.6 65 9.0 75 10.4 85 11.8 95 13.1
6 0.8 16 2.2 26 3.6 36 5.0 46 6.4 56 7.7 66 9.1 76 10.5 86 11.9 96 13.3
7 1.0 17 2.4 27 3.7 37 5.1 47 6.5 57 7.9 67 9.3 77 10.7 87 12.0 97 13.4
8 1.1 18 2.5 28 3.9 38 5.3 48 6.6 58 8.0 68 9.4 78 10.8 88 12.2 98 13.6
9 1.2 19 2.6 29 4.0 39 5.4 49 6.8 59 8.2 69 9.5 79 10.9 89 12.3 99 13.7
10 1.4 20 2.8 30 4.2 40 5.5 50 6.9 60 8.3 70 9.7 80 11.1 90 12.5 100 13.8
2002 ENGINE TORQUE PATTERNS
ENGINE SIZE CYLINDER HEAD CYLINDER BASE CRANKCASE
370 cc
N/A
440 cc
0725-318 0726-412
550 cc
0728-138 725-318B 0728-137

2
570 cc
MD0259A 0726-376 737-027A
1000 cc
0729-587 0729-585 0729-590
600 cc (Triple)
0729-587 0729-585 0731-342
500 cc
600 cc (Twin)
0733-524 725-318B 0734-050
800 cc
0728-138 725-318B 736-280A
2-151
Piston Replacement Guide (1976-2000)
ENGINE SIZE YEAR PISTON RING PISTON & RING SET
0691-398 0691-399
0691-569 0691-571
120 cc 2000 (+ 0.010 in.) (+ 0.010 in.) 0694-026
0691-570 0691-572
(+ 0.020 in.) (+ 0.020 in.)
3005-130 3004-825
340 cc (F/C & F/A) 1976-2000 3002-761 3002-740 3005-472
3004-448
370 cc 1999-2000 3005-447 3004-825 3005-476
3005-342
440 cc (F/C & F/A) 1980-2000 3005-156 3002-742 3005-474
3004-530
3005-342
3005-156 3002-742 3005-586
440 cc F/C (Z) 1995-1998, 2000 3004-530 3002-076
3005-474
3002-927
3002-835
440 cc F/C (Z) 1999 3005-342 3005-530 3005-684
3005-384
3005-177
3003-885 3005-586
440 cc (L/C) 1978-2000 3003-840 3002-738 3005-475
3003-477
3002-596
440 cc (ZR) 1991-1995 3004-515 3003-989 3003-993
3003-974 3003-831
3005-356
3005-254
440 cc (ZR) 1996-1998 3005-095 3004-768 3005-370
3004-954
440 cc (Sno-Pro) 1998 3005-356 3004-768 3005-178
3005-250
500 cc (Twin) 1998-2000 3005-122 3005-123 3005-173
3005-407
550 cc (EFI & 1993-2000 3004-684 3003-760 3005-437
CARB) 3004-198
3004-062
3005-436
580 cc (EFI & 3005-187
1993-2000 3004-542 3004-067 3004-075
CARB) 3004-542
3004-066
600 cc (Twin) 1998-2000 3005-438 3003-714 3005-445
3005-388
600 cc (Triple) 1995-2000 3005-031 3004-768 3005-62
3004-767
3005-382
700 cc (EFI & 1994-1996, 1999-
CARB) 2000 3004-920 3003-822 3004-325
3004-143
800 cc (Triple) 1995-2000 3004-738 3004-528 3004-762
3004-936
900 cc 1993-1997 3004-079 3004-086
3004-078
3003-822
1000 cc 1998-2000 3005-218 3005-220
3005-219
1990-1999 3002-476 3003-683 3004-909
60 cc
1976-1989 3002-476 3002-477 (+.0040 in.)
NOTE: The top part number in each case is the latest part. Those part numbers listed below the top number are also good replacement parts.
2-152
Piston Replacement Guide (2001/2002)
ENGINE SIZE YEAR PISTON RING PISTON & RING SET
120 cc 2001/2002 0691-398 0691-399 0694-026
370 cc 2001/2002 * 3004-825 3005-762/913
440 cc 2001/2002 * 3002-742 3005-474/920
500 cc (Carb) 2001/2002 * 3005-828 3005-796
500 cc EFI 2001 * 3005-828 3005-815
550 cc 2001/2002 * 3003-760 3005-437/949
570 cc F/C 2002 * 3006-004 3006-003
580 cc 2001 * 3004-067 3004-075
600 cc (Twin) 2001/2002 * 3005-749 3005-748
600 cc (Triple) 2001/2002 * 3005-838 3005-787/981
800 cc (Twin) 2001/2002 * 3005-865 3005-779/3006-029
2
800 cc (Triple) 2001 3004-738 3004-528 3004-762
1000 cc 2001/2002 * 3003-822/3005-865 3005-220/3006-044
* Not a Service Part
2-153
ENGINE PISTON TRAVEL VERSUS CRANK ANGLE CHART
2-154
When using any of the charts below, first know the engine stroke and timing in degrees; then select the proper chart and read across from the degree figure to
find timing in either mm or inches.
600 cc (Triple) 500 cc - 600 cc (Twin) 1000 cc 370 cc - 440 cc - 570 cc 800 cc (Twin)
550 cc *
57 mm stroke 62.7 mm stroke 64.6 mm stroke 65 mm stroke 66 mm stroke 76 mm stroke
Degree mm in. mm in. mm in. mm in. mm in. mm in.
BTDC BTDC BTDC BTDC BTDC BTDC BTDC BTDC BTDC BTDC BTDC BTDC BTDC
5 0.137 0.005 0.150 0.006 0.153 0.006 0.157 0.006 0.160 0.006 0.182 0.007
6 0.197 0.007 0.216 0.009 0.221 0.009 0.226 0.009 0.230 0.009 0.262 0.010
7 0.268 0.010 0.295 0.012 0.300 0.012 0.308 0.012 0.313 0.012 0.356 0.014
8 0.350 0.014 0.384 0.015 0.392 0.015 0.402 0.016 0.409 0.016 0.465 0.018
9 0.443 0.017 0.486 0.019 0.496 0.020 0.508 0.020 0.517 0.020 0.588 0.023
10 0.546 0.021 0.600 0.024 0.612 0.024 0.627 0.025 0.638 0.025 0.726 0.029
11 0.661 0.026 0.725 0.029 0.740 0.029 0.757 0.030 0.772 0.030 0.878 0.035
12 0.785 0.031 0.862 0.034 0.879 0.035 0.901 0.035 0.917 0.036 1.044 0.041
13 0.921 0.036 1.011 0.040 1.031 0.041 1.056 0.042 1.076 0.042 1.224 0.048
14 1.067 0.042 1.171 0.046 1.195 0.047 1.223 0.048 1.246 0.049 1.417 0.056
15 1.223 0.048 1.343 0.053 1.370 0.054 1.403 0.055 1.429 0.056 1.625 0.064
16 1.390 0.055 1.526 0.060 1.556 0.061 1.594 0.063 1.624 0.064 1.847 0.073
17 1.567 0.061 1.720 0.068 1.755 0.069 1.797 0.071 1.830 0.072 2.082 0.082
18 1.755 0.069 1.926 0.076 1.965 0.077 2.012 0.079 2.049 0.081 2.331 0.089
19 1.952 0.077 2.143 0.084 2.186 0.086 2.238 0.088 2.280 0.090 2.594 0.102
20 2.160 0.085 2.371 0.093 2.418 0.095 2.476 0.097 2.522 0.099 2.869 0.113
21 2.377 0.093 2.609 0.103 2.662 0.105 2.725 0.107 2.776 0.109 3.158 0.124
22 2.604 0.102 2.859 0.113 2.916 0.115 2.986 0.118 3.041 0.120 3.460 0.136
23 2.841 0.112 3.119 0.123 3.182 0.125 3.257 0.128 3.318 0.131 3.775 0.149
24 3.088 0.121 3.390 0.133 3.458 0.136 3.540 0.139 3.606 0.142 4.103 0.162
25 3.344 0.132 3.671 0.145 3.745 0.147 3.834 0.151 3.905 0.154 4.443 0.175
26 3.609 0.142 3.962 0.156 4.042 0.159 4.138 0.163 4.215 0.166 4.796 0.189
27 3.884 0.153 4.264 0.168 4.350 0.171 4.453 0.175 4.536 0.179 5.161 0.203
28 4.168 0.164 4.576 0.180 4.668 0.184 4.778 0.188 4.867 0.192 5.538 0.218
29 4.461 0.175 4.897 0.193 4.996 0.197 5.114 0.201 5.209 0.205 5.927 0.233
30 4.763 0.187 5.228 0.206 5.334 0.210 5.459 0.215 5.561 0.219 6.328 0.249
31 - - - - - - 5.815* 0.229* 5.923 0.233 - -
32 - - - - - - 6.181* 0.243* 6.295 0.248 - -
33 - - - - - - 6.556* 0.258* 6.677 0.263 - -
CYLINDER HEAD VOLUME TESTS
CYLINDER HEAD VOLUME 4. Insert buret into spark plug hole and open buret
(Squish-Gap Method) valve. Run oil into the spark plug hole until it
reaches the top of the spark plug hole. Turn off the
To check the squish gap, a micrometer and a heavy buret valve.
piece of solder will be needed.
5. Check the buret scale to see how much oil has
1. Remove the spark plugs from the engine. been used to fill the combustion chamber. From
the total amount, subtract 2.20 cc or 2.44 cc.
2. Insert the solder piece down through the spark Compare the findings with the chart.
plug hole and push it up against the inner cylinder
bore towards the MAG-side of the engine. NOTE: The above procedure will work fine on a
new engine. Engines with many hours of use, may
3. Pull the recoil rope and crank the engine over require a small change in the procedure. In step 3,
several times while the solder is being held firmly remove the cylinder head. Wipe a small amount of
in place. heavy grease around the outer diameter of the pis-
ton to seal space between the piston and cylinder
4. Remove the solder from the cylinder. Using the
2
bore. Replace head and tighten to specification;
micrometer, measure the very end of the squeezed then continue with steps 4 and 5.
solder piece. Record the reading.
CYLINDER HEAD VOLUME
NOTE: If the solder hasn’t been squeezed by the (Flat Plate Method)
piston, a larger piece of solder must be used.
Repeat procedure. The third method of checking for proper combustion
chamber volume will require a 1/8 in. or 3/16 in. thick
5. Using the opposite end of the solder piece, insert it piece of plexiglass, some heavy grease, and a buret.
down through the spark plug hole towards the
PTO-side of the engine. Push on the solder until it The plexiglass piece must be flat and also large enough
contacts the inner cylinder bore. to cover the entire gasket surface of the cylinder head.
Using a 3/16 in. drill bit, drill two holes through the
6. Pull the recoil rope and crank the engine over plexiglass piece. Locate the holes one inch apart inside
several times. Remove the solder from the the combustion chamber area (towards center of
cylinder and measure the squeezed end with a piece).
micrometer. Record reading and refer to the chart.
1. Remove the cylinder head from the engine. Clean
NOTE: Measure from PTO to MAG-side of the all carbon from the combustion chamber area.
piston to accurately measure the squish gap.
Never measure across piston, exhaust to carbure- 2. Position the cylinder head squarely in a vise with
tor side, as the piston will rock and the reading its gasket surface up. Leave a BR9ES spark plug
won’t be accurate. in place and grip the metal portion of the spark
plug for holding the cylinder head.
Readings may vary from side to side. Make sure the
smaller reading is within the specifications listed. 3. Apply a light coat of grease to the gasket surface
of the head. Squeeze the piece of plexiglass firmly
CYLINDER HEAD VOLUME down onto the gasket surface. The grease will act
(Cylinder Head as a sealant between the two pieces.
Installed Method)
4. Using a buret filled with light oil, fill the
To check the cc volume, a measuring tool called a combustion chamber through either of the two
buret will be needed. It is capable of measuring a liq- holes drilled in the plexiglass. Continue to fill the
uid in cc volumes. combustion chamber until the fluid appears at the
bottom of the second hole. Stop filling procedure
1. Fill buret with 10W engine oil. and take a reading off the buret as to how much
2. Remove the spark plugs from the cylinders. fluid was used. The specification found in the
chart includes the spark plug volume, so there
3. Run piston up to TDC (Top Dead Center). won’t be any need to subtract from the reading.
2-155
CYLINDER HEAD VOLUME SPECIFICATIONS
ENGINE TYPE SQUISH - GAP HEAD INSTALLED FLAT PLATE
VOLUME (cc) VOLUME (cc)
340 cc 1990-2000 mm 1.70-2.99 16.6-20.1 19.5
in. .067-.118
370 cc 1999-2002 mm 2.27-2.95 19.1-22.0 24.3-25.1
in. .089-.116
440 cc 1999 Z mm .91-2.2 20.5-25.8 24.9
in. .036-.087
440 cc F/C 1984-2002 mm 1.39-1.87 20.4-26.4 25.2
in. .055-.074
440 cc F/C 2000-2001 Z (Sno-Pro) mm 2.3 17.8-19.4 24.2
in. .090
700 cc 1991-1995 (Carb) mm 1.76-2.32 29.6-33.4 43.2
1999-2000 in. .069-.091
440 cc L/C (L/W) 1996 Jag, Panther mm 1.29-2.15 21.2 25.7
1997-1999 ZL in. .051-.084
550 cc 1993-2002 mm 1.52-2.00 27.7-29.9 33.7-34.7
in. .060-.079
570 cc F/C 2002 mm 1.3 27.01 28.8
in. .051
580 cc 1993-2001 mm 1.47-2.01 25.3 35.5
in. .057-.079
900 cc 1993-1997 Thundercat mm 1.78-2.15 23.3-28.5 36.4
in. .070-.085
800 cc (Triple) 1995-2001 mm 1.46-2.01 22.4 31.3
in. .057-.079
600 cc (Triple) 1995-2002 mm 1.00-1.59 17.4-19.5 18.5
in. .039-.062
440 cc 1997 ZR mm .94-1.67 16-18 17.2
in. .037-.066
440 cc 1998 ZR (Consumer Model) mm 1.09-1.82 16.6-18.6 17.8
in. .043-.072
500 cc (Twin) 1998 -2001 (w/o APV) mm 1.3 19.4-21.9 20.8
in. .051
500 cc (Twin) 2001-2002 (w/APV) mm 1.53 22.78 20.7
in. .060
600 cc (Twin) 1998 -2001 (w/o APV) mm 1.3 25.9 26.1
in. .051
600 cc (Twin) 2000-2002 (w/APV) mm 1.36 27.8 28.4
in. .054
800 cc (Twin) 2001 mm 1.55 32.9-35.9 38.3
in. .061
800 cc (Twin) 2002 mm 1.58 34.6 38.3
in. .062
1000 cc 1998-2002 mm 1.99 28.4-31.7 37.7
in. .078
NOTE: For accurate reading when using the head installed volume method, subtract 2.44 cc from the
total amount of fluid used (if using a BR9EYA spark plug) or 2.20 cc (if using a BR9ES spark plug).
! CAUTION
The above specifications are not intended to be used for engine modification. Reducing the head volume
to the smaller specification could cause piston detonation problems which is not a warranty situation.
2-156
CRANKSHAFT RUNOUT SPECIFICATIONS
728-144A
2
Engine Bore X A B C G Runout D, E, F Point
Stroke
(µ .002)
370 cc 60 X 65
mm 100 µ 0.15 55 µ 0.15 100 22 D 35 F 22
440 cc (in.) 65 X 65 (3.937 µ 0.0006) (2.165 µ 0.006) (3.937) (.866) (1.377) (.866)
(µ .002)
550 L/C-E mm 103 µ 0.02 60 µ 0.02 102 24 D 30 F 10
AH50L (in.) 70 X65 (4.055 µ 0.0007) (2.362 µ 0.0007) (4.015) (.944) (1.181) (.393)
(µ .002)
120 cc mm D .10 F .10
(in.) 60 X 42 -- -- -- -- (0.004) (0.004)
(µ .002)
340 cc mm 93 µ 0.15 53 µ 0.15 94 22 D 35 F 15
(in.) 60 X 60 (3.661 µ 0.006) (2.087 µ 0.006) (3.701) (.866) (1.377) (.590)
(µ .002)
500 F/C-CCI mm 103 µ 0.02 55 µ 0.02 100 22 D 35 F 15
AL50A (in.) 70 X 65 (4.055 µ .0007) (2.165 µ 0.0007) (3.937) (.866) (1.377) (.590)
(µ .002)
500 F/C-E mm 103 µ 0.02 55 µ 0.02 100 22 D 35 F 15
AM50A (in.) 70 X 65 (4.055 µ .0007) (2.165 µ 0.0007) (3.937) (.866) (1.377) (.590)
(µ .002)
440 L/C-CI mm 103 µ 0.02 60 µ 0.2 102 24 D 30 F 10
AH44L (in.) 68 X 60 (4.055 µ .0007) (2.362 µ 0.007) (4.015) (.944) (1.181) (.393)
(µ .002)
530 L/C mm 103 µ 0.02 60 µ 0.2 102 24 D 30 F 10
AA53L (in.) 72 X 65 (4.055 µ 0.008) (2.362 µ 0.008) (4.015) (.945) (1.181) (.393)
(µ .002)
650 L/C 78 X 68
mm 130 µ 0.15 64 µ 0.15 116 µ 0.2 28 D 35 F 15
700 L/C (in.) 81 X 68 (5.118 µ .006) (2.520 µ 0.006) (4.567 µ 0.007) (1.102) (1.377) (.590)
(µ .002)
440 L/C-LW mm 108.5 µ 0.15 55 µ 0.15 95 µ 0.4 22 D 30.5 F 10
AJ44L (in.) 68 X 60 (4.271 µ 0.006) (2.165 µ 0.006) (3.740 µ .015) (.866) (1.200) (.393)
(µ .002)
550 cc 73.4 X 65
mm 112.5 µ 0.15 60 µ 0.15 106 26 D 30 F 5
580 cc (in.) 75.4 X 65 (4.409 µ 0.006) (2.362 µ 0.006) (4.174) (1.024) (1.181) (.197)
(µ .002)
440 L/C-LWR mm 109.5 µ 0.15 60 µ 0.15 106 24 D 30 F 5
(in.) 68 X 60 (4.311 µ 0.006) (2.362 µ 0.006) (4.173) (0.945) (1.181) (.197)
(µ .002)
440 L/C-ZR mm 114 µ 0.16 66.5 µ 0.15 106 26 D 30 F 5
AR44L1 (in.) 66.5 X 63 (4.48 µ 0.006) (2.62 µ 0.006) (4.173) (1.024) (1.181) (.197)
(µ .002)
500 cc 71 X 62.7
mm 114 µ 0.15 66.5 µ 0.15 105.8-106 30 D 30 F 5
600 cc (Twin) (in.) 78 X 62.7 (4.88 µ 0.006) (2.62 µ 0.006) (4.165-4.173) (1.2) (1.181) (.197)
(µ .002)
570 cc 73.8 X 66
mm 119 µ 0.15 62.3 µ 0.15 109.7 24 D 30 F 15
(in.) (4.70 µ 0.006) (2.45 µ 0.006) (4.320) (0.945) (1.181) (.590)
(µ .002)
800 cc (Twin) 81 X 76
mm 125.5 µ 0.15 68 µ 0.15 123 + 0-0.4 30 D 30 F 15
(in.) (4.94 µ 0.006) (2.68 µ 0.006) (4.84 + 0-0.015) (1.2) (1.181) (.590)
NOTE: Measure in from the shaft end the specified amount when checking runout at points D-F. When checking runout in the center, place indicator
on center of bearing as shown at Point E. Maximum runout at any of the 3 measuring points is ±0.05 mm (0.002 in.).
2-157
CRANKSHAFT RUNOUT SPECIFICATIONS (cont)
0731-579
Model Bore X A B C G Runout

Stroke D, E, F Point
(µ .002)
mm A1 102.8 µ 0.15
600 cc (in.) (4.047 µ 0.006)
(Triple) mm A2 105.3 µ 0.15 58 µ 0.15 99 µ 0.15 26 D 30 F 15
(in.) 66.5 X 57 (4.145 µ 0.0006 (2.303 µ 0.0006) (3.897 µ 0.0006) (1.023) (1.181) (.590)
(µ .002)
A1 & A2
800 cc mm 124.4 µ 0.015 64 µ 0.15 112 µ 0.15 30 D 5 F 15
(Triple) (in.) 72 X 65 (4.897 µ 0.0006) (2.519 µ 0.0006) (4.409 µ 0.0006) (1.181) (.197) (.590)
(µ .002)
A1 & A2
900 cc mm 124.4 µ 0.15 64 µ 0.15 112 µ 0.15 30 D 5 F 15
(in.) 76 X 65 (4.897 µ 0.0006) (2.519 µ 0.0006) (4.409 µ 0.0006) (1.181) (.197) (.590)
(µ .002)
1000 cc mm 124.4 µ 0.15 64 µ 0.15 111.8-112 26 D 30 F 5
(in.) 81 X 64.6 (4.900 µ 0.006) (2.520 µ 0.006) (4.402-4.409) (1.0236) (1.181) (0.197)
NOTE: Measure in from the shaft end the specified amount when checking runout at points D-F. When
checking runout in the center, place indicator on center of bearing as shown at Point E. Maximum runout at
any of the 3 measuring points is ±0.05 mm (0.002 in.).
CRANKSHAFT REPAIR
For those who have crankshaft work sent out to another shop, it is advisable to 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 column. Specifications are called out in both mil-
limeters and inches.
NOTE: We have given the proper location for checking crankshaft runout as the very edge of the straight
portion of the shaft where the oil seal makes contact. From the drawings, note that Suzuki has called out
three check points: at either end, out on the taper as shown, and also on the center bearing race. The
crankshaft is still supported on the outer bearings using V blocks. The maximum runout shouldn’t exceed
0.05 mm (0.002 in.).
2-158
EXHAUST PIPE TEMPERATURE
MODEL PROBE LOCATION** NORMAL PRE-IGNITION
in. mm °F °C °F °C
Wildcat (89-96), 1** 25.4 1120 604 1180 638
ZR 700 (94-95, 99-2000),
Powder Special 700 (99-2000)
El Tigre 6000 (87-89) 1** 25.4 1200 649 1300 705
El Tigre EXT (90-91) 1** 25.4 1160 627 1250 677
El Tigre EXT (89) 1** 25.4 1105 596 1200 649
Prowler (90-94) 1** 25.4 1150 621 1250 677
Pantera (90-92) 1** 25.4 1150 621 1250 677
EXT 550 EFI (93), Prowler (95), 1** 25.4 1150 621 1250 677
Pantera (93-94)
Jag Z (92-94), Z 440 (95-2002), 1** 25.4 1086 586 1100 593
Bearcat 440 (95-2000)
Prowler Special (91-92), 1** 25.4 1170 632 1220 660
ZR 440 (94-2002)
Jag 440 (86-89)
Cougar (88-90)
1**
1**
25.4
25.4
1112
1230
600
666
1200
1250
649
677 2
Cougar (91-94), 1** 25.4 1150 621 1250 677
ZL 440 (97-2000),
Jag & Panther L/C (96)
Panther (88) 1** 25.4 1230 666 1300 705
EXT 550 (91-93), Bearcat W/T 1** 25.4 1150 621 1250 677
(95-2002), Cougar (95-98),
Cheetah 550 (94),
Panther 550 (99-2001),
Pantera 550 (2002),
ZL 550 (2001-2002)
Jag 440 F/C (90-2000) 1** 25.4 1150 621 1250 677
Panther 440 (89-2002) 1** 25.4 1150 621 1250 677
EXT 580 Z (93), ZR 580 (94-97), 1** 25.4 1150 621 1250 677
EXT 580 (95-98),
Pantera 580 (95-2001)
Thundercat 900 (93-97), 5** 127 1230 666 1300 705
ZRT 800 (95-2001),
Pantera 800 (99)
ZRT 600 (95-2002) (3 cyl), 2.5** 63.5 1200 649 1350 732
Triple Touring 600 (99-2001)
ZL 500 (98-2002), 3.937* 100* 1080 582 1160 627
ZR 500 (98-2002),
Powder Special 500 (9-2000),
Mountain Cat 500 (2002)
Mountain Cat 600 (2001-2002), 3.937* 100* 1115 602 1200 649
Powder Special 600 (99-2000),
Pantera 600 (2002),
ZL 600 (99-2002),
ZR 600 (98-2002)
Pantera 1000 (2000-2001), 3.937* 100* 1175 635 1250 677
Mountain Cat 1000 (2001-2002),
Thundercat 1000 (98-2002)
Panther 370 (2001), 1** 25.4 1086 586 1100 593
Z 370 (99-2002)
ZL 800 (2001-2002), 3.937* 100* 1250 677 1330 721
ZR 800 (2002),
ZRT 800 (2001),
Mountain Cat 800 (2001-2002)
* Measuring from the piston skirt out.

** Probe location measured down the exhaust manifold from the gasket surface of the flange.
NOTE: The 570 cc specifications were not avail-
able at time of publication.
2-159
EXHAUST PIPE TEMPERATURE
PROBE LOCATION
0730-217 0730-216
730-216A 730-216B
NOTE: Refer to Exhaust Pipe Temperature chart for specific MODEL designation and PROBE LOCATION
specifications.
2-160
SECTION 3 — ENGINE-RELATED ITEMS
TABLE OF
CONTENTS
Axial Fan/Belt (370/440 cc) ..................................... 3-2

Repairing Water Pump (Twin) ................................. 3-4
Repairing Water Pump (600 cc Triple) .................... 3-8
Repairing Water Pump (1000 cc) .......................... 3-11
Pressure Testing Engine ....................................... 3-13
Liquid Cooling System .......................................... 3-13
Cooling System Schematics ................................. 3-14
Recoil Starter (120 cc Model)................................ 3-17
Recoil Starter ........................................................ 3-20
Arctic Power Valve (APV) System ......................... 3-23
3-1
4. Remove the fan with shaft.
Axial Fan/Belt 5. Drive the bearings from the fan case and account
(370/440 cc) for the spacer between the bearings.
REMOVING FAN
1. Remove the four cap screws securing the recoil
starter to the fan case.
2. Remove the three cap screws securing the recoil
starter pulley and fan drive pulley to the flywheel;
then remove the recoil starter pulley and fan drive
pulley.
3. Remove the cap screws and flange nuts securing
the fan case assembly to the engine; then remove
the fan case from the engine compartment.
A910
DISASSEMBLING
NOTE: A circlip is positioned between the bear-
1. Remove the fan cover; then remove the belt. ings. The bearings must be driven from the center
to the outside of the fan case.
2. Using the Fan Spanner Wrench (p/n 0644-139),
remove the nut, lock washer, and washer securing 6. Remove the circlip from the fan case.
pulley halves.
A911
AB102
CLEANING AND INSPECTING
3. Slide the outer pulley half, shim(s), fan belt, and
inner pulley half off the shaft and account for the NOTE: Whenever a part is worn excessively,
key and the fan belt. cracked, or damaged in any way, replacement is
necessary.
1. Clean all axial fan components.

2. Inspect the fan case and shaft threaded areas for
damage or stripped threads; then check the shaft
keyway and key for excessive wear.
3. Inspect the fan for broken, bent, or damaged
vanes.
4. Inspect the bearings for smooth rotation.
5. Inspect the pulley halves for cracks, gouges, or
other damage.
A908
6. Inspect the fan belt for cracks, tears, or fraying.
3-2
ASSEMBLING
KEY
1. Drive Pulley
2. Belt
3. Fan
4. Key
5. Bearing
6. Spacer
7. Circlip
8. Pulley Half
9. Shim
10. Washer
11. Lock Washer
12. Nut
13. Shaft
14. Cap Screw A913
15. Fan Assy
7. Using the fan spanner wrench, secure the pulley
with a washer, lock washer, and nut. Tighten the
nut to 2.5-4 kg-m (18-29 ft-lb).
0733-277
INSTALLING FAN
1. Install the circlip into the groove of the fan case.
1. Place the fan case assembly on the engine; then
secure with flange nuts and cap screws. Tighten
the flange nuts to 1.8-2.2 kg-m (13-16 ft-lb).
Tighten the cap screws to 0.4-0.7 kg-m (3-5 ft-lb).
2. Place the new fan belt into position on the upper
3
pulley.
3. Place the fan drive pulley onto the fan belt and
align one of its holes with one of the mounting
holes in the flywheel; then start a cap screw into
the aligned holes and finger-tighten.
4. Rotate the fan drive pulley clockwise while
observing the other two holes in the pulley. When
A911
they align with the two holes in the flywheel, start
the remaining two mounting cap screws.
2. Press a bearing into the fan case until it is seated
against the circlip. 5. Tighten the three cap screws only to position the
fan drive pulley on the flywheel; then remove the
3. From the opposite side of the fan case, install the three cap screws and install the recoil starter
spacer and press the remaining bearing into the fan pulley. Apply red Loctite #271 to the threads of
case until it is seated. the three cap screws and install them into the
flywheel. Tighten the three cap screws evenly to
NOTE: The spacer is positioned between the two 0.8-1.2 kg-m (6-9 ft-lb).
fan-case bearings.
6. Check the fan belt tension. Adjust as necessary.
4. Insert the fan with shaft through the fan bearings.
7. Install the fan cover and secure with six screws.
5. Install the key into the shaft. Tighten the screws to 1.1 kg-m (8 ft-lb).
6. Slide the inner pulley half, required shim(s), fan 8. Install the recoil starter. Secure with four cap
belt, and outer pulley half onto the shaft. screws. Tighten to 1.1 kg-m (8 ft-lb).
REPLACING FAN BELT
1. Remove the fan cover and the recoil starter.
2. Remove the three cap screws securing the recoil
starter pulley and the fan drive pulley to the
flywheel.
3. Remove the fan drive pulley and fan belt from the
engine.
4. Place the new fan belt into position on the upper
pulley.
3-3
5. Place the fan drive pulley onto the fan belt and
align one of its holes with one of the mounting
holes in the flywheel; then start a cap screw into
the aligned hole and finger-tighten.
6. Rotate the fan drive pulley clockwise while
observing the other two holes in the pulley. When
they align with the two holes in the flywheel, start
the remaining two cap screws.
7. Tighten the three cap screws only to position the
fan drive pulley on the flywheel; then remove the
three cap screws and install the recoil starter
pulley. Apply red Loctite #271 to the threads of
the three cap screws and install into the flywheel. B075
Tighten the three cap screws evenly to 0.8-
1.2 kg-m (6-9 ft-lb). 3. Install the fan cover. Tighten the screws to 1.1 kg-
m (8 ft-lb).
ADJUSTING BELT TENSION
1. Remove the fan cover.
2. Using the fan spanner wrench, remove the nut,
lock washer, and washer securing the pulley
halves.
3. Slide the outer pulley half off the shaft and
account for any shim(s).
4. Add or remove shim(s) to attain correct belt
tension.
AB040
NOTE: To increase belt tension, remove shim(s);
NOTE: With the new belt installed, check fan belt to decrease belt tension, install shim(s).
tension (see Checking Belt Tension).
5. Install the fan belt and the outer pulley half on the
8. Install the fan cover. Tighten the screws to 1.1 kg- shaft and, using the fan spanner wrench, secure
m (8 ft-lb). Install the recoil starter. Tighten the pulley with a washer, lock washer, and nut.
cap screws to 1.1 kg-m (8 ft-lb). Tighten to 2.5-4 kg-m (18-29 ft-lb).
CHECKING BELT TENSION 6. Recheck belt tension; adjust if necessary.
1. Remove the fan cover. 7. Install fan cover. Tighten the screws to 1.1 kg-m
(8 ft-lb).
Repairing
Water Pump (Twin)
NOTE: A bleed hole is located at the bottom of

the water pump housing. If there are any signs of
coolant leakage from the bleed hole, the water
pump seals must be replaced. When servicing the
water pump, use Water Pump Bearing and Seal Kit
(p/n 0644-084).
AB075
1. Remove the expansion chamber from the engine
2. Squeeze the belt at midspan and observe the belt compartment.
deflection. The maximum belt deflection on either 2. Attach a long piece of fuel hose to the engine
side must not exceed 6 mm (1/4 in.). If the coolant drain valve (located on the front lower half
deflection is not within specifications, adjust the of the crankcase). Route the fuel hose outside the
belt tension. engine compartment and into a container. Open
the drain valve and remove the filler cap. Once the
coolant stops flowing, remove the hose and tighten
the drain valve.
3-4
3. Remove the coolant hose from the water pump
cover.
4. Remove the screws securing the water pump
cover; then remove the cover and account for the
O-ring seal.
AN232
10. Remove the oil-injection pump retainer and shaft

from the opposite side of the crankcase. Account
for the thrust washer located between the retainer
and shaft flange.
AN180
5. Loosen the throttle body/carburetor flange clamps;

then remove the throttle body/carburetors.
6. Remove the mounting hardware securing the
engine to the front-end assembly. Remove the
3
hose from the thermostat housing and tip the
engine forward.
7. Remove either lower union cap screw securing the
lower check valve assembly. Remove the two
screws securing the oil-injection pump and pull
the oil pump from the engine. Leave the pump
hose and cable attached. AN231
8. Remove the cap screw securing the impeller. 11. Using the long seal driver, drive the water pump
seal from the crankcase.
AN233
AN250
9. Remove the impeller from the shaft.
NOTE: If the impeller wont slide off the shaft, ring securing the inner seal in the crankcase.
start the cap screw into the shaft and tap on the
cap screw driving the shaft back out of the impel-
ler.
3-5
AN249 AN262
13. Using the hooked end of the long seal driver, pull 4. Using a pair of snap ring pliers, install the snap
the inner seal free of the crankcase. ring securing the inner seal in the crankcase.
ASSEMBLING
1. Wipe the seal area clean using a clean rag.
AN249

AN248 position until it seats itself against its flange.
2. Position the inner seal onto the seal driver (spring
side towards the crankshaft). Gently tap into
position.
AN261

of the oil-injection pump driveshaft; then install
AN259 Oil Seal Installation Tool (p/n 0644-219) at the
end of the shaft. Twist the shaft as it is pushed
3. Using a small screwdriver, apply a light coat of through the oil and water pump seals; then remove
grease to the inner seal lips. the tool. Position the shim on the oil pump end of
the shaft.
3-6
AN231 AN178
7. Install the oil-injection pump retainer O-ring and 11. Apply sealant to the crankcase seam; then install
retainer. the alignment pins into the crankcase (if removed).
AN184 AN179
8. Install the O-ring and the oil-injection pump. 12. Position the O-ring into the water pump cover;
Make sure the pump shaft and oil pump align. then install the cover. Secure with the screws.
Secure with two screws and washers. Tighten the Tighten to 1.1 kg-m (8 ft-lb).
AN180
AN183
13. Set the engine down into position and secure to the
9. Place the lower check valve into position; then front-end assembly. Tighten to specifications.
secure with the gaskets and union cap screw.
Tighten securely. 14. Connect the coolant hose to the water pump cover
and secure with the clamp.
cap screw and washer. Be sure the rubber side of 15. Install the throttle body/carburetors and secure
the washer is directed towards the impeller. Apply with clamps.
and tighten to 0.8-1.2 kg-m (6-9 ft-lb). 16. Install the expansion chamber and secure with
springs.
NOTE: When installing the springs, the long
hook portion of the spring must be attached to the
exhaust manifold or premature spring failure will
result.
3-7
17. Install the thermostat hose and fill the cooling 8. Remove the cap screw securing the impeller.
system with antifreeze. Start and run the engine.
Check for leaks and recheck the cooling system to 9. Pull the impeller from the shaft. If the impeller
make sure it has been properly filled. wont slide off the shaft, start the cap screw into the
shaft and tap on the cap screw driving the shaft
back out of the impeller.
Repairing Water Pump

(600 cc Triple)
REMOVING AND DISASSEMBLING

the water pump housing. If there are any signs of
(p/n 0644-084).
1. Mark the three expansion chambers for assembly

purposes; then remove the expansion chambers AN232
from the engine compartment. 10. Remove the oil pump retainer and shaft from the
2. Attach a long piece of fuel hose to the engine opposite side of the crankcase. Account for the
coolant drain (located on the front lower half of thrust washer located between the retainer and
the crankcase). Route the fuel hose outside the shaft flange.
engine compartment and into a container. Open
the drain and remove the filler cap. Once the
coolant stops flowing, remove the hose and tighten
the drain valve.
3. Remove the coolant hose from the water pump
cover.
4. Remove the water pump cover and account for the
O-ring seal.
AN231
11. Using the long seal driver, drive the water pump
seal from the crankcase.
AN180
5. Mark the three carburetors for assembly purposes.

Loosen the carburetor flange clamps; then remove
the three carburetors and lay to the side.
6. Remove the cap screws securing the engine to the
front-end assembly. Remove the hose from the
thermostat housing and tip the engine forward. AN250
7. Remove the screws securing the oil pump and pull 12. Remove the snap ring securing the inner seal in the
the oil pump from the engine. Leave the oil pump crankcase.
hose and cable attached.
3-8
AN249 AN262
13. Using the hooked end of the long seal driver, pull 4. Install the snap ring securing the inner seal in the
the inner seal free of the crankcase. crankcase.
ASSEMBLING AND INSTALLING
1. Wipe the seal area clean using a clean rag.
AN249

AN248 position until it seats itself against its flange.
2. Position the inner seal onto the seal driver (spring
side towards the crankshaft). Gently tap into
position.
AN261

of the oil pump driveshaft; then install Oil Seal
AN259 Installation Tool (p/n 0644-219) at the end of the
shaft. Twist the shaft as it is pushed through the oil
3. Apply a thin coat of grease to the inner seal lips. and water pump seals; then remove the tool.
Position the shim on the oil pump end of the shaft.
3-9
AN231 AN178
7. Install the oil-injection pump retainer O-ring and 10. Apply sealant to the crankcase seam; then install
retainer. the alignment pins into the crankcase if removed.
AN184 AN179
8. Install the O-ring and the oil-injection pump. 11. Position the O-ring into the water pump cover;
Make sure the oil-pump shaft and oil pump align. then install the cover. Secure with five screws.
Secure with two screws and washers. Tighten the Tighten securely.
two screws securely.
AN180
AN183
12. Fill the cooling system with antifreeze. Start and
9. Place the impeller into position and secure with a run the engine. Check for leaks and recheck the
cap screw and washer. Be sure the rubber side of cooling system to make sure it has been properly
the washer is directed towards the impeller. Apply filled.
3-10
3. Slide the center section of the water pump from
Repairing Water Pump the shaft. Inspect both the rear and front seals. If
either appear in poor condition, replacement is
(1000 cc) necessary.

the water pump housing. If there is any sign of
(p/n 0644-084).
AQ112
4. To remove seals, pull the rear seal from the center

section using the puller.
3
AQ104
1. Remove the recoil starter and magneto housing;

then remove the water pump cover.
AQ011
5. Using the seal driver, drive the front seal from the
center section.
AQ095
2. Secure the crankshaft using a spanner wrench;

then remove the cap screw securing the impeller.
Remove the impeller from the shaft.
AQ012
AQ096
3-11
NOTE: Shown are the seals and O-rings required

to rebuild the water pump. Clean the center sec-
tion seal area and inspect the center section for
any signs of wear or scoring in the impeller area.
AQ016
4. Install the water pump center section on the

crankcase. Install the new impeller sealing ring on
the backside of the impeller.
AQ013
1. Using the seal driver, install the front mechanical

seal. Drive the seal down into the center section
until it is firmly seated against its metal flange.
AQ008
5. Install the impeller and secure with a cap screw

(coated with blue Loctite #242) and flat washer.
The washer has a rubber coated side which must
face the impeller. Tighten the cap screw to 0.8-
1.2 kg-m (6-9 ft-lb).
AQ014
6. Install the outer water pump cover and O-ring seal.
2. Using the driver, install the rear seal. The spring Secure the cover with five screws.
side of the seal must face outward. The seal outer
surface must be flush with the case.
AQ005
AQ015 7. Install the magneto housing and recoil starter.
3. With the rear seal installed, apply a generous 8. Fill the cooling system with antifreeze. Start and
amount of grease to the seal lips; then install the run the engine. Check for leaks and recheck the
O-rings and coat with grease. cooling system to make sure it has been properly
filled.
3-12
Pressure Testing ! CAUTION
Engine Be sure the cooling system is throughly filled
using the following procedure.
1. Elevate the front of the snowmobile 30-60 cm (12-
1. Test the engine for air leaks using the following 14 in.).
procedure and Pressure Testing Kit (p/n 0144-
127). 2. Remove the coolant tank cap and check coolant
level. The coolant tank should be filled to the
a. Install a plug into each intake-manifold port coolant level line.
and tighten the flange clamps securely.
3. Install the coolant tank cap; then start the engine.
b. Place a rubber plug and cover on each exhaust Run the engine at 3000-3500 RPM until the
port and secure. bottom heat exchangers become hot to the touch.
Stop the engine and allow the system to cool.
c. Connect the tester pump to an impulse fitting
on the crankcase; then plug any remaining 4. Lower the front of the snowmobile and elevate the
impulse fittings and pressurize the crankcase to rear of the snowmobile 12-14 in. Repeat the
8 psi and close the valve. procedures in step 3.
5. Check the coolant level. Add coolant as required
! CAUTION to the coolant tank (coolant tank should be filled to
DO NOT exceed 8 psi pressure or damage to the coolant level line). Repeat procedure until coolant
level stabilizes in the coolant tank.
3
seals will result.
NOTE: If coolant is required, mix coolant for a
temperature of -36°C (-34°F). Follow mixing recom-
mendations of the manufacturer of the coolant.
! CAUTION
It is extremely important that the Filling Cooling
System procedure is followed very closely and
the cooling system is properly filled. If the
system isn’t properly filled, piston damage will
occur.
INSPECTING COOLANT HOSES

AN128D AND CLAMPS
d. Monitor the pressure gauge. The pressure must All coolant hoses and connections should be checked
not drop at a rate of more than 1 psi per minute. annually for deterioration, cracks, and wear.
e. If the pressure drops faster than specified, All coolant hoses and clamps should be replaced every
inspect for an air leak with soapy water or by four years.
completely submerging the pressurized engine
in clean fresh water. Repair as needed. INSPECTING THERMOSTAT
1. Inspect the thermostat for corrosion, wear, or
! CAUTION spring damage.
When submerging the engine to test for air leaks, 2. Using the following procedure, inspect the
all external electrical components must be thermostat for proper operation.
removed to avoid damage.
a. Suspend the thermostat in a container filled
with water.
Liquid Cooling
System b. Heat the water and monitor the temperature
with a thermometer.
The liquid cooling system consists of heat exchangers, c. The thermostat should open at 50°C (122°F).
water pump, and thermostat. The system should be Once the thermostat starts to open,
inspected for leaks or damage whenever an overheating IMMEDIATELY remove the thermostat as it
problem is experienced. will lock in the open position if allowed to open
fully.
FILLING COOLING SYSTEM
NOTE: The thermostat is of the lock-open type. If
the thermostat is ever allowed to fully open, it will
remain open and replacement will be necessary.
3-13
The following schematics are representative of the dif-
Cooling System ferent styles of 2-stroke cooling systems in the 2002
Arctic Cat snowmobiles. Some components may vary
Schematics from model to model; therefore, the technician should
use discretion and sound judgment when servicing a
particular cooling system.
0734-451
KEY
1. Coolant Reservoir
2. Spacer
3. Guard
4. Vent Hose
5. Washer
6. Lock Washer
7. Cap Screw
8. Rivet
9. Lock Washer
10. Cap Screw
11. Cap
12. Lock Nut
13. Clamp
14. Hose
15. Hose
16. Heat Exchanger
17. Heat Exchanger
18. Clamp
19. Hose
20. Hose
21. Decal
22. Wire Form Bracket
23. Heat Exchanger
24. Washer
25. Cable Tie
26. Rivet
27. Hose
28. Clamp
29. Cable Tie
0735-951
3-14
KEY
2. Hose
3. Clamp
4. Decal
5. Hose
6. Cable Tie
7. Lock Nut
8. Clamp
9. Hose
10. Hose
11. Hose
12. Clamp
13. Cable Tie
14. Heat Exchanger
15. Machine Screw
16. Rivet
17. Cap
18. Heat Exchanger
19. Heat Exchanger
20. Hose
21. Washer
3
0736-023
KEY
2. Hose
3. Clamp
4. Decal
5. Hose
6. Rivet
7. Lock Nut
8. Washer
9. Hose
10. Hose
11. Heat Exchanger
12. Clamp
13. Cable Tie
14. Hose Guard
15. Cap Screw
16. Rivet
17. Cap
18. Heat Exchanger
19. Hose
20. Hose
21. Cable Tie
22. Clamp
0736-104
3-15
KEY
2. Hose
3. Clamp
4. Decal
5. Hose
6. Rivet
7. Lock Nut
8. Cable Tie
9. Hose
10. Hose
11. Heat Exchanger
12. Clamp
13. Cable Tie
14. Hose Guard
15. Machine Screw
16. Rivet
17. Cap
18. Heat Exchanger
19. Hose
20. Hose
21. Washer
0735-980
KEY
2. Hose
3. Clamp
4. Decal
5. Hose
6. Rivet
7. Lock Nut
8. Clamp
9. Hose
10. Hose
11. Heat Exchanger
12. Clamp
13. Cable Tie
14. Guard
15. Machine Screw
16. Rivet
17. Cap
18. Heat Exchanger
19. Hose
20. Hose
21. Hose
22. Double T-Fitting
23. Hose
24. Clamp
25. Cover
26. Cable Tie
0736-041
3-16
4. Remove the screw securing the plate to the roller.
Recoil Starter
(120 cc Model)
NOTE: It will be necessary to remove the engine

to access the recoil starter (see Section 2).
REMOVING/DISASSEMBLING
! WARNING
Always wear safety glasses when servicing the
recoil starter.
GR502D
1. Remove the cap screws securing the recoil starter.
5. Remove the plate.
GR304D
GR503D
2. Pull the rope out of the housing and align with the
notch in the roller; then release the spring pressure 6. Mark the ratchets for assembling purposes. The
on the roller. ratchets must be installed in their respective holes.
GR501D GR504D
3. Remove the knot from the end of the rope. 7. Remove the ratchets and account for the springs.
GR100D GR505D
3-17
NOTE: Note the orientation of the recoil spring
for assembling purposes.
GR506D
8. Slowly remove the reel. Account for the spring.

GR115D
! WARNING 3. Inspect the flat areas of the reel for wear.
Exercise extreme caution when removing as the
spring may disengage and cause severe injury.
INSPECTING

necessary.
1. Inspect the spring retaining notch in the recoil

housing.
GR116D
ASSEMBLING/INSTALLING
1. Apply a coat of grease to the housing and reel.
GR113D
2. Inspect the loop of the recoil spring for wear or

cracking.
GR119D
GR114D
3-18
GR506D
GR121D
2. Install the reel assembly with rope wound in the

appropriate direction.
! WARNING
Exercise extreme caution when installing as the
spring may disengage and cause severe injury.
3
GR505D
4. Install the plate and secure it with the screw.
GR507D
GR503D
GR111D
3. Install the springs and ratchets.
GR502D
3-19
5. Route the recoil rope through the rope guide of the DISASSEMBLING
recoil housing and through the recoil handle; then
tie a knot in the rope. ! WARNING
Always wear safety glasses when servicing the
recoil starter.
1. Secure the recoil starter in a vise.
! WARNING
During the disassembly procedure, continuous
downward pressure must be exerted on the reel so
it does not accidentally disengage and cause injury.
2. Rotate the roller counterclockwise until the notch

of the roller is near the rope guide in the case.
GR501D Guide the rope into the notch and slowly allow the
6. Wind the rope counterclockwise 3-4 turns around roller to retract until all recoil spring tension is
the roller. released.
7. Secure the recoil starter to the engine shroud.
B522
GR304D ! WARNING
NOTE: At this point, install the engine (see Sec- Care must be taken when allowing the recoil roller
tion 2). to unwind. Make sure all spring tension is released
before continuing.
3. While exerting downward pressure on the friction

Recoil Starter plate, remove the nut and washer or cap screw.
REMOVING
1. Tie a slip-knot in the starter rope below the
console and allow the rope to slowly retract
against the starter case.
2. Remove the knot at the handle, remove the handle,
and account for the handle cap; then thread the
rope through the bushing in the console.
3. Remove the cap screws securing the starter
assembly to the magneto case; then remove the
starter assembly.
B523
4. Slowly release the plate and lift the plate with

friction spring free of the recoil roller.
5. Remove the friction spring from the plate.
3-20
4. Inspect the center hub for wear, cracks, or damage.
5. Inspect the rope for breaks or fraying.
6. Inspect the main spring for cracks, crystallization,
or abnormal bends.
7. Inspect the handle for damage, cracks, or
deterioration.
ASSEMBLING
B524
6. Remove the pawl; then remove the return spring.
B525
7. Carefully lift the roller free of the case making

sure the main spring does not accidentally
disengage from the case.
! WARNING KEY
1. Starter Assy 9. Nut
Care must be taken when lifting the roller free of the 2. Starter Roller 10. Starter Rope
case. 3. Main Spring 11. Cap Screw
4. Ratchet Set 12. Starter Pulley
5. Friction Spring 13. Bolt
8. Remove the main spring from the case by lifting 6. Washer 14. Decal
the spring end up and out. Hold the remainder of 7. Return Spring 15. Pawl
the spring with thumbs and alternately release 8. Friction Plate
each thumb to allow the spring to gradually release 732-515A
from the case.
1. Hook the end of the main spring around the
NOTE: Do not remove the main spring unless mounting lug in the case.
replacement is necessary. It should be visually
inspected in place to save time. 2. Insert the main spring into the case; then wind it in
a counterclockwise direction until the complete
9. Unwind the rope from the roller, untie the slip- spring is installed.
knot, and remove the rope.
NOTE: The main spring must seat evenly in the
CLEANING AND INSPECTING recoil case.
NOTE: Whenever a part is worn excessively, 3. Insert the rope through the hole in the roller and tie
cracked, or damaged in any way, replacement is a knot in the end; then wrap the rope
necessary. counterclockwise around the roller leaving
approximately 50 cm (20 in.) of rope free of the
1. Clean all recoil starter components. roller.
2. Inspect all springs, washers, and pawl for wear or 4. Apply low-temperature grease to the main spring
damage. and hub.
3. Inspect the roller and case for cracks or damage. 5. Align the hook in the end of the main spring with
the notch in the roller.
3-21
6. Carefully slide the roller over the hub and engage
the spring with the roller.
7. Install the return spring making sure the end is
properly installed in the hole in the roller; then
install the pawl making sure the return spring is
properly preloaded.
B526
11. With 50 cm (20 in.) of rope exposed, hook the

rope in the notch of the roller.
12. Rotate the roller four or five turns counter-
clockwise; then release the rope from the notch
and allow the rope to retract.
B525
13. Pull the rope out two or three times to check for
8. Slide the end of the rope through the rope guide of correct tension.
the case; then tie a slip-knot in the rope.
NOTE: Increasing the rotations in step 12 will
9. Place the friction spring into position on the increase spring tension.
friction plate making sure the head of the spring is
opposite the flat of the inner hole. Apply a low- INSTALLING
temperature grease to the plate.
1. Place the starter assembly into position against the
magneto case.
2. Secure the starter with cap screws. Tighten to
0.7 kg-m (5 ft-lb) on the triple models, to 1 kg-m
(7 ft-lb) on the L/C twin models, or to 1.1 kg-m (8
ft-lb) on the F/C models.
NOTE: Before tightening the cap screws, slowly
pull the recoil rope until the pawl engages; then
tighten the cap screws. This will center the recoil
against the magneto case.
3. Thread the rope through the bushing in the

console; then install the handle and secure with a
B524 knot. Seat the cap.
10. Place the plate into position making sure the flat of 4. Release the slip-knot in the rope.
the inner hole is correctly positioned in the hub.
Apply blue Loctite #242 to the threads; then
secure the drive plate with a washer and nut or
with a cap screw. Tighten the nut to 1 kg-m
(7 ft-lb) or tighten the cap screw to 0.8-2.1 kg-m
(6-9 ft-lb).
3-22
COMPONENTS
Arctic Power Valve The main components of the APV system are the
(APV) System exhaust valves, return springs, actuating cables, and
the servomotor (servo).
The Arctic Power Valve (APV) System adjusts the size The exhaust valves are connected to the actuating
of the exhaust ports to produce maximum horsepower cables and, along with the return springs, are contained
on the top end while providing excellent low end inside the APV housing on the exhaust side of each
power and increased touring fuel economy. cylinder. The other end of the actuating cable is con-
nected to the servo. There is also a vent hose on each
THEORY APV housing to relieve the pressure of “blowby”
gases that may escape from the cylinder.
Two-cycle engines and their exhaust systems are
designed to produce maximum horsepower in a given OPERATION
RPM range. This RPM range will change according to
how high (or low) the exhaust port is in relation to the At idle and low speed operation, the exhaust valves are
cylinder. Engines designed for racing have a “high held in the “low port” position by the return spring.
port” exhaust system and will produce more horse- When engine RPM reaches a predetermined point, the
power at higher RPM but only with the loss of low end CDI/ECU will send a signal to the servo which will
power and overall fuel economy. “Low port” engines cycle and pull the exhaust valves into the up or “high
will produce maximum horsepower in the low RPM port” position. The RPM at which the valves open is
ranges and provide good mid-range fuel economy, but different with each model.
they sacrifice top end performance. MAINTENANCE
ENGINE MODEL
APV VALVE POSITION
ONE STAGE RPM RANGES
The APV system requires only periodic cleaning and
cable adjustment. The cables should be checked every
3
Acceleration Deceleration 1000-2000 miles and adjusted as necessary. To ensure
Down Up Down maximum performance and minimize maintenance
600 cc Twin 0 - 6999 7250 and Above 6900 and Below requirements, Arctic Cat recommends using Arctic Cat
800 cc 0 - 6799 6800 and Above 6300 and Below Synthetic APV Oil. Using oils other than the recom-
600 cc Triple 0 - 6949 6950 and Above 6650 and Below mended oil may increase the frequency of required
ENGINE MODEL TWO STAGE RPM RANGES cleaning due to increased buildup of carbon deposits.
Acceleration Deceleration
CABLE ADJUSTMENT
Down Middle Down
500 cc 0 - 6949 6950 - 7199 6700 and Below Proper cable adjustment is critical to the operation of
the APV system. While it is recommended that the
The APV system does not increase engine horsepower, cable adjustment be inspected every 1000-2000 miles,
but it does allow the engine to be designed for maxi- the cable should not need adjustment often. To check
mum top end horsepower without the losses associated the cable adjustment, use the following procedure.
with a “high port” exhaust system.
1. Remove the two bolts securing the servo cover.
735-476B
AP116A
2. Using a small screwdriver, remove the cable

retaining cover.
3-23
NOTE: When measuring the cables, keep them
as close to their installed position as possible.
6. While holding the cable housing, lightly pull on

one cable end to remove any slack.
7. Measure the amount of exposed cable from the
cable housing to the end of the cable.
AP117A
3. Rotate the servo actuator counterclockwise to

loosen the cable; then pull the cable housings out
of the holder.
0735-516
NOTE: Repeat steps 6 and 7 for each cable; then

compare the measurements to the chart.
APV CABLE LENGTH

ENGINE MINIMUM CENTER MAXIMUM
MODEL
500 cc 34.1 mm 35.1 mm 36.1 mm
(1.34 in.) (1.38 in.) (1.42 in.)
600 cc Twin 32.1 mm 33.1 mm 34.1 mm
(1.26 in.) (1.30 in.) (1.34 in.)
AP118A 800 cc 29.6 mm 30.6 mm 31.6 mm
(1.17 in.) (1.20 in.) (1.24 in.)
4. Pull the cable up and out of the cable housing 600 cc Triple 34.4 mm 35.4 mm 36.4 mm
(1.35 in.) (1.39 in.) (1.43 in.)
holder; then slide each cable drum to the left and
out of the servo actuator.
NOTE: The measurements must be equal and
within the specifications from the chart. If the mea-
surements are within specifications, no adjust-
m e n t i s n e c e s s a r y. I f t h e y a r e n o t w i t h i n
specifications, proceed to step 8.
8. Loosen the jam nut on the cable to be adjusted;

then using the adjusting nuts, lengthen or shorten
the housing as needed.
AP118B
NOTE: Before proceeding with the cable adjust-

ment, ensure that the exhaust valves are free to
move.
5. While holding the cable housing firmly, pull the

cable as far out as it will go; then release. Repeat
three to four times. The cable/exhaust valve
should move freely without binding. If the cable/ 0735-837
exhaust valve does not move freely, the exhaust 9. Once the proper length has been attained, hold the
valve assembly will need to be removed for further adjusting nut in place and tighten the jam nut
inspection. securely.
10. Install the actuating cables into the servo.
3-24
SERVICING
There are two styles of power valves in use in the 2002
Arctic Cat engines. The “flat style” valve is on the 500
cc and 800 cc engines, and the “round style” valve is
on all 600 cc engines.
Removing/Disassembling
(500/800 cc)
NOTE: To avoid a parts mix-up, it is recom-

mended that only one valve assembly at a time be
removed from the engine.
1. Remove the valve assembly from the engine (see AP125

Section 2).
Cleaning and Inspecting
1. Remove all carbon deposits with solvent and a soft
abrasive such as a Scotch-Brite pad.
2. Inspect all parts for nicks, burrs, or other signs of
unusual wear.
Assembling/Installing
(500/800 cc)
3
AP121
2. Remove the retaining screw securing the exhaust

valve to the valve stopper.
AP124A
1. Slide the return spring over the end of the

actuating cable.
AP123
NOTE: Make sure that the small cable end spring
3. Hold the valve stopper securely and pull the cable stays in place at the end of the cable.
back and up until it clears the top of the stopper;
then slowly release the cable and remove it from 2. Place the valve stopper on the cable and slide it
the valve stopper. down until the cable end is inside the stopper.
3-25
AP125 AP120
3. Slide the exhaust valve through the retaining plate 6. Slide the valve cover onto the studs on the engine.
and insert it into the valve stopper. Secure with the Secure with four nuts. Tighten to 0.9-1.3 kg-m
retaining screw. Tighten to 0.6 kg-m (4 ft-lb). (6.5-9.5 ft-lb).
AP123 AP119
4. Slide the valve assembly into the proper cylinder. 7. Perform steps 6-10 in Cable Adjustment in this
sub-section.
Removing/Disassembling (600 cc)
NOTE: To avoid a parts mix-up, it is recom-

mended that only one valve assembly at a time be
removed from the engine.
1. Remove the valve assembly from the engine (see

Section 2).
AP121
NOTE: The flat side of the retaining plate must

be down.
5. Secure the valve assembly to the cylinder with two

Allen-head cap screws (coated with blue Loctite
#242). Tighten to 0.9-1.3 kg-m (6.5-9.5 ft-lb).
AP154
2. Slide the exhaust valve/valve guide assembly off

the retaining pin and free of the valve stopper.
Repeat with the second exhaust valve/valve guide
assembly.
3-26
Assembling/Installing (600 cc)
AP162
3. Remove the retaining pin from the valve stopper.
AP156A
1. Slide the return spring onto the cable end.

NOTE: Make sure the small cable end spring
3
stays in place at the end of the cable.
2. Place the valve stopper on a clean surface with the

slotted side up; then place the cable in the slot and
AP163 pull the cable through the stopper until the cable
end and return spring are in place in the stopper.
4. Slide the valve stopper back on the cable until the Secure with the retaining pin.
cable end and return spring clear the stopper.
Remove the valve stopper and return spring from
the cable.
AP157
NOTE: The retaining pin is inserted long end first

AP164 from the right side of the valve stopper. Ensure
that the retaining pin washer is in the recess in the
Cleaning and Inspecting valve stopper.
1. Remove all carbon deposits with solvent and a soft 3. Assemble the exhaust valve and valve guide as
abrasive such as a Scotch-Brite pad. shown.
2. Inspect all parts for nicks, burrs, or other signs of
unusual wear.
3-27
AP165 AP153
4. One at a time, slide each of the exhaust valve/ 7. Slide the valve cover onto the studs on the engine.
valve guide assemblies through the retaining plate Secure with four nuts. Tighten securely.
and onto the pin in the valve stopper.
AP119
AP162
8. Perform steps 6-10 in Cable Adjustment in this
NOTE: The single center mounting hole on the sub-section.
retaining plate should be up.
TROUBLESHOOTING
5. Slide the valve assembly into the proper cylinder. (Carbureted Models)
The APV system has a self-cleaning and self-testing
mode built in. Every time that the engine is started, the
servo will cycle once, and this will wipe-off the carbon
that has accumulated on the exhaust valves. The CDI
unit also monitors the voltages at the servo during this
cycle to assure they are within operational tolerances.
If all voltages are within tolerance, the system is ready
for operation. If the voltages are not within tolerance,
the servo will cycle two more times. If the voltages
remain out of tolerance, the system will not operate.
Problem: Engine loses power; no top end
Condition Remedy
AP154
1. Exhaust valves sticking in 1. Remove carbon deposits,
6. Secure the valve assembly to the cylinder with down position burrs, etc.
three Allen-head cap screws (coated with blue 2. Cables adjusted too long 2. Inspect—adjust
Loctite #242). Tighten to 1.1 kg-m (8 ft-lb). Problem: Poor acceleration; hesitation
Condition Remedy
1. Exhaust valve sticking in 1. Remove carbon deposits,
up position burrs, etc.—inspect/
replace return spring
2. Cables adjusted too short 2. Inspect—adjust
3-28
TROUBLESHOOTING (EFI Models)
Problem: Engine loses power; no top end
The APV system used on EFI models is very similar to Condition Remedy
that found on carbureted models. The self-cleaning 1. Exhaust valves sticking in 1. Remove carbon deposits,
and self-testing modes are much alike. The main dif- down position burrs, etc.
ference between the two is the higher total electrical 2. Cables adjusted too long 2. Inspect—adjust
power required by the EFI and APV systems com- 3. Lighting coil output 3. Inspect—replace stator
bined. Because of these more demanding power voltage out of tolerance
requirements, the EFI APV system gets power from Problem: Poor acceleration; hesitation
the stator lighting coil. The ECU constantly monitors Condition Remedy
the power output of the lighting coil, and if the lighting 1. Exhaust valve sticking in 1. Remove carbon deposits,
coil output gets too high or too low, the ECU will acti- up position burrs, etc.—inspect/
vate the “limp-home” mode. The “limp-home” mode replace return spring
is an ECU operated engine RPM limiter. When acti- 2. Cables adjusted too short 2. Inspect—adjust
vated, the “limp-home” mode will be seen as an imme- 3. Lighting coil output 3. Inspect—replace stator
diate loss of engine horsepower. voltage out of tolerance
For example, if the headlight and taillight are disabled, Troubleshooting EFI engines with the APV system
the ECU will sense a high voltage condition and acti- should be done with the Arctic Cat EFI Analyzer (p/n
vate the “limp-home” mode. Adding more than 4 amps 0644-342). To update your existing EFI Analyzer,
of accessories will create a low voltage condition and order Kit (p/n 0644-341).
activate the “limp-home” mode.
NOTE: When running an APV equipped EFI
engine on a dynamometer, first connect a Voltage
Regulator (p/n 0603-142, 2-wire) or (p/n 0630-643,
3-wire) between the lighting coil and the ECU.
3
There must also be a minimum 2.5 amp load
installed in-line between the voltage regulator and
the ECU (a 2.5 amp load is equivalent to one high
beam headlight bulb).
3-29
NOTES
3-30
SECTION 4 - FUEL SYSTEMS
TABLE OF
CONTENTS
Fuel System (Carbureted) ....................................... 4-2
Fuel System (Batteryless EFI) .............................. 4-40
Fuel System (Related Items)................................. 4-67
4-1
Fuel System Pre-Maintenance
(Carbureted) Checks
This sub-section has been organized for servicing car-
bureted fuel systems; however, some components may Before troubleshooting the fuel system, several simple
vary from model to model. The technician should use checks should be performed. Many times what appears
discretion and sound judgment when removing/ disas- to be a serious problem is only a minor one.
sembling and assembling/installing components.
1. Make sure the gas tank shut-off valve was in the
Whenever any maintenance or inspection is made on OPEN position.
the fuel system in which fuel leakage may occur, there
should be no welding, smoking, or open flames in the 2. Turn the shut-off valve to the CLOSED position;
area. then remove the in-line fuel filter. If the filter is
dirty, replace the filter.
in this sub-section are used for clarity purposes NOTE: Determine which style in-line fuel filter is
only and are not designed to depict actual condi- being replaced and remove and install accord-
tions. ingly.
3. Install a new filter making sure the arrow on the

filter is directed toward the fuel pump.
Fuel System
(Carbureted)
Table of Contents
Pre-Maintenance Checks........................................ 4-2
Changing Main Jet(s)(VM-Style) ............................. 4-3
Changing Main Jets (TM-Style) .............................. 4-4
Carburetor Schematics ........................................... 4-4
Removing Carburetor (BV-Style)............................. 4-6
Removing Carburetor (VM-Style)............................ 4-7
Removing Carburetors (TM-Style) .......................... 4-8
Disassembling Carburetor (BV-Style)...................... 4-8
Disassembling Carburetor (VM-Style)................... 4-10
Disassembling Carburetors (TM-Style) ................. 4-12 735-390A
Cleaning Carburetor.............................................. 4-14
Inspecting Carburetor............................................ 4-15
Assembling Carburetor (BV-Style) ........................ 4-15
Assembling Carburetor (VM-Style) ....................... 4-16
Assembling Carburetors (TM-Style) ...................... 4-18
Installing Carburetor (BV-Style)............................. 4-20
Installing Carburetor (VM-Style)............................ 4-21
Installing Carburetors (TM-Style) .......................... 4-22
Adjusting Carburetor (BV-Style) ............................ 4-23
Adjusting Carburetor(s) (VM-Style) ....................... 4-24
Adjusting Carburetors (TM-Style).......................... 4-28
Throttle Cable (BV-Style) ...................................... 4-29
Throttle Cable (VM-Style)...................................... 4-31
Throttle Cable (TM-Style)...................................... 4-32
Choke Cable (VM-Style) ....................................... 4-33
Choke Cable (TM-Style)........................................ 4-34 726-065A
2002 Carburetor Specifications (Production) ........ 4-35
Mikuni Tuning Components................................... 4-36
Major Tuning Components .................................... 4-37
Troubleshooting Fuel System (Carbureted) .......... 4-38
4-2
4. Check the hoses to ensure that all are correctly
connected; then check for cracks. If any cracks are
evident in the hoses, replace them making sure
none are against any hot or moving parts. Hoses
must fit tightly. If hoses do not fit tightly, cut 6
mm (1/4 in.) from the end and install.
5. Check the impulse hose for cracks or any possible
air leaks. The hose must fit tightly at both ends. If
loose or cracked, replace the hose.
6. Check each carburetor vent hose for kinks or
obstructions; remove any obstructions.
728-272A
7. Check each carburetor float chamber drain hose
for water or debris. If seen, clean by removing the
plug and draining the drain hose into a small
container.
8. Check the gas tank vent hose and fuel hose for
obstructions; remove any obstructions.
9. Turn the shut-off valve to the OPEN position.
725-067A
Changing Main Jet(s)
(VM-Style)
4
The carburetor main jet(s) must be changed in con-
junction with the changes in temperature, altitude, and
type of gasoline being used.
1. Loosen each carburetor flange clamp and remove
each carburetor from the intake flange and boot.
2. Remove the drain plug and O-ring from each
carburetor float chamber and drain the gas into
either a small container or an absorbent towel.
3. Using the Main Jet Wrench (p/n 0644-065), thread
the main jet out of each carburetor. Account for
734-292A the baffle ring. Install the new main jet with baffle
ring and tighten securely.
4. Install the drain plug and O-ring; then tighten
securely.
734-292B
0728-054
5. Install and secure each carburetor.
4-3
6. Install the drain plug with O-ring; then tighten
Changing Main Jets securely.
(TM-Style) 7. Push the carburetors back into position and into
the intake flanges; then tighten the flange clamps.
The carburetor main jets must be changed in conjunc-
tion with the changes in temperature, altitude, and type 8. Place the air-intake silencer into position in the
of gasoline being used. engine compartment making sure the carburetors
are properly positioned in the boot and secure with
1. Remove the machine screw and washer securing the screws.
the mounting plate (for the ignition coil and fuel
pump) to the air-intake silencer. 9. Place the ignition coil/fuel pump mounting plate
into position on the air-intake silencer and secure
with the machine screw and washer.
Carburetor
Schematics
BV-18
AN613D
2. Remove the screws securing the air-intake

silencer; then move the silencer forward and out of
the engine compartment.
3. Loosen the carburetor flange clamps and slide the
carburetors out of the intake flanges. Tilt the
carburetors forward to access the main jets.
4. Remove the drain plug (with O-ring) from each
carburetor float chamber and drain the gas into
either a small container or an absorbent towel.
5. Using the Main Jet Wrench (p/n 0644-065), thread KEY
1. Carburetor Assy 12. Spring
the main jet out of each carburetor. Account for 2. Gasket 13. Pilot Jet
the washer. Install the new main jet and washer 3. Float 14. Screw
and tighten securely. 4. Gasket 15. Ring
5. Drain Plug 16. Float Chamber
6. Main Jet 17. Drain Screw
7. Spring 18. Gasket
8. Float Pin 19. Hose
9. Needle Jet 20. Clamp
10. Nozzle 21. Screw
11. Adjuster Screw
0735-414
0734-280
4-4
KEY VM-32 VM-38
KEY
1. Mixing Body 15. Spring 28. Hose
Assy 1. Mixing Body 13. Mixing Body 27. Baffle Ring
16. Spring 29. Starter Plunger Top Assy
2. Float Chamber 28. E-Clip
17. Idle Speed 30. Screw w/Spring 2. Piston Valve 14. Spring
3. Plate Screw Washer 29. Main Jet
Spring 15. Idle Speed
4. Piston Valve 18. Drain Screw 31. Plate 30. E-Clip Washer
3. Plate Screw
5. Jet Needle 19. Washer 32. O-Ring 31. Float
4. Jet Needle 16. Float Chamber
6. Main Jet 20. Float Pin 33. Washer 32. Screw Guide
5. Piston Valve 17. O-Ring
7. Baffle Ring 21. Needle Valve 34. Screw w/ 33. Pilot Jet
6. Needle Jet 18. Starter Plunger
8. Needle Jet Assy Washer Cap 34. Magnet Block
7. Screw w/Spring
9. E-Clip 22. Float Arm 35. Magnet Block Washer 19. Washer 35. Machine Screw
10. Float 23. Piston Valve 36. Self-Tapping 8. Plate 20. Spring 36. Machine Screw
Spring Screw 37. Washer
11. Cap 9. Float Arm 21. Starter Plunger
24. Pilot Jet 37. Magnetic 38. Magnetic Switch
12. Screw w/Spring Switch 10. Needle Valve 22. Air Vent Tube
Washer 25. Gasket Assy 39. Self-Tapping
38. Cap 23. Pilot Air Screw
13. Mixing Body 26. Starter Plunger 11. Washer Screw
Spring 39. Hose Plate 24. Spring
Top 12. Gasket 40. Cap
27. Starter Plunger 25. Drain Plug
14. Pilot Air Screw 41. Washer
Cap 26. Float Arm Pin
4
0735-853 0736-643
KEY VM-34 KEY

TM-36/TM-38 (Triple)
1. Mixing Body 15. Spring 28. Hose 1. Mixing Body 15. E-Clip 30. Lever Assy
Assy 16. Spring 29. Starter Plunger 2. Screw w/ 16. Washer 31. Throttle Valve
2. Float Chamber 17. Idle Speed 30. Screw w/Spring Washer 17. Clip 32. Pilot Jet
3. Plate Screw Washer 3. Top Cap 18. Bushing 33. Cap
4. Piston Valve 18. Drain Screw 31. Plate 4. Gasket 19. O-Ring 34. Fuel Mixture
5. Jet Needle 19. Washer 32. O-Ring 5. Plunger Cap 20. Screw Screw
6. Main Jet 20. Float Pin 33. Washer 6. Guide 21. Washer 35. Float Assy
7. Baffle Ring 21. Needle Valve 34. Screw w/ 7. Spring 22. Washer 36. O-Ring
8. Needle Jet Assy Washer 8. Starter Plunger 37. Screw
23. Starter Jet
9. E-Clip 22. Float Arm 35. Magnet Block 9. Gasket 38. O-Ring
24. Washer
10. Float 23. Piston Valve 36. Self-Tapping 10. Funnel Assy 39. Float Chamber
Spring Screw 25. Main Jet
11. Cap 11. Screw 26. Spring 40. Washer
24. Pilot Jet 37. Magnetic
12. Screw w/Spring Switch 12. Screw 27. Plate 41. O-Ring
Washer 25. Gasket
38. Cap 13. Plug 28. E-clip 42. Washer
13. Mixing Body 26. Starter Plunger
Spring 39. Plate 14. Plate 29. Jet Needle 43. Air Screw
Top
27. Starter Plunger 40. Washer 44. Spring
14. Pilot Air Screw
Cap
0737-025 0735-335
4-5
TM-36/TM-38 (Triple) TM-38/TM-40 (Twin)
KEY KEY
1. Carburetor 12. Bracket 23. Inlet T-Fitting 1. Carburetor Assy 13. Sensor Assy
Assy 13. Shaft 24. Seal 2. Carburetor Assy 14. Screw w/Washers
2. Carburetor 14. Washer 25. Lever 3. Bracket 15. Screw
Assy
15. E-Clip 26. Machine Screw 4. Idle Speed Screw 16. Spring
3. Carburetor
Assy 16. Lever 27. Hose 5. Spring 17. Spacer
4. Idle Speed 17. Spacer 28. Clip 6. Screw 18. Screw
Screw 18. Screw 29. Spacer 7. Screw 19. Throttle Lever Shaft Assy
5. Spring 19. Throttle Lever 30. Sleeve 8. Spacer 20. Lever Ring Screw
6. Screw Shaft Assy 31. Bolt 9. Sleeve 21. Lever Ring
7. Screw 20. Lever Ring 32. Spacer 10. Spring 22. Bolt
Screw
8. Screw 33. Spring 11. T-Fitting 23. Clip
21. Synchronizing
9. Spring Nut 34. Sensor Assy 12. Hose
10. Bracket 22. Spring 35. Screw w/
11. Screw Washers
0735-336 0736-229
KEY TM-38/TM-40 (Twin)

1. Mixing Body 15. Retaining Plate 28. Starter Jet
2. Screw w/ 16. Retaining Plate 29. Pilot Jet
Washer
3. Top Cap
Screw
17. Lever Assy
30. Spring Removing Carburetor
4. Gasket 18. Bushing
31.
32.
Main Jet
Float Assy
(BV-Style)
5. Plunger Cap 19. Clip 33. O-Ring
6. Spring 20. Plate 34. Screw
7. Starter Plunger 21. Washer 35. Float Chamber 1. Remove the wing nut securing the air cleaner end
8. Gasket
9. Funnel Assy
22. E-Clip
23. Fuel Mixture
36. Gasket cap to the air cleaner housing.
37. Screw
10. Screw Screw
38. Drain Plug
11. Throttle Valve 24. Cap
39. O-Ring
2. Remove the cap screw and flanged nuts securing
12. Jet Needle 25. Spring
40. O-Ring the air cleaner housing to the carburetor and
13. Washer 26. Washer
27. Rubber Washer
41. Washer engine.
14. E-Clip 42. Air Screw
A002
0735-683
4-6
7. Slide the carburetor off the mounting studs.
Account for a gasket, insulator block, and a
gasket.
GF314D
3. Remove the air breather hose from the air cleaner

housing; then remove the air cleaner housing from
the carburetor. Account for the gasket. GF318D
Removing Carburetor
(VM-Style)
NOTE: On twin carburetor models, remove the

carburetors using this basic procedure. 4
position.
A001
2. Loosen the screw and lock plate securing the
mixing body top.
position. 3. Remove the mixing body top by rotating it
counterclockwise; then remove the top with
5. Remove the fuel supply hose. spring, plate, jet needle with E-clip, and piston
valve from the carburetor.
6. Disconnect the rod and spring from the carburetor.
AH100
GF317D
4. Remove the brass choke-cable housing from the
carburetor. Account for a washer.
4-7
Removing Carburetors
(TM-Style)
1. Remove the machine screw and washer securing

the mounting plate (for the ignition coil and fuel
pump) to the air-intake silencer.
AH099
5. Disconnect the fuel hose from the carburetor inlet

fitting.
AN613D
2. Remove the screws securing the air-intake

silencer; then move the silencer forward and out of
the engine compartment.
3. Disconnect the throttle cable and choke cable.
4. Remove the fuel supply hose from the fuel inlet T-
AH284D fitting.
6. If applicable, disconnect the safety switch wiring 5. Loosen the carburetor flange clamps; then slide
harness connector from the main wiring harness. the carburetors out of the flanges and out of the
engine compartment.
7. Loosen the carburetor-flange clamp; then remove
the carburetor. 6. Remove the float chamber vent hoses.
Disassembling
Carburetor
(BV-Style)
1. Rotate the high-speed adjuster screw clockwise

while noting the number of rotations (for
assembling purposes) until lightly seated; then
remove the high-speed adjuster screw.
AH283D
NOTE: Slide the carburetor into the air-intake

silencer boot until free of the flange; then remove
carburetor.
! CAUTION
Keep MAG-side and PTO-side carburetors
identified for installing purposes.
GF319D
4-8
2. Remove the pilot jet.
GF323D
GF320D
3. Remove the drain bolt securing the float chamber

to the carburetor.
GF324D
4
6. Remove the main jet and the nozzle from the
carburetor tower.
GF321D
4. Remove the splash ring from the carburetor tower.
GF325D
GF322D
5. Remove the pin securing the float to the carburetor

body; then remove the float and needle valve
assembly.
GF326D
4-9
Disassembling
Carburetor
(VM-Style)
NOTE: On twin carburetor models unless there

is a problem with the safety switches, do not
loosen or remove the screws securing the switch
to the carburetor.
1. Remove the four screws and lock washers

securing the float chamber; then remove the float AH138
chamber and gasket.
4. Remove the needle valve retainer; then remove the
needle valve. Remove the seat and account for two
washers and a plate.
AH144
NOTE: The floats should be removed only if

replacement is necessary or the float chamber
B347
requires cleaning with carburetor cleaner.
5. Remove the main jet and baffle ring; then remove
2. Remove the caps from the float towers; then the main jet extender guide from the needle jet.
remove the floats. Remove the drain plug and O- Push the needle jet out through the top of the
ring. carburetor.
B344 AH084
3. Remove the float arm pin; then remove the float 6. Remove the pilot jet.
arm.
! CAUTION
Use care when removing the float arm pin or the
towers may break. Also, the pin must be
removed from its flattened side.
4-10
9. Remove the throttle cable from the piston valve;
then remove the valve.
B352
7. While counting the rotations for installing

purposes, rotate the pilot air screw clockwise until AH074
lightly seated; then remove the pilot air screw and
spring. 10. Remove the Phillips-head screw securing the
throttle cable retainer to the piston valve; then
remove the retainer. Account for the jet needle
with E-clip and two washers.
NOTE: Note the position of the E-clip on the jet
needle for assembly purposes.
B350
8. Remove the idle speed screw and spring.
AH042
! CAUTION
If an engine problem has been experienced due
to improper gas/air mixture, verify the carburetor
jetting and E-clip position with the Specification
Chart and Main Jet Chart on the snowmobile for
altitude, temperature, and type of gasoline.
11. Separate the starter plunger assembly from the

B351
choke cable by compressing the spring and
removing the plunger from the cable; then remove
the spring. Thread the plunger cap off the cable.
4-11
Disassembling
Carburetors
(TM-Style)
! CAUTION
Do not loosen the lever assembly from the
throttle lever shaft. If the lever assembly is
loosened, the carburetors must be synchronized.
AH615D
2. Loosen the screw securing the jet needle retaining

plate; then slide the plate out of the way.
AH631DA
NOTE: The carburetors do not have to be

removed to change jet needles or main jets; how-
ever, changing throttle valves requires removing
the funnel assemblies. The clearance between the
AH616DA
throttle valve, mixing body, and funnel assembly
(approximately 0.50 mm or 0.020 in.) is normal and
should not be a concern.
3. Using a pair of needle-nose pliers, remove the jet
needle assembly. Account for the E-clip and
washer.
AH622DA
NOTE: Disassemble the carburetors using this AH617D
basic procedure.
4. Remove the Phillips-head screw and the drain plug
(with O-ring) securing the float chamber to the
1. Loosen the screws (with washers) securing the top mixing body. Remove the chamber and account
cap to the mixing body; then slide the cap off the for the O-ring.
body. Account for the gasket.
4-12
AH618D AH621D
5. Remove the main jet (with washer), pilot jet, and NOTE: It may be necessary to use a spray lubri-
starter jet. cant such as WD-40 to aid in removing the float
assembly.
! CAUTION
To remove the throttle valve, the jet needle must
be removed or damage to the jet needle will
result.
8. Remove the Phillips-head screws securing the

funnel assembly to the mixing body.
4
AH619DA
6. Remove the screws securing the float assembly.
AH622DA
9. Move the throttle lever to the full-open position;

then remove the funnel assembly. Account for the
gasket.
AH620D
7. Remove the float assembly by lifting it up and out

of the mixing body. Account for the O-ring.
AH623D
10. Move the throttle lever slightly open; then rotate

the throttle valve out of the mixing body.
4-13
AH624D AH628D
11. While counting the rotations for installing

purposes, rotate the fuel mixture screw clockwise
until lightly seated; then remove the mixture
screw. Account for a rubber washer, washer, Cleaning Carburetor
spring, and cap.
! CAUTION ! CAUTION
Do not force a mixture screw when seating. DO NOT place any non-metallic components in
Forcing a mixture screw may result in damage to parts-cleaning solvent or carburetor cleaner
the screw taper and/or mixing body. because damage or deterioration will result.
1. Place all metallic components in a wire basket and

submerge in carburetor cleaner.
2. Soak for approximately 30 minutes; then rinse
with fresh parts-cleaning solvent.
3. Wash all non-metallic components with soap and
water. Rinse thoroughly.
4. Dry all components with compressed air only
making sure all holes, orifices, and channels are
unobstructed.
5. Blow compressed air through all hoses to remove
AH626D
any obstructions.
NOTE: In the following step, only one E-clip
needs to be removed to free the throttle valve from ! WARNING
the lever assembly.
Always wear safety glasses when drying compo-
12. Remove the E-clip securing the plate to the throttle nents with compressed air.
valve; then slide the throttle valve to one side and
remove. Account for the plate, washer, clip, and ! CAUTION
bushings.
DO NOT use wire or small drill bits to clean
carburetor orifices, holes, or channels. Distorted
or damaged orifices, holes, or channels can
result in poor carburetor operation.
AH627D
4-14
Inspecting Carburetor

necessary.
1. Inspect the mixing body for cracks, nicks, stripped

threads, and any other imperfections in the casting.
2. Inspect the piston/throttle valve for cracks, score
marks, or imperfections in the casting.
A739
3. On the VM-style, inspect the condition of the
piston valve spring. 12. On the BV-style, inspect the condition of the
throttle return spring.
4. Inspect the float for perforations or damage.
5. Inspect the gaskets, O-rings, and washers for
distortion, tears, or noticeable damage.
Assembling Carburetor
6. When applicable, inspect the tips of the idle speed (BV-Style)
screw, jet needle, pilot air screw, needle valve, and
fuel mixture screw for wear, damage, or distortion.
1. Install the nozzle and main jet into the carburetor
NOTE: On the VM-style when inspecting the inlet tower.
needle, inspect the side guides and tip for wear. If
the guides show any sign of wear, replace the inlet
4
needle.
7. Inspect the pilot jet and main jet for obstructions

or damage.
8. Inspect the starter plunger and seat for wear or
damage.
9. Inspect the carburetor mounting flanges for
damage and tightness.
! CAUTION
GF326D
An air leak between the carburetor and engine
will cause a lean condition and severe engine
damage will result.
10. On the TM-style, inspect the throttle shaft seal for

damage and signs of leaking.
11. On the BV-style, place the carburetor insulator on
a surface plate covered with #400 grit wet-or-dry
sandpaper. Move the insulator over the surface
plate using a figure eight motion. The motion
should produce an even wear pattern over the
entire sealing area.
! CAUTION GF325D
Water or parts-cleaning solvent must be used in 2. Place the needle valve assembly and the float into
conjunction with the wet-or-dry sandpaper or position and secure to the carburetor body with the
damage to the sealing surfaces may result. pin.
4-15
5. Install the pilot jet.
GF324D
GF320D
6. Install the high-speed adjuster screw and rotate the

screw clockwise until lightly seated; then rotate
the screw counterclockwise the proper number of
rotations as noted during disassembling.
GF323D
3. Install the splash ring onto the carburetor tower.
GF319D
Assembling Carburetor
(VM-Style)
1. Install the idle speed screw and spring.

GF322D
4. Secure the float chamber to the carburetor with the

drain bolt.
B351
2. Install the pilot air screw and spring. Rotate

clockwise until lightly seated; then turn
GF321D counterclockwise the same number of turns as
noted in disassembling for an initial setting.
4-16
B350 B347
6. Place the float arm into position and secure with

! CAUTION the pin.
DO NOT force the pilot air screw when seating.
Forcing the screw will result in damage to the
carburetor body.
3. Install the pilot jet.
4
AH138
7. Check the float arm height. Using a calipers,

measure the distance from the gasket surface to the
top of the float arm (with the carburetor inverted).
B352 If measurement is not within specifications, adjust
by bending the actuating tab.
4. Insert the needle jet into position from the top of
the carburetor making sure the groove in the
needle jet is aligned with the pin in the mixing
body; then place the jet extender, baffle ring, and
main jet into position and secure.
AH046
FLOAT ARM HEIGHT

VM-32/34 22-24 mm (0.86-0.94 in.)
AH084 VM-38 17-19 mm (0.66-0.74 in.)
5. In order, place a washer, plate, washer, and inlet 8. Place the O-ring and drain plug into position and
seat into position and secure. Install the inlet secure; then place the floats into position making
needle valve and secure with the retainer. sure the word UP is properly positioned. Press the
caps onto the float towers.
4-17
11. Place the cable retainer into the piston valve and
secure with the Phillips-head screw. Place the
spring and plate over the throttle cable and
compress the spring. Guide the cable end down
into the cable retainer slot and slide the cable end
to the center of the piston valve. Release the spring
and retainer plate to lock the cable in position.
B344
9. Place the gasket and float chamber into position

and secure with the four screws and lock washers
making sure the hose plates are properly
positioned on the two front screws. Install the vent
hoses.
AH075
NOTE: The round part of the cable end must

come through the hole in the plate. If it doesn't, the
cable isn't assembled to the piston valve correctly.
12. Thread the plunger cap onto the choke cable. Place
the spring over the cable end and compress.
Position the cable end into the starter plunger and
release the spring.
AH137
Assembling Carburetors
10. Place the E-clip into position on the jet needle. (TM-Style)
From the bottom of the jet needle, slide the E-clip
washer up against the E-clip. Place the jet needle
into the piston valve. Place an E-clip washer on 1. Place the throttle valve into the mixing body
the jet needle above the E-clip. making sure the cutaway faces the funnel
assembly side; then slide the bushing assembly/
NOTE: Place the E-clip in the proper position as plate onto the lever assembly. Secure the assembly
noted in disassembly. with the remaining bushings with clip, plate,
washer, and E-clip.
NOTE: When installing the throttle valve, the cut-
away must face the funnel assembly side.
725-266C
AH628D
4-18
AH627D AH622DA
2. Making sure the cap, spring, washer, and rubber 5. Accounting for the O-ring from disassembly,
washer are accounted for from disassembly, install install the float assembly by pressing in on the
the fuel mixture screw in the mixing body. screw mounting holes; then secure the float
assembly with the screws.
NOTE: It may be necessary to use a spray lubri-
cant such as WD-40 to aid in installing the float
assembly.
AH626D
3. Rotate the fuel mixture screw clockwise until

lightly seated; then rotate the mixture screw
counterclockwise the same number of turns as
noted in disassembling for an initial setting. AH621D
! CAUTION
Do not force the mixture screw when seating.
Forcing the mixture screw may result in damage
to the screw taper and/or mixing body.
4. Move the throttle lever to the full-open position;

then secure the funnel assembly w/gasket to the
mixing body.
AH620D
6. Install the starter jet, pilot jet, and main jet (with
washer).
AH623D
4-19
AH619DA AH616DA
7. Place the float chamber and O-ring into position 9. Place the top cap and gasket on the mixing body;
on the mixing body; then secure with the screw then secure with the screws (with washers).
and drain plug (with O-ring).
AH615D
AH618D
NOTE: If the lever assembly was loosened from
8. Place the washer and E-clip (above the washer) the throttle lever shaft, the carburetors must be
onto the jet needle; then install the jet needle synchronized.
assembly into the mixing body. Secure with the
retaining plate and screw.
Installing Carburetor
(BV-Style)
1. Place the carburetor into position on the mounting

studs accounting for a gasket, insulator block, and
a gasket.
AH617D
GF318D
2. Connect the rod and spring to the carburetor.
4-20
GF317D GF314D
3. Install the fuel supply hose on the carburetor.

4. Place the gasket and air cleaner housing into
position on the carburetor; then install the air
breather hose.
A002
4
6. Secure the air cleaner end cap to the air cleaner
with the wing nut.
GF316D position and check the fuel system for leakage.
8. Adjust the carburetors (see appropriate Adjusting
Carburetor in this sub-section).
Installing Carburetor
(VM-Style)
NOTE: On twin carburetor models, install the

carburetors using this basic procedure.
A001
1. Place the carburetor into position in the flange and
air-intake silencer boot; then tighten the flange
5. Place the air cleaner housing and carburetor on the clamp making sure the carburetor is level. Do not
engine and secure with the flanged nuts and cap over-tighten the flange clamp as it will damage the
screw. carburetor flange.
4-21
6. If applicable, connect the safety switch harness to
the main wiring harness.
position.
8. Adjust the carburetors (see appropriate Adjusting
Carburetors in this sub-section).
Installing Carburetors
AH103
(TM-Style)
NOTE: Slide the carburetor into the air-intake

silencer boot; then slide the carburetor into the 1. Prior to installing the carburetors, the carburetor
flange. throttle valves must be checked for
synchronization.
2. Connect the fuel hose to the carburetor inlet
fitting. A. With the throttle in the idle position, select a
small drill bit that will just fit under the
3. Thread the brass choke-cable housing into the cutaway of the fixed throttle valve.
carburetor making sure the washer is properly
positioned and tighten securely. B. Using the same drill bit, check the clearance
under the adjustable throttle valve cutaway. If
clearance is different from the first carburetor
checked, adjust the throttle valve by loosening
the lever ring locking screw; then using an
open-end wrench, rotate the synchronizing nut
in either direction until the clearance is the
same as the first carburetor checked.
AH099
4. Place the piston valve into position making sure

the full-length groove in the piston valve is aligned
with the pin in the mixing chamber bore.
0734-445
C. After synchronization has been attained, hold

the synchronizing nut with the open-end
wrench and tighten the lever ring locking
screw.
2. Place the carburetors (with float chamber vent
hoses) in the engine compartment and into the
carburetor boot; then tighten the clamps.
3. Connect the fuel supply hose to the fuel inlet T-
fitting.
AH100
5. Secure the mixing body top by tightening the 4. Connect the throttle cable and choke cables.
screw and lock washer making sure the mixing 5. At this point, there must be free-play gap in the
body top plate is properly positioned. throttle lever.
4-22
Adjusting
Carburetor
(BV-Style)
The carburetor has been calibrated for average riding

conditions; however, altitude, temperature, and general
wear may necessitate certain carburetor adjustments.
Since carburetor adjustments critically affect engine
performance, three external adjustments can be made
on the carburetor. These are the idle speed screw, pilot
733-081C
air screw, and throttle cable.
NOTE: If throttle cable free-play is incorrect, the

throttle safety switch will be activated prematurely
and the engine will not start.
NOTE: If cable free-play must be corrected, uti-

lize the jam nuts on the throttle cable bracket until
no free-play is attained.
6. Place the air-intake silencer into position in the

engine compartment making sure the carburetors
are properly positioned in the boot and secure with
screws.
7. Place the ignition coil/fuel pump mounting plate 0735-464
4
into position on the air-intake silencer and secure
with the machine screw and washer. IDLE SPEED SCREW
The idle speed screw controls the seating position of
the throttle valve which in turn determines the proper
idle speed. Rotate the screw clockwise to increase
engine idle speed and counterclockwise to decrease
engine idle speed.
PILOT AIR SCREW
The pilot air screw determines the fuel/air mixture for
idling. To adjust the pilot air screw, use the following
procedure:
1. Carefully rotate the pilot air screw clockwise until
a light “seating resistance” is felt.
AN613D
8. Adjust the carburetors (see appropriate Adjusting ! CAUTION

Carburetors in this sub-section). DO NOT force the pilot air screw when seating;
damage to the pilot air screw will result.
2. Rotate the pilot air screw counterclockwise 1 turn.

3. Start the engine and “fine tune” the pilot air screw
until the engine idles smoothly.
THROTTLE CABLE
The correct throttle cable adjustment is when (with the
engine OFF) the carburetor throttle is completely open
(against its limit) while the throttle lever lightly con-
tacts the handlebar grip. The throttle arm on the carbu-
retor should also contact the speed control screw when
the throttle lever is released.
4-23
To adjust the throttle cable, use the following proce-
dure: Adjusting
! WARNING Carburetor(s)
(VM-Style)
Do not attempt to adjust the throttle cable with the
engine running. Personal injury could result.
! CAUTION
1. Loosen the throttle cable wire binding screw.
The air-intake silencer and boots must be in
position whenever the engine is run. If the
silencer is removed and the engine is run, a lean
condition will result. Therefore, DO NOT run the
engine when the air-intake silencer is removed.
ADJUSTING CHOKE CABLE(S)
1. Be sure the ignition switch key is in the OFF

position and the brake lever lock is set.
2. Loosen the jam nut securing the choke cable
adjuster. Rotate the choke cable adjuster
clockwise until it bottoms against the brass
plunger cap.
0735-459
3. Slowly rotate the choke cable adjuster
2. Pull all slack from the throttle cable wire and exert counterclockwise while checking the choke lever
slight tension on the wire. for free-play. As soon as all free-play has been
removed from the end of the lever, stop rotating
3. Tighten the throttle cable wire binding screw. the adjuster.
! WARNING 4. With free-play removed from the lever, slowly

rotate the choke cable adjuster once again
DO NOT operate the snowmobile when any compo- clockwise while checking the choke cable lever
nent in the throttle system is damaged, frayed, for free-play. Adjust until 3 mm (1/8 in.) free-play
kinked, worn, or improperly adjusted. If the snow- between front bottom edge of lever and housing is
mobile is operated when the throttle system is not
functioning properly, personal injury could result. attained. Securely tighten the adjuster jam nut.
SPEED CONTROL SCREW

The maximum speed of the snowmobile can be
reduced by adjusting the speed control screw.
To reduce the maximum speed, rotate the speed con-
trol screw clockwise. DO NOT EVER INCREASE
THE MAXIMUM SPEED BEYOND THE ORIGI-
NAL 8 MPH MAXIMUM!
0732-848
5. On twin carburetor models, repeat steps 3 and 4 on

each carburetor.
NOTE: On twin carburetor models if a carburetor
choke cable is adjusted too tight, the engine will
only operate on 1 cylinder at idle.
4-24
ADJUSTING PISTON VALVE(S)
NOTE: On some models, the air-intake silencer

is a one-piece unit, and the silencer boot(s) can be
removed to access the intake bore(s). Remove the
boots; then proceed to step 4.
NOTE: On some models, the air-intake silencer

includes a cover/tool tray assembly and a baffle/
reso nator, an d the silencer boo t can not b e
removed to access the intake bores. Proceed to
step 1.
1. Open the air-intake silencer cover; then remove

the 3 Phillips-head screws securing the cover/tool 733-081C
tray assembly to the silencer. NOTE: If cable free-play gap is not correct, rotate
each swivel adapter an equal amount until recom-
2. Tip the cover/tool tray assembly forward and out mended free-play is achieved. Each piston valve
of its slots and remove the assembly. must be resting against the tip of its idle speed
screw.
3. Using a large flat-blade screwdriver, remove the
resonator tabs from the air-intake silencer slots NOTE: On twin carburetor models if throttle
and remove the resonator to access the intake cable free-play is incorrect, the carburetor safety
bores. switches will be activated prematurely and the
engine will not start.
NOTE: The resonator can be removed more eas-
ily by removing the back tabs first. 9. On some models, install the air-intake silencer
4. Rotate each idle speed screw counterclockwise
boot(s); on some models, install the baffle/
resonator and the cover/tool tray assembly. 4
until all spring tension is removed.
SYNCHRONIZING PISTON VALVES
5. Loosen the jam nut securing each throttle cable (Sight Glass Method)
swivel adapter; then rotate the swivel adapter
clockwise until the piston valve bottoms in the NOTE: Arctic Cat recommends using the Carbu-
piston valve bore. retor Synchronizer (p/n 0644-069). If the carburetor
synchronizer is not available, use the following
6. In turn on each carburetor, place a finger lightly procedure.
against the side of the piston valve; then rotate the
carburetor swivel adapter counterclockwise until 1. Compress the throttle lever until the dot in each
slight upward movement of the valve is noted. sight glass on the side of the carburetors is visible.
7. In turn on each carburetor, place a finger against 2. Rotate each swivel adapter until the dots are
either piston valve. Rotate the idle speed screw equally centered in each sight glass.
clockwise until it contacts the valve.
8. Compress the throttle lever to the full-open
position; then rotate each idle speed screw
clockwise 2 complete turns. Release the throttle
lever.
NOTE: On single carburetor models, the throttle
control is equipped with a 2-wire throttle control
sw itch connec tor. Th e re must be fr ee -p la y
between the lever and the control housing.
NOTE: On twin carburetor models, the throttle

control is equipped with a 3-prong emergency
stop switch connector. There must be free-play AH096A
between the lever and the control housing.
4-25
2. Tip the cover/tool tray assembly forward and out
of its slots and remove the assembly.
3. Using a large flat-blade screwdriver, remove the
resonator tabs from the air-intake silencer slots
and remove the resonator to access the intake
bores.
ily by removing the back tabs first.
4. Check to make sure the piston valves start to open

at the exact same moment by placing a thumb and
0000-084 finger against the valves; then lightly compress the
throttle lever.
NOTE: It is important that the dots are entirely
within sight glasses, are as equally centered as 5. With slight pressure being applied to the throttle
possible in the sight glasses, and that one dot is lever, the piston valves should start to open at the
not significantly higher or lower than another. exact same time. Compress and release the throttle
lever several times to assure accurate
3. With the piston valves synchronized, tighten the determination of piston valve opening.
swivel adapter jam nuts securely. Slide the rubber
throttle cable caps down over the swivel adapters. 6. If a piston valve starts to open before another,
rotate the swivel adapter on the valve which is
lifting first clockwise, just enough to synchronize
the valves. Recheck by repeating steps 4-6.
AH125
NOTE: There must be free-play in the throttle

lever. AH096A
! WARNING 7. Tighten the swivel adapter jam nuts securely.

Slide the rubber throttle cable caps down over the
Be sure to tighten the swivel adapter jam nuts swivel adapters.
securely. If a swivel adapter jam nut is not tight-
ened, the adjuster can rotate out of the carburetor
cap causing the piston valve not to return to the
full-closed position.
SYNCHRONIZING PISTON VALVES

(Mechanical Method)
NOTE: Arctic Cat recommends using the Carbu-

retor Synchronizer (p/n 0644-069). If the carburetor
synchronizer is not available, use the following
procedure.

the 3 Phillips-head screws securing the cover/tool
AH125
tray assembly to the silencer.
4-26
NOTE: There must be free-play in the throttle NOTE: Make engine idle adjustment only after
lever. the engine has reached running temperature.
Since the idle speed screw(s) have not been
adjusted, apply slight throttle pressure to keep the
! WARNING engine running. Allow engine to warm up for 2-3
minutes.
Be sure to tighten the swivel adapter jam nuts
securely. If a swivel adapter jam nut is not tight-
ened, the adjuster can rotate out of the carburetor 2. On twin carburetor models after the engine has
cap causing the piston valve not to return to the been allowed to warm up for 2-3 minutes, adjust
full-closed position. engine idle by first rotating the PTO-side
carburetor idle speed screw clockwise until the
8. After synchronization has been attained, install the tachometer reads 1480 RPM.
resonator and cover/tool tray assembly.
3. On twin carburetor models, rotate the MAG-side
ADJUSTING PILOT AIR SCREW(S) carburetor idle speed screw clockwise until
tachometer reads 1500 RPM.
1. While counting the rotations, carefully rotate each
pilot air screw clockwise until lightly seated.
4
AH055
AH006 4. On twin carburetor models, rotate the PTO-side

carburetor idle speed screw clockwise until the
tachometer reads slightly above 1500 RPM; then
! CAUTION rotate the idle speed screw counterclockwise to
Do not force a pilot air screw when rotating it achieve exact 1500 RPM reading. The piston
clockwise; damage to the pilot air screw needle valves should now be synchronized and the engine
tip will result. should idle without holding any throttle pressure.
2. Rotate each pilot air screw counterclockwise the NOTE: If the engine has no ignition spark with
same number of turns as noted in step 1 for an the throttle in the idle position but has proper
initial setting. spark with the throttle lever slightly compressed,
the carburetor safety switches must be reposi-
3. Synchronize the oil-injection pump (see Related tioned.
Items in this section).
5. Test the throttle control lever by compressing and
ADJUSTING ENGINE IDLE SPEED releasing it several times. The lever must return to
the idle position quickly and completely.
1. With the snowmobile on a shielded safety stand,
start the engine, release the brake lever lock, and ! WARNING
thoroughly warm up. Fine-tune each idle speed
screw and each pilot air screw until the engine DO NOT operate the snowmobile when any compo-
idles smoothly at the desired RPM (1500 RPM is nent in the throttle system is damaged, frayed,
recommended). kinked, worn, or improperly adjusted. If the snow-
functioning properly, personal injury could result.
4-27
ADJUSTING CHOKE CABLE (Triple)
Adjusting Carburetors 1. Be sure ignition switch key is in the OFF position
(TM-Style) and the brake lever lock is set.
2. Loosen the jam nuts securing the choke cable to
! CAUTION the bracket at the carburetor.
The air-intake silencer and boots must be in
position whenever the engine is run. If the
silencer is removed and the engine is run, a lean
condition will result. Therefore, DO NOT run the
engine when the air-intake silencer is removed.
ADJUSTING CHOKE CABLES (Twin)
1. Be sure ignition switch key is in the OFF position

and the brake lever lock is set.
2. Loosen the jam nut securing each choke cable
adjuster on the side of the carburetor.
0735-857
3. Slowly rotate one jam nut while checking the

choke lever for free-play. As soon as all free-play
has been removed from the end of the choke lever,
stop rotating the jam nut.
4. With free-play removed from the lever, slowly
rotate the jam nut again while checking the choke
lever for free-play. Adjust until 3 mm (1/8 in.)
free-play between front bottom edge of lever and
housing is attained. Securely tighten the jam nuts.
SYNCHRONIZING THROTTLE VALVES
0735-774
3. Slowly rotate one choke cable adjuster while the 3 Phillips-head screws securing the cover/tool
checking the choke lever for free-play. As soon as tray assembly to the silencer.
all free-play has been removed from the end of the
choke lever, stop rotating the adjuster. 2. Tip the cover/tool tray assembly forward and out
of its slots and remove the assembly.
4. With free-play removed from the lever, slowly
rotate the adjuster again while checking the choke 3. Using a large flat-blade screwdriver, remove the
lever for free-play. Adjust until 3 mm (1/8 in.) resonator tabs from the air-intake silencer slots
free-play between front bottom edge of lever and and remove the resonator to access the intake
housing is attained. Securely tighten the jam nut. bores.
ily by removing the back tabs first.
4. With the throttle in the idle position, select a small

drill bit that will just fit under the cutaway of the
fixed throttle valve.
5. Using the same drill bit, check the clearance under
each adjustable throttle valve cutaway. If
clearance is different from the first carburetor
checked, adjust the throttle valve by loosening the
lever ring locking screw; then using an open-end
wrench, rotate each synchronizing nut in either
0732-848 direction until the clearance is the same as the first
carburetor checked.
5. Repeat steps 3 and 4 on the other carburetor.
4-28
ADJUSTING AIR SCREWS
1. While counting the rotations, carefully rotate the

air screws clockwise until lightly seated.
! CAUTION
Do not force an air screw when rotating it
clockwise; damage to the air screw will result.
2. Rotate the air screws counterclockwise the exact

number of rotations ± 1/4 turn from the seated
position as an initial setting.
0734-445
ADJUSTING ENGINE IDLE SPEED
6. After synchronization has been attained, hold the
synchronizing nut with the open-end wrench and NOTE: Make engine idle adjustment only after
tighten the lever ring locking screw. the engine has reached running temperature.
Since the idle speed screw has not been adjusted,
apply slight throttle pressure to keep the engine
7. Install the resonator and cover/tool tray assembly. running. Allow engine to warm up for 2-3 minutes.
ADJUSTING FUEL MIXTURE SCREWS
1. After the engine has been allowed to warm up for
1. While counting the rotations, carefully rotate the 2-3 minutes, fine-tune the idle speed screw until
fuel mixture screws clockwise until lightly seated. the tachometer reads 1500 RPM.
2. Test the throttle control lever by compressing and
releasing it several times. The lever must return to
the idle position quickly and completely. 4
! WARNING
DO NOT operate the snowmobile when any compo-
nent in the throttle system is damaged, frayed,
kinked, worn, or improperly adjusted. If the snow-
functioning properly, personal injury could result.
0735-774
Throttle Cable
(BV-Style)
REMOVING AND INSPECTING
1. Remove the C-clip securing the lever pin in the

throttle lever; then remove the pin and the lever.
0735-857
! CAUTION
Do not force a fuel mixture screw when rotating it
clockwise; damage to the mixture screw taper
may result.
2. Rotate each fuel mixture screw counterclockwise A979

the same number of turns as noted in step 1 for an
initial setting. 2. Disconnect the throttle cable from the lever; then
slide the cable out of the lever.
4-29
A980 0735-459
3. Remove the C-clip securing the cable in the 6. Inspect the throttle cable for damage or fraying.
throttle control; then remove the cable from the
throttle control. INSTALLING
1. Route the cable through the slot in the throttle

control and insert the cable into the throttle
control. Secure the cable with a C-clip.
A981
A981
2. Seat the cable drum into the throttle lever recess;

then secure the throttle lever to the throttle control
with a pin and C-clip.
A982
4. Remove the handlebar pad and cut the cable tie

securing the throttle cable to the steering post.
NOTE: Note the location of the cable tie for
assembly.
5. Loosen the throttle cable binding screw; then A980

loosen the throttle cable jam nuts and remove the
throttle cable.
4-30
NOTE: The speed control screw is designed to
reduce the maximum speed of the snowmobile.
! WARNING
DO NOT operate the snowmobile when any compo-
nent in the throttle system is damaged, frayed,
kinked, worn, or improperly adjusted.
Throttle Cable
A979 (VM-Style)
3. Place the throttle cable into the throttle cable
bracket and secure with jam nuts. NOTE: Determine which type of cable is being
replaced and remove and install accordingly.
4. Slide the tip of the throttle cable into the throttle
actuator and tighten the binding screw. REMOVING
5. Secure the throttle cable to the steering post with a KEY

cable tie; then install the handlebar pad. 1. Retaining Ring
2. Throttle Cable
NOTE: At this point, spray the binding screw 3. Cable Tie
drum (located on the carburetor throttle arm) with 4. E-Ring
WD-40 or an equivalent lubricant. 5. Washer
ADJUSTING
6. Nut
4
1. The correct throttle cable adjustment is when (with
the engine OFF) the carburetor throttle is
completely open (against its limit) while the
throttle control lever lightly contacts the hand grip.
The throttle arm on the carburetor should also 734-533A
contact the throttle stop screw when the throttle
control is released. Adjust by using the following
procedure. KEY
1. Retaining Clip
2. Throttle Cable
2. Loosen the throttle cable wire binding screw. 3. E-Ring
4. Washer
5. Cable Tie
6. Jam Nut
736-742A
1. Loosen the throttle cable adjuster jam nuts.

2. Remove the mixing body tops.
0735-459
3. Remove the throttle cables from the piston valves.
3. Pull all slack from the throttle cable wire and exert
slight tension on the wire. 4. Remove the throttle cables from the mixing body
tops.
4. Tighten the throttle cable wire binding screw.
5. Remove the handlebar pad and console.
6. Remove the cable ties securing the throttle cable.
7. Remove the throttle cable end from the throttle
lever.
4-31
8. Using Throttle Cable Removal Tool (p/n 1639-
963), push down on the throttle cable retaining
clip; then remove the cable from the throttle
Throttle Cable
switch assembly. (TM-Style)
NOTE: On twin carburetor models, it may be nec-

essary to remove the PTO-side carburetor. KEY
1. Retaining Clip
2. Throttle Cable
9. Remove the E-ring securing the oil-injection cable 3. E-Ring
to the control arm. Account for a washer. 4. Washer
5. Cable Tie
10. Loosen the jam nut securing the adjustment cable; 6. Jam Nut
then remove the cable from the oil-injection pump.
INSTALLING
1. Route the throttle cable from the throttle switch

assembly to the carburetors and oil-injection
pump; avoid any sharp bends or moving parts.
735-869A
2. Install the oil-injection adjustment cable on the
REMOVING
oil-injection pump; secure with the jam nuts.
1. Loosen the throttle cable adjuster jam nut at the
3. Install the oil-injection cable on the control arm; bracket.
secure with a washer and E-ring.
2. Remove the throttle cable from the pulley on the
NOTE: Install the PTO-side carburetor if removed. throttle lever shaft.
4. Install the throttle cable into the throttle switch 3. Remove the handlebar pad and console.
assembly making sure it snaps into place.
4. Remove the throttle cable from the throttle lever.
5. Install the throttle cable end on the throttle lever.
6. Secure the throttle cable to the steering post with 963), push down on the throttle cable retaining
cable ties. clip; then remove the cable from the throttle
switch assembly.
7. Install the handlebar pad and console.
6. Open the belt guard; then remove the drive belt.
8. Attach the throttle cable to each throttle valve. The
valve must seat in the groove of the throttle cable 7. Remove the oil-injection cable from the control
end; then thread the throttle cable into each mixing arm.
body top.
NOTE: Some models are equipped with “control
9. Install each piston valve and mixing body top on rod” actuated oil pump. The control rod simply
the carburetor(s). Tighten securely. snaps off and on at the control arm.
10. Adjust the carburetor(s) (see appropriate 8. Loosen the jam nut securing the adjustment cable;
Adjusting Carburetors in this sub-section). then remove the cable from the oil-injection pump.
! CAUTION INSTALLING
Compress the throttle control lever to ensure 1. Install the oil-injection adjustment cable on the
free movement. If the throttle cable sticks or oil-injection pump; secure with the jam nuts.
binds, correct the problem before starting the
engine. 2. Install the oil-injection cable on the control arm.
11. Synchronize the oil-injection pump (see Related 3. Route the throttle cable from the carburetor to the
Items sub-section). throttle switch assembly making sure it snaps into
place.
4-32
4. Remove the screws securing the console.
! CAUTION
5. Position the choke lever in the middle-choke
Avoid any sharp bends and hot or moving position; then remove the knurled nut securing the
components or damage may occur. choke lever housing to the console.
4. Install the throttle cable on the throttle lever.
5. Install the handlebar pad and console.
6. Install the throttle cable into the throttle lever shaft
pulley.
7. Install the throttle cable into the bracket; then
adjust the jam nut to attain no free-play between
the throttle lever and the control housing.
NOTE: There must be no free-play between the
lever and the control housing.
725-001A
! CAUTION
Compress the throttle control lever to ensure 6. Slide the choke lever housing from the console.
free movement. If the throttle cable sticks or
binds, correct the problem before starting the 7. Cut any cable ties used to secure the choke cable
engine. and remove the choke cable from the engine
compartment.
8. Synchronize the oil-injection pump (see Related
Items sub-section). INSTALLING
4
1. Position the choke lever in the middle-choke
9. Install the drive belt; then close and secure the belt position; then from the back side of the console,
guard. insert the choke lever housing through the console.
Secure with the knurled nut.
2. Route the choke cable from the console to each
Choke Cable carburetor; avoid any sharp bends or moving parts.
(VM-Style) 3. Install each brass choke cable housing onto the
cable end; then install each spring and brass
REMOVING plunger.
1. Bend down the lock tabs locking each brass choke 4. Place the lock tab washer on each brass housing
cable housing on each carburetor. and insert a choke plunger into each carburetor.
2. Using a 12-mm wrench, remove each brass choke 5. Thread each brass choke cable housing into each
cable housing from each carburetor. Account for carburetor and tighten. Bend the lock tab up to
the lock tab washers. secure the brass housing. Adjust the choke cable
(see appropriate Adjusting Carburetors in this sub-
3. Remove each brass plunger and spring from the section).
cable end; then remove each brass choke cable
housing. 6. Place the console into position and secure with the
screws.
4-33
INSTALLING
Choke Cable 1. Position the choke lever in the middle-choke
(TM-Style) position; then from the back side of the console,
insert the choke lever housing through the console.
Secure with the knurled nut.
REMOVING
2. Route the choke cable from the console to the
1. Loosen the jam nuts securing the choke cable to carburetors; avoid any sharp bends or moving
the bracket. parts.
2. Remove the cable from the starter plunger lever. 3. Install the choke cable into the bracket; then
secure with jam nuts making sure the choke lever
3. Position the choke lever in the middle-choke has 3 mm (1/8 in.) free-play between the edge of
position; then remove the knurled nut securing the the lever and the housing.
choke housing to the console.
732-848B
725-001A
4. Place the console into position and secure.
4. Remove the console.
5. Slide the choke cable from the console.
4-34
2002 CARBURETOR SPECIFICATIONS
(Production)
PILOT AIR FUEL MIXTURE

MODEL TYPE MAIN JET NEEDLE JET JET NEEDLE PILOT JET CUTAWAY SCREW SCREW
(TURNS OUT) (TURNS OUT)
Pantera 550 VM-38 340 P-2 (480) 6DH8-3 40 3.0 1 -
Panther 440 VM-34 280 P-4 (480) 6DH2-3 35 2.5 1 -
Z 370/370 es VM-32 250 P-6 (159) 6DH7-3 40 2.5 1 -
Z 440/440 es VM-34 280 P-4 (480) 6DH2-3 35 2.5 1 -
Z 570 VM-34 250 P-2 (480) 6DF7-3 40 2.5 1 3/4 -
ZL 500 TM-38 330 (Fixed) 9EH6-58-3 40 3.5 1 1/2 2
ZL 550/550 esr VM-38 340 P-2 (480) 6DH8-3 40 3.0 1 -
ZR 500 TM-38 330 (Fixed) 9EH6-58-3 40 3.5 1 1/2 2
ZR 600 TM-38 330 (Fixed) 9DFH4-60-3 40 3.0 1 1/2 2
Bearcat Wide Track VM-38 340 P-2 (480) 6DH8-3 40 3.0 1 -
Panther 570 VM-34 250 P-2 (480) 6DF7-3 40 2.5 1 3/4 -
ZRT 600 TM-36 310 (Fixed) 9DH2-59-4 45 2.5 1 1
Thundercat TM-38 320 (Fixed) 9DFH3-56-3 35 3.0 1 1/2 2
ZR 800 TM-40 430 (Fixed) 9DFH2-59-4 50 3.0 2 2
Mountain Cat 570* VM-34 200 P-2 (480) 6DF7-1 40 2.5 1 1/2 -
Mountain Cat 800* TM-40 350 (Fixed) 9DFH2-59-2 50 3.0 1 3/4 1 1/2
4
Mountain Cat 500* TM-38 250 (Fixed) 9EH6-58-2 40 3.5 1 2
Mountain Cat 1000* TM-38 260 (Fixed) 9DFH2-58-3 35 3.0 1 1 3/4
*Initially set up at the factory for operation between 5000-9000 feet
THROTTLE PILOT SCREW

MODEL TYPE MAIN JET MAIN AIR JET PILOT OUTLET PILOT JET VALVE (TURNS OUT)
ZR 120 BV-18 77.5 1.5 1.0 42.5 130 1
4-35
MIKUNI TUNING COMPONENTS
MAIN JETS AVAILABLE NEEDLE JETS AVAILABLE(VM-Style)
JET P/N JET P/N NEEDLE P/N NEEDLE P/N
120 6505-270 390 6505-078 JET JET
130 6505-216 400 6505-124 O-6 (480) 6505-931 Q-2 (480) 6505-641
140 6505-217 410 6505-212 O-8 (182) 6505-181 Q-3 (480) 6505-599
150 6505-168 420 6505-125 O-8 (480) 6505-824 Q-4 (166) 6505-214
160 6505-064 430 6505-146 P-0 (159) 6505-155 Q-4 (480) 6505-636
170 6505-065 440 6505-126 P-0 (166) 6505-007 Q-5 (159) 6505-119
180 6505-056 450 6505-147 P-0 (169) 6505-051 Q-5 (166) 6505-520
190 6505-066 460 6505-127 P-0 (480) 6505-598 Q-5 (480) 6505-580
200 6505-144 470 6505-148 P-2 (480) 6505-595 Q-6 (166) 6505-506
210 6505-145 480 6505-149 P-4 (159) 6505-221 Q-8 (480) 6506-112
220 6505-137 490 6505-150 P-4 (166) 6505-502 R-0 (166) 6505-505
230 6505-067 500 6505-151 P-4 (480) 6505-540 Z-4 (224) 6505-808
240 6505-079 520 6505-530 P-4 (169) 6505-164 Z-5 (224) 6505-541
250 6505-068 530 6505-170 P-5 (480) 6505-542 Z-6 (224) 6505-597
260 6505-017 540 6505-531 P-6 (159) 6505-247 Z-8 (224) 6505-572
270 6505-069 560 6505-172 P-6 (166) 6505-268 Z-9 (224) 6505-618
280 6505-080 580 6505-211 P-6 (480) 6505-539 AA-0 (224) 6505-544
290 6505-123 590 6505-173 P-6 (251) 6505-235 AA-1 (224) 6505-609
300 6505-128 600 6505-532 P-8 (159) 6505-298 AA-2 (224) 6505-545
310 6505-136 620 6505-174 P-8 (166) 6505-433 AA-3 (224) 6505-604
320 6505-074 640 6505-533 P-8 (480) 6505-543 AA-4 (224) 6505-605
330 6505-070 650 6505-534 Q-0 (159) 6505-260 AA-5 (224) 6505-099
340 6505-076 660 6505-535 Q-0 (166) 6505-190 AA-8 (224) 6505-571
350 6505-071 680 6505-169 Q-0 (480) 6505-529 BB-0 (224) 6505-182
360 6505-038 700 6505-536 Q-2 (166) 6505-508 BB-5 (224) 6505-180
370 6505-072 710 6505-537
380 6505-077 720 6505-538 JET NEEDLES AVAILABLE
JET P/N JET P/N
PISTON VALVES AVAILABLE NEEDLE NEEDLE
(VM-Style) (VM-Style) (TM-Style)
SLIDE CARBURETOR P/N 6CH3 6505-519 9CFH1-56 6506-116
SIZE (mm) 6DH2 6505-252 9DH2-59 6506-110
2.0 28-30 6505-048 6DH3 6505-509 9DH5-61 6506-114
3.0 28-30 6505-161 6DH4 6505-003 9DEH1-55 6506-118
3.0 30 6505-510 6DH7 6505-215 9DEH2-57 6506-115
3.5 30 6505-528 6DH8 6505-236 9EGY01-57 6506-192
1.5 32-34 6505-256 6DF7 6506-297 9EH09 6506-173
2.5 32-34 6505-246 7DJ2 6505-549 9EH2-57 6506-111
3.0 32-34 6505-439 7DH2 6505-097 9EH6-60 6506-117
3.5 32-34 6505-248 7DH5 6505-814 9EH7-62 6506-113
2.5 34 6505-500 9DFH2-58 6506-200
2.5 34 6505-614* 9DFH2-59 6506-201
3.0 34 6505-507 9DFH3-56 6506-186
3.0 34 6505-561* 9DEH3 6506-182
2.0 36 6505-877 9DFH1-56 6506-221
3.0 36 6505-592* 9EH6-59 6506-228
2.5 38 6505-254 9DH9-54 6506-272
3.0 38 6506-643* 9EH6-58 6506-290
3.5 38 6505-436 9DFH4-60 6506-260
3.5 38 6505-525
3.5 38 6505-526 INLET NEEDLE ASSEMBLIES AVAILABLE
3.5 38 6505-554 (VM-Style)
3.5 38 6505-613* SEAT DIA. CARB. SIZE P/N
4.0 38 6505-504 (mm)
3.5 40 6505-575* 1.5 mm (Steel) 28, 30, 32, 34 6505-026
1.0 40-44 6505-092 1.5 mm (Viton) 28, 30, 32, 34 6505-160
2.0 40-44 6505-179 1.5 mm (Steel) 28 — 34 GVM 6505-245
2.5 40-44 6505-570 1.5 mm (Steel) 36, 38, 40, 44 6505-103
3.5 40-44 6505-548 1.5 mm (Viton) 36, 38, 40, 44 6505-171
3.0 40-44 6506-809 1.8 mm (Viton) 36, 38, 40, 44 6505-175
3.5 40-44 6505-813* 2.0 mm (Viton) 36, 38, 40, 44 6505-176
THROTTLE VALVES AVAILABLE INLET NEEDLE ASSEMBLIES AVAILABLE

(TM-Style) (TM-Style)
SLIDE CARBURETOR P/N SEAT DIA. CARB. SIZE P/N
SIZE (mm) (MM)
2.0 38 6506-119 1.5 mm (Steel) 38 6506-121
3.0 38 6506-120 1.8 mm (Steel) 38 6506-144
3.0 38 6506-232
3.5 38 6506-210 PILOT JETS AVAILABLE
2.5 40 6506-273 JET NO. P/N JET NO. P/N
* For models with carburetor switch. 17.5 6505-218 35 6505-029
20 6505-138 40 6505-047
22.5 6505-310 45 6505-278
25 6505-075 50 6505-262
27.5 6505-503 52.5 6505-261
30 6505-073 55 6505-255
4-36
MAJOR TUNING COMPONENTS
To assist you in selecting four major tuning components of the VM-style and TM-style carburetors, listed
below are the jet needles, needle jets, pilot jets, and piston/throttle valves (slides) on charts according to
their size.
PILOT
TUNING1
NOTE: The above needle jets may come in differ- PISTON

ent types; for example, (159) - (166) - (480) - (224).
When selecting a new needle jet, use the correct
series or type.
JET
NOTE: The above chart shows the average per-

formance of a given needle between 1/4 and 3/4
throttle. Needles are constructed in such a way
that at any given point, the needle could be richer
or leaner than the rating it has.
4-37
Troubleshooting
Fuel System
(Carbureted)
Problem: Carburetor Too Rich (0-1/4 Opening)

Condition Remedy
1. Choke plunger will not seat 1. Adjust — service — replace choke cable —
plunger assembly
2. Pilot air screw (VM-style) too far in 2. Adjust pilot air screw
3. Fuel mixture screw (TM-style) too far out 3. Adjust fuel mixture screw
4. Pilot air passage obstructed — damaged 4. Remove obstruction — replace pilot air screw
— carburetor
5. Float/inlet needle obstructed — damaged — 5. Remove obstruction — replace inlet needle
adjusted incorrectly
— float — adjust float tab
6. Pilot jet loose
6. Tighten pilot jet
Problem: Carburetor Too Rich (1/4-3/4 Opening)
Condition Remedy
1. Pilot air screw (VM-style) too far in 1. Adjust pilot air screw
2. Fuel mixture screw (TM-style) too far out 2. Adjust fuel mixture screw
3. Needle jet — jet needle worn — adjusted 3. Replace needle jet — replace — adjust jet
incorrectly — incorrect needle E-clip
4. Pilot air passage obstructed — damaged 4. Remove obstruction — replace pilot air screw
— carburetor
5. Pilot jet loose 5. Tighten pilot jet
6. Float/inlet needle obstructed — damaged — 6. Remove obstruction — replace inlet needle —
adjusted incorrectly float — adjust float tab
7. Main jet loose — too large 7. Tighten — replace main jet
8. Primary air passage obstructed 8. Remove obstruction
Problem: Carburetor Too Rich (3/4-WOT Opening)
Condition Remedy
1. Main jet loose — too large 1. Tighten — replace with smaller main jet
3. Needle jet — jet needle worn — adjusted 3. Replace needle jet — replace — adjust jet
incorrectly — incorrect needle E-clip
4-38
Problem: Carburetor Too Lean (0-1/4 Opening)
Condition Remedy
1. Choke plunger remains seated 1. Adjust — service choke cable — plunger
assembly
2. Pilot air screw (VM-style) too far out — 2. Adjust — replace pilot air screw
damaged
3. Fuel mixture screw (TM-style) too far in — 3. Adjust — replace fuel mixture screw
damaged
4. Throttle valve sticks open — damaged — worn 4. Service — replace throttle valve — throttle
cable — spring
5. Pilot jet — outlet obstructed 5. Remove obstruction
kinked — damaged
Problem: Carburetor Too Lean (1/4-3/4 Opening)
Condition Remedy
1. Pilot air screw (VM-style) too far out — 1. Adjust — replace pilot air screw
damaged
2. Fuel mixture screw (TM-style) too far in — 2. Adjust — replace fuel mixture screw
damaged
3. Needle jet obstructed
4. Pilot jet — outlet — main jet obstructed
3. Remove obstruction
4. Remove obstruction
4
6. Jet needle E-clip position incorrect 6. Adjust E-clip
kinked — damaged
Problem: Carburetor Too Lean (3/4-WOT Opening)
Condition Remedy
1. Main jet obstructed — too small 1. Remove obstruction — replace with larger main
jet
3. Needle jet — jet needle obstructed 3. Remove obstruction
4. Float chamber vent hose (TM-style) 4. Service — replace float chamber vent hose
obstructed — kinked — damaged
Problem: General Fuel System (Engine Cuts Out at High RPM)
Condition Remedy
1. Fuel delivery inadequate 1. Repair — replace fuel pump — impulse hose
3. Gasoline contaminated 3. Replace gasoline — de-ice — clean carburetors
Problem: General Fuel System (One Cylinder Runs Lean)
Condition Remedy
1. Carburetor-to-cylinder air leak 1. Repair — replace gaskets — flanges — service
intake ports — tighten clamps
2. Carburetors (VM-style) not aligned vertically 2. Align carburetors vertically
3. Primary compression (crankcase) low 3. Troubleshoot engine
4. Carburetors not synchronized 4. Synchronize carburetors
4-39
The electrical control unit (ECU) has a self-diagnostic
Fuel System mode built in. It is a very valuable factor in trouble-
shooting. Once the problem area has been determined
(Batteryless EFI) from the trouble code flashed by the LED (light emit-
ting diode) located under the left end of the ECU, fol-
low the troubleshooting procedure in this sub-section.
This sub-section has been organized for servicing EFI
fuel systems; however, some components may vary When troubleshooting the batteryless EFI system, spe-
from model to model. The technician should use dis- cial tools are required. These special tools are the fol-
cretion and sound judgment when removing/ disas- lowing.
sembling and assembling/installing components.
A. EFI Analyzer (p/n 0644-212)
All 2002 EFI models are equipped with the batteryless
EFI system. B. Fuel Pressure Tester (p/n 0644-203)
NOTE: Some illustrations and photographs used C. Fluke Model 73 Multimeter (p/n 0644-191)
and are not designed to depict actual conditions. D. Peak Voltmeter (p/n 0644-300)
If the EFI analyzer at your dealership was purchased
before February 1, 1998, it must be updated with an
Update Kit (p/n 0644-256) before it can be used to
Fuel System troubleshoot any of the 1997-2002 batteryless EFI
(Batteryless EFI) models (without the Arctic Power Valve System). The
Table of Contents update kit consists of a wiring harness and a new
EPROM chip. The update kit can be ordered from your
distributor or the Arctic Cat Parts Department.
Introduction ........................................................... 4-40
Arctic Cat Batteryless EFI System ........................ 4-41 NOTE: Troubleshooting EFI engines with the
Individual EFI Components ................................... 4-42 APV system should be done with the Arctic Cat
Self-Diagnostic EFI System .................................. 4-45 EFI Analyzer (p/n 0644-342). To update your exist-
Trouble Codes ....................................................... 4-46 ing EFI Analyzer, order Kit (p/n 0644-341).
ECU ...................................................................... 4-47
Testing Individual Components ............................. 4-48
EFI Analyzer.......................................................... 4-51
Recommended EFI Troubleshooting Sequence
(Kokusan Mode)................................................. 4-53
Testing Individual EFI Components....................... 4-54
Peak Voltage Tests and Specifications
(2002 Models) .................................................... 4-56
Throttle Position Sensor ........................................ 4-57
Throttle Body Flange............................................. 4-57
Throttle Body Assembly ........................................ 4-58
Throttle Cable........................................................ 4-59
Basic EFI System Information............................... 4-60
EFI Component Voltage/Resistance Chart -
Air Temperature ................................................. 4-61
EFI Component Voltage/Resistance Chart -
Water Temperature ............................................ 4-62 AE131
EFI EPROM Chip Usage Chart (1991-1998) ........ 4-63
EFI EPROM Chip Usage Chart (1999-2001) ........ 4-64
Troubleshooting Fuel System (EFI)....................... 4-64
EFI Wiring Diagrams ............................................. 4-65
Introduction
The batteryless EFI system is lightweight in design
and is made up of a number of components which are
explained in this sub-section. The batteryless EFI sys-
tem eliminates the worry of battery maintenance or
AE124
changing main jets to compensate for altitude or tem-
perature. This EFI system will provide quick and easy
starting under all conditions.
4-40
4. A lighting coil located on the stator plate provides
output to operate accessories and the lighting
system.
5. An electrical control unit (ECU) calculates input
from five sensors (intake air temperature sensor,
water temperature sensor, throttle position sensor,
ignition timing sensor, barometric pressure sensor)
to provide the engine with the correct fuel mixture
and timing for optimum operation.
EFI FEATURES
AE114
1. Automatic compensation for temperature.
2. Automatic compensation for altitude.
3. Optimum throttle response through high pressure
injection.
4. Quick starting in every condition.
5. Improved fuel efficiency with maximum mileage
in every condition.
6. Engine RPM more stable in every condition.
PRECAUTIONS
4
AE141
! WARNING
Whenever working on the fuel system if a fuel hose
is removed from any component, slowly bleed the
Arctic Cat Batteryless pressure from the hose into an absorbent towel
before removing the hose from the component.
EFI System
! WARNING
The Arctic Cat Batteryless EFI System operates off a Always tighten fuel hose clamps securely.
series of coils located on the stator.
The batteryless EFI system is made up of the follow-
ing components.
1. Charge coils (1 and 2) which are located on the
stator provide AC voltage to operate the CDI unit.
The CDI unit is located within the ECU. The AC
voltage is converted to DC voltage within the
ECU.
2. A fuel pump coil located on the stator operates the
low voltage, high output fuel pump. At cranking
speed, the high output fuel pump provides enough
fuel to charge the fuel rail.
0729-325
3. An injector coil located on the stator provides the
injectors with DC voltage for operation through ! CAUTION
the ECU.
Always use resistor-type spark plugs and spark
plug caps. Non-resistor components will cause
the ECU to malfunction.
4-41
STARTING 1. Ignition Timing Sensor
1. To start an engine for the first time or after 2. Intake Air Temperature Sensor
performing service work on the fuel system, place
the emergency stop switch and the ignition switch 3. Water Temperature Sensor
in the ON position. Disconnect the yellow water
temperature sensor lead wire at the ECU. Crank 4. Throttle Position Sensor
the engine over 6-8 times with the recoil starter.
With the water temperature sensor lead 5. Barometric Pressure Sensor
disconnected, the fuel system will call for
maximum mixture and the system will charge The fuel is first drawn into the electric fuel pump
faster. After 6-8 brisk pulls on the recoil starter through two pick-up valves and hoses. The fuel is then
rope, reconnect the yellow sensor lead. The engine routed through a high-pressure fuel hose to the fuel
should start in 2-3 additional pulls. After charging rail.
the fuel system, the engine should start in 3-4 pulls
when cold. The fuel pressure is maintained at 37.9 ± 2.2 psi (600
cc) and 48 ± 2.2 psi (800 cc) in the fuel rail by the fuel
2. Start the engine without compressing the throttle. regulator. If pressure exceeds this amount, the regula-
When the engine starts for the first time, do not tor opens and returns excess fuel to the gas tank
touch the throttle. It will idle slowly and may stop. through the fuel return hose (600 cc).
Repeat this procedure until the engine starts and
builds RPM on its own. This may require 3-4 With the fuel pressure maintained at a constant psi, the
restarts. Once the engine has been started and run, ECU evaluates the information it receives from the
the next cold start should occur in 2-3 pulls of the five electrical sensors and opens the injectors for pre-
recoil starter rope. cise periods of time (pulse widths) to meet engine
demands.
FLOODED ENGINE
NOTE: The entire EFI system depends on all
If the engine should become flooded, set the brake coils functioning properly on the stator.
lever lock, compress the throttle lever to the full-open
position, and crank the engine over until it starts and
clears itself. Release the brake lever lock.
FUEL SYSTEM Individual EFI
The EFI fuel system consists of the following compo-
Components
nents.
ECU
1. Gas tank
The ECU is the brain of the EFI system. It uses five
2. Electric high output fuel pump sensor inputs to determine the correct fuel/air ratio for
the engine given the existing conditions of altitude and
3. Two pick-up valves with micron screens temperature.
4. High-pressure fuel hose
5. Fuel rail
6. Fuel pressure regulator *
7. Throttle body assembly
8. Injectors
9. Fuel return hose (600 cc)
10. ECU
* On the 800 cc, the regulator is in the fuel pump. AO152D
These above components are grouped into the fuel If any of the sensors should fail while the engine is
handling system. They work together along with five running, the ECU will sense a problem and go into a
electrical sensors (listed below) and the ECU to pro- “limp home” mode. This is an over-rich condition and
vide the engine with a precise fuel mixture for com- will greatly reduce performance. However, the engine
bustion. The five sensors are the following. will be protected from a possible lean condition and
engine damage.
4-42
The ECU is equipped with a light emitting diode The intake air temperature sensor is mounted on the
(LED), which will flash a series of pulses when a prob- front of the air-intake silencer. Its purpose is to sense
lem exists with any of the sensors. By observing the air temperature entering the air-intake silencer and
code, the technician can determine the problem sensor engine. The ECU sends current to this sensor, and
by comparing the code flashed with the trouble code (depending on the temperature) the sensor will pass a
chart (see Trouble Codes in this sub-section). certain amount of current through the sensor to
ground. The ECU measures how much current passes
through the sensor to ground. From this measurement,
the ECU determines the air temperature and calculates
the fuel/air mixture ratio. This sensor is very sensitive
to temperature change. Resistance will drop as the
temperature rises.
WATER TEMPERATURE SENSOR
AO153D
NOTE: There are no repairs that can be made to

the ECU.
If the ECU is not receiving current from one of the

output coils on the stator, that circuit will not operate.
Coils on the stator are the capacitor charge coil which
operates the CDI within the ECU, the injector coil AO069
4
which operate the injectors, the fuel pump coil which
operate the fuel pump, and the lighting coil which The water temperature sensor is located on the bottom
operates all accessories and the lighting system. Refer of the thermostat manifold. This sensor is very sensi-
to the wiring diagram in this sub-section. tive to temperature change. The ECU measures the
current flow through the sensor to ground. From this
measurement, the ECU can determine the engine cool-
ant temperature and calculate the correct fuel/air mix-
ture ratio.
NOTE: If the coolant temperature rises above
80° C (176° F), the temperature sensor starts to
close which also will start to richen the fuel mix-
ture. Once the engine coolant temperature reaches
93° C (200° F), the temperature sensor is fully
closed which will signal the ECU to go into the rich
mode to protect the engine from overheating. At
this time, the overheat light will be illuminated. The
overheat sensor, which illuminates the overheat
light, closes at 93° C (200 ° F) ± 6° F.
AO132D
THROTTLE POSITION SENSOR
INTAKE AIR TEMPERATURE SENSOR
AO136D
AO135D
4-43
The throttle position sensor, located at the end of the NOTE: This sensor is not replaceable. If it should
throttle shaft, is a potentiometer (a potentiometer is, fail, the ECU must be replaced.
essentially, a voltage divider). This sensor transforms
the throttle-valve position into output voltage to the FUEL INJECTORS
ECU. In addition, the sensor detects the opening or
closing speed of the throttle valve and feeds that rate
of voltage change to the ECU.
NOTE: The input from the throttle position sen-
sor is one of the main inputs for the ECU calcula-
tion of fuel/air mixture ratio.
IGNITION TIMING SENSOR
AO139D
The fuel injectors are positioned in the top of each

throttle body. O-rings seal the top and bottom of each
injector, and they are held in position by a locking
plate secured to the fuel rail.
0729-627
This sensor is located on the top of the magneto case

near the cylinder on some models. On other models the
sensor is located inside the magneto case next to the
flywheel, and on these models, the recoil starter and
the flywheel must be removed to access the sensor.
This sensor is triggered by a small metal disc precisely
mounted to the flywheel flange. Each time the metal
disc rotates past the sensor, a signal is sent to the ECU.
From this signal, the ECU determines ignition and AO140D
injection timing and RPM.
The fuel injector is an electromagnetic injection valve
BAROMETRIC PRESSURE SENSOR controlled by a signal from the ECU. The coil used in
the injector is a high-pressure resistance type. The
ECU determines the optimum fuel injection time and
duration based on signals from the five sensors.
When voltage is sent to the fuel injector, it energizes
the coil and opens the needle valve, thereby injecting
fuel. Because the fuel pressure (pressure differential
between fuel line and manifold) is kept constant, the
amount of fuel injected is determined by the duration
of time the valve is open.
The injectors are coded with symbols (Q-O-V). When
replacement of a fuel injector is necessary, the injector
must be replaced with an injector of the same code
AO155D symbol.
This sensor is located inside the ECU and is part of the
ECU unit. Its purpose is to sense atmospheric pressure.
From this information, the ECU determines the correct
fuel/air mixture ratio.
4-44
Check the following components before considering
the fuel pump assembly to be defective.
A. Fuel pump coil - see coil test procedure.
B. Emergency stop switch and ignition switch
must be ON and in good working order.
C. Fuel pump - see fuel pump test procedure.
D. Wiring harness and connectors - clean the
connectors and test the harness.
E. ECU.
AO138DA
FUEL PRESSURE REGULATOR

The fuel pressure regulator is attached to the end of the
fuel rail (600 cc) and in the fuel pump (800 cc). The Self-Diagnostic
fuel pressure regulator maintains the fuel pressure at a EFI System
constant level of 37.9 ± 2.2 psi (600 cc) or 48 ± 2.2 psi
(800 cc).
INTRODUCTION
The Electronic Control Unit (ECU) contains a built-in,
self-diagnostic system which detects trouble within the
five-sensor signal network and then flashes a code on
the LED signal light, located under the left end of the
ECU.
4
AO141D
On the 600 cc when fuel pressure exceeds the specifi-

cation, the spring-loaded diaphragm in the regulator
opens allowing fuel to flow through the return hose
back to the gas tank.
FUEL PUMP CIRCUIT AO153D
The fuel pump and its circuit are provided with current The fuel system and the ignition system remain two
from the fuel pump coil on the stator. separate systems. In a no-start situation, first deter-
mine if the problem is caused by lack of spark or by a
fuel delivery problem.
Using the EFI Ignition Analyzer, equipped with the
update EPROM (chip) and test harness, connect the
test harness to the ECU diagnostic connectors. Con-
nect the test harness red external lead to the positive
terminal of a 12-volt battery and connect the black
external test harness lead to the negative terminal.
If any of the circuits are faulty, a trouble code will now
be flashed by the LED.
If no code is flashed, turn on the analyzer. Press the
AO142D MENU SELECT buttons until the words KOKUSAN
appear on the display; then press the TEST button. The
For this circuit to function correctly, five components analyzer is now programmed for testing the Arctic Cat
must be in good working order. Batteryless EFI System.
4-45
Using the MENU SELECT buttons, press the button Charge Coil (1)/Charge Coil (2)
repeatedly until Memory Problem Diagnosis Test Resistance Test
appears on the display; then press the TEST button. If
any sensors have intermittent problems, they will be The charge coils power the CDI system and the ECU.
indicated on the display. To test these coils, disconnect the 3-wire connector
from the ECU to the stator.
Proceed to individual components test procedures cov-
ered throughout this section. 1. Set the meter selector to the OHMS scale and test
between the black/red and green/red wires.
The code flashed from the LED will first be a number
of flashes. Count the number of flashes and refer to 2. The meter must show 17 ohms ± 20%.
Trouble Codes in this sub-section. The code repeats
itself with approximately a 2-second delay between 3. Test between the green/red and brown/white
each series of flashes. wires.
NOTE: When reading the LED flash sequence, 4. The meter must show 17 ohms ± 20%.
have paper and pencil available to write down the
codes being flashed. More than one code may be NOTE: If either test is not within specifications,
flashed. the stator must be replaced. Refer to the wiring
diagram in this sub-section.
Once the problem area has been determined, check the Injector Coil Resistance Test
components involved using the Fluke Model 73 Multi-
meter (p/n 0644-191) or the EFI Analyzer (p/n 0644- The injector coil located on the stator powers the two
302) depending on which test is being made. injectors.
NOTE: If the EFI analyzer has been updated with 1. Disconnect the double-wire plug with two blue/
the new EPROM chip, select the proper EFI system white leads from the stator to the ECU.
being tested (ARCTCO for Battery System and
KOKUSAN for Batteryless System). Press the 2. Set the meter selector to the OHMS scale.
TEST button on the analyzer and the analyzer will
remain on the system selected until it is turned off.
If the analyzer is turned off during the test proce- 3. Connect a meter lead to each of the blue/white
dure, reselect the proper system being tested leads. The meter must show 19 ohms ± 20%.
before proceeding.
NOTE: If reading is not within the specification,
recheck to confirm test results. If still out of toler-
ance, replace the stator.
Trouble Codes NOTE: If the resistance test is good, a peak read-

ing voltage test should also be made. Refer to
Peak Voltage Tests and Specifications in this sub-
Number of section.
Trouble
Flashes
Fuel Pump Coil Resistance Test
1 Open or short circuit in throttle position
sensor. The fuel pump coil powers the fuel pump through the
2 Open or short circuit in water ECU.
temperature sensor.
NOTE: With the engine running, there should
3 Open or short circuit in intake air 12.3-12.9 DC volts supplied to the fuel pump for
temperature sensor. operation. To test fuel pump coil resistance, use
4 Open or short circuit in barometric the following procedure.
pressure sensor.
5 Failure in injector(s).
1. Disconnect the double-plug with the two orange
wires from the ECU.
TROUBLESHOOTING INDIVIDUAL
COMPONENTS 2. Set the meter selector to the OHMS scale. Connect
a meter lead to each of the two orange leads.
NOTE: With the Arctic Cat Batteryless EFI Sys-
tem, it is extremely impo rtant that the ECU 3. The meter must show 1.9 ohms ± 20%.
receives the proper current output from four coils
(two charge coils, an injector coil, and a fuel pump NOTE: If reading is out of tolerance, recheck to
coil) to function as designed. If a problem exists, confirm reading. If still out of tolerance, replace
these coils should be checked using the following the stator.
procedures.
4-46
NOTE: If the resistance test is good, a peak read- 5. Press the analyzer MENU SELECT buttons
ing voltage test should also be made. Refer to repeatedly until the words Memory Problem
Peak Voltage Tests and Specifications in this sub- Diagnosis Test appears on the display.
section.
Lighting Coil Resistance Test Memory Problem Diagnosis Test
The lighting coil located on the stator provides AC 6. Press the analyzer TEST button. If all sensors are
power to the lighting system and accessories through a good, SENSORS ALL O.K. will appear on the
charging system. To test the lighting coil resistance, display. If any of the sensors have intermittently
follow this procedure. failed or are faulty, they will appear on the display.
Proceed then to checking the faulty sensor
1. Disconnect the 3-wire connector at the engine. individually as covered in this section.
2. Set the meter selector to the OHMS scale. NOTE: Once problem areas have been deter-
mined, always check the component(s) for clean
3. Test between the two yellow leads. and tight connections.
4. The meter must show 0.10 ohm ± 20%. 7. To erase the memory of the ECU, press the TEST
NOTE: If reading is out of tolerance, recheck to button once again; then push the MENU SELECT
confirm reading. If still out of tolerance, replace buttons until Diagnosis Memory Clear appears on
the stator. the display. Turn the analyzer OFF and then back
ON again. Reselect KOKUSAN mode; then
proceed to the Memory Problem Diagnosis Test
and push the TEST button. The display should
indicate SENSORS ALL O.K. which indicates the
ECU memory has been cleared.
REMOVING
4
ACTIVATING ECU MEMORY
NOTE: There isn’t a test for the ECU. If a problem
NOTE: The ECU memory on the 1997- 2002 Arc- is suspected in this unit, try another ECU. When
tic Cat Batteryless EFI system (without the APV using another ECU, it must be a 1997, 1998, 1999,
system) can be activated only by using the EFI 2000, 2001, and/or 2002 model with a batteryless
Analyzer (p/n 0644-212) which has had the updated system. The ECU may be sent to the Arctic Cat
EFI Analyzer Test Harness and EPROM Update Kit Service Department for testing. Please contact the
(p/n 0644-256) installed. Service Department before sending any units.
NOTE: Testing EFI engines with the APV system 1. Disconnect the two wiring harness leads from the
should be done with the Arctic Cat EFI Analyzer (p/ front of the ECU.
n 0644-342). To update your existing EFI Analyzer,
order Kit (p/n 0644-341). 2. Remove the four screws securing the ECU to the
air-intake silencer.
The ECU has a self-diagnostic mode built into the unit.
It is a very valuable tool in troubleshooting. Once the 3. Remove the ECU.
problem area code has been flashed by the light emit-
ting diode (LED) located at the end of the ECU, follow NOTE: If there are any questions concerning
the troubleshooting procedure in this sub-section. lead or harness connections, there is an battery-
less EFI system wiring diagram in the back of this
The ECU also has a memory mode for determining if section.
any of the five sensors have intermittently failed. To
activate the memory system, follow these steps. INSTALLING
1. Connect the analyzer test harness to the ECU 1. Secure the ECU to the air-intake silencer with the
diagnostic connector. screws.
2. Connect the analyzer test harness red and black NOTE: Make sure the diagnostic connector plug
faces the oil reservoir.
leads to a 12-volt battery.
3. Turn the analyzer switch ON. 2. Connect the wiring harness leads to the ECU.
4. Press the analyzer MENU SELECT buttons NOTE: Make sure all connectors are clean and
repeatedly until KOKUSAN appears on the tight. Apply dielectric grease to all connectors.
display. Once the word KOKUSAN appears on
the display, press the TEST button. The analyzer is
now set up to test the batteryless EFI system.
4-47
FUEL INJECTORS
Testing Individual
Components
NOTE: For the following tests, use the Fluke

Model 73 Multimeter (p/n 0644-191) or a multimeter
of the same quality.
THROTTLE POSITION SENSOR

(All Models)
1. Disconnect the TPS wiring harness connector.

AO139D
2. Using TPS Adjustment Tool (p/n 0644-299), con-
nect its wiring harness to the TPS. Connect the Testing Resistance/Voltage
two Fluke meter leads (red and black) using the 1. Disconnect the fuel injector wiring harness.
two pin jack adapters provided with the adjust-
ment tool to the red and black jacks of the TPS 2. Set the meter selector to the OHMS scale.
adjustment tool.
3. Test between the two injector terminals. Test
NOTE: Before using the TPS adjustment tool, specification is 2.4-3.3 ohms.
verify its battery condition. The battery used in the
tool is a 9-volt battery. To check battery condition,
use a digital volt/ohmmeter set on DC volt scale.
Test between the adjustment tool black and red
jacks. Insert the red lead of the digital voltmeter
into the red jack of the adjustment tool and the
black lead of the digital voltmeter into the black
jack of the adjustment tool. If voltage is found
below 4.9 volts, replace the battery.
3. Set the multimeter selector to the DC scale; then

SLOWLY depress the throttle lever. The meter
reading should show a smooth rise all the way to
wide-open throttle. Repeat this step until it is
assured that there are no open areas or “peaks” in AO144D
the reading.
4. If not within specifications, replace the injector.
NOTE: If a reading contains open areas or
peaks, the throttle position sensor may be faulty. Removing
Refer to the proper Checking/Adjusting TPS proce-
dure in Section 5 - Digital 3-D Ignition in this man-
ual. ! CAUTION
The fuel supply hose may be under pressure.
4. Disconnect the adjustment tool harness from the Place an absorbent towel around the connection
TPS. Connect the snowmobile TPS harness to the to absorb fuel; then remove the hose slowly to
TPS. release the pressure.
NOTE: Before installing the TPS harness con- 1. Loosen the clamp securing the fuel supply hose to
nector, apply dielectric grease to the connector the fuel rail; then remove the hose from the fuel
pins. rail.
2. Disconnect the wiring harness from each injector.
3. Remove the two screws securing the injector hold-
down plate to the throttle body assembly; then
remove the plate from the injectors.
4-48
5. Connect the wiring harness to the injectors making
sure the number 1 harness is connected to the
MAG-side injector.
AO145D
4. Remove the fuel injectors from the throttle body

assembly.
0729-627
NOTE: This sensor is located on the top of the

magneto case on some models. On other models
the sensor is located inside the magneto case next
to the flywheel, and on these models, the recoil
starter and the flywheel must be removed to
access the sensor.
Testing Resistance
1. Disconnect the two leads from the sensor to the 4

main wiring harness.
2. Set the meter selector to the OHMS scale.
AO146D
3. Test between the green/white and brown leads
Installing from the sensor. Test specification is 152-228
1. Apply a light coat of oil to all O-rings; then install ohms.
the upper and lower O-rings onto each injector.
2. Install the injectors into the throttle body
assembly.
3. Place the injector hold-down plate into position on
top of the injectors and secure with two screws.
4. Connect the fuel delivery hose to the fuel rail and
secure with a clamp.
NOTE: When securing the fuel delivery hose,
position the clamp as shown.
AO147D
Removing
1. Open the rubber boot that protects the main wiring

harness connections; then disconnect the ignition
timing sensor from the ECU wiring harness.
2. Remove the two screws securing the sensor to the
magneto housing.
3. Remove the sensor.
0729-325
4-49
Installing Testing Fuel Pressure Regulator
1. Using two screws coated with blue Loctite #242, 1. Using the Fuel Pressure Tester (p/n 0644-203),
secure the sensor to the magneto housing (inner connect the tester to the regulator fuel inlet.
mounting hole).
2. Connect the sensor to the ECU wiring harness;
then close the rubber boot.
3. Secure loose wires with cable ties.
ELECTRIC FUEL PUMP
1. Remove the hardware securing the console to the

gas tank and frame; then move the console out of
the way.
2. Disconnect the fuel pump (white two-wire
connector) from the main wiring harness.
AO053
3. Connect the positive lead of a 12-volt power NOTE: A short piece of 3/8 in. I.D. hose will be
supply to the red wire and the negative lead of the needed to make the above connections.
12-volt power supply to the black wire.
2. Pressurize the regulator to 2.0-2.2 kg/cm² (28-31.3
4. The pump should operate (it would be heard psi). Turn the pressure tester shut off valve to the
running). OFF position. Observe the gauge for several
NOTE: If the fuel pump fails to operate, the pump minutes and note if there is any loss of pressure. If
is defective and must be replaced. pressure begins to drop, the cause may be a
ruptured diaphragm, worn spring, or leaking
FUEL PRESSURE REGULATOR (600 cc) valve. If the regulator fails to build or maintain
pressure, replace the regulator.
Removing
NOTE: If there is a drop in pressure, check the
1. Loosen the clamp securing the fuel return hose to hose connections to ensure there are no leaks.
the fuel regulator; then remove the hose.
Installing
2. Remove the two screws securing the fuel pressure
regulator to the fuel rail; then slowly remove the 1. Position the O-ring on the fuel pressure regulator;
regulator. Account for the O-ring. then place the regulator into position on the fuel
rail. Secure with two screws.
2. Connect the fuel return hose to the regulator; then
secure with a clamp.
AO149D
! CAUTION
0729-325
Since the regulator may be under pressure,
remove it slowly to release the pressure. Place
an absorbent towel around the connection to
absorb fuel.
4-50
WATER TEMPERATURE SENSOR
Testing Resistance
NOTE: The water temperature sensor is very

sensitive to temperature change. Before the resis-
tance test is conducted, it is important to know the
coolant temperature. If the engine has been oper-
ated recently and the coolant is warm, the resis-
tance will measure lower than if the coolant was at
room temperature or colder. For accurate test
results, check the coolant temperature in the filler
neck using a thermometer. AO135D
1. Disconnect the water temperature sensor wiring 2. Set the meter selector in the OHMS position and
harness from the main harness. test the two leads located in the sensor connector.
Compare with the EFI Component Voltage/
2. Set the meter selector to the OHMS position and Resistance Chart - Air Temperature in this sub-
test the resistance between the two leads from the section.
sensor.
NOTE: The intake air temperature sensor
3. Compare the resistance reading to the EFI employs a thermistor, which is very sensitive to
Component Voltage/Resistance Chart - Water temperature changes. Resistance will change as
Temperature in this sub-section. If resistance is temperature varies.
not within the specification, replace the sensor.
Removing
NOTE: A water temperature sensor voltage test
1. Disconnect the wiring harness from the intake air
4
can be made using the EFI Analyzer. Please refer
to the analyzer test procedures provided on the temperature sensor.
following pages.
2. Using a standard screwdriver, pry the sensor end
Removing to end to remove it from the air-intake silencer.
Account for two push pins.
1. Drain the cooling system.
Installing
2. Remove the throttle body assembly.
1. Place the sensor into position in the air-intake
3. Disconnect the wiring harness from the water silencer and secure with push pins.
temperature sensor.
2. Connect the wiring harness to the intake air
4. Remove the sensor from the water temperature temperature sensor. Secure the sensor leads with
case. cable ties so they do not rub on any other
components.
Installing
1. Apply teflon tape to the threads of the water

temperature sensor; then install the sensor.
EFI Analyzer
2. Connect the wiring harness to the sensor.
3. Install the throttle body assembly. NOTE: Troubleshooting EFI engines with the
APV system should be done with the Arctic Cat
4. Fill the cooling system. EFI Analyzer (p/n 0644-342). To update your exist-
ing EFI Analyzer, order Kit (p/n 0644-341).
GENERAL INFORMATION
Testing Resistance
The EFI Analyzer (p/n 0644-302) makes it possible for
NOTE: It is very important to know the compo- technicians to easily perform EFI system troubleshoot-
nent temperature before conducting this test. ing in a short period of time.
Allow the engine to reach room temperature.
Before an EFI analyzer purchased prior to February 1,
1. Disconnect the wiring harness from the intake air 1998, can be used on the batteryless EFI system, it
temperature sensor. must be updated with the Harness and EPROM Update
Kit (p/n 0644-301) available from your Arctic Cat
Parts Department. All analyzers purchased after June
1, 1998, were updated at Arctic Cat.
4-51
To use the analyzer on the batteryless EFI system, a At this point, select one of the modes by pushing the
12-volt battery to power the analyzer is necessary. Fol- TEST button, or the analyzer will not continue past
low the instructions under Analyzer Setup for testing this point. If testing a batteryless EFI system, select
the batteryless EFI system. KOKUSAN on the display by pushing the TEST but-
ton. The entire system can now be tested by moving to
Analyzer Nomenclature the next test using the MENU SELECT buttons.
If the analyzer is turned off during the test procedure,
the test function on the display will automatically start
over at the top of the list when turned back on. This
means the selection of the system being tested must be
repeated before continuing.
Once a test has been completed, press the TEST button
again to cancel the test, which allows the selection of a
different test using one of the MENU SELECT but-
tons.
NOTE: If the new updated EPROM chip has not
730-222A
been installed, the EFI (Battery System) can be
tested; however, without the new Test Harness
1. LCD - Liquid Crystal Display. and EPROM Update Kit (p/n 0644-301), the new
Arctic Cat Batteryless EFI System cannot be
2. Power-Light illuminates when the analyzer is tested. All EFI analyzers purchased after February
1, 1998, were updated at Arctic Cat.
properly connected to the snowmobile EFI
analysis test plug.
Menu List Organization
(Kokusan Mode)
3. On/Off Switches.
1. Engine RPM
4. Menu Select (up/down) - Enables selection of a
test function quickly. 2. Diagnosis memory clear
5. Test - Once the test function is selected, push the 3. Memory problem diagnosis test
button to complete the test. The button also
cancels the current test so the next test function 4. Existing problem diagnosis test
can be selected.
5. Barometric pressure
Analyzer Test Function
(Batteryless System) 6. Water temperature
If the EFI analyzer has been updated with the 1998 7. Intake air temperature
Harness and EPROM chip, it can be used to trouble-
shoot the 1997-2002 batteryless EFI system (without 8. Throttle valve angle in degrees
the APV system). There is, however, special informa-
tion which can be retrieved from the 2000-2002 ECU 9. Ignition timing
such as total running time on engine, running times by
temperature, maximum RPM by temperature, EPROM Kokusan Special Mode
chip change check, number of fuel changes by wire
disconnect, and last fuel type used. This information The 2000-2002 batteryless EFI system has an updated
can only be retrieved with an EFI analyzer which has ECU. With the 2000-2002 ECU, the snowmobile can
been updated with either the 1999 Harness and be run with either regular gasoline or oxygenated gas-
EPROM Chip Update Kit (p/n 0644-301) or the 1999 oline. Special instructions located on top of the tool
EFI Analyzer EPROM chip (p/n 0643-068). box lid will instruct to disconnect two wires located in
front of the ECU if oxygenated gasoline is used. If reg-
If the EFI analyzer has been updated with the new ular gasoline is to be used, the two wires in front of the
EPROM chip (p/n 0643-068) when the MENU ECU must remain connected or the mixture will be too
SELECT buttons are pressed, there will be three rich.
modes to select from. First mode, ARCTCO, is used to
troubleshoot the battery style EFI systems used in
1998 and prior year models. The second mode,
KOKUSAN, is used to troubleshoot the 1997-2002
batteryless EFI system. The third mode, KOKUSAN
SPECIAL, is used only to retrieve special information
(explained earlier) found only on the 2001-2002 bat-
teryless EFI system ECU.
4-52
4. Push either MENU SELECT button on the
analyzer until KOKUSAN mode appears on the
display; then push the TEST button. The analyzer
is now ready to test the batteryless EFI system.
5. To retrieve information found under Kokusan
Special Mode, push Menu Select button until
Kokusan Special Mode appears on the display;
then push the TEST button. The analyzer is now
ready to test the special areas shown on the menu
list under Kokusan Special Mode.
734-482A NOTE: When testing the batteryless EFI system,

KOKUSAN mode must be on the display. Once the
Menu List Organization TEST button is pressed with KOKUSAN mode on
(Kokusan Special Mode) the display, the analyzer will stay in this mode until
it is turned OFF.
1. Throttle Adjust - given in both volts and degree.
NOTE: Each time the analyzer is turned OFF,
2. Fuel Change Number - number of times fuel leads reselection of the KOKUSAN mode is necessary.
have been switched between regular gasoline and The ARCTCO mode, which will also appear on the
oxygenated gasoline. display when the MENU SELECT buttons are
pressed, is for testing an EFI (battery system).
3. Last Gasoline Type - in case of engine failure,
what the system was last set for - regular gasoline EFI Components Not
or oxygenated gasoline. Tested by Analyzer
4. Other Rom Check - will indicate if the EPROM

chip has been changed. If none appears on the
When troubleshooting the EFI system with the EFI
Analyzer, there are EFI components the analyzer will
NOT diagnose. These components, (in the following
4
display, the EPROM chip has not been changed
since the ECU was assembled. list) must be tested using a good digital volt/ohmmeter
or a fuel pressure gauge using recommended proce-
5. Maximum Revolutions by Temperature - provides dures in this sub-section and in Section 5.
a range in increments of 10° from -30° C to -101°
C. Will show engine RPM for each temperature 1. Fuel Pump Coil - Injection Coil - Timing Sensor.
range and if the engine has been operated in the
range. 2. Ignition Primary Coil.
6. Running Time by Temperature - will indicate how 3. Ignition Secondary Coil.

long the engine has been run in each temperature 4. Fuel Pressure Regulator - Maintains fuel pressure
range from 40° C to 101° C in increments of 10°. at 37.9 ± 2.2 psi (600 cc) and 48 ± 2.2 psi (800 cc).
7. Total Running Time - will show total hours on the 5. Electric Fuel Pump - Located in the gas tank.
engine. Supplies fuel under pressure to fuel injectors.
8. Barometric Pressure - provides current air 6. Switches and Stator Coils - Supplies all systems
pressure. with electrical current.
To test an batteryless EFI system using the EFI Ana-
lyzer, follow all instructions carefully and completely.
Analyzer Setup Recommended EFI
1. Before connecting the analyzer to the snowmobile, Troubleshooting
always check to make sure the analyzer is OFF;
then connect the analyzer batteryless test harness
Sequence
(equipped with red and black external leads) to the (Kokusan Mode)
ECU diagnosis connector.
When troubleshooting the batteryless EFI system, use
2. Attach the red external lead to the positive the following troubleshooting sequence to locate prob-
terminal of a 12-volt battery; then connect the lems quickly and efficiently.
negative external lead to the negative post.
EXISTING PROBLEM DIAGNOSIS TEST
3. Press the ON button of the analyzer. At this point,
the power light of the analyzer must be This should be the first test made. In this mode, the
illuminated. analyzer tests the following components all at once.
4-53
A. Throttle Position Sensor 4. Press the TEST button. If all sensors are good,
SENSORS ALL O.K. will appear on the display.
B. Intake Air Temperature Sensor If any of the sensors listed under Existing Problem
Diagnosis Test are defective, that sensor will be
C. Water Temperature Sensor indicated on the display. Proceed then to check the
defective sensor individually as covered in this
D. Barometric Pressure Sensor section.
E. Fuel Injectors NOTE: If proceeding to another test, first press
the TEST button once again to cancel the present
After pushing the TEST button on the analyzer, the test. To select a different test function, use the
display will indicate either SENSORS ALL O.K. or MENU SELECT buttons.
which of the sensors are defective. Check these com-
ponents individually using the recommended proce- MEMORY PROBLEM DIAGNOSIS TEST
dures in this sub-section. (Engine Off) FUNCTION
MEMORY PROBLEM DIAGNOSIS TEST NOTE: When using an analyzer which has been
updated with the new EPROM chip, first select
This should be the second test made. In this mode, the KOKUSAN by pressing the TEST button. This will
analyzer will reveal any problems in the sensor area allow the testing of the batteryless EFI system.
which might have occurred intermittently as the snow-
mobile was being operated. 1. With the analyzer OFF, connect its wiring harness
to the diagnosis test plug. Connect the external
If there were any such intermittent problems, the prob- leads of the harness to a good 12-volt battery.
lem area will be shown on the display. Check the indi-
cated area for a wire connection problem or loose or 2. Switch the analyzer ON.
corroded connections.
3. With both indicator lights illuminated, press the
MENU SELECT buttons repeatedly until Memory
Problem Diagnosis Test appears on the display.
Testing Individual EFI Memory Problem Diagnosis TEST
Components
4. Press the analyzer TEST button. If there has been
NOTE: For all of the following tests using the EFI an intermittent problem in a sensor, that sensor
Analyzer, the analyzer power light must be illumi- will be indicated on the display. Make necessary
nated. If not illuminated, the problem must be cor- repairs.
rected before proceeding. Also the analyzer must
be properly connected to a 12-volt battery. NOTE: If proceeding to another test, first press
EXISTING PROBLEM DIAGNOSIS TEST test. To select a different test function, use the
(Engine Off) FUNCTION MENU SELECT buttons.
NOTE: When using an analyzer which has been CLEARING MEMORY

KOKUSAN by pressing the TEST button. This will 1. With the analyzer harness attached to the
allow the testing of the batteryless EFI system. diagnosis test plug, press the MENU SELECT
buttons until the words Diagnosis Memory Clear
1. With the analyzer OFF, connect its harness to the appear on the display.
diagnosis test plug. Connect the external leads of
the harness to a good 12-volt battery. Diagnosis Memory Clear
2. Switch the analyzer ON.
2. Press the analyzer TEST button and the words
3. With analyzer power light illuminated, press the Please Key Off should appear on the LCD; then
MENU SELECT buttons repeatedly until the turn the analyzer switch to the OFF position.
words Existing Problem Diagnosis Test appear on Immediately turn the analyzer switch to the ON
the display. position and the memory should now be clear.
Existing Problem Diagnosis TEST Please Key Off
NOTE: To check if the memory is clear, perform

Memory Problem Diagnosis Test to see if all sen-
sors test good. If a problem still remains on mem-
ory, repeat Clearing Memory procedure.
4-54
THROTTLE VALVE ANGLE TEST 7. Compress the throttle lever to the “full-open”
(Degrees/Volts) FUNCTION position (engine not running). The test
specification must be within the tolerance shown
The correct throttle valve angle is extremely important in chart. If the test specification is out of tolerance,
for proper engine operation. If the throttle valve angle grasp the throttle cable next to the throttle shaft
isn’t correct in the idle position, the engine may be and pull on the cable. If the test specification is
very difficult to start “cold.” If the throttle valve angle now within tolerance, adjust the throttle cable. If
isn't correct in any of the off-idle positions, engine the throttle valve angle remains out of tolerance,
damage or poor performance may result because of an replace the throttle body assembly.
incorrect mixture.
8. If the specifications listed below ARE
DISPLAYED during the test, replace the throttle
body assembly.
NOTE: When using an analyzer which has been
KOKUSAN by pressing the TEST button. This will Throttle Valve Angle - Degrees/Volts
allow the testing of the batteryless EFI system. Degrees/Volts RPM Range
2.25/0.570 Idle to 3000
1. Connect the analyzer harness to the diagnosis test
plug. Make sure the analyzer is OFF.
NOTE: If the Throttle Position Sensor should fail,
2. Switch the analyzer ON. the ECU will go into the “limp home” mode and the
above readings in the idle position will be dis-
played.
3. With the analyzer power light illuminated, press
the MENU SELECT buttons on the analyzer
repeatedly until the words Throttle Valve Angle NOTE: If proceeding to another test, first press
appear on the display. test. To select a different test function, use the
Throttle Valve Angle

MENU SELECT buttons.
4
(Engine Off) FUNCTION
NOTE: When performing the Throttle Valve
Angle Test, test both the idle and full-open throttle NOTE: When using an analyzer which has been
positions. Specifications are given for both posi- updated with the new EPROM chip, first select
tions in degrees and volts. Kokusan by pressing the TEST button. This will
allow the testing of batteryless EFI system.
4. With the throttle in the “idle” position (engine not
running), press the analyzer TEST button. The 1. With the analyzer OFF, connect its harness to the
throttle valve angle should now appear on the diagnosis test plug. Connect the external leads of
display. the harness to a good 12-volt battery.
Throttle Valve Angle - Degrees 2. Switch the analyzer ON.
Model Idle Full-Open
3. With the analyzer power light illuminated, press
800 cc 5.210°-5.720° 77.265°-86.135° the MENU SELECT buttons repeatedly until
600 cc 3.715°-4.065° 77.265°-86.135° Intake Air Temperature appears on the display.
Throttle Valve Angle - Voltage Intake Air Temperature

Full-Open
Model Idle (Volts)
(Volts) 4. Press the analyzer TEST button and the intake air
800 cc 0.690-0.710 3.575-3.937 temperature will be indicated on the display.
600 cc 0.625-0.647 3.575-3.937 NOTE: Intake air temperature will be displayed in
both °C and °F.
5. If the “idle” position throttle valve angle or
voltage isn't within test specifications, push down NOTE: The temperature indicated should be
on the throttle shaft to make sure it is fully closed. close to room temperature if the snowmobile
If the test specifications are now within tolerance, hasn't recently been run. Consider what tempera-
loosen the throttle cable. ture the snowmobile is actually at.
6. If the “idle” position throttle valve angle test 5. If when testing the intake air temperature sensor,
specification remains out of tolerance, adjust the an indicated temperature of -40° C and °F is noted
idle speed screw. If the throttle valve angle cannot and the actual snowmobile temperature isn't close
be corrected by either an idle speed screw or cable to this temperature, replace the sensor. The ECU
adjustment, replace the throttle body assembly. will automatically go to -40° C and °F when the
intake air temperature sensor fails.
4-55
NOTE: If proceeding to another test, first press 3. Start the engine and test between the two orange
the TEST button once again to cancel the present leads. Reading should be approximately 13 to 15
test. To select a different test function, use the volts.
MENU SELECT buttons.
ECU Output To Fuel Pump (Running)
BAROMETRIC PRESSURE SENSOR
TEST (Engine Off) FUNCTION 1. With the engine running, test between the red and
black leads in the pump connector.
NOTE: When using an analyzer which has been
updated with the new EPROM chip, first select 2. Reading should be 12 to 15 volts (600 cc) or 18-26
KOKUSAN by pressing the TEST button. This will volts (800 cc).
allow the testing of the batteryless EFI system.
NOTE: If the output between the orange leads to
1. With the analyzer OFF, attach its harness to the the ECU are within tolerance but the ECU output is
diagnosis test plug. low, replace the ECU. If the ECU output is within
specifications but the fuel pump fails to operate,
2. Switch the analyzer ON. replace the fuel pump.
3. With the analyzer power light illuminated, press Injector Coil Output Test (Static)
the MENU SELECT buttons repeatedly until the
words Barometric Pressure appear on the display. 1. Remove the spark plugs and ground them to the
cylinder heads.
Barometric Pressure
2. Unplug the double lead connector at the ECU
4. Press the analyzer TEST button and actual area having two blue/white wires.
barometric pressure will be indicated.
3. Test between the two blue/white leads in the
NOTE: Actual area barometric pressure can be connector harness from the stator plate.
obtained from a local airport, radio station, etc.
4. Pull the recoil starter rope briskly. Reading should
5. If the barometric pressure sensor has failed, the be approximately 80 volts.
ECU will automatically go to the barometric
pressure shown below. If these readings APPEAR Injector Coil Output Test (Running)
on the display, replace the ECU.
1. Install the spark plugs and tighten securely.
Model Barometric Pressure
2. Connect the double lead connector to the ECU
800 cc 880 mm/hg (34.65 in./hg) leaving just enough room to make contact with the
600 cc 880 mm/hg (34.65 in./hg) meter leads.
3. Start the engine and test between the two blue/
white leads in the double connector. Reading
should be approximately 20 to 22 volts.
Peak Voltage Tests ECU Output To The Injectors (Number
and Specifications 1 Injector)
(2002 Models)
1. Using two paper clips, insert them into the number
1 (MAG-side) connector (yellow and yellow/red
Fuel Pump Coil Test (Static) leads) at the injector from the back side. Leave the
connector attached to the injector. Touch red
1. Remove the spark plugs and ground them to the meter lead to yellow and black meter lead to
cylinder heads. yellow/red.
2. Unplug orange leads from stator and test between 2. Start the engine. Reading should be approximately
the two orange wires from the stator. 20 volts.
3. Pull the recoil starter rope briskly. Reading should NOTE: Repeat the same test as above for injec-
be 13 volts or higher. tor number 2. Switch meter leads to the green and
green/red leads. Reading should be approximately
Fuel Pump Coil Test (Running) 20 volts.
1. Connect the two orange leads from the stator to the Charge Coil (2) Test (Static)
ECU.
1. Remove the spark plugs and ground them to the
2. Insert a paper clip into each orange wire connector cylinder heads.
making contact with its terminal.
2. Unplug the triple plug connector from the ECU.
4-56
3. Test between the green/red and brown/white wires 2. Unplug the yellow and black leads from ECU to
in the triple plug connector from the stator. Pull the water temperature sensor. Test between the
the recoil starter rope briskly. Reading should be yellow and black leads from the ECU. Pull the
85-94 volts. recoil starter rope briskly. Reading should be
approximately 4.5 to 5 volts.
Charge Coil (1) Test (Static)
NOTE: If either the air temperature or water tem-
1. Remove the spark plugs and ground them to the perature sensor output test is low, retest to con-
cylinder heads. firm results. If either test remains out of
specification, replace the ECU.
2. Unplug the triple plug connector from the ECU.
3. Test between the black/red and green/red wires in
the triple plug connector from the stator. Pull the
recoil starter rope briskly. Reading should be 100- Throttle
110 volts. Position Sensor
ECU Output To Secondary Coil
(Static) It is not possible to replace the throttle position sensor
on the batteryless EFI system. If the sensor should
1. Remove the spark plugs and ground them to the malfunction, the complete throttle body assembly must
cylinder heads. be replaced.
2. Contact one small lead with the black meter leads NOTE: It is important to order a throttle body
and the other small lead with the red meter lead. assembly with the same symbol marking on the
Pull the recoil starter rope briskly. Reading should injectors as the ones being replaced. The symbol
be 130-143 volts. is located on the side of the injector top.
NOTE: If the CDI unit isn’t within specifications
and if the charge coil (1) and charge coil (2) read-
4
ings were within specifications, replace the ECU.
Throttle Body
Ignition Timing Sensor Output (Static)
Flange
cylinder heads.
REMOVING
2. Unplug the 2-lead connector of the timing sensor
harness. Test between the green/white and brown 1. Loosen the clamps securing the throttle body
wires in the connector from the sensor. assembly to the throttle body flanges.
3. Pull the recoil starter rope briskly. Reading should 2. Remove the throttle body assembly from the
be 1.5 volts or higher. flanges.
Air Temperature Sensor Output 3. In turn on each flange, remove the two nuts, lock
Voltage Test From ECU washers, and flat washers securing the intake
flange to the cylinder; then remove the flange.
cylinder heads. INSTALLING
2. Unplug the blue and black leads from the air 1. Apply a thin coat of high-temperature silicone to
temperature sensor. the cylinder side of each flange; then attach each
flange to a cylinder and secure each with two flat
3. Test between the blue and black leads from the washers, lock washers, and nuts. Tighten to 1.5-
ECU. Pull the recoil starter rope briskly. Reading 1.9 kg-m (11-14 ft-lb).
should be approximately 4.5 to 5 volts.
2. Install the flange clamps on the flanges; then place
Water Temperature Sensor Output the throttle body assembly into the flanges and
Voltage Test From ECU secure with the clamps.
1. Remove the spark plugs and ground them to the 3. Secure all wires and hoses with cable ties.
cylinder heads.
4-57
REMOVING
Throttle Body 1. Disconnect the wiring harness from each injector
Assembly and from the throttle valve sensor connector.
2. Remove the coolant hose from the PTO-side of the
KEY
throttle body and plug it to prevent leakage.
1. Throttle Body Assembly
2. Fuel Pressure Regulator 600 cc 3. Remove the fuel return hose (600 cc) and supply
3. Bolt hose from the fuel pressure regulator (600 cc) and
4. Delivery Pipe delivery pipe. Label for assembly.
5. Fuel Injector
6. Screw
7. Control Rod ! CAUTION
8. Rod End
9. Spring Pin Since the fuel supply hose may be under
10. Hose pressure, remove it slowly to release the
11. Hose Clamp pressure. Place an absorbent towel around the
12. O-Ring Set connection to absorb fuel.
4. Loosen the flange clamps.

5. Slide the throttle body assembly out of the flanges;
then loosen the jam nut securing the throttle cable
and remove.
6. Remove the throttle body.
0736-279
KEY
1.
2.
Throttle Body Assembly
Delivery Pipe
800 cc
3. Fuel Injector AR113
4. Screw
5. Hose INSTALLING
6. Hose Clamp
7. O-Ring Set
1. Attach the throttle cable to the throttle body.
Secure with jam nut.
2. Place the throttle body assembly into position.
Make sure the flanges and boots are positioned
properly. Secure with flange clamps.
3. Secure the fuel supply hose and return hose (600
cc) to the delivery pipe and regulator (600 cc).
! CAUTION
These hoses must be connected to the correct
fittings.
4-58
963), push down on the throttle cable retaining
clip; then remove the cable from the throttle
switch assembly.
INSTALLING/ADJUSTING
1. Install the throttle cable into the throttle switch

assembly making sure the cable snaps into place.
2. Install the throttle cable end on the throttle lever.
3. Route the throttle cable from the throttle switch
assembly to the throttle body assembly and oil-
0729-325
injection pump; avoid any sharp bends or moving
4. Secure the coolant hose to throttle body assembly. components.
5. Connect the wiring harness to each injector and 4. Attach the throttle cable to the throttle body.
throttle valve sensor.
5. Install the oil-injection cable adjuster on the oil-
6. Place the rear of the snowmobile on a shielded injection pump; secure with the jam nuts.
safety stand and start the engine without touching
the throttle. It may idle slowly and stop. Restart 6. Install the oil-injection cable on the control arm;
using the same procedure until the engine starts secure with a washer and E-clip.
and builds RPM on its own.
7. Secure the throttle cable to the steering post with
cable ties.
! WARNING
Check all hose connections for leakage. Repair as
8. Install the handlebar pad. 4
necessary. 9. Adjust the throttle cable tension by turning the jam
nuts in the appropriate direction until there is 0.75-
7. Check the cooling system. 1.5 mm (0.030-0.060 in.) free-play in the throttle
lever and the butterfly completely opens and
8. Adjust the throttle cable as necessary. closes. Tighten the jam nuts securely.
Throttle Cable
REMOVING
1. Open the belt guard and remove the belt.

2. Remove the driven pulley.
3. Remove the E-clip securing the oil-injection cable
to the oil-injection pump control arm. Account for
a washer. 733-081C
4. Loosen the oil-injection cable jam nuts. ! CAUTION

5. Loosen the throttle cable jam nuts. Compress the throttle control lever to ensure
free movement. If the throttle cable sticks or
6. Remove the throttle cable from the throttle body binds, correct the problem before starting the
assembly. engine.
7. Remove the handlebar pad. 10. Synchronize the oil-injection pump.

0736-975
8. Remove the cable ties securing the throttle cable. 11. Install the driven pulley.
9. Remove the throttle cable end from the throttle 12. Install the belt and secure the belt guard.
lever.
4-59
BASIC EFI SYSTEM INFORMATION
Item Description
Basic system Fuel supply system Electronically controlled multi-point injection
Ignition system (CDI system) Digital
Air/fuel flow System O/N (throttle opening/engine revolution) system & atmospheric
meter pressure compensation
Component parts Throttle opening sensor
Atmospheric pressure sensor
Injection system One time simultaneous injection per revolution
(synchronized ignition)
Fuel system Fuel pressure Regulated high pressure 37.9 ± 2.2 psi (600 cc)/ 48 ± 2.2 psi
(800 cc)
Fuel return (600 cc) Pressure regulated by pressure regulator. There are fuel
returns.
Throttle System 1 stage x duplex (1 bore/cylinder)
system Diameter of the bore 46 x 2 (Effective area equivalent to 40)
Type of valve Butterfly type
Operating angle 80° (full closed angle 10°)
Radius of drum R25 (at wire center)
Adjusting system for idle revolution Throttle adjusting screw type
Control unit Fuel injection control
Fuel pump Gear type
Component parts and specifications
Fuel system
Injection Side feed type

Pressure regulator (600 cc) Diaphragm type
Fuel filter Fine screens on pick-up hose
Fuel piping High pressure specification 37.9 ± 2.2 psi (600cc)/ 48 ± 2.2 psi
(800 cc)
Throttle body 1 bore/cylinder x duplex
Sensor, etc.
Throttle sensor Revolution scrubbing type potentiometer

Pressure sensor Semiconductor type
Water temperature sensor Thermistor type
Intake air temperature sensor Thermistor type
Cable harness Equivalent to current harness
Other Batteryless EFI System
4-60
EFI COMPONENT VOLTAGE/RESISTANCE CHART -
AIR TEMPERATURE
TEMP/C TEMP/F VOLTAGE OHMS TEMP/C TEMP/F VOLTAGE OHMS

100 212 0.113 555 28 82 1.230 8540
98 208 0.121 595 26 79 1.322 9530
96 205 0.128 635 24 75 1.413 10520
94 201 0.136 675 22 72 1.505 11510
92 198 0.143 715 20 68 1.596 12500
90 194 0.151 755 18 64 1.716 14020
88 190 0.162 819 16 61 1.836 15540
86 187 0.173 883 14 57 1.955 17060
84 183 0.184 947 12 54 2.075 18580
82 180 0.195 1011 10 50 2.195 20100
80 176 0.206 1075 8 46 2.323 23060
78 172 0.222 1160 6 43 2.452 26020
76 169 0.238 1245 4 39 2.580 28980
74 165 0.253 1330 2 36 2.709 31940
4
72 162 0.269 1415 0 32 2.837 34900
70 158 0.285 1500 -2 28 2.969 39940
68 154 0.308 1640 -4 25 3.101 44980
66 151 0.331 1780 -6 21 3.233 50020
64 147 0.353 1920 -8 18 3.365 55060
62 144 0.376 2060 -10 14 3.497 60100
60 140 0.399 2200 -12 10 3.610 76080
58 136 0.432 2410 -14 7 3.722 92060
56 133 0.465 2620 -16 3 3.835 108040
54 129 0.498 2830 -18 -0.4 3.947 124020
52 126 0.531 3040 -20 -4 4.060 140000
50 122 0.564 3250 -22 -8 4.142 156000
48 118 0.612 3595 -24 -11 4.224 172000
46 115 0.659 3940 -26 -15 4.306 188000
44 111 0.707 4285 -28 -18 4.388 204000
42 108 0.754 4630 -30 -22 4.470 220000
40 104 0.802 4975 -32 -26 4.522 261000
38 100 0.869 5490 -34 -29 4.574 302000
36 97 0.937 6005 -36 -32 4.625 343000
34 93 1.004 6520 -38 -36 4.677 384000
32 90 1.072 7035 -40 -40 4.729 425000
30 86 1.139 7550
4-61
EFI COMPONENT VOLTAGE/RESISTANCE CHART -
WATER TEMPERATURE
TEMP/C TEMP/F VOLTAGE OHMS TEMP/C TEMP/F VOLTAGE OHMS

110 230 0.115 129 28 82 1.377 1800
108 226 0.129 137 26 79 1.459 1950
106 223 0.143 145 24 75 1.541 2100
104 219 0.157 153 22 72 1.623 2250
102 216 0.171 161 20 68 1.705 2400
100 212 0.185 169 18 64 1.806 2670
98 208 0.192 180 16 61 1.907 2940
96 205 0.199 191 14 57 2.008 3210
94 201 0.206 202 12 54 2.109 3480
92 198 0.213 213 10 50 2.210 3750
90 194 0.220 224 8 46 2.327 4170
88 190 0.235 240 6 43 2.444 4590
86 187 0.250 256 4 39 2.561 5010
84 183 0.265 273 2 36 2.678 5430
82 180 0.280 289 0 32 2.795 5850
80 176 0.295 305 -2 28 2.901 6510
78 172 0.317 327 -4 25 3.007 7170
76 169 0.339 349 -6 21 3.113 7830
74 165 0.361 371 -8 18 3.219 8490
72 162 0.383 393 -10 14 3.325 9150
70 158 0.405 415 -12 10 3.421 9422
68 154 0.438 445 -14 7 3.517 9694
66 151 0.471 475 -16 3 3.613 9966
64 147 0.504 505 -18 -0.4 3.709 10238
62 144 0.537 535 -20 -4 3.805 10510
60 140 0.570 565 -22 -8 3.885 13688
58 136 0.598 609 -24 -11 3.965 16866
56 133 0.626 653 -26 -15 4.045 20044
54 129 0.654 697 -28 -18 4.125 23222
52 126 0.682 741 -30 -22 4.205 26400
50 122 0.710 785 -32 -26 4.267 30520
48 118 0.759 849 -34 -29 4.329 34640
46 115 0.808 913 -36 -32 4.391 38760
44 111 0.857 977 -38 -36 4.453 42880
42 108 0.906 1041 -40 -40 4.515 47000
40 104 0.955 1105 -42 -44 4.553 55100
38 100 1.023 1214 -44 -47 4.591 63200
36 97 1.091 1323 -46 -51 4.629 71300
34 93 1.159 1432 -48 -54 4.667 79400
32 90 1.227 1541 -50 -58 4.705 87500
30 86 1.295 1650
4-62
EFI EPROM CHIP USAGE CHART (1991-1998)
PART MODEL SYSTEM FUEL COLOR/ PART MODEL SYSTEM FUEL COLOR/
NUMBER SYMBOL NUMBER SYMBOL
3004-103 1991 700 Battery Gas Red 3004-305 1994 440 Battery Ethanol Blue
3004-104 1991 700 Battery Gas Yellow 3004-662 1995 700 Battery Gas Red
3004-105 1991 700 Battery Gas Blue 3004-663 1995 700 Battery Gas Yellow
3004-242 1991 700 Battery Ethanol Red 3004-664 1995 700 Battery Gas Blue
3004-243 1991 700 Battery Ethanol Yellow 3004-732 1995 700 Battery Ethanol Red
3004-244 1991 700 Battery Ethanol Blue 3004-733 1995 700 Battery Ethanol Yellow
3004-240 1992 550 Battery Ethanol Yellow 3004-735 1995 580 Battery Ethanol Red
3004-241 1992 550 Battery Ethanol Blue 3004-736 1995 580 Battery Ethanol Yellow
3004-246 1992 700 Battery Ethanol Yellow 3004-933 1996 580 Battery Gas Red
3004-247 1992 700 Battery Ethanol Blue 3004-934 1996 580 Battery Gas Yellow
3004-291 1993 700 Battery Gas Red 3004-935 1996 580 Battery Gas Blue
4
3004-292 1993 700 Battery Gas Yellow 3004-938 1996 580 Battery Ethanol Red
3004-293 1993 700 Battery Gas Blue 3004-939 1996 580 Battery Ethanol Yellow
3004-248 1993 700 Battery Ethanol Red 3004-940 1996 580 Battery Ethanol Blue
3004-248 1993 700 Battery Ethanol Yellow 3005-036 1997 580 Battery* Gas Red
3004-250 1993 700 Battery Ethanol Blue 3005-037 1997 580 Battery* Gas Yellow
3004-271 1993 550 Battery Gas Red 3005-038 1997 580 Battery* Gas Blue
3004-272 1993 550 Battery Gas Yellow 3005-092 1997 580 Battery* Ethanol Red
3004-273 1993 550 Battery Gas Blue 3005-093 1997 580 Battery* Ethanol Yellow
3004-239 1993 550 Battery Ethanol Red 3005-094 1997 580 Battery* Ethanol Blue
3004-240 1993 550 Battery Ethanol Yellow 3005-088 1997 580 Batteryless Gas O
3004-241 1993 550 Battery Ethanol Blue 3005-089 1997 580 Batteryless Gas Q
3004-681 1994 700 Battery Gas Red 3005-090 1997 580 Batteryless Gas V
3004-682 1994 700 Battery Gas Yellow 3005-098 1997 580 Batteryless Ethanol O
3004-683 1994 700 Battery Gas Blue 3005-099 1997 580 Batteryless Ethanol Q
3004-312 1994 700 Battery Ethanol Red 3005-100 1997 580 Batteryless Ethanol V
3004-313 1994 700 Battery Ethanol Yellow 3005-036 1998 580 Battery Gas Red
3004-314 1994 700 Battery Ethanol Blue 3005-037 1998 580 Battery Gas Yellow
3004-902 1994 580 Battery Gas Red 3005-038 1998 580 Battery Gas Blue
3004-903 1994 580 Battery Gas Yellow 3005-092 1998 580 Battery Ethanol Red
3004-904 1994 580 Battery Gas Blue 3005-093 1998 580 Battery Ethanol Yellow
3004-309 1994 580 Battery Ethanol Red 3005-094 1998 580 Battery Ethanol Blue
3004-304 1994 440 Battery Ethanol Yellow
* DC EPROM will not interchange with previous years.
NOTE: Kokusan EPROM must be marked K.
4-63
EFI EPROM CHIP USAGE CHART (1999-2001*)
PART MODEL SYSTEM FUEL COLOR/ PART MODEL SYSTEM FUEL COLOR/
NUMBER SYMBOL NUMBER SYMBOL
3005-463 1999 600 Batteryless Both O 3005-672 2000 600 Batteryless Both O
3005-464 1999 600 Batteryless Both Q 3005-673 2000 600 Batteryless Both Q
3005-465 1999 600 Batteryless Both V 3005-674 2000 600 Batteryless Both V
3005-819 2001 580 Batteryless Both O
NOTE: Kokusan EPROM must be marked K. 3005-820 2001 580 Batteryless Both Q
3005-821 2001 580 Batteryless Both V
* It is not possible to replace the EPROM chip on 2002

models.
Troubleshooting Fuel
System (EFI)
Problem: Too Rich

Condition Remedy
1. LED trouble code 1. Replace problem sensor
2. Fuel pressure too high 2. Replace regulator
3. Fuel return hose obstructed 3. Service — replace hose — remove obstruction
4. Injectors leaking 4. Replace injectors
Problem: Too Lean
Condition Remedy
1. LED trouble code 1. Replace problem sensor
2. Fuel pressure too low 2. Replace regulator/fuel pump
3. Vent hose obstructed 3. Remove obstruction
4. Fuel filter(s) obstructed 4. Replace fuel filter(s)
4-64
EFI Wiring Diagram (600 cc)
0686-733
4-65
EFI Wiring Diagram (800 cc)
0686-846
4-66
Fuel System
(Related Items)
Some components may vary from model to model.

The technician should use discretion and sound judg-
ment when removing and installing components.
Whenever any maintenance or inspection is made on
the fuel system in which fuel leakage may occur, there
should be no welding, smoking, or open flames in the
area.
AB078
NOTE: Some illustrations and photographs used 7. Pull the oil-injection pump away from the engine
and are not designed to depict actual conditions. and account for a gasket.
8. Turn the pump sideways; then remove the lower
union bolt. Account for two gaskets. Remove the
pump.
Fuel System 9. Remove the remaining union bolts securing the
(Related Items) check valves to the pump. Account for two
Table of Contents gaskets.
10. Remove the check valves. Account for two
Oil-Injection Pump................................................. 4-67
Synchronizing Oil-Injection Pump ......................... 4-68
Bleeding Oil-Injection System ............................... 4-68
gaskets. 4
INSTALLING
Testing Oil-Injection Pump .................................... 4-69
Testing Oil-Injection Check Valves ........................ 4-70
Fuel Pump (Carbureted Models)........................... 4-70
1. In turn on each front union bolt, install a gasket,
Air-Intake Silencer (One-Piece Style) ................... 4-72 check valve, and gasket; then install on the oil-
Air-Intake Silencer (Cover/Tool Tray Style)............ 4-72 injection pump.
Gas Tank/Seat Assembly ...................................... 4-73
2. Place the gasket and oil-injection pump near the
engine; then install the lower union bolt through a
gasket, check valve, and gasket.
Oil-Injection Pump 3. Position the oil-injection pump on the engine

making sure the oil-injection pump gear is
correctly aligned with the oil-injection pump drive
REMOVING gear.
1. Turn the gas tank shut-off valve to the CLOSED 4. Secure the pump with two screws, lock washers,
position. and washers. Tighten screws to 0.7 kg-m (5 ft-lb).
2. If applicable, remove the carburetors. 5. Connect the two oil-delivery hoses to the adapter
plates. Secure with clamps.
3. Disconnect the oil-supply hose from the pump and
plug to prevent oil drainage. 6. Connect the oil-injection cable/control rod to the
pump and secure.
4. Remove the two oil-delivery hoses from the
adapter plates. 7. Connect the oil-supply hose to the oil-injection
pump inlet fitting. Secure with the clamp.
5. Disconnect the oil-injection cable/control rod.
8. Bleed the oil-injection system (see Bleeding Oil-
6. Remove the two screws, lock washers, and Injection System in this sub-section).
washers securing the oil-injection pump and
retainer to the crankcase. 9. Check the oil-injection system synchronization
(see Synchronizing Oil-Injection Pump in this sub-
section). Tighten the jam nuts securely.
10. If applicable, install the carburetors.
11. Turn the shut-off valve to the OPEN position.
4-67
Synchronizing Oil- Bleeding Oil-Injection
Injection Pump System
CHECKING
! CAUTION
1. With the ignition switch key in the OFF position, Whenever bleeding the oil-injection system, use
move the throttle lever to the full-open position. a 100:1 gas/oil mixture in the gas tank to ensure
adequate engine lubrication. Failure to use the
2. Check the alignment of the mark on the pump 100:1 mixture during oil-injection system
housing and the mark on the control arm. If the bleeding will result in severe engine damage.
marks align, the oil-injection pump is
synchronized with the carburetors and no 1. Fill the oil reservoir with recommended injection
adjustment is necessary. If the marks do not align, oil.
adjust until alignment is attained.
2. Place an absorbent towel below the oil bleed
screw; then remove the bleed screw from the
pump. Allow the oil to flow through the oil-supply
hose until the hose is filled with oil and free of air
bubbles; then install the bleed screw.
NOTE: To aid in bleeding the oil system, blow
into the vent hose to force the oil toward the pump.
The oil reservoir cap must be on for this proce-
dure.
727-185C
ADJUSTING
1. Loosen the jam nuts securing the cable/control rod

adjuster.
2. Move the throttle lever to the full-open position.
3. Rotate the jam nuts/control rod in the proper
direction until the marks align. 727-185C
4. Lock the jam nuts to secure the adjustment. 3. Using a shielded safety stand, raise the rear of the
snowmobile. Engage the brake lever lock; then
start the engine and allow it to idle.
4. Using a stiff wire with a hooked end, pull the
control arm upward to the full-open position.
! WARNING
Keep hands and clothing away from all moving or
rotating parts.
5. Idle the engine until oil flowing to the top of the

oil-delivery hoses is free of air bubbles.
6. When oil flows free of all air bubbles, shut the
engine off and check for leakage.
7. Release the brake lever lock.
4-68
5. Secure the tool to the oil reservoir by twisting the
Testing rubber strap one half turn and placing the rubber
strap around the tool and the oil reservoir filler
Oil-Injection Pump neck.
! WARNING
! WARNING
Keep hands and clothing away from all moving or
Always wear safety glasses when performing this rotating parts.
test.
6. Start the engine and run the engine at 3000 RPM
1. Clamp off the oil-supply hose between the oil for 3 minutes with the control arm in the FULL-
reservoir and oil pump; then remove the supply CLOSED position. Compare the amount of oil
hose from the pump. used against the specifications on the chart.
2. Attach a suitable length of oil-supply hose to the 7. Using a stiff wire, pull the oil-injection control
oil pump; then using Oil Injection Usage Tool (p/n arm to the FULL-OPEN position. Run the engine
0644-007), fill the hose with Arctic Cat 50:1 at 3000 RPM for 2 minutes. Compare the amount
Injection Oil. of oil used against the specifications on the chart.
NOTE: On APV equipped engines, use Arctic Cat
Synthetic APV 2-Cycle Oil (p/n 2639-512).
Oil Consumption @3000 RPM
FULL-
FULL-OPEN
MODEL CLOSED
3 Minutes 2 Minutes
370 cc
440 cc
0.975-1.86 cc
2.5-4.6 cc
5.4-6.6 cc
6.2-9.2 cc
4
500 cc 2.0-3.9 cc 11.3-14.1 cc
550 cc 2.0-4.3 cc 10.2-15.5 cc
570 cc * *
600 cc Twin 2.0-3.9 cc 11.3-14.1 cc
600 cc Triple 1.1-2.2 cc 11.3-14.1 cc
AE108 600 cc EFI 1.727-4.247 cc 9.224-11.558 cc
800 cc 1.3-2.0 cc 12.2-18.4 cc
NOTE: When filling the oil-supply hose with oil,
do not insert the usage tool until it is tight in the 1000 cc 1.3-3.7 cc 16.2-19.8 cc
hose. There must be enough room around the tip
of the tool and the hose to allow air in the hose to * Specifications not available at time of
escape. publication.
3. Fill the usage tool with recommended oil to the 0 8. If the oil-injection pump output does not meet the
line. specifications, see Testing Oil-Injection Check
Valves in this sub-section.
4. Wipe the tip of the tool to remove excess oil; then
attach the tool to the oil-supply hose and remove 9. Disconnect the oil usage tool, remove the plug
the bulb. from the reservoir, attach the oil-supply hose to
the oil reservoir, and remove the vacuum pump.
10. Bleed the oil-injection system (see Bleeding Oil-
Injection System in this sub-section).
4-69
Testing Oil-Injection Fuel Pump
Check Valves (Carbureted Models)
In the event there is an engine problem due to lack of NOTE: When servicing a fuel pump, determine
lubrication, the oil-injection pump check valves should which style pump is being serviced and follow the
be tested using a vacuum pump to make sure the check appropriate procedure.
valves are operating properly.
PRELIMINARY CHECKS
When testing the check valves, remove them from the
pump assembly. 1. Make sure the gas tank shut-off valve is in the
OPEN position.
1. Remove the check valves from the oil-injection
pump. 2. Make sure there is adequate gasoline in the gas
tank.
KEY 3. Make sure all hoses are clear and free of kinks and
1. Gasket
2. Check Valve
obstructions.
3. Gasket
4. Union 4. Make sure the fuel filter is not plugged or
damaged.
5. Make sure fuel and impulse hoses are in good
condition.
6. Make sure there is evidence of good impulse at the
crankcase impulse fitting.
TESTING PRESSURE
731-551A
1. Connect a pressure gauge between fuel pump and
2. Attach the vacuum test pump hose to the check carburetor using a piece of fuel hose and a T-
valve. fitting.
3. Squeeze the vacuum pump handle and watch the 2. Place snowmobile on a safety stand and start the
pump gauge. The check valve should release at engine. At the following engine speeds, the
4.5-5 lb and again reset itself at 3.5-4 lb. If specified pressures must be indicated.
“release” and “reset” are not within specifications,
replace the check valve. RPM psi kg/cm²
4. Record the “release” and “reset” readings for the 1000-2000 3.0-3.5 0.21-0.25
valve; then perform the test on the other valve. 3000-4000 4.5-5.5 0.32-0.39
The “release” and “reset” readings must fall within 5000-6000 6.0-7.0 0.42-0.49
specifications and must be within 1.5 lb of each
other. If either or both are not met, replace the
check valves. 3. Remove gauge and hose and connect fuel hose to
carburetor.
5. If the check valves are within specifications but TESTING VACUUM
the oil-injection usage is not, replace the oil-
injection pump. NOTE: Make sure adequate fuel is in the carbure-
tor for this test.

position; then disconnect fuel supply hose from
the shut-off valve.
2. Connect a vacuum gauge directly to the fuel pump
inlet fitting.
4-70
3. With snowmobile on a safety stand, start the
KEY
engine and accelerate to 2000-3000 RPM for a 1. Packing
period of 30 seconds. Note maximum reading of 2. Diaphragm
gauge. Reading must be within the range listed. 3. Packing
4. Valve Section w/Grommets
Acceptable Fuel Pump Vacuum (2-3000 RPM)

in.-hg mm-hg
7-10 175-250
4. Stop engine. Connect fuel hose. Turn the shut-off

valve to the OPEN position.
SERVICING
KEY
1. Case
2. Membrane 0728-279
3. Diaphragm
4. Gasket 2. Remove the screws securing the fuel pump; then
5. Case from the top of the fuel pump, remove the top,
6. Screw
packing, diaphragm, packing, valve section,
packing, diaphragm, and packing.
NOTE: Be sure all fuel pump components are
clean and the fittings are tight.
3. Push the grommets out of the valve section; then

remove the valve from each grommet. 4
4. Place a valve onto each grommet; then push each
valve with grommet into the valve section.
0727-830
5. In sequence on the bottom of the fuel pump, place
1. Scribe a line across the fuel pump sections. a packing, diaphragm, packing, valve section,
packing, diaphragm, packing, and top.
2. Remove the screws securing the fuel pump; then
from the top of the fuel pump, remove the top NOTE: Make sure the scribed line made during
case, gasket, diaphragm, and membrane. disassembly is aligned.
NOTE: Be sure all fuel pump components are 6. Secure the fuel pump with the screws. Tighten
clean and the fittings are tight. securely.
3. In sequence on the bottom case of the fuel pump, SERVICING
place the membrane, diaphragm, gasket, and top
case.
NOTE: Make sure the scribed line made during
disassembly is aligned and the tabs on the two
lower packings align with the tabs on the bottom
and valve section of the pump.
4. Secure the fuel pump with the screws. Tighten

securely.
SERVICING
1. Scribe a line across the fuel pump sections.
730-349N
4-71
1. Scribe a line across the fuel pump sections. 2. Remove the Phillips-head screws and lock
washers securing the fuel pump sections; then
2. Remove the screws and lock washers securing the from the top of the fuel pump, remove the cap,
fuel pump; then from the top of the fuel pump, gasket, diaphragm, gasket, valve section, gasket,
remove the cap, thick packing, diaphragm, thin diaphragm, and gasket.
rubber packing, valve section, thin rubber packing,
diaphragm, and thick packing. NOTE: Be sure all fuel pump components are
clean and the fittings are tight.
3. Push the grommets out of valve section; then
remove the valve from each grommet. 3. Push the grommets out of the valve section; then
remove the valve from each grommet.
NOTE: Be sure all fuel pump components are
clean and the fittings are tight. 4. Place a valve onto each grommet; then push each
valve with grommet into the valve section of the
4. Place a valve onto each grommet; then push each fuel pump.
valve with grommet into the valve section of the
fuel pump. 5. In sequence on the bottom of the fuel pump, place
a gasket, diaphragm, gasket, valve section, gasket,
5. In sequence on the bottom of the fuel pump, place diaphragm, gasket, and cap.
a thick packing, diaphragm, thin rubber packing,
valve section, thin rubber packing, diaphragm, NOTE: Make sure the scribed line made during
thick rubber packing, and cap. disassembly is aligned and the tabs on the two
upper gaskets align.
NOTE: Make sure the scribed line made during
disassembly is aligned and the tabs on the two 6. Secure the fuel pump with the Phillips-head
lower packings align with the tabs on the bottom screws and lock washers. Tighten securely.
and valve section of the pump.
6. Secure the fuel pump with the screws and lock

washers. Tighten securely.
Air-Intake Silencer
SERVICING (One-Piece Style)
The air-intake silencer is a specially designed compo-

nent used to silence the incoming fresh air and also to
catch the fuel that “spits back” out of the carburetors.
The carburetors are calibrated with the air-intake
silencer in position; therefore, the engine must never
be run with the air-intake silencer removed.
1. Check for holes or cracks in the silencer.

2. Periodically clean the silencer by blowing fresh air
734-292C
through it.
Air-Intake Silencer
(Cover/Tool Tray Style)
The air-intake silencer is a specially designed compo-

nent used to silence the incoming fresh air and also to
catch the fuel that “spits back” out of the throttle body/
carburetors. The throttle body/carburetors are cali-
brated with the air-intake silencer in position; there-
fore, the engine must never be run with the air-intake
silencer removed.
734-292D

1. Scribe a line across the fuel pump sections.
1. Check for holes or cracks in the silencer.
4-72
2. Periodically clean the silencer by removing the NOTE: If applicable, remove the backrest and
cover/tool tray assembly and vacuuming the rack (see Section 7).
interior of the silencer.
1. Remove the console (see Section 7).
2. Remove the two cap screws, washers, and lock
nuts (located in the rear compartment) securing the
Gas Tank/Seat seat to the tunnel.
Assembly 3. Remove the vent hose from the gas tank.
NOTE: Determine which style gas tank/seat 4. Disconnect the wiring harness from the fuel pump.
assembly is being removed and installed and use
the specific sub-section accordingly. ! CAUTION
Since the fuel supply hose may be under
! WARNING pressure, remove it slowly to release the
pressure. Place an absorbent towel around the
Whenever any maintenance is performed on the connection to absorb fuel.
fuel system, there should be no welding, smoking,
open flames, etc., in the area.
5. Label the fuel hoses “supply” and “return”; then
remove the hoses from the fuel pump.
REMOVING (EFI Models)
6. Raise the rear of the seat high enough to
disconnect the taillight wiring harness; then
remove the seat.
INSTALLING (EFI Models)
4
1. Place the seat in position on the tunnel; then
connect the taillight wiring harness.
2. Connect the vent hose to the gas tank.
3. Connect the fuel supply and return hoses to the
fuel pump. Secure with clamps.
NOTE: The fuel hoses must be connected to
KEY their respective fittings and tightened securely or
1. Gas Tank/Seat- 16. Rivet 31. Self-Tapping leakage will result.
Base 17. Clamp Screw
2. Plug 18. Fuel Pump 32. Machine Screw
3. Tape Assy 33. T-Fitting 4. Attach the wiring harness to the fuel pump.
4. Foam 19. Fuel Pump 34. Hose
5. Washer
6. Insert
20. Retaining Ring
21. Spring
35. Clamp
36. Cover
5. Secure the seat to the tunnel with two screws,
7. Lock Nut 22. Hose 37. Staple washers, and lock nuts.
8. Cap Screw 23. Harness 38. Seat Wire
9. Washer 24. Connector 39. Foam 6. Install the console (see Section 7).
10. Cap Nut 25. O-Ring 40. Seat Wire
11. Retaining Ring 26. Hose 41. Hose NOTE: If applicable, install the backrest and rack
12. Cap 27. Fuel Pickup 42. Clamp
13. Seal 28. Fuel Pickup 43. Clip
(see Section 7).
14. Gasket 29. Washer 44. Vent
15. Extension 30. Washer 45. Float Arm Assy
0735-090
4-73
REMOVING (Carbureted Models) 4. Slide the gas tank/seat assembly rearward; then
remove the vent hose from the gas tank fitting.
Disconnect the taillight wiring harness and
remove.
5. Drain all gasoline from the tank; then (if
necessary) remove the tank outlet assembly and
vent fitting.
INSTALLING (Carbureted Models)
1. If removed, apply teflon tape to the threads of the

tank outlet fitting and vent fitting; then thread each
into the tank.
2. Slide the gas tank/seat assembly into position.
Install the vent hose on the vent fitting and connect
the gas hose to the shut-off valve.
KEY
1. Gas Tank/Seat-Base 17. Cap Nut
2. Tank Outlet 18. Clamp ! CAUTION
3. Hose 19. Insert
4. Vent 20. Extension Check the vent and gas hoses to be sure they are
5. Strainer 21. Washer not kinked or making contact with the driven
6. Staple 22. Foam shaft.
7. Clip 23. Seat Wire
8. Hose 24. Self-Tapping Screw
9. Cap 25. Cover 3. Place the gas tank/seat assembly into position,
10. Seal 26. Rivet connect the taillight harness, and secure with lock
11. Seat Wire 27. Fuel Level Sensor nuts and washers.
12. Foam 28. Gasket
13. Lock Nut 29. Washer
14. Washer 30. Machine Screw
4. Install and secure the console.
15. Cap Screw 31. Clamp
16. Washer
0735-157
NOTE: If applicable, remove the backrest and

rack (see Section 7).
1. Remove the two lock nuts and washers (located in

the rear tool compartment) securing the seat to the
tunnel.
2. Remove the hose from the gas tank shut-off valve.
Plug the hose to prevent drainage.
3. Remove the screws securing the console; then AL142D
remove the console. 5. Turn the gas tank shut-off valve to the OPEN
position.
6. Inspect the entire fuel system for leaks.
NOTE: If applicable, install the backrest and rack
(see Section 7).
AL142D
4-74
SECTION 5 — ENGINE
ELECTRICAL SYSTEMS
TABLE OF
CONTENTS
2002 Electrical Specifications Chart ....................... 5-2
Resistance Tests Chart ........................................... 5-2
Electrical Specifications (Individual)........................ 5-3
Transistorized Ignition System (120 cc Model)...... 5-13
Testing Electrical Components.............................. 5-13
Troubleshooting/Testing Ignition System
120 cc Model...................................................... 5-13
5
EFI Models......................................................... 5-14
Fan Cooled Models ............................................ 5-15
Twin L/C & Triple Models.................................... 5-19
Digital 3-D Ignition
(500/600/800/1000 cc Models) .......................... 5-22
Testing Main Wiring Harness (120 cc Model)........ 5-24
Testing Electrical Resistances
120 cc Model...................................................... 5-24
EFI Models......................................................... 5-25
370 cc Models/440 cc Panther Model ................ 5-27
500/600 cc Twin Carburetor Models................... 5-28
440 cc Z Models/550 cc Models ........................ 5-29
600 cc Triple Model ............................................ 5-31
800 cc Carbureted Models ................................. 5-32
570/1000 cc Models........................................... 5-33
Peak Voltage Tests (Fan Cooled Models).............. 5-35
Peak Voltage Tests (Carbureted APV Models) ...... 5-36
Peak Voltage Tests (EFI Models/550/
1000 cc Models)................................................. 5-37
Testing Low-Oil Light Sensor................................. 5-37
Testing High Temperature Sensor ......................... 5-38
Testing High Temperature Warning Light .............. 5-38
Testing Fuel Gauge ............................................... 5-38
Testing Fuel Gauge Sender .................................. 5-38
Testing Electric Fuel Pump.................................... 5-39
Electric Start Components
Solenoid ............................................................. 5-39
Charging Diode .................................................. 5-39
Fuse ................................................................... 5-39
Ignition Switch - Electric Start Function ............. 5-39
Starter Motor ...................................................... 5-40
Troubleshooting Electric Start ............................ 5-46
Wire Color Code and Function Description........... 5-47
Ignition Timing....................................................... 5-48
2002 Ignition Timing Specifications....................... 5-49
2002 Wiring Diagram Index (Ignition).................... 5-56
2002 Wiring Diagrams........................................... 5-57
5-1
2002 ELECTRICAL SPECIFICATIONS CHART
IGNITION TIMING SPARK PLUG GAP LIGHTING
ENGINE IGNITION SPARK PLUG IGNITION
MODEL COIL OUTPUT
5-2
MODEL MANUFACTURER Degrees mm in. (NGK) mm in. TYPE
@3000 RPM
120 cc AA12A1 Kokusan Denki Fixed N/A N/A BPR6ES 0.7-0.8 0.028-0.031 TRANSISTORIZED 12V/55W
370 cc AA37A4 Kokusan Denki *18 ➆ 2.012 0.079 BR9EYA 0.7-0.8 0.028-0.031 OPEN 12V/185W
440 cc AS44A5 Kokusan Denki *18 ➆ 2.012 0.079 BR9EYA 0.7-0.8 0.028-0.031 OPEN 12V/185W
500 cc AU50L6 Kokusan Denki 25 ➆ 3.671 0.145 BR9EYA 0.7-0.8 0.028-0.031 OPEN 12V/210W
570 cc AA56A1 Kokusan Denki *18 ➆ 2.049 0.081 BR9EYA 0.7-0.8 0.028-0.031 OPEN 12V/210W
550 cc ACB55L3 Kokusan Denki *33 ➆ 6.556 0.258 BR9EYA 0.7-0.8 0.028-0.031 OPEN 12V/180W
600 cc EFI AD60L6 Kokusan Denki 24 ➃ 3.390 0.133 BR9EYA 0.7-0.8 0.028-0.031 OPEN 12V/175W
600 cc Twin Carb AF60L6 Kokusan Denki 24 ➆ 3.390 0.133 BR9EYA 0.7-0.8 0.028-0.031 OPEN 12V/210W
600 cc Triple AG60L8 Kokusan Denki 18 ➆ 2.012 0.079 BR9EYA 0.7-0.8 0.028-0.031 OPEN 12V/210W
800 cc Carb AA78L2 Kokusan Denki 14 ➆ 1.417 0.056 BR9EYA 0.7-0.8 0.028-0.031 OPEN 12V/210W
800 cc EFI AB78L2 Kokusan Denki 26 ➈ 4.796 0.189 BR9EYA 0.7-0.8 0.028-0.031 OPEN 12V/190W
1000 cc AA10L5 Kokusan Denki 16 ➂ 1.556 0.061 BR9EYA 0.7-0.8 0.028-0.031 OPEN 12V/185W
➀ 6000 RPM ➄ 5000 RPM * Engine Warm
➁ 4000 RPM ➅ 1800 RPM
➂ 3250 RPM ➆ 2000 RPM
➃ 3500 RPM ➇ 3000 RPM
➈ 2500 RPM
RESISTANCE TESTS CHART

KOKUSAN
ITEM 600 cc - 370 cc,

600/800 cc 440 cc (Z), 800 cc 500 cc 600 cc -
Twin 1000 cc 570 cc 440 cc 120 cc
EFI 550 cc (carbureted) Triple
(carbureted) (Panther)
Ignition Coil — Primary 0.34 ± 20% 0.30 ± 20% 0.30 ± 15% 0.34 ± 15% 0.30 ± 15% 0.30 ± 20% 0.34 ± 20% 0.34 ± 15% 0.30 ± 15% N/A
OR ↔ B OR ↔ B OR ↔ B POS ↔ NEG OR ↔ B OR ↔ B OR ↔ B POS ↔ NEG OR ↔ B
Ignition Coil — Secondary 8500 ± 20% 8500 ± 20% 8500 ± 20% 7900 ± 20% 8500 ± 20% 8500 ± 20% 8500 ± 20% 7900 ± 20% 8500 ± 20% N/A
HT ↔ HT HT ↔ HT HT ↔ HT HT ↔ HT HT ↔ HT HT ↔ HT HT ↔ HT HT ↔ HT HT ↔ HT
HT ↔ POS HT ↔ POS
Lighting Coil 0.15 ± 20% 0.10 ± 20% 0.22 ± 20% 0.15 ± 20% 0.15 ± 20% 0.10 ± 20% 0.15 ± 20% 0.15 ± 20% 0.22 ± 20% 0.57 ± 20%
Y↔Y Y↔Y Y↔Y Y↔Y Y↔Y Y↔Y Y↔Y Y↔Y Y↔Y Y↔Y
Abbreviation:
Stator Coil (Charge) N/A N/A N/A N/A N/A N/A N/A N/A 160 ± 20% N/A
B — Black
R/W ↔ B/R BL — Blue
(DC Power) 0.89 ± 20% N/A N/A N/A N/A 0.65 ± 20% 0.89 ± 20% 0.89 ± 20% N/A N/A W — White
R/Y ↔ Y/R R/Y ↔ Y/R R/Y ↔ Y/R R/Y ↔ Y/R Y — Yellow
(Charge 1) N/A 17 ± 20% 160 ± 20% 15 ± 20% 15 ± 20% N/A N/A N/A N/A N/A R — Red
G — Green
B/R ↔ G/R R/W ↔B/W B/R ↔ G/R B/R ↔ G/R BR — Brown
(Charge 2) N/A 17 ± 20% 17 ± 20% 15 ± 20% 15 ± 20% N/A N/A N/A N/A N/A GRND — Ground
BR/W ↔G/R B/R ↔ R/W BR/W ↔ G/R BR/W ↔ G/R N/A — Not Applicable
OR — Orange
Ignition Timing Sensor 190 ± 20% 190 ± 20% N/A 190 ± 20% 185 ± 20% 185 ± 20% 190 ± 20% 100 ± 20% N/A N/A POS — Positive
HT — High Tension
G/W ↔ BR G/W ↔ BR G/W ↔ BR G/W ↔ BR G/W ↔ BR G/W ↔ BR G/W ↔ BR NEG — Negative
Injection Coil N/A 19 ± 20% N/A N/A N/A N/A N/A N/A N/A N/A
BL/W ↔ BL/W
Fuel Pump Coil N/A 1.9 ± 20% N/A N/A N/A N/A N/A N/A N/A N/A
OR ↔ OR
Spark Plug Cap 5000 ± 20% 5000 ± 20% 5000 ± 20% 5000 ± 20% 5000 ± 20% 5000 ± 20% 5000 ± 20% 5000 ± 20% 5000 ± 20% 5000 ± 20%
NOTE: EFI Models must use both resistor type spark plugs and spark plug caps.
Electrical
Specifications
(120 cc)
NOTE: The ignition system is transistorized.
Description Resistance Test + Test Connections -

Test Value
Lighting Coil 0.46-0.68 ohm yellow yellow
Spark-Plug Cap 4000-6000 ohms cap end cap end
Description Test Value + Test Connections -
Voltage Regulator 11-13 AC volts yellow brown
@ 2500-2700 RPM
Ignition Switch Less than 1 ohm terminal terminal
(key in OFF position)
Description Standard
Ignition Timing Fixed
Lighting Coil Output 12V/55W
Ignition Type Transistorized
Spark Plug NGKBPR6ES
Spark-Plug Gap 0.7-0.8 mm
(0.028-0.031 in.)
5-3
Electrical
Specifications
(370 cc/440 cc Panther)
NOTE: The ignition system is a Normally Open Ignition (NOI).

Test Value
Ignition Coil
Primary 0.25-0.34 ohm orange black
Secondary 6800-10,200 ohms high tension wire high tension wire
Stator Coil (Charge) 128-192 ohms red/white black/red
@ 2500-2700 RPM
Low Oil-Light Sending Less than 1 ohm terminal terminal
Unit (float end down)
Description Peak Voltage Test
RPM** 2000**
Primary Coil 170-187V
Secondary Coil 150-165V
Stator Coil (Charge) 200-220V
Lighting Coil 9.0-9.9V
Ignition Timing* 18° BTDC @ 2000 RPM
2.012 mm (0.079 in.)
Ignition Type CDI/NOI
(Normally Open Ignition)
Spark Plug NGKBR9EYA
(0.028-0.031 in.)
* Timing to be checked only with the engine at normal operating temperature.

** Engine RPM is approximate. Tests were made by pulling the recoil starter rope briskly, not with the engine
running.
NOTE: Lighting coil output is unregulated voltage.
5-4
Electrical
Specifications
(500 cc)

Test Value
Ignition Coil
DC Power Coil 0.71-1.07 ohms red/yellow yellow/red
Ignition Timing Sensor 152-228 ohms green/white brown
Voltage Regulator 11-13 AC volts red brown
@ 2500-2700 RPM
High Temperature Open (water temperature terminal ground
Sensor lower than 190°F)
Up to 20 ohms terminal ground
(water temperature
High Temperature
higher than 230°F)
Less than 10 ohms terminal terminal 5
Warning Light
RPM* 2000*
DC Power Coil 14.0-15.5V
Ignition Timing 25° BTDC @ 2000 RPM
3.671 mm (0.145 in.)
(0.028-0.031 in.)
* Engine RPM is approximate. Tests were made by pulling the recoil starter rope briskly, not with the engine
running.
5-5
Electrical
Specifications
(440 cc Z/550 cc)

Test Value
Ignition Coil
Charge Coil (1) 128-192 ohms red/white black/white
Charge Coil (2) 13.6-20.4 ohms black/red red/white
@ 2500-2700 RPM
(water temperature
higher than 230°F)
High Temperature Less than 10 ohms terminal terminal
Warning Light
Description Peak Voltage Test Description Standard
RPM** 2000** Ignition Timing* 18° BTDC @2000 RPM
(440 cc Z) 2.012 mm (0.079 in.)
Primary Coil 177-195V Ignition Timing* 33° BTDC @ 2000 RPM
(550 cc) 6.556 mm (0.258 in.)
Secondary Coil 170-187V Lighting Coil Output 12V/185W
(440 cc Z)
Charge Coil (1) 9.0-9.9V Lighting Coil Output 12V/180W
(550 cc)
Charge Coil (2) 9.0-9.9V Ignition Type CDI/NOI
Lighting Coil 10-11V Spark Plug NGKBR9EYA
(0.028-0.031 in.)

running.
5-6
Electrical
Specifications
(570 cc)

Test Value
Ignition Coil
Charge Coil (1) 12-18 ohms black/red green/red

Charge Coil (2) 12-18 ohms brown/white green/red
@ 2500-2700 RPM
RPM**
2000**
5
Charge Coil (1) 69-76V
Ignition Timing* 18° BTDC @ 2000 RPM
2.049 mm (0.081 in.)
(0.028-0.031 in.)

running.
5-7
Electrical
Specifications
(600 cc - Twin Carbureted)

Test Value
Ignition Coil
@ 2500-2700 RPM
(water temperature
higher than 230°F)
Warning Light
RPM* 2000*
3.390 mm (0.133 in.)
(0.028-0.031 in.)
running.
5-8
Electrical
Specifications
(600/800 cc EFI)

Test Value
Ignition Coil
Charge Coil (2) 13.6-20.4 ohms brown/white green/red
Charge Coil (1) 13.6-20.4 ohms black/red green/red
Injection Coil 15.2-22.8 ohms blue/white blue/white
Fuel Pump Coil 1.52-2.28 ohms orange orange
Up to 20 ohms
(water temperature
higher than 230°F)
terminal ground
5
Warning Light
Description Peak Voltage Test Description Standard
RPM* 2000* Ignition Timing 24° @ 3500 RPM
(600 cc EFI) 3.390 mm (0.133 in.)
Primary Coil 160-176V Ignition Timing 26° @ 2500 RPM
(800 cc EFI) 4.796 mm (0.189 in.)
Secondary Coil 130-143V Lighting Coil Output 12V/175W
(600 cc EFI)
Charge Coil (1) 100-110V Lighting Coil Output 12V/190W
(800 cc EFI)
Charge Coil (2) 85-94V Ignition Type CDI/NOI
Lighting Coil 6.0-6.6V Spark Plug NGKBR9EYA
Description Standard Spark-Plug Gap 0.7-0.8 mm
(0.028-0.031 in.)
running.
5-9
Electrical
Specifications
(600 cc Triple)

Test Value
Ignition Coil
Primary 0.29-0.39 ohm positive spade terminal negative spade terminal
Secondary
(Dual Lead) 6320-9480 ohms high tension wire high tension wire
(Single Lead) 6320-9480 ohms high tension wire positive spade terminal
@ 2500-2700 RPM
(water temperature
higher than 230°F)
Warning Light
RPM* 2000*
Ignition Timing 18° BTDC @2000 RPM
2.012 mm (0.079 in.)
(0.028-0.031 in.)
running.
5-10
Electrical
Specifications
(800 cc - Carbureted)

Test Value
Ignition Coil
@ 2500-2700 RPM
(water temperature
High Temperature
higher than 230°F)
Less than 10 ohms terminal terminal 5
Warning Light
RPM* 2000*
1.417 mm (0.056 in.)
(0.028-0.031 in.)
running.
5-11
Electrical
Specifications
(1000 cc)

Test Value
Ignition Coil
Primary 0.29-0.39 ohm positive spade terminal negative spade terminal
Secondary
(Dual Lead) 6320-9480 ohms high tension wire high tension wire
(Single Lead) 6320-9480 ohms high tension wire positive spade terminal
Charge Coil (1) 12-18 ohms black/red green/red
Charge Coil (2) 12-18 ohms brown/white green/red
@ 2500-2700 RPM
(water temperature
higher than 230°F)
Warning Light
RPM* 2000*
1.556 mm (0.061 in.)
(0.028-0.031 in.)
running.
5-12
The working voltage (VS) of the unit circuit is at level
Transistorized Ignition A when the engine is started, but as the engine speed
increases, the wave form of the voltage changes and
System advances to level B.
(120 cc Model)
The transistorized ignition system has no contact

points. Therefore, this ignition system does not require
periodic reconditioning of contact point surfaces or
point gap adjustment. As a result, a strong spark is pro-
duced even at low speeds so maximum reliability can
be ensured.
OPERATION
GEN-0009
Testing Electrical
Components
All tests of the engine electrical components should be
made using the digital Fluke Model 73 Multimeter
GEN-0008
(p/n 0644-191). Replace any component that does not
have a test value within specifications.
When the recoil starter handle is pulled, the flywheel is
turned. An electromotive force generated in the pri- NOTE: Whenever using a digital-style tester,
“open (infinite resistance)” denotes an overload
5
mary winding of the ignition coil makes the transistor
(TR1) conduct through the resistor (R) and forms the and the meter reading will be OL since the meter is
primary circuit (indicated by dashed lines). not calibrated to register resistance values of that
magnitude.
As the flywheel turns faster, the primary current NOTE: Whenever testing switches, less than 1
increases, and the terminal voltage of the circuit con- ohm is desirable with the switch in the activated
sisting of the resistor (R) and the transistor (TR1) position.
increases. This increases the working voltage at the
connection of the series circuit (r1 + r2) connected in
parallel to the primary circuit. As the flywheel turns
further, the terminal voltage of the resistor (r2) in the
resistor circuit (r1 + r2) rises to the level of working Troubleshooting
voltage of the transistor (TR2) when the ignition tim-
ing approaches the rated RPM, and, thus, the transistor
Ignition System
(TR2) is turned on. As a result, the base current of (120 cc Model)
(TR1) flowing through the resistor (R) is by-passed,
and the transistor (TR1) is turned off from the conduc- 1. Remove the spark plug and visually check its
tive state. condition. Replace if fouled. Adjust spark plug
gap to 0.7 mm (0.028 in.). Attach the high tension
The current flowing through the primary winding (2) lead to the spark plug and ground the plug on the
is thus interrupted, and rapid change occurs in the cylinder head.
magnetic flux across the ignition coil. The result is a
high surge voltage in the secondary winding (3). NOTE: Make sure the emergency stop switch is
in the ON (UP) position, the ignition switch is in the
SPARK ADVANCE RUN position, and the tether cord is connected to
CHARACTERISTIC the tether switch.
As noted above, the unit circuit detects a voltage and 2. Crank the engine over and check for a spark. If no
makes switching to produce a high voltage required to spark is present, disconnect the main wiring
produce a spark. On the other hand, the wave form of harness from the engine. Crank the engine over. If
the voltage generated in the primary winding changes spark is now present, the problem is either one or
as the flywheel turns. more of the following items.
5-13
A. Defective ignition switch
B. Defective emergency stop switch Troubleshooting
C. Defective wiring harness
Ignition System
(EFI Models)
D. Defective tether
When troubleshooting the standard “normally open”
ignition system, use the following procedure.
Testing Main Wiring 1. Remove the spark plugs and visually check their
condition. Replace any fouled plug. Attach the
Harness spark plugs to the high tension leads and ground
(120 cc Model) them on the cylinder heads.
! CAUTION
NOTE: The main wiring harness test can be
made using the Fluke Model 73 Multimeter (p/n Before checking for spark, place all the engine
0644-191). switches in the deactivated position. In the event
the engine could be flooded, pull the starter rope
1. Disconnect the engine wires from the main wiring (slowly at first) several times to clear the engine
harness. of excess fuel.
2. At the main wiring harness engine connector,

connect the red tester lead to the violet wire; then ! CAUTION
connect the black tester lead to the engine ground Never crank the engine over without grounding
(brown wire). the spark plugs. Damage to coils and/or CDI unit
may result.
3. With the ignition switch in the RUN position, the
emergency stop switch in the ON position, and the NOTE: Make sure the ignition switch and the
tether cord connected, the meter must read no emergency stop switch are in the ON position.
resistance. If the meter reads resistance,
disconnect the ignition switch from the main 2. Crank the engine over and check for spark. If no
wiring harness. If the meter now reads no spark is present, check to make sure the throttle
resistance, replace the ignition switch. cable is properly tensioned. Compress the throttle
control and while holding the throttle control in
this position, crank the engine over and check for
spark. If spark is now present, adjust the throttle
cable tension.
3. If no spark is present, disconnect the main wiring
harness from the engine. Crank the engine over. If
spark is present, the problem is either one or more
of the following:
A. Defective emergency stop switch
B. Defective safety switch in throttle-control
housing
725-704A C. Corroded or loose wire connection at the
4. If the meter continues to read resistance with the throttle-control housing or main wiring harness
ignition switch disconnected, disconnect the D. Defective ignition switch
emergency stop switch. If the meter now reads no
resistance, replace the emergency stop switch. E. Fouled spark plugs
5. If the meter continues to read resistance with both F. Defective charge coil (#1 and/or #2)
the ignition switch and the emergency stop switch
disconnected, disconnect the wires to the tether G. Defective ignition timing sensor
switch. If the meter now reads no resistance,
replace the tether switch. H. Defective ECU or loose or corroded connection
in wiring harness
6. If the meter continues to read resistance with all
three switches disconnected, replace the main NOTE: To check these possible causes, proceed
wiring harness. to Testing Ignition System.
5-14
2. Disconnect the throttle control switch connector;
Testing Ignition System then connect one ohmmeter lead to the brown wire
and the other lead to the black/white wire of the
(EFI Models) emergency stop switch.
3. With the throttle lever in the idle position and the
NOTE: There must be free-play between the emergency stop knob in the up (RUN) position,
throttle lever and the control housing. the meter must read no resistance (open). If the
meter reads resistance (closed), replace the switch.
MAIN WIRING AND SAFETY
SWITCHES 4. With the throttle lever in the idle position and the
emergency stop knob in the down (STOP)
1. Check the wiring connections coming from the position, the meter must read resistance (closed).
ignition key and emergency stop switches. The If the meter reads no resistance (open), replace the
throttle control switch connector is located on the switch. With the emergency stop knob still in the
front side of the steering post. If any of the down (STOP) position, move the throttle lever to
connections appear dirty or corroded, clean them the wide open position. The meter must read no
with fine sandpaper and compressed air; then resistance (open). If the meter reads resistance
connect all wires and squeeze the connections with (closed), replace the switch.
a pliers for additional tightness.
5. Connect one ohmmeter lead to the brown wire and
2. Disconnect the main wiring harness connector the other lead to the violet wire. With the
coming from the engine stator assembly. emergency stop knob in the down (STOP)
Disconnecting this connector will bypass the main position, the meter must read resistance (closed).
wiring harness and all switches which will not If the meter reads no resistance (open), replace the
allow the engine to be shut off without first switch. With the emergency stop knob in the up
installing an additional auxiliary ground wire. (RUN) position, the meter must read no resistance
(open). If the meter reads resistance (closed),
3. Insert an auxiliary ground wire into the black wire replace the switch.
of the four-wire main harness connector on the
engine side. To stop the engine once it has been
started, touch the auxiliary ground wire to the
engine.
4. Support the rear of the snowmobile up on a
Troubleshooting 5
shielded safety stand; then set the brake lever lock. Ignition System
Inspect the complete throttle mechanism to assure (Fan Cooled Models)
that it's working properly.
5. Attempt to start the engine. To stop the engine (if When troubleshooting the standard “normally open”
the engine starts), touch the auxiliary ground wire ignition system, use the following procedure.
installed into the four-wire connector to a ground
on the engine. If the engine fails to start, the 1. Remove the spark plugs and visually check their
problem is with the coils mounted on the engine, condition. Replace any fouled plug. Attach the
high tension coil assembly, or the ECU. If the spark plugs to the high tension leads and ground
engine starts, the problem is with the switches, them on the cylinder heads.
main wiring harness, or throttle cable free-play.
! CAUTION
IGNITION KEY SWITCH Before checking for spark, place all the engine
switches in the deactivated position. In the event
1. Disconnect the ignition key switch connectors; the engine could be flooded, pull the starter rope
then connect the ohmmeter leads to each of the (slowly at first) several times to clear the engine
ignition key switch terminals. of excess fuel.
2. With the switch in the OFF position, the meter
must read less than 1 ohm of resistance. ! CAUTION
3. With the switch in the ON position, the meter must Never crank the engine over without grounding
read OL (infinite resistance). the spark plugs. Damage to coils and/or CDI unit
may result.
THROTTLE CONTROL SWITCH
NOTE: Make sure the ignition switch and the
1. Verify that the throttle cable has free-play between emergency stop switch are in the ON position.
the throttle lever and control housing.
5-15
2. Crank the engine over and check for spark. If no MAIN WIRING AND SAFETY
spark is present, check to make sure the throttle SWITCHES
cable is properly tensioned. Compress the throttle
control and while holding the throttle control in 1. Check the wiring connections coming from the
this position, crank the engine over and check for ignition key and throttle control switches. The
spark. If spark is now present, adjust the throttle two-wire throttle control switch connector is
cable tension. located on the front side of the steering post. If any
of the connections appear dirty or corroded, clean
NOTE: On all models, there must be 0.75-1.5 mm them with fine sandpaper and compressed air; then
(0.030-0.060 in.) free-play between the throttle connect all wires and squeeze the connections with
lever and the control housing. a pliers for additional tightness.
2. Disconnect the main wiring harness four-wire
connector coming from the engine stator
assembly. Disconnecting the connector will
bypass the main wiring harness and all switches
which will not allow the engine to be shut off
without first installing an additional auxiliary
ground wire.
3. Insert an auxiliary ground wire into the black wire
of the four-wire main harness connector on the
engine side. To stop the engine once it has been
started, touch the auxiliary ground wire to the
engine.
733-081C 4. Support the rear of the snowmobile up on a
shielded safety stand; then set the brake lever lock.
3. If no spark is present, disconnect the main wiring Inspect the complete throttle mechanism to assure
harness from the engine. Crank the engine over. If that it's working properly.
spark is present, the problem is either one or more
of the following. 5. Attempt to start the engine. To stop the engine (if
the engine starts), touch the auxiliary ground wire
A. Defective emergency stop switch installed into the four-wire connector to a ground
B. Defective safety switch in throttle-control on the engine. If the engine fails to start, the
housing problem is with the coils mounted on the engine,
high tension coil assembly, or the CDI unit. If the
C. Grounded or shorted wire connection at the engine starts, the problem is with the switches,
throttle-control housing or main wiring harness main wiring harness, or throttle cable free-play.
D. Defective ignition switch MAIN HARNESS
NOTE: To check these possible causes, proceed 1. Disconnect the main wiring harness four-wire
to Testing Ignition System. If no spark is present, connector coming from the engine stator
proceed to Arctic Cat Ignition Analyzer in this sec-
tion. assembly. Connect one ohmmeter lead to the
violet wire and the other lead to the brown wire on
the chassis side of the main wiring harness four-
wire connector. With all switches in the RUN
position, the meter must read no resistance (open).
Testing Ignition System 2. If the meter reads resistance (closed), test the
(Single Carburetor F/C Models) Ignition Key Switch and Throttle Control Switch
independently of each other.
NOTE: The throttle control is equipped with a
two-wire throttle control switch connector. There IGNITION KEY SWITCH
must be 0.75-1.5 mm (0.030-0.060 in.) throttle cable
free-play between the throttle lever and the control 1. Disconnect the ignition key switch connectors;
housing. then connect the ohmmeter leads to each of the
ignition key switch terminals.
2. With the key switch in the OFF position, the meter
must read resistance (closed). If the meter reads no
resistance (open), the switch must be replaced.
5-16
THROTTLE CONTROL SWITCH 3. With all switches in the RUN position, the meter
NOTE: The throttle control has a two-wire wiring resistance (open), proceed to testing Emergency
harness connector located on the front side of the Stop/Throttle Switch, Carburetor Safety Switches,
steering post. Whenever working with a two-wire and Ignition Key Switch.
throttle control switch, the throttle cable must be
adjusted so there is 0.75-1.5 mm (0.030-0.060 in.)
free-play between the throttle lever and control EMERGENCY STOP/
housing. THROTTLE SWITCH
1. Verify that the throttle cable has the specified 1. If the meter read no resistance (open) in the
amount of free-play between the throttle lever and previous test, locate the wiring harness coming
control housing. from the emergency stop/throttle switch assembly.
2. Disconnect the two-wire throttle control switch 2. Disconnect the three-wire connector. Using an
connector; then connect the ohmmeter leads to ohmmeter, connect one meter lead to the black
each of the switch wires. wire and the other meter lead to the black/red wire
in the connector.
3. With the throttle lever in the idle position and the
emergency stop knob in the down (STOP) 3. With the emergency stop knob, located on top of
position, the meter must read resistance (closed). the throttle control, in the ON (pulled up) position
If the meter reads no resistance (open), replace the and the throttle lever compressed, the meter must
switch. read resistance (closed).
4. Depress the throttle lever with the emergency stop 4. If the meter reads no resistance (open) and the
knob in the up (RUN) position. The meter must lever/control housing free-play is correct, replace
read no resistance (open). If the meter reads the throttle switch.
resistance (closed), replace the switch. 5. If the meter reads resistance (closed) but the
5. With the throttle lever depressed and the engine will not start, with the ohmmeter leads still
emergency stop knob in the down (STOP) connected, alternately release and compress the
position, the meter must read resistance (closed). throttle lever; then move the emergency stop knob
If the meter reads no resistance (open), replace the down and up.
switch. 6. The meter must read no resistance (open) when the
throttle lever is released and the emergency stop
5
knob is in either the UP or the DOWN position.
7. If the meter reads resistance (closed), replace the
Testing Ignition System throttle switch.
(Twin Carburetor F/C Models)
8. Connect one meter lead to the black/red wire and
the other meter lead to the black/white wire.
NOTE: There must be 0.75-1.5 mm (0.030-0.060
in.) free-play between the throttle lever and the 9. With the throttle lever released (idle position) and
control housing (see Section 4 - Adjusting Carbu- the emergency stop knob in the DOWN position,
retors). the meter must read no resistance (open).
10. If above tests were good, proceed to testing
MAIN WIRING AND SAFETY Carburetor Safety Switches and Ignition Key
SWITCHES Switch.
1. Check the wire connections at the ignition key
switch and at the emergency stop switch. This CARBURETOR SAFETY SWITCHES
connector is located on the front side of the 1. If the meter read no resistance (open) in the
steering post. If any of the connections appear previous test, disconnect the carburetor safety
dirty or corroded, clean with fine sandpaper and switches one at time and test for a closed circuit.
compressed air; then connect all wires and squeeze
connections with a pliers for added tightness. 2. Attach the two ohmmeter leads to the two leads
coming from each carburetor switch. The meter
2. Disconnect the main wiring harness connector must read resistance (closed).
coming from the engine. Using an ohmmeter,
connect one lead to the black wire in the connector 3. If the meter reads no resistance (open), the switch
of the main harness. Connect the remaining must either be adjusted or replaced (see
ohmmeter lead to the brown wire in the connector Synchronizing Carburetor Safety Switches in this
of the main harness. sub-section). If the meter reads resistance (closed),
proceed to testing Ignition Key Switch.
5-17
IGNITION KEY SWITCH NOTE: The correct throttle lever/housing gap
should be in a range of 9.5 - 12.7 mm (0.375-0.500
1. If the meter read resistance (closed) in the in.) the moment the meter reading changes from
previous test, disconnect the ignition key switch open to closed. A switch that changes from open
connectors and connect the ohmmeter leads to to closed before the other one is the switch that
each of the leads from the switch. must be raised to attain safety switch synchroniza-
tion.
2. With the key switch in the OFF position, the meter
resistance (open), replace the switch.
SYNCHRONIZING CARBURETOR
SAFETY SWITCHES
Before synchronizing the carburetor safety switches,
check to make certain the carburetor idle speed screws
are adjusted equally and the piston valves are synchro-
nized. The carburetor safety switches affect ignition
spark at idle only. If ignition spark problems are
observed at partial or full-throttle positions, the prob-
lem is not with the carburetor safety switches.
733-082A
in.) free-play between the throttle lever and the 4. If an adjustment is necessary, loosen the switch
control housing. bracket screws, move the switch up, tighten the
screws, and then reset using step 3.
1. Inspect the cable free-play gap between the
throttle lever and the control housing at idle. NOTE: After completion of any adjustments,
Adjust the throttle cable swivel adapter at the top throttle lever “side pressure” should not cause an
of each carburetor for 0.75-1.5 mm (0.030-0.060 ignition miss at idle. Carburetor switches set too
in.) cable free-play gap between the throttle lever low or an excessively tight throttle cable makes
the shutdown system very sensitive to throttle
“nibs” and the control housing. While observing if lever “side pressure” near idle. To test carburetor
there is any cable free-play gap, apply slight safety switch synchronization, follow steps 5-9.
pressure to the throttle lever to take up any cable
slack that may be present. However, do not apply 5. Reconnect the carburetor safety switch
enough pressure to actually raise the carburetor connectors. Place the rear of the snowmobile on a
slides during this adjustment. After cable free-play shielded safety stand; then start the engine and
is properly adjusted, tighten the jam nut on each allow it to warm up for 3-4 minutes.
carburetor securely.
6. Hold both the top and bottom of the throttle lever
pin so that depression of the throttle lever does not
move the lever pin in its control slot.
733-081C
2. To determine which switch needs adjusting,

disconnect both carburetor safety switches from 0728-916
the main wiring harness connector.
7. Slowly depress the throttle lever to increase engine
3. Connect a digital ohmmeter to one carburetor RPM.
safety switch connector; then compress the throttle
lever while observing the meter reading and NOTE: It is very important that engine RPM be
measure the gap between the throttle lever and allowed to increase slowly, since most engines
control housing at the moment the meter reading have a “rich area” at approximately 2500 RPM.
changes from open to closed. Repeat this step for
the other carburetor safety switch.
5-18
8. Observe the tachometer and the drive clutch to 2. Crank the engine over and check for spark. If no
determine the moment the carburetor safety spark is present, check to make sure the carburetor
switches shut down the ignition. Since retaining throttle cables are properly tensioned. Compress
the throttle lever pin prevents the switch in the the throttle control and while holding the throttle
throttle control housing from closing, the control in this position, crank the engine over and
carburetor safety switches should shut down the check for spark. If spark is now present, adjust the
ignition at or slightly after clutch engagement. carburetor throttle cable tension.
9. Repeat steps 6-8 several times. If ignition 3. If no spark is present, disconnect the main wiring
shutdown always occurs at or slightly after clutch harness from the engine. Crank the engine over. If
engagement, the carburetor safety switches are spark is present, the problem is either one or more
synchronized. of the following:
10. Again, inspect the gap between the throttle lever A. Defective emergency stop switch
and the control housing at idle. Adjust the throttle
cable swivel adapter at the top of each carburetor B. Defective safety switch in throttle-control
for 0.75-1.5 mm (0.030-0.060 in.) cable free-play handle
gap between the throttle lever “nibs” and the C. Corroded or loose wire connection at the
control housing. While observing if there is any throttle-control housing or main wiring harness
cable free-play gap, apply slight pressure to the
throttle lever to take up any cable slack that may D. Defective ignition switch
be present. However, do not apply enough
pressure to actually raise the carburetor slides NOTE: To check these possible causes, proceed
during this adjustment. After cable free-play is to Testing Ignition System. If no spark is present,
properly adjusted, tighten the jam nut on each proceed to Peak Voltage Tests.
carburetor securely.
NOTE: After completion of any adjustments,
throttle lever “side pressure” should not cause an
ignition miss at idle. Carburetor safety switches Testing Ignition System
set too low or an excessively tight throttle cable (Twin L/C & Triple Models)
makes the shutdown system very sensitive to
throttle lever “side pressure” near idle.
NOTE: There must be 0.75-1.5 mm (0.030-0.060 5
in.) throttle cable free-play between the throttle
lever and the control housing.
Troubleshooting MAIN WIRING AND SAFETY
Ignition System SWITCHES
(Twin L/C & Triple Models)
1. Check the wiring connections coming from the
ignition key, emergency stop, and carburetor
When troubleshooting the standard “normally open” switches (on VM-style). The throttle control
ignition system, use the following procedure. switch connector is located on the front side of the
steering post. If any of the connections appear
1. Remove the spark plugs and visually check their dirty or corroded, clean them with fine sandpaper
condition. Replace any fouled plug. Attach the and compressed air; then connect all wires and
spark plugs to the high tension leads and ground squeeze the connections with a pliers for
them on the cylinder heads. additional tightness.
! CAUTION 2. Disconnect the main wiring harness connector
coming from the engine stator assembly.
Before checking for spark, place all the engine Disconnecting this connector will bypass the main
switches in the deactivated position. In the event wiring harness and all switches which will not
the engine could be flooded, pull the starter rope allow the engine to be shut off without first
(slowly at first) several times to clear the engine
of excess fuel. installing an additional auxiliary ground wire.
3. Insert an auxiliary ground wire into the black wire
! CAUTION of the main harness connector on the engine side.
To stop the engine once it has been started, touch
Never crank the engine over without grounding the auxiliary ground wire to the engine.
the spark plugs. Damage to coils and/or CDI unit
may result. 4. Support the rear of the snowmobile up on a
shielded safety stand; then set the brake lever lock.
NOTE: Make sure the ignition switch and the Inspect the complete throttle mechanism to assure
emergency stop switch are in the ON position. that it's working properly.
5-19
5. Attempt to start the engine. To stop the engine (if 5. Connect one ohmmeter lead to the brown wire and
the engine starts), touch the auxiliary ground wire the other lead to the violet wire. With the
installed into the connector to a ground on the emergency stop knob in the down (STOP)
engine. If the engine fails to start, the problem is position, the meter must read resistance (closed).
with the coils mounted on the engine, high tension If the meter reads no resistance (open), replace the
coil assembly, or the CDI unit. If the engine starts, switch. With the emergency stop knob in the up
the problem is with the switches, main wiring (RUN) position, the meter must read no resistance
harness, or throttle cable free-play. (open). If the meter reads resistance (closed),
replace the switch.
MAIN HARNESS
CARBURETOR SAFETY SWITCHES
1. Disconnect the main wiring harness connector (VM-Style)
coming from the engine stator assembly. Connect
one ohmmeter lead to the violet wire and the other 1. Disconnect both carburetor safety switches at the
lead to the brown wire on the chassis side of the carburetors from the main wiring harness.
main wiring harness four-wire connector. With all
switches in the RUN position, the meter must read 2. Connect the ohmmeter leads to one of the
no resistance (open). carburetor safety switches. With the throttle lever
in the idle position, the ohmmeter must read no
2. If the meter reads resistance (closed), test the resistance (open). If the meter reads resistance
Ignition Key Switch, Throttle Control Switch, and (closed), adjust the switch (see Synchronizing
Carburetor Safety Switches independently of each Carburetor Safety Switches in this sub-section).
other. Test the remaining switch.
IGNITION KEY SWITCH SYNCHRONIZING CARBURETOR

SAFETY SWITCHES
1. Disconnect the ignition key switch connectors; (VM-Style)
then connect the ohmmeter leads to each of the
ignition key switch terminals. Before synchronizing the carburetor safety switches,
check to make certain the carburetor idle speed screws
2. With the switch in the OFF position, the meter are adjusted equally and the throttle valves are syn-
must read less than 1 ohm resistance. chronized. The carburetor safety switches affect igni-
3. With the switch in the ON position, the meter must tion spark at idle only. If ignition spark problems are
read OL (infinite resistance). observed at partial or full-throttle positions, the prob-
lem is not with the carburetor safety switches.
THROTTLE CONTROL SWITCH
1. Verify that the throttle cable has 0.75-1.5 mm in.) free-play between the throttle lever and the
control housing.
(0.030-0.060 in.) free-play between the throttle
lever and control housing. 1. Inspect the cable free-play gap between the
2. Disconnect the throttle control switch connector; throttle lever and the control housing at idle.
then connect one ohmmeter lead to the brown wire Adjust the throttle cable swivel adapter at the top
and the other lead to the black/white wire of the of each carburetor for 0.75-1.5 mm (0.030-0.060
emergency stop switch. in.) cable free-play gap between the throttle lever
“nibs” and the control housing. While observing if
3. With the throttle lever in the idle position and the there is any cable free-play gap, apply slight
emergency stop knob in the up (RUN) position, pressure to the throttle lever to take up any cable
the meter must read no resistance (open). If the slack that may be present. However, do not apply
meter reads resistance (closed), replace the switch. enough pressure to actually raise the carburetor
slides during this adjustment. After cable free-play
4. With the throttle lever in the idle position and the is properly adjusted, tighten the jam nut on each
emergency stop knob in the down (STOP) carburetor securely.
position, the meter must read resistance (closed).
If the meter reads no resistance (open), replace the
switch. With the emergency stop knob still in the
down (STOP) position, move the throttle lever to
the wide open position. The meter must read no
resistance (open). If the meter reads resistance
(closed), replace the switch.
5-20
5. Reconnect the carburetor safety switch
connectors. Place the rear of the snowmobile on a
shielded safety stand; then start the engine and
allow it to warm up for 3-4 minutes.
6. Hold both the top and bottom of the throttle lever
pin so that depression of the throttle lever does not
move the lever pin in its control slot.
733-081C
2. To determine which switch needs adjusting,

disconnect both carburetor safety switches from
the main wiring harness connector.
3. Connect a digital ohmmeter to one carburetor
safety switch connector; then compress the throttle
lever while observing the meter reading and
measure the gap between the throttle lever and 0728-916
control housing at the moment the meter reading
changes from open to closed. Repeat this step for 7. Slowly depress the throttle lever to increase engine
the other carburetor safety switch. RPM.
NOTE: The correct throttle lever/housing gap NOTE: It is very important that engine RPM be
should be in a range of 9.5 - 12.7 mm (0.375-0.500 allowed to increase slowly, since most engines
in.) the moment the meter reading changes from have a “rich area” at approximately 2500 RPM.
open to closed. A switch that changes from open
to closed before the other one is the switch that 8. Observe the tachometer and the drive clutch to
must be raised to attain safety switch synchroniza-
tion.
determine the moment the carburetor safety
switches shut down the ignition. Since retaining 5
the throttle lever pin prevents the switch in the
throttle control housing from closing, the
carburetor safety switches should shut down the
ignition at or slightly after clutch engagement.
9. Repeat steps 6-8 several times. If ignition
shutdown always occurs at or slightly after clutch
engagement, the carburetor safety switches are
synchronized.
10. Again, inspect the gap between the throttle lever
and the control housing at idle. Adjust the throttle
cable swivel adapter at the top of each carburetor
for 0.75-1.5 mm (0.030-0.060 in.) cable free-play
gap between the throttle lever “nibs” and the
733-082A control housing. While observing if there is any
4. If an adjustment is necessary, loosen the switch cable free-play gap, apply slight pressure to the
bracket screws, move the switch up, tighten the throttle lever to take up any cable slack that may
screws, and then reset using step 3. be present. However, do not apply enough
pressure to actually raise the carburetor slides
NOTE: After completion of any adjustments, during this adjustment. After cable free-play is
throttle lever “side pressure” should not cause an properly adjusted, tighten the jam nut on each
ignition miss at idle. Carburetor switches set too carburetor securely.
low or an excessively tight throttle cable makes
the shutdown system very sensitive to throttle NOTE: After completion of any adjustments,
lever “side pressure” near idle. To test carburetor throttle lever “side pressure” should not cause an
safety switch synchronization, follow steps 5-9. ignition miss at idle. Carburetor safety switches
set too low or an excessively tight throttle cable
makes the shutdown system very sensitive to
throttle lever “side pressure” near idle.
5-21
TESTING TPS (All Models)
Digital 3-D Ignition For procedures for testing the TPS, see Testing Indi-
(500/600/800/ vidual Components in the Batteryless EFI sub-section
1000 cc Models) of Section 4.
The advantage of a 3-D ignition system is it actually NOTE: Procedure for testing the TPS is the same
has up to twelve slightly different timing curves which on carbureted models and EFI models.
are controlled by both throttle position and engine
RPM. This system allows the ECU to select the timing CHECKING TPS (Carbureted
curve best suited to the operating conditions providing Models)
both maximum performance and increased engine
durability. 1. Remove the carburetor assembly from the engine
compartment (see Section 4).
When checking the ignition timing, a couple points 2. Loosen the idle adjustment screw until it is not in
must be remembered. First, since the ignition timing is contact with the throttle lever.
affected by the throttle position, the throttle position
sensor (TPS) must be in good operating condition and
adjusted correctly. Second, the ignition timing must be
checked according to the following chart. Never
remove the drive belt to make the timing check.
Always place the rear of the snowmobile on a shielded
safety stand and allow the track to rotate freely.
Ignition Fail-Safe
Engine RPM Timing Timing
± 2° ± 2°
500 cc 2000 25° 12°
600 cc 2000 24° 12°
(Carb - Twin) AO171
600 cc (EFI) 3500 24° 16°
3. Depress the throttle lever to raise the throttle
600 cc (Triple) 2000 18° 12° valves (slides); then insert Pin Gauge (p/n 0644-
800 cc (Carb) 2000 14° 12° 345) into the TPS-side carburetor throat beneath
800 cc (EFI) 2500 26° 12° the valve. Slowly release the throttle lever
1000 cc 3250 16° 14° allowing the valve to rest on the gauge.
When checking ignition timing, it is important that the

timing light be connected to the number 1 spark plug
wire, which is the MAG-side cylinder. If the number 2
cylinder spark plug wire is used, the timing light may
show a 2° error in ignition timing when ignition timing
is actually correct.
For example, the correct ignition timing on the 1000 cc
is 16° ± 2° BTDC at 3250 RPM.
To quickly check TPS operation, measure the timing
according to the chart; then disconnect the TPS wiring AO170
and recheck the timing. A system with a functioning
TPS will show a change of approximately 4°. This is NOTE: The pin gauge MUST be installed on the
known as “Fail-Safe Ignition Timing” and is built into engine side of the carburetor.
the system to protect the engine should the TPS fail. If
this change is not seen, the TPS may have failed and NOTE: Before using the TPS adjustment tool,
must be checked. verify its battery condition. The battery used in the
tool is a 9-volt battery. To check battery condition,
If the ignition timing isn’t 16° ± 2° at 3250 RPM, the use a digital volt/ohmmeter set on DC volt scale.
TPS should be checked for proper adjustment using Test between the adjustment tool black and red
the TPS Adjustment Tool (p/n 0644-299) and a digital jacks. Insert the red lead of the digital voltmeter
voltmeter. into the red jack of the adjustment tool and the
black lead of the digital voltmeter into the black
jack of the adjustment tool. If voltage is found
5-22
4. Using TPS Adjustment Tool (p/n 0644-299), CHECKING/ADJUSTING TPS
connect its wiring harness to the TPS. Connect the (EFI Models)
two digital voltmeter leads (red and black) using
the two pin jack adapters provided with the NOTE: Before using the TPS adjustment tool,
adjustment tool to the white and black jacks of the verify its battery condition. The battery used in the
TPS adjustment tool. tool is a 9-volt battery; also, the Test Harness (p/n
0686-627) must be plugged into the analyzer for
5. With the throttle in the closed position (valve testing voltage.
resting on the pin gauge), compare the reading on
the voltmeter to the chart. If the reading is at the To check battery condition, use a digital volt/ohmme-
prescribed specification, proceed to step 6. If the ter set on DC volt scale. Test between the adjustment
reading is not at the prescribed specification, tool black and red jacks. Insert the red lead of the digi-
proceed to Adjusting TPS (Carbureted Models) in tal voltmeter into the red jack of the adjustment tool
this sub-section. and the black lead of the digital voltmeter into the
black jack of the adjustment tool. If voltage is found
Closed Idle Wide-Open
Engine
Position RPM Position 1. Using TPS Adjustment Tool (p/n 0644-299),
500 cc 0.56V 1500 3.796-4.222V connect its wiring harness to the TPS. Connect the
600 cc (Twin) 0.56V 1500 3.796-4.222V two digital voltmeter leads (red and black) using
600 cc (Triple) 0.56V 1500 3.639-4.056V the two pin jack adapters provided with the
800 cc 0.56V 1500 3.941-4.370V adjustment tool to the white and black jacks of the
TPS adjustment tool.
1000 cc 0.56V 1500 3.796-4.222V
2. Ensure that the throttle cable has the proper
6. Hold the throttle in the wide-open position; then amount of free-play.
compare the reading on the voltmeter to the chart.
If the reading is not within the specification range, 3. With the throttle in the idle position, compare the
recheck the closed position reading. If the closed reading on the voltmeter to the chart. If the reading
position reading is correct and the wide-open is at the prescribed specification, proceed to step 6.
position reading is not, the TPS is faulty and must If the reading is not at the prescribed specification,
be replaced. proceed to step 4.
7. If both voltmeter readings are correct, remove the
test harness and pin gauge, install the carburetor Engine
Idle
Position
Wide-Open
Position
5
assembly (see Section 4), and connect the 600 cc 0.64V 3.575-3.937V
snowmobile TPS harness to the TPS.
0.69-
800 cc 0.71V 3.575-3.937V
NOTE: Before installing the TPS harness con-
nector, apply dielectric grease to the connector
pins. 4. Using TPS Screwdriver (p/n 0644-344), loosen the
two retaining screws securing the TPS to the
ADJUSTING TPS (Carbureted throttle body.
Models) 5. Adjust the TPS to obtain the correct idle position
reading; then tighten the two retaining screws
1. Using TPS Screwdriver (p/n 0644-344), loosen the securely.
two retaining screws securing the TPS to the
carburetor. 6. Depress the throttle lever slowly. The meter
reading should show a smooth rise all the way to
2. Adjust the TPS to obtain the correct closed wide-open throttle. Repeat this step until it is
position reading on the voltmeter. assured that there are no open areas or “peaks” in
3. Tighten the two retaining screws securely. the reading.
4. To verify TPS position is correct, proceed to steps

6 and 7 of Checking TPS (Carbureted Models) in
this sub-section.
5-23
7. Disconnect the adjustment tool harness from the 3. With the ignition switch in the RUN position, the
TPS. Connect the snowmobile TPS harness to the emergency stop switch in the ON position, and the
newly installed or adjusted TPS. tether cord connected, the meter must read no
resistance. If the meter reads resistance,
NOTE: Before installing the TPS harness con- disconnect the ignition switch from the main
nector, apply dielectric grease to the connector wiring harness. If the meter now reads no
pins. resistance, replace the ignition switch.
REPLACING TPS (All Models)
1. Disconnect the throttle cable from the throttle
shaft.
2. Turn the idle adjustment screw counterclockwise
until it is not in contact with the throttle lever.
3. Disconnect the TPS wiring harness connector.
Using TPS Screwdriver (p/n 0644-344), remove
the two retaining screws securing the TPS to the
carburetor/throttle body.
4. Install the new TPS and secure with two retaining
screws, flat washers, and lock washers. 725-704A
5. Adjust the TPS using the appropriate procedures 4. If the meter continues to read resistance with the
in this sub-section. ignition switch disconnected, disconnect the
emergency stop switch. If the meter now reads no
FAIL-SAFE IGNITION TIMING resistance, replace the emergency stop switch.
Engines equipped with the 3-D ignition system have a 5. If the meter continues to read resistance with both
protective feature called “fail-safe” ignition timing the ignition switch and the emergency stop switch
which prevents engine damage should the TPS fail. If disconnected, disconnect the wires to the tether
the TPS does fail, the engine will run normally at low switch. If the meter now reads no resistance,
RPM but will run poorly at high RPM. This will allow replace the tether switch.
the operator to get the snowmobile to safety with little 6. If the meter continues to read resistance with all
or no engine damage. three switches disconnected, replace the main
wiring harness.
NOTE: The engine will continue to operate this
way until the TPS is replaced.
Testing Electrical
Testing Main Wiring Resistances
Harness (120 cc Model)
(120 cc Model)
NOTE: The following test procedure starts by
testing the resistance of the spark plug cap and
NOTE: The main wiring harness test can be working back to the stator under the flywheel.
made using the Fluke Model 73 Multimeter (p/n Replace any component that does not have a test
0644-191). value within specifications.
1. Disconnect the engine wires from the main wiring
harness. SPARK PLUG CAP
2. At the main wiring harness engine connector, 1. Remove the spark plug cap from the high tension
connect the red tester lead to the violet wire; then lead by rotating it counterclockwise.
connect the black tester lead to the engine ground 2. Set the selector in the X1K position.
(brown wire).
3. Connect one tester lead to one end of the cap and
the other tester lead to other end of the cap.
5-24
B170 AK051D
4. Spark plug cap resistance must be between 4000- 4. Ignition coil primary resistance must be between
6000 ohms. 0.24-0.36 ohm.
LIGHTING COIL IGNITION COIL (Secondary)

1. Disconnect the two yellow wires from the main 1. Remove the spark-plug caps from the high tension
wiring harness. wires.
2. Set the selector to the OHMS position. 2. Set the selector in the X1K position.
3. Connect the tester leads to the two yellow leads on 3. Connect the red meter lead to one high tension
the engine-side connectors. wire; then connect the black meter lead to the
other high tension wire.
4. Lighting coil resistance must be between 0.46-
0.68 ohm.
Testing Electrical
5
Resistances
(EFI Models)
NOTE: Resistance tests of the engine electrical

components should be made using the Fluke Mul-
timeter only. Analog-style multitesters may not be
accurate enough to use in these critical tests. AK050D
Replace any component that does not have a test
value within specifications. 4. Ignition coil secondary resistance must be between
6800-10,200 ohms.
IGNITION COIL (Primary)
CHARGE COIL (1)
1. Disconnect the double wire plug from the ECU to
the ignition coil. 1. Disconnect the triple-wire plug from the ECU to
the magneto.
2. Set the selector in the X1 position.
3. Connect the red meter lead to the orange lead; then
connect the black meter lead to the black lead. 3. Connect the red meter lead to the black/red wire
in the plug; then connect the black meter lead to
the green/red wire in the plug.
5-25
AK015
AK014 4. Lighting coil resistance must be between 0.08-

0.12 ohm.
4. Charge coil (1) resistance must be between 13.6-
20.4 ohms. IGNITION TIMING SENSOR
CHARGE COIL (2) 1. Disconnect the two timing sensor leads (green/
white and brown) from the ECU.
1. Disconnect the triple-wire plug from the ECU to
the magneto. 2. Set the selector in the X100 position; then connect
the meter leads to the sensor leads.
3. Ignition timing sensor resistance must be between
3. Connect the red meter lead to the brown/white 152-228 ohms.
wire in the plug; then connect the black meter lead
to the green/red wire in the plug. SPARK-PLUG CAP
1. Remove the spark-plug caps from the high tension
wires.
2. Set the selector in the X1K position.
3. In turn on each cap, touch a tester lead to each end
of the spark-plug cap.
AK013
4. Charge coil (2) resistance must be between 13.6-

20.4 ohms.
LIGHTING COIL
1. Disconnect the main wiring harness from the
engine. B170
2. Set the selector in the X1 position. 4. Spark-plug cap resistance must be between 4000-
6000 ohms.
3. Connect the two meter leads to each of the yellow
leads in the connector from the engine. IGNITION SWITCH
1. Remove the main wiring harness connectors from
the ignition switch.
2. Rotate the key to the OFF position.
3. The meter must read less than 1 ohm resistance
between the ignition switch terminals.
4. Rotate the key to the RUN position.
5. The meter must read OL (infinite resistance).
5-26
4. Ignition coil secondary resistance must be between
Testing Electrical 6800-10,200 ohms.
Resistances STATOR COIL (Charge)
(370 cc Models/440 cc Panther
Model) 1. Disconnect the triple-wire plug from the CDI unit
to the magneto.
NOTE: Resistance tests of the engine electrical 2. Set the selector in the X100 position.
timeter only. Analog-style multitesters may not be 3. Connect the red meter lead to the red/white wire in
accurate enough to use in these critical tests. the plug; then connect the black meter lead to the
Replace any component that does not have a test black/red wire in the plug.
value within specifications.

1. Disconnect the two connectors from the CDI unit
to the ignition coil.
3. Connect the red meter lead to the orange lead; then
connect the black meter lead to the black lead.
AK013
4. Charge coil resistance must be between 128-192

ohms.
LIGHTING COIL
5
engine.
AK051D
4. Ignition coil primary resistance must be between leads in the connector from the engine.
0.25-0.34 ohm.
IGNITION COIL (Secondary)

wires.
3. Connect the red meter lead to one high tension
wire; then connect the black meter lead to the
AK015

0.26 ohm.
SPARK-PLUG CAP
wires.
AK050D
5-27
AK051D
4. Ignition coil primary resistance must be between

B170 0.27-0.41 ohm.
4. Spark-plug cap resistance must be between 4000- IGNITION COIL (Secondary)
6000 ohms.
IGNITION SWITCH wires.
1. Remove the main wiring harness connectors from 2. Set the selector in the X1K position.
2. Rotate the key to the OFF position. wire; then connect the black meter lead to the
Testing Electrical
Resistances
(500/600 cc Twin Carburetor
Models)
AK050D
NOTE: Resistance tests of the engine electrical 4. Ignition coil secondary resistance must be between
components should be made using the Fluke Mul- 6800-10,200 ohms.
accurate enough to use in these critical tests.
Replace any component that does not have a test DC POWER COIL
NOTE: On APV-equipped carbureted models, the
IGNITION COIL (Primary) traditional charge coil(s) have been replaced by a
single DC power coil on the stator.
1. Disconnect the double wire plug from the CDI unit 1. Disconnect the two plugs (red/yellow and yellow/
to the ignition coil. red) to the DC power coil.
2. Set the selector in the X1 position. 2. Set the selector in the X1 position.
3. Connect the red meter lead to the orange wire in 3. Connect the red meter lead to one wire; then
the plug; then connect the black meter lead to the connect the black meter lead to the other wire.
black wire.
4. DC power coil resistance must be between 0.71-
1.07 ohms.
LIGHTING COIL
engine.
5-28
2. Set the selector in the X1 position. 2. Rotate the key to the OFF position.
3. Connect the two meter leads to each of the yellow 3. The meter must read less than 1 ohm resistance
leads in the connector from the engine. between the ignition switch terminals.
Testing Electrical
Resistances
(440 cc Z Models/550 cc Models)

AK015 components should be made using the Fluke Mul-
4. Lighting coil resistance must be between 0.12- accurate enough to use in these critical tests.
0.18 ohm. Replace any component that does not have a test
1. Disconnect the two timing sensor leads (green/
white and brown) from the CDI unit. 1. Disconnect the double wire plug from the CDI unit
2. Set the selector in the X100 position; then connect
the meter leads to the sensor leads. 2. Set the selector in the X1 position.
3. Ignition timing sensor resistance must be between 3. Connect the red meter lead to the orange wire in
152-228 ohms. the plug; then connect the black meter lead to the
SPARK-PLUG CAP
black wire in the plug.
5
wires.
AK051D

0.25-0.34 ohm.

wires.
B170
4. Spark-plug cap resistance must be between 4000-
6000 ohms. 3. Connect the red meter lead to one high tension
wire; then connect the black meter lead to the
IGNITION SWITCH other high tension wire.

5-29
AK050D AK013
4. Ignition coil secondary resistance must be between 4. Charge coil (2) resistance must be between 13.6-
6800-10,200 ohms. 20.4 ohms.
CHARGE COIL (1) LIGHTING COIL

1. Disconnect the triple-wire plug from the CDI unit 1. Disconnect the main wiring harness from the
to the magneto. engine.
2. Set the selector in the X100 position. 2. Set the selector in the X1 position.
3. Connect the red meter lead to the red/white wire in 3. Connect the two meter leads to each of the yellow
the plug; then connect the black meter lead to the leads in the connector from the engine.
black/white wire in the plug.
AK015
AK014
4. Charge coil (1) resistance must be between 128- 0.26 ohm.
192 ohms.
SPARK-PLUG CAP
CHARGE COIL (2)
1. Disconnect the triple-wire plug from the CDI unit wires.
to the magneto.
3. Connect the red meter lead to the black/red wire in of the spark-plug cap.
the plug; then connect the black meter lead to the
red/white wire in the plug.
5-30
B170 AK051D
4. Spark-plug cap resistance must be between 4000- 4. Ignition coil primary resistance must be between
6000 ohms. 0.29-0.39 ohm.
IGNITION SWITCH IGNITION COIL (Secondary)

1. Remove the main wiring harness connectors from 1. Remove the spark-plug caps from the high tension
the ignition switch. wires.
2. Rotate the key to the OFF position. 2. Set the selector in the X1K position.
3. The meter must read less than 1 ohm of resistance 3. On the dual lead coil, connect the red meter lead to
between the ignition switch terminals. one high tension wire; then connect the black
meter lead to the other high tension wire.
4. On the single lead coil, connect the red meter lead
5. The meter must indicate OL (infinite resistance). to one high tension wire; then connect the black
meter lead to the positive spade terminal.
5
Testing Electrical
Resistances

AK050D
1. Disconnect the spade connectors from the ignition 6320-9480 ohms on both coils.
coil body.
DC POWER COIL
3. Connect the red meter lead to the positive spade NOTE: On APV-equipped carbureted models, the
terminal; then connect the black meter lead to the traditional charge coil(s) have been replaced by a
negative spade terminal. single DC power coil on the stator.
1. Disconnect the two plugs (red/yellow and yellow/

red) from the CDI unit to the DC power coil.
3. Connect the red meter lead to one wire; then
connect the black meter lead to the other wire.
1.07 ohms.
5-31
IGNITION TIMING SENSOR IGNITION SWITCH
1. Disconnect the two timing sensor leads (green/ 1. Remove the main wiring harness connectors from
white and brown) from the CDI unit. the ignition switch.
2. Set the selector in the X10 position; then connect 2. Rotate the key to the OFF position.
3. The meter must read less than 1 ohm of resistance
3. Ignition timing sensor resistance must be between between the ignition switch terminals.
80-120 ohms.
LIGHTING COIL 5. The meter must read OL (infinite resistance).
engine.
2. Set the selector in the X1 position. Testing Electrical
3. Connect the two meter leads to each of the yellow Resistances
leads in the connector from the engine. (800 cc Carbureted Models)


1. Disconnect the double wire plug from the CDI unit
AK015
4. Lighting coil resistance must be between 0.12- 3. Connect the red meter lead to the orange lead; then
0.18 ohm. connect the black meter lead to the black lead.
SPARK-PLUG CAP
wires.
AK051D

0.24-0.36 ohm.

wires.
B170
4. Spark-plug cap resistance must be between 4000- 3. Connect the red meter lead to one high tension
6000 ohms. wire; then connect the black meter lead to the
5-32
2. Set the selector in the X100 position; then connect
3. Ignition timing sensor resistance must be between
148-222 ohms.
SPARK-PLUG CAP
wires.
AK050D of the spark-plug cap.
6800-10,200 ohms.
DC POWER COIL
NOTE: On APV-equipped carbureted models, the
traditional charge coil(s) have been replaced by a
single DC power coil on the stator.
1. Disconnect the two plugs (red/yellow and yellow/

red) from the CDI unit to the DC power coil.
3. Connect the red meter lead to one wire; then B170
connect the black meter lead to the other wire.
4. Spark-plug cap resistance must be between 4000-
6000 ohms.
5
0.78 ohm.
IGNITION SWITCH
LIGHTING COIL
1. Disconnect the main wiring harness from the the ignition switch.
engine.
2. Rotate the key to the OFF position.
3. Connect the two meter leads to each of the yellow between the ignition switch terminals.
leads in the connector from the engine.
Testing Electrical
Resistances
(570/1000 cc Models)

AK015
4. Lighting coil resistance must be between 0.08- Replace any component that does not have a test
0.12 ohm. value within specifications.
IGNITION TIMING SENSOR IGNITION COIL (Primary)
1. Disconnect the two timing sensor leads (green/ 1. Disconnect the double wire plug from the CDI
white and brown) from the CDI unit. unit to the ignition coil (570 cc) or the spade
connectors from the external coil body (1000 cc).
5-33
2. Set the selector in the X1 position. CHARGE COIL (1)
3. Connect the red meter lead to the orange wire in 1. Disconnect the three-wire plug (570 cc) or the
the plug (570 cc) or to the positive spade terminal four-wire plug (1000 cc) from the CDI unit to the
(1000 cc); then connect the black meter lead to the magneto.
black wire in the plug (570 cc) or to the negative
spade terminal (1000 cc). 2. Set the selector in the X1 position.
3. Connect the red meter lead to the black/red wire in
the plug; then connect the black meter lead to the
green/red wire in the plug.
AK051D

0.25-0.34 ohm (570 cc) or between 0.29-0.39 ohm
(1000 cc). AK014
4. Charge coil (1) resistance must be between 12-18

IGNITION COIL (Secondary) ohms.
wires. CHARGE COIL (2)
2. Set the selector in the X1K position. 1. Disconnect the three-wire plug (570 cc) or the
four-wire plug (1000 cc) from the CDI unit to the
3. On the 570 cc, connect the red meter lead to one magneto.
high tension wire; then connect the black meter
lead to the other high tension wire. 2. Set the selector in the X1 position.
4. On the dual lead coil (1000 cc), connect the red 3. Connect the red meter lead to the brown/white
meter lead to one high tension wire; then connect wire in the plug; then connect the black meter lead
the black meter lead to the other high tension wire. to the green/red wire in the plug.
AK050D AK013
5. On the single lead coil (1000 cc), connect the red 4. Charge coil (2) resistance must be between 12-18
meter lead to one high tension wire; then connect ohms.
the black meter lead to the positive spade terminal.
6800-10,200 ohms (570 cc) or between 6320-9480 1. Disconnect the green/white and brown wires from
ohms on both coils (1000 cc). the timing sensor to the main harness.
5-34
AO102D B170
2. Set the selector in the X10 position. 4. Spark-plug cap resistance must be between 4000-
6000 ohms.
3. Connect the red tester lead to the green/white wire;
then connect the black tester lead to the brown IGNITION SWITCH
wire.
4. Ignition timing sensor resistance must be between 1. Remove the main wiring harness connectors from
148-222 ohms (570 cc) or 152-228 ohms (1000 the ignition switch.
cc). 2. Rotate the key to the OFF position.
LIGHTING COIL 3. The meter must read less than 1 ohm resistance
engine. 4. Rotate the key to the RUN position.
2. Set the selector in the X1 position. 5. The meter must read OL (infinite resistance).

leads in the connector from the engine. 5
Peak Voltage Tests
(Fan Cooled Models)
NOTE: The following tests should be made using

the Fluke Model 73 Multimeter (p/n 0644-191) with
Peak Voltage Reading Adapter (p/n 0644-307).
NOTE: Peak voltage test specifications are on

the Electrical Specifications (Individual) pages in
this section.
The Fluke Multimeter w/Adapter can perform the fol-

lowing tests.
AK015
4. Lighting coil resistance must be between 0.12- A. Stator/Charge Coil(s) Output

0.18 ohm. B. Lighting Coil Output
SPARK-PLUG CAP C. Primary/Secondary Coil Output
1. Remove the spark-plug caps from the high tension D. Voltage Regulator Output
wires.
2. Set the selector in the X1K position. !WARNING
Most voltages generated by the ignition system
3. In turn on each cap, touch a tester lead to each end are sufficient to interrupt pacemakers! All techni-
of the spark-plug cap. cians, especially those using pacemakers, must
avoid contact with all electrical connections
when making these tests.
5-35
STATOR (Charge) COIL OUTPUT
1. Connect the red meter lead to the red/white wire
Peak Voltage Tests
from the stator; then connect the black meter lead (Carbureted APV Models)
to the black/red wire from the stator.
2. Pull the recoil starter rope briskly. Meter reading NOTE: The following tests should be made using
must be within specification. the Fluke Model 73 Multimeter (p/n 0644-191) with
LIGHTING COIL OUTPUT NOTE: Peak voltage test specifications are on
the Electrical Specifications (Individual) pages in
1. Connect the red meter lead to one yellow wire; this section.
then connect the black meter lead to the other
yellow wire. The Fluke Multimeter w/Adapter can perform the fol-
2. Pull the recoil starter rope briskly. Meter reading lowing tests.
must be within specification.
A. DC Power Coil Output
B. Voltage Regulator Output
CHARGE COIL (1) OUTPUT C. Primary/Secondary Coil Output
1. Connect the red meter lead to the red/white wire D. Lighting Coil Output
(440 cc) or to the black/red wire (570 cc); then
connect the black meter lead to the black/white
wire (440 cc) or to the green/red wire (570 cc). ! WARNING
2. Pull the recoil starter rope briskly. Meter reading are sufficient to interrupt pacemakers! All techni-
must be within specification. cians, especially those using pacemakers, must
avoid contact with all electrical connections after
CHARGE COIL (2) OUTPUT the engine has been started.
1. Connect the red meter lead to the black/red wire DC POWER COIL OUTPUT
(440 cc) or to the brown/white wire (570 cc); then
connect the black meter lead to the red/white wire 1. Connect the red meter lead to the red/yellow wire
(440 cc) or to the green/red wire (570 cc). from the stator; then connect the black meter lead
to the yellow/red wire from the stator.
2. Pull the recoil starter rope briskly. Meter reading
must be within specification. 2. Pull the recoil starter rope briskly. Meter reading
PRIMARY COIL OUTPUT
VOLTAGE REGULATOR OUTPUT
1. Connect the red meter lead to the orange wire;
then connect the black meter lead to the black 1. Connect the red meter lead to the red wire from the
wire. regulator; then connect the black meter lead to the
brown wire from the regulator.
must be within specification. 2. Pull the recoil starter rope briskly. Meter reading
SECONDARY COIL OUTPUT
PRIMARY COIL OUTPUT
wire; then connect the black meter lead to the 1. Connect the red meter lead to the orange wire
other high tension wire. (500/600/800 cc twin) or to the positive spade
terminal (600 cc triple); then connect the black
2. Pull the recoil starter rope briskly. Meter reading meter lead to the black wire (500/600/800 cc twin)
must be within specification. or to the negative spade terminal (600 cc triple).
VOLTAGE REGULATOR OUTPUT 2. Pull the recoil starter rope briskly. Meter reading
1. Connect the red meter lead to the yellow wire
from the regulator; then connect the black meter SECONDARY COIL OUTPUT
lead to the brown wire from the regulator.
2. Pull the recoil starter rope briskly. Meter reading wire; then connect the black meter lead to the
must be within specification. other high tension wire.
5-36
2. Pull the recoil starter rope briskly. Meter reading LIGHTING COIL OUTPUT
1. Connect the red meter lead to one yellow wire;
LIGHTING COIL OUTPUT then connect the black meter lead to the other
yellow wire.
1. Connect the red meter lead to one yellow wire;
then connect the black meter lead to the other 2. Pull the recoil starter rope briskly. Meter reading
yellow wire. must be within specification.
2. Pull the recoil starter rope briskly. Meter reading PRIMARY COIL OUTPUT
1. Connect the red meter lead to the orange wire
(EFI/550 cc) or to the positive spade terminal
(1000 cc); then connect the black meter lead to the
black wire (EFI/550 cc) or to the negative spade
Peak Voltage Tests terminal (1000 cc).
(EFI Models/550/1000 cc Models)
NOTE: The following tests should be made using
the Fluke Model 73 Multimeter (p/n 0644-191) with SECONDARY COIL OUTPUT
NOTE: Peak voltage test specifications are on wire; then connect the black meter lead to the
the Electrical Specifications (Individual) pages in other high tension wire.
this section.
The Fluke Multimeter w/Adapter can perform the fol- must be within specification.
lowing tests.
VOLTAGE REGULATOR OUTPUT
A. Charge Coil (1) Output (550/1000 cc)
B. Charge Coil (2) Output
C. Lighting Coil Output
1. Connect the red meter lead to the yellow wire from
the regulator; then connect the black meter lead to 5
the brown wire from the regulator.
D. Primary/Secondary Coil Output
E. Voltage Regulator Output must be within specification.
! WARNING
are sufficient to interrupt pacemakers! All techni- Testing Low-Oil
cians, especially those using pacemakers, must
avoid contact with all electrical connections
Light Sensor
when making these tests.
The low-oil light sensor is a magnetic switch. Its oper-
CHARGE COIL (1) OUTPUT ation is based on a magnet located around the inside
diameter of a 1/2 in. hole in a plastic float. The switch
1. Connect the red meter lead to the black/red wire located in the stem of the sending unit is positioned
(EFI/1000 cc) or to the red/white wire (550 cc); through the hole in the float. When the float drops to
then connect the black meter lead to the green/red the lower part of the stem, the magnet closes the elec-
wire (EFI/1000 cc) or to the black/white wire (550 trical contacts (located in the stem) allowing the cur-
cc). rent to pass on to the warning light.
2. Pull the recoil starter rope briskly. Meter reading If the sensor should fail, it must be replaced. To test
must be within specification. the sensor, use the following procedure.
CHARGE COIL (2) OUTPUT 1. Remove the sensor from the oil reservoir by
twisting and pulling upwards. Wipe excess oil
1. Connect the red meter lead to the brown/white from the sensor.
wire (EFI/1000 cc) or to the black/red wire (550
cc); then connect the black meter lead to the green/ 2. Unplug the sensor from the wiring harness.
red wire (EFI/1000 cc) or to the red/white wire
(550 cc). 3. Using an ohmmeter, set the selector on the X1K
position.
5-37
4. Touch each of the meter leads to one of the two 2. Temporarily place a jumper wire from the main
wires coming from the sensor. With the sensor in wiring harness sensor connector to any convenient
its normal position (float end down), the meter chassis ground (or any brown wire).
should read resistance.
3. If the high temperature warning light is not
5. If the meter reads no resistance, check to make illuminated with the engine running (and the
sure good contact has been made with each of the harness terminal grounded), test the light bulb. An
wires coming from the sensor. If the meter still ohmmeter must read less than 10 ohms across the
reads no resistance, replace the sensor. bulb filament.
6. While maintaining contact between the meter 4. If the bulb does not illuminate even when tested
leads and the sensor, raise the float. The meter good, use the ohmmeter to test the bulb harness.
must read no resistance. If the meter reads Also test the red/white wire continuity from the
resistance, replace the sensor. temperature sensor connector to the bulb
connector.
7. If the sensor tested out satisfactory but the light
doesn’t illuminate with only a small amount of oil
in the reservoir, check the bulb.
8. If the bulb is in good condition, check for voltage Testing Fuel Gauge
at the connection where the sensor plugs into the
accessory wiring harness. Using a multimeter set
on the 50 ACV scale, start the engine and allow it 1. Disconnect the fuel gauge from the hood wiring
to idle. Touch the red lead of the voltmeter to the harness.
red wire in the two-prong connector. Touch the
black lead to the black wire in the wiring harness. 2. Connect the positive lead of a 12-volt power
At idle, the meter should read 5 to 6 volts (AC). If supply to the yellow wire and the negative lead of
no voltage is present but the lights on the the 12-volt power supply to the brown wire.
snowmobile operate normally, either check the 3. The fuel gauge needle should peg in the negative
wiring harness for a broken wire or replace the (empty) direction.
harness.
4. With the fuel gauge still connected to the 12-volt
power supply (from step 2), install a jumper wire
(such as a paper clip) between the brown wire and
the gray wire.
Testing High
Temperature Sensor 5. The fuel gauge needle should peg in the positive
(full) direction.
1. Disconnect the main wiring harness connector NOTE: A fuel gauge failing these testing proce-
from the temperature sensor. dures is defective and must be replaced.
2. Connect an ohmmeter between the sensor terminal

and any convenient chassis ground (or any brown
wire). The ohmmeter must read less than 20 ohms
of resistance with the water temperature more than Testing
+230°F. The ohmmeter must read no resistance Fuel Gauge Sender
with the water temperature less than +190°F.
NOTE: It may be easier to remove the sensor 1. Remove the hardware securing the console to the
from the water manifold for testing purposes. fuel tank and frame; then move the console out of
Immerse the sensor body (only up to the threads) the way.
in automatic transmission fluid and slowly heat
the fluid. The ohmmeter must indicate the above 2. Disconnect the fuel gauge sender unit (black two-
resistances when connected between the sensor wire connector) from the main wiring harness.
terminal and the sensor body/chassis.
3. Connect the ohmmeter leads to the two sender
wires.
4. Compare the reading to the chart following.
Testing Fuel Gauge Sender
High Temperature Position Ohms
Warning Light Full 4-6
1/2 37.6-56.4
1. Disconnect the main wiring harness connector Empty 76-114
from the temperature sensor.
5-38
Testing Charging Diode
Electric Fuel Pump (Electric Start Models)
1. Remove the hardware securing the console to the TESTING

gas tank and frame; then move the console out of
the way. 1. Disconnect the electric start harness from the main
wiring harness.
2. Disconnect the fuel pump (white two-wire
connector) from the main wiring harness. ! CAUTION
3. Connect the positive lead of a 12-volt power To prevent ohmmeter damage when testing
supply to the red wire and the negative lead of the circuits on snowmobiles equipped with an
12-volt power supply to the black wire. electric start, be sure to disconnect the battery
before testing.
4. The pump should operate (it would be heard
running). 2. Connect the ohmmeter positive lead (red) to the
NOTE: If the fuel pump fails to operate, the pump diode yellow wire and the ohmmeter negative lead
is defective and must be replaced. (black) to the diode red wire. The ohmmeter must
read between 300 and 700 ohms.
3. Connect the ohmmeter positive lead (red) to the
diode red wire and the ohmmeter negative lead
Solenoid (black) to the diode yellow wire. The ohmmeter
must read OPEN (infinite resistance).
(Electric Start Models)
TESTING
Fuse
NOTE: The electric start solenoid may be tested
using either one of the following methods.
(Electric Start Models)
5
Method #1 TESTING
1. Disconnect the electric start harness from the main 1. Remove the fuse from the fuse holder.
wiring harness.
2. Connect the ohmmeter across the fuse end-caps.
2. Place the ohmmeter leads across the solenoid coil
terminals (brown wire and red/white wire). 3. The ohmmeter must read less than 1 ohm of
resistance.
3. The ohmmeter must read between 3 and 5 ohms.
Method #2
1. Connect the battery to the solenoid coil terminals Ignition Switch -
(brown wire and red/white wire).
Electric Start Function
2. A loud, audible “click” should be heard as the (Electric Start Models)
solenoid internal contacts make connection.
3. Disconnect the battery from the solenoid. TESTING
4. A loud, audible “click” should be heard as the
solenoid internal contacts release. ! CAUTION
NOTE: An in-line ammeter would measure To prevent ohmmeter damage when testing
between 2 and 4 amps of solenoid coil current flow circuits on snowmobiles equipped with an
with the battery connected. electric start, be sure to disconnect the battery
before testing.
! CAUTION 1. Disconnect the wiring harness from the ignition
NEVER connect an in-line ammeter with the large switch; then remove the switch from the console.
starter cables because the 200 amps of current
flow will instantly damage most ammeters.
5-39
2. Using the ohmmeter, test the connections 1. If applicable, remove the snap ring securing the
indicated in the following chart. If the meter does primary gear to the starter motor; then remove the
not read as specified or has more than one ohm of gear and account for the spring washer.
resistance, the switch must be replaced.
2. Remove the two long through-bolts. As the bolts
Lead to Lead to Meter are being removed, hold pressure against the
Position Terminal Terminal Reading commutator cap.
OFF -M +M CLOSED
ON -M +M OPEN
ON B A CLOSED
START -M +M OPEN
START B S CLOSED
AI050
3. Slowly remove the cap and account for the four

brush holder springs.
0000-126
NOTE: Some ignition-switch terminals may not

be labeled (-M, +M, A, B, or S). Refer to the wiring
harness diagram of the ignition switch when con-
necting the ohmmeter.
Starter Motor
AI026
REMOVING 4. Using a plastic hammer, tap the end plate/drive
1. Disconnect the battery. cap free of the starter case and slide the cap free
from the armature shaft. Account for any washers.
2. Remove the expansion chamber(s).
3. Remove the nut and washer(s) securing the
positive cable; then remove cable from the starter
motor.
4. Remove the drive clutch.
5. Remove the hardware securing the starter motor
and end plate/drive cap assembly to the bracket;
then remove the starter motor assembly.
DISASSEMBLING
NOTE: For assembly purposes, scribe a refer-
ence line on the end plate/drive cap, commutator AI027
cap, and the case.
5. Slide the armature free of the starter case.
5-40
necessary.
1. Thoroughly clean all components except the

armature and brushes in parts-cleaning solvent;
then dry with compressed air.
AI028
6. Lift all brushes from the brush holder and account

for the four brush springs.
7. Using a 5/16-in. socket, remove the two cap
screws securing the ground brushes to the
commutator cap. Remove the brushes and brush
holder from the cap.
AI029
! CAUTION
Do not wash the armature and brushes in any
kind of solvent. Use only compressed air and
clean dry cloth in cleaning these components.
2. Inspect all threaded areas for damaged or stripped

threads.
3. Inspect the brush holder assembly and brushes for
5
damage or wear. Using a calipers, measure the
length of the brushes. If brush measurement is less
AI036
than 7.5 mm (0.30 in.), replace brushes as a set
8. Using a 7/16-in. wrench, remove the nut securing along with new brush springs.
the cable stud to the cap. Account for the number
of and the position of washers.
AI030
4. Inspect brush leads for cracks, wear, or fraying. If

AI037
any of these conditions exist, replace the brushes
9. While holding the brush wires, pull the stud from as a set along with new brush springs.
the end cap. Account for the plastic insulator. 5. Inspect the commutator cap bushing for wear.
Using a calipers, measure inner diameter at the cap
bushing. If found to be 8.6 mm (0.338 in.) or
larger, replace the cap.
5-41
AI031 AI033
6. Inspect the end plate/drive cap bushing for wear. NOTE: After cleaning any buildup from the com-
Using a calipers, measure the inner diameter of the mutator, use compressed air to clean.
cap bushing. If found to be 13.2 mm (0.523 in.) or
larger, replace the cap. 9. Inspect the armature for shorting. Use the
multitester and the following procedure:
A. Set the selector on the X1K position; then touch
the leads and zero the meter.
B. Touch the black tester lead to the armature
shaft.
C. Using the red tester lead, probe the commutator
end of the armature. The meter indicator should
not move. If the indicator needle moves, the
armature must be replaced.
AI032
7. Inspect the brass commutator end of the armature

for any burned spots or damage. If the commutator
is slightly burned or damaged, the armature must
be replaced. This is a molded commutator and no
attempt to turn it down in a lathe should be tried.
! CAUTION
Do not use emery cloth to clean the commutator
as emery particles will become imbedded in the
brass commutator resulting in a short circuit. AI034
Use only #00 grit sandpaper.
10. Inspect the armature for shorting. Use a “growler”
8. Inspect the commutator for buildup in the grooves. and the following procedure:
Buildup in the grooves must be removed to A. Place the armature in the “growler.”
prevent any chance of arcing between individual
sections of the commutator. Carefully remove any B. While holding a metal strip over the armature,
buildup using a thinly ground hacksaw blade. Do rotate the armature an entire revolution. If the
not cut any deeper than the original groove which metal strip vibrates at any point on the
can be seen by looking at the commutator from the armature, the armature is shorted and must be
side. replaced.
5-42
0725-653 AI038
11. Inspect the ground brushes to make sure they are

properly grounded. Use the multitester and the ! CAUTION
following procedure: Check the stud to make sure insulator is
between stud and cap on backside.
A. Set the selector on the X1K position; then touch
the leads and zero the meter. 2. In order from disassembling, place the washers on
B. Touch the black tester lead to a ground brush. the stud. Apply a small amount of red Loctite #271
to the stud threads and secure with the nut. Tighten
C. Touch the red tester lead to the commutator to 0.7 kg-m (5 ft-lb).
cap. The meter needle should move to the right.
If the needle does not move to the right, check
that the ground connection is tight and clean.
Recheck for proper ground. If there still isn't
any meter needle movement, replace the
brushes as a set along with new brush springs.
AI039
3. Place the brush holder into position in the

commutator cap.
NOTE: Position the longest positive brush lead
beneath the ground wire on right side.
AI035
4. Place a cap screw through the left ground brush
ASSEMBLING lead eyelet and position the eyelet flat against the
brush holder. Secure with a cap screw.
1. Install the stud with the positive brush set attached
in the commutator cap. Make sure the insulator is 5. Place the right ground brush eyelet flat against the
in position over the stud and the longest brush lead brush holder and secure with a cap screw. The
is positioned to the right of the stud hole. eyelet stem must be positioned to the top of the
threaded hole boss in the commutator cap.
5-43
AI040 AI043
6. Place the four brush springs into the brush holder 11. Carefully place the starter case and armature
and place each brush (flat side down) on top of the assembly into the commutator cap. Again, check
springs. to make sure the scribed marks of these two
components are aligned. With the case flat on the
NOTE: Apply a small amount of low-temperature assembly tool, slowly pull the tool from the starter
grease to the cap bushings. motor. The case should then drop into place.
7. Place a wave washer and a thrust washer on the
armature shaft; then slide the front cap into
position.
8. Apply a thin coat of grease to the armature shaft
and slide the drive gear and spring washer onto the
shaft. Secure with a snap ring.
9. Start the commutator end of the armature
assembly into the starter case at the end with the
fields nearest the end of the housing. Align the
marks on the front cap and case.
AI044
12. Apply red Loctite #271 to the threads of the two

through-bolts; then install and secure the bolts.
Tighten to 1-1.4 kg-m (7-10 ft-lb).
NOTE: The starter shouldn’t be picked up until
the two through-bolts have been secured. Spring
pressure from the brush springs will push the
commutator cap off the case.
DISASSEMBLING PINION
AI042
1. Remove the pinion assembly. Account for any
10. Compress the four brushes (flat side down) into washers and spacers.
the brush holder. Hold the brushes in position 2. Remove the stopper, spring, and pinion gear from
using the Starter Assembly Tool (p/n 0644-052). the shaft.

PINION
necessary.
1. Using parts-cleaning solvent, wash grease from

the pinion gear. Dry with compressed air.
2. Inspect the pinion gear for wear. If the gear is
worn or chipped, replace the pinion assembly.
5-44
3. Inspect the inner gear and housing. If the gear 4. Holding the starter firmly down on a work bench,
shows any signs of wear, replace the pinion touch the red jumper cable to the positive cable
assembly. stud of the starter.
4. Inspect the inner housing for tightness and cracks.
If the housing shows any signs of being loose or ! WARNING
cracked, replace the pinion assembly. Be sure to keep clear of the pinion gear area as it
will spin at a high RPM when the red cable is
5. Inspect the pinion return spring for wear. If the touched to the positive stud. Personal injury may
spring shows any worn areas, replace the spring. result if contact is made with a spinning pinion.
ASSEMBLING/INSTALLING PINION NOTE: Starter motor must instantly spin at a
high RPM. The pinion must snap out against the
1. Apply a thin coat of grease to the gear; then slide stopper. If the motor does not spin, remove the red
the pinion onto the driveshaft along with the return cable immediately. Check the battery condition
spring and stopper. and all connections. If everything checks out satis-
factorily and the starter does not spin, disassem-
2. Slide the spacers and washers onto the shaft and ble the motor and check for pinched or broken
install the assembled pinion gear assembly. Slide wires.
the remaining thrust washer onto the bracket side
of the shaft. INSTALLING
3. Install the pinion assembly.
1. Place the starter motor into the bracket; then
secure with existing hardware. Tighten to 1.7-2.1
TESTING STARTER MOTOR kg-m (12-15 ft-lb).
NOTE: Before installing the starter motor, per- 2. Attach the red positive cable to the positive stud
form test to ensure proper operation using the fol- terminal and secure with a nut and washers. While
lowing procedure. tightening the nut, hold the cable in position so it
is parallel with the starter.
1. Attach a black jumper cable to a good ground on
the starter.
! CAUTION
2. Attach the opposite end of the black jumper cable
to the negative post of a good 12V battery.
Check the cable installation to make sure it isn’t
near any moving parts or against any sharp
5
3. Attach the red jumper cable to the positive post of edges.
the battery.
3. Secure the positive cable to the starter motor with
a long cable tie.
4. Connect the cable to the positive post of the
battery; then connect the negative cable to the
negative post.
5. Install the drive clutch.
6. Install the expansion chamber(s).
5-45
Troubleshooting
Electric Start
Problem: Hot or Smoking Wires

Condition Remedy
1. System wired incorrectly 1. Check wiring against wiring diagram
Problem: Starter Does Not Turn Over
Condition Remedy
1. Battery discharged 1. Check/charge the battery
2. Connection loose 2. Check tightness of all connections
3. Grounding improper 3. Check ground connections
4. Fuse blown — not installed 4. Check — replace fuse
5-46
Wire Color Code and COLOR
Violet
FUNCTION — DESCRIPTION
Ignition System “Shut-Off”
Function Description The violet wire connects the ignition system
CDI module to the throttle control switches.
Ignition spark is interrupted when any of the
switches close, connecting the violet wire to
NOTE: The following wire color code and func- a common ground.
tion description will assist in using the Main Har- Red/White High Temperature Warning Light
ness and Hood Harness wiring diagrams (see #1
Section 6). Note that some colors are numbered.
Some models use a speedometer with a
When a numbered color appears on either of the high temperature warning light. The red/
wiring diagrams, refer to this color code descrip- white #1 wire connects the high temperature
tion page, and it will provide you with additional sensor to the temperature warning light. The
information. “temp” light will illuminate when the sensor
connects the red/white #1 wire to common
COLOR FUNCTION — DESCRIPTION ground.
Brown Electrical Common; Red/White Solenoid Coil Power
#2
Chassis Ground
The red/white #2 wire connects the ignition
The brown wire is connected to the chassis switch (12 volt DC) power to the solenoid.
at the engine stator plate and also through The solenoid will activate when the ignition
the voltage regulator chassis bolt (prior to switch connects the red/white #2 wire to the
1989, the taillight harness also had a chassis + 12 VDC battery power.
connection). The headlight bracket is
grounded on some models to reduce the Red #1 Brakelight
bracket RFI emissions. All brown wires are The red #1 wire connects the brake control
common ground. assembly switch to the brakelight filament.
Yellow AC Power; 13 Volts AC (Alternating The brakelight will illuminate when the brake
Current) switch connects the red #1 wire to 13 VAC
power.
The yellow wire is connected to the engine
stator plate lighting coil and the voltage regu- Red #2 Electric Start Battery Power;
lator. The voltage produced by the lighting 12 Volts DC (Direct Current)
coil is very engine RPM dependent. The volt- The red #2 wire connects the battery positive
age regulator is necessary to maintain 13.5 post (+12 VDC) to the ignition switch through
VAC on the yellow wire whenever the engine
exceeds about 3000 RPM. All yellow wires
are 13 VAC. The signal on the yellow wire is
the fuse holder. All electric start red #2 wires
are +12 VDC. If the fuse “blows,” all red #2
wires are disconnected from the battery and
5
AC. Not only is the voltage level of this signal battery charging (via the charging diode) dis-
RPM dependent, but the signal frequency continues until the fuse is replaced.
(cycles per second) is RPM dependent as Red #3 Low Oil Warning Light
well. The electric tachometer uses this
changing frequency phenomenon to indi- The red #3 wire connects the low oil sensor
cate the engine RPM. An electric tachometer to the “oil” warning light. The “oil” light will
will operate properly when connected to any illuminate when the sensor connects the red
yellow (13 VAC) and brown (common #3 wire to 13 VAC power.
ground) wire pair. Gray Electric Fuel Level Gauge
White Headlight Low Beam Some models are equipped with an electric
The white wire connects the dimmer switch fuel level gauge. The gray wire connects the
to the headlight bulb. The low beam filament in-tank resistive sensor to the gauge. As the
will illuminate when the dimmer switch con- fuel level rises, the sensor resistance
nects the white wire to 13 VAC power. decreases, and the gauge needle rises; con-
versely, as the fuel level goes down, the sen-
Blue Headlight High Beam and Indicator sor resistance increases, and the gauge
Light needle drops.
The blue wire connects the dimmer switch to Orange Reverse Alarm
the headlight bulb. The high beam will illumi- Some models are equipped with a reverse
nate when the dimmer switch connects the gear and reverse alarm. The orange wire
blue wire to 13 VAC power. Some models connects the reverse switch to the reverse
use a tachometer with a high beam indicator alarm. The reverse alarm will “beep” when
light. The high beam indicator light will also the switch connects the orange wire to 13
illuminate when the dimmer switch connects VAC power.
the blue wire to 13 VAC power.
Yellow/Red DC Power Coil
and Red/ Some models are equipped with a DC Power
Yellow Coil. The yellow/red and red/yellow wires
provide power to the Arctic Power Valve
(APV).
5-47
ADJUSTING
Ignition Timing 1. Remove the recoil starter, starter pulley, and
flywheel.
CHECKING 2. Loosen the two screws securing the stator plate
and rotate the stator plate in the proper direction to
1. Connect a timing light to the MAG-side spark plug attain correct timing.
lead.
NOTE: Rotate the stator plate clockwise to retard
2. Using a shielded safety stand, raise the rear of the the timing or counterclockwise to advance the tim-
snowmobile off the floor and start the engine. ing. The stamped marks on the stator plate at the
Gradually increase the engine speed to the upper socket-head cap screw mounting hole can
specified RPM; the pointer should align with the be used for timing.
proper timing mark on the flywheel.
3. Tighten the screws securing the stator plate.
3. If timing is not correct, adjust the ignition timing.
4. Install the flywheel, starter pulley, and recoil
starter.
5. Recheck timing for accuracy and adjust if
necessary.
5-48
2002 Ignition Timing
Specifications
Table of Contents
370 cc ................................................................... 5-49
440 cc ................................................................... 5-50
550 cc ................................................................... 5-50
570 cc .................................................................. 5-51
500 cc .................................................................. 5-51
600 cc EFI ............................................................. 5-52
600 cc (Triple) ....................................................... 5-52
800 cc (Carbureted) .............................................. 5-53
600 cc (Twin - Carbureted).................................... 5-53
800 cc (EFI) .......................................................... 5-54
1000 cc ................................................................. 5-54
370 cc 5
NOTE: For timing purposes on the 370 Ignition Timing - Engine Warm
cc, use a dial indicator and scribe a mark BTDC - 18°/2000 RPM - 2.012 mm (0.079 in.)
on the flywheel for 18° BTDC.
734-489A
5-49
440 cc
NOTE: For timing purposes on the 440
cc, use a dial indicator and scribe a mark
Ignition Timing - Engine Warm

BTDC -18°/2000 RPM - 2.012 mm (0.079 in.)
726-863A
550 cc
NOTE: For timing purposes on the 550

cc, use a dial indicator and scribe a mark

BTDC - 33°/2000 RPM - 6.556 mm (0.258 in.)
730-215A
5-50
570 cc
BTDC -18°/2000 RPM - 2.049 mm (0.081 in.)
NOTE: For timing purposes on the 570 cc, use a dial

indicator and scribe a mark on the flywheel for 18°
BTDC.
732-629B
5
500 cc
NOTE: For timing purposes on the 500 cc, use a dial Ignition Timing
indicator and scribe a mark on the flywheel for 25° BTDC - 25°/2000 RPM - 3.671 mm (0.145 in.)
BTDC.
731-248F
5-51
600 cc EFI
Ignition Timing
0734-459
600 cc (Triple)
NOTE: For timing purposes on the 600 cc (Triple), Ignition Timing
use a dial indicator and scribe a mark on the flywheel BTDC - 18°/2000 RPM - 2.012 mm (0.079 in.)
for 18° BTDC.
731-248F
5-52
800 cc (Carbureted)
NOTE: For timing purposes on the 800 cc (carbu- Ignition Timing
reted), use a dial indicator and scribe a mark on the fly- BTDC - 14°/2000 RPM - 1.417 mm (0.056 in.)
wheel for 14° BTDC.
731-248F
600 cc (Twin - Carbureted)

Ignition Timing
BTDC - 24°/2000 RPM - 3.390 mm (0.133 in.) 5
733-584B
5-53
800 cc (EFI)
NOTE: For timing purposes on the 800 cc (EFI), use a Ignition Timing
dial indicator and scribe a mark on the flywheel for 26° BTDC - 26°/2500 RPM - 4.796 mm (0.189 in.)
BTDC.
731-248F
1000 cc
NOTE: For timing purposes on the 1000 cc, use Ignition Timing
a dial indicator and scribe a mark on the flywheel BTDC - 16°/3250 RPM - 1.556 mm (0.061 in.)
for 16° BTDC.
731-248G
5-54
NOTES
5-55
2002 Wiring Diagram
Index (Ignition)
This chart is designed to direct the technician to the

appropriate Ignition Harness Wiring Diagram. Select
the snowmobile model from the chart to determine the
correct diagram.
Snowmobile Models Ignition Harness Snowmobile Models Ignition Harness

Bearcat W/T B Z 570/570 esr A
Mountain Cat 500 H Z 570 SS A
Mountain Cat 570 A ZL 500 H
Mountain Cat 600 EFI/600 ZL 550/550 esr B
EFI LE G
ZL 600 EFI/600 EFI esr G
Mountain Cat 800/800 LE I ZL 600 EFI SS G
Mountain Cat 800 EFI/800 ZL 800 EFI esr K
K
EFI LE ZL 800 EFI SS K
Mountain Cat 1000 E ZR 120 J
Pantera 550 B ZR 500 H
Pantera 600 EFI G ZR 500/500 LE/500 CC H
Pantera 800 EFI K ZR 600 F
Panther 440 D ZR 600 EFI/600 EFI CC G
Panther 570 esr/570 r A ZR 800/800 CC I
Thundercat E ZR 800 EFI/800 EFI CC K
Z 370/370 es D ZRT 600 C
Z 440/440 es B
5-56
Harness A
0737-378
5-57
Harness B
0737-410
5-58
Harness C
0737-414
5-59
Harness D
0737-411
5-60
Harness E
0737-412
5-61
Harness F
0737-413
5-62
Harness G
0737-416
5-63
Harness H
0737-415
5-64
Harness I
0737-417
5-65
Harness J
0737-331
5-66
Harness K
0737-379
5-67
SECTION 6 — CHASSIS
ELECTRICAL SYSTEMS
6
TABLE OF
CONTENTS
Brakelight Switch (Hydraulic System) ..................... 6-2

Brakelight Switch (Mechanical System) .................. 6-2
Headlight Dimmer Switch ........................................ 6-3
Testing Handlebar Warmer Elements
(ON/OFF Function) .............................................. 6-4
Testing Thumb Warmer Element
(ON/OFF Function) .............................................. 6-4
Testing Handlebar Warmer Elements
(HI/OFF/LO Function) .......................................... 6-4
Testing Thumb Warmer Element
Testing Handlebar Warmer Switch
(ON/OFF Function) .............................................. 6-4
Testing Handlebar Warmer Switch
Testing Thumb Warmer Switch
(OFF/ON Function) .............................................. 6-5
Testing Thumb Warmer Switch
Testing Passenger Handwarmer Switch.................. 6-5
Testing Passenger Handwarmer Elements ............. 6-5
Wire Color Code and Function Description............. 6-7
2002 Wiring Diagrams (Main and Hood) ................. 6-8
6-1
INSTALLING
Brakelight Switch 1. Slide the brakelight switch into the brake control
(Hydraulic System) assembly until the self-locking tabs snap into
position. Give the switch body a light pull to make
sure the switch is properly secured.
TESTING/REMOVING
2. Connect the switch harness to the main wiring
1. Disconnect the wiring harness from the brake harness. Position the wires so they will not be
control. either pinched or come in contact with any moving
components. Start the engine and check the switch
2. To test the brakelight switch, connect one tester for proper operation.
lead to the #1 terminal; then connect the other lead
to the #4 terminal.
Brakelight Switch
(Mechanical System)
TESTING/REMOVING
1. Disconnect the wiring harness from the brake

control.
Terminal Corresponding Wire Wire Usage

Color
1 Yellow Power Supply
727-650A
2 Blue Headlight -
High Beam
3. With the brake lever compressed, the meter must
read resistance. With the brake lever released, the 3 White Headlight -
meter must read no resistance. If the meter does Low Beam
not read as specified, the brakelight switch is 4 Red Brakelight
defective and must be replaced.
2. Connect one tester lead to the #1 terminal; then
4. To remove the switch, use a small screwdriver to connect the other lead to the #4 terminal.
compress the plastic locking tabs by pushing in on
the tabs; then slide the switch free of the brake
control.
727-650A
3. With the brake lever compressed, the meter must

AF201D read less than 1 ohm of resistance. With the brake
lever released, the meter must read no resistance.
If the meter does not read as specified, the
brakelight switch is defective and must be
replaced.
4. Use a small screwdriver to compress the plastic
locking tabs by pushing in on the tabs; then slide
the switch free of the brake control.
6-2
REMOVING
1. Remove the handlebar pad.

2. Remove the screws from the cover plate securing
the dimmer switch.
AF907D
INSTALLING
1. Slide the brakelight switch into the brake control

assembly until the self-locking tabs snap into
position. Give the switch body a light pull to make
sure the switch is properly secured. AF908D
2. Connect the switch harness to the main wiring 3. Remove the plate and lift the switch free of the
harness. Position the wires so they will not be control.
either pinched or come in contact with any moving
components. Start the engine and check the switch
for proper operation.
Headlight
Dimmer Switch
TESTING
1. Disconnect the headlight dimmer switch plug

6
(located next to the air-intake silencer). AF909D
2. Use the tester connections indicated in the INSTALLING

following chart. If the meter does not read as
specified, the headlight dimmer switch is defective 1. Place the dimmer switch into the control and
and must be replaced. secure with the cover plate and screws.
2. Connect the four-prong plug; then install and
Position Lead to Lead to Meter secure the handlebar pad.
Terminal Terminal Reading
(Wire Color) (Wire Color)
High Beam 1 (Yellow) 2 (Blue) Less than 1
ohm
High Beam 1 (Yellow) 3 (White) OL
Low Beam 1 (Yellow) 2 (Blue) OL
Low Beam 1 (Yellow) 3 (White) Less than 1
ohm
6-3
4. In the element connector, connect the ohmmeter
Testing Handlebar between the green/black and yellow lead wires
Warmer Elements 5. The meter must read between 12.6 and 15.4 ohms.
(ON/OFF Function)
6. Replace any element measuring less than or more
than the specified amount.
1. Remove the handlebar pad; then disconnect the
handlebar warmer two-wire connector. NOTE: Repeat test for the other element.
2. In the element connector, connect the ohmmeter 7. Connect the leads; then install and secure the
between the green/white and yellow lead wires. handlebar pad.
3. The meter must read between 7.2 and 8.8 ohms.

4. Replace any element measuring less than or more
than the specified amount. Testing Thumb
NOTE: Repeat test for the other element.
Warmer Element
(HI/OFF/LO Function)
5. Connect the leads; then install and secure the
handlebar pad. 1. Remove the handlebar pad; then disconnect the
thumb warmer three-wire connector.
2. In the element connector, connect on ohmmeter
lead to the green/white lead; then connect the other
Testing Thumb Warmer ohmmeter lead to the yellow lead.
Element
(ON/OFF Function) 3. The meter must read between 3.6 and 4.4 ohms.
4. In the element connector, connect one ohmmeter
1. Remove the handlebar pad; then disconnect the lead to the green/black lead; then connect the other
thumb warmer two-wire connector. ohmmeter lead to the yellow lead.
2. In the element connector, connect one ohmmeter 5. The meter must read between 10.8 and 13.2 ohms.
lead to the green/white lead; then connect the other
ohmmeter lead to the yellow lead. NOTE: If either test is not within specification,
replace the thumb warmer element.
3. The meter must read between 2.7 and 3.3 ohms.
NOTE: If the test is not within specification, handlebar pad.
replace the thumb warmer element.

handlebar pad.
Testing Handlebar
Warmer Switch
(ON/OFF Function)
Testing Handlebar
Warmer Elements 1. Remove the handlebar pad.
(HI/OFF/LO Function)
2. Disconnect the handlebar warmer two-wire
connector.
1. Remove the handlebar pad; then disconnect the
thumb warmer three-wire connector. 3. In the switch connector, connect the ohmmeter
leads to each terminal.
2. In the element connector, connect one ohmmeter
lead to the green/white lead; then connect the other 4. With the switch in the OFF position, the meter
ohmmeter lead to the yellow lead. must read an open circuit. With the switch in the
ON position, the meter must read 1 ohm or less
3. The meter must read between 7.2 and 8.8 ohms. resistance.
handlebar pad.
6-4
Testing Handlebar Testing Thumb
Warmer Switch Warmer Switch
(HI/OFF/LO Function) (HI/OFF/LO Function)
1. Remove the handlebar pad. 1. Remove the handlebar pad.

2. Disconnect the handlebar warmer three-wire 2. Disconnect the thumb warmer three-wire
connector. connector.
3. In the switch connector, connect the ohmmeter 3. In the switch connector, connect one ohmmeter
leads to the green/white and yellow lead wires. lead to the green/white lead; then connect the other
ohmmeter lead to the yellow lead.
4. With the switch in the OFF (middle) position, the
meter must read an open circuit. With the switch 4. With the switch in the OFF (middle) position, the
in the HI position, the meter must read 1 ohm or meter must read an open circuit. With the switch
less resistance. in the HI position, the meter must read 1 ohm or
less resistance.
5. In the switch connector, connect the ohmmeter
leads to the green/black and yellow leads. 5. In the switch connector, connect one ohmmeter
lead to the green/black lead; then connect the other
6. With the switch in the OFF (middle) position, the ohmmeter lead to the yellow lead.
meter must read an open circuit. With the switch
in the LO position, the meter must read 1 ohm or 6. With the switch in the OFF (middle) position, the
less resistance. meter must read an open circuit. With the switch
in the LO position, the meter must read 1 ohm or
7. Connect the leads; then install and secure the less.
handlebar pad.
handlebar pad.
Testing Thumb
Warmer Switch
(OFF/ON Function)
Testing Passenger
Handwarmer Switch
6
1. Disconnect the lead wires from the switch.
2. Disconnect the thumb warmer two-wire
connector. 2. Connect the ohmmeter leads to each of the lead
wires.
3. In the switch connector, connect the ohmmeter
leads to each terminal. 3. With the switch in one position, the meter must
read OL (infinite resistance).
4. With the switch in the OFF position, the meter
must read an open circuit. With the switch in the 4. When the switch is moved to the other position,
ON position, the meter must read 1 ohm or less the meter must read less than 1 ohm of resistance.
resistance.
handlebar pad.
Testing Passenger
Handwarmer Elements
NOTE: During this test, resistance will vary due

to temperature; therefore, this test should be made
at room temperature of 20° C (68° F).
1. Disconnect the lead wires from the main wiring

harness.
6-5
2. Connect the lead wires from the green/white wire
from the element; then connect the other
ohmmeter lead to the yellow wire fron the
element.
3. The meter must read between 7.6-9.2 ohms.
6-6
Wire Color Code and COLOR FUNCTION — DESCRIPTION
Function Description Violet Ignition System “Shut-Off”
The violet wire connects the ignition system
CDI module to the throttle control switches.
Ignition spark is interrupted when any of the
NOTE: The following wire color code and func- switches close, connecting the violet wire to
tion description will assist in using the Main Har- a common ground.
ness and Hood Harness wiring diagrams in this Red/White High Temperature Warning Light
section. Note that some colors are numbered.
When a numbered color appears on either of the #1
wiring diagrams, refer to this color code descrip- Some models use a speedometer with a
tion page, and it will provide you with additional high temperature warning light. The red/
information. white #1 wire connects the high tempera-
ture sensor to the temperature warning
light. The “temp” light will illuminate when
Color FUNCTION — DESCRIPTION the sensor connects the red/white #1 wire
to common ground.
Brown Electrical Common; Chassis Ground Red/White Solenoid Coil Power
The brown wire is connected to the chassis #2
at the engine stator plate and also through
the voltage regulator chassis bolt (prior to The red/white #2 wire connects the ignition
1989, the taillight harness also had a chas- switch (12 volt DC) power to the solenoid.
sis connection). The headlight bracket is The solenoid will activate when the ignition
grounded on some models to reduce the switch connects the red/white #2 wire to the
bracket RFI emissions. All brown wires are + 12 VDC battery power.
common ground.
Red #1 Brakelight
Yellow AC Power; 13 Volts AC (Alternating
The red #1 wire connects the brake control
Current) assembly switch to the brakelight filament.
The brakelight will illuminate when the
The yellow wire is connected to the engine brake switch connects the red #1 wire to 13
stator plate lighting coil and the voltage reg- VAC power.
ulator. The voltage produced by the lighting
coil is very engine RPM dependent. The Red #2 Electric Start Battery Power;
voltage regulator is necessary to maintain
13.5 VAC on the yellow wire whenever the 12 Volts DC (Direct Current)
engine exceeds about 3000 RPM. All yel-
low wires are 13 VAC. The signal on the The red #2 wire connects the battery posi-
yellow wire is AC. Not only is the voltage tive post (+12 VDC) to the ignition switch
level of this signal RPM dependent, but the through the fuse holder. All electric start red
signal frequency (cycles per second) is #2 wires are +12 VDC. If the fuse “blows,”
RPM dependent as well. The electric all red #2 wires are disconnected from the
tachometer uses this changing frequency battery and battery charging (via the charg-
phenomenon to indicate the engine RPM. ing diode) discontinues until the fuse is
An electric tachometer will operate properly replaced.
when connected to any yellow (13 VAC)
and brown (common ground) wire pair. Red #3 Low Oil Warning Light
White Headlight Low Beam The red #3 wire connects the low oil sensor
to the “oil” warning light. The “oil” light will
The white wire connects the dimmer switch illuminate when the sensor connects the
to the headlight bulb. The low beam fila- red #3 wire to 13 VAC power.
ment will illuminate when the dimmer switch
connects the white wire to 13 VAC power. Gray Electric Fuel Level Gauge
Blue Headlight High Beam Some models are equipped with an electric
fuel level gauge. The gray wire connects
and Indicator Light the in-tank resistive sensor to the gauge.
As the fuel level rises, the sensor resis-
The blue wire connects the dimmer switch tance decreases, and the gauge needle
to the headlight bulb. The high beam will rises; conversely, as the fuel level goes
illuminate when the dimmer switch con- down, the sensor resistance increases, and
nects the blue wire to 13 VAC power. Some the gauge needle drops.
models use a tachometer with a high beam
indicator light. The high beam indicator light Orange Reverse Alarm
will also illuminate when the dimmer switch
connects the blue wire to 13 VAC power. Some models are equipped with a reverse
gear and reverse alarm. The orange wire
connects the reverse switch to the reverse
alarm. The reverse alarm will “beep” when
the switch connects the orange wire to 13
VAC power.
6-7
2002 Wiring Diagrams appropriate Main Harness Wiring Diagram and Hood
Harness Wiring Diagram. Select the snowmobile from
(Main and Hood) the chart to determine the correct diagram.
Snowmobile Models Main Hood Snowmobile Models Main Hood

Harness Harness Harness Harness
Bearcat W/T K III Z 570 D I
Mountain Cat 500 Q V Z 570 esr C I
Mountain Cat 570 O I Z 570 SS F I
Mountain Cat 600 EFI/ T I ZL 500 S V
600 EFI LE
Mountain Cat 800/800 LE U I ZL 550 P I
Mountain Cat 800 EFI/ V I ZL 550 esr J I
800 EFI LE
Mountain Cat 1000 U I ZL 600 EFI M I
Pantera 550 G II ZL 600 EFI esr W I
Pantera 600 EFI L II ZL 600 EFI SS Y I
Pantera 800 EFI N II ZL 800 EFI esr X I
Panther 440 D I ZL 800 EFI SS Z I
Panther 570 esr C I ZR 120 R IV
Panther 570 r B I ZR 500/500 LE/500 CC Q V
Thundercat AA II ZR 600 U I
Z 370 A I ZR 600 EFI/600 EFI CC T I
Z 370 es H I ZR 800/800 CC U I
Z 440 D I ZR 800 EFI/800 EFI CC V I
Z 440 es I I ZRT 600 E I
6-8
Harness A
(p/n 0686-507)
0737-326
6-9
Harness B
(p/n 0686-581)
0737-464
6-10
Harness C
(p/n 0686-581)
0737-339
6-11
Harness D
(p/n 0686-576)
0737-329
6-12
Harness E
(p/n 0686-679)
0737-330
6-13
Harness F
(p/n 0686-760)
0737-340
6-14
Harness G
(p/n 0686-776)
0737-303
6-15
Harness H
(p/n 0686-686)
0737-332
6-16
Harness I
(p/n 0686-693)
0737-333
6-17
Harness J
(p/n 0686-670)
0737-465
6-18
Harness K
(p/n 0686-657)
0737-335
6-19
Harness L
(p/n 0686-774)
0737-355
6-20
Harness M
(p/n 0686-694)
0737-336
6-21
Harness N
(p/n 0686-775)
0737-356
6-22
Harness O
(p/n 0686-766)
0737-357
6-23
Harness P
(p/n 0686-689)
0737-337
6-24
Harness Q
(p/n 0686-748)
0737-358
6-25
Harness R
(p/n 0686-684)
0737-331
6-26
Harness S
(p/n 0686-698)
0737-466
6-27
Harness T
(p/n 0686-750)
0737-359
6-28
Harness U
(p/n 0686-749)
0737-360
6-29
Harness V
(p/n 0686-764)
0737-361
6-30
Harness W
(p/n 0686-694)
0737-362
6-31
Harness X
(p/n 0686-770)
0737-364
6-32
Harness Y
(p/n 0686-769)
0737-365
6-33
Harness Z
(p/n 0686-761)
0737-366
6-34
Harness AA
(p/n 0686-752)
0737-367
6-35
Harness I
(p/n 0686-515)
0737-324
6-36
Harness II
(p/n 0686-588)
0737-327
6-37
Harness III
(p/n 0686-587)
0737-328
6-38
Harness IV
(p/n 0686-684)
0737-331
6-39
Harness V
(p/n 0686-699)
0737-338
6-40
SECTION 7 — STEERING AND BODY
TABLE OF
CONTENTS
Steering and Body................................................... 7-2

Steering Post (120 cc)............................................. 7-2
Steering Post (AWS III) ........................................... 7-5
Steering Post (AWS V) ............................................ 7-7
Ski ......................................................................... 7-11
Ski (120 cc) ........................................................... 7-12
Ski Wear Bar ......................................................... 7-13
Drag Link ............................................................... 7-14
Tie Rods (120 cc) .................................................. 7-15
Front Tie Rods....................................................... 7-16
Spindle (120 cc) .................................................... 7-18
Spindle .................................................................. 7-19 7
Steering Tie Rod ................................................... 7-21
Ski Alignment (120 cc) .......................................... 7-22
Ski Alignment ........................................................ 7-22
Front Suspension A-Arms (120 cc) ....................... 7-24
Front Suspension Arms......................................... 7-25
Front Suspension (Ski) Shock Absorber ............... 7-27
Sway Bar ............................................................... 7-28
Console (EFI Models) ........................................... 7-29
Console (Carbureted Model - Style A) .................. 7-30
Console (Carbureted Models - Style B)................. 7-31
Belly Pan (120 cc) ................................................. 7-34
Belly Pan ............................................................... 7-35
Seat/Cushion/Taillight Housing (120 cc) ............... 7-41
Taillight Housing .................................................... 7-43
Windshield............................................................. 7-44
Backrest/Rack/Taillight Assembly.......................... 7-44
Tunnel/Rear Bumper/Snowflap.............................. 7-46
Headlight Assembly (120 cc)................................. 7-49
Headlight Assembly (1 Bulb Halogen)................... 7-50
Adjusting Headlight Aim (1 Bulb Halogen) ............ 7-51
Headlight Assembly (3 Bulb Halogen)................... 7-51
Adjusting Headlight Aim (3 Bulb Halogen) ............ 7-52
Torque Specifications ............................................ 7-53
Torque Specifications (120 cc) .............................. 7-53
Torque Specifications (General Bolts) ................... 7-53
7-1
Steering and Body
This section has been organized into sub-sections for
servicing steering and body components; however,
some components may vary from model to model. The
technician should use discretion and sound judgment
when removing and installing components.
A999
Steering Post
(120 cc)
REMOVING
NOTE: Perform steps 1-8 for both the brake and

throttle cables.

2. Remove the C-clips securing the brake and throttle A980
lever pins in the brake housing and throttle
control; then remove the pins and levers. 4. Remove the C-clip securing the throttle cable in
the throttle control; then remove the cable from the
throttle control.
A979
A981
A998
3. Disconnect the brake and throttle cables from the A982

levers; then slide the cables out of the levers.
5. Cut the cable ties securing the cables to the
steering post.
7-2
6. Using a sharp knife, cut the grip off the handlebar. INSPECTING
7. Using a solvent, clean the old adhesive from the NOTE: Whenever a part is worn excessively,
handlebar. cracked, or damaged in any way, replacement is
necessary.
8. Loosen the screw securing the emergency stop
switch to the handlebar; then remove the stop 1. Inspect all welded areas for cracks or deteriora-
switch. tion.
9. Remove the two cap screws and lock nuts securing 2. Inspect the steering post and bearing retainers for
the upper steering post bearing retainer; then cracks, bends, or wear.
remove the retainer and bearing.
3. Inspect the steering post bearings for wear, cracks,
or deterioration.
4. Inspect the tie rod ends for wear or damage.
INSTALLING
A023A
10. Pull the steering post up and out of the lower

bearing.
11. Remove the lock nuts securing the tie rods to the
steering post.
KEY
1. Steering Post 12. Brake Cable 23. Washer
7
2. Handlebar Grip 13. Cap Screw 24. Tie Rod End
3. Retaining Ring 14. Bearing 25. Hex Nut
4. Throttle/Brake Retainer 26. Tie Rod
Lever 15. Bearing 27. Hex Nut
5. Spring Pin 16. Support 28. Tie Rod End
6. Engine Stop 17. Tether Switch 29. Throttle Cable
Decal Assy
30. Lock Washer
7. Throttle Control 18. Tether Cord
31. Engine Stop
8. Pin 19. Spring Switch
9. Pad Cover 20. Rivet 32. Cable Tie
A024 10. Pad 21. Lock Nut
11. Brake Housing 22. Lock Nut
NOTE: Use an additional wrench to keep the tie
rod end shaft from turning while removing the tie 0737-141
rod lock nut.
1. Place the lower steering post bearing and retainer
12. Remove the steering post from the engine into position on the front end; then loosely secure
compartment. with cap screws and lock nuts.
13. Remove the two cap screws and lock nuts securing 2. Place the steering post into position in the engine
the lower steering post bearing retainer; then compartment and secure the tie rods to the steering
remove the retainer and bearing. post with washers and lock nuts. Tighten to 2.5-
2.8 kg-m (18-20 ft-lb).
NOTE: Use an additional wrench to keep the tie
rod end shaft from turning while tightening the tie
rod lock nut.
7-3
3. Slide the end of the steering post into the lower
steering post bearing and place the upper end of
the steering post on the support.
A981
A025
4. Place the upper steering post bearing into position

on the steering post and secure the steering post/
bearing assembly to the support with the bearing
retainer, cap screws, and lock nuts.
5. Tighten the upper and lower retainer cap screws
securely.
A982
9. Seat each cable drum into its lever recess; then

secure each with a pin and C-clip.
A026
NOTE: Check all fasteners to ensure they are

tight. Turn the handlebar full-left and full-right sev-
eral times to ensure free movement.
6. Apply Handlebar Adhesive (p/n 0636-071) to the A980

bore of the handlebar grip; then using a rubber
hammer, drive the grip into position.
! WARNING
The handlebar adhesive is extremely flammable.
This product contains acetone. The vapors
released can be easily ignited. Keep away from
heat, sparks, and open flame. Use only in a well
ventilated area. Avoid prolonged breathing of
vapor. Avoid eye and skin contact. Keep container
closed when not in use.
7. Place the emergency stop switch onto the right

handlebar and secure with the screw.
A999
8. Route the throttle cable through the slot in the
throttle control and insert the cable end into the
throttle control. Secure the cable with a C-clip.
7-4
A979 AL089
4. Tip the snowmobile upright. Remove the

handlebar pad.
Steering Post 5. Remove the four lock nuts and cap screws
(AWS III) securing the adjuster caps to the adjuster block;
then remove the caps. Place the handlebar
assembly to the side. Remove the adjuster block.
REMOVING
6. Remove the four machine screws securing the
1. Tip the snowmobile on its side. Remove the console.
screws securing the skid plate.
7. Remove the two cap screws and lock nuts securing
2. Remove the two cap screws and lock nuts securing the steering post to the steering support. Account
the lower steering post bracket to the front end for the backing plate, two washers, bearing caps,
assembly. Account for the two washers, bearing bearing halves, and washers.
caps, bearing halves, and washers.
7
AL090
AL046
8. Carefully slide the steering post out of the chassis.
3. Remove the cotter pin, cap screw, and lock nut Be careful not to hook any wires or hoses.
securing the steering arm to the steering post.
INSPECTING

necessary.
1. Inspect all welded areas for cracks or deteriora-

tion.
2. Inspect the steering post and steering-post brackets
for cracks, bends, or wear.
3. Inspect the bearing halves, bearing caps, and
bearing housings for cracks or wear.
7-5
INSTALLING 3. Secure the console with the machine screws. Make
sure all wiring connections are secure.
4. Place the adjuster block, handlebar assembly, and
adjuster caps into position; then secure with four
cap screws and lock nuts. Tighten lock nuts evenly
to 1.4 kg-m (10 ft-lb).
5. Install the handlebar pad.
6. Tip the snowmobile on its side. On the lower end
of the steering post, apply a light oil to the bearing
halves and place into position around the steering
post; then place the bearing cap and bearing
housing into position. Install the backing plate and
secure with two cap screws, washers, and lock
nuts. Tighten to 2.5 kg-m (18 ft-lb).
KEY
1. Steering Post 8. Steering Post 16. Backing Plate
2. Washer Half Bearing 17. Lock Nut
3. Tie Rod Ball 9. Bearing Cap 18. Tie Rod Ball
Joint 10. Adjuster Cap Joint
4. Cap Screw 11. Adjuster Block 19. Cotter Pin
5. Lock Nut 12. Washer 20. Cap Screw
6. Cap Screw 13. Cap Screw 21. Hex Nut
7. Upper Bearing 14. Lower Bearing 22. Tie Rod Tube
Housing Housing 23. Hex Nut
15. Lock Nut
0736-026
1. Carefully slide the steering post into position in AL046

the chassis. Be careful not to hook any wires or
hoses. 7. Place the tie rod into position. Secure with a cap
screw (coated with green Loctite #609) and lock
2. On the upper end of the steering post, apply a light nut. Tighten to 4.2 kg-m (30 ft-lb). Install the
oil to the bearing halves and place into position cotter pin and spread the pin.
around the steering post; then place the bearing
cap between the steering support and the steering
post. Place the bearing housing into position and
secure with two cap screws, washers, and lock
AL089
8. Install the skid plate. Secure with screws.

NOTE: Turn the handlebar to the full-left and full-
AL090 right to ensure free movement.
7-6
4. Tip the snowmobile upright. Remove the
Steering Post handlebar pad.
(AWS V)
REMOVING
1. Tip the snowmobile on its side. Remove the

screws securing the skid plate.
AL136D
5. Remove the four lock nuts and cap screws

securing the adjuster caps to the adjuster block;
then remove the caps. Place the handlebar
assembly to the side. Remove the adjuster block.
AL144D
2. Remove the cotter pin, cap screw, and lock nut

securing the tie rod to the steering post.
AL147D

console to the gas tank.
AL146D
7
the lower steering post bracket to the front end
assembly. Account for the backing plate, two
washers, bearing caps, bearing halves, and
washers.
AL142D

the steering post to the steering support. Account
for the two washers, bearing caps, bearing halves,
washers, and backing plate.
AL145D
7-7
AL090 AL151D
8. Remove the sheet metal screws securing the recoil 11. Remove the cap screws securing the oil reservoir
starter rope cup. to the steering support. Account for the lock nut
and a flat washer.
AL149D
AL152D
9. Remove the cap screws securing the recoil starter
rope wire form. Account for the lock nut. 12. Remove the cap screws securing the air-intake
silencer to the steering support. Account for the
washers, lock washers, and spacers.
AL150D
10. Remove the cap screws securing the steering AL153D

support to the footrest (both sides).
13. Move the air-intake silencer forward.
7-8
AL154D
14. Carefully slide the steering post out of the chassis.

Be careful not to hook any wires or hoses.
INSPECTING
KEY
1. Steering Post 10. Bearing 18. Washer
NOTE: Whenever a part is worn excessively, 2. Riser Housing 19. Lock Nut
cracked, or damaged in any way, replacement is 3. Adjuster Cap 11. Backing Plate 20. Ball Joint
necessary. 4. Adjuster Cap 12. Washer 21. Hex Nut
5. Cap Screw 13. Lock Nut 22. Tie Rod Tube
14. Lock Nut
1. Inspect all welded areas for cracks or deteriora- 6.
7.
Tube Closure
Cap Screw 15. Plate
23.
24.
Hex Nut
Ball Joint
tion. 8. Bearing Cap 16. Washer
9. Half Bearing 17. Cap Screw
2. Inspect the steering post and steering-post brackets 0736-577
for cracks, bends, or wear.
1. Carefully slide the steering post into position in
3. Inspect the bearing halves, bearing caps, and the chassis. Be careful not to hook any wires or
bearing housings for cracks or wear. hoses.
INSTALLING 2. Secure the air-intake silencer to the steering
support with the washers, lock washers, spacers,
and cap screws.
AL153D
3. Secure the oil reservoir to the steering support

with the washer and lock nut.
KEY
1. Steering Post 9. Bearing 16. Lock Nut
2. Cap Screw Housing 17. Washer
3. Adjuster Cap 10. Backing Plate 18. Ball Joint
4. Adjuster Block 11. Washer 19. Hex Nut
5. Lock Nut 12. Lock Nut 20. Tie Rod Tube
6. Cap Screw 13. Backing Plate 21. Hex Nut
7. Housing Cap 14. Cap Screw 22. Ball Joint
8. Half Bearing 15. Washer
0736-614
7-9
AL152D AL149D
4. Secure the steering support to the footrest (both 7. On the upper end of the steering post, apply a light
sides) with the cap screws. oil to the bearing halves and place into position
cap between the steering support and the steering
post. Place the bearing housing into position and
secure with the backing plate, two cap screws,
washers, and lock nuts. Tighten to 2.5 kg-m
(18 ft-lb).
AL151D
5. Secure the recoil starter rope wire form with the

cap screws and lock nut.
AL090
8. Secure the console with the Phillips-head screws.
AL150D
6. Secure the recoil starter rope cup with the sheet

metal screws.
AL142D
9. Place the adjuster block, handlebar assembly, and

adjuster caps into position; then secure with four
cap screws and lock nuts. Tighten lock nuts evenly
to 1.4 kg-m (10 ft-lb).
7-10
AL147D AL145D
10. Secure the handlebar pad. 13. Install the skid plate. Secure with screws.
AL136D AL144D
11. Tip the snowmobile on its side; then place the tie NOTE: Turn the handlebar to the full-left and full-
rod into position. Secure with a cap screw (coated right to ensure free movement.
with green Loctite #609) and lock nut. Tighten to
4.2 kg-m (30 ft-lb). Install the cotter pin and
spread the pin.
Ski
REMOVING 7
1. Place the front of the snowmobile on a support
stand.
2. Remove the cotter pin; then remove the slotted nut
and cap screw securing the ski assembly to the
spindle. Remove the ski. Account for the rubber
damper and washers.
AL146D
12. On the lower end of the steering post, apply a light

oil to the bearing halves and place into position
cap and bearing housing into position. Install the
backing plate and secure with two cap screws,
washers, and lock nuts. Tighten to 2.5 kg-m
(18 ft-lb).
AL095D
7-11
INSPECTING

necessary.
1. Inspect the ski for cracks or deterioration.

2. Inspect the ski for abnormal bends or cracks.
3. Inspect the wear bar for wear.
4. Inspect all hardware and the spindle bushings for
wear and damage.
5. Inspect the rubber damper for damage or wear.
INSTALLING KEY
1. Spindle 8. Ski Insert 15. Lock Nut
2. Grease Fitting 9. Wear Bar 16. Washer
3. Spindle Insert 10. Washer 17. Spindle Cap
4. Bearing 11. Cotter Pin 18. Decal
5. Damper 12. Cap Screw 19. Axle
6. Ski Saddle 13. Lock Nut
7. Ski 14. Washer
0736-533
1. Position the ski over the saddle.

2. Apply a low-temperature grease to the non-
threaded portion of the cap screw; then slide the
cap screw (with washer as required) through the
ski and saddle accounting for the rubber damper.
NOTE: Install the cap screw so the lock nut will
be located to the inside of the ski.
KEY 3. Apply red Loctite #271 to the threads of the cap

1.
2.
Ski
Wear Bar
10.
11.
Bearing
Bearing
19.
20.
Lock Nut
Plastic Handle
screw; then tighten the lock nut (with washer as
3. Washer 12. Spindle Insert 21. Cap Screw required) to 6.2 kg-m (45 ft-lb).
4. Lock Nut 13. Grease Fitting 22. Washer
5. Cap Screw 14. Spacer 23. Lock Nut 4. Place the cotter pin into the ski cap screw and
6. Lock Nut 15. Cotter Pin 24. Machine Screw spread the pin.
7. Damper 16. Ski Saddle 25. Decal
8. Spindle Axle 17. Ski Saddle 26. Washer
9. Spindle Insert 27. Spindle Cap
18. Cap Screw
Ski
0736-423
(120 cc)
REMOVING
1. Place the cap screw and lock nut securing the ski
to the spindle.
7-12
Ski Wear Bar
The ski wear bar is a replaceable bar attached to the
underside of the ski. The purpose of the wear bar is to
assist in turning the snowmobile, to minimize ski
wear, and to maintain good steering control. If the
snowmobile is operated primarily in deep snow, ski
wear bar wear will be minimal; however, if the snow-
mobile is operated on terrain where the snow cover is
minimal, the ski wear bar will wear faster. Arctic Cat
recommends that the ski wear bars be checked once a
A027 week and replaced if worn to 1/2 of original diameter.
2. Remove the ski and account for two washers. REMOVING
INSPECTING 1. Remove ice and snow buildup from the ski.
NOTE: Whenever a part is worn excessively, 2. With the gas tank nearly empty (less that 1/4 full),
cracked, or damaged in any way, replacement is lay the snowmobile on its side.
necessary.
1. Inspect all hardware and spindle axles for any ! CAUTION

signs of damage. A piece of cardboard should be used to protect
the finish on the hood.
2. Inspect the welded areas for cracks or deteriora-
tion. 3. Remove the lock nuts and washers securing the
wear bar to the ski. Account for any spacers.
3. Inspect the ski for abnormal bends or cracks.
INSTALLING
KEY
1. Ski
2. Wear Bar
3. Cap Screw
4. Washer
5. Lock Nut
6. Spindle
7. Grease Fitting
7
8. Axle
9. Spindle Cap
10. Decal
11. Lock Nut
12. Washer
13. Insert 0735-453
0736-145
1. Place the ski the ski into position on the spindle;

then secure with a cap screw, two washers, and a
lock nut.
! CAUTION
Do not over-tighten the ski lock nut or binding
will occur.
2. Tighten the lock nut securely making sure the ski

is free to pivot.
731-037D
4. Pry the rear of the wear bar down until the wear
bar studs are clear of the ski; then slide the wear
bar rearward until the front of the wear bar is free
from the ski.
5. Remove the wear bar.
7-13
INSTALLING 3. On the side from which the drag link will be
removed, remove the self-tapping screws securing
1. Place spacers (if applicable) on the wear bar studs; the steering boot to the front end (bulk head).
then insert the front of the wear bar into the hole at
the front of the ski and swing the wear bar upward. 4. Remove the cap screws and lock nuts securing the
steering tie rod to the steering arm. Account for
! WARNING washers.
DO NOT bend the ski wear bar excessively when
installing. Excessive bending of the ski wear bar
may cause premature wear, breakage, and possible
injury.
2. Insert the wear bar studs into the holes in the ski.
3. Center the wear bar studs in the holes and install
the washers and lock nuts.
4. Tighten lock nuts securely.
AL092
Drag Link
5. Move the drag link from side to side to gain access
to the lock nuts and cap screws securing the
REMOVING steering arms to the drag link; then remove the cap
screws and lock nuts. Account for washers and
1. Remove the expansion chamber if necessary. drag link bearing axles.
2. Remove the lock nuts securing the tie rods to the 6. From the opposite side from which the boot was
spindles on both sides of the snowmobile. Account removed, carefully pull the steering boot over the
for O-rings and washers. tie rod end; then remove the drag link.
NOTE: Note whether the tie rod is installed on NOTE: Applying soapy water to the steering
the top side or on the bottom side of the spindle boot will aid in pulling the boot over the tie rod
arm for installing purposes. end.
7. Place the drag link in a vise and remove the tie rod
ends from the drag link.
INSPECTING

necessary.
1. Inspect the entire drag link (especially in the areas

where the ball joints attach) for any signs of
cracks, wear, or damage.
AL108
2. Inspect the bearings, inserts, and axles for wear or
damage.
AL655D
7-14
INSTALLING 4. Secure the steering tie rod to the steering arm with
a cap screw (coated with green Loctite #609),
washer, and a lock nut. Tighten to 4.2 kg-m (30 ft-
lb).
5. Place the steering boot into position on the front
end (bulk head). Secure with self-tapping screws.
6. Install the tie rods (threaded area coated with
green Loctite #609) on the spindle arms as noted
during removing. Secure with O-rings, washers,
and lock nuts. Tighten to 3.5 kg-m (25 ft-lb).
KEY
1. Drag Link 9. Lock Nut 17. Lock Nut
2. Bearing 10. Cap Screw 18. Ball Joint
3. Steering Arm 11. Washer 19. Hex Nut
4. Insert 12. Lock Nut 20. Tie Rod Tube
5. Steering Arm 13. Axle 21. Hex Nut
6. Cap Screw 14. Cap Screw 22. Ball Joint
7. Washer 15. Cap Screw 23. O-Ring
8. Washer 16. Washer 24. Lock Nut AL108
0736-486
1. Place the drag link in a vise; then secure the tie rod
to the drag link with cap screws, washers, and
lock nuts (threads coated with green Loctite #609).
2. Slide the drag link in from the side of the snowmo-
bile from which the steering boot was removed;
then carefully slide the boot over the tie rod end.
NOTE: Applying soapy water to the steering
boot will aid in sliding the boot over the tie rod
end. AL655D
7
3. Secure the drag link to the steering and idler arms NOTE: Check all drag link and ball joint fasten-
with cap screws (coated with green Loctite #609), ers to ensure they are tight. Turn the handlebars
washers, bearing axles, and lock nuts. Tighten to full-left and full-right several times to ensure free
4.2 kg-m (30 ft-lb). movement.
7. Install and secure the expansion chamber (if

removed).
8. Check and adjust ski alignment (see appropriate
Ski Alignment in this section).
Tie Rods
(120 cc)

AL092
1. Remove the tie rod from the spindle.
7-15
1. Slide the tie rod through the steering boot; then
install the jam nuts and thread the ball joints onto
the tie rod.
NOTE: Each jam nut and ball joint is either a
right-hand or left-hand thread; therefore, each can
only be installed on one end of the tie rod. The
right-hand thread is the inside ball joint and jam
nut.
2. Secure the tie rod to the steering post. Tighten to

2.5-2.8 kg-m (18-20 ft-lb).
3. Secure the steering post to the front end (see steps
A028
3-5 of Steering Post (120 cc) - Installing sub-
2. Remove the tie rod from the steering post (see section).
steps 10-12 of Steering Post (120 cc) - Removing
sub-section). 4. Secure the tie rod to the spindle with a lock nut.
3. Loosen the jam nuts securing the tie rod; then
remove the ball joints from the tie rod. Slide the tie
rod from the steering boot.

necessary.
1. Inspect the ball joints and tie rods for damaged

threads or wear.
2. Inspect the ball joints and tie rods for cracks or
unusual bends. A034
3. Wash the ball joint in parts-cleaning solvent. Dry NOTE: The ball joint must be installed on the
with compressed air. Inspect the ball joint pivot bottom side of the spindle arm.
area for wear. Apply a low-temperature grease to
the ball joint. 5. Lock the jam nuts against the tie rod; then adjust
ski alignment (see appropriate Ski Alignment in
! WARNING this section).
Always wear safety glasses when using com-
pressed air.
! WARNING
ASSEMBLING AND INSTALLING Neglecting to lock the jam nuts against the tie rod
may cause loss of snowmobile control and possible
personal injury.
Front Tie Rods
1. Remove the lock nut securing the tie rod to the

spindle. Account for a washer and O-ring.
KEY
1. Cap Screw 4. Lock Nut 8. Hex Nut NOTE: Note whether the tie rod is installed on
2. Bearing 5. Lock Nut 9. Tie Rod the top side or on the bottom side of the spindle
Retainer 6. Washer 10. Hex Nut arm for installing purposes.
3. Bearing 7. Tie Rod End 11. Tie Rod End
735-373A
7-16
1. Slide the tie rod through the steering boot and

retainer; then install the jam nuts on the ball joints
and thread the ball joints onto the tie rod.
NOTE: Each jam nut and ball joint is either a
right-hand or left-hand thread; therefore, each can
only be installed on one end of the tie rod. The
right-hand thread is the inside ball joint and jam
nut.
2. Secure the tie rod to the ball joint on the forked

end of the drag link with a cap screw, washers, and
AL108
lock nut. Tighten to 2.8 kg-m (20 ft-lb).
3. Secure the steering arm to the drag link with a cap
screw, lock nut, and washers. Tighten to 4.2 kg-m
(30 ft-lb).
4. Position an O-ring and washer on the ball joint
assembly (threads coated with green Loctite
#609). Install the ball joint on the spindle arm as
noted in removing; then secure with a lock nut.
AL655D
2. Remove the self-tapping screws or rivets securing

the steering boot and retainer to the front end.
3. Turn the handlebar in the appropriate direction;
then remove the cap screw and lock nut securing
the steering arm to the drag link. Account for
washers.
4. Loosen the jam nut securing each ball joint to the
tie rod; then remove the ball joints from the tie AL108
rod. Slide the rod from the steering boot. Remove
the jam nuts from the ball joints. 7

necessary.
1. Inspect the ball joints and tie rods for damaged

threads or wear.
2. Inspect the ball joints and tie rods for cracks or
unusual bends.
AL655D
3. Wash the ball joints in parts-cleaning solvent. Dry
with compressed air. Inspect the ball joint pivot 5. Place the steering boot and retainer into position
area for wear. Apply a low-temperature grease to and secure with self-tapping screws or rivets.
the ball joints.
6. Adjust ski alignment (see appropriate Ski Align-
ment in this section).
! WARNING
pressed air.
7-17
7. Apply blue Loctite #242 to the jam nut threaded 5. Remove the two cap screws and lock nuts securing
area and tighten the jam nuts against the tie rod to the spindle to the suspension A-arms. Account for
1.7-2.1 kg-m (12-15 ft-lb). all mounting hardware.
! WARNING
Neglecting to lock the jam nuts against the tie rod
personal injury.
Spindle
(120 cc)
REMOVING
A0165
1. Position the front of the snowmobile up onto a
safety stand. 6. Inspect the tie-rod ball joint in place. If damage,
wear, or unusual bends are noted, loosen the jam
2. Remove the ski. nut; then remove the ball joint from the tie rod.
3. Remove the lock nut securing the tie-rod ball joint INSPECTING
to the spindle (account for the washer); then
remove the ball joint from the spindle. NOTE: Whenever a part is worn excessively,
necessary.
1. Inspect the spindle for excessive wear, cracks,

bends, or imperfections.
2. Inspect all welds for cracking.
3. Inspect the suspension A-arm axle area for wear.
4. Secure the spindle in a vise. Rotate the spindle
clockwise and counterclockwise. The movement
shou ld be s mo oth an d free. If the sp indle
movement is rough or binding, grease the spindle
with a good low-temperature grease. Rotate the
A028 spindle. If the movement remains rough, replace
4. Remove the cap screw and lock nut securing the the spindle.
shock to the spindle. Account for two shock NOTE: When greasing the spindle, use enough
bushings. grease so that it can be seen coming out at both
the top and bottom of the spindle.
5. Inspect the spindle axle for wear, damage, or loose

fit.
INSTALLING
1. Place the shock mounting bracket into position on

the spindle; then place the A-arms into the spindle.
Secure with cap screws and lock nuts. Tighten
securely.
AO166
7-18
5. Remove the safety stand from beneath the front
frame assembly.
Spindle
REMOVING
1. Position the front of the snowmobile up on a safety

stand.
AO165
2. Remove the ski.
2. Place the tie-rod ball joint into position on the
bottom side of the spindle arm and secure with a 3. Remove the lock nut and cap screw securing the
lock nut (threads coated with blue Loctite #243) shock absorber to the spindle. Account for all
tightened to 2.5-2.8 kg-m (18-20 ft-lb). mounting hardware.
AL156D
AO28
3. Place the lower shock eyelet w/shock bushings 4. Remove the lock nut securing the tie-rod ball joint
into the shock mounting bracket. Secure with the to the spindle (account for the washer and the O-
cap screw and lock nut. Tighten securely. ring); then remove the ball joint from the spindle.
NOTE: Note whether the tie rod is installed on
the top side or on the bottom side of the spindle
arm for installing purposes. 7
AO166
4. Install the ski.

AL158D
7-19
4. Secure the spindle in a vise. Rotate the spindle
clockwise and counterclockwise. The movement
shou ld be s mo oth an d free. If the sp indle
movement is rough or binding, grease the spindle
with a good low-temperature grease. Rotate the
spindle. If the movement remains rough, replace
the spindle.
NOTE: When greasing the spindle, use enough
grease so that it can be seen coming out at both
the top and bottom of the spindle.
5. Inspect the spindle axle and bearings for wear,

AL655D damage, or loose fit. Replace the bearings as a set.
5. Remove the two cap screws and lock nuts securing NOTE: Replacing the ski bolt bushings is diffi-
the spindle to the suspension arms. Account for all cult. The existing bushings will be damaged dur-
mounting hardware. ing removal. Be careful, however, not to damage
the spindle when removing the bearing. Press the
new bushings into the spindle.
INSTALLING
1. Place the upper and lower suspension arm ends

with bushings in position into the spindle. Secure
with cap screws and lock nuts. Tighten to
4.2 kg-m (30 ft-lb).
2. Place the steering tie-rod ball joint into position
(threads coated with green Loctite #609) on the
spindle arm as noted during removing (with
washer and O-ring) and secure with a lock nut.
AL159D
AL108
AL160D
6. Inspect the tie-rod ball joint in place. If damage,

wear, or unusual bends are noted, loosen the jam
nut; then remove the ball joint from the tie rod.
INSPECTING

necessary.
1. Inspect the spindle for excessive wear, cracks,

bends, or imperfections.
2. Inspect all welds for cracking. AL655D
3. Inspect the suspension arm bushings and axle area 3. Install the ski.
for wear.
7-20
4. Align the lower shock eyelet with the mounting INSPECTING
hole in the spindle; then secure with the cap screw,
optional washers, and lock nut. Tighten to NOTE: Whenever a part is worn excessively,
3.2 kg-m (23 ft-lb). cracked, or damaged in any way, replacement is
necessary.
5. Remove the safety stand from beneath the front
end. 1. Inspect the ball joints for damaged threads or
wear.
2. Inspect the tie rod for damage, unusual bends, or
wear.
Steering Tie Rod
INSTALLING
REMOVING 1. Position the handlebar in the straight-ahead

position; then position the skis straight ahead.
1. Remove the screws securing the skid plate; then
remove the skid plate. 2. Thread the jam nuts onto the ball joints; then
equally thread the ball joints onto the steering tie
NOTE: The front machine screw on some mod- rod.
els is secured with a washer and lock nut.
NOTE: There must be an approximate equal
number of threads exposed on each ball joint.
3. Place the tie-rod assembly into position; then

rotate the steering tie rod until the holes in the ball
joints align with the holes in the steering post and
steering arm.
4. Ensure correct handlebar/ski alignment (adjust
steering tie rod as necessary); then apply blue
Loctite #242 to the jam nut threaded area and
tighten to 1.7-2.1 kg-m (12-15 ft-lb).
5. Secure the tie-rod assembly with the two cap
AL144D
screws (coated with green Loctite #609), washers,
and slotted nuts. Tighten to 4.2 kg-m (30 ft-lb);
2. Remove the cotter pins, cap screws, and slotted then install the cotter pins and spread the cotter
nuts securing the steering tie rod to the steering pins.
post and steering arm; then remove the tie-rod
assembly.
7
AL089
AL089 ! WARNING
3. Loosen the jam nuts securing the ball joints to the Neglecting to lock the jam nuts against the tie rod
steering tie rod; then remove the ball joints. personal injury.
6. Install the skid plate; then secure with screws.

NOTE: The front machine screw on some mod-
els is secured with a washer and lock nut.
7-21
4. While holding the straight ski in position, rotate
the tie rod until the measurement between the skis
is within specifications.
5. When the ski alignment is correct, apply blue
Loctite #243 to the jam nut threaded areas and
tighten each jam nut securely against the tie rod.
! WARNING
Neglecting to lock the tie rod by tightening the jam
nuts may cause loss of snowmobile control and
possible personal injury.
AL144D
Ski Alignment
Ski Alignment
(120 cc) CHECKING
Toe-Out Range
CHECKING
1.6-6.4 mm (1/16-1/4 in.)
1. Turn the handlebar to the straight-ahead position.
NOTE: Track tension and alignment must be
2. Measure the distances to the inside edges of the properly adjusted prior to checking or adjusting
skis in two places. Make sure the measurements ski alignment. Ski alignment must be performed
are taken behind the spindle mount and ahead of on a flat, level surface. Ski toe-out must fall within
the spindle mount. the range of 1.6- 6.4 mm (1/16-1/4 in.).
1. Raise the front end of snowmobile just high

enough to keep the skis from contacting the floor;
then tighten the ski mounting cap screws to
3.6 kg-m (26 ft-lb).
2. Turn the handlebar to the straight-ahead position
until the hole in the middle of the drag link is
aligned with the notch (half-moon shaped) in the
chassis. Visually inspect the handlebar for being
centered and in the straight-ahead position.
0735-446
NOTE: Ski alignment is correct when the skis are

parallel to each other (equal measurements front
and rear) or when the skis have up to a maximum
of 6 mm (1/4 in.) toe out (front measurement 6 mm
(1/4 in.) more than rear measurement).
3. If ski alignment is not as specified, the snowmo-

bile will have a tendency to wander and may be
difficult to control; therefore, an adjustment is
necessary. 0734-407
ADJUSTING NOTE: If the handlebar is not in the straight-

ahead position when the hole in the middle of the
1. Make sure the ignition key is in the OFF position. drag link aligns with the notch in the chassis, the
steering tie rod must be adjusted. When handlebar
2. Visually examine the skis to determine which ski alignment is correct, apply blue Loctite #242 to the
is out of alignment with respect to the handlebar. jam nut threaded area and tighten to 1.7-2.1 kg-m
(12-15 ft-lb). Tighten both jam nuts against the
3. Open the hood and loosen the jam nut on each end steering tie rod.
of the tie rod.
7-22
3. With the drag link centered and handlebar in the 7. Measure the distance from the straightedge to the
straight-ahead position, secure the handlebar to right-side ski wear bar bolts in two places: 18-20
prevent the drag link and handlebar alignment cm (7-8 in.) in front of the spindle and 18-20 cm
from becoming disturbed during the remainder of (7-8 in.) behind the spindle. Record the measure-
the alignment procedure. ments taken for the right side.
NOTE: Track tension and alignment must be ! WARNING
properly adjusted prior to placing the straightedge
against the outside edge of the track. The measurement from the front and rear wear bar
bolts to the straightedge can be equal (ski parallel
4. Place a long straightedge against the outside edge to the track), but the front measurement must never
be less (ski toed-in) or poor handling will be experi-
of the track so it lies near the inside edge of the enced. The front wear bar bolt measurement to the
left-side ski. straightedge must not exceed the measurement
from the rear wear bar bolt to the straightedge (ski
toed-out) by more than 3.9 mm (5/32 in.).
8. If ski alignment is not as specified, adjust the

alignment of the ski(s) not parallel to the straight-
edge.
ADJUSTING
NOTE: The following procedure can be used to

adjust the alignment of either ski.
1. Unlock the appropriate adjustment tie rod(s) by

loosening the jam nuts.
729-887B
NOTE: The outside jam nuts are left-hand thread.
NOTE: The straightedge should be long enough Care should be taken to rotate them in the proper
to extend from the back of the track to the front of direction.
the ski.
5. Measure the distance from the straightedge to the

left-side ski wear bar bolts in two places: approxi-
mately 18-20 cm (7-8 in.) in front of the spindle
and 18-20 cm (7-8 in.) behind the spindle. Record
the measurements taken for the left side.
0729-883
2. Adjust ski alignment by rotating the adjustment tie

rod.
3. When ski alignment is correct, apply blue Loctite
#242 to the jam nut threaded area and tighten to
729-887A 1.7-2.1 kg-m (12-15 ft-lb). Tighten both jam nuts
against the tie rod.
6. Place the straightedge against the outside edge of
the track so it lies near the inside edge of the right- ! WARNING
side ski.
Neglecting to lock the tie rod by tightening the jam
7-23
VERIFYING
1. With the drag link centered and handlebar in the

straight-ahead position, verify ski alignment by
measuring across from the outside edge of the left-
side wear bar bolts to the outside edge of the right-
side wear bar bolts (without using the straight-
edge) in two places: approximately 18-20 cm (7-8
in.) in front of the spindle and 18-20 cm (7-8 in.)
behind the spindle.
2. The measurement from in front of the spindle to
the outer edge of the wear bar bolts (without using
the straightedge) must not exceed the rear AO167
measurement by more than 1.6-6.4 mm (1/16-1/4
in.) toe-out. 4. Remove the lock nuts securing the A-arms to the
chassis; then push the cap screws as far forward as
possible.
0734-408
! WARNING AO169A
The measurement taken in front of the spindle must 5. Angle the rear of each A-arm downward and slide
never be less than the measurement taken behind
the spindle or poor handling will be experienced. them off the cap screws. Account for two outer
Neglecting to lock the tie rod by tightening the jam axles and an inner axle for each arm.
Front
Suspension A-Arms
(120 cc)
REMOVING

safety stand. A033
2. Remove the spindle (see appropriate Spindle in NOTE: If the cap screw must be removed, it will
this section). be necessary to remove the belly pan (see appro-
priate Belly Pan in this section).
NOTE: The ski does not have to be removed
from the spindle for this procedure. INSPECTING
3. Remove the cap screw and lock nut securing the NOTE: Whenever a part is worn excessively,
upper shock eyelet to the upper A-arm; then necessary.
rem ove the shock. A ccount for two shock
bushings.
1. Inspect the A-arm welded areas for cracks or any
signs of deterioration.
7-24
2. Inspect the axles for wear or damage. 4. Remove the cap screws and lock nuts securing the
spindle to the front suspension arms. Account for
3. Inspect the tubing for signs of being twisted or all mounting hardware.
bent.
INSTALLING
KEY AL159D
1. Upper A-Arm 7. Cap Screw
2. Lower A-Arm 8. Lock Nut
3. Axle 9. Shock Mounting
4. Axle Bracket
5. Axle 10. Washer
6. Cap Screw 11. Lock Nut
0736-880
1. Slide the A-arms onto the cap screws and swing

them up into position on the front end; then tightly
secure with lock nuts.
2. Install the spindle (see appropriate Spindle in this
section).
AL160D
5. On models with a sway bar, remove the cap screw

Front and lock nut securing the sway bar link to the front
Suspension Arms suspension arm.
6. Remove the screws and lock nut securing the skid
REMOVING plate; then remove the skid plate.
1. Remove the expansion chamber if necessary.

7
safety stand.
3. Remove the lock nuts and cap screws securing the
shock absorber; then remove the shock absorber.
Account for all mounting hardware.
AL144D
7. If applicable, remove the self-tapping screws

securing the steering boot to the front end.
8. Remove the cap screws and lock nuts securing the
suspension arms to the front end; then remove the
arms.
AL156D
7-25
INSPECTING 1. Inspect the arm welded areas for cracks or any
signs of deterioration.
cracked, or damaged in any way, replacement is 2. Inspect the bearings and axles for wear or damage.
necessary.
3. Inspect the arm tubing for signs of twisting or
bending.
INSTALLING
KEY
1. Lower Arm
2. Bearing
3. Upper Arm
4. Bearing
5. Axle
6. Washer
7. Axle Tube
8. Axle Tube
9. Axle
10. Axle
11. Washer
12. Cap Screw
13. Washer
14. Cap Screw
15. Lock Nut
16. Cap Screw
17. Lock Nut
18. Lock Nut
0736-484
KEY
1. Lower Arm
2. Bearing
3. Upper Arm
4. Bearing
5. Axle
6. Washer
7. Tube
8. Tube
9. Axle
10. Tube
11. Washer
12. Cap Screw
13. Cap Screw
14. Cap Screw
15. Lock Nut
16. Cap Screw
17. Lock Nut
18. Lock Nut
19. Tube
20. Washer
0735-968
7-26
1. Place the suspension arms into position on the 6. Place the shock absorber into position and secure
front end and secure with the cap screws and lock to the front end and spindle with two cap screws,
nuts. Tighten the upper arm cap screw and lock washers, axles, spacers, sleeves, and lock nuts.
nut to 4.6 kg-m (33 ft-lb). Tighten the lower arm Tighten to 3.9 kg-m (28 ft-lb).
cap screw and lock nut to 7.6 kg-m (55 ft-lb).
2. If applicable, place the steering boot into position
on the front end. Secure with the self-tapping
screws.
3. Install the skid plate and secure with the screws,
washer, and lock nut.
AL157D
AL144D
4. If applicable, place the sway bar link into position

on the suspension arm and secure with cap screw
and lock nut.
5. Accounting for mounting hardware, install the
spindle onto the suspension arm with the cap AL156D
screws and lock washers.
7. Install and secure the expansion chamber if
removed.
Front Suspension (Ski) 7

Shock Absorber
REMOVING

safety stand taking all pressure off the skis.
AL160D
2. Remove the cap screws securing the shock
absorber to the front end assembly and spindle;
then remove the shock absorber. Account for all
mounting hardware.
AL159D
7-27
AL156D AL156D
NOTE: Note the number of threads exposed

between the spring adjuster and shock housing
for installing purposes.
Sway Bar
3. Using the Shock Spring Removal Tool (p/n 0644-
057), remove the spring from the shock body by
compressing the spring; then remove the spring REMOVING
retainer from the top of the spring. Inspect the
shock absorber by quickly compressing and 1. Remove the lock nuts and cap screws securing the
extending the shock plunger while firmly holding sway bar arm to the links and remove.
the shock body. Resistance must be felt in both
directions. 2. Remove the lock nuts and cap screws securing the
sway bar arms to the sway bar; then remove the
CLEANING AND INSPECTING arms. Pull the sway bar out and account for two
bearings.
cracked, or damaged in any way, replacement is INSPECTING
necessary.
1. Inspect the shock absorber seal area for signs of cracked, or damaged in any way, replacement is
excessive oil leakage. necessary.
2. Inspect the shock absorber mounting eyelet, 1. Inspect the sway bar for any signs of twisting,
bushings, and sleeve for wear or damage. fatigue, or wear.
3. Inspect the threaded shock sleeve for damage or 2. Inspect the sway bar arms for cracks or damage.
wear. Clean the sleeve and apply a light coat of
grease to the threads before installing. 3. Inspect the links, bushings, bushing retainers, and
hardware for damage or wear.
INSTALLING
INSTALLING
1. Using the shock spring tool, place the spring on
the shock absorber and secure with the retainer. Key
1. Washer
2. Adjust the retainer nut (spring adjuster) until the 2.
3.
Washer
Lock Nut
specified amount of threads are exposed between 4. Cap Screw
the spring adjuster and the shock housing (noted in 5. Cap Screw
removing) as an initial setting. 6. Lock Nut
7. Link
3. Install the bushings, sleeves, and spacers into each 8.
9.
Cap Screw
Lock Nut
shock end; then place the shock absorber into 10. Sway Bar
position. Install both cap screws from the front. 11. Bearing
Tighten the lock nuts to 3.9 kg-m (28 ft-lb). 12. Arm
736-034A
7-28
1. Place the sway bar into position; then install a KEY
bearing on each end of the sway bar. 1. Console 11. Washer
2. Door 12. Mounting Bracket
2. Slide the sway bar arms onto the sway bar until the 3. Ignition Switch 13. Machine Screw
4. Key 14. Reservoir Assy
holes in the arms align with the notches in the 5. Spacer 15. Cap Screw
sway bar. Install the cap screws and lock nuts. 6. Lock Washer 16. Lock Washer
Tighten to 1.8 kg-m (13 ft-lb). 7. Decal 17. Retainer Bracket
8. Retaining Nut 18. Backing Plate
NOTE: Make sure the arms are positioned on the 9. Self-Tapping Screw 19. Lock Nut
10. Self-Tapping Screw
same flat on both ends of the sway bar.
3. Place the links into position on the sway bar arms;

then secure with cap screws and lock nuts. Tighten
to 3.2 kg-m (23 ft-lb).
Console
(EFI Models)
NOTE: Determine which style console is being

removed and installed and refer to the appropriate
illustration for component details; then remove
and install accordingly. 0736-633
KEY
KEY 1. Console 8. Retaining Nut
1. Console 8. Retaining Nut 2. Door 9. Self-Tapping Screw
2. Door 9. Self-Tapping Screw 3. Ignition Switch 10. Self-Tapping Screw
3. Ignition Switch 10. Self-Tapping Screw 4. Key 11. Washer
4. Key 11. Washer 5. Spacer 12. Outlet w/Nut
5. Spacer 6. Lock Washer 13. Decal - Left
6. Lock Washer 7. Decal - Right
7. Decal
0736-467
0736-668
7-29
REMOVING 3. Remove the console.
1. Remove the self-tapping screws securing the INSTALLING
console; then raise the console.
1. Place the console into position.
NOTE: If applicable, remove the cap screws and
washers securing the remote adjuster clamp to the 2. Connect the wiring harness to the ignition switch.
console; then lay the adjuster on the air-intake
silencer. 3. Secure the console with the self-tapping screws.
2. Disconnect the wiring harness from the ignition NOTE: If applicable, place the remote adjuster
switch. and clamp into position on the console; then
secure with the cap screws and washers. Tighten
securely.
Console
(Carbureted Model - Style A)
KEY
1. Console 24. Cable Tie
2. 12V Receptacle 25. Cable Tie
3. Foam 26. Main Harness
4. Washer 27. Headlight Harness
5. Self-Tapping Screw 28. Fuse
6. Machine Screw 29. Ignition Nut
7. Ignition Switch 30. Clip
8. Key 31. Spacer
9. Choke Cable
10. Choke Lever Kit
11. Choke Nut
12. Washer
13. Ignition Nut
14. Decal
15. Plate
16. Rivet
17. Latch Cup
18. Rivet
19. Washer
20. Washer
21. Lock Nut
22. Voltage
Regulator
23. Cap Screw
0735-935
REMOVING 3. Remove the cotter pin and pin securing the shift
lever to the shift pivot; then pull the shift lever out
1. Pull the recoil starter rope outward; then tie a slip- of the console.
knot in the recoil rope near the case. Slowly allow
the rope to retract to the knot. 4. Remove the four screws securing the steering post
cover; then remove the steering post cover.
2. Untie the knot in the end of the recoil starter rope;
then remove the handle from the rope. Account for
the cap.
7-30
Console
(Carbureted Models - Style B)
NOTE: Determine which type of console is being

removed and installed and refer to the appropriate
illustration for component details; then remove
and install accordingly.
KEY
1. Console 7. Self-Tapping 12. Choke Cable
2. Door Screw 13. Self-Tapping
3. Decal 8. Lock Washer Screw
AF906D
4. Decal 9. Ignition Nut 14. Washer
10. Choke Lever Kit 15. Spacer
5. Remove the screws securing the console; then 5. Ignition Switch
11. Choke Nut 16. Nut
6. Key
raise the console.
6. Disconnect the wiring harness from the ignition
switch. Remove the knurled nut securing the
choke assembly to the console; then slide the
choke cable out of the console.
7. If applicable, remove the primer; then remove the
console.
INSTALLING
1. Place the console into position; then (if applicable)

install the primer.
2. Connect the wiring harness to the ignition switch.
Secure the choke assembly to the console with the
knurled nut.
0736-438
3. Secure the console with screws.
KEY
4. Secure the steering post cover with four screws. 1. Console 9. Choke Cable
2. Door 10. Nut
3. Ignition Switch 11. Choke Nut
5. Slide the shift lever into the hole in the console; 4. Key 12. Decal
then secure the shift lever to the shift pivot with
the pin and cotter pin.
5.
6.
7.
Spacer
Lock Washer
Decal
13.
14.
15.
Self-Tapping Screw
Self-Tapping Screw
Washer
7
6. Thread the recoil starter rope through the console 8. Nut
and handle. Tie a knot at the end of the recoil rope.

Seat the cap. Remove the slip-knot and allow the
rope to retract.
0736-596
7-31
KEY KEY
1. Console 7. Decal 13. Self-Tapping 1. Console 7. Ignition Nut 13. Self-Tapping
2. Door 8. Nut Screw 2. Door 8. Lock Washer Screw
3. Ignition Switch 9. Choke Cable 14. Self-Tapping 3. Decal 9. Spacer 14. Self-Tapping
Screw Screw
4. Key 10. Choke Lever Kit 4. Decal 10. Choke Cable
5. Spacer 11. Choke Nut 5. Ignition Switch 11. Choke Lever Kit
6. Lock Washer 12. Decal 6. Key 12. Choke Nut
0736-811 0736-526
KEY KEY
1. Console 10. Choke Lever Kit 17. Machine Screw 1. Console 9. Nut
2. Door 11. Choke Nut 18. Reservoir Assy 2. Door 10. Choke Lever Kit
3. Ignition Switch 12. Decal 19. Cap Screw 3. Decal 11. Choke Nut
4. Key 13. Self-Tapping 20. Lock Washer 4. Decal 12. Choke Cable
5. Spacer Screw 21. Retainer 5. Ignition Switch 13. Self-Tapping Screw
6. Lock Washer 14. Self-Tapping Bracket 6. Key 14. Self-Tapping Screw
Screw
7. Decal 22. Backing Plate 7. Retaining Nut 15. Washer
15. Washer
8. Nut 23. Lock Nut 8. Lock Washer 16. Spacer
16. Mounting
9. Choke Cable Bracket
0736-718 0735-798
7-32
KEY KEY
1. Console 9. Choke Cable 1. Console 7. Self-Tapping 11. Washer
2. Door 10. Choke Lever Kit 2. Door Screw 12. Choke Cable
3. Ignition Switch 11. Choke Nut 3. Decal 8. Lock Washer 13. Choke Lever Kit
4. Key 12. Decal 4. Decal 9. Spacer 14. Choke Nut
5. Spacer 13. Self-Tapping Screw 5. Ignition Switch 10. Self-Tapping 15. Retaining Nut
Screw
6. Lock Washer 14. Self-Tapping Screw 6. Key
7. Decal 15. Washer
8. Nut
0736-796 0736-957
KEY KEY
1. Console 7. Decal 13. Decal 1. Console 8. Lock Washer 14. Self-Tapping
2. Door 8. Nut 14. Self-Tapping 2. Door 9. Spacer Screw
3. Ignition Switch 9. Choke Cable Screw 3. Decal 10. Choke Cable 15. Washer
4. Key 10. Choke Lever Kit 15. Self-Tapping 4. Decal 11. Choke Lever Kit
Screw
5. Spacer 11. Choke Nut 5. Ignition Switch 12. Choke Nut
16. Washer
6. Lock Washer 12. Outlet w/Nut 6. Key 13. Self-Tapping
7. Nut Screw
0736-546 0736-771
7-33
REMOVING
1. Remove the self-tapping screws securing the

console; then raise the console.
NOTE: If applicable, remove the cap screws and
washers securing the remote adjuster clamp to the
console; then lay the adjuster on the air-intake
silencer.
2. Disconnect the wiring harness from the ignition

switch and the outlet (if applicable). Remove the
choke nut securing the choke assembly to the
console; then slide the choke cable out of the
A040
console.
4. Using a piece of cardboard to protect the finish, tip
3. Remove the console. the snowmobile on the right side and using a #20
INSTALLING
drill bit, drill out the belly pan rivets.
1. Place the console into position.

2. Connect the wiring harness to the ignition switch
and the outlet (if applicable). Secure the choke
assembly to the console with the choke nut.
3. Secure the console with the self-tapping screws.
NOTE: If applicable, place the remote adjuster
and clamp into position on the console; then
secure with the cap screws and washers. Tighten
securely.
AL174D
NOTE: It is not necessary to remove the tie rod

Belly Pan boots.
(120 cc)
the snowmobile on the left side and using a #20
REMOVING drill bit, drill out the belly pan rivets.
1. Remove the hood. 6. With all belly pan rivets removed, return the
snowmobile to the upright position; then slide the
2. Remove the two cap screws securing the belly pan belly pan forward and up until it clears the front
to the front end; then account for washers and lock end.
washers.
INSPECTING

necessary.
1. Inspect for gouges, cuts, and tears.

2. Inspect the two belly pan threaded bosses and
ensure that they are in good shape.
INSTALLING
1. Slide the belly pan into position on the front end;

A039A then secure with cap screws, lock washers, and
washers (forward) and Phillips-head screws
3. Remove the two Phillips-head screws securing the (rearward).
belly pan to the footrest supports.
2. Install the three belly pan rivets in each ski-well.
7-34
the snowmobile on its side and install the
remaining belly pan rivets; then return the
snowmobile to the upright position.
4. Install the hood.
Belly Pan
NOTE: The following procedure is for a typical AL172D

Arctic Cat snowmobile belly pan. Some compo-
nents will vary from model to model. The techni- 4. Open the belt guard; then remove the speedometer
cian should use discretion and sound judgment.
cable from the speedometer drive.
REMOVING LEFT-SIDE 5. Cut the cable ties securing the speedometer cable
to the belly pan; then route the speedometer cable
1. Remove the left-side louver. away from the belt guard.
6. Remove the left-side front belly pan cap screw.
AL170D
2. Remove the left-side louver foam.

AL173D

the snowmobile on the right side; then remove the
torx-head screws securing the belly pan to the 7
frame and tunnel.
AL171D
3. Remove the left-side cap screw securing the

bumper to the air-intake silencer plenum.
AL175D
8. Remove the screws securing the left-side steering

tie rod boot; then remove the boot.
7-35
AL177D AL181D
9. Remove the shock absorber bolt. 12. Remove the front belly pan-to-nosepiece torx-
head screws.
AL178D
AL182D
10. Remove the torx-head screws securing the belly
pan underneath the shock mount. 13. Remove the belly pan assembly from the snowmo-
bile.
INSPECTING LEFT-SIDE
1. Inspect for gouges, cuts, and tears.

2. Inspect all belly pan threaded bosses that they are
in good shape.
INSTALLING LEFT-SIDE
1. Place the belly pan assembly in position in the

frame.
2. Secure the front belly pan to the nosepiece with
AL179D torx-head screws.
11. Remove the front belly pan-to-nosepiece Phillips-
head screws.
AL182D
7-36
3. Secure the front belly pan to the nosepiece with
Phillips-head screws.
AL177D
7. Install the torx-head screws securing the belly pan

AL181D to the frame and tunnel; then return the snowmo-
bile to an upright position.
4. Install the torx-head screws securing the belly pan
underneath the shock mount.
AL175D
AL179D 8. Install the left-side front belly pan cap screw.

5. Install the shock absorber bolt. Tighten to
3.9 kg-m (28 ft-lb).
AL173D
9. Route the speedometer cable through the belt

AL178D guard; then install cable ties to secure the speed-
ometer cable to the belly pan.
6. Install the left-side steering tie rod boot. Secure
with the screws. 10. Place the speedometer cable through the speedom-
eter drive; then close the belt guard.
11. Install the left-side cap screw securing the bumper
to the air-intake silencer plenum.
7-37
AL172D AL183D
12. Insert the left-side louver foam. 2. Remove the right-side louver.
AL171D AL184D
13. Install the left-side louver. 3. Remove the right-side louver foam.
AL170D AL185D
REMOVING RIGHT-SIDE 4. Remove the right-side cap screws securing the

1. Remove the right-side front belly pan cap screw.
Account for a flat washer and a lock nut.
AL186D
7-38
the snowmobile on the left side; then remove the
right-side belly pan torx-head screws from the
center belly pan and tunnel.
AL179D
9. Remove the front belly pan-to-nosepiece Phillips-

head screw.
AL188D
6. Remove the screws securing the right-side steering

tie rod boot; then remove the boot.
AL181D
10. Remove the front belly pan-to-nosepiece torx-

head screws.
AL190D
7. Remove the shock absorber.
AL182D
11. Remove the belly pan from the frame.
AL178D INSPECTING RIGHT-SIDE
8. Remove the belly pan torx-head screws under- 1. Inspect for gouges, cuts, and tears.
neath the shock mount.
2. Inspect all belly pan threaded bosses that they are
in good shape.
INSTALLING RIGHT-SIDE
1. Place the belly pan assembly in position in the

frame.
7-39
2. Install the nosepiece torx-head screws to the front
belly pan.
AL178D
6. Install the right-side steering tie rod boot. Secure

AL182D with the screws.
3. Install the nosepiece Phillips-head screw to the
front belly pan.
AL190D
7. Install the right-side belly pan torx-head screws to

AL181D the center belly pan and tunnel; then return the
snowmobile to an upright position.
4. Install the belly pan torx-head screws underneath
the shock mount.
AL188D
AL179D 8. Install the right-side cap screws securing the

5. Install the shock absorber. Tighten to 3.9 kg-m
(28 ft-lb).
7-40
Seat/Cushion/
Taillight Housing
(120 cc)
REMOVING
1. Remove the retaining nut securing the ignition

switch to the console; then slide the switch
forward and out of the console.
AL186D
9. Insert the right-side louver foam.
A041
2. Remove the screw securing the choke knob to the

cable; then remove the knob.
AL185D
10. Install the right-side louver.
7
A042
3. Remove the two nuts securing the choke cable to

AL184D
the console; then slide the cable forward and out of
the console.
11. Install the right-side front belly pan cap screw,
washer, and lock nut.
A043
AL183D
7-41
4. Pull the recoil starter rope out approximately 60 8. Raise the flap at the rear of the seat and remove the
cm (24 in.); then tie a slip-knot in the starter rope two cap nuts securing the seat assembly to the
below the console and allow the rope to slowly tunnel. Account for two washers.
retract against the starter case.
9. Raise the rear of the seat assembly high enough to
5. Remove the knot at the handle and remove the disconnect the taillight wiring harness; then
handle; then thread the rope through the bushing in disconnect the taillight from the main wiring
the console. harness.
position; then disconnect the fuel hose from the
carburetor.
! WARNING
Whenever any maintenance or inspection is made
on a fuel system when there may be fuel leakage,
there should be no welding, smoking, open flames,
etc., in the area.
7. Remove the vent hose from the top of the gas tank.
A045
10. Remove the seat assembly.

NOTE: If necessary, use a sharp tool to pry out
all staples securing the seat cover to the plastic
seat base; then remove the cover from the seat
base and seat foam.
A044
7-42
INSTALLING
NOTE: If the seat cover was removed, position

the cover over the seat foam and plastic seat base.
Check to make sure it is positioned straight; then
fold the rear edge of the cushion down and around
the base. Using a staple gun and 6 mm (1/4 in.) sta-
ples, staple the rear flap of the cushion to the base
in the same areas as the original staples were
located. Position staples 2.5 cm (1 in.) apart. Fold
the sides of the cushion down around the bottom
edge of the base. Position the staples in the same
areas as the original staples were located.
KEY
1. Seat Assy 30. Cable Tie
2. Gas Tank/Seat-Base 31. Cable Clip
3. Seat Cover 32. Bushing
4. Foam
5. Cap
6. Seal
7. Seat Wire
8. Seat Wire
9. Shut-Off Valve
10. Fuel Hose
11. Fuel Filter
12. Teflon Tape
13. Taillight Assy
14. Bulb
15. Washer
16. Nut w/Lock Washer
17. Washer
18. Cap Nut
19. Choke Cable
20. Staple
21. Nut
22. Decal
23. Retaining Nut
24. Ignition Switch
25. Ignition Switch Key
26. Lock Nut
27. Cap Screw
28. Decal
29. Push Nut
1. Place the seat assembly into position and connect

0736-891
8. Connect the fuel hose to the carburetor and turn

7
the taillight wiring harness. the gas tank shut-off valve to the OPEN position.
2. Secure the seat assembly to the tunnel with
washers and cap nuts.
3. Connect the vent hose to the top of the gas tank. Taillight Housing
4. Thread the recoil starter rope through the bushing
in the console and the handle; then tie a knot at the REMOVING
end of the rope and pull the handle up and onto the
knot. 1. Remove the four screws securing the taillight lens
to the housing. Account for a gasket.
5. Untie the slip-knot at the starter case and allow it
to slowly rewind into the case. 2. Remove the four machine screws securing the
backing plate to the taillight housing.
6. Slide the choke cable through the console and
secure with two lock nuts; then using a screw 3. Remove the two screws, lock washers, and
(coated with blue Loctite #243), secure the choke washers securing the seat base to the tunnel. Lift
knob to the end of the cable. the seat from the tunnel. Disconnect the taillight
wiring harness.
7. Slide the ignition switch into position on the
console; then secure with the retaining nut. 4. Remove the two lock nuts and washers securing
the taillight housing to the rear of the seat base.
Pull the housing free of the base.
7-43
INSTALLING 1. Remove the O-rings securing windshield to the
hood.
KEY
1. Taillight w/Socket Assy 2. Remove the caps covering the screws; then
2. Bulb remove the screws w/snaps.
3. Gasket
4. Lens 3. Remove the windshield.
5. Retaining Screw
INSTALLING
1. Place the windshield into position and install the

O-rings.
2. Secure the windshield to the hood with screws w/
snaps. Install the caps.
728-384B
1. Connect the wiring harness and place the seat into

position. Secure with two screws, lock nuts, and
washers. Backrest/Rack/Taillight
Assembly
2. Place the taillight housing into position and secure
to the seat base with two lock nuts and washers.
Tighten securely. REMOVING
3. Install the taillight bulb, gasket, and lens. Secure 1. Remove the cap screws, washers, and cap nuts
lens with four screws. securing the rack to the backrest.
4. Secure the backing plate to the taillight housing 2. In turn on each side, remove the two cap screws
with the existing machine screws. (inside the tunnel) securing the backrest assembly
to the tunnel. Account for the washers.
3. Disconnect the passenger handwarmer wiring
harness.
Windshield
4. Remove the backrest assembly from the tunnel.
Account for the two spacers.
REMOVING
KEY
1. Windshield
2. O-Ring
3. Expansion Nut
4. Machine Screw
5. Snap and Cap
731-745A
7-44
INSTALLING
KEY
1. Backrest 27. Cap Screw
2. Cover 28. E-Ring
3. Axle 29. T-Nut
4. Cup Washer 30. Reflector
5. Tension Block 31. Clip
6. Washer 32. Lever
7. Lock Washer 33. O-Ring
8. Washer 34. Self-Tapping
9. Spacer Screw
10. Lock Nut 35. Retainer
11. Machine Screw 36. Handhold
12. Retainer 37. Warmer
Element
13. Machine Screw
38. Handgrip
14. Adjuster Arm
39. Washer
15. Retaining
Screw 40. Lever
16. Lens 41. Deflector
17. Gasket 42. Warmer
Harness (L)
18. Bulb
43. Washer
19. Housing
44. Washer
20. Retainer
45. Washer
21. Bracket
46. Self-Tapping
22. Bracket Screw
23. Switch 47. Decal
24. Cover 48. Decal
25. Nut w/Washer 49. Warmer
26. Bracket Harness (R)
0736-253
KEY
1. Backrest
2. Cover
3. Machine Screw
4. Cap Nut
5. Rack
6. Handgrip
7. Machine Screw
8. Tube Closure
9. Bracket
10. Cap Screw
11. Rivet
12. Washer
13. Decal
7
14. Decal
15. Foam
0733-368
1. Place the backrest assembly and spacers (located 3. In turn on each side, install the 1/4-in. cap screw in
on the rear hole on each side) into position and the front hole and the 5/16-in. cap screw in the rear
align holes with tunnel mounting holes. hole. Secure with a flat washer and lock nut.
Tighten securely.
2. Install the cap screws with washers from the inside
of the tunnel and secure with the washers and lock 4. Connect the passenger handwarmer wiring
nuts. Tighten securely. harness.
5. Place the rack into position and secure with the
cap screws, washers, and cap.
7-45
Tunnel/Rear Bumper/
Snowflap
NOTE: Determine which style tunnel assembly is

being disassembled and refer to the appropriate
illustration for component details; then remove/
disassemble and install/assemble accordingly.
Some components will vary from model to model.
The technician should use discretion and sound
judgment.
Key
1. Tunnel Assy 31. Washer
2. Plate 32. Cap Screw
3. Plate 33. Plug
4. Rivet 34. Decal
5. Bracket 35. Cable Tie
6. Plate 36. Voltage Regulator
7. Lock Nut 37. Lock Nut
8. Rivet
9. Bracket
10. Footrest
11. Support
12. End Cap
13. Rivet
14. Decal
15. Cover
16. Decal
18. Washer
19. Reflector
20. Clip
21. Snowflap
22. Rivet
23. Washer
24. Cap Screw
25. Bumper
26. Cap Screw
27. Flag Assy
28. Flag
29. Flag Pole
30. Mount
0736-883
7-46
KEY
1. Tunnel Assy
2. End Plate
3. Rivet
4. Bracket
5. Rivet
6. Mounting Plate
7. Tunnel Roll
8. Bumper
9. Snowflap
10. U-Nut
11. U-Nut
12. Decal
13. Decal
14. Machine Screw
15. Washer
16. Lock Nut
17. Reflector
18. Retaining Clip
19. Clamp
20. Rivet
21. Bracket
22. Plug
23. Decal
24. Decal
25. Decal
26. Decal
27. Clamp
28. Rivet
0737-009
KEY
1. Tunnel Assy
2. Bracket
3. Mounting Plate
4. Rivet
5. Decal
6. Decal
7. Rear Bumper
9. Footrest
10. Plug
11. Trim
12. Clamp
7
13. Decal
14. Decal
15. Bracket
16. Washer
17. Lock Nut
18. U-Nut
19. Machine Screw
20. Snowflap
21. U-Nut
22. Rivet
0736-077
7-47
KEY
1. Tunnel Assy 31. Cushion Snap
2. Bracket 32. Rivet
3. Mounting Plate 33. Insert
4. Rivet
5. Decal
6. Decal
7. Rivet
8. Plug
9. End Plate
10. Reflector
11. Retaining Clip
12. Bumper
13. Decal
14. Decal
15. Machine Screw
16. Washer
17. Lock Nut
18. Snowflap
19. U-Nut
20. Bracket
21. Rivet
22. Clamp
23. U-Nut
24. Rivet
25. Plug
26. Roll
27. Pad
28. Machine Screw
29. Lock Nut
30. Machine Screw
0736-108
KEY
1. Tunnel Assy
2. Bracket
3. Mounting Plate
4. Rivet
5. Washer
6. Decal
7. Rear Bumper
9. Footrest
10. Wear Strip
11. Rivet
12. Clamp
13. Decal
14. Decal
15. Bracket
16. Washer
17. Lock Nut
18. U-Nut
19. Machine Screw
20. Snowflap
21. U-Nut
22. Decal
23. Plug
24. Trim
25. Reflector
26. Clip
27. Rivet
28. Rivet
29. Machine Screw
0735-831
7-48
KEY
1. Tunnel Assy 31. Lock Nut
2. Mounting Plate 32. Self-Tapping Screw
3. Bracket 33. Seal
4. Rivet 34. Seal
5. Pad 35. Cap Screw
6. Decal 36. Lock Washer
7. Seal 37. Cap
8. Plate 38. Bracket
9. Plate 39. Lever
10. Guide 40. Bracket
11. Machine Screw 41. Rivet
12. Bumper 42. Spring
13. Cap Screw 43. Clamp
14. Carriage Bolt 44. Rivet
15. Hinge 45. Washer
17. Lock Nut 47. Disc
18. Reflector 48. Insert
19. Machine Screw 49. Cap
20. Snowflap
21. Plate
22. Plate
23. Plate
24. Insert
25. Plate
26. Plate
27. Clip
28. Plug
29. Decal
30. Footrest
0736-590
REMOVING/DISASSEMBLING
NOTE: The snowflap can be removed without Headlight Assembly

removing the bumper by removing the three (120 cc)
bumper/snowflap cap screws.
1. Remove the cap screws securing the bumper REMOVING

assembly to the tunnel. Account for the U-nuts and NOTE: The bulb portion of the headlight is frag-
cap screws. ile. HANDLE WITH CARE. When replacing the
headlight bulb, the bulb assembly must first be
2. Slide the bumper/snowflap off the tunnel. removed from the housing. Do not touch the glass
7
portion of the bulb. If the glass is touched, it must
3. Remove the cap screws securing the snowflap to be cleaned with a dry cloth before installing.
the bumper and separate the bumper and snowflap.
Account for cap screws, washers, and lock nuts. 1. Peel back the rubber headlight socket cap; then
push in and turn the headlight socket counter-
ASSEMBLING/INSTALLING clockwise and remove it from the headlight
1. Secure the snowflap to the bumper with the cap housing.
screws, washers, and lock washers taking care to 2. Remove the caps covering the four headlight
place the washers next to the underside of the adjustment screws; then remove the adjustment
snowflap. Finger-tighten the cap screws to the screws. Remove the headlight from the hood.
lock nuts; then tighten the cap screws securely.
2. Place the bumper assembly into position on the
tunnel and secure with the cap screws and U-nuts.
Tighten the cap screws securely.
A038
7-49
INSTALLING
1. Secure the headlight housing to the hood with the

four adjustment screws; then snap the caps on the
screws.
NOTE: The hood cable is secured with the lower
right-hand adjustment screw.
2. Insert the headlight bulb socket into the headlight

housing; then rotate the socket clockwise to lock it
into the housing.
3. Place the rubber headlight socket cap over the 0731-844
headlight housing bead around the socket.
5. Remove the headlight adjustment thumb screws;
NOTE: To adjust headlight aim, adjust the four then remove the headlight assembly.
adjustment screws until maximum illuminaton for
the operator is apparent. NOTE: Halogen bulbs must not come in contact
with hands or foreign contaminants.
INSTALLING
Headlight Assembly 1. Place the headlight assembly into position. Secure
(1 Bulb Halogen) with a push rivet and two adjustment thumb
screws.
REMOVING
2. While holding bulb by the base, firmly install the
NOTE: The bulb portion of the headlight is frag- bulb in the harness connector.
ile. HANDLE WITH CARE. When replacing the
headlight bulb, the bulb assembly must first be 3. Install bulb assembly (with harness attached) into
removed from the housing. Do not touch the glass headlight housing. Make sure the bulb is firmly
portion of the bulb. If the glass is touched, it must seated in the headlight housing.
be cleaned with a dry cloth before installing.
4. Install the retaining ring onto the back of the
1. To release the retaining ring, depress the ring and headlight. Depress the ring and rotate it clockwise
rotate it counterclockwise. Slide the retaining ring to lock in place.
down the wiring harness.
2. With the harness connector attached to the bulb,
carefully withdraw the bulb from the headlight
housing.
3. Grasp the bulb by the metal base and carefully
remove the headlight harness from the bulb.
4. Between the top center of the headlight and hood,
there is a reusable plastic push rivet. From the
front using a medium-sized standard screwdriver,
push the center post of the rivet back.
AL084D
5. Check headlight aim (see appropriate Adjusting

Headlight Aim in this section).
! WARNING
Do not operate the snowmobile unless headlight
beam is adjusted properly. An incorrectly adjusted
beam will not provide the operator the optimum
amount of light.
7-50
Adjusting Headlight Assembly
Headlight Aim (3 Bulb Halogen)
(1 Bulb Halogen)
REMOVING HEADLIGHT BULB
The headlight HIGH/LOW beam can be adjusted ver- NOTE: The bulb portion of the headlight is frag-
tically and horizontally. The geometric center of the ile. HANDLE WITH CARE. When replacing the
HIGH beam light zone is to be used for vertical and headlight bulb, the bulb assembly must first be
horizontal aiming. removed from the housing. Do not touch the glass
portion of the bulb. If the glass is touched, it must
1. Position the snowmobile on a level floor so the be cleaned with a dry cloth before installing.
headlight is approximately 8 m (25 ft) from an
aiming surface (wall or similar surface). 1. Pull the wiring harness retaining clip away from
the headlight bulb base and disconnect the wiring
2. Measure the distance from the floor to the harness from the bulb.
midpoint of the headlight.
3. Using the measurement obtained in step 2, make a
horizontal mark on the aiming surface.
4. Make a vertical mark which intersects the
horizontal mark on the aiming surface directly in
front of the headlight.
5. Start the engine. Move the headlight dimmer
switch to the HIGH beam position. DO NOT USE
THE LOW BEAM.
6. Observe the headlight beam aim. Proper aim is
when the most intense beam is centered on the 0733-178
vertical mark 5 cm (2 in.) below the horizontal
mark on the aiming surface. 2. Rotate the headlight bulb base counterclockwise
and remove the bulb from the headlight housing.
INSTALLING HEADLIGHT BULB
! CAUTION
Do not touch the glass portion of the bulb. If the
glass portion is touched, it must be cleaned with
a dry cloth before installing.
7
1. While holding the bulb by its base, insert the bulb
into the headlight housing and rotate it clockwise
until it locks into the housing.
0734-485
2. Plug the wiring harness into the headlight bulb
base making sure the retaining clip locks onto the
7. Rotate the adjustment thumb screws until the base.
correct aim is obtained.
3. Check headlight aim (see appropriate Adjusting
Headlight Aim in this section).
! WARNING
Do not operate the snowmobile unless headlight
beam is adjusted properly. An incorrectly adjusted
beam will not provide the operator the optimum
amount of light.
7-51
5. Engage the brake lever lock and start the engine.
Adjusting Move the headlight dimmer switch to the HIGH
beam position. DO NOT USE LOW BEAM.
Headlight Aim
(3 Bulb Halogen) 6. Observe the headlight beam aim. Proper aim is
when the most intense beam is centered on the
vertical mark 5 cm (2 in.) below the horizontal
The headlight can be adjusted for vertical aim of the mark on the aiming surface.
HIGH/LOW beam. The geometric center of HIGH
beam zone is to be used for vertical aiming.
1. Position the snowmobile on a level floor so the
headlight is approximately 8 m (25 ft) from an
aiming surface (wall or similar surface).
NOTE: There should be an “average” operating
load on the snowmobile when adjusting headlight
aim.
2. Measure the distance from the floor to midpoint of

the headlight.
3. Using the measurement obtained in step 2, make a
horizontal mark on the aiming surface. 0734-485
7. Adjust the headlight housing mounting screws

4. Make a vertical mark which intersects the until correct aim is obtained. Shut the engine off;
horizontal mark on the aiming surface directly in then disengage the brake lever lock.
front of the headlight.
7-52
Torque Specifications Torque Specifications
(120 cc)
ITEM TORQUE
ITEM TORQUE
Ski ft-lb 45
kg-m 6.2 Tie Rod End (inner & outer) ft-lb 18-20
kg-m 2.5-2.8
Handlebar Adjuster Block ft-lb 10
kg-m 1.4
Steering Post Bearing Housings ft-lb 18
kg-m 2.5
Steering Post/Tie Rod ft-lb
kg-m
30
4.2
Torque Specifications
Drag Link/Tie Rods ft-lb 20
(General Bolts)
kg-m 2.8
Drag Link/Steering-Idler Arms ft-lb 30
kg-m 4.2 Thread Torque
Type of Bolt Diameter
Spindle Arm/Tie Rod ft-lb 25 (mm) kg-m ft-lb
kg-m 3.5
Tie Rod Jam Nuts ft-lb 5 0.2-0.4 1.5-3.0
12-15
kg-m 1.7-2.1 6 0.4-0.7 3.0-5.0
(Conventional or 4
Suspension Arms/Spindle ft-lb 30 Marked Bolt)
kg-m 4.2 8 1.0-1.6 7.0-11.5
Shock Absorber/Spindle ft-lb 28 10 2.2-3.5 16.0-25.5
kg-m 3.9
5 0.3-0.6 2.0-4.5
Front Suspension A-Arm (upper) ft-lb 33
kg-m 4.6 6 0.8-1.2 6.0-8.5
(7 Marked Bolt)
Front Suspension A-Arm (lower) ft-lb 55 8 1.8-2.8 13.0-20.0
kg-m 7.6
Sway Bar Arm ft-lb 13 10 4.0-6.0 29.0-43.5
kg-m 1.8
Ball Joint/Sway Bar ft-lb 23
kg-m 3.2
7-53
NOTES
7-54
SECTION 8 — DRIVE TRAIN
AND BRAKE SYSTEMS
TABLE OF
CONTENTS
Drive Train and Brake Systems ............................... 8-2
Drive Chain and Sprockets (120 cc)........................ 8-2
Drive Belt................................................................. 8-4
Drive Clutch............................................................. 8-4
Driven Pulley ......................................................... 8-10
Drive Clutch/Driven Pulley..................................... 8-16
Drive Train Schematics (w/Reverse) ..................... 8-19
Drive Train Schematics (w/o Reverse) .................. 8-23
Drive Train/Brake Disc (w/Reverse)....................... 8-26
Drive Train/Brake Disc (w/o Reverse).................... 8-34
Chain Adjuster....................................................... 8-40
Brake System (Hydraulic)...................................... 8-43
Brake Lever/Master Cylinder Assembly
(Hydraulic System)............................................. 8-49
Brake System (120 cc) .......................................... 8-51
Brake System (Mechanical/Quick-Adjust) ............. 8-53
8
Brake Control (Mechanical/Quick-Adjust) ............. 8-60
2002 Drive System Specifications (Production) .... 8-64
Chain Case Performance Specifications
With Tension Pad Tightener System .................. 8-66
Chain Case Performance Specifications
With Roller Tightener System ............................ 8-66
Drive System Components ................................... 8-67
Arctic Cat Cam Arms............................................. 8-68
Comet Cam Arms.................................................. 8-70
Comet-To-Arctic Cat Cam Arm Conversion
Chart .................................................................. 8-71
Chains & Sprockets............................................... 8-71
Arctic Cat Drive Belt Dimension Chart .................. 8-72
Arctic Cat Drive Belt Replacement Chart .............. 8-73
Center-To-Center/Offset Specifications................. 8-75
Torque Specifications (120 cc) .............................. 8-76
Torque Specifications ............................................ 8-76
Troubleshooting Drive Clutch/Driven Pulley .......... 8-77
Troubleshooting Drive Belt .................................... 8-78
Troubleshooting Hydraulic Brake System.............. 8-79
8-1
3. Remove the two nuts securing the muffler to the
Drive Train and engine.
Brake Systems
This section has been organized into sub-sections for
servicing drive train and brake systems; however,
some components may vary from model to model. The
technician should use discretion and sound judgment
when removing and installing components.
A019
Drive Chain 4. Press down on the muffler and pull it to the side
until the muffler flange clears the engine exhaust
and Sprockets studs; then remove the muffler from the engine
(120 cc) compartment. Account for the exhaust gasket.
5. Compress and hold the brake lever; then remove
REMOVING the cap screw securing the rear chain sprocket to
the driveshaft. Release the lever.
1. Remove the screws securing the front and rear
chain guards; then remove the guards from the 6. Remove the snap ring securing the brake band.
engine compartment. Note the position of the hood Account for a washer.
cable.
A003
A017A
7. Loosen the rear brake cable adjustment jam nut
NOTE: It will be necessary to support the hood and slide the cable out of the brake bracket. Set the
once the hood cable is removed. band assembly aside.
2. Remove the muffler hold-down spring from the
muffler and support bracket.
A005
A018
8-2
8. Secure the centrifugal clutch with a pair of INSTALLING
channel-lock pliers at the outer clutch collar; then
remove the cap screw securing the clutch. Account
for a washer and a spacer.
KEY
1. Cap Screw
2. Carriage Bolt
3. Bearing
4. Track Drive Assy
5. Drive Sprockets
6. Driveshaft
7. Key
8. Chain Sprocket
9. Lock Nut
10. Washer
11. Chain
A020 12. Spacer
13. Bearing
9. Slide the chain sprocket and clutch with the drive 14. Lock Washer
chain off the respective shafts and remove from
the engine compartment. Account for the rear 736-148A
driveshaft key. 1. Position the key on the rear driveshaft; then slide
the chain sprocket/clutch/drive chain assembly
into position.
cracked, or damaged in any way, replacement is 2. Secure the clutch with a pair of channel-lock pliers
necessary. at the outer clutch collar; then install the cap screw
(coated with blue Loctite #243) with washer and
1. Thoroughly wash all metallic components in parts- spacer. Tighten to 2.1-2.3 kg-m (15-16.5 ft-lb).
cleaning solvent. Dry using compressed air.
water.
3. Inspect the sprocket driveshaft for damage or for
stripped threads.
4. Inspect the keyways in the driveshaft, chain
sprocket, and clutch for wear or damage.
5. Inspect the chain and chain sprocket for wear or
damage.
6. Inspect the driveshaft sprockets for wear or A020
8
damage.
3. Slide the brake band over the clutch and position
the brake cable in the bracket; then secure the
brake band with a washer and snap ring.
A003
8-3
4. Tighten the rear brake cable adjustment jam nut Drive belt construction has an influence on the way the
securely; then adjust brake lever travel as drive clutch and driven pulley will shift and on the
necessary. See Brake System (120 cc) in this amount of power that will be transmitted through the
section. system. ONLY ARCTIC CAT DRIVE BELTS
SHOULD BE USED. Different brands of belts may
not have the same construction causing either more
friction or more slippage when the belt is wedged
between the sheaves and, thus, a loss of efficiency.
NOTE: A stiff belt causes a HP loss to the track.
As a belt warms up, it gets more flexible and trans-
mits power with less HP loss.
Drive Clutch
A005
CHANGING CAM ARMS
5. Compress and hold the brake lever; then install the The cam arms on the drive clutch can be changed
cap screw (coated with blue Loctite #243) and without disassembling the clutch. To change the cam
washer securing the rear chain sprocket. Tighten arms, use the following procedure.
the cap screw securely; then release the lever.
1. Check to make sure the ignition switch is in the
6. Place the exhaust gasket into position on the OFF position.
engine exhaust studs.
2. Remove the drive belt.
7. Place the muffler into position in the engine
compartment; then press down on the muffler and 3. Compress the movable sheave approximately 2.5
swing the intake pipe onto the engine exhaust cm (1 in.) and while holding it in this position,
studs. Secure with two nuts and the hold-down insert a flat bar firmly between the bottom side of
spring. the spider and the inner surface of the movable
sheave. Slowly release the movable sheave.
8. Place the front and rear chain guards into position
making sure the hood cable is properly positioned. 4. Remove the lock nuts from the three cam arm
Tighten securely. pins.
5. Remove the cam arm pins one at a time; then
remove the cam arm with bushing and account for
the washers.
Drive Belt
NOTE: When installing cam arms, always use
new lock nuts. Make sure the head of each cam
The belt dimensions and construction are two factors arm pin is positioned towards the direction of
that influence the performance of the drive system. drive clutch rotation. Tighten nuts until they con-
The two belt dimensions that are important to the per- tact the shoulder of the cam arm pin; then tighten
formance of the snowmobile are the outside circumfer- an additional 1/8 turn.
ence and the width. Both of these dimensions will
influence shifting characteristics.
KEY
If the drive belt is longer than specified, the drive 1.
2.
Lock Nut
Cam Arm
clutch and driven pulley will not have the full shift 3. Bushing
ratio. Also, a too-long drive belt will cause poor accel- 4. Washer
eration and a decrease in top speed. 5. Pin
If the drive belt is shorter than specified, the drive

clutch and driven pulley will have a different shift pat-
tern because they are in different ratios from those for
which they were originally matched. A too-short drive
belt will cause a loss in performance and a bog on
engagement.
733-452B
NOTE: A drive belt that is worn thin may produce
the same effect as one that is too long.
8-4
6. Change the cam arms and secure with new lock DISASSEMBLING
nuts and existing pins making sure the head of
each pin is positioned toward the direction of drive NOTE: Note the timing marks on the cover, spi-
clutch rotation. der, and movable sheave. These must be aligned
when assembling the drive clutch for balance pur-
NOTE: The drive clutch rotates counterclock- poses.
wise.
1. Loosen the nine machine screws securing the
cover. Remove every other cap screw and lock
! WARNING washer from the cover; then while firmly holding
Do not run the engine with the drive belt removed
the cover, remove the four remaining screws and
or the bar in the clutch. lock washers equally.
REMOVING
1. Open the belt guard; then remove the drive belt

and the plug from the belly pan.
2. Remove the bolt and lock washer securing the
drive clutch to the crankshaft.
AM059D
2. Remove the cover and spring.
AN380D
NOTE: Before installing the clutch puller, apply

oil to the threads of the puller and a small amount
of grease to the tip of the puller.
3. Using the Clutch Puller (p/n 0644-207) and an

impact wrench or a breaker bar and the Drive
Clutch Spanner Wrench (p/n 0644-136), tighten
the puller. If the drive clutch will not release, AM061D
sharply strike the head of the puller. Repeat this
step until the clutch releases. 3. Position the drive clutch over the Clutch Holder
(p/n 0644-058).
8
NOTE: The holder should either be secured in a
vise or bolted to a sturdy work bench.
AN381D
4. Remove the drive clutch from the engine

compartment. Account for any spacers.
AM063D
8-5
4. Secure the drive clutch to the holder using the 8. Remove the spider, spacer washers, and movable
clutch bolt and lock washer. sheave.
9. Using a pair of pliers, remove the six spider
buttons.
AM064D
5. Using the Thin Wall Deep Socket (p/n 0644-138),

remove the spider retainer nut. AM070D
10. Using a punch, push each pin from the roller.

Account for the roller washers (one on each side of
each roller).
AM065D
6. Using a small torch, heat the threaded area of the

spider. Place the Spider Removal Tool (p/n 0644-
085) over the heated spider and break spider loose AM071D
by turning it counterclockwise.
11. Remove the three cam arm pins and lock nuts
securing the cam arms to the movable sheave; then
remove each cam arm and account for the
bushings and the washers.
KEY
1. Lock Nut
2. Cam Arm
3. Bushing
4. Washer
5. Pin
AM067D
NOTE: Applying heat to the spider threaded area

will aid in clutch disassembly. The heat will loosen
the Loctite used during assembly. 733-452B
7. Remove the drive clutch from the clutch holder

using the clutch puller and the same procedure as
pulling the drive clutch from the crankshaft.
8-6
CLEANING AND INSPECTING 6. Inspect the bushing in the movable sheave for
wear, damage, or cracks. Measure the inside
NOTE: Whenever a part is worn excessively, diameter of the bushing and the outside diameter
cracked, or damaged in any way, replacement is of the stationary sheave hub. The difference
necessary. (clearance) must be less than 0.20 mm (0.008 in.).
If movable sheave bushing is not within
1. Using parts-cleaning solvent, wash grease, dirt, specifications, replace the movable sheave.
and foreign matter off all components; dry with
compressed air.
2. Remove any drive belt dust accumulation from the
stationary sheave, movable sheave, and bushings
using parts-cleaning solvent only.
! CAUTION
Do not use steel wool or a wire brush to clean
components having a bushing; damage to the
bushing will result.
3. Inspect stationary sheave, movable sheave, spider,

and cover for cracks or imperfections in the
casting. AM023D
4. Inspect the cam arm pins for wear or bends.

5. Inspect the bushing in the cover for wear, damage,
or cracks. Measure the inside diameter of the
bushing and the outside diameter of the stationary
sheave hub. The difference (clearance) must be
less than 0.20 mm (0.008 in.). If cover bushing is
not within specifications, replace the cover.
AM079D
7. Inspect the spring for proper compression rate

qualities.
P/N Color Rate Rate

@ 2 9/16 in. @ 1 5/16 in.
0646-148 Red/Blue 53 lb 224 lb
AM078D
0646-150
0646-149
Silver
Red
72 lb
74 lb
188 lb
228 lb
8
0646-147 Yellow/Green 114 lb 267 lb
0646-155 Purple 121 lb 240 lb
0646-229 Yellow/White 122 lb 285 lb
0646-248 Orange/White 143 lb 290 lb
8. Inspect the cam arms for any uneven wear pattern

or damage to the bushings.
9. Inspect all threaded areas for any cracked or
stripped threads.
10. Inspect rollers for damage or wear.
AM077D 11. Inspect the roller bushings for damage or fraying.
12. Inspect the stationary sheave and shaft for damage
or wear.
8-7
ASSEMBLING
AM071D
KEY 3. Place the spider buttons into position; then tap into
1. Stationary 5. Pin 10. Spacer Washer place until firmly seated.
Sheave 6. Lock Nut 11. Spider Assy
2. Movable Sheave 7. Cam Arm 12. Lock Washer NOTE: If a spider button does not fit tightly, it
3. Cover 8. Bushing 13. Machine Screw
4. Retainer Nut
must be replaced.
9. Washer 14. Spring
0736-321 4. Align the spider and movable sheave timing

marks.
! WARNING
! CAUTION
Never reuse the lock nuts on the cam arm pins.
Failure to align the spider and movable sheave
timing marks will cause drive clutch to be out of
1. Place a cam arm with bushing and washers into balance resulting in clutch and crankshaft
position on the movable sheave; then secure with damage.
the cam arm pin and lock nut. Carefully tighten the
lock nut until it contacts the cam arm pin shoulder;
then tighten an additional 1/8 turn. Repeat 5. Place the movable sheave, spacer washers, and
procedure on the other two cam arms making sure spider into position on the stationary sheave hub.
the head of each pin is positioned toward the Make sure all threads are clean and free of oily
direction of drive clutch rotation. residue. Apply green Loctite #620 to the entire
threaded area of the shaft and thread the spider
NOTE: The drive clutch rotates counterclock- onto the shaft. Tighten the spider using the spider
wise. removal tool to 34.5 kg-m (250 ft-lb).
NOTE: Allow the Loctite to cure at room temper-
KEY ature for 24 hours.
1. Lock Nut
2. Cam Arm
3. Bushing
4. Washer
5. Pin
733-452B
2. Place a roller and washers (one on each side of the

roller) into position on the spider; then install the AM072A
pin. Repeat procedure on the other two rollers.

6. Apply green Loctite #620 to the threads of the
stationary shaft above the spider. Install the spider
retainer nut and tighten to 11.8 kg-m (85 ft-lb).
8-8
INSTALLING
1. Install any spacers as accounted for in removing;

then insert the clutch bolt with lock washer.
NOTE: Be sure to wipe the clutch taper and
crankshaft taper clean of any oil film or dirt before
installing the drive clutch.
2. Place the clutch into position on the crankshaft.

3. Using a 12-point 1/2-in. socket and the drive
clutch spanner wrench, tighten the clutch bolt to
6.9-7.6 kg-m (50-55 ft-lb).
AM066
NOTE: Grasp the movable sheave and lift it ! CAUTION

upward; then release it. It must move freely and
not bind at any point. When installing the drive clutch, do not tighten
the clutch bolt with any kind of impact tool.
Tighten clutch bolt using a hand torque wrench
7. Place the spring and cover into position making only. Failure to do so could result in stationary
sure the timing mark on the cover is properly sheave damage.
aligned; then compress the spring and install the
nine machine screws coated with blue Loctite
#242 and lock washers. Tighten evenly to
1.4 kg-m (10 ft-lb).
AF477D
4. Check alignment between the drive clutch and

driven pulley (see Drive Clutch/Driven Pulley in
AM075 this section).
AM076
AF468D
! CAUTION 5. Install the drive belt. Check drive belt deflection

Care must be taken when installing the cover not (see Drive Clutch/Driven Pulley in this section).
to damage the bushing. Secure the belt guard and install the plug in the
belly pan.
! WARNING
Never operate the engine without the belt guard
secured.
8-9
6. Either test drive the snowmobile or run the engine
for five minutes; then tighten the drive clutch bolt
to 6.9-7.6 kg-m (50-55 ft-lb).
Driven Pulley
REPLACING CAM ARM BUSHINGS REMOVING
1. Using a vise, spread the jaws just enough to allow 1. Open the hood; then open the belt guard.
room for the bushing to pass between.
2. Remove the drive belt.
2. Position the cam arm over the spread jaws.
driven pulley; then account for and note the
position of any alignment washers.
AM094
3. Slide a new bushing onto one of the cam arm pins;

then position the pin through the cam arm bushing.
SC013D
4. Slide the driven pulley off the driven shaft; then

remove pulley from the engine compartment.
NOTE: If the driven pulley is tight on the shaft,
pull the driven pulley off using the Driven Pulley
Puller (p/n 0744-023).
5. Remove the key, alignment washers, and stub

shaft from the driven shaft.
AM095
4. Using the new bushing as a tool, drive the worn

bushing from the cam arm. When the head of the
cam arm pin contacts the cam arm, the new
bushing will be properly seated.
AF120D
AM096
8-10
DISASSEMBLING
1. Scribe a line across all driven pulley components

to ensure correct assembly and pulley balance.
SC003D
4. Remove the spring.
SC001D
2. Place the driven pulley on a work fixture so the

roller plate is directed upward.
B458D
5. Slide the movable sheave off the stationary shaft;

then remove any thrust washers located between
the sheaves noting the position of washers for
assembling purposes.
SC002D
NOTE: To aid in driven pulley servicing, use a

roll of duct tape as a work fixture. The work fixture
will increase the stability of the pulley during the
repair procedure.
3. Remove the three lock nuts securing the roller

plate; then carefully slide the plate off the
stationary shaft allowing the spring to release
tension.
8
! WARNING
The roller plate is under spring pressure. Care must B459D
be taken when removing the lock nuts to prevent
the plate from ejecting prematurely.
B460
8-11
6. Remove the three socket head screws and lock
washers securing the torque bracket (cam) to the
stationary sheave; then remove torque bracket.
SC006D
AI062
7. Place the roller plate on a work fixture (roll of duct

tape, etc.).
SC007D

necessary.
SC004D
1. Using parts-cleaning solvent, wash grease, drive
8. Using a 1/8-in. punch, remove the spring pin belt dust, and foreign matter off all components.
securing the roller, roller pin, and thrust washer to
the plate. ! CAUTION
Do not use steel wool or a wire brush to clean
driven pulley components. A wire brush or steel
wool will cause the sheaves to be gouged (thus,
the drive belt may not slide properly between
sheaves). Decreased performance and possible
accelerated drive belt wear will result.
2. Inspect the rollers for damage, cracks, or wear.

3. Inspect the sheaves for any gouges, cracks, or
other damage. Also, inspect threaded areas of
sheaves for damaged or stripped threads.
4. Inspect the torque bracket (cam) for cracks or
SC005D damage. The ramp portions of the bracket and
caps must be free of gouges and damage. Minor
9. Using the Roller Pin Removal Tool (p/n 0644- scratches may be repaired using #320 grit wet-or-
276) from inside the plate, drive the roller pin out dry sandpaper.
of the plate. Account for the pin, thrust washer,
and roller.
8-12
REMOVING BEARINGS
To remove driven pulley bearings, use the Bearing
Removal and Installation Tool (p/n 0644-167) and the
following procedure.
! WARNING
Always wear safety glasses when using the bearing
driver.
NOTE: To remove the movable sheave bearing,

heat must be applied around the bearing.
B465
1. Place the movable sheave (or roller plate) flat on a
5. Inspect spring for distortion, crystallization, or press.
breaks.
2. Using the bearing tool, press the bearing out.
6. Inspect the roller plate, rollers, pins, and spring
mounting holes for cracks, damage, or wear.
7. Inspect the roller plate and movable sheave
bearings for wear. For each respective bearing,
measure the outside diameter of the shaft and the
inside diameter of the bearing. Compare the
readings. Clearance between the shaft and the
respective bearing must not exceed 0.5 mm
(0.020 in.). If the clearance exceeds the
specification, the bearing must be replaced.
AF154
INSTALLING BEARINGS
NOTE: Before installing a bearing, apply red

Loctite #271 to the outside face of the bearing.
1. Place the movable sheave (or roller plate) flat on a

press.
2. Using the bearing tool, press the bearing into
position. The bearing must be flush with the
B466D
8
outside of the bearing boss.
3. Wipe off excess Loctite. Allow the Loctite to cure
for 24 hours at room temperature.
B467
8-13
ASSEMBLING
KEY
1. Movable Sheave
2. Stationary Sheave
3. Torque Bracket (Cam)
4. Lock Washer
5. Socket Head Screw
6. Spring
7. Roller Plate
8. Bearing
9. Lock Nut
10. Spring Pin
11. Thrust Washer
12. Roller Thrust Washer
13. Roller
14. Roller Pin
15. Cover
16. Cover
0733-501
1. Place the roller and thrust washer (toward the

outside of the roller plate) and secure with the
roller pin.
2. Secure the roller, thrust washer, and pin into
position with the spring pin. Drive the pin in until
it is flush with the plate.
AI062
4. Place any thrust washers (as noted during

disassembly) on the stationary sheave shaft.
SC012D
3. Place the torque bracket (cam) into position on the

stationary sheave making sure the degree number
on the bracket aligns with the part number on the
stationary sheave. Install the three socket head
screws and lock washers. DO NOT tighten at this
time.
B460
5. Align the scribed line made during disassembly;

then slide the movable sheave onto the stationary
sheave shaft.
8-14
10. Rotate the movable sheave to ensure free
movement without binding.
11. Rotate the torque bracket (cam) until it is tight;
then using a long hex wrench, tighten the three
socket-head cap screws securing the bracket.
B459D
6. Place the sheaves on a work fixture (roll of duct

tape, etc.).
7. Place the spring over the stationary sheave hub
and hook the turned down end of the spring into
the hole in the casting of the stationary sheave. SC011D
INSTALLING
1. Slide the alignment washers onto the end of the

driven shaft.
2. Install the key in the driven shaft keyway; then
place the stub shaft into the driven pulley. Place
the driven pulley on the shaft. Align its keyway
with the driven shaft keyway.
NOTE: A small amount of Loctite Anti-Seize
Thread Compound (p/n 0678-146) applied to the
driven shaft will aid in fu ture driven pulley
removal.
B458D
8. Place the roller plate over the spring and hook the 3. Secure the driven pulley by installing any
turned-up end of the spring in the 3rd hole alignment washers, the washer, and cap screw.
(standard spring tension) of the plate. Tighten the cap screw to 2.6-3.3 kg-m (19-
24 ft-lb).
9. While holding the sheaves to prevent them from
rotating, grasp the plate and rotate it
approximately 120° clockwise until the mounting
holes align; then push the plate into position and
install the three lock nuts. Tighten the lock nuts to 8
1.5-1.8 kg-m (11-13 ft-lb).
NOTE: The line scribed during disassembly
should be aligned.
SC013D

Drive Clutch/Driven Pulley in this section); adjust
as necessary.
5. Install the drive belt and check drive belt
deflection (see Drive Clutch/Driven Pulley in this
section). Secure the belt guard.
SC003D
8-15
Drive Clutch/
Driven Pulley
CHECKING OFFSET
If premature drive belt wear is experienced or if the
drive belt turns over, parallelism/offset must be
checked. Also, parallelism/offset must be checked
whenever either the drive clutch or driven pulley is
serviced. To check the parallelism/offset, use the
Clutch Alignment Bar (p/n 0644-003) and the follow-
AF465D
ing procedure.
1. Open the belt guard and remove the drive belt.
2. Install the clutch alignment bar between the drive
clutch sheaves and against the outside edge of the
driven pulley stationary sheave.
3. Allow the alignment bar to rest on the drive clutch
shaft.
733-912B
CORRECTING OFFSET
1. To correct offset, the driven pulley must be moved

laterally on the driven shaft. Remove the cap
screw and washers securing the driven pulley; then
remove the driven pulley.
0733-912 shaft, pull the driven pulley off using the Driven
NOTE: The alignment bar must extend beyond
the front edge of the drive clutch. 2. To move the driven pulley inward on the shaft,
remove washer(s) as required from behind the
4. With the bar against the outside edge of the driven pulley.
pulley stationary sheave at points A and B, the bar
should just clear the inside edge of the stationary 3. To move the driven pulley outward on the shaft,
sheave of the drive clutch and rest on the add alignment washer(s) as required behind the
stationary shaft. If the bar does not clear the inside driven pulley.
edge or is more than 1.5 mm (0.060 in.) from the
inside edge, the offset must be corrected. NOTE: Make sure the keyways match when
installing the driven pulley. Arrange washers to
NOTE: On the model with a wide ratio driven pul- allow the least amount of “float” on the driven
ley with the bar against the outside edge of the shaft. A maximum of 1.5 mm (0.060 in.) of float is
driven pulley stationary sheave at points A and B, acceptable.
the bar should have between 2.5-4 mm (0.100-
0.160 in.) clearance to the inside edge of the sta- 4. Install the driven pulley and secure with a cap
tionary sheave of the drive clutch while resting on screw and washers. Tighten the cap screw to 2.6-
the stationary shaft. If the clearance is not within 3.3 kg-m (19-24 ft-lb).
specifications, the offset must be corrected.
8-16
CHECKING PARALLELISM
1. Check parallelism of the drive clutch/driven pulley

using the alignment bar and reference points X and
Y with the alignment bar against the driven pulley
at points A and B. Using a calipers or a machinist's
scale, measure X and Y from the back side of the
alignment bar. Measurements X and Y must be
equal or measurement Y must be more than
measurement X, but Y must not exceed
measurement X by more than 1.6 mm (0.062 in.).
AN610D
2. Recheck both offset and parallelism to ensure

accuracy and make further adjustments as
necessary.
NOTE: After parallelism and offset have been
corrected, check for proper drive belt deflection.
This is critical for optimum performance.
CORRECTING PARALLELISM (Torque

Bumper w/Shims)
733-912A
1. To correct parallelism, minor adjustments can be
made by removing shims from or installing shims
on the left-rear engine mount.
A. Loosen the cap screws securing the engine
mounting brackets to the front end.
B. Add or remove shims as needed to attain cor-
rect parallelism.
C. When parallelism is correct, secure the engine
mounting brackets to the front end.
2. Recheck both offset and parallelism to ensure
accuracy and make further adjustments as
AF041
necessary.
NOTE: The offset must be correct before check-
ing parallelism. NOTE: After parallelism and offset have been
corrected, check for proper drive belt deflection.
2. If parallelism is not within specifications, the
parallelism must be corrected.
8
CORRECTING PARALLELISM (Engine
Snubber w/Engine Plate)
CORRECTING PARALLELISM (Torque
Bumper w/Bearing Support Bracket) 1. To correct parallelism, minor adjustments can be
1. To correct parallelism, minor adjustments can be made by adjusting the engine snubber on the left-
made by adjusting the torque bumper on the left- rear engine mount.
rear engine mount. A. Loosen the cap screws securing the engine
A. Loosen the cap screws and nuts securing the plate to the engine mounts.
engine mounting brackets to the front end. B. Either lengthen or shorten the snubber and peri-
B. Using the jam nuts on the torque bumper, adjust odically check the parallelism measurement.
parallelism and periodically check the parallel- When the parallelism measurement is correct,
ism. When the parallelism is correct, tighten the loosen the snubber to allow 1.5 mm (0.060 in.)
cap screws and nuts securing the engine mount- clearance between the snubber and the engine;
ing brackets to the front end; then tighten the then lock the jam nuts on the snubber and
torque bumper jam nuts allowing 1.5 mm tighten the cap screws securing the engine
(0.060 in.) clearance between the torque plate.
bumper and the engine.
8-17
2. Recheck both offset and parallelism to ensure 4. Using a stiff ruler centered between the drive
accuracy and make further adjustments as clutch and driven pulley, push down on the drive
necessary. belt just enough to remove all slack. Note the
amount of deflection on the ruler at the bottom of
NOTE: After parallelism and offset have been the straightedge. The deflection should be within
corrected, check for proper drive belt deflection. the range of 25-31 mm (1-1 1/4 in.).
NOTE: Push down on the belt with the ruler only
DRIVE BELT DEFLECTION until the bottom of the belt flexes upward; then
read the amount of deflection.
Drive belt length, condition, and deflection are all
important for peak performance. To check and adjust 5. To correct drive belt deflection, washers can be
drive belt deflection, use the following procedure. removed or added between the stationary and
movable sheaves of the driven pulley.
1. Turn the engine off; then open the belt guard.
NOTE: If the drive belt deflection is above speci-
2. Make sure the drive belt is sitting at the top of the fications, the snowmobile will bog and lack power
driven pulley sheaves. at clutch engagement. For good performance,
proper belt deflection is critical.
3. Place a straightedge on top of the drive belt. The
straightedge should reach from the drive clutch to 6. Secure the belt guard.
the top of the driven pulley.
8-18
Drive Train
Schematics (w/Reverse)
NOTE: Determine which type of drive train is

being serviced and refer to the appropriate illustra-
tion for component details; then disassemble and
assemble accordingly. Some components will vary
from model to model. The technician should use
discretion and sound judgment when removing
and installing components.
KEY
Chain Case Assy
1. Sprocket Assy 29. Bearing
2. Sprocket 30. Reverse Shaft
3. Spring Retainer 31. Reverse Idler
4. Slip Pin Spacer
5. Compression 32. Lock Nut
Spring 33. Spring Washer
6. Cap Screw 34. Sprocket
7. Lock Nut 35. Lock Nut
8. Bearing 36. Flange Plate
9. Shaft Spacer 37. Bearing
10. Chain 38. O-Ring Seal
11. Driveshaft Exten- 39. Bearing
sion 40. Lock
12. Reverse Gear Nut
13. Thrust Washer
14. Thrust Bearing
15. Retaining Ring
16. Return Spring
17. Shaft Retainer
18. Spring Pin
19. Tab Lock Washer
20. Washer
21. Cap Screw
22. Cap Screw
23. Washer
24. Thrust Washer
25. Reverse Idler
Assy
26. Bearing
27. Aligner Pin
28. Reverse Idler
Assy
0736-617
8
8-19
KEY
1. Track Drive Assy 31. Brake Pad Set Drive & Driven Shafts/
2. Drive Sprocket 32. Brake Pad Piston Quick-Adjust Brake Assy
3. Driveshaft 33. Cap Screw
4. Drive Bushing 34. Lock Washer
5. Flange Plate/ 35. Brake Cable
Bearing Assy Bracket
6. Bearing 36. Brake Caliper
7. Flange Plate Assy
8. Carriage Bolt 37. Alignment Ball
9. Solder Ring 38. Compression
Spring
10. Drive Adapter
39. Washer
11. Grease Fitting
40. Brake Caliper Nut
12. Cable Adapter
41. Spring Pin
13. Lock Nut
42. Return Spring
14. Brake Disc
43. Brake Adjuster
15. Key Knob
16. Driven Shaft 44. Compression
17. Key Spring
18. Cap Screw 45. Brake Adjuster
19. Bearing Screw
20. Flange Plate 46. E-Ring
21. Lock Nut 47. Activator Arm
22. Washer 48. Clevis Pin
23. Stub Shaft 49. Washer
24. Driven Pulley 50. Cotter Pin
25. Washer 51. Clevis
26. Washer 52. Brake Caliper
27. Washer Mounting Bolt
28. Cap Screw 53. Washer
29. Snap Ring
30. Stationary Pad
Backing Plate
0736-488
KEY
1. Track Drive Assy 22. Washer Drive & Driven Shafts/
2. Drive Sprocket 23. Stub Shaft Hydraulic Brake Assy
3. Driveshaft 24. Driven Pulley
4. Drive Bushing 25. Washer
5. Flange Plate/ 26. Washer
Bearing Assy 27. Washer
6. Flange Plate 28. Cap Screw
7. Carriage Bolt 29. Brake Caliper
8. Bearing Assy
9. Solder Ring 30. Housing
10. Lock Nut 31. Housing
11. Cable Adapter 32. Cap Screw
12. Drive Adapter 33. Bleed Screw
13. Grease Fitting 34. Brake Pad Set
14. Brake Disc 35. Retaining Pin
15. Key 36. O-Ring
16. Driven Shaft 37. O-Ring
17. Key 38. Piston
19. Lock Nut 40. Cap Screw
20. Bearing 41. Lock Washer
21. Flange Plate 42. Washer
0736-535
8-20
KEY
1. Track Drive 32. Cap Screw Drive & Driven Shafts/
Assy* 33. Bleed Screw
2. Drive Sprocket 34. Brake Pad Set Hydraulic Brake Assy
3. Driveshaft 35. Retaining Pin
4. Drive Bushing 36. Housing
5. Sprocket 37. O-Ring
6. Flange Plate 38. O-Ring
7. Carriage Bolt 39. Piston
9. Drive Adapter 41. Cap Screw
10. Grease Fitting 42. Lock Washer
11. Cable Adapter 43. Washer
12. Driven Shaft 44. Bearing
13. Key 45. Flange Plate
14. Disc Hub 46. Solder Ring
15. Brake Disc
16. Socket Head
Screw
17. Lock Nut
18. Stub Shaft
19. Key
20. Bearing
21. Flange Plate
22. Cap Screw
23. Lock Nut
24. Washer
25. Driven Pulley
26. Washer
27. Washer
28. Washer
29. Cap Screw
30. Brake Caliper
Assy
31. Housing
* Sprocket style will vary from model to model.
0735-974
KEY
1. Screw Housing Chain Tensioner Assy
2. Cover
3. Power Spring
4. Self-Tapping
Screw
5. Chain Adjuster
Shaft
6. Chain Adjuster
Screw
7. O-Ring
8. Compression
Spring
9.
10.
Button Head
Rivet
Machine Screw
8
11. Roller Arm
12. Washer
13. Bearing
14. Tightener Roller
15. Shaft
16. Roller Arm Nut
17. Cap Screw
18. Washer
19. Lock Nut
0735-834
8-21
KEY
1. Retaining Ring Shift Lever Assy
2. Reverse Alarm
3. Alarm Switch
4. Switch Boot
5. Bracket
6. Axle
7. Bushing
8. Washer
9. Cap Screw
10. Lever
11. Clevis Pin
12. Cotter Pin
13. Shift Pivot
14. Lock Nut
15. Shift Linkage
Assy
16. Rod End
17. Jam Nut
18. Linkage Rod
19. Jam Nut
20. Rod End
21. Cap Screw
22. External Tooth
Lock Washer
23. Cap Screw
24. Washer
25. Decal
26. Wiring Harness
27. Cable Tie
0735-067
KEY
1. Shift Lever 33. Axle Shift Lever Assy
2. Grip 34. Cap Screw
3. Nut 35. Cap Screw
4. Pivot Axle 36. Cable Tie
5. Cap Screw 37. Bracket
6. Washer 38. Grommet
7. Lock Washer 39. Nut
8. Cam
9. Cap Screw
10. Lock Washer
11. Washer
12. Lock Nut
13. Shift Linkage
Assy
14. Rod End
15. Nut
16. Shift Rod
17. Nut
18. Rod End
19. Bearing
20. Alarm Switch
21. Switch Boot
22. Reverse Alarm
23. Retaining Ring
24. Pivot
25. Bearing
26. Axle
27. Bearing
28. Cap Screw
29. Lock Nut
30. Cap Screw
31. Lock Washer
32. Washer
0735-923
8-22
Drive Train
Schematics (w/o Reverse)
NOTE: Determine which type of drive train is

being serviced and refer to the appropriate illustra-
tion for component details; then disassemble and
assemble accordingly. Some components will vary
from model to model. The technician should use
discretion and sound judgment when removing
and installing components.
KEY Chain Case Assy

1. Chain Case w/ 26. Sprocket
Studs 27. Washer
2. Ribbed Bolt 28. Bushing
3. Stud O-Ring 29. Tightener Arm
4. Ribbed Bolt 30. Lock Nut
5. Stud 31. Pad
6. Lock Nut 32. Spring Assy
7. Washer 33. Cotter Pin
8. Lock Nut 34. Seal
9. Washer 35. Chain Case
10. Carriage Bolt Cover
11. Washer 36. Cap Screw
12. Carriage Bolt 37. Lock
13. Cap Screw Washer
14. Lock Washer 38. Plug
16. Seal 40. Oil Level Stick
17. Bearing 41. O-Ring
18. Bearing 42. Vent Cover
19. Lock Nut 43. Self-Tapping
Screw
20. Sprocket
44. Plug
21. Cap Screw
45. Guard
22. Pyramidal
Washer 46. Carriage Bolt
23. Chain 47. Washer
24. Lock Nut 48. Cover Assy
25. Spring Washer
0736-799 8
8-23
KEY
1. Chain Case w/ 30. Bushing Chain Case Assy
Studs 31. Tightener Arm
2. Ribbed Bolt Assy
3. O-Ring 32. Washer
4. Ribbed Bolt 33. Lock Nut
5. Stud 34. Tightener Arm
7. Nut 36. Roller
8. Lock Nut 37. Bearing
10. Carriage Bolt 39. Washer
11. Carriage Bolt 40. Spring Assy
12. Washer 41. Cotter Pin
13. Lock Washer 42. Cover
14. Cap Screw 43. Cap Screw
15. Chain Adjuster 44. Lock Washer
16. Nut 45. Plug
17. Seal 46. O-Ring
18. Washer 47. Oil Level
19. Adapter Stick
20. Bearing 48. O-Ring
21. Seal 49. Vent Cover
22. Flange Plate 50. Self-Tapping
Screw
23. Bearing
51. Seal
24. Lock Nut
52. Carriage Bolt
25. Sprocket
53. Guard
26. Spring Washer
54. Washer
27. Lock Nut
55. Cover Assy
28. Chain
29. Sprocket
0736-578
KEY Drive & Driven Shafts/

1. Track Drive Assy 31. Brake Pad Set
2. Drive Sprocket 32. Brake Pad Piston
Quick-Adjust Brake Assy
3. Driveshaft 33. Cap Screw
4. Drive Bushing 34. Lock Washer
5. Flange Plate/ 35. Brake Cable
Bearing Assy Bracket
6. Bearing 36. Brake Caliper
7. Flange Plate Assy
8. Carriage Bolt 37. Alignment Ball
9. Solder Ring 38. Compression
Spring
10. Drive Adapter
39. Washer
11. Grease Fitting
40. Brake Caliper Nut
12. Cable Adapter
41. Spring Pin
13. Lock Nut
42. Return Spring
14. Brake Disc
43. Brake Adjuster
15. Key Knob
16. Driven Shaft 44. Compression
17. Key Spring
18. Cap Screw 45. Brake Adjuster
19. Bearing Screw
20. Flange Plate 46. E-Ring
21. Lock Nut 47. Activator Arm
22. Washer 48. Clevis Pin
23. Stub Shaft 49. Washer
24. Driven Pulley 50. Cotter Pin
25. Washer 51. Clevis
26. Washer 52. Brake Caliper
27. Washer Mounting Bolt
29. Snap Ring
30. Stationary Pad
Backing Plate
0736-488
8-24
KEY
1. Track Drive Assy 31. Housing Drive & Driven Shafts/
2. Drive Sprocket 32. Cap Screw
3. Driveshaft 33. Bleed Screw Hydraulic Brake Assy
4. Drive Bushing 34. Brake Pad Set
5. Bearing /wLock 35. Retaining Pin
Collar 36. Housing
7. Carriage Bolt 38. O-Ring
8. Lock Nut 39. Piston
9. Drive Adapter 40. Washer
10. Grease Fitting 41. Cap Screw
11. Cable Adapter 42. Lock Washer
12. Driven Shaft 43. Washer
13. Key 44. Flange Plate/
14. Disc Hub Bearing Assy
15. Brake Disc 45. Solder Ring
16. Socket Head Cap
Screw
17. Lock Nut
18. Stub Shaft
19. Key
20. Bearing w/Lock
Collar
21. Flange Plate
22. Cap Screw
23. Lock Nut
24. Washer
25. Driven Pulley
26. Washer
27. Washer
28. Washer
29. Cap Screw
30. Brake Caliper
Assy
0735-891
KEY
1. Track Drive 32. Cap Screw Drive & Driven Shafts/
Assy* 33. Brake Caliper
2. Drive Sprocket Assy Hydraulic Brake Assy
3. Driveshaft 34. Housing
4. Drive Sprocket 35. Cap Screw
5. Drive Bushing 36. Bleed Screw
6. Flange Plate 37. Brake Pad Set
7. Flange Plate 38. Retaining Pin
8. Carriage Bolt 39. Housing
9. Bearing w/Lock 40. O-Ring
Collar 41. O-Ring
10. Solder Ring 42. Piston
8
11. Cable Adapter 43. Washer
12. Drive Adapter 44. Cap Screw
13. Grease Fitting 45. Lock Washer
15. Lock Nut
16. Brake Disc
17. Disc Hub
18. Socket Head Cap
Screw
19. Key
20. Driven Shaft
21. Key
22. Bearing
23. Flange Plate
24. Lock Nut
25. Cap Screw
26. Washer
27. Stub Shaft
28. Driven Pulley
29. Washer
30. Washer
31. Washer
* Sprocket style will vary from model to model.
0736-830
8-25
NOTE: Tip the snowmobile on its left side posi-
Drive Train/Brake Disc tioning the chain case side of the snowmobile up.
Place a piece of cardboard under the side of the
(w/Reverse) snowmobile to prevent scratching of bumper and
belly pan.
DISASSEMBLING
! CAUTION
1. Remove the chain-case drain plug located on the Before tipping the snowmobile on its side, pull
lower back side of the chain case inside the tunnel the mirrors close to the hood or damage may
and drain the chain case lubricant. occur.
2. Disconnect the battery cables. Remove the battery 6. Disconnect the shift linkage from the arm on chain
and battery tray. case.
3. Open the belt guard and remove the drive belt. 7. Remove the cap screw from the center of the chain
4. Remove the cap screw and washer securing the case.
driven pulley; then account for and note the
position of any alignment washers.
AI025
8. Remove the cap screws securing the chain case

SC013D
cover; then remove the cover by pulling outward
5. Slide the driven pulley off the driven shaft; then and lifting up so the shift fork clears the large
remove the driven pulley from the engine inner washer.
compartment. Account for the key, stub shaft, and
alignment washers.
AI010
9. Remove the screw from the chain adjuster housing

and install an 8-32 set screw to lock the chain
adjuster in position.
AF120D
8-26
AF426 AF439
10. Remove the shim washer from the idler sprocket. 13. Remove the lock nut securing the top sprocket.
AF436 AF432
11. Remove the outer idler sprocket from the shaft. 14. Remove the spring washer in front of the top
sprocket.
8
AF437
AF444
12. Slide the small rubber alignment pin from the face
of the inner idler sprocket and place in safe 15. Set the brake lever lock. Remove the cap screw
location until assembly. and large washer securing the bottom sprocket.
NOTE: The bottom sprocket cap screw and
washer are spring loaded.
8-27
AF428 AF427
16. Remove the reverse gear. 19. Check the idler gear shaft. If the shaft surface is
rough, remove the shaft using a pair of vise-grip
pliers. Rotate the shaft counterclockwise.
20. Remove the shoulder nut securing the chain
tightener arm; then remove the arm from the chain
case.
AF442
17. Remove the top sprocket, chain, and idler gear.

Account for one shim washer located behind the
idler gear.
AF447
21. Remove the three lock nuts securing the top

bearing flange plate. Remove the flange plate,
seal, and bearing.
AF433
NOTE: If the chain is too tight and wont allow the

top sprocket to be removed, remove the PTO-side
driven shaft bearing. This will allow the driven
shaft to be lifted at the PTO-side and will loosen
the chain.
AI018
18. Remove the driveshaft extension, bottom sprocket, 22. Remove the three lock nuts securing the bottom
and spacer washer. bearing flange plate. Remove the flange plate,
seal, and bearing.
23. Remove the screw securing the air-intake silencer
to the steering support; then pull the silencer
forward and place it on the carburetor/throttle
body assembly.
8-28
NOTE: Using a hold-down strap, secure the air- 31. Slide the driveshaft toward the MAG-side until the
intake silencer to the engine. PTO-side of the driveshaft is out of its mounting
hole. Tilt the end of the driveshaft away from the
24. Loosen the set screw on the PTO-side driven shaft tunnel and slide the driveshaft free of the tunnel.
collar. Drive the collar clockwise (opposite shaft Remove the track.
rotation) until it is free.
NOTE: A fine file should be used to remove any
burrs left by the collar set screw.
25. Remove the lock nuts and carriage bolts securing

the PTO-side driven shaft flange plates.
AF055
32. Scribe a line on the driveshaft along the edge of

each sprocket to aid in assembly. Loosen the set
screw on the collar and drive the collar clockwise
until free; then remove the bearing and flange
plates from the driveshaft.
AF002D
33. Press the sprockets off the driveshaft.
26. Force the driven shaft toward the PTO-side
(rotating the shaft to prevent the brake disc from 34. Remove the six socket-head cap screws and lock
binding on the shaft) until brake disc is free. nuts securing the brake disc to the hub; then
Account for the key. separate disc and hub.
27. Continue to slide the driven shaft until it is out of
the PTO-side. Account for a bearing, two flange
plates, and the PTO-side driven shaft collar.
28. Remove the skid frame from the tunnel (see
Section 9).
29. Remove the three PTO-side lock nuts securing the
driveshaft flange bearing assembly and cable
adapter. Remove the adapter and speedometer
cable.
8
AF446

necessary.
1. Thoroughly wash all metallic components in parts-

AF053 water.
30. Tap the driveshaft toward the chain case to unseat 3. Inspect the driveshaft and driven shaft for
the MAG-side bearing. Remove the bearing. damaged splines or stripped threads.
4. Inspect the bearings for any roughness or damage.
5. Inspect the seals for any breaks or damage.
8-29
6. Inspect the track for cuts, gouges, or wear. ASSEMBLING
7. Inspect the keyways in the driven shaft and the 1. Secure the hub to the brake disc with six socket-
brake hub for wear or damage. head cap screws (coated with red Loctite #271)
and lock nuts. Tighten lock nuts to 0.4 kg-m
8. Inspect the brake disc for wear or cracks. (36 in.-lb).
9. Inspect the track drive sprockets for wear or
damage.
10. Inspect the top sprocket for any chipped or worn
teeth.
11. Inspect the bottom sprocket teeth for wear. Turn
the inner sprocket bearing by hand and inspect for
any signs of being rough.
12. Inspect the three bottom sprocket drive pins.
Check the pin edges for chipping and wear.
13. Inspect the drive pin springs for tension by AF445
pushing each pin into the sprocket and releasing it.
It must snap back out without any signs of 2. Press the sprockets on the driveshaft noting the
binding. If any of these items (pins, bearing, scribed marks on the shaft and the timing mark
sprocket, teeth) appear worn, replace the sprocket found on one tooth of each sprocket. The timing
as an assembly. mark is the letter T molded into the outer surface
of one drive tooth. All the T markings must be in
alignment.
NOTE: Sprocket style will vary from model to
model.
AI019
14. Inspect the idler gear sprocket teeth and bearings.

Rotate the inner bearings by hand. Check each
sprocket tooth for any signs of chipping and wear.
0728-351
15. Closely inspect the drive chain for broken links.
16. Inspect the reverse gear. Inspect the teeth for wear
and chipping. Inspect the edges of drive pin holes
for any signs of chipping and wear.
17. Remove the snap ring from the reverse gear.
Remove the outer thrust washer, thrust bearing,
and inner thrust washer. Inspect the thrust bearing
by placing it between the two thrust washers and
rotating the thrust washer. Rotation must feel
smooth. If any roughness is noted, replace the
thrust washers and bearing as a set.
18. Inspect the chain tightener bearing. Rotate the 0727-829
tightener roller and check for smooth rotation. If
rotation feels rough, replace roller and bearing
assembly.
8-30
7. Slide the MAG-side bearing onto the driveshaft
(inner race flange must be positioned toward drive
chain); then install the O-ring and flange plate.
Secure with three carriage bolts and lock nuts.
NOTE: Prior to installation, lubricate the O-ring
with Low-Temp Snowmobile Grease (p/n 0636-
593).
8. Install the brake hub key into the driven shaft

keyway; then slide the brake disc into position on
the splined end of the driven shaft.
727-829A
9. Install the PTO-side bearing with collar and flange
NOTE: Make sure all sprockets are installed cor- plates on the driven shaft; do not tighten the collar
rectly to ensure correct timing of the sprockets. at this time. Place the driven shaft into position
The bearing is positioned between the flange making sure the brake disc and flange plates are
plates. properly positioned. Secure the PTO-side bearing
and flange plates with two carriage bolts and lock
3. Assemble the driveshaft components on the PTO- nuts. Tighten to 2.2-2.5 kg-m (16-18 ft-lb).
side of the driveshaft. Install the bearing lock
collar; then install the flange bearing assembly 10. On the MAG-side driven shaft, install the bearing,
with the bolts facing towards the tunnel. O-ring, and flange plate. Secure with three lock
NOTE: Prior to installation, lubricate the O-ring
with Low-Temp Snowmobile Grease (p/n 0636-
593).
! CAUTION
Tighten the flange plate nuts evenly or the O-ring
seal may be damaged.
NOTE: If washers were removed from behind the

upper sprocket, install them at this time.
AF055
11. Install the spacer washer on the driveshaft.
4. Position the front of the track up into the tunnel.

Install the driveshaft with the splined end through
its mounting hole in the chain case.
5. Place the PTO-side of the driveshaft into position
by sliding the bolts of the flange bearing assembly
through the holes in the tunnel.
8
6. Place the cable adapter into position on the flange
bearing assembly bolts. Secure with three lock
AF090
12. Install the bottom sprocket and driveshaft

extension.
AF053
8-31
AF427 AF432
13. Position one shim washer on the idler gear shaft. NOTE: If the PTO-side driven shaft bearing was
removed to make the sprocket installation easier,
install the bearing and flange plate. Lock the bear-
ing collar by driving it in the direction of rotation to
lock the collar to the bearing and shaft. Tighten the
collar set screw.
16. Place the rubber alignment pin into position in the

idler sprocket; then slide the outer idler gear on the
shaft. Install shim washer on the shaft.
AF430
14. Position the chain around the lower reverse

sprocket; then place the idler sprocket and top
sprocket into the chain. Slide sprockets into
position on the idler shaft and driven shaft.
AF436
17. If the lower reverse sprocket was disassembled,

assemble the thrust washer, bearing, and thrust
washer. Secure with the snap ring. Apply
transmission lube to the bearing and rotate by
hand.
AF441
NOTE: If the chain tension is too tight to allow

installation of the top sprocket, remove the PTO-
side driven shaft bearing. This will allow the driven
shaft to be lifted at the PTO-side and will allow the
sprocket to slide onto the splined end of the driven
shaft.
15. Secure the top sprocket with a spring washer (with

the high side directed away from the sprocket) and AI021
lock nut (coated with red Loctite #271). Tighten
the lock nut to 4.8-5.5 kg-m (35-40 ft-lb). 18. Slide the reverse gear onto the driveshaft
extension; then position the spring into the reverse
gear and secure with heavy washer and cap screw.
8-32
24. Place the shift pivot and reverse switch bracket
into position on the cover; then secure the chain-
case cover with cap screws and lock washers.
Tighten the cap screws to 1.7-2.1 kg-m (12-
15 ft-lb).
25. Place the shift linkage into position on the back
side of the arm and secure with a cap screw and
lock nut. Tighten to 1.7-2.1 kg-m (12-15 ft-lb).
26. Place the reverse lever into position on the shift
pivot and secure with a clevis pin and cotter pin.
AF428
27. Secure the chain-case cover with cap screws and
lock washers. Tighten the cap screws to 1.7-
19. Install the chain tensioner arm, apply blue Loctite 2.1 kg-m (12-15 ft-lb).
#242 to the stud threads, and tighten the shoulder
nut to 0.6-0.7 kg-m (4-5 ft-lb). 28. On the PTO-side of the track driveshaft, slide the
lock collar against the bearing, drive the collar in
20. Remove the set screw from the chain adjuster the direction of rotation until tight, and tighten the
housing and install the adjuster plug. collar set screw.
21. Check that the chain-case O-ring seal is positioned

correctly on the housing.
22. Position the shift fork behind the large thrust
washer and bearing on the reverse gear; then
position the cover on the housing.
AF054
29. Install the skid frame (see Section 9).

30. Remove the hold-down strap securing the air-
intake silencer; then place the silencer into
position making sure the boot is properly
AF075 positioned on the carburetor/throttle body
assembly. Secure the silencer to the steering
screw; then install the cap screw through the
center of the cover and into the idler shaft. Tighten
support with the two screws.
31. Apply a light coat of grease or Loctite Anti-Seize
8
the cap screw enough to draw the idler shaft into Thread Compound (p/n 0678-146) to the driven
the cover. shaft; then install the driven shaft alignment
washers (as required) and key. Install the stub
shaft and the driven pulley, alignment washers (as
required), washer, and cap screw. Tighten to 2.6-
3.3 kg-m (19-24 ft-lb).
NOTE: Make sure the keyways match when
installing the driven pulley. Arrange washers to
allow the least amount of float on the driven shaft.
A maximum of 1.5 mm (0.060 in.) float is allowable.
AI025
8-33
4. If no contact is noted, loosen the jam nuts securing
the lower shift linkage and adjust the linkage rod
until the gauge is pushed out of the chain case
0.254-0.381 mm (0.010-0.015 in.). Lock the
adjustment by tightening the jam nuts securely
against the tie rod ends.
NOTE: To adjust the linkage rod, the shift lever
must be moved to the forward position.
5. Install the inspection plug.

6. Start the engine; then test the shifting
SC013D
characteristics of the reverse transmission. Adjust
as necessary.
32. Check the alignment of the drive clutch/driven
pulley (see Drive Clutch/Driven Pulley in this ! CAUTION
section).
The linkage must be properly adjusted. If the
33. Assure that the chain case drain plug is tightened linkage is too short, damage to the shift fork may
to 4.8 kg-m (35 ft-lb); then pour 354 ml (12 fl oz) occur. If the linkage is adjusted too long, the
gears will not shift totally into reverse.
of Arctic Cat Transmission Lube (p/n 0636-817)
into the chain case.
34. Install the drive belt and check belt deflection.
Secure the belt guard. Drive Train/Brake Disc
35. Install and secure the battery tray and battery; then (w/o Reverse)
connect the battery cables making sure to connect
the positive cable first. DISASSEMBLING
ADJUSTING REVERSE LINKAGE
1. Remove the chain-case drain plug (located on the
1. Start the engine; then test the shifting lower back side of the chain case inside the tunnel)
characteristics of the reverse transmission. and drain the chain case lubricant.
2. If adjustment of the reverse gear is necessary, stop 2. Open the belt guard and remove the drive belt.
the engine and remove the chain case inspection
plug located behind the oil level stick; then insert 3. Remove the cap screw and washer securing the
the Reverse Gear Adjustment Gauge (p/n 0644- driven pulley; then account for and note the
244) completely into the inspection hole. position of any alignment washers.
SC013D
0731-734
3. Pull the shift lever into the reverse position while 4. Slide the driven pulley off the driven shaft; then
holding the adjustment gauge firmly against the remove the driven pulley from the engine
chain case cover. Slight outward pressure should compartment. Account for the stub shaft, key, and
be felt on the gauge as the lever locks into reverse. alignment washers.
8-34
AF120D AF345D
5. Remove the cap screws and lock washers securing

the chain-case cover; then remove the cover.
AF344D
9. Slide both sprockets with chain off the shafts.

AF111D Account for washer(s) behind the top sprocket.
Release the brake lever lock.
6. Loosen the mechanical chain tensioner bolt; then
remove the cotter pins and washers securing the NOTE: If a sprocket will not slide off the shaft,
tensioner spring to the link pins. Remove the thread the nut onto the shaft; then use a puller to
spring, rollers, and washers. loosen the sprocket. The nut will prevent damage
to the threads.
10. Remove the six lock nuts securing the top and
bottom chain case flange plates. Remove the
flange plates, seals, and bearings.
AF347D
7. Remove the flex nut securing the front roller cage

and roller. Remove the cage and roller.
8. Set the brake lever lock; then remove the lock nut AF116D
and spring washer securing the bottom sprocket
and the lock nut and spring washer securing the 11. Remove the screws securing the air-intake silencer
top sprocket. to the steering support; then pull the silencer
forward and place it on the carburetors/throttle
body.
NOTE: Using a hold-down strap, secure the air-
intake silencer to the engine.
8-35
12. Loosen the set screw on the PTO-side driven shaft 20. Scribe a line on the driveshaft along the edge of
collar. Drive the collar clockwise (opposite shaft each sprocket to aid in assembly. Loosen the set
rotation) until it is free. screw on the collar and drive the collar clockwise
until free; then remove the bearing and flange
NOTE: A fine file should be used to remove any plates from the driveshaft.
burrs left by the collar set screw.
21. Press the sprockets off the driveshaft.
13. Remove the two lock nuts and carriage bolts
securing the PTO-side driven shaft flange plate. 22. Remove the six socket-head cap screws and lock
nuts securing the brake disc to the hub; then
14. Force the driven shaft toward the PTO-side separate disc and hub.
(rotating the shaft to prevent the brake disc from
binding on the shaft) until the brake disc is free.
Account for the key.
15. Continue to slide the driven shaft until it is out of
the PTO-side. Account for a bearing, flange plate,
and the PTO-side driven shaft collar.
16. Remove the skid frame from the tunnel (see
Section 9).
17. Remove the three PTO-side lock nuts securing the
driveshaft flange bearing assembly and the
speedometer cable adapter. Remove the cable
adapter and speedometer cable. AF446

necessary.

water.
3. Inspect the driveshaft and driven shaft for
AF053
damaged splines or stripped threads.
18. Tap the driveshaft toward the chain case to unseat 4. Inspect the bearings for any roughness or damage.
the MAG-side bearing. Remove the bearing.
5. Inspect the seals for any breaks or damage.
19. Slide the driveshaft toward the MAG-side until the
PTO-end of the driveshaft is out of its mounting 6. Inspect the track for cuts, gouges, or wear.
hole. Tilt the end of the driveshaft away from the
tunnel and slide the driveshaft free of the tunnel. 7. Inspect the keyways in the driven shaft and the
Remove the track. brake hub for wear or damage.
8. Inspect the brake disc for wear or cracks.
9. Inspect the chain, sprockets, and chain tensioner
components for wear or damage.
10. Inspect the track drive sprockets for wear or
damage.
AF055
8-36
ASSEMBLING
1. Secure the hub to the brake disc with the six

socket-head cap screws and lock nuts. Tighten the
lock nuts to 0.4 kg-m (36 in.-lb).
727-829A
NOTE: Make sure the sprockets are installed

correctly and the bearing is positioned between
the flange plates ensuring correct timing of the
sprockets.
AF445
3. Assemble the driveshaft components on the PTO-
2. Press the sprockets on the driveshaft noting the end of the driveshaft. Install the bearing lock
scribed marks on the shaft and the timing mark collar; then install the flange bearing assembly
found on one tooth of each sprocket. The timing with the bolts facing towards the tunnel.
mark is the letter T molded into the outer surface
of one drive tooth of the inside sprockets and on 4. Position the front of the track into the tunnel.
the inside surface of the outside sprockets. All the Install the driveshaft with the splined end through
T markings must be in alignment. its mounting hole in the chain case.
NOTE: Sprocket style will vary from model to
model.
AF055
0728-351
5. Place the PTO-end of the driveshaft into position
by sliding the bolts of the flange bearing assembly
through the holes in the tunnel.
8
6. Place the cable adapter into position on the flange
bearing assembly bolts. Secure with three lock
0727-829
AF053
8-37
7. Slide the MAG-side bearing onto the driveshaft
(inner race flange must be positioned toward drive
chain); then install the O-ring seal and flange
plate. Insert the cap screws from the inside of the
tunnel through the chain case, seal, and flange.
Secure with three lock nuts. Tighten to 2.2-
2.5 kg-m (16-18 ft-lb).
8. Place the bottom sprocket onto the splines. Finger-
tighten a lock nut (threads coated with blue Loctite
#242) and spring washer. DO NOT TIGHTEN AT
THIS TIME.
9. Install the brake hub key into the driven shaft AF345D
keyway.
13. Check the alignment of the sprockets using the
10. Install the PTO-side bearing with collar and flange following procedure.
plate on the driven shaft; do not tighten the collar
at this time. Place the driven shaft into position A. Place a straightedge against the faces of the
making sure the brake disc and flange plate are sprockets.
properly positioned. Secure the PTO-side bearing
and flange plate with two carriage bolts and lock B. Using a feeler gauge, check for clearance along
nuts. Tighten to 2.2-2.5 kg-m (16-18 ft-lb). the faces of both sprockets. If clearance
exceeds 0.8 mm (0.030 in.), shimming is neces-
11. On the MAG-side of the driven shaft, apply sary.
Scotch Bond Adhesive #4174 to the bearing
seating area adjacent to the shaft splines. Install
the bearing, seal, and flange plate. Secure with
three lock nuts. Tighten to 2.2-2.5 kg-m (16-
18 ft-lb).
NOTE: If washers were removed from behind the
top sprocket; install them at this time.
12. Loop the chain around the bottom sprocket and

slide the top sprocket with chain onto the driven
shaft. Secure the top sprocket with a lock nut
(threads coated with blue Loctite #242) and spring
washer. Tighten to 4.8-5.5 kg-m (35-40 ft-lb).
Tighten the bottom sprocket lock nut to 4.8- 0725-171
5.5 kg-m (35-40 ft-lb).
NOTE: Sprockets can only be shimmed out.
14. On the PTO-side of the driven shaft and the track

driveshaft, slide the lock collar against the bearing,
drive the collar in the direction of rotation until
tight, and tighten the collar set screw to 0.4 kg-m
(36 in.-lb).
AF344D
AF058
15. Install the skid frame (see Section 9).
8-38
16. Remove the hold-down strap securing the air- 21. Tighten the mechanical chain tensioner finger-
intake silencer; then place the silencer into tight; then lock the jam nut against the chain case.
position making sure the boot is properly
positioned on the carburetors/throttle body.
17. Secure the silencer to the steering support with the
two screws.
18. Apply a light coat of grease or Loctite Anti-Seize
Thread Compound (p/n 0678-146) to the driven
shaft; then install the driven shaft alignment
washers (as required) and key. Install the driven
pulley, stub shaft, alignment washers (as
required), washer, and cap screw. Tighten the cap
screw to 2.6-3.3 kg-m (19-24 ft-lb).
NOTE: Make sure keyways match when install- AF347D
ing the driven pulley. Arrange washers to allow the
least amount of float on the driven shaft. A maxi- 22. Place the front roller cage and roller into position
mum of 1.5 mm (0.060 in.) float is allowable. and secure with the flex lock nut.
23. Install the drain plug and tighten to 4.8 kg-m
(35 ft-lb); then pour 236 ml (8 fl oz) of Arctic Cat
Transmission Lube (p/n 0636-817) into the chain
case.
24. Check the position of the chain-case cover O-ring
seal; then place the chain-case cover into position
and secure with six cap screws and lock washers.
AF057
19. Check the alignment of the drive clutch/driven

pulley (see Drive Clutch/Driven Pulley in this
section).
20. Tip the snowmobile onto the PTO-side using
cardboard to prevent scratching the belly pan; then
install the washers, rollers, and spring. Secure with
two washers and cotter pins.
25. Install the drive belt and check drive belt

AF111D
8
deflection (see Drive Clutch/Driven Pulley in this
section). Secure the belt guard.
AF113D
8-39
4. Using a small piece of wire, remove the small
Chain Adjuster spring from the end of the adjuster screw.
1. Remove the small plug from the adjuster housing

and install an 8-32 set screw into the threaded hole
of the adjuster housing.
AF401
5. While holding the end cap in position, remove the

three cap screws securing the end cap to the
adjuster housing.
AF416
2. Using a 3/4-in. wrench, remove the chain adjuster

from the chain case.
AF419
6. Slowly and carefully lift the end cap from the

adjuster housing until it is free of the hooked end
of the spring.
AF417
3. Remove the adjuster stem from the end of the

adjuster screw.
AF420
7. Remove the O-ring seal from the adjuster housing.

8. Carefully lift the spring from the housing and
AF418
secure the spring using a cable tie.
8-40
1. Apply a light coat of oil to the threads of the

adjuster bolt; then turn the adjuster bolt clockwise
into the housing a few turns.
AF421
9. Remove the set screw from the adjuster housing;

then remove the adjuster socket from the housing
by pulling it free of the adjuster bolt.
AF423
2. Slide the adjuster socket over the end of the

adjuster bolt and push the socket down firmly into
position. Rotate the adjuster socket clockwise until
its flange seats against the housing inner surface.
AF422
10. Rotate the adjuster bolt counterclockwise until it is

free of the housing; then remove the adjuster bolt.
AF424
3. With the flat surface of the adjuster socket located

under the threaded hole in the housing, install an
8-32 set screw.
8
AF423
11. Wash all components in parts-cleaning solvent and

inspect all components for any signs of wear.
AF403
8-41
AF425 AF400
4. Install the bent tab of the spring into the slot of the 8. Install the three cap screws (coated with blue
adjuster socket with the outer hooked end of the Loctite #242) and tighten to 1 kg-m (7 ft-lb).
spring positioned in the clockwise direction.
AF419
AF406
9. Apply a thin coat of grease to the spring and place
5. With the spring in position, remove the cable tie the spring into position in the end of the adjuster
used to prevent it from unwrapping. bolt.
6. Place the O-ring seal into position; then set the end
cap into position. Make sure its tab is hooked into
the end of the spring.
AF401
10. Use a thin coat of grease on the stem shaft to hold

it in position; then place the stem into the end of
AF405 the adjuster bolt.
7. While holding the end cap down into position,
rotate the end cap 20 turns clockwise to tension the
spring.
8-42
Brake System
(Hydraulic)
! WARNING
Use only Arctic Cat approved Hi-Temp Brake Fluid
(p/n 0638-315). Never substitute or mix different
types or grades of brake fluid. Brake loss may
occur. Brake loss can result in severe injury or even
death.
AF418 CHECKING BRAKE LEVER TRAVEL

11. Securely tighten the adjuster assembly to the chain 1. Compress the brake lever fully.
case.
NOTE: Do not pump the brake lever as it will pro-
duce an inaccurate reading.
2. Measure the distance between the brake lever and

the handlebar. The distance must be greater than
2.54 cm (1 in.).
AF417
12. Remove the set screw from the adjuster housing

and install the cap screw.
734-505A
3. If the distance is less than specified, check the

brake fluid level (see Checking and Adding Brake
Fluid in this sub-section), inspect for leakage, and
check the brake pads (see Checking and Replacing
Brake Pads in this sub-section).
! WARNING
8
Do not operate the snowmobile if the distance
between the compressed brake lever and handlebar
AF416 is less than 2.54 cm (1 in.). Brake loss may occur.
Brake loss can result in severe personal injury.
8-43
CHECKING AND ADDING BRAKE FLUID 1. Slide a piece of flexible tubing over the ball of the
bleeder valve and direct the other end into a
1. With the master cylinder in a level position, check container.
fluid level in the reservoir. The brake fluid level
must be just below the high mark.
0730-434
0734-397 2. Slowly compress the brake lever and hold. Open

the bleeder valve to release the fluid; then
2. If the brake fluid level is below the low mark, compress the brake lever repeatedly until all brake
remove the reservoir cover and add approved fluid is expelled. Close the bleeder valve.
brake fluid until the fluid level is just below the
high mark. Install and secure the reservoir cover. 3. Add new approved brake fluid to the reservoir;
DO NOT allow moisture to contaminate the brake then compress the brake lever and hold. Open the
system. bleeder valve. Repeat the compression until brake
fluid flows free of air bubbles and appears clean.
! CAUTION NOTE: It may be necessary to refill the reservoir
Brake fluid is highly corrosive. Do not spill brake a number of times to eliminate all air bubbles in
fluid on any surface of the snowmobile. the system.
4. When the brake fluid is free of all air and the brake
! WARNING lever feels firm when compressed, fill the
Do not overfill the master cylinder reservoir. Over- reservoir to a level just below the high mark; then
filling the reservoir may cause the brake system to install and secure the cover. Remove the tube from
hydraulically lock. Use only approved brake fluid. the bleeder valve.
Never substitute or mix different types or grades of
brake fluid. Brake loss may occur. Brake loss can 5. Proceed to bleed the brake system (see Bleeding
result in severe injury or even death. Brake System in this sub-section).
CHANGING BRAKE FLUID BLEEDING BRAKE SYSTEM
The brake fluid must be changed on a regular basis If the brake lever feels spongy when applied, the brake
and/or whenever the brake fluid has been overheated system may need to be bled. To bleed the brake sys-
or contaminated. The brake fluid should be changed tem, use the following procedure.
every 1000 miles or at the end of the snowmobiling
season, whichever occurs first. 1. Remove the master cylinder reservoir cover and
fill the reservoir to the high mark with approved
Arctic Cat recommends the removal and disassembly brake fluid.
of the brake caliper assembly when changing the brake
fluid (see Removing/Installing Caliper in this sub-sec- ! CAUTION
tion).
Brake fluid is highly corrosive. Do not spill brake
fluid on any surface of the snowmobile.
! CAUTION
fluid on any surface of the snowmobile. ! WARNING
Use only approved brake fluid. Any substitute may
! WARNING result in a loss of brakes.
Use only Arctic Cat approved brake fluid. Any sub-

stitute may result in a loss of brakes.
8-44
! WARNING
Do not use brake fluid from a container that has
been opened for a long period of time. Unsealed
brake fluid containers will absorb moisture and can
contaminate the fluid inside.
2. Slide a piece of flexible tubing over the ball of the

container.
0730-434
2. Remove the retaining pin securing the brake pads

to the caliper assembly.
3. Pull both brake pads out of the caliper assembly.
0730-434
3. Slowly compress the brake lever and hold. Open

the bleeder valve to release the fluid and air. When
the fluid stops flowing, close the bleeder valve;
then release the brake lever.
4. Repeat step 3 until the brake fluid flows free of air
bubbles.
AF255D
NOTE: It may be necessary to refill the reservoir
during the bleeding process. 4. Using a large screwdriver, slowly push both brake
pistons into the caliper.
5. When the brake fluid is free of all air and the brake
lever feels firm when compressed, fill the ! CAUTION
reservoir to a level just below the high mark; then
install and secure the cover. Remove the tube from Care must be taken not to pry against the brake
the bleeder valve. disc when pushing on the pistons or severe
damage may occur.
CHECKING AND REPLACING
BRAKE PADS
To check and replace the brake pads, use the following
5. Position the new brake pads into the caliper and
secure with the retaining pin. 8
procedure. NOTE: When installing new brake pads, always
install them as a set. Never install just one pad or
1. Measure the thickness of both brake pads. The use brake pads which have been used in another
brake pad thickness must be greater than 3.2 mm snowmobile.
(0.125 in.). If the brake pad thickness is less than
specified, replacement of both pads is necessary.
AF255D
8-45
6. Compress the brake lever repeatedly to ensure
correct positioning of the brake pads; then release.
NOTE: When new brake pads are installed, a bur-
nishing process is required. Drive the snowmobile
slowly and compress the brake lever repeatedly
until the pads just start to heat up; then allow them
to cool down. This process stabilizes the pad
material and extends the life of the pads.
REMOVING CALIPER

container. AF255D
5. Loosen the upper cap screws securing the caliper

halves; then remove the two cap screws, lock
washers, and flat washers securing the brake
caliper to the chain case.
0730-434
2. Open the bleeder valve and compress the brake

lever several times to drain the reservoir of fluid.
3. Remove the brake hose from the caliper. Use an AF261D
absorbent towel to collect any remaining brake
fluid. 6. Remove the caliper assembly from the engine
compartment.
DISASSEMBLING
1. Position a piece of wood between the pistons.

Using low-pressure compressed air, blow into the
caliper brake hose fitting to remove the brake
pistons.
! WARNING
pressed air.
AF262D
! CAUTION
fluid on any surface of the snowmobile.
4. Remove the retaining pin securing the brake pads

to the caliper assembly; then remove the brake
pads.
AF248
8-46
2. Remove the two cap screws securing the caliper
halves. Account for the small O-ring.
3. Remove the piston O-rings and discard.
AF267
5. Inspect the condition of the brake pads. Replace if

damaged or worn. The brake pad thickness must
be greater than 3.2 mm (0.125 in.). If the brake
AF264 pad thickness is less than specified, replacement of
both pads is necessary.
6. Inspect the brake hose for cracks and deterioration
NOTE: Whenever a part is worn excessively, and check the condition of the threaded
cracked, or damaged in any way, replacement is connectors.
necessary.
ASSEMBLING
1. Inspect the brake pistons for gouges, cracks,
pitting, scuffing, or corrosion. If any of these
conditions exist, replace the piston. KEY 8. Bleed Screw
1. Retaining Pin 9. Brake Pad Set
2. Cap Screw 10. Housing
2. Clean the piston outer surface by using a Scotch- 3. Washer 11. Housing
Brite pad and clean brake fluid as a cleaner. 4. Brake Caliper Assy 12. Cap Screw
5. Housing O-Ring 13. Lock Washer
6. O-Ring 14. Washer
! CAUTION 7. Piston
Do not use any sharp cleaning tool on the piston

surface as it may cause damage. Parts-cleaning
solvent must not be used as it can damage the
piston O-ring.
736-850A
1. Apply approved brake fluid to the new O-ring;

then install the O-ring into the groove of each
caliper half.
8
AF230
3. Inspect the brake caliper for gouges, cracks,

pitting, scuffing, or corrosion. If any of these
conditions exist, replace the caliper.
4. Clean the caliper inner wall surface using a soft
Scotch-Brite pad and clean brake fluid. Wipe
caliper wall clean with a clean rag and brake fluid. AF251
NOTE: Always use a new O-ring when assem-

bling the brake caliper.
8-47
2. In each caliper half, apply approved brake fluid to
the brake piston; then while twisting, install the
piston with the open side facing out.
AF261D
2. Install the brake hose on the caliper and tighten

securely.
AF266
AF262D
AF269
3. Install the brake pads. Secure with the retaining
3. Place the small O-ring into position; then assemble pin.
the two caliper halves. Secure with the cap screws.
Do not tighten at this time.
AF255D
AF264
INSTALLING CALIPER
1. Secure the caliper assembly on the chain case

using two cap screws, lock washers, and flat
washers. Tighten the cap screws to 4.2 kg-m
(30 ft-lb). Tighten the upper cap screws to 5 kg-m
(36 ft-lb).
AF237D
8-48
4. Bleed the brake system (see Bleeding Brake 3. Place an absorbent towel around the connection to
System in this sub-section). absorb brake fluid. Remove the brake fluid hose
from the master cylinder.
NOTE: If new brake pads were installed, a bur-
nishing process is required. Drive the snowmobile
slowly and compress the brake lever repeatedly ! CAUTION
until the pads just start to heat up; then allow them Brake fluid is highly corrosive. Do not spill brake
to cool down. This process stabilizes the pad fluid on any surface of the snowmobile.
material and extends the life of the pads.
4. Remove the two torx-head screws and clamp
securing the brake assembly to the handlebar; then
remove the assembly from the handlebar.
Brake Lever/Master DISASSEMBLING
Cylinder Assembly
(Hydraulic System) 1. Remove the screw and lock nut securing the brake
lever.
REMOVING

container. Remove the reservoir cover; then open
the bleeder valve. Allow the brake fluid to drain
completely.
AF202
2. Remove the two screws securing the reservoir

cover; then remove the cover.
0730-434
2. Using a small screwdriver, push in on the self-

locking tab; then slide the brakelight switch free of
the brake control.
8
AF204
3. Remove the two screws securing the reservoir to

the master cylinder.
4. Compress the locking tabs of the reservoir and
remove the reservoir from the master cylinder.
Account for an O-ring seal.
AF201D
8-49
ASSEMBLING
AF205
INSPECTING
KEY
NOTE: Whenever a part is worn excessively, 1. Brake Assy 9. Machine Screw 17. Switch Assy
cracked, or damaged in any way, replacement is 2. Brake Lever 10. O-Ring 18. Dimmer Knob
necessary. 3. Lever Mounting 11. Master Cylinder 19. Handwarmer
Screw 12. Lock Washer Switch
4. Lock Nut 13. Screw 20. Cover Plate
1. Inspect the screw securing the brake lever for wear 5. Reservoir 14. Clamp 21. Self-Tapping
and for cracked, stretched, or damaged threads. 6. Gasket 15. Dimmer Control
Screw
7. Cover Assy 22. Brakeline
23. Adapter Fitting
2. Inspect the O-ring for deterioration and distortion. 8. Screw 16. Dimmer Control
Housing
0733-786
AF206
AF207
3. Inspect the reservoir for cracks and leakage.
1. Apply approved high temperature brake fluid to
4. Inspect the brake fluid hose for cracks, the O-ring seal; then install the seal on the
deterioration, and the condition of the fittings reservoir.
(threaded and compression).
2. Install the reservoir on the master cylinder. Secure
with two screws.
AF205
8-50
3. Install the brake lever. Secure with a screw and a
new lock nut. Tighten the lock nut just to the point
of ensuring free brake lever movement.
Brake System (120 cc)
! WARNING REMOVING AND INSPECTING

Do not over-tighten the lock nut. Over-tightening
the lock nut will cause the brake lever to bind. The
lever must work freely and fully return to its stop
after installation.
KEY
1. Lock Nut 7. Roller 14. Brake Band
2. Bushing 8. Washer 15. Retaining Pin
AF202 3. Rivet 9. Cap Screw 16. Washer
4. Chain Ten- 10. Bracket 17. Snap Ring
! WARNING sioner
5. Spring
11.
12.
Cap Screw
Spacer
18.
19.
Spacer
Washer
6. Tab 13. Clutch 20. Lock Washer
A new lock nut must be used to secure the brake
lever. 736-148B
INSTALLING 1. Remove the forward drive chain guard.
1. Position the brake assembly on the handlebar. NOTE: It will be necessary to support the hood
Secure with two torx-head machine screws and once the hood cable is removed.
clamp; tighten securely.
2. Loosen the Allen-head retaining pin securing the
2. Install the hose on the master cylinder. Tighten brake cable to the brake band.
securely.
3. Loosen the jam nut securing the threaded portion
of the brake cable to the brake bracket; then
remove the brake cable from the bracket and brake
band. Account for a spring.
4. Remove the snap ring securing the brake band to
the mounting bracket; then remove the brake band 8
from the engine compartment.
AF911D
3. Slide the brakelight switch into the brake control

until the self-locking tab snaps into position.
Lightly pull on the switch to make sure it is
properly secured.
4. Bleed the brake system.
A003
5. Remove the C-clip securing the brake lever pin in

the brake housing; then remove the pin and lever.
8-51
A998 A999
6. Disconnect the brake cable from the lever; then

slide the brake cable out of the lever.
A998
3. Place the brake band into position on the bracket

A999 and secure with a washer and snap ring.
7. Remove the handlebar pad and cut the cable tie

securing the brake cable to the steering post.
NOTE: Note the location of the cable tie for
assembly.
8. Inspect the brake band and brake cable for wear.

NOTE: The brake band pad material thickness
must be at least 1.6 mm (1/16 in.) or replacement is
necessary.
9. Inspect the brake cable for damage or fraying.

A003
INSTALLING
4. Slide the spring onto the brake cable; then insert
1. Route the cable through the slot in the brake the cable end into the brake band. Tighten
housing and insert the cable end into the housing. securely.
2. Seat the cable drum into the brake lever recess;
then secure the brake lever with a pin and C-clip.
A004
8-52
5. Secure the threaded portion of the brake cable to NOTE: The brake band should lock tightly when
the bracket with the jam nuts. the brake lever is compressed and should disen-
gage when the lever is released. If adjustment is
necessary, use the following steps.
1. Loosen the rearward jam nut on the brake cable.

2. Tighten the forward jam nut to set up the brake.
3. Check the brake lever travel distance periodically
while tightening the forward jam nut. When the
distance is within the specified range of 6-13 mm
(1/4-1/2 in.), tighten the rearward jam nut to
secure the adjustment.
A005
6. Secure the brake cable to the steering post with a Brake System
cable tie; then install the handlebar pad. (Mechanical/Quick-Adjust)
CHECKING BRAKE LEVER TRAVEL

REMOVING
1. Compress the brake lever fully.
1. Remove the cotter pin, washer, pin, and clevis
2. Check the distance between the brake lever and from the brake actuator arm.
the lever stop. The distance must be within a range
of 6-13 mm (1/4-1/2 in.).
AF297D
2. Remove the recoil starter rope from the brake

0725-565
cable bracket.
8
3. If travel distance is not as specified, adjust the
brake lever travel. 3. Loosen the jam nut on the brake cable and remove
the cable from the bracket.
ADJUSTING BRAKE LEVER TRAVEL
4. Loosen and remove the two mounting cap screws
(account for the front alignment ball) and remove
the brake caliper.
0735-457
AF460D
8-53
AF293D AF354
DISASSEMBLING 4. Remove the movable brake pad.

1. Remove the snap ring on the stationary side of the 5. Remove the brake piston.
caliper.
AF353
AF318A
6. Remove the brake actuator arm return spring.
2. Remove the brake pad support plate.
AF351A
AF356
7. Loosen and remove the three cap screws securing
3. Remove the stationary brake pad. the brake cable bracket and remove the bracket.
8-54
AF326 AF333
8. Remove the brake actuator arm assembly from the 11. On the rear of the caliper, loosen and remove the
caliper. jam nut, washer, spring, and ball assembly.
AF283 AF331
9. Pull out on the quick-adjust knob and turn CLEANING AND INSPECTING
counterclockwise to remove.
necessary.
1. Using a calipers, measure the stationary and

movable brake pads. The movable brake pad
thickness must exceed 12.7 mm (0.500 in.). The
stationary brake pad thickness must exceed
6.22 mm (0.245 in.).
8
AF328
10. Remove the adjustment bolt and spring from the

quick-adjust knob.
0730-504
NOTE: When replacing brake pads, always

replace both pads as a set.
2. Wash all brake components with parts-cleaning

solvent and dry thoroughly.
8-55
3. Inspect all brake components for signs of wear,
fatigue, cracks, or stripped threads.
4. Inspect the spring for cracks, stretching, or
unusual bends.
5. Inspect the brake cable for any signs of fraying or
broken strands. Replace as needed.
ASSEMBLING
1. In the rear mounting hole of the caliper,

temporarily install the mounting cap screw. In
sequence, install the alignment ball (apply a small
AF329
amount of grease to the ball), spring, washer, and
jam nut. Turn the jam nut in until slight spring 4. With the actuator shaft arm in the 11 oclock
pressure is felt; then remove the mounting cap position (located over the front mounting hole),
screw. install the actuator shaft into the brake caliper
assembly.
AF331
AF338
2. Apply Arctic Cat Hi-Temp Wheel Bearing Grease
(p/n 0436-094) to the actuator shaft. 5. Place the brake cable bracket and rope guide into
position and secure with the three cap screws and
lock washers.
AF327
3. Insert the adjustment bolt with spring and quick-

AF352A
adjust knob into the actuator assembly and turn in
2 or 3 turns. 6. Install the brake arm actuator return spring.
8-56
AF351A AF318A
7. Install the brake piston making sure that the slot in 10. Install the brake pad support plate with the large
the piston aligns with the roll pin in the caliper. tab located in the opening of the snap ring.
AF325A AF322
8. Install the movable (thick) brake pad into the 11. Install the stationary (thin) brake pad into the
caliper making sure that the slot in the pad aligns caliper making sure the slot in the pad aligns with
with the roll pin in the caliper. the small tab on the support plate. Use a rubber
band to hold the pad and plate in position.
INSTALLING
1. With the rubber band holding the stationary pad

and support plate in position, install the caliper
assembly over the brake disc. Remove the rubber
band.
8
AF320
9. Install the snap ring into the caliper making sure

that the sharp edge of the snap ring faces out and
the opening faces down.
! WARNING
Be sure the snap ring is fully seated. Personal AF321A
injury may result if the snap ring isnt seated prop-
erly within the slot of the caliper. ! CAUTION
Make sure that the brake pads are properly
positioned in the caliper or damage to the brake
system will result.
8-57
2. Apply green Loctite #609 to the rear mounting cap
screw with washer and install. DO NOT
TIGHTEN AT THIS TIME.
AF462D
5. Insert the cable end into the rear slot of the clevis.
Install the pin through the clevis and actuator arm;
AF460D then install the washer. Install a new cotter pin into
the clevis pin and spread the cotter pin.
3. Apply a small amount of grease to the alignment
ball and install into the front of the caliper. Apply
green Loctite #609 to the front cap screw with
washer; then install and tighten both cap screws to
4.2 kg-m (30 ft-lb).
AF340
6. Pull out on the quick-adjust knob and turn

clockwise until there is 6-13 mm (1/4-1/2 in.) free-
play at the brake lever.
AF293D
0727-451
AF458D
7. Set the brake lever lock; then securely tighten the
4. Place the brake cable into the rear slot of the brake jam nut on the upper mounting cap screw.
cable bracket and tighten securely.
8-58
NOTE: If the quick-adjust knob has reached its
maximum adjustment (cannot be rotated any fur-
ther clockwise), both brake pads must be
replaced.
! WARNING
DO NOT attempt to adjust the brake with the flange
nuts on the brake cable bracket. Incorrect brake
adjustment may occur causing possible brake fail-
ure.
AF298
8. Release the brake lever lock and recheck the

brake lever free-play (adjust as needed); then place
the recoil starter rope into the guide portion of the
brake cable bracket.
ADJUSTING BRAKE LEVER TRAVEL
1. Rotate the brake disc alternately forward and

backward while slowly compressing the brake
lever.
0730-151
2. At the point where the disc is locked, check the
distance between the brake lever and lever stop. 4. To increase brake lever travel (loosen the brake),
The distance must be within a range of 6-13 mm pull out on the quick-adjust knob and rotate the
(1/4-1/2 in.). knob counterclockwise periodically checking the
brake lever travel. Once the desired brake lever
travel is obtained, release the knob into a secured
position.
REPLACING BRAKE PADS
! CAUTION
The brake pads must be replaced as a set. Do not
under any circumstances ever replace only one
of the brake pads.
1. Using a 1/2-in. socket, remove the front brake

assembly guide pin. Slowly pull the pin from the
0727-451 assembly and catch the alignment ball as it drops
from the hole in the front of the caliper assembly. 8
! WARNING 2. Remove the rear guide pin; then slide the brake
Before making any adjustment, make certain the caliper assembly forward free of the brake disc.
brake quick-adjust knob isnt hot. If the snowmobile
has just been used, allow some time for the knob to 3. Remove the stationary brake pad from the caliper
cool or burns may result. assembly.
3. To decrease brake lever travel (set up brake), pull 4. Tip the caliper on its side and allow the movable
out on the spring-loaded quick-adjust knob and brake pad to drop free of the caliper assembly.
rotate the knob clockwise periodically checking
the brake lever travel distance until the correct 5. Place the new movable brake pad into position;
travel distance is attained. Once the correct brake then temporarily secure with a rubber band to hold
lever travel has been obtained, release the knob it in place.
into a secured position.
6. With the backing plate in position (wide tab
positioned between the snap ring ears), install the
stationary brake pad making sure the notch in the
pad is aligned with small tab of the backing plate.
Using a rubber band, temporarily secure the pad.
8-59
7. Place the brake assembly back into position over
the brake disc. Apply green Loctite #609 to the
rear guide pin; then install the rear guide pin.
8. Insert the alignment ball into the hole at the front
of the caliper, apply green Loctite #609 to the
front guide pin, and install the front guide pin.
Tighten the two alignment pins to 4.2 kg-m
(30 ft-lb). Cut and remove the two rubber bands.
NOTE: When new brake pads have been
installed, a burnishing process is required. Drive
the snowmobile slowly and compress the brake
lever repeatedly until the pads just start to heat up;
AL138D
then allow them to cool down. This process stabi-
lizes the pad material and extends the life of the
pads. 3. Loosen the jam nut securing the brake cable to the
brake cable bracket.
Brake Control
(Mechanical/Quick-Adjust)

handlebar pad to the handlebar.
AF462D
4. Disconnect the brake cable from the seat in the

brake lever and remove the lever; then slide the
brake cable free of the brake control.
AL136D
2. Remove the retaining ring, washer, and pin

securing the brake lever.
AL140D
5. Remove the brake lever from the brake control

housing.
6. Remove the four screws securing the console; then
raise the console to gain access to the main wiring
harness.
7. Disconnect the brake control wiring harness from
AL137D the main wiring harness.
8-60
AL141D
8. Cut the cable ties holding the wiring harnesses and

cables to the steering post noting their locations
for installing purposes.
9. Using a sharp knife, cut the grip off the handlebar;
then using a solvent, clean adhesive from the
handlebar. Key
1. Spring 12. Actuator
10. Remove the machine screw securing the brake 2. Brake Cable 13. Pin
control to the handlebar; then slide the brake 3. Brake Lever 14. Dimmer Switch
4. Axle 15. Washer
control off the handlebar. 5. Knob 16. Retaining Ring
6. Handwarmer Control 17. Grip
7. Machine Screw 18. Housing
8. Spring 19. Flange Nut
9. Self-Tapping Screw 20. Brake Control Assy
10. Retaining Ring 21. Handwarmer Element
11. Cover Plate
735-820A
1. Slide the brake control onto the handlebar and

secure with the machine screw.
AL143D
AL143D
2. Connect the wiring harness at the console.

3. Connect the brake control wiring harness to the
main wiring harness; then secure the harnesses
with cable ties.
8-61
7. Secure the brake lever with the pin, washer, and
retaining ring.
AL141D
4. Place the console into position and secure with

four screws making sure all wiring harnesses are AL138D
positioned under the console.
NOTE: Secure wiring harnesses and cables to
the steering post with cable ties as noted in
removing.
5. Connect the end of the brake cable to the seat of

the brake lever.
AL137D
8. Secure the handlebar pad to the handlebar with the

Phillips-head screws.
9. Apply Handlebar Grip Adhesive (p/n 0636-071) to
the bore of the handlebar grip; then using a rubber
hammer, drive the grip into position.
AL140D
! WARNING
6. Secure the brake cable to the bracket by tightening
the jam nut. The handlebar adhesive is extremely flammable.
The product contains acetone and the vapors, when
released, can be easily ignited. Keep away from
heat, sparks, and open flame. Use only in a well-
ventilated area. Avoid prolonged breathing of
vapor. Avoid eye and skin contact. Keep container
closed when not in use.
AF462D
8-62
NOTES
8-63
2002 DRIVE SYSTEM SPECIFICATIONS (Production)
DRIVE CLUTCH DRIVE SPRING CAM ARM DRIVEN PULLEY
MODEL
P/N P/N COLOR P/N GRAMS P/N SPRING COLOR
Bearcat W/T 0725-296 0646-149 Red 0746-527 50.5 0726-102 0648-012 Blue
Mountain Cat 500* 0725-336 0646-229 Yellow/White 0746-523 47.0 0726-129 0648-114 Red/White
Mountain Cat 570* 0725-360 0646-229 Yellow/White 0746-592 52.0 0726-132 0148-227 Yellow
Mountain Cat 600 EFI*/ 0725-343 0646-229 Yellow/White 0746-618 51.5 0726-129 0648-114 Red/White
600 EFI LE*
Mountain Cat 800*/800 LE* 0725-346 0646-147 Yellow/Green 0746-614 64.0 0726-114 0648-114 Red/White
Mountain Cat 800 EFI*/ 0725-346 0646-147 Yellow/Green 0746-614 64.0 0726-114 0648-114 Red/White
800 EFI LE*
Mountain Cat 1000* 0725-355 0646-149 Red 0746-600 50.0 0726-133 0648-114 Red/White
Pantera 550 0725-301 0646-149 Red 0746-527 50.5 0726-088 0148-227 Yellow
Pantera 600 EFI 0725-326 0646-149 Red 0746-592 52.0 0726-130 0648-114 Red/White
Pantera 800 EFI 0725-347 0646-155 Purple 0746-634 70.5 0726-113 0648-114 Red/White
Panther 440 0725-301 0646-149 Red 0746-527 50.5 0726-101 0148-227 Yellow
Panther 570 0725-357 0646-149 Red 0746-539 53.0 0726-088 0148-227 Yellow
Thundercat 0725-358 0646-149 Red 0746-588 54.5 0726-134 0648-114 Red/White
Z 370 0725-344 0646-147 Yellow/Green 0746-502 44.5 0726-120 0648-012 Blue
Z 440 0725-301 0646-149 Red 0746-527 50.5 0726-098 0148-227 Yellow
Z 570/570 SS 0725-357 0646-149 Red 0746-539 53.0 0726-088 0148-227 Yellow
Z 570 esr 0725-357 0646-149 Red 0746-539 53.0 0726-088 0148-227 Yellow
ZL 500 0725-330 0646-147 Yellow/Green 0746-618 51.5 0726-131 0648-114 Red/White
ZL 550/550 esr 0725-301 0646-149 Red 0746-527 50.5 0726-124 0148-227 Yellow
ZL 600 EFI/600 EFI esr 0725-326 0646-149 Red 0746-592 52.0 0726-117 0648-114 Red/White
ZL 600 EFI SS/600 EFI SS 0725-326 0646-149 Red 0746-592 52.0 0726-117 0648-114 Red/White
esr/600 EFI SS (EB)
ZL 800 EFI esr 0725-347 0646-155 Purple 0746-634 70.5 0726-113 0648-114 Red/White
ZL 800 EFI SS 0725-347 0646-155 Purple 0746-634 70.5 0726-113 0648-114 Red/White
ZR 500/500 CC 0725-330 0646-147 Yellow/Green 0746-618 51.5 0726-131 0648-114 Red/White
ZR 500 LE (EB) 0725-330 0646-147 Yellow/Green 0746-618 51.5 0726-130 0648-114 Red/White
ZR 600 0725-323 0646-147 Yellow/Green 0746-539 53.0 0726-117 0648-114 Red/White
ZR 600 EFI/600 EFI CC 0725-323 0646-147 Yellow/Green 0746-539 53.0 0726-113 0648-114 Red/White
ZR 800/800 CC 0725-347 0646-155 Purple 0746-634 70.5 0726-113 0648-114 Red/White
ZR 800 EFI/800 EFI CC 0725-347 0646-155 Purple 0746-634 70.5 0726-113 0648-114 Red/White
ZRT 600 0725-323 0646-147 Yellow/Green 0746-539 53.0 0726-113 0648-114 Red/White
* Initially set up at the factory for operation between 5000-9000 feet.
8-64
2002 DRIVE SYSTEM SPECIFICATIONS (Production)
TORQUE BRACKET CHAIN DRIVE
GEAR BELT ENGAGEMENT
MODEL RATIO RPM PEAK RPM
P/N DEGREE PITCH P/N P/N
Bearcat W/T 0648-025 47 18/40 70 0602-968 0627-014 3500 7800
Mountain Cat 500* 0648-014 49 19/40 70 1602-041 0627-020 4800 82-8400
Mountain Cat 570* 0648-126 53/51 19/40 70 1602-041 0627-020 4500 71-7300
Mountain Cat 600 EFI*/ 0648-014 49 19/40 70 1602-041 0627-020 4500 82-8300
600 EFI LE*
Mountain Cat 800*/ 0648-005 55 20/39 70 1602-041 0627-020 3800 73-7500
800 LE*
Mountain Cat 800 EFI*/ 0648-005 55 20/39 70 1602-041 0627-020 3800 73-7500
800 EFI LE*
Mountain Cat 1000* 0648-016 57/50 20/39 70 1602-041 0627-020 3800 8500
Pantera 550 0648-014 49 19/39 70 1602-041 0627-021 3500 7800
Pantera 600 EFI 0148-222 51 19/39 70 1602-041 0627-020 3500 82-8300
Pantera 800 EFI 0648-024 55/53 24/39 72 1602-042 0627-020 3500 73-7500
Panther 440 0148-222 51 20/39 70 1602-041 0627-021 3500 7000
Panther 570 0648-014 49 19/39 70 1602-041 0627-021 3500 71-7300
Thundercat 0648-016 57/50 24/39 72 1602-042 0627-020 3500 8500
Z 370 0648-002 53 18/44 72 0107-372 0627-021 3800 7200
Z 440 0648-002 53 20/39 70 0107-216 0627-021 3500 7000
Z 570/570 SS 0648-014 49 20/39 70 1602-041 0627-021 3500 71-7300
Z 570 esr 0648-014 49 19/39 70 1602-041 0627-021 3500 71-7300
ZL 500 0648-126 53/51 20/39 70 1602-041 0627-020 4200 82-8400
ZL 550/550 esr 0648-014 49 20/39 70 1602-041 0627-020 3500 78-8000
19/39 (esr) 8000 (esr)
ZL 600 EFI/600 EFI esr 22/41 72 1602-042
0648-002 53 19/39 (esr) 70 (esr) 1602-041 0627-020 3500 82-8300
(esr)
ZL 600 EFI SS/600 EFI SS 22/41 72 1602-042
esr/600 EFI SS (EB) 0648-002 53 19/39 (esr) 70 (esr) 1602-041 0627-020 3500 82-8300
(esr)
ZL 800 EFI esr 0648-024 55/53 24/39 72 1602-042 0627-020 3500 73-7500
ZL 800 EFI SS 0648-024 55/53 24/39 72 1602-042 0627-020 3500 73-7500
8
ZR 500/500 CC 0648-126 53/51 20/39 70 1602-041 0627-020 4200 82-8400
ZR 500 LE (EB) 0148-222 51 20/39 70 1602-041 0627-020 4200 82-8400
ZR 600 0648-002 53 20/39 70 1602-041 0627-020 4000 82-8300
ZR 600 EFI/600 EFI CC 0648-024 55/53 22/41 72 1602-042 0627-020 4000 82-8300
ZR 800/800 CC 0648-024 55/53 24/39 72 1602-042 0627-020 3500 73-7500
ZR 800 EFI/800 EFI CC 0648-024 55/53 24/39 72 1602-042 0627-020 3500 73-7500
ZRT 600 0648-024 55/53 23/40 72 1602-042 0627-020 4200 84-8500
* Initially set up at the factory for operation between 5000-9000 feet.
8-65
CHAIN CASE PERFORMANCE SPECIFICATIONS
WITH TENSION PAD TIGHTENER SYSTEM
CHAIN CASE PERFORMANCE SPECIFICATIONS* MPH/RPM (Engine)
TENSION
CHAIN SPRING TENSION
SPROCKETS RATIO PITCH CLIPS** PADS*** 6000 7000 8000 9000 10,000
24/35 .686 70 2L 2TK 79.0 92.2 105.4 118.5 131.7
22/33 .667 68 2L 2TK 76.8 89.6 102.5 115.3 128.1
21/33 .636 68 2S 2TK 73.3 85.5 97.7 109.9 122.1
24/39 .615 72 2L 2TK 70.8 82.7 94.5 106.3 118.1
22/37 .595 70 2L 2TN 68.5 80.0 91.4 102.8 114.2
20/35 .571 68 2L 2TK 65.8 76.7 87.7 98.7 109.6
21/37 .568 70 2L 2TK 65.4 76.3 87.2 98.2 109.1
19/35 .543 68 2S 2TN 62.6 73.0 83.4 93.8 104.3
20/39 .513 70 2L 2TK 59.1 68.9 78.8 88.6 98.5
21/41 .512 72 2S 2TN 59.0 68.8 78.6 88.4 98.3
20/41 .488 72 2S 2TN 56.2 65.6 75.0 84.3 93.7
18/37 .486 68 2L 2TN 56.0 65.3 74.6 84.0 93.3
16/33 .484 66 2L 2TK 55.8 65.0 74.3 83.6 92.9
19/41 .463 72 2L 2TK 53.3 62.2 71.1 80.0 88.9
18/39 .461 70 2S 2TN 53.2 62.1 71.0 79.8 88.7
17/37 .459 68 2L 2TK 52.9 61.7 70.5 79.3 88.1
* USE AS A GUIDE ONLY (MPH = 0.0192 x RPM x Ratio)
** SPRING CLIPS: L-p/n 0107-236, S-p/n 0107-235
*** TENSION PADS: Thick-p/n 0107-411, Thin-p/n 0107-228
NOTE: MPH must be multiplied by 1.12 to compensate for Arctic Cat overdrive clutch.
Example: 20/39 at 8000 RPM = 78.8 x 1.12 = 88.3.
CHAIN CASE PERFORMANCE SPECIFICATIONS WITH

ROLLER TIGHTENER SYSTEM
CHAIN CASE PERFORMANCE SPECIFICATIONS* MPH/RPM (Engine)
TENSION
CHAIN SPRING
SPROCKETS RATIO PITCH P/N ROLLER 6000 7000 8000 9000 10,000
18/44 .409 72 0707-026 Roller 47.1 53.7 61.4 69.2 76.8
18/40 .450 70 0707-026 Roller 51.8 60.4 69.1 77.8 86.4
19/40 .475 70 0702-130 Roller 54.0 63.0 72.0 81.2 90.0
23/40 .575 72 0702-130 Roller 65.6 76.6 87.5 98.4 109.0
24/39 .615 72 0702-130 Roller 70.8 82.6 94.5 106.3 118.0
20/39 .513 70 0702-130 Roller 59.1 68.9 78.8 88.6 98.5
19/39 .487 70 0707-026 Roller 56.1 65.5 74.8 84.2 93.5
* USE AS A GUIDE ONLY
8-66
DRIVE SYSTEM COMPONENTS
Below is a list of Comet Drive Clutch, Arctic Drive Clutch, and Driven Pulley components that are
available through the Arctic Cat Service Parts Department. Hopefully, this information will be useful when
doing any fine-tuning on the drive system. Now there is virtually a cam arm weight for all needs.
ARCTIC CAT DRIVE CLUTCH
SPRINGS - ARCTIC DRIVEN CAM ARMS
p/n Color Rate @ 1 7/16” p/n Grams p/n Grams
0748-025 Green 157 lb 0746-500 54.0 0746-583 46.5
0648-114 Red/White 116 lb 0746-501 48.5 0746-584 45.0
0746-502 44.5 0746-585 49.0
0148-227 Yellow 92 lb 0746-503 41.0 0746-586 45.0*
0648-012 Blue 79 lb 0746-523 47.0 0746-587 50.0
0648-010 White 58 lb 0746-524 48.5 0746-588 54.5
0148-176 Black 42 lb 0746-525 44.0 0746-589 45.0
0746-526 42.0 0746-590 40.5*
0746-527 50.5 0746-591 44.0
0746-528 46.5* 0746-592 52.0
SPRINGS - COMET DRIVE 0746-529 49.5* 0746-593 45.5
p/n Color Rate @ Rate @ 0746-530 53.5* 0746-594 44.5
2 3/8” 1 3/8” 0746-531 44.5 0746-595 41.5
0646-154 Purple 136 lb 254 lb 0746-532 44.0* 0746-596 44.5
0146-526 Yellow/Green 134 lb 264 lb 0746-533 47.5* 0746-597 43.5
0646-083 Red 92 lb 222 lb 0746-534 51.5* 0746-598 44.0
0746-535 52.5 0746-600 50.0
0646-097 Blue/Red 68 lb 197 lb
0746-536 45.0* 0746-602 42.5
0646-084 White 78 lb 178 lb 0746-537 39.5* 0746-604 41.5
0646-096 Silver 85 lb 169 lb 0746-538 49.5 0746-605 52.0
0646-192 Orange 120 lb 270 lb 0746-539 53.0 0746-606 48.4
0746-540 46.5 0746-607 46.0
0746-546 48.0 0746-608 47.5
ARCTIC CAT DRIVE CLUTCH SPRING CHART 0746-549 46.0 0746-609 52.0
p/n Rate @ Rate @ Color 0746-559 55.5 0746-610 50.0
2 9/16 in. 1 5/16 in. 0746-560 55.0 0746-611 47.0
LIGHT 0646-148 53 lb 224 lb Red/Blue 0746-561 50.0 0746-614 64.0
0646-150 72 lb 188 lb Silver 0746-562 42.0 0746-615 62.0
0746-565 43.5 0746-616 66.0
0646-149 74 lb 228 lb Red 0746-566 48.0 0746-617 60.0
0646-147 114 lb 267 lb Yellow/Green 0746-568 50.0 0746-618 51.5
0646-155 121 lb 240 lb Purple 0746-570 47.0 0746-619 47.0
0746-576 46.0 0746-633 68.0
0646-229 122 lb 285 lb Yellow/White
0746-579 46.5 0746-634 70.5
HEAVY 0646-248 143 lb 290 lb Orange/White 0746-581 52.5 0746-635 58.0
0746-582 48.5 0746-636 63.0
8
NOTE: The Arctic Cat drive clutch spring has a 0746-638 48.0
smaller O.D. than the Comet and cannot be inter- * Notched Cam Arm
changed. DRIVEN CAMS (Torque Brackets)
p/n Degree
0148-222 51
COMET CAM ARMS 0648-001 52/44
0648-002 53
p/n Grams p/n Grams p/n Grams
0648-005 55
0646-085 40.0 0646-156 45.0 0646-164 49.5 0648-006 57
0646-030 41.0 0646-078 45.0 0646-105 50.5 0148-180 45
0646-019 42.0 0646-009 46.5 0646-102 50.5 0648-011 48/44
0646-015 43.5 0646-021 46.5 0646-100 52.5 0648-014 49
0646-018 43.5 0646-199 46.5 0646-165 51.5 0648-016 57/50
0648-026 42
0646-079 44.0 0646-115 47.0 0646-117 53.0 0648-025 47
0146-525 44.0 0646-157 47.5 0646-099 54.0 0648-024 55/53
0646-002 44.0 0146-514 48.0 0646-163 54.0 0648-107* 57/50
0646-162 44.0 0646-031 48.5 0646-098 56.5 0648-125 51/49
0646-027 44.5 0646-080 48.5 0646-249 50.0 0648-126 53/51
0146-530 44.5 0646-124 49.5 0646-250 44.5 * Base is 0.100 thicker than that of p/n 0648-016. Used on
1999 800 cc.
8-67
ARCTIC CAT CAM ARMS
AR-CAM
8-68
ARCTIC CAT CAM ARMS
99-CAM
8-69
COMET CAM ARMS
COMET-CM
8-70
COMET-TO-ARCTIC CAT CAM ARM
CONVERSION CHART
ARCTIC CAT ARCTIC CAT ARCTIC CAT ARCTIC CAT
COMET P/N P/N COMET P/N P/N COMET P/N P/N COMET P/N P/N
0646-085 N/A 0146-530 0746-531 0646-123 N/A 0646-165 0746-534
0646-030 0746-503 0646-027 0746-502 0646-157 0746-533 0646-100 0746-535
0646-019 0746-526 0646-078 N/A 0646-080 0746-524 0646-117 0746-539
0646-018 N/A 0646-156 0746-536 0646-031 0746-501 0646-099 0746-500
0146-525 N/A 0646-009 N/A 0646-124 0746-538 0646-163 0746-530
0646-002 N/A 0646-021 0746-540 0646-164 0746-529 0646-098 N/A
0646-079 0746-525 0646-199 0746-528 0646-102 0746-527 0646-249 N/A
0646-250 N/A
CHAINS & SPROCKETS

For reference, all spockets and chains available from Arctic Cat are listed below.
NOTE: Added to the list are wide 15 link chains with corresponding wide sprockets. These chains and
sprockets are 3 mm (1/8 in.) wider than the 13 link chains and corresponding sprockets and approximately
25% stronger.
UPPER SPROCKETS WIDE CHAIN (13 Link)
NUMBER OF TEETH P/N PITCH P/N
15 0107-217 68 0602-495
16 0107-340 70 1602-041
17 0107-218 72 1602-042
18 0107-341 WIDE CHAIN (15 Link)
19 0107-219 68 1602-036
20 0107-409 70 0602-968
21 0107-408 72 0602-972
22 0107-301 74 1602-037
23 0602-363
WIDE SPROCKET (w/13 Link Chain)
24 0107-508 (UPPER)
LOWER SPROCKETS NUMBER OF TEETH P/N
18 0602-445
NUMBER OF TEETH P/N
19 0602-444
33 0107-513
20 0602-456
35 0107-325
21 0602-494
35* 0702-074
22 0602-455
37 0107-407
23 0602-452
39 0107-220
24 0602-446
39* 0702-072
19* 0602-470
40 0107-903
41 0107-369 WIDE SPROCKET (w/15 Link Chain)
(UPPER)
STANDARD CHAINS 20 0602-967
18 0602-995
8
PITCH P/N
64 0107-322 19 0602-973
66 0107-358 23 1602-118
68 0107-215 24 0602-974
70 0107-216 WIDE SPROCKET (w/13 Link Chain)
70* 0602-371 (LOWER)
72 0107-372 NUMBER OF TEETH P/N
* Reverse and 2-Speed Chain 35 0602-457
39 0602-451
40 0602-453
39* 0702-170
40* 0702-393
41 1602-119
42 0602-909
44 0602-812
44* 0702-400
WIDE SPROCKET (w/15 Link Chain)
(LOWER)
35* 0602-142
39* 0702-370
40* 0702-394
44* 0702-383
* Reverse and 2-Speed Sprocket
8-71
ARCTIC CAT DRIVE BELT DIMENSION CHART
BELT P/N LENGTH WIDTH
0100-022 41 3/8 ± 3/64 inch 1 3/16 inch
0100-032 43 1/2 ± 3/64 inch 1 3/16 inch
0100-042 46 3/4 ± 3/64 inch 1 3/16 inch
0100-043 46 9/16 ± 3/64 inch 1 3/16 inch
0100-066 45 7/16 ± 3/64 inch 1 3/16 inch
0100-080 44 1/8 ± 3/8 inch 1 3/16 inch
0100-088 43 1/8 ± 3/16 inch 1 3/16 inch
0100-092 43 13/16 ± 3/16 inch 1 1/4 inch
0227-002 47 1/2 ± 3/16 inch 1 1/4 inch
0227-007 43 1/4 ± 3/16 inch 1 1/4 inch
0227-010 49 ± 3/16 inch 1 1/4 inch
0227-011 44 ± 3/16 inch 1 1/4 inch
0227-014 45 1/2 ± 3/16 inch 1 1/4 inch
0227-016 45 1/16 ± 3/16 inch 1 1/4 inch
0227-017 42 13/16 ± 3/16 inch 1 1/4 inch
0227-019 43 1/4 ± 3/16 inch 1 1/4 inch
0227-020 46 11/16 ± 3/16 inch 1 1/4 inch
0227-022 45 1/2 ± 3/16 inch 1 1/4 inch
0227-023 45 7/16 ± 1/8 inch 1 1/4 inch
0227-026 43 1/4 ± 3/16 inch 1 1/4 inch
0227-027 43 1/4 ± 3/16 inch 1 1/4 inch
0227-030 43 1/2 ± 3/16 inch 1 3/8 inch
0227-032 43 5/8 ± 3/16 inch 1 3/8 inch
0227-100 45 1/2 ± 3/16 inch 1 3/8 inch
0227-101 43 5/16 ± 3/16 inch 1 3/8 inch
0227-103 43 5/8 ± 3/16 inch 1 3/8 inch
*0627-001 43 5/8 ± 3/16 inch 1 3/8 inch
*0627-002 43 3/8 ± 3/16 inch 1 3/8 inch
*0627-004 43 5/16 ± 3/16 inch 1 3/8 inch
*0627-006 43 5/8 ± 3/16 inch 1 3/8 inch
*0627-008 45 3/4 ± 3/16 inch 1 3/8 inch
**0627-009 47 3/4 ± 3/16 inch 1 3/8 inch
***0627-010 47 3/4 ± 3/16 inch 1 3/8 inch
**0627-011 45 3/4 ± 3/16 inch 1 3/8 inch
**0627-012 47 3/4 ± 3/16 inch 1 3/8 inch
0627-013 49 ± 3/16 inch 1 7/16 inch
0627-014 49 ± 3/16 inch 1 7/16 inch
***0627-020 47 3/4 ± 3/16 inch 1 13/32 inch
**0627-021 47 3/4 ± 3/16 inch 1 13/32 inch
* High Performance Belt
** Double-Cog High Performance Belt
*** Double-Cog High Performance Belt w/Hard Compound
NOTE: The difference between Drive Belt (p/n 0627-010) and Drive Belt (p/n 0627-020) is width. If one of
these belts is substituted for the other, the driven pulley will need a shim added or a shim removed to
obtain correct belt deflection. Both of these belts are constructed of “hard compound” and should be used
only when recommended. If these belts are used when a softer compound belt is recommended (such as a
p/n 0627-012 or 0627-021), the engine will run at a higher RPM.
8-72
ARCTIC CAT DRIVE BELT REPLACEMENT CHART
1967 1977 1991
Panther P8, P12, P15 .......................... 0100-022 El Tigre 4000, 5000 ............................. 0227-020 Lynx ..................................................... 0227-030
Pantera 5000F/A, 5000F/C .................. 0227-020 Jag AFS, Panther................................. 0227-103
1968 Panther 4000 ....................................... 0227-007 * Jag Long Track .................................... 0227-103
Cougar ................................................. 0100-022 Panther 5000 ....................................... 0227-019 Super Jag ............................................ 0227-103
Panther P-20 w/o Kohler Eng............... 0100-032 Cheetah 4000 ...................................... 0227-019 Jag 340 Mountain Cat.......................... 0227-100
w/Kohler Eng. .................................. 0100-022 Jag 3000 .............................................. 0227-014 Cougar, Cheetah Touring..................... 0227-103
Lynx 2000T, 2000S .............................. 0227-007 * Pantera, Prowler .................................. 0227-103
1969 El Tigre EXT ........................................ 0227-103
1978 Prowler Special.................................... 0227-103
Panther Models, P35H ......................... 0100-042 EXT Special ......................................... 0227-103
P17J, P19J, K or S, P22J or H ............. 0100-043 Lynx 2000S, 2000T.............................. 0227-007 *
Jag 2000, 3000 .................................... 0227-014 Wildcat 700 .......................................... 0627-006
P12K, P19H, P20W, P23K................... 0100-066
Panther 4000 ....................................... 0227-007 *
P17H .................................................... 0100-080
Panther 5000 ....................................... 0227-019 1992
P27H .................................................... 0100-088
Cheetah 5000 ...................................... 0227-019 Jag, Jag Special .................................. 0227-103
1970 El Tigre 5000F/A, 6000L/C .................. 0227-019 Super Jag ............................................ 0227-103
Pantera 5000F/A, 5000F/C .................. 0227-020 Jag AFS L/T......................................... 0227-103
Panther P246, P292, P295, P340 Eng. 0100-080 Cheetah ............................................... 0227-103
P303, P299 Eng. ................................. 0100-088
P440 Eng. ........................................... 0100-092
1979 Cougar................................................. 0227-103
Lynx 2000S, 2000T.............................. 0227-007 * Lynx, Lynx Deluxe................................ 0227-030
P634, P760, P793 Eng. ...................... 0100-042 Lynx Mountain Cat............................... 0227-103
Jag 2000, 3000, FC/OI ........................ 0227-014
1971 Panther 5000F/C.................................. 0227-019 Pantera ................................................ 0227-103
El Tigre 5000F/A, 6000L/C .................. 0227-019 Prowler, Prowler Special...................... 0227-103
Panther & Puma Pantera 5000F/C.................................. 0227-020 EXT, EXT Special ................................ 0227-103
P303 (303cc), P340, Trail Cat................................................ 0227-019 Panther ................................................ 0227-103
PM340 (340cc) ............................... 0100-088 El Tigre 340 & 440 Wildcat (AWS) ..................................... 0627-008
P399, PM399 (398cc), P440, .....................................................Special Edition Wildcat EFI (AFS)................................ 0627-006
PM440 (436cc) ................................ 0100-092 0227-026
P650, PM650 (634cc)...................... 0100-042 1993
Lynx L295 (292cc), L303 (303cc), 1980 Jag, Jag 440 Z ..................................... 0227-103
L340 (340cc) .................................. 0100-080 Jag AFS L/T......................................... 0227-103
Ext E295 (292cc) ................................. 0100-088 Lynx 2000S, 2000T.............................. 0227-007 *
Jag 2000, 3000, 3000F/C .................... 0227-014 Cheetah ............................................... 0227-103
E340 (339cc), E399 (398cc), Cougar................................................. 0227-103
E440 (436cc) ................................... 0100-092 Trail Cat 3000, 4000............................. 0227-019
Panther, Pantera, Lynx, Lynx Deluxe................................ 0227-030
1972 ............................................. El Tigre 5000, 6000 Lynx Mountain Cat............................... 0227-103
0227-019 Pantera ................................................ 0227-103
Lynx 292AL, Panther 292AP Prowler, Prowler 440Z ......................... 0227-103
Kawasaki KT 150B)......................... 0100-080
Puma 340APU, Cheetah 340AC,
1981 EXT, EXT 580 Z ................................... 0227-103
Panther ................................................ 0227-103
Panther 340AP (Kawasaki TIA 340S1), Jag ....................................................... 0227-014 Wildcat ................................................. 0627-011
Panther 303WP Trail Cat................................................ 0227-019 Thundercat .......................................... 0627-010
(Wankel KM 914)............................ 0100-088 Panther, Pantera .................................. 0227-019 ZR Models ........................................... 0627-012
Puma 399APU, Cheetah 399AC, El Tigre 5000 ....................................... 0227-030
Panther 399AP (Kawasaki TIA 400S1), El Tigre 6000 ....................................... 0227-032 1994
Cheetah 440AC, Panther 440AP
(Kawasaki TIA 440S1)..................... 0100-092 1984 Puma, Puma Deluxe, Puma 2-Up........ 0227-103
Jag, Jag 440Z ...................................... 0227-103
Ext (All Engines) .................................. 0227-002 Panther ................................................ 0227-030 Cheetah Models .................................. 0227-103
El Tigre 6000 ....................................... 0227-032 Cougar................................................. 0227-103
1973 Pantera ................................................ 0227-103
Lynx 292 .............................................. 0100-080 1985 Prowler EFI .......................................... 0227-103
Puma 440............................................. 0100-092 Jag ....................................................... 0227-100 EXT 580 Models .................................. 0627-012
Cheetah 340 ........................................ 0227-007 * Panther, Pantera .................................. 0227-030 Panther Deluxe .................................... 0227-103
Cheetah 400, 440 ................................ 0227-007 * Cougar ................................................. 0227-030 Wildcat EFI .......................................... 0627-011
Panther 340.......................................... 0227-007 * El Tigre 6000 ....................................... 0227-032 ZR Models ........................................... 0627-012
Panther 400, 440.................................. 0227-007 * Thundercat .......................................... 0627-010
Panther Wankel.................................... 0100-088 1986
El Tigre 250, 340.................................. 0227-011 Jag ....................................................... 0227-100 1995
El Tigre 400, 440.................................. 0227-011 Panther, Pantera .................................. 0227-030 Puma, Puma Deluxe, Puma 2-Up........ 0227-103
Ext 290, 340......................................... 0227-020 Cougar, Cheetah F/C ........................... 0227-030 Jag, Jag Deluxe ................................... 0227-103
Ext 440, 650......................................... 0227-020 El Tigre, Cheetah L/C .......................... 0227-032 Panther ................................................ 0227-103
1974 Bearcat 340 ......................................... 0627-013
1987 Bearcat 440 & 550 ............................... 0627-014
Lynx I 292 ............................................ 0227-011 Jag 340, 440 ........................................ 0227-100 Cougar................................................. 0627-012
8
Lynx I 295 ............................................ 0227-007 * Super Jag ............................................ 0227-030 Prowler................................................. 0627-012
Lynx II 340, 440 ................................... 0227-007 * Panther, Pantera .................................. 0227-030 Pantera ................................................ 0627-012
Cheetah 340, 440 ................................ 0227-007 * Cougar, Cheetah F/C ........................... 0227-030 EXT...................................................... 0627-012
Panther 295W, 340, 440 ...................... 0227-007 * El Tigre 5000, 6000 ............................. 0227-032 EXT Powder Special ............................ 0627-010
El Tigre 295, 340, 400, 440.................. 0227-014 Cheetah L/C......................................... 0227-032 Wildcat, Wildcat Touring ...................... 0627-010
Thundercat .......................................... 0627-010
1975 1988 Z440 .................................................... 0627-012
El Tigre Z, 340, 440 ............................. 0227-020 Jag 340, 440, Jag Deluxe .................... 0227-100 ZR440, ZR580 ..................................... 0627-012
Pantera................................................. 0227-007 * Super Jag, Panther .............................. 0227-030 ZR700 .................................................. 0627-010
Lynx 250 .............................................. 0227-017 Cougar, Pantera................................... 0227-101 ZRT800................................................ 0627-010
Cheetah 295 ........................................ 0227-016 El Tigre 5000, 6000 ............................. 0227-101
Cheetah 340, 440 ................................ 0227-007 Cheetah Touring, L/C........................... 0227-101
Panther 340, 440.................................. 0227-007 Wildcat 650 .......................................... 0627-004 Extended life drive belts for high altitude operation
Jag 340 ................................................ 0227-014 are available under the following part numbers:
1976 1989 Standard Extended

Jag 340, Jag Deluxe ............................ 0227-100 Belt Life Belt
El Tigre 4000, 5000.............................. 0227-020 Super Jag, Jag AFS............................. 0227-032
Pantera 5000........................................ 0227-020 0227-030 = 0627-002
Panther, Cougar................................... 0227-032 0227-032 = 0627-001
Panther 4000........................................ 0227-007 * Pantera, Cheetah Touring .................... 0227-032
Cheetah 4000 ...................................... 0227-007 * 0227-100 = 0627-003
El Tigre 6000, EXT .............................. 0227-032 0227-101 = 0627-004
Panther 5000........................................ 0227-019 Wildcat 650 .......................................... 0627-001
Cheetah 5000 ...................................... 0227-019 0227-103 = 0627-006
0627-008 = 0627-011
Jag 2000, 3000 .................................... 0227-014 1990
Lynx 250 .............................................. 0227-017
Arctic Z................................................. 0227-022 Jag 340 ................................................ 0227-100 * Also Available in Kevlar (Fiber B)
Cross Country Cat ............................... 0227-020 Jag Mountain Cat................................. 0227-100
Panther, Jag AFS................................. 0227-103 Material — part 0227-019
Cougar, Cheetah Touring..................... 0227-103
Pantera, El Tigre EXT .......................... 0227-103
Wildcat 650 .......................................... 0627-006
Prowler................................................. 0227-103
8-73
ARCTIC CAT DRIVE BELT REPLACEMENT CHART
(Continued)
1996 1998 2000

Puma, Puma Deluxe, Puma 2-Up........ 0227-103 Jag 340, Panther 340 .......................... 0627-012 Bearcat 340 ......................................... 0627-013
Jag, Jag Deluxe, Jag L/C ..................... 0227-103 Jag 440, Jag 440 DLX ......................... 0627-012 Bearcat 440 I/440 II/Wide Track .......... 0627-014
Z440, Panther Deluxe, Panther L/C ..... 0627-012 Z 440, Panther 440 .............................. 0627-012 Pantera Models ................................... 0627-020
Bearcat 340 ......................................... 0627-013 Panther 550 ......................................... 0627-021 Panther 340/440 .................................. 0627-012
Bearcat 440 & 550 ............................... 0627-014 Bearcat 340 ......................................... 0627-013 Panther 550 ......................................... 0627-021
Cougar, Cougar 2-Up, Cougar M/C ..... 0627-012 Bearcat 440, Bearcat Wide Track ........ 0627-014 Powder Special Models ....................... 0627-020
Pantera ................................................ 0627-012 Cougar, Cougar DLX, Cougar M/C...... 0627-021 Thundercat Models.............................. 0627-020
EXT EFI Models .................................. 0627-012 Pantera 580 ......................................... 0627-021 Triple Touring 600 ................................ 0627-020
EXT 580............................................... 0627-012 Pantera 800 ......................................... 0627-020 Z Models.............................................. 0627-021
EXT 580 Powder Special ..................... 0627-010 EXT EFI ............................................... 0627-020 ZL 440/550 .......................................... 0627-021
Wildcat Models .................................... 0627-010 EXT EFI DLX ....................................... 0627-021 ZL 500/580/600/700 ............................ 0627-020
Thundercat, ZRT 800, ZRT 600........... 0627-010 EXT 600, EXT 600 Touring.................. 0627-020 ZR Models ........................................... 0627-020
ZR 580 Models, ZR440........................ 0627-012 Powder Special, Powder Special EFI .. 0627-020 ZRT Models ......................................... 0627-020
Powder Extreme .................................. 0627-020
1997 Thundercat, Thundercat M/C............... 0627-020 2001
Puma, Puma Deluxe, Puma 2-Up........ 0627-012 ZRT 600, ZRT 800............................... 0627-020 Bearcat W/T ........................................ 0627-014
Jag, Jag Deluxe ................................... 0627-012 ZR 600, ZR 600 EFI ............................ 0627-020 Mountain Cat Models .......................... 0627-020
Panther, Panther L/C ........................... 0627-012 ZL 440 ................................................. 0627-021 Pantera Models ................................... 0627-020
Z440, ZL440 ........................................ 0627-012 ZL 500, ZR 500.................................... 0627-020 Panther 370 Models ............................ 0627-013
Bearcat 340 ......................................... 0627-013 ZR 440................................................. 0627-020 Panther 440 Models ............................ 0627-012
Bearcat 440 & 550 ............................... 0627-014 Panther 550 ......................................... 0627-021
Cougar, Cougar M/C............................ 0627-012 1999 Thundercat .......................................... 0627-020
Pantera ................................................ 0627-012 Jag 340 DLX, Panther 340 .................. 0627-012 Triple Touring 600 ................................ 0627-020
EXT EFI Models .................................. 0627-012 Jag 440, Jag 440 DLX ......................... 0627-012 Z Models.............................................. 0627-021
Powder Special EFI ............................. 0627-012 Panther 440 ......................................... 0627-012 ZL Models............................................ 0627-020
Thundercat, ZRT 800, ZRT 600........... 0627-010 Panther 550 ......................................... 0627-021 ZR Models ........................................... 0627-020
ZR 580, ZR440 .................................... 0627-010 Bearcat 340, Bearcat 440 I.................. 0627-013 ZRT Models ......................................... 0627-020
EXT 600, Powder Extreme .................. 0627-010 Bearcat 440 II, Bearcat Wide Track ..... 0627-014
Powder 580 Carb ................................. 0627-010 Pantera 580 EFI................................... 0627-021 2002
Pantera 800 ......................................... 0627-020 Bearcat W/T ........................................ 0627-014
Triple Touring 600 ................................ 0627-020 Mountain Cat Models .......................... 0627-020
Powder Special 500 EFI ...................... 0627-020 Pantera 550 ......................................... 0627-021
Powder Special 600 Models ................ 0627-020 Pantera Models (EFI) .......................... 0627-020
Powder Special 700............................. 0627-020 Panther Models ................................... 0627-021
Thundercat, Thundercat M/C............... 0627-020 Thundercat .......................................... 0627-020
Z 370 ................................................... 0627-021 Z Models.............................................. 0627-021
Z 440 ................................................... 0627-021 ZL Models............................................ 0627-020
ZL 440 ................................................. 0627-021 ZR Models ........................................... 0627-020
ZL 500 Models, ZL 600 Models ........... 0627-020 ZRT 600............................................... 0627-020
ZR 500 Models .................................... 0627-020
ZR 600 Models .................................... 0627-020
ZR 700................................................. 0627-020
ZRT 600, ZRT 800............................... 0627-020
8-74
CENTER-TO-CENTER/OFFSET SPECIFICATIONS
CENTER-TO- OFFSET CENTER-TO- OFFSET
YEAR MODELS CENTER YEAR MODELS CENTER
cm in. mm in. cm in. mm in.
1977 Lynx 2000S, 2000T, 1992 Lynx, Jag, Panther, Cougar,
Panther 4000, 5000, Pantera, Prowler, Cheetah
Cheetah 5000 25.9 10.200 11.53 0.454 Touring, Super Jag, EXT,
Jag 3000 28.9 11.375 11.53 0.454 Wildcat EFI 25.9 10.200 34.67 1.365
El Tigre 4000, 5000, Wildcat AWS 28.9 11.375 34.67 1.365
Pantera F/C, F/A 30.5 12.000 11.53 0.454 1993 Lynx, Jag, Panther, Cougar,
1978 Lynx 2000S, 2000T, Pantera, Prowler, Cheetah
Panther 4000, 5000, Touring, EXT Models 25.9 10.200 34.67 1.365
Cheetah 5000, Wildcat AWS Models 28.9 11.375 34.67 1.365
El Tigre 5000, 6000 25.9 10.200 11.53 0.454 Thundercat 30.9 12.200 34.67 1.365
Jag 2000, 3000 28.9 11.375 11.53 0.454 1994 Jag, Puma, Panther,
Pantera F/C, F/A 30.5 12.000 11.53 0.454 Cougar, Pantera, Prowler,
1979 Lynx 2000S, 2000T Cheetah Models 25.9 10.200 34.67 1.365
Panther, Wildcat EFI Models (AWS) 28.9 11.375 34.67 1.365
El Tigre 5000, 6000, EXT Models, ZR Models,
Trail Cat 25.9 10.200 11.53 0.454 Thundercat Models 30.9 12.200 34.67 1.365
All Jag 28.9 11.375 11.53 0.454 1995 Puma Models, Jag Models,
Pantera 30.5 12.000 11.53 0.454 Panther 25.5 10.200 34.67 1.365
1980 Lynx 2000S, 2000T, Cougar, Prowler 2-Up,
Trail Cat 3000, 4000, Pantera, All EXT Models,
Panther, Pantera, Z440, ZR580, ZR440,
El Tigre 5000 25.9 10.200 11.53 0.454 Thundercat, ZR700,
El Tigre 6000 25.9 10.200 10.54 0.415 Wildcat, ZRT 800 30.9 12.200 34.67 1.365
All Jag 28.9 11.375 11.53 0.454 Bearcat Models 30.9 12.200 34.67 1.367
1981 Jag 28.9 11.375 11.53 0.454 1996 Puma Models, Jag Models 25.5 10.200 34.67 1.365
Trail Cat, Panter, Pantera 25.9 10.200 11.53 0.454 Panther, Cougar, Pantera,
El Tigre 5000, 6000 25.9 10.200 34.67 1.365 All EXT Models, 440, ZR580,
ZR440,Thundercat, ZRT600
1984 Panther, El Tigre 25.9 10.200 34.67 1.365
Wildcat, ZRT800 30.9 12.200 34.67 1.365
1985 Jag 28.9 11.375 34.67 1.365 Bearcat Models 30.9 12.200 34.72 1.367
Panther, Pantera, 1997 Puma Models, Jag Models,
Cougar, El Tigre 25.9 10.200 34.67 1.365
Panther Models, Z440 30.9 12.200 34.67 1.365
1986 Jag 28.9 11.375 34.67 1.365 Cougar, Pantera, All EXT
Panther, Cougar, Models, ZR440, Thundercat,
Pantera, El Tigre, ZRT600, ZRT800, ZL440 30.9 12.200 34.67 1.365
Cheetah F/C, L/C 25.9 10.200 34.67 1.365 Bearcat Models 30.9 12.200 34.72 1.367
1987 Jag 28.9 11.375 34.67 1.365 Powder Special, Powder
Super Jag, Panther, Extreme, Powder EFI 30.9 12.200 34.67 1.365
Cougar, Pantera, ZR580EFI 30.9 12.200 11.53 0.454
El Tigre 5000, 6000,
Cheetah F/C, L/C 25.9 10.200 34.67 1.365 1998 Jag Models, Panther Models,
Z 440, Cougar Models,
1988 Jag 340, 440 28.7 11.300 34.67 1.365
Pantera Models, EXT Models,
Super Jag, Panther, Powder Special Models, Powder
Cougar, Pantera, Extreme, Thundercat Models,
El Tigre 5000, 6000, ZRT600, ZRT800, ZR600,
Cheetah Touring, L/C, ZL440, ZL500, ZR500, ZR440 30.9 12.200 34.67 1.365
Wildcat 650 25.9 10.200 34.67 1.365
Bearcat Models 30.9 12.200 34.72 1.367
1989 Jag 340, Jag Deluxe 28.7 11.300 34.67 1.365
1999 Jag Models, Panther Models,
Super Jag, Jag AFS,
8
Z Models, Pantera Models, Triple
Panther, Cougar, Pantera, Touring 600,
El Tigre 6000 & EXT, Powder Special Models,
Cheetah Touring, Wildcat 650 25.9 10.200 34.67 1.365 Thundercat Models, ZL Models,
1990 Jag 340 28.7 11.300 34.67 1.365 ZR Models, ZRT Models 30.9 12.200 34.67 1.365
Super Jag, Jag AFS, Bearcat Models 30.9 12.200 34.72 1.367
Panther, Cougar, 2000 Bearcat Models 30.9 12.200 34.72 1.367
Pantera, El Tigre EXT, All Remaining Models 30.9 12.200 34.67 1.365
Cheetah Touring,
2001 Bearcat W/T 30.9 12.200 34.72 1.367
Wildcat 650, Prowler 25.9 10.200 34.67 1.365
All Remaining Models 30.9 12.200 34.67 1.365
1991 Jag 340 Mountain Cat 28.7 11.300 34.67 1.365
2002 Bearcat W/T 30.9 12.200 34.72 1.367
Lynx, Jag AFS, Super Jag, All Remaining Models 30.9 12.200 34.67 1.365
Panther, Cougar, Pantera,
El Tigre EXT, Prowler,
Cheetah Touring, Prowler
Special, EXT Special,
Wildcat 700 25.9 10.200 34.67 1.365
8-75
Torque Specifications Torque Specifications
(120 cc)
ITEM TORQUE
Drive Clutch ft-lb 50-55
ITEM TORQUE
kg-m 6.9-7.6
Centrifugal Clutch ft-lb 15-16.5
Spider ft-lb 250
kg-m 2.1-2.3
kg-m 34.5
Spider Retainer Nut ft-lb 85
kg-m 11.8
Drive Clutch Cover ft-lb 10
kg-m 1.4
Driven Pulley Roller Plate kg-m 11-13
1.5-1.8
Driven Pulley ft-lb 19-24
kg-m 2.6-3.3
Chain Case ft-lb 35-40
Top Sprocket kg-m 4.8-5.5
Chain Case ft-lb 19-24
Bottom Sprocket kg-m 2.6-3.3
(w/Reverse)
Chain Case Bottom ft-lb 35-40
Sprocket (w/o Reverse) kg-m 4.8-5.5
Hub/Brake Disc in.-lb 36
kg-m 0.4
Flange Plate ft-lb 16-18
kg-m 2.2-2.5
Brake Caliper/Chain Case ft-lb 30
kg-m 4.2
Chain Case Cover ft-lb 12-15
kg-m 1.7-2.1
Chain Case Drain Plug ft-lb 35
kg-m 4.8
8-76
Troubleshooting
Drive Clutch/
Driven Pulley
Problem: Midrange Shift-Up (Too Quickly - Lowers RPM)

Condition Remedy
1. Drive clutch spring weak 1. Replace drive clutch spring
2. Driven pulley spring weak 2. Replace driven pulley spring
3. Driven pulley spring preload tension 3. Increase spring preload tension
inadequate
4. Center-to-center distance too close 4. Adjust center-to-center distance
5. Driven pulley bearing worn — damaged 5. Replace bearing — movable sheave
Problem: Midrange Shift-Up (Too Slowly - Raises RPM)
Condition Remedy
1. Drive clutch components dirty 1. Clean drive clutch components
2. Driven pulley components dirty 2. Clean driven pulley components
3. Driven pulley spring preload tension 3. Decrease spring preload tension
excessive
4. Driven pulley bearing worn — dirty 4. Clean — replace bearing — movable sheave
Problem: Excessive Belt Deposits
Condition Remedy
1. Offset adjusted incorrectly 1. Adjust offset
2. Drive clutch/driven pulley sheaves rough — 2. Repair — replace — clean drive clutch/driven
damaged — dirty pulley
3. Driven pulley movable sheave travel impaired 3. Service driven pulley
4. Driven pulley bearing worn — dirty 4. Clean — replace bearing — movable sheave
Problem: Excessive Belt Drag—Impaired Drive Clutch Disengagement
Condition Remedy
1. Drive clutch components dirty — damaged 1. Clean — replace drive clutch components
2. Drive belt does not meet measurement 2. Replace drive belt
specifications
Problem: Engine RPM Suddenly Increases—Drive Clutch Vibrates
Condition Remedy
8
1. Cam arm pin bent — damaged 1. Replace pin
2. Cam arm damaged — broken 2. Replace cam arm
3. Drive clutch out of balance 3. Align — replace components — drive clutch
Problem: Driven Pulley Vibrates
Condition Remedy
1. Sheave rivets loose — broken 1. Replace sheave
2. Driven pulley out of balance 2. Service — replace driven pulley
8-77
Problem: Drive Clutch Engagement (Before Specified RPM)
Condition Remedy
1. Drive clutch spring weak — bent 1. Replace spring
2. Cam arms incorrect — worn 2. Replace cam arms
Problem: Drive Clutch Engagement (After Specified RPM)
Condition Remedy
1. Drive clutch spring incorrect 1. Replace spring
2. Spider buttons worn 2. Replace buttons
Problem: Drive Clutch Sticks
Condition Remedy
1. Drive clutch components dirty 1. Clean drive clutch components
2. Movable sheave bent — binding 2. Clean — replace movable sheave
Problem: Drive Clutch Jerks—Shifts Erratically
Condition Remedy
1. Drive clutch dirty 1. Clean — drive clutch components
2. Rollers worn 2. Replace rollers
3. Cam arms rough 3. Polish — replace cam arms
5. Sheaves dirty 5. Clean sheaves
Troubleshooting
Drive Belt
Problem: Drive Belt Glazed

Condition Remedy
specifications
2. Drive clutch spring tension inadequate 2. Replace drive clutch spring
3. Drive clutch components dirty — damaged 3. Clean — replace drive clutch
4. Offset — parallelism — center-to-center 4. Adjust offset — parallelism — center-to-center
distance adjusted incorrectly distance
Problem: Drive Belt Lugs Torn Off—Frayed—Worn in One Spot
Condition Remedy
specifications
2. Offset — parallelism — center-to-center 2. Adjust offset — parallelism — center-to-center
distance adjusted incorrectly distance
3. Drive clutch engagement — idle RPM too high 3. Service drive clutch — reduce idle RPM
4. Drive clutch components dirty — damaged 4. Clean — replace drive clutch components
5. Driven pulley/shaft rotation impaired 5. Service driven pulley/shaft — chain-case
components
8-78
Troubleshooting
Hydraulic Brake
System
Problem: Caliper Leaks

Condition Remedy
1. Caliper O-ring deteriorated — severed 1. Replace O-ring
2. Piston — O-ring damaged 2. Repair piston — replace piston — O-ring
Problem: Lever Spongy — Bottoms Out
Condition Remedy
1. Brake system air bubbles present 1. Bleed brake system
2. Master cylinder damaged — faulty 2. Replace master cylinder
Problem: Oscillation Feedback in Lever
Condition Remedy
1. Brake pad residue present on brake disc 1. Replace pads — clean disc
2. Caliper loose 2. Tighten mounting bolts
3. Brake disc warped — cracked — damaged — 3. Replace disc — driven shaft bearing
misaligned
Problem: Loss of Brake
Condition Remedy
1. Brake fluid overheated — contaminated 1. Replace fluid
3. Caliper — brake hose leaking 3. Replace caliper O-ring — repair piston —
replace piston — O-ring — brake hose
4. Air ducts obstructed — missing 4. Remove obstruction — replace air ducts
5. Brake lever linkage damaged 5. Repair — replace lever — mounting bolt
Problem: Brakes Drag
Condition Remedy
2. Brake disc warped — damaged — misaligned 2. Replace disc — driven shaft bearing
3. Brake pads worn — tapered 3. Replace pads
Problem: Snowmobile Won’t Stop — Have to Pull Too Hard on Lever 8
Condition Remedy
1. Pads/brake disc glazed 1. Replace pads — clean disc
2. Brake lever binding 2. Loosen pivot bolt — replace master cylinder
3. Caliper pistons binding 3. Service caliper assembly
8-79
NOTES
8-80
SECTION 9 — TRACK/REAR
SUSPENSION
TABLE OF
CONTENTS
Understanding the Suspension ............................... 9-2
Suspension Setup Basics ....................................... 9-3
2002 Suspension Mounting Location Chart ............ 9-6
Chassis and Skid Frame
Mounting Locations (2002) .................................. 9-7
Servicing Chart ..................................................... 9-12
Slide Rail Schematics ........................................... 9-13
Front Arm Schematics........................................... 9-19
Rear Arm Schematics ........................................... 9-23
Idler Wheels Schematics....................................... 9-29
Articulating Skid Frame Schematic ....................... 9-36
Repair Procedure 1 ............................................... 9-37
Repair Procedure 4 ............................................. 9-113
Drive Sprocket Location ...................................... 9-130
Drive Track Usage Chart ..................................... 9-144
Drive Track Lug Patterns ..................................... 9-146
Idler Wheel Selection Chart ................................ 9-147
Torque Specifications .......................................... 9-148
Rebuildable Shock Absorber Usage Guide ......... 9-149
Rebuildable Shock Accessory Part Numbers...... 9-152
Shock Absorber Usage Guide............................. 9-153
Rear Spring Selection Chart ............................... 9-156
Front Suspension Ski Springs ............................. 9-157
Front Suspension Sway Bar ................................ 9-158
Rear Suspension (Front Arm Springs) ................ 9-159
Standard Shock & Spring Chart - 2002 Models .. 9-160
Optional Rear Arm Spring Chart - 2002 Models . 9-161
9
Rebuildable Shock Piston Depth Chart .............. 9-162
Rebuildable Shock Tools Required...................... 9-163
Rebuildable Shock Rebuild Kits .......................... 9-163
2002 Valve Stacks ............................................... 9-164
Servicing IFP Style Shocks ................................. 9-166
Servicing Front Arm Quick-Adjust Shock ............ 9-170
Installing Internal Travel Limiting Spacers ........... 9-179
Servicing Rebuildable Shocks & Remote
Reservoir w/Clicker .......................................... 9-182
Bearing Cap and Shaft Seal................................ 9-186
Shaft Eyelet ......................................................... 9-187
Ski Shocks Bottom-Out Bumper.......................... 9-188
Pressurizing Rebuildable Shocks........................ 9-188
Troubleshooting Track ......................................... 9-189
9-1
UNDERSTANDING THE SUSPENSION
GENERAL
Quick acceleration and the ability to go through the
turns with power are the most important handling
qualities. This section explains how the skid frame
functions to provide these two important handling
qualities. Before proceeding, however, note these
terms.
Weight Transfer — A shift in the center of gravity in
any direction depends on the force applied.
Track Tension — The amount of tightness or loose-
ness of the track when correctly mounted in the chas-
0728-180
sis.
Under acceleration when the center of gravity is trans-
Spring Tension — The amount of force exerted on the ferred to the rear of the machine, the rear suspension
spring by either fork tension adjustment or eyebolt collapses slightly. This brings the rear arm point
adjustment. downward and with the front arm stationary, the tee-
ter-totter effect reduces the pressure on the skis, posi-
Ski Pressure — The amount of force exerted down- tion A.
ward on the skis.
However, for controlled cornering, more pressure is
Good weight transfer characteristics are needed for needed on the skis. So when the driver decelerates
fast acceleration (shift of weight from skis to track) coming into a corner, the center of gravity is trans-
and for cornering (shift of weight back to skis to hold ferred forward, putting the required pressure onto the
the front end in turns). Effective weight transfer skis and reducing the pressure on the rear suspension,
depends on suspension tension, position of rider, and position C.
the position of the front arm limiter.
To understand how the suspension system works,
think of the entire system in terms of three points; the
skid frame rear axle center, the skid frame front arm,
and the ski saddle center.
Assume that the front arm functions as a stationary
pivot point between the rear axle center and the ski
saddle center. Also assume that the ski saddle center is
the same height off the ground as the rear axle center.
This produces the standard position arrangement.
0728-181
This is essentially what weight transfer is all about —

the shift of weight to the rear of the machine for posi-
tive traction and good acceleration or to the front of
the machine for positive handling and cornering con-
trol.
9-2
SUSPENSION SETUP BASICS
FRONT ARM SPRING TENSION The two limiter straps on AWS models can be short-
ened if desired. This adjustment must be made to suit
NOTE: Read the following information closely as driving style and some test driving time. With the rear
it pertains to all suspensions used in the last sev- arm in its present mounting location, no advantage has
eral years. If there are any questions, please con- been noted from changing the strap length. If the front
tact the Arctic Cat Service Department. arm straps are shortened, the result will be more ski
pressure and aggressive steering.
It is desirable to run with very light front arm spring
tension. When riding in 4 in. or more of snow, the SKI SHOCK ABSORBER SPRINGS
machine will be quicker if the front spring tension is
adjusted lightly. The shock absorber springs have been matched to the
shock valving and rear suspension. These springs are
If the spring tension is adjusted too stiff, the track the result of hours of testing and comparison riding
angle at the front of the skid frame is steep. This steep trying many different combinations of springs and
angle prevents the snowmobile from getting up on shocks. If there is a need to make changes, there are
plane and slows down by 5 to 8 mph. several spring and shock sizes to choose from. While
making these changes, keep the following points in
When riding in sticky snow (springtime or warm days) mind.
or hill climbing on hard snow, it may be desirable to
stiffen the front arm spring tension. When this is done, Heavier Or Stiffer Springs
weight is transferred back quicker. The problem with
too much front arm spring tension is that the feel of the 1. These will require shocks with more rebound con-
snowmobile becomes very short. The reason for this is trol, or the front end will become like a pogo stick.
the front arm becomes the pivot point between the
spindles and rear of the machine. With dominant 2. With stiffer springs, the front end will become
spring tension on the front arm, the suspension is basi- more aggressive in the corners as more weight will
cally contacting the snow from a point below the front be transferred to the skis when decelerating. Also,
arm to the skis or the spindle pressure point. This more weight is transferred to the rear on accelera-
makes for a very short and darting machine on the tion and can cause the rear shocks and spring to
trail. This is especially true when decelerating and the bottom out.
center of gravity is transferred forward.
3. If the springs are too stiff for general riding condi-
A good method for adjusting the front spring tension tions and style, the ride comfort is gone.
follows.
Spring Tension Too Soft
NOTE: On those models having a coil spring
over the front arm shock absorber, the spring ten- 1. Front end bottoms out; hard on front end parts.
sion should be set as soft as possible when oper-
ating on trails and in deep snow. 2. Less aggressive steering in corners on decelera-
tion, and less weight is transferred to the skis
because of softer springs.
3. Less weight gets transferred to rear of the machine
upon acceleration.
NOTE: When softening the ski springs, also
9
soften the rear to match entire suspension.
! CAUTION
If the ski shock spring is adjusted too loose, the
spring retainer may fall out. If the spring is
adjusted beyond specification, the spring will
coil bind and spring adjuster damage will occur.
0729-662
FRONT ARM SPRING TENSION TOO
FRONT ARM LIMITER STRAPS STIFF
Under no circumstances should the front arm limiter
strap be lengthened. If lengthened, it may cause shock 1. Slows machine down in loose snow.
absorber travel problems. 2. Causes the machine to dart and dive as a result of
less track on the ground on deceleration.
9-3
NOTE: It has been our experience that a tight
front arm works well under only two conditions:
sticky snow conditions in the spring of the year
and in hill climbing on hard packed snow.
It has also been our experience with AFS models that

with the front arm adjusted too soft, the spring may
come off the roller. There haven't been any other prob-
lems in handling caused by a soft front arm.
REAR ARM SPRING TENSION
The rear spring tension is adjusted for the weight of
the driver. There are three possible adjustments.
0730-847
1st block position - set for up to 150 lb The drawbacks of moving the rear arm forward are
that the suspension may bottom out quicker and some
2nd block position - set for 150 to 200 lb travel is lost.
3rd block position - set for over 200 lb
0728-038
727-720A
NOTE: When making any changes to the front or
REAR ARM MOUNTING POSITION rear suspension, the change should be made at
(Between Rails) both ends to keep the suspension balanced. For
example, installing stiffer springs in front may
For 2002, there are several mounting holes found in require installing the next step stiffer spring in
back to keep everything in balance.
the rails for installing the rear arm.
The holes have been added to the suspension to pro- WISH BONE ARM SUSPENSION
(All Models with
vide adjustment to fine-tune the suspension to driving Rubber Mounting Bushings)
styles.
Proper setup on the AWS style front-end assembly
If the ride is too soft, moving the rear arm back with rubber mounting bushings starts by making sure
between the rails will stiffen the ride. By moving the the wishbone arms are parallel. To check, follow the
rear arm forward, it will collapse quicker and allow procedure below.
more transfer of weight to the back of the suspension.
This will also affect the handling by providing a softer 1. Lift the front-end assembly high enough so the
ride and also easier steering. skis are off the floor. Place a support under the
belly pan.
NOTE: Please add the third hole to any FasTrack
suspension on 1994 through 1997 models. It can 2. Remove both shock absorbers.
easily be done by drilling a 3/8 in. hole 3/4 in.
behind the last hole in the rails. 3. Standing in front of the machine, view the wish-
bone arms to see if they are parallel with the chas-
! CAUTION sis. If they are not level, proceed to step 4.
The rear arm mounting position between the rails 4. Lift each ski assembly separately until it is level or
on all 1998 Panther models must remain in the parallel, then place a support (block of wood)
rear mounting hole. If the arm is moved forward,
rear arm and rear shock damage will occur. under the ski to hold arms parallel.
5. Remove the exhaust pipe.
9-4
6. Loosen the four bolts securing the upper and lower 8. Tighten the four bolts securing the two arms on
wishbone arms to the front end assembly. each side to 9.7 kg-m (70 ft-lb).
9. Install the shock absorber making sure to tighten
the two mounting bolts.
NOTE: The above procedure is not required on
AWS front-end assemblies having solid bushings
in the A-Arms. The bolts should be checked for
proper torque on these models.
10. Install the exhaust pipe.

NOTE: It is important that the ski tips are slightly
elevated. Preloading the skis in the slightly
upward position enhances the handling character-
istics of the snowmobile.
0729-883
7. Lift each ski assembly to maximum travel and set

back down on support. Standing in front, check
once again to make sure arms are parallel.
9-5
2002 SUSPENSION MOUNTING LOCATION CHART
NOTE: The Rear Arm Mounting Position refers to where the rear arm mounts into the tunnel. The Rear Arm To Rail Position refers to where the
9-6
lower portion of the rear arm mounts between the slide rails.
SHOCK
MODEL TRACK LENGTH & SKID FRAME FRONT ARM REAR ARM REAR ARM TO SHOCK LINK LINK ROD
LUG HEIGHT MOUNTING POSITION MOUNTING POSITION RAIL POSITION ROD P/N LENGTH
Z 370 Models 15" x 121" x .750" Fastrack— Upper Above Second 0704-350 11.750 in.
Formed Rail Running Board Hole Back (298.45 mm)
Panther 440 15" x 136" x .750" Fastrack—Formed Rail Upper Above N/A 0704-603 12.600 in.
with Torque Link Running Board (320.04 mm)
Panther 570 Models 15" x 136" x .750" Fastrack—Stamped Rail Upper Above N/A 0704-603 12.600 in.
Z 440 Models 15" x 121" x .750" Fastrack—Formed Rail Upper Above Second 0704-350 11.750 in.
Running Board Hole Back (298.45 mm)
Z 570/570 esr 15" x 121" x .850" Fastrack—Formed Rail Upper Above Second 0704-350 11.750 in.
Running Board Hole Back (298.45 mm)
Z 570 SS 15" x 121" x .850" Fastrack—Stamped Rail Upper Above Second 0704-350 11.750 in.
with Torque Link Running Board Hole Back (298.45 mm)
ZL 500/550/600 EFI 15" x 121" x 1.00" Fastrack—Stamped Rail Upper Above Second 0704-350 11.750 in.
ZL 800 Models 15" x 121" x 1.00" Fastrack—Stamped Rail Upper Above Second 0704-350 11.750 in.
Pantera Models 15" x 136" x .750" Fastrack—Stamped Rail Upper Above No Adjustment 0704-603 12.600 in.
ZRT 600 15" x 121" x 1.00" Fastrack—Stamped Rail Upper Above Second 0704-350 11.750 in.
ZR 500 — 15" x 121" x .850" Fastrack—Stamped Rail Upper Above Second 0704-350 11.750 in.
ZR 600/600 EFI with Torque Link Running Board Hole Back (298.45 mm)
ZR 800/800 EFI/800 EFI CC 15" x 121" x 1.00" Fastrack—Stamped Rail Upper Above Second 0704-361 11.050 in.
ZR 600 EFI CC 15" x 121" x 1.00" Fastrack—Stamped Rail Upper Above Second 0704-361 11.050 in.
Thundercat 15" x 121" x 1.00" Fastrack—Stamped Rail Upper Above Second 0704-350 11.750 in.
Mountain Cat 1000 15" x 151" x 2.00" Fastrack—Stamped Rail Upper Below Second 0704-350 11.750 in.
Mountain Cat 500 15" x 136" x 1.40" Fastrack—Stamped Rail Upper Below Forward Hole 0704-334 13.500 in.
Mountain Cat 570 15" x 136" x 1.40" Fastrack—Stamped Rail Lower Below First 0704-334 12.600 in.
Mountain Cat 600 EFI 15" x 136" x 2.00" Fastrack—Stamped Rail Upper Below Forward Hole 0704-334 13.500 in.
Mountain Cat 800/800 LE 15" x 144" x 2.00" Fastrack—Stamped Rail Upper Below Second 0704-350 11.750 in.
Mountain Cat 600 EFI LE 15" x 136" x 2.00" Fastrack—Stamped Rail Upper Below Forward Hole 0704-350 11.750 in.
with Torque Link Running board (298.45 mm)
Bearcat Wide Track 20" x 156" x 1.00" Fastrack—Formed Rail — Lower Below Second 0704-350 11.750 in.
Articulating Running Board Hole Back (298.45 mm)
CHASSIS AND SKID FRAME
MOUNTING LOCATIONS (2002)
The suspensions have several possible mounting loca-
tions in the slide rails and tunnel. However, it is rec-
ommended by Arctic Cat Inc. that when disassembling ! CAUTION
and assembling the suspension, all stock mounting It is extremely important that all stock mounting
locations be used as shown in the following illustra- locations be used. If any alterations to the skid
tions. frame are made, shock absorber and suspension
damage may occur.
ZR Models
737-323A
9-7
ZL 500/550/600 EFI/800 EFI Models
735-284A
Mountain Cat 500/570/600 EFI Models
0735-282
9-8
Mountain Cat 600 EFI LE/800/800 LE/800 EFI/800 EFI LE/1000 Models
0737-443
Pantera Models — Panther Models
IDLER WHEEL MTG HOLE*

9
*Pantera 800 EFI

735-315A
9-9
Z 370/370 es — Z 440/440 es — Z 570/570 esr
0735-288
Thundercat — Z 570 SS — ZL 600 EFI SS — ZL 800 EFI SS
0737-325
9-10
Bearcat Wide Track
0735-309
9-11
Servicing Chart

appropriate Skid Frame Schematics and Repair Proce-
dure for servicing the rear suspension. Select the
snowmobile model from the list and follow the chart to
attain schematic designation and repair procedure.
Articulating
Slide Rail Front Arm Rear Arm Idler Wheels Skid Frame Repair
Snowmobile Models Style Style Style Style Style Procedure
Bearcat W/T L B C B A 4
Mountain Cat 500 D C F I N/A 3
Mountain Cat 570 D C F I N/A 3
Mountain Cat 600 EFI D C F I N/A 3
Mountain Cat 600 EFI LE E D E H N/A 2
Mountain Cat 800/800 EFI E D E G N/A 3
Mountain Cat 800 LE/
800 EFI LE I D E G N/A 2
Mountain Cat 1000 I D E G N/A 2
Pantera 550 G C B C N/A 3
Pantera 600 EFI G C B C N/A 3
Pantera 800 EFI G C B C N/A 3
Panther 440 G C B C N/A 3
Panther 570 esr/570 r G C B C N/A 3
Thundercat C F K J N/A 2
Z 370/370 es A A A A N/A 3
Z 440/440 es A A A A N/A 3
Z 570/570 esr A A A A N/A 3
Z 570 SS C F K J N/A 2
ZL 500 B C D D N/A 3
ZL 550/550 esr B C D D N/A 3
ZL 600 EFI/600 EFI esr B C D D N/A 3
ZL 600 EFI SS C F K J N/A 2
ZL 600 EFI SS (EB) C F H K N/A 2
ZL 800 EFI esr B C D D N/A 3
ZL 800 EFI SS C F K J N/A 2
ZR 120 H N/A G L N/A 1
ZR 500 F D J E N/A 2
ZR 500 LE (EB) J G I M N/A 2
ZR 500 CC K E J F N/A 2
ZR 600 EFI F D J E N/A 2
ZR 600 EFI CC K E J F N/A 2
ZR 800 EFI/800 EFI CC K E J F N/A 2
ZRT 600 F H E N N/A 2
9-12
NOTE: Some components illustrated in this
Slide Rail sub-section may vary from actual conditions.
Schematics The technician should use discretion and sound
judgment when removing and installing compo-
nents.
KEY
1. Formed Rail Style A
2. Crossbrace
3. Lock Nut
4. Washer
5. End Cap
6. Cap Screw
7. Machine Screw
8. Wear Strip
9. Cap Screw
10. Shock Pad
11. Solid Rivet
12. Push Nut
13. Rear Axle Housing Spacer
14. Cap Screw
15. Lock Nut
16. Track Assy
17. Guide Clip
18. Wear Clip
0730-954
KEY
1. Formed Rail Style B
2. Crossbrace
3. Lock Nut
4. Washer
5. End Cap
6. Cap Screw
7. Machine Screw
8. Wear Strip
9. Cap Screw
10. Shock Pad
11. Rivet
12. Track Assy
13. Guide Clip
14. Wear Clip
15. Bracket
16. Cap Screw
9
17. Track Adjuster
18. Mounting Bracket
19. Cap Screw
20. Lock Nut
0735-060
9-13
KEY Style C
1. Formed Rail
2. Crossbrace
3. Lock Nut
4. Washer
5. End Cap
6. Cap Screw
7. Machine Screw
8. Wear Strip
9. Cap Screw
10. Pad
11. Rivet
12. Track Assy
13. Wear Clip w/Guide
14. Reservoir Clamp
15. Retaining Bracket
16. Cap Screw
17. Adjuster
19. Cap Screw
20. Lock Nut
21. Brace
22. Pad
23. Rivet
24. Push Nut
25. Axle
26. Lock Washer
27. Cap Screw
28. Lock Nut
29. Cap Screw
30. Cap Screw
31. Washer
32. Coupler Block
33. Bushing
34. Lock Nut
35. Washer
0736-990
KEY Style D
1. Formed Rail
2. Crossbrace
3. Lock Nut
4. Washer
5. End Cap
6. Cap Screw
7. Machine Screw
8. Wear Strip
9. Cap Screw
10. Shock Pad
11. Rivet
12. Track Assy
13. Guide Clip
14. Wear Clip
16. Cap Screw
17. Track Adjuster
19. Cap Screw
20. Nut
21. Brace
22. Shock Pad
23. Push Nut
24. Rivet
25. Cap Screw
26. Lock Nut
27. Shock Pad
28. Washer
0737-067
9-14
KEY Style E
1. Formed Rail
2. Crossbrace
3. Lock Nut
4. Washer
5. End Cap
6. Cap Screw
7. Machine Screw
8. Wear Strip
9. Cap Screw
10. Shock Pad
11. Rivet
12. Track Assy
13. Guide Clip
14. Wear Clip
16. Cap Screw
17. Track Adjuster
19. Cap Screw
20. Lock Nut
21. Brace
22. Shock Pad
23. Push Nut
24. Rivet
25. Cap Screw
26. Lock Nut
27. Shock Pad
28. Washer
0736-654
KEY Style F
1. Formed Rail
2. Crossbrace
3. Lock Nut
4. Washer
5. End Cap
6. Cap Screw
7. Machine Screw
8. Wear Strip
9. Cap Screw
10. Shock Pad
11. Rivet
12. Bracket
13. Cap Screw
14. Bracket
15. Lock Nut
16. Brace
17. Axle
18. Lock Washer
19. Cap Screw
20. Cap Screw
21.
22.
23.
Washer
Lock Nut
Cap Screw
9
24. Track Adjuster
25. Shock Pad
26. Rivet
27. Push Nut
28. Track Assy
30. Cap Screw
31. Washer
32. Coupler Block
33. Bushing
34. Lock Nut
0736-579
9-15
Style G
KEY
1. Formed Rail
2. Crossbrace
3. Lock Nut
4. Washer
5. End Cap
6. Cap Screw
7. Machine Screw
8. Wear Strip
9. Cap Screw
10. Pad
11. Rivet
12. Track Assy
13. Guide Clip
14. Wear Clip
16. Cap Screw
17. Adjuster
19. Cap Screw
20. Lock Nut
21. Lock Nut
22. Washer
23. Spring Tension Block
24. Screw
25. Push Nut
26. Pad
27. Rivet
0734-227
Style H
KEY
1. Formed Rail
2. Wear Strip
3. Lock Nut
4. Cap Screw
5. Washer
6. End Cap
7. Machine Screw
8. Cap Screw
9. Washer
10. Crossbrace Axle
11. Push Nut
12. Backing Plate
13. Bracket
14. Lock Washer
15. Pad
16. Solid Rivet
17. Track Assy
18. Lock Nut
19. Cap Screw
20. Guide Clip
736-149A
9-16
Style I
KEY
1. Formed Rail
2. Crossbrace
3. Lock Nut
4. Washer
5. End Cap
6. Cap Screw
7. Machine Screw
8. Wear Strip
9. Cap Screw
10. Pad
11. Rivet
12. Track Assy
13. Guide Clip
14. Wear Clip
16. Cap Screw
17. Adjuster
19. Cap Screw
20. Lock Nut
21. Brace
22. Pad
23. Push Nut
24. Rivet
25. Cap Screw
26. Lock Nut
27. Pad
28. Washer
0736-786
KEY Style J
1. Formed Rail
2. Axle
3. Lock Nut
4. Washer
5. End Cap
6. Cap Screw
7. Machine Screw
8. Wear Strip
9. Cap Screw
10. Shock Pad
11. Rivet
12. Track Assy
13. Cap Screw
16. Cap Screw
17. Track Adjuster
19. Cap Screw
9
20. Lock Nut
21. Reservoir Clamp
22. Brace
23. Shock Pad
24. Push Nut
25. Rivet
26. Lock Washer
27. Cap Screw
28. Support
29. Washer
0736-434
9-17
Style K
KEY
1. Formed Rail
2. Crossbrace
3. Lock Nut
4. Washer
5. End Cap
6. Cap Screw
7. Machine Screw
8. Wear Strip
9. Cap Screw
10. Pad
11. Rivet
14. Cap Screw
15. Lock Nut
16. Cap Screw
17. Adjuster
18. Pad
19. Rivet
20. Push Nut
21. Brace
22. Axle
23. Lock Washer
24. Cap Screw
25. Track Assy
27. Reservoir Clamp
28. Cap Screw
29. Washer
30. Coupler Block
31. Bushing
0736-615
Style L
KEY
1. Formed
Rail
2. Crossbrace
3. Lock Nut
4. Washer
5. End Cap
6. Cap Screw
7. Machine Screw
8. Wear Strip
9. Cap Screw
10. Solid Rivet
11. Shock Pad
12. Push Nut
13. Rear Axle Housing Spacer
14. Cap Screw
15. Track Assy
16. Guide Clip
17. Wear Clip
18. Lock Nut
0731-197
9-18
Front Arm sub-section may vary from actual conditions.
Schematics judgment when removing and installing compo-
nents.
KEY Style A
1. Front Arm
2. Bearing
3. Grease Fitting
4. Bushing
5. Limiter Strap
6. Cap Screw
7. Washer
8. Lock Nut
9. Bumper
10. Rivet
11. Cap Screw
12. Spacer
13. Lock Nut
14. Cover
15. Spring
16. Retainer Nut
17. Sleeve
18. Shock Absorber
19. Retainer
20. Axle
21. Cap Screw
22. Cap Screw
23. Lock Nut
24. Axle
25. Washer
26. Lock Washer
27. Cap Screw
0736-494
KEY Style B
1. Front Suspension Arm
2. Bearing
3. Grease Fitting
4. Cap Screw
5. Lock Nut
6. Limiter Strap
7. Cap Screw
8. Washer
9. Lock Nut
10. Shock Absorber
11. Inner Carriage Axle
12. Bushing
13. Lock Washer
14. Spacer
9
15. Cap Screw
16. Compression Spring
17. Sleeve
18. Retainer Nut
19. Spring Retainer
20. Track Guide Bumper
21. Rivet
22. Compression Spring Cover
23. Cap Screw
24. Cap Screw
25. Serrated Axle
26. Lock Nut
27. Washer
0736-644
9-19
KEY Style C
1. Front Arm
2. Grease Fitting
3. Bushing
4. Bearing
5. Axle Tube
6. Axle
7. Cap Screw
8. Lock Nut
9. Shock Absorber
10. Bushing
11. Axle
12. Cap Screw
13. Cap Screw
14. Axle
15. Retainer
16. Sleeve
17. Retainer Nut
18. Spring
19. Shock Cover
20. Limiter Strap
21. Cap Screw
22. Washer
23. Lock Nut
24. Cap Screw
25. Adjuster
26. Washer
27. Axle
28. Cap Screw
29. Lock Washer
30. Washer
0736-515
KEY Style D
1. Front Arm
2. Grease Fitting
3. Bushing
4. Washer
5. Spacer
6. Axle
7. Washer
8. Cap Screw
9. Cap Screw
10. Bumper
11. Rivet
12. Lock Nut
13. Shock Absorber
14. Lock Nut
15. Adjuster
16. Cap Screw
17. Cap Screw
18. Spring Retainer
19. Axle
20. Cover
21. Cap Screw
22. Washer
23. Washer
24. Spring
25. Adjuster Nut
26. Limiter Strap
0736-583
9-20
KEY Style E
2. Grease Fitting
3. Bushing
4. Washer
5. Spacer
6. Axle
7. Washer
8. Cap Screw
9. Cap Screw
10. Bumper
11. Rivet
12. Lock Nut
13. Shock Absorber
14. Lock Nut
15. Adjuster
16. Cap Screw
17. Cap Screw
18. Retainer
19. Axle
20. Cover
21. Cap Screw
22. Washer
23. Washer
24. Spring
25. Lock Nut
26. Limiter Strap
27. Adjuster Nut
28. Cable Tie
0736-620
KEY Style F
2. Grease Fitting
3. Bushing
4. Washer
5. Spacer
7. Washer
8. Cap Screw
9. Cap Screw
10. Bumper
11. Rivet
12. Lock Nut
13. Shock Absorber
14. Lock Nut
15. Adjuster
16. Cap Screw
17. Cap Screw
18. Retainer
19. Axle
20. Cover
21.
22.
23.
Cap Screw
Washer
Adjuster Nut
9
24. Spring
25. Cable Tie
26. Limiter Strap
27. Washer
0736-457
9-21
KEY Style G
2. Grease Fitting
3. Bushing
4. Washer
5. Spacer
6. Axle
7. Washer
8. Cap Screw
9. Cap Screw
10. Bumper
11. Rivet
12. Lock Nut
13. Shock Absorber
14. Lock Nut
15. Adjuster
16. Cap Screw
17. Cap Screw
18. Lock Nut
19. Axle
20. Cover
21. Cap Screw
22. Washer
23. Cable Tie
24. Spring
25. Washer
26. Limiter Strap
27. Retainer
0736-430
KEY Style H
2. Grease Fitting
3. Bushing
4. Washer
5. Spacer
6. Axle
7. Washer
8. Cap Screw
9. Cap Screw
10. Bumper
11. Rivet
12. Lock Nut
13. Shock Absorber
14. Lock Nut
15. Adjuster
16. Cap Screw
17. Cap Screw
18. Retainer
19. Axle
20. Cover
21. Cap Screw
22. Washer
23. Washer
24. Spring
25. Lock Nut
26. Limiter Strap
0736-032
9-22
Rear Arm sub-section may vary from actual conditions.
nents.
KEY
1. Idler Arm Style A
2. Bearing
3. Grease Fitting
4. Bushing
5. Rear Arm
6. Cap Screw
7. Lock Nut
8. Cap Screw
9. Axle
10. Axle Tube
11. Limiter Strap
12. Cap Screw
13. Washer
14. Lock Nut
15. Axle
16. Adjuster Block
17. Ring
18. Collar
19. Set Screw
20. Idler Wheel
21. Bearing
22. Ring
23. Spring
24. Sleeve
25. Axle
26. Lock Nut 32. Shock Absorber
27. Axle 33. Bushing
28. Link 34. Sleeve
30. Cap Screw 36. Lock Washer
31. Spacer 37. Washer
0736-498
KEY Style B
1. Idler Arm
2. Bushing
3. Grease Fitting
4. Rear Arm
5. Axle
6. Axle Tube
7. Cap Screw
8. Limiter Strap
9. Cap Screw
10. Washer
11. Lock Nut
12. Arm
13. Bushing
14. Washer
15. Axle
16. Spacer
9
17. Idler Wheel
18. Bearing
19. Ring
20. Spring
21. Adjuster Block
22. Ring
23. Axle
24. Sleeve
25. Cap Screw
26. Washer
27. Lock Nut
28. Shock Absorber
29. Bushing
30. Sleeve 36. Cap Screw
31. Link 37. Lock Nut
32. Axle 38. Lock Washer
0736-735
9-23
KEY Style C
1. Idler Arm
2. Bushing
3. Bearing
4. Grease Fitting
5. Serrated Axle
6. Idler Axle
7. Sleeve
8. Spring
9. Idler Wheel
10. Bearing
11. Retaining Ring
12. Lock Collar
13. Set Screw
14. Spring Adjuster Block
15. Retaining Ring
16. Lock Washer
17. Cap Screw
18. Sleeve
19. Axle Tube
20. Cap Screw
21. Stud Bolt
23. Link Axle
24. Shock Absorber
25. Lock Nut
26. Spacer
27. Shock Link
28. Cap Screw
29. Bushing
30. Lock Nut
31. Cap Screw
32. Washer 36. Lock Nut
33. Rear Arm 37. Limiter Strap
0736-584
KEY Style D
1. Idler Arm
2. Bushing
3. Grease Fitting
4. Rear Arm
5. Axle
6. Idler Wheel
7. Bearing
8. Retaining Ring
9. Suspension Spring
10. Axle
11. Washer
12. Pivot Idler Arm
13. Lock Washer
14. Spacer
15. Bushing
16. Axle Tube
17. Cap Screw
18. Spring Block
19. Retainer Ring
20. Axle
21. Cap Screw
22. Lock Nut
23. Lock Nut
24. Sleeve
25. Spacer
26. Washer
27. Link Axle
28. Link
29. Cap Screw
30. Cap Screw
31. Shock Absorber
32. Cap Screw
34. Washer 37. Axle
35. Sleeve 38. Bushing
0736-532
9-24
KEY Style E
1. Idler Arm
2. Bushing
3. Grease Fitting
4. Rear Arm
5. Axle
6. Idler Wheel
7. Bearing
8. Retaining Ring
10. Axle
11. Washer
12. Pivot Idler Arm
13. Lock Washer
14. Spacer
15. Bushing
16. Axle Tube
17. Cap Screw
18. Spring Block
19. Retainer Ring
20. Axle
21. Cap Screw
22. Lock Nut
23. Lock Nut
24. Sleeve
25. Spacer
26. Washer
27. Link Axle
28. Link
29. Cap Screw
30. Cap Screw
31. Shock Absorber
32. Cap Screw
33. Lock Nut
35. Sleeve 37. Axle
0736-667
KEY Style F
1. Idler Arm
2. Bushing
3. Grease Fitting
4. Rear Arm
5. Axle
6. Idler Wheel
7. Bearing
8. Retaining Ring
10. Axle
11. Washer
12. Pivot Idler Arm
13. Lock Washer
14. Spacer
15. Bushing
16. Axle Tube
17. Cap Screw
18. Spring Block
19. Retainer Ring
20. Axle
21.
22.
23.
Cap Screw
Lock Nut
Lock Nut
9
24. Sleeve
25. Spacer
26. Washer
27. Link Axle
28. Link
29. Cap Screw
31. Shock Absorber 37. Lock Nut
32. Cap Screw 38. Bushing
33. Lock Nut 39. Limiter Strap
35. Sleeve 41. Washer
0735-317
9-25
Style G
KEY
1. Rear Arm
2. Grease Fitting
3. Bearing
4. Sleeve
5. Spring
6. Cap Screw
7. Lock Washer
8. Washer
9. Axle
10. Axle
11. Retaining Ring
12. Adjusting Cam (Block)
736-150A
KEY Style H
1. Idler Arm
2. Bushing
3. Grease Fitting
4. Rear Arm
5. Axle
6. Idler Wheel
7. Bearing
8. Retaining Ring
10. Axle
11. Washer
12. Pivot Idler Arm
13. Lock Washer
14. Spacer
15. Bushing
16. Axle Tube
17. Cap Screw
18. Spring Block
19. Retainer Ring
20. Axle
21. Cap Screw
22. Lock Nut
23. Lock Nut
24. Sleeve
25. Spacer
26. Washer
27. Link Axle
28. Link
29. Cap Screw
30. Cap Screw
31. Shock Absorber
32. Cap Screw
33. Lock Nut
35. Sleeve 37. Axle
0736-461
9-26
KEY Style I
1. Idler Arm
2. Bushing
3. Grease Fitting
4. Rear Arm
5. Axle
6. Idler Wheel
7. Bearing
8. Retaining Ring
10. Axle
11. Washer
12. Pivot Idler Arm
13. Lock Washer
14. Spacer
15. Bushing
16. Axle Tube
17. Cap Screw
18. Spring Block
19. Retainer Ring
20. Axle
21. Cap Screw
22. Lock Nut
23. Lock Nut
24. Sleeve
25. Spacer
26. Washer
27. Link Axle
28. Link
29. Cap Screw
30. Cap Screw
31. Shock Absorber
32. Cap Screw
33. Lock Nut
34. Washer
35. Sleeve
36. Cap Screw
0736-432
KEY Style J
1. Idler Arm
2. Bushing
3. Grease Fitting
4. Rear Arm
5. Axle
6. Idler Wheel
7. Bearing
8. Retaining Ring
10. Axle
11. Washer
12. Pivot Idler Arm
13. Lock Washer
14. Spacer
15. Bushing
16. Axle Tube
17. Cap Screw
18. Spring Block
19. Retainer Ring
20. Axle
21.
22.
23.
Cap Screw
Lock Nut
Lock Nut
9
24. Sleeve
25. Spacer
26. Washer
27. Link Axle
28. Link
29. Cap Screw
30. Cap Screw
31. Shock Absorber
32. Cap Screw
33. Lock Nut
35. Sleeve 37. Axle
0736-589
9-27
KEY Style K
1. Idler Arm
2. Bushing
3. Grease Fitting
4. Rear Arm
5. Axle
6. Idler Wheel
7. Bearing
8. Retaining Ring
10. Axle
11. Washer
12. Pivot Idler Arm
13. Lock Washer
14. Spacer
15. Bushing
16. Axle Tube
17. Cap Screw
18. Spring Block
19. Retainer Ring
20. Axle
21. Cap Screw
22. Lock Nut
23. Lock Nut
24. Sleeve
25. Spacer
26. Washer
27. Link Axle
28. Link
29. Cap Screw
31. Shock Absorber 37. Lock Nut
32. Cap Screw
33. Lock Nut
34. Washer
35. Sleeve
0736-727
9-28
Idler Wheels sub-section may vary from actual conditions.
nents.
KEY
1. Bracket Style A
2. Washer
3. Idler Wheel
4. Insert
5. Ring
6. Bearing
7. Insert
8. Bracket
9. Axle
10. Cap Screw
11. Lock Nut
12. Spring Slide
13. Washer
14. Cap Screw
15. Bracket
16. Spacer
17. Pivot
18. Grease Fitting
19. Axle
20. Axle
21. Support
22. Washer 33. Nut
23. Axle 34. Lock Washer
24. Spacer 35. Spacer
25. Bushing 36. Bushing
26. Idler Wheel 37. Idler Wheel
27. Washer 38. Insert
28. Housing 39. Washer
29. Track Adjuster 40. Cap
31. Lock Nut 42. Insert
32. Cap Screw 43. Insert
0736-496
KEY Style B
1. Idler Wheel
2. Retaining Ring
3. Wheel Insert
4. Bearing
5. Wheel Insert
6. Washer
7. Cap Screw
8. Washer
9. Front Shock Bracket
10. Idler Wheel Spacer
11. Idler Wheel Axle
12. Lock Nut
13. Cap Screw
15. Wheel Bracket
16. Spring Slide
17. Shock Pivot
9
18. Grease Fitting
19. Spring Tension Block
20. Washer
21. Lock Nut
22. Cap Screw
24. Wear Block
25. Retaining Clip
26. Lock Nut
27. Overload Spring
Bushing
28. Overload Spring Assy
29. Rivet
30. Washer
31. Spacer
32. Axle
33. Spacer
34. Axle
35. Idler Wheel
36. Wheel Insert
37. Wheel Insert
0736-582
9-29
KEY
1. Idler Wheel
Style C
2. Insert
3. Insert
4. Bearing
5. Retaining Ring
6. Idler Wheel
7. Idler Wheel
8. Insert
9. Bushing
10. Spacer Bushing
11. Spacer
12. Spring Slide
13. Axle
14. Spacer
15. Nut
16. Cap Screw
17. Lock Washer
18. Cap Screw
19. Washer
20. Cap Screw
21. Lock Nut
22. Cap Screw
23. Spacer
24. Lock Nut 38. Axle
25. Mounting Block 39. Cap
26. Pivot 40. Overload Spring Assy
27. Spacer 41. Wear Block
28. Washer 42. Rivet
29. Mounting Bracket 43. Washer
30. Cap Screw 44. Retaining Clip
31. Washer 45. Bushing
35. Spacer 49. Idler Wheel
36. Axle 50. Axle
37. Grease Fitting 51. Spacer
0736-733
KEY Style D
1. Idler Wheel
2. Insert
3. Insert
4. Bearing
5. Retaining Ring
6. Idler Wheel
7. Idler Wheel
8. Insert
9. Bushing
10. Spacer Bushing
11. Spacer
12. Spring Slide
13. Axle
14. Spacer
15. Nut
16. Cap Screw
17. Lock Washer
18. Lock Nut
19. Washer
20. Cap Screw
21. Lock Nut
22. Cap Screw
23. Spacer
24. Axle
25. Mounting Block
26. Bracket
27. Spacer
28. Pivot
29. Axle
30. Cap Screw
32. Slide Block 38. Cap Screw
33. Washer 39. Cap
34. Washer 40. Idler Wheel
36. Axle 42. Grease Fitting
0736-530
9-30
KEY Style E
1. Idler Wheel
2. Insert
3. Insert
4. Bearing
5. Ring
6. Idler Wheel
7. Idler Wheel
8. Idler Wheel
9. Idler Wheel
10. Insert
11. Axle
12. Washer
13. Spacer
14. Mounting Block
15. Cap Screw
16. Washer
17. Axle
18. Washer
19. Cap Screw
20. Lock Nut
21. Washer
22. Cap Screw
23. Spacer
24. Washer
25. Axle
26. Pivot 37. Axle
27. Grease Fitting 38. Bushing
30. Insert 41. Bushing
32. Slide Block 43. Cap
33. Spring Slide 44. Cap Screw
34. Washer 45. Nut
35. Cap Screw 46. Lock Washer
0736-619
KEY Style F
1. Idler Wheel
2. Insert
3. Insert
4. Bearing
5. Ring
6. Idler Wheel
7. Idler Wheel
8. Idler Wheel
9. Idler Wheel
10. Insert
11. Axle
12. Washer
13. Spacer
14. Mounting Block
15. Cap Screw
16. Insert
17. Washer
18. Cap Screw
19. Washer
20. Lock Nut
21.
22.
23.
Cap Screw
Cap Screw
Spacer
9
24. Washer
25. Axle
26. Pivot
27. Grease Fitting
28. Spacer
29. Slide Block 37. Washer
30. Spring Slide 38. Bushing
32. Spacer 40. Cap
33. Spacer 41. Cap Screw
34. Axle 42. Nut
35. Bushing 43. Lock Washer
0736-652
9-31
KEY Style G
1. Idler Wheel
2. Wheel Insert
3. Wheel Insert
4. Bearing
5. Retaining Ring
6. Idler Wheel
7. Idler Wheel
8. Wheel Insert
9. Idler Wheel
10. Axle
11. Washer
12. Spacer
13. Cap Screw
14. Washer
15. Lock Nut
16. Mounting Block
17. Cap Screw
18. Washer
19. Axle
20. Washer
21. Cap Screw
22. Spacer
23. Pivot
24. Grease Fitting
25. Axle
26. Washer
27. Spacer
28. Slide Block
29. Spring Slide 37. Washer
30. Cap Screw 38. Bushing
31. Axle 39. Cap Screw
32. Cap Screw 40. Cap
34. Spacer 42. Nut
35. Bushing 43. Lock Washer
0736-787
KEY Style H
1. Idler Wheel
2. Wheel Insert
3. Wheel Insert
4. Bearing
5. Retaining Ring
6. Idler Wheel
7. Idler Wheel
8. Wheel Insert
9. Adjuster Bushing
10. Spacer Bushing
11. Spacer
12. Spring Slide
13. Axle
14. Spacer
15. Nut
16. Cap Screw
17. Lock Washer
18. Cap Screw
19. Washer
20. Cap Screw
21. Lock Nut
22. Cap Screw
23. Spacer
24. Axle
25. Mounting Block
26. Pivot
27. Grease Fitting
28. Cap Screw
29. Axle 37. Axle
30. Cap Screw 38. Axle
31. Washer 39. Idler Wheel Cap
36. Axle 44. Spacer
0736-660
9-32
KEY Style I
1. Idler Wheel
2. Wheel Insert
3. Wheel Insert
4. Bearing
5. Retaining Ring
6. Idler Wheel
7. Idler Wheel
8. Wheel Insert
9. Idler Wheel
10. Axle
11. Bracket
12. Washer
13. Spacer
14. Washer
15. Cap Screw
16. Mounting Block
17. Cap Screw
18. Washer
19. Axle
20. Cap Screw
21. Lock Nut
22. Spacer
23. Pivot
24. Grease Fitting
25. Axle
26. Spacer
27. Bushing
28. Spacer
29. Washer
30. Bushing
32. Cap 38. Axle
33. Cap Screw 39. Slide Block
34. Nut 40. Spring Slide
35. Lock Washer 41. Washer
0736-700
KEY Style J
1. Idler Wheel
2. Wheel Insert
3. Wheel Insert
4. Bearing
5. Retaining Ring
6. Idler Wheel
7. Idler Wheel
8. Wheel Insert
9. Adjuster Bushing
10. Spacer Bushing
11. Spacer
12. Spring Slide
13. Axle
14. Spacer
15. Nut
16. Cap Screw
17. Lock Washer
18. Cap Screw
19. Washer
20. Cap Screw
21.
22.
23.
Lock Nut
Spacer
Axle
9
24. Mounting Block
25. Pivot
26. Grease Fitting
27. Spacer
28. Axle
32. Washer 40. Cap
36. Idler Wheel 44. Cap Screw
0737-139
9-33
KEY Style K
1. Idler Wheel
2. Wheel Insert
3. Wheel Insert
4. Bearing
5. Retaining Ring
6. Idler Wheel
7. Idler Wheel
8. Wheel Insert
9. Adjuster Bushing
10. Spacer Bushing
11. Spacer
12. Spring Slide
13. Axle
14. Spacer
15. Nut
16. Cap Screw
17. Lock Washer
18. Cap Screw
19. Washer
20. Cap Screw
21. Lock Nut
22. Cap Screw
23. Spacer
24. Axle
25. Mounting Block
26. Pivot
27. Spacer
28. Spacer
30. Support 38. Idler Wheel
34. Washer 42. Cap
0736-456
Style L
KEY
1. Spacer
2. Lock Nut
3. Washer
4. Cap Screw
5. Limiter Strap
6. Cap Screw
7. Lock Washer
8. Washer
9. Spacer
10. Idler Wheel
11. Axle
736-150B
9-34
KEY Style M
1. Idler Wheel
2. Wheel Insert
3. Wheel Insert
4. Bearing
5. Retaining Ring
6. Idler Wheel
7. Idler Wheel
8. Wheel Insert
9. Adjuster Bushing
10. Spacer Bushing
11. Spacer
12. Spring Slide
13. Axle
14. Spacer
15. Nut
16. Cap Screw
17. Lock Washer
18. Cap Screw
19. Washer
20. Cap Screw
21. Lock Nut
22. Cap Screw
23. Spacer
24. Axle
25. Mounting Block
26. Pivot
27. Spacer
28. Washer
29. Axle
30. Washer 37. Grease Fitting
34. Washer 41. Spacer
36. Insert 43. Cap
0736-429
KEY Style N
1. Idler Wheel
2. Wheel Insert
3. Wheel Insert
4. Bearing
5. Retaining Ring
6. Idler Wheel
7. Idler Wheel
8. Idler Wheel
9. Idler Wheel
10. Insert
11. Washer
12. Cap Screw
13. Axle
14. Spacer
15. Bushing
16. Spacer
17. Washer
18. Bushing
19. Cap
20. Spacer
21.
22.
23.
Axle
Washer
Spacer
9
24. Cap Screw
25. Nut
26. Lock Washer
27. Spacer
30. Lock Nut 39. Axle
33. Spring Slide 42. Spacer
35. Spacer 44. Mounting Block
36. Pivot 45. Cap Screw
0736-943
9-35
Articulating Skid
Frame Schematic
KEY Style A
1. Swing Arm
2. Mounting Bracket
3. Lock Nut
4. Washer
5. Track Guide Bumper
6. Spring Bracket
7. Idler Wheel
8. Wheel Insert
9. Wheel Insert
10. Bearing
11. Retaining Ring
12. Idler Wheel
13. Washer
14. Cap Screw
15. Adjuster Bushing
16. Track Adjuster
17. Lock Nut
18. Cap Screw
19. Cap Screw
20. Nut
21. Lock Washer
22. Track Adjuster Spacer
23. Washer
24. Slide Block Axle
25. Outer Axle
26. Washer 37. Idler Wheel Cap
27. Mounting Bracket 38. Stud Bolt
28. Slide Block 39. Swing Arm Axle
29. Washer 40. Serrated Axle
30. Lock Nut 41. Rear Arm Bushing
31. Spring 42. Spacer
33. Rear Axle 44. Washer
34. Axle Tube 45. Idler Wheel
35. Spacer Bushing 46. Wheel Insert
36. Center Spacer 47. Cap Screw
0736-581
9-36
Repair Procedure 1 -
Track/Rear Suspension
This Track/Rear Suspension sub-section (Repair Pro-

cedure 1) has been organized so each procedure can be
completed individually and efficiently. Each sub-sec-
tion has (as necessary) Removing, Disassembling,
Cleaning and Inspecting, Assembling, and Installing
procedures. Some components may vary from model
to model. The technician should use discretion and
sound judgment when removing and installing compo- AO163A
nents.
4. Remove the support stand; then tip the snowmo-
NOTE: Some illustrations and photographs used bile onto one side using a piece of cardboard to
in this sub-section are used for clarity purposes protect against scratching. Remove the axle and
only and are not designed to depict actual condi- skid frame.
tions.
End Cap
Removing
Skid Frame NOTE: The skid frame does not have to be
removed for this procedure.
NOTE: Many service procedures can be per-
formed without removing the skid frame. Closely REMOVING
observe the note introducing each subsequent
sub-section for this important information. 1. Remove the lock nut, washer, and cap screw
securing the end cap.
1. Loosen the jam nuts and the two track tension
adjusting bolts.
AG297D
0735-454
2. Using a hammer, tap the end cap off the rail. 9
2. Place a support stand under the rear bumper; then
remove the two cap screws securing the upper NOTE: Whenever a part is worn excessively,
idler wheel assembly to the tunnel. Remove the cracked, or damaged in any way, replacement is
idler wheel assembly. necessary.
NOTE: The support stand should hold the snow- 1. Inspect the end cap area of the slide rail for cracks
mobile level and not raised off the floor.
and wear.
3. Remove the four cap screws securing the skid 2. Inspect the end cap for any signs of cracking or
frame and axle to the tunnel. wear.
9-37
3. Clean both the slide rail area and the end cap. 1. Remove the machine screw and lock nut securing
Using compressed air, clean the areas of dirt and the wear strip to the front of the slide rail.
gravel.
! WARNING
pressed air.
4. Inspect the cap screw for cracked, stretched, or

damaged threads. Use a new lock nut when assem-
bling.
INSTALLING
1. Position the end cap on the slide rail; then align the
hole in the end cap with the hole in the slide rail. AG298D
2. Secure with a cap screw and new lock nut. Tighten 2. Using a pipe wrench and starting from either end,
to 1.1 kg-m (8 ft-lb). hook the edge of the wear strip with the pipe
wrench jaw and twist the wear strip off the slide
rail. Move the pipe wrench 7.5 cm (3 in.) and
again twist the wear strip off the rail. Repeat this
procedure until the wear strip is free of the rail.
Wear Strip
NOTE: The wear strip can also be driven off the
slide rail; however, it is quicker to use a pipe
NOTE: The skid frame should be removed for wrench.
this procedure.
REMOVING
NOTE: Prior to removing the wear strips, inspect cracked, or damaged in any way, replacement is
each wear strip for wear. The wear strip must be necessary.
10.7 mm (0.42 in.) thick or thicker. If the wear strip
measurement is less than specified, replacement
of both wear strips is necessary. 1. Clean the slide rail using parts-cleaning solvent
and compressed air.
! WARNING
Always wear safety glasses while using com-
pressed air.
2. Inspect the slide rail for cracks. If any cracks are

found, replace the slide rail.
3. Using a straightedge, inspect the slide rail for any
unusual bends. Place the straightedge along the
bottom surface of the slide rail. If the rail is found
to be bent, it must be replaced.
0735-677 4. Place the straightedge along the side of the slide
rail. If rail is found to be bent, it must be replaced.
NOTE: It is possible to remove and install a wear
strip without removing the skid frame. To do this,
remove the machine screw and lock nut securing
the wear strip at the front of the slide rail; then
align the wear strip with openings (windows) in the
track and drive it rearward off the slide rail. Apply
low-temperature grease to the new wear strip and
slide rail; then align the wear strip with openings
(windows) in the track and drive it forward onto the
slide rail. Secure with the machine screw and lock
nut.
9-38
INSTALLING
NOTE: Apply a light coat of grease to the slide Rear Suspension Arm/
rail surface to aid in installing new wear strips. If Rear Springs
there are any sharp edges on the lower portion of
the rail, use a file to remove them.
NOTE: The skid frame must be removed for this
procedure.
DISASSEMBLING
1. Remove the cap screws securing the rear arm to

the skid frame; then remove the rear arm. Account
for and note the location of all hardware.
AG534D
1. Starting from the back, start the wear strip onto the
rail; then using a block of wood and a hammer,
drive the wear strip forward into position.
AO159
2. Remove the rear springs and sleeves from the rear

arm.
INSPECTING
NOTE: Whenever part is worn excessively,

necessary.
AG535D
1. Inspect all rear arm weldments for cracks or
unusual bends.
2. Secure with a machine screw and lock nut.
Tighten securely. 2. Inspect all tubing for cracks or unusual bends.
3. Inspect the axles for wear or damage.
4. Inspect the upper and lower bushings for wear or
damage.
5. Inspect the two adjusting cams (adjuster blocks)
for damage. 9
6. Inspect the springs for excessive wear, cracks, or
imperfections.
ASSEMBLING
1. Apply a light coat of grease to the axles and the

bushing areas.
2. Place the rear arm into position on the skid frame;
then secure the arm to the skid frame with existing
hardware. Tighten securely.
9-39
Rear Idler Wheels NOTE: Whenever a part is worn excessively,
and Axle cracked, or damaged in any way, replacement is
necessary.
NOTE: The skid frame must be removed for this 1. Clean the bearings with a clean cloth.
procedure (see Removing Skid Frame in this sub-
section). 2. Inspect all idler wheel bearings. Rotate each bear-
ing (by hand) and if any roughness or binding is
DISASSEMBLING noted, replace the idler wheel assembly.
1. Remove the cap screws and large flat washers 3. Inspect all idler wheel inserts (inner and outer) for
securing the outer idler wheels. Remove the idler any cracks.
wheels from the shaft.
4. Inspect the outer rubber portion of the idler wheels
NOTE: The large wheel insert is positioned next for cracks and poor bonding.
to the inner plastic adjuster bushing. The idler
wheel must be installed with the large wheel insert 5. Inspect the plastic hub of each idler wheel for
properly positioned. cracking.
6. Inspect the axle for wear and damaged threads.
Damaged threads may be repaired with a 3/8 x 16
tap.
ASSEMBLING
1. Assemble the rear axle brackets on the slide rails.

Secure each bracket with two cap screws and lock
nuts. Tighten securely.
2. In order, slide the axle through an axle bracket;
then place a spacer bushing, spacer, and spacer
bushing on the axle. Slide the axle through the
AG328
opposite axle bracket.
2. Remove the two cap screws and lock nuts securing 3. Place the plastic adjuster bushings on the axle (on
each of the rear axle brackets to the rails. Remove the outside of each axle bracket). Make sure the
the brackets and account for spacers. adjuster bushing is positioned towards the adjust-
ing bolt.
4. Place the rear idler wheels on the axle (with the
large insert directed inward) and secure with two
cap screws (coated with blue Loctite #243) and
washers. Tighten securely.
AG330
3. Carefully slide the axle out of the rear spacer and

note the position of the spacer bushings.
9-40
Upper Idler Wheels Slide Rail
NOTE: The skid frame does not have to be NOTE: The skid frame must be removed for this
removed for this procedure. procedure.
REMOVING REMOVING
1. Remove the two cap screws securing the upper NOTE: When it is necessary to replace one or
idler wheel assembly to the tunnel; then remove both slide rails, it is recommended that one slide
the assembly. rail be removed at a time. The remaining slide rail
will then hold the crossbraces and brackets in
their correct assembly order. This method is much
quicker than to completely disassemble the entire
skid frame.
1. Remove the cap screw, washer, and lock nut

securing the end cap to the slide rail. Remove the
end cap from the slide rail.
A013
2. Account for and note the location of all mounting

hardware.
INSPECTING

cracked, or damaged in any way, replacement is AG297D
necessary.
2. Remove the cap screw, lock washer, and flat
1. Inspect each idler wheel for cracks or damage. washer securing the cross-brace axle to the slide
rail.
2. Rotate the idler wheel bearing (by hand) and
inspect for binding or roughness.
3. Inspect the axle and spacers for cracks or bends.
INSTALLING
1. Lightly grease the axle; then slide the inner spacer

onto the axle.
2. Slide the axle through the rear arm limiter strap;
then slide an idler wheel followed by an outer
9
spacer onto each end of the axle.
3. Place the idler wheel/axle assembly into position AO160
in the tunnel and secure with cap screws (coated
with blue Loctite #243). Tighten securely. 3. Remove the cap screws securing the rear suspen-
sion arm to the bracket.
4. Remove the three cap screws and lock nuts secur-
ing the rear suspension arm bracket and backing
plate to the slide rail.
9-41
7. Remove the push nut and rivet securing the shock
pad to the slide rail. Remove the shock pad.
AO162
5. Remove the cap screw securing the rear idler

wheel to the axle. Slide the wheel off the axle. AO161
8. Remove the slide rail from the skid frame.

INSPECTING

necessary.
1. Inspect the slide rail for cracks or unusual bends.

2. Inspect the wear strip for wear. The wear strip
must be 10.7 mm (0.42 in.) thick or thicker. If the
wear strip measurement is less than specified,
replacement of both wear strips is necessary.
AG328
6. Remove the two cap screws securing the rear idler

wheel bracket; then remove the bracket.
0735-677
AG330
9-42
INSTALLING 4. Secure the rear suspension arm to the bracket with
existing hardware. Tighten securely.
1. Install the rear idler wheel bracket and spacer; then
secure with cap screws and nuts.
AO159
AG330 5. Secure the cross-brace axle to the slide rail with

cap screws (threads coated with blue Loctite
2. Install the rear idler wheel (with the large diameter #243). Tighten securely.
insert positioned to the inside) and secure the rear
idler wheel with a cap screw (coated with blue
Loctite #243) and large washer. Tighten securely.
AO160
6. Place the shock pad into position and secure with a

AG328 rivet and push nut.
3. Secure the rear suspension arm bracket and back-
ing plate to the slide rail with cap screws and lock
nuts. Tighten securely.
9
AO161
7. Place the end cap onto the rail and secure with the
cap screw, washer, and lock nut. Tighten securely.
AO162
9-43
4. Press down on the muffler and pull it to the side
Drive Chain until the muffler flange clears the engine exhaust
studs; then remove the muffler from the engine
and Sprocket compartment. Account for the exhaust gasket.
REMOVING the cap screw securing the rear chain sprocket to
1. Remove the screws securing the front and rear
chain guards; then remove the guards from the 6. Remove the snap ring securing the brake band.
engine compartment. Note the position of the hood Account for a washer.
cable.
A003
A017A
7. Loosen the rear brake cable adjustment jam nut
NOTE: It will be necessary to support the hood and slide the cable out of the brake bracket. Set the
once the hood cable is removed. band assembly aside.
2. Remove the muffler hold-down spring from the

muffler and support bracket.
A005
8. Secure the centrifugal clutch with a pair of chan-

A018 nel-lock pliers at the outer clutch collar; then
remove the cap screw securing the clutch. Account
3. Remove the two nuts securing the muffler to the for a washer and a spacer.
engine.
A020
A019
9-44
9. Slide the chain sprocket and clutch with the drive 2. Wash all non-metallic components with soap and
chain off the respective shafts and remove from water.
the engine compartment. Account for the rear
driveshaft key. 3. Inspect the sprocket driveshaft for damage or for
stripped threads.
4. Inspect the keyways in the driveshaft, chain
NOTE: Whenever a part is worn excessively, sprocket, and clutch for wear or damage.
necessary. 5. Inspect the chain and chain sprocket for wear or
damage.
cleaning solvent. Dry using compressed air. 6. Inspect the driveshaft sprockets for wear or dam-
age.
INSTALLING
KEY
1. Cap Screw
2. Carriage Bolt
3. Bearing
4. Track Drive Assy
5. Drive Sprocket
6. Driveshaft
7. Key
8. Chain Sprocket
9. Lock Nut
10. Washer
11. Chain
12. Inner Spacer
13. Centrifugal Clutch
14. Brake Band
15. Retainer Pin
16. Washer
17. Snap Ring
18. Outer Spacer
19. Washer
20. Lock Washer
21. Cap Screw
735-370A
1. Position the key on the rear driveshaft; then slide 3. Slide the brake band over the clutch and position
the chain sprocket/clutch/drive chain assembly the brake cable in the bracket; then secure the
into position. brake band with a washer and snap ring.
2. Secure the clutch with a pair of channel-lock pliers
at the outer clutch collar; then install the cap screw
(coated with blue Loctite #243) with washer and
spacer. Tighten to 2.1-2.3 kg-m (15-16 ft-lb).
A003
4. Tighten the rear brake cable adjustment jam nut

securely; then adjust brake lever travel as neces-
sary (see Section 8 in this manual).
A020
9-45
the cap screw securing the rear chain sprocket to
3. Slide the chain sprocket off the driveshaft and set
aside. Account for the key.
4. Remove the four lock nuts securing the drive
sprocket bearings to the tunnel; then remove the
four carriage bolts from the tunnel.
A005
5. Compress and hold the brake lever; then install the

cap screw (coated with blue Loctite #243) and
washer securing the rear chain sprocket. Tighten
the cap screw securely; then release the lever.
6. Place the exhaust gasket into position on the
engine exhaust studs.
7. Place the muffler into position in the engine com-
partment; then press down on the muffler and A021
swing the intake pipe onto the engine exhaust
studs. Secure with two nuts and the hold-down 5. Position the bearing flanges so they are directed
spring. towards the rear; then spread the tunnel slightly
and slide the driveshaft assembly out of the tunnel.
8. Place the front and rear chain guards into position
making sure the hood cable is properly positioned.
Tighten securely.
Drive Chain, Track,

and Driveshaft

procedure.
REMOVING A022
1. Remove the five machine screws securing the rear 6. Remove the cap screws securing the upper idler
chain guard; then remove the guard. wheel assembly to the tunnel; then remove the
assembly from the tunnel.
A017A
A013
7. Remove the track from the tunnel.
9-46
INSPECTING 3. Inspect the track for cuts, gouges, or wear.
NOTE: Whenever a part is worn excessively, 4. Inspect the keyways in the driveshaft and in the
cracked, or damaged in any way, replacement is chain sprocket for wear or damage.
necessary.
5. Inspect the chain and chain sprocket for damage or
1. Inspect the driveshaft for damage and for stripped wear.
threads.
6. Inspect the track drive sprockets for wear or dam-
2. Inspect the bearings for roughness or damage. age.
INSTALLING
KEY
1. Lock Washer
2. Carriage Bolt
3. Bearing
4. Track Drive Assy
5. Drive Sprocket
6. Driveshaft
7. Key
8. Chain Sprocket
9. Lock Nut
10. Cap Screw
11. Washer
12. Chain
735-370B
NOTE: The snowmobile should be tipped on its

side for this procedure.
! CAUTION
A piece of cardboard should be used to protect
the finish on the hood.
1. Place the track into position in the tunnel.
A021 9
3. Place the upper idler wheel assembly into position
in the tunnel; then secure with cap screws. Tighten
securely.
4. Install the skid frame (see Installing Skid Frame in
this sub-section).
5. Place the snowmobile in the upright position.
A022
6. Place the key on the driveshaft; then slide the
2. Slide the driveshaft assembly into position in the chain sprocket w/chain onto the driveshaft. Secure
tunnel; then secure with carriage bolts and lock with a cap screw (coated with blue Loctite #243),
nuts. Tighten securely. lock washer, and washer. Tighten securely.
9-47
7. Inspect the chain for proper engagement with the
clutch sprocket and the chain sprocket. Track Tension
8. Inspect that the chain tensioner assembly is in
place and functioning properly. NOTE: Track tension and track alignment are
interrelated; therefore, always check both, even if
9. Install the rear chain guard and secure with five only one adjustment seems necessary.
machine screws. Tighten securely.
Track tension is directly related to the overall perfor-
mance of the snowmobile. If the track is too loose, it
may slap against the tunnel causing wear, or it may
Installing Skid Frame ratchet on the track drive sprockets. Arctic Cat recom-
mends that the track tension be checked once a month
and adjusted accordingly.
1. Place a piece of cardboard on the floor to protect
against scratching and tip the snowmobile onto ! WARNING
one side.
Track tension must be properly maintained. Per-
2. Pull the track away from the tunnel and spread sonal injury could result if a track is allowed to
become excessively loose.
open; then place the skid frame into the track.
3. Position the front of the skid frame into the tunnel CHECKING
and align the rear suspension arm with the appro-
priate mounting hole in the tunnel. Slide the lock ! WARNING
washer onto the cap screw; then secure the arm to
DO NOT attempt to check or adjust track tension
the tunnel with the cap screw and lock washer. with engine running. Turn ignition key to the OFF
Thread the cap screw in only half way. DO NOT position. Personal injury could result from contact
TIGHTEN AT THIS TIME. with a rotating track.
NOTE: To aid in centering the rear arm with the 1. Remove excess ice and snow buildup from the
holes in the tunnel, position the skid frame and track, track drive sprockets, and the inside of the
track at a 45° angle to the bottom of the tunnel.
skid frame.
4. Place the snowmobile in the upright position; then 2. Place the rear of the snowmobile up on a safety
secure the opposite side upper idler wheel assem- stand high enough so the track is free of the floor.
bly.
3. Without exerting any pressure on the track, mea-
5. Securely tighten all upper idler wheel mounting sure the distance between the bottom of the wear
hardware. strip and the inside surface of the track. The mea-
surement must be within specifications. If the
6. Tighten all skid frame/axle mounting cap screws measurement is not within specifications, an
securely. adjustment is necessary.
7. Check track tension; adjust as necessary (see
Track Tension in this sub-section).
735-669A
9-48
ADJUSTING
1. Loosen the idler wheel cap screws. Track Alignment

2. Loosen the rear idler wheel adjusting bolt jam Proper track alignment is obtained when the rear idler
nuts. wheels are equal distance from the inner track drive
lugs. Excessive wear to the idler wheels, drive lugs,
and track will occur if the track is improperly aligned.
Arctic Cat recommends that the track alignment be
checked once a week or whenever the track tension is
adjusted.
CHECKING
! WARNING
Make sure the ignition key is in the OFF position
and the track is not rotating before checking or
adjusting track alignment. Personal injury could
result if contact is made with a rotating track.
0735-454
1. Remove excess ice and snow buildup from the
NOTE: To ensure proper track tension adjust- track, track drive sprockets, and the inside of the
ment, perform all adjustments on both sides of the skid frame.
snowmobile.
2. Position the tips of the skis against a wall; then
3. If the deflection (distance between the bottom of using a shielded safety stand, raise the rear of the
the wear strip and the inside of the track) exceeds snowmobile off the floor making sure the track is
specifications, tighten the adjusting bolts to take free to rotate.
up excessive slack in the track.
4. If the distance between the bottom of the wear
strip and the inside surface of the track is less than ! WARNING
specified, loosen the adjusting bolts to increase the The tips of the skis must be positioned against a
slack in the track. wall or similar object for safety.
5. Check track alignment (see Track Alignment in 3. Start the engine and accelerate slightly. Use only
this sub-section). enough throttle to turn the track several revolu-
tions. SHUT ENGINE OFF.
6. When proper track tension is obtained, tighten the
adjusting bolt jam nuts against the axle housings. NOTE: Allow the track to coast to a stop. DO
NOT apply the brake because it could produce an
7. Tighten the idler wheel cap screws securely. inaccurate alignment condition.
NOTE: Since track tension and track alignment 4. When the track stops rotating, check the relation-
are interrelated, always check both even if only
one adjustment seems necessary. ship of the rear idler wheels and the inner track
drive lugs. If the distance from the rear idler
wheels to the inner track drive lugs is the same on
! WARNING
9
both sides, no adjustment is necessary.
If jam nuts are not tightened properly, the adjusting
bolts could loosen causing the track to become
extremely loose and, under some operating condi-
tions, allow the idler wheels to climb over the track
lugs forcing the track against the tunnel causing
the track to “lock.” If a track “locks” during opera-
tion, severe personal injury could result.
0727-729
9-49
5. If the distances from the rear idler wheels to the
inner track drive lugs are not the same on both
sides, an adjustment is necessary.
ADJUSTING
1. On the side of the track which has the inner track This Track/Rear Suspension sub-section (Repair Pro-
drive lugs closer to the rear idler wheel, loosen the cedure 2) has been organized so each procedure can be
idler wheel cap screw and the adjusting bolt jam completed individually and efficiently. Each sub-sec-
nut; then rotate the adjusting bolt clockwise 1 to 1 tion has (as necessary) Removing, Disassembling,
1/2 turns. Cleaning and Inspecting, Assembling, and Installing
sound judgment when removing and installing compo-
nents.
in this sub-section are used for clarity purposes
only and are not designed to depict actual condi-
tions.
Removing
0735-454 Skid Frame
2. Check track alignment and continue adjustment
until proper alignment is obtained. NOTE: Many service procedures can be per-
formed without removing the skid frame. Closely
NOTE: Make sure correct track tension is main- observe the note introducing each sub-section for
tained after adjusting track alignment (see Track this important information.
Tension in this sub-section).
1. On models with remote adjuster, rotate the remote
3. After proper track alignment is obtained, tighten reservoir adjuster knob counterclockwise to
both the adjusting bolt jam nut and the idler wheel reduce pressure on the skid frame front shock
cap screw securely. absorber.
! WARNING 2. On models with the remote adjuster, disconnect

the quick-adjuster located under the driven pulley;
If a jam nut is not tightened properly, the adjusting then route the hose out of tunnel and out of the
bolt could loosen causing the track to become dan- holding bracket on the inside of the tunnel.
gerously loose.
4. Field test the track under actual conditions; then ! CAUTION

make additional adjustments as necessary. If this is not done, damage to the hose may
result.
3. Loosen the jam nuts and two track-tension adjust-

ing bolts.
AG670D
9-50
while holding the flared bushing, remove the rear
cap screws securing the skid frame to the tunnel.
Wear Strips
Account for lock washers and flat washers.
REMOVING
NOTE: The support stand should hold the snow-
mobile level but not raised off the floor. NOTE: It is possible to remove and install a wear
5. Remove the front cap screws securing the skid remove the machine screw and lock nut securing
frame to the tunnel. Account for a flat washer and the wear strip at the front of the slide rail; then
a lock washer. align the wear strip with openings (windows) in the
track and drive it rearward off the slide rail. Apply
6. Remove the support stand; then tip the snow- low-temperature grease to the new wear strip and
mobile onto one side using a piece of cardboard to slide rail; then align the wear strip with openings
protect against scratching. Remove the skid frame. (windows) in the track and drive it forward onto the
nut.
NOTE: The skid frame should be removed for

this procedure (see Removing Skid Frame in this
sub-section).
1. Remove the machine screw and lock nut securing

the wear strip to the front of the slide rail.
AG671D
AG504D
2. Using a pipe wrench and starting from either end,

hook the edge of the wear strip with the pipe
wrench.
9
AG505D
9-51
CLEANING AND INSPECTING INSTALLING
NOTE: Whenever a part is worn excessively, NOTE: Apply a light coat of grease to the slide
cracked, or damaged in any way, replacement is rail surface to aid in installing a new wear strip. If
necessary. there are any sharp edges on the lower portion of
1. Clean the slide rail using parts-cleaning solvent
and compressed air.
! WARNING
Always wear an approved pair of safety glasses
when using compressed air.

AG534D
1. From the back, start the wear strip onto the rail;
then using a block of wood and a hammer, drive
the wear strip forward into position.
AG529D

AG535D

AG536D
9-52
2. Inspect the end cap for any signs of cracking or
End Caps wear.
NOTE: The skid frame does not have to be

REMOVING
1. Remove the lock nut, washers, and cap screw

AG508D
3. Clean both the slide rail area and the end cap.
Using compressed air, clean the areas of dirt and
gravel.
! WARNING
AG506D
2. Using a hammer, tap the end cap off the rail. 4. Inspect the cap screw for cracked, stretched, or
CLEANING AND INSPECTING bling.
NOTE: Whenever a part is worn excessively, INSTALLING

necessary. 1. Position the end cap on the slide rail; then align the
hole in the end cap with the hole in the slide rail.
1. Inspect the end cap area of the slide rail for cracks
and wear. 2. Secure with a cap screw, washers, and lock nut.
9
AG507D
9-53
Shock Pads Front Outer
Idler Wheels
removed for this procedure. NOTE: The skid frame does not have to be
REMOVING
REMOVING
1. Using a 3/16-in. drill bit drill out the rivets secur-
ing the shock pad to the slide rail. Account for the 1. Remove the cap screws and lock nuts securing the
retaining brackets. front outer idler wheel and the idler wheel
mounting block. Account for flat washers and an
axle.
AG476D
2. Remove the shock pad. AG678D
INSPECTING

necessary.
1. Inspect the pad and retaining brackets for damage

or wear.
2. Inspect the rivet holes in the slide rail for damage
or elongation.
INSTALLING
1. Place the pad and retaining brackets into position AG686D

on the slide rail.
2. Note the locations of the flat washers for assembly
2. Secure the pad assembly with rivets. purposes. The washers are to be installed next to
the idler wheels.
AG531D
AG622D
9-54
CLEANING AND INSPECTING E. Install the insert.
necessary.
1. Clean the bearing with a clean cloth.

2. Inspect each idler wheel and each plastic hub for
cracks or damage.
4. If a bearing must be replaced, use this procedure.
AG540D
! CAUTION
INSTALLING
Do not remove the bearing unless it is absolutely
necessary. The bearing will be damaged during 1. Secure the mounting block on the slide rail with a
removal.
cap screw and lock nut. Tighten to 3.2 kg-m
(23 ft-lb).
A. Remove the wheel insert and the snap ring.
B. Using a hydraulic press, press the bearing out
the inside of the wheel.
C. Press the new bearing (on its outer race) into
the idler wheel.
AG686D
2. Place the idler wheel and axle against the mount-

ing block making sure there is a flat washer on
both sides of the idler wheel.
AG538D
D. Install the snap ring making sure the “sharp

side” is directed away from the bearing.
AG622D
AG539D
9-55
Rear Inner
Idler Wheels

REMOVING

the idler wheel axle shaft to the slide rails.
AG623D
3. Secure the idler wheel assembly with a cap screw

and a lock nut. Tighten cap screws to 3.2 kg-m
(23 ft-lb).
AG592D
2. Slide the rear idler wheel assembly rearward and

lift the idler wheel assembly from the suspension.
Account for one long spacer, two short spacers,
AG618D
and four flat washers.
AG459D

necessary.

2. Inspect each idler wheel and plastic hub for cracks
or damage.
3. Rotate the idler wheel bearings (by hand) and
9-56
! CAUTION
necessary. The bearing will be damaged during
removal.

C. Press the new bearing (on its outer race) into AG540D
the idler wheel.
INSTALLING
1. Position the idler wheels with spacer and spacer

washers (one on each side of idler wheel) on the
axle.
AG538D

AG459D
2. Slide the inner wheel assembly into position

between the rails. Secure the axle with two cap
screws and lock washers (coated with red Loctite
#271). Tighten to 3.2 kg-m (23 ft-lb).
NOTE: To prevent possible damage to the skid
frame, make sure to install the idler wheels in their
proper mounting locations.
AG539D
E. Install the insert.

9
AG592D
9-57
Rear Upper Idler
Wheels/Rear Springs

section).
REMOVING
1. Using the Rear Suspension Spring Tool (p/n 0144-

311), remove the spring from the adjusting cam.
AG677D
! WARNING 4. Remove the idler wheel.

Care must be taken when removing the spring or NOTE: It may be necessary to use the Idler
damage or injury could result. Wheel Puller Kit (p/n 0644-122) to remove the
wheel.
AG624DA
AG461D
2. Mark the offset pivot idler and the idler arm for
assembly purposes. 5. Remove the cap screw and flat washer securing
the spring slide to the rail. Account for a slide
block and washer.
AG675D
3. Remove the cap screws securing the offset pivot AG593D

idler arm assembly to the idler arm; then remove
the offset pivot arm idler assembly. Account for a 6. Remove the spring and sleeve from the idler arm.
flanged axle, flared bushing, idler spacer collar,
and lock nuts.
9-58
AG681D
NOTE: Use the same procedure for the other

side. AG539D
INSPECTING E. Install the insert.

necessary.

or damage.
AG540D
! CAUTION
5. Inspect the spring, spring slide, sleeve, washers,
Do not remove the bearing unless it is absolutely slide block insert, and shaft area for wear.
removal. 6. Inspect the adjusting cams and arms for cracks.
A. Remove the wheel insert and the snap ring. INSTALLING
B. Using a hydraulic press, press the bearing out 1. Slide the sleeve and spring onto the idler arm.
the idler wheel.
AG655D
2. Place the spring slide and slide block (with spring

in slide block) into position on the slide rail.
AG538D Secure with a cap screw (coated with red Loctite
#271) and washer. Tighten to 3.2 kg-m (23 ft-lb).
9-59
AG680D AG677D
5. Place the flanged axle with a thin flat washer

through the notched side of the offset pivot idler
arm assembly.
NOTE: If the flanged axle in the offset pivot idler
arm is loose, it must be cleaned and green Loctite
#609 must be applied to it prior to installation.
6. Align the marks on the idler arm to the centerline

of the offset pivot idler arm assembly. Secure the
offset pivot idler arm to the idler arm with cap
screws and lock nuts. Tighten to 2.6 kg-m
(19 ft-lb).
AG593D
3. Install the rear upper idler wheel on the idler arm.
AG675D
7. Place the short spring leg onto the adjusting cam

AG545D using the rear suspension spring tool.
4. Install the idler spacer collar onto the idler arm.
AG624DA
9-60
Rear Axle and
Idler Wheels

section).
DISASSEMBLING
1. Remove the cap screw and large flat washer secur-

ing the outer rear idler wheel. Remove the outer
AG628D
idler wheel from the shaft.
3. Carefully slide the shaft out from the inner idler
wheels and note the position of the spacers and
washers.
AG548D
NOTE: The large flat side of the wheel insert is

positioned next to the inner plastic adjuster bush-
AG805D
ing. The idler wheel must be installed with the
wheel insert properly positioned.
2. Loosen the track adjusting bolts. Slide the outer NOTE: Whenever a part is worn excessively,
adjuster bushings off the axle. cracked, or damaged in any way, replacement is
necessary.
1. Clean the bearings with a clean cloth.

2. Inspect all idler wheel inserts (inner and outer) for
any cracks.
for cracks and poor bonding.
4. Inspect the plastic insert of each idler wheel for
cracks. 9
5. Inspect the shaft for wear and damaged threads.
AG627D
6. Inspect all idler wheel bearings. Turn each bearing
(by hand) and if any roughness or binding is noted,
! CAUTION
removal.
9-61
B. Using a hydraulic press, press the bearing out ASSEMBLING
1. In order from the right-hand side, slide the axle
C. Press the new bearing (on its outer race) into through the slide rail axle bracket; then place a flat
the idler wheel. washer, short spacer with bushings, inner idler
wheel with insert, long spacer with bushings, and
flat washer on the axle. Slide the axle through the
opposite slide rail axle bracket. Place the plastic
adjuster bushings on the axle (on the outside of
each axle bracket). Make sure the hole in the
adjuster bushing is aligned directly with the
adjusting bolt.
AG538D

AG805D
AG539D
AG551D
2. Place the outer idler wheels on the axle (with the

large flat of the insert directed inward) and secure
with two cap screws (coated with red Loctite
#271) and large flat washers. Tighten cap screws
to 3.2 kg-m (23 ft-lb).
AG540D
AG548D
3. Adjust track alignment (see Track Alignment in

this sub-section).
9-62
4. Adjust track tension deflection (see Track Tension
in this sub-section).
Idler Arm

section).
DISASSEMBLING
AG553D
1. Remove the rear upper idler wheels and springs NOTE: Mark the hole that the upper shock links
(see Rear Upper Idler Wheels/Rear Springs in this are mounted in for assembly purposes.
sub-section).
AG554D
AG545D
3. Remove the cap screw and lock nut securing the
2. Remove the cap screw and lock nut securing the upper shock links to the idler arm. Account for a
upper shock eyelet to the idler arm. Account for a lock nut, spacer, flat washers, and axle links.
spacer, lock nut, and bushings.
9
AG682D
AG467D
AG556D
9-63
NOTE: Note the mounting hole from which the
rear arm was removed for assembly purposes.
AG477D
AG683D

rear arm to the slide rail. Account for the serrated
axles and axle tube.
AG561D

necessary.
AG558D
2. Inspect each idler wheel for cracks or damage.
3. Inspect the bushings (located in the arm pivot
area) for wear or damage.
4. Inspect all welds and the tubing of the upper arm
for cracks or unusual bends.
5. Inspect the two adjusting cams for damage.
check for binding or roughness.
AG560D 7. If a bearing must be replaced, use this procedure.
rear arm to the idler arm. Account for the alumi- ! CAUTION
num axle and bushing assemblies. Do not remove the bearing unless it is absolutely
removal.

the idler wheel.
9-64
1. Install the rear arm onto the idler arm with an alu-
minum axle, bushing assemblies, cap screw, and a
AG538D

AG477D
NOTE: Install the rear arm assembly into the

appropriate mounting hole as noted during disas-
sembly.
2. Place the rear arm assembly into position (with the

brace facing towards the front side) between the
slide rails. Secure with a cap screw and lock nut.
AG539D
AG558D
3. Position the shock links in the appropriate holes of

the idler arm brackets (see Chassis and Skid Frame
Mounting Locations in this section). Place a
spacer between the center of the brackets; then
place a flat washer on the cap screw. Insert the
axle links into the upper shock link eyelets; then
9
AG540D
insert the cap screw with washer through the eye-
ASSEMBLING lets. Secure with a cap screw, washer, and lock
nut. Tighten to 3.2 kg-m (23 ft-lb).
AG562D
9-65
Front Arm/Front Shock
Absorber/Front Inner
Idler Wheels

section), and the rear springs must be removed
from the adjusting cams.
REMOVING
AG556D
NOTE: On models with remote adjuster, cut the
cable ties securing the front shock absorber hose
to the front arm.
1. Remove the lower cap screws and lock nuts secur-

ing the limiter straps to the rail support. Account
for flat washers.
AG682D
4. Place the upper shock eyelet with bushings

between the idler arm brackets making sure the
spacer is properly positioned between the brack-
ets. Secure with a cap screw and lock nut. Tighten
to 3.2 kg-m (23 ft-lb).
AG632D

upper front shock absorber eyelet to the front arm.
Pull the shock eyelet free of the bracket. Account
for a serrated axle.
AG467D
NOTE: Do not over-tighten the shock absorber

cap screw as the shock eyelet must be free to
pivot.
5. Grease the idler arm and rear arm grease fittings AG582D
with a low-temperature grease.
6. Install the rear upper idler wheels, rear springs, front arm to the front arm mounting brackets.
and offset pivot idler (see Rear Upper Idler
Wheels/Rear Springs in this sub-section).
9-66
6. Remove the cap screw and lock washer securing
one side of the shock mount axle. Clean the Loc-
tite from the axle threads and cap screw threads;
then reinstall the cap screw. Remove the opposite-
side cap screw and lock washer; then clean the
Loctite from the axle threads and cap screw
threads. Remove the first cap screw and washer;
then remove the axle and account for spacers, flat
washers, and shock bushings. Discard the cap
screws.
! CAUTION
AG565D It may be necessary to heat the cap screws. Care
must be taken to prevent damage to other
4. Remove the front arm and account for the two components.
front arm spacers.
NOTE: New cap screws must be used when
installing the shock mount axle.
AG485D
5. Remove the cap screws securing the front outer AG567D

idler wheels to the idler wheel mounting block.
Account for a lock nuts, axles, inserts, and flat
washers.
NOTE: On models with remote adjuster, loosen

AG568D
9
AG566D the three Allen-head screws securing the remote
reservoir; then slide the reservoir assembly over
and remove the reservoir with hoses.
9-67
6. Inspect the shock absorber eyelet welds (at each
end) for any cracks, signs of separation, or for
unthreading.
7. Inspect the shock absorber and reservoir hoses (on
models with remote adjuster) for damage.
INSTALLING
1. On models with remote adjuster, place the remote

reservoir into position making sure the hose is
directed to the left-side of the skid frame. Secure
with the three Allen-head screws coated with red
AG591D
Loctite #271. Tighten the outside screws first.
NOTE: The center Allen-head screw will not bot-
! CAUTION tom on its shoulder when tightened. It bottoms on
Care must be taken when removing the remote the cross-shaft to hold the assembly centered.
reservoir that the hoses are not kinked or
damaged.
7. Using a plastic mallet, tap the axle from the lower

shock eyelet.
INSPECTING

necessary.
1. Inspect all front arm weldments for cracks or

unusual bends.
AG591D
2. Closely inspect all tubing for cracks or unusual
bends. 2. Install the axle into the lower shock eyelet bushing
assembly. Apply grease to the axle; then install the
3. Inspect the bearings, bushings, and front arm spac- spacers.
ers for wear or damage.
4. Inspect the two rear track guide bumpers. If worn,
drill out the rivets securing the bumpers to the arm
and replace with new bumpers.
AG568D
3. Place the shock mount axle into position on the

skid frame making sure the spacers and washers
are properly positioned. Secure with new cap
AG486D screws (coated with green Loctite #609) and wash-
ers. Tighten to 4.2 kg-m (30 ft-lb).
5. Inspect the shock absorber for any signs of oil
leakage especially at the point where the shock
shaft enters the shock body.
9-68
AG567D AG480D
4. Position the front arm with spacers into the mount- NOTE: On models with remote adjuster, secure
ing brackets. Secure with cap screws and lock the shock absorber hose to the left upper arm and
nuts. Tighten to 4.2 kg-m (30 ft-lb). slide rail using cable ties. Pull the cable ties tight
to prevent the hose from sliding. Compress the
front arm to assure the hose does not interfere
with the suspension.
AG565D
5. Secure the upper shock eyelet and serrated axle in

the appropriate mounting hole of the front arm AG590D
(standard arm mounting position). Secure with a
cap screw and lock nut. Tighten to 3.2 kg-m 7. Secure the front outer idler wheels to the idler
(23 ft-lb). wheel mounting blocks with cap screws, flat
washers, inserts, axles, and lock nuts. Tighten to
3.2 kg-m (23 ft-lb).
9
AG564D
6. Secure the limiter straps with cap screws, washers, AG572D

9-69
AG512D AG662D
3. Tap the idler wheel assembly rearward until it

clears the mounting brackets; then lift the idler
wheel assembly upward until the shaft clears the
Rear Shock Absorber rails.
and Shock Links
NOTE: Before removing the skid frame by using

the Rear Suspension Spring Tool (p/n 0144-311),
remove the spring from the adjusting cam.
! CAUTION
Care must be taken when removing the spring
from the adjusting cam or damage or injury
could result.

procedure (see Removing Skid Frame in this sub- AG569D
section).
NOTE: Lay components out in order as they are
DISASSEMBLING removed.
1. Remove the rear inner idler wheels (see Rear Inner 4. Remove the spacer, washer, idler wheel with
Idler Wheels in this sub-section). inserts, washer, and inner bushing. Repeat the
same procedure on the other side of the shock
pivot bracket. Remove the idler wheel axle.
AG592D
2. Note the hole location that the spring slides are in; AG492D
then remove the cap screws and flat washers
securing the spring slides to the rails. Account for
slide blocks.
9-70
AG663D AG657D
5. Disengage the shock absorber at the lower eyelet.

Account for washers, axle links, bushings, shock
sleeve, cap screw, and a lock nut.
AG665D
AG596D
necessary.
1. Clean shock pivot and idler wheel axle in part-

cleaning solvent. Dry with compressed air.
! WARNING
2. Clean the idler wheel bearings with a clean cloth.

3. Closely inspect the torque link arm and axles for
AG664D
wear, bends, or damaged splines at either end.
6. Disengage the shock absorber at the upper eyelet

and remove the shock absorber. Account for a
4. Inspect the idler wheels for signs of cracking,
wear, or outer rubber separation from plastic
9
sleeve, cap screw, lock nut, and bushings. wheel.
inspect for any signs of binding or roughness.
! CAUTION
removal.
A. Remove the snap ring.
9-71
1. Secure the rear shock links and the lower shock
C. Press the new bearing (on its outer race) into absorber eyelet to the shock pivot bracket. Place
the idler wheel. the bushings and shock sleeve into the shock eye-
let; then install the axle links into the rear shock
links. Secure the assembly by installing a cap
screw and flat washer through the shock link
assembly, shock pivot bracket and shock eyelet
assembly, shock link assembly, and a flat washer.
Secure the assembly with a lock nut. Tighten to
3.2 kg-m (23 ft-lb).
AG538D

AG595D
AG539D

shaft enters the shock body. AG596D
8. Inspect the rubber shock bushings located in the 2. Secure the shock absorber to the idler arm with
shock absorber eyelets for cracks or deterioration. bushings, sleeve, lock nut, and a cap screw.
end) for any cracks or signs of separation.
10. Inspect the welds securing the eyelets of the shock
links for cracks or signs of separation. Either weld
the eyelet or replace the shock link.
11. Inspect the axle surfaces for any signs of corro-
sion. If corrosion is found, lightly buff the surface
of the axle with #400 wet-or-dry sandpaper; then
apply a light coat of grease.
AG657D
9-72
3. Apply a thin coat of low-temperature grease to the 6. Secure the rear inner idler wheel axle assembly
bushing and idler wheel axle and slide the bushing (see Rear Inner Idler Wheels in this sub-section).
and axle into the shock pivot bracket. Have equal
amounts of the axle exposed on either side of the
bracket tube.
AG592D
AG597D
4. Slide a washer onto the axle; then install an idler Slide Rails
wheel (with its larger bearing insert side facing the
shock pivot), washer, and spacer. Repeat the same
procedure on the other side of the shock pivot NOTE: The skid frame must be removed for this
bracket. procedure (see Removing Skid Frame in this sub-
section).
REMOVING
NOTE: When it is necessary to replace one or

both slide rails, it is recommended that one slide
rail be removed at a time. The remaining slide rail
will then hold the crossbraces, axles, and brackets
in their correct assembly order. Always mark the
mounting hole locations during disassembly to
speed up the assembly process and to prevent any
damage. This method is much quicker than to
completely disassemble the entire skid frame. To
replace either rail, use the following procedure.
AG492D 1. Remove the end cap from the slide rail. Account
for a cap screw, lock nut, and two flat washers.
5. Lower the idler wheel assembly down between the
rails. Align the axle with the mounting hole just
below the front arm mounting brackets (as noted
during disassembly). Secure the spring slides
(with spring legs in position), slide blocks, and
front inner idler wheel axle assembly to the rails.
9
AG506D

AG662D
9-73
front outer idler wheel and the idler wheel mount-
ing block. Account for flat washers and an axle.
AG509D

wrench jaw and twist the wear strip off the slide AG512D
slide rail; however, it is quicker to use the pipe
wrench.
AG686D

the front shock mount axle. Discard the cap
screws.
! CAUTION
AG510D
It may be necessary to heat the cap screws.
4. Remove the cap screws securing the crossbraces to
the slide rail.
NOTE: On models with remote adjuster, cut the
cable ties securing the hose to the slide rail and
arm.
AG514D
7. Remove the short spring leg from the adjusting

cam.
AG511D
9-74
10. Remove the cap screws securing the front arm
mounting bracket. Account for lock nuts.
AG624DA
8. Remove the cap screw and flat washer securing

the spring slide to the rail. Account for a spacer AG638D
and the slide block.
11. Mark the mounting position of the rear inner idler
wheels.
AG515D
AG668D
12. Remove the cap screws and lock nut securing the
rear inner idler wheels.
AG680D
9. Mark the mounting position of the front arm

mounting bracket.
9
AG592D
13. Mark the mounting position of the rear arm limiter

and rear arm.
AG637D
9-75
AG683D AG626D
14. Remove the cap screw, lock washer, and lock nut
from the rear arm limiter shaft.
AG551D
NOTE: The adjusting bolt may have to be loos-

AG639D ened to remove the adjuster bushing.
rear arm to the rail.
AG627D
NOTE: At this point, the slide rail should be free

AG694D of the skid frame components and can be
removed.
16. Remove the idler wheel insert; then remove the
cap screw and flat washer securing the rear idler 17. Remove the cap screws and lock nuts securing the
wheel. Remove the idler wheel; then remove the track adjuster bracket.
adjuster bushing.
9-76
AG527D
18. Using a drill and a 3/16-in. drill bit, drill out the
rivets and remove the shock pads. Note the shock
pad location for installation. Account for the
retaining brackets. AG530D
AG528D 0727-726
INSPECTING INSTALLING
NOTE: Whenever a part is worn excessively, 1. Install the shock pads and retaining brackets; then
cracked, or damaged in any way, replacement is secure with rivets.
necessary.
9
AG531D
2. Secure the track adjuster bracket with the cap

AG529D screws and lock nuts. Tighten to 1.5 kg-m
(11 ft-lb).
9-77
5. Install the rear inner idler wheels in the appropri-
ate hole as noted during disassembly and secure
with cap screws (coated with red Loctite #271)
AG527D
3. Place the rail into position; then install the adjuster

bushing and rear idler wheel. Secure with a cap
screw (coated with red Loctite #271) and flat
washer. Tighten to 3.2 kg-m (23 ft-lb); then install AG592D
the wheel insert.
6. Secure the front arm mounting bracket with the
cap screws (coated with red Loctite #271) and lock
AG551D
AG497D
7. Place the spring into the slide blocks; then place

the spring slide and slide block assembly into posi-
tion on the slide rail. Secure with a cap screw
(coated with red Loctite #271) and washer.
AG626D
4. Install the rear arm limiter cap screw (coated with

red Loctite #271) in the appropriate hole (as noted
during disassembly) and tighten to 3.2 kg-m
(23 ft-lb).
AG680D
9-78
AG593D AG512D
8. Secure the front shock absorber axle with a new 11. Secure the crossbraces with cap screws (coated
cap screw (coated with green Loctite #609) and with red Loctite #271). Tighten to 1.5 kg-m
lock washer. Tighten to 4.2 kg-m (30 ft-lb). (11 ft-lb).
NOTE: Make sure the axle threads are clean;
also, always use new cap screws whenever install-
ing.
AG511D
12. Install the rear arm in the appropriate hole as noted

during disassembly; then secure with a cap screw
AG514D (coated with red Loctite #271) and lock nut.
9. Secure the outer idler wheel mounting block with
the cap screw and lock nut. Tighten to 3.2 kg-m
(23 ft-lb).
9
AG694D
NOTE: Apply a light coat of grease to the slide

AG686D rail surface to aid in installing a new wear strip. If
there are any sharp edges on the lower portion of
10. Secure the outer idler wheel to the mounting block the rail, use a file to remove them.
with a cap screw, flat washers, idler wheel, axle,
and a lock nut. Tighten to 3.2 kg-m (23 ft-lb).
9-79
14. Secure the end cap onto the slide rail using a cap
screw, flat washers, and a lock nut. Tighten to
1.1 kg-m (8 ft-lb).
AG534D
the wear strip forward into position. Secure with a AG506D
machine screw and lock nut. Tighten to 1.1 kg-m
(8 ft-lb). NOTE: On models with remote adjuster, install
all cable ties securing the hose to the slide rail and
arm.
15. Install the short spring leg onto the adjusting cam.
AG535D
AG516DA
16. Adjust suspension.

17. After the skid frame has been installed, adjust
track tension deflection (see Track Tension in this
sub-section) and track alignment (see Track Align-
ment in this sub-section).
AG509D
9-80
Installing Skid Frame Track Tension
1. Place a piece of cardboard on the floor to protect ! WARNING

against scratching and tip the snowmobile onto
one side. Deactivate all switches.
2. Pull the track away from the tunnel and spread CHECKING DEFLECTION
1. Tip the snowmobile on its side.
3. Position the front of the skid frame into the tunnel
and align the front arm with the appropriate 2. Hook a spring scale around a track clip at mid-
mounting hole in the tunnel. Insert the cap screw span; then pull the track down with the scale to 9
with washers through the tunnel mounting hole kg (20 lb) and measure the distance between the
and through the front arm. DO NOT TIGHTEN bottom of the wear strip and the inside surface of
AT THIS TIME. Repeat this procedure on the the track clip. Track deflection must be within
other side. specifications.
NOTE: To aid in centering the front arm with the Rear Suspension Setup After Break-In
hole in the tunnel, position the skid frame and Style Tension Tension
FasTrack w/o Torque 19-25 mm 25-32 mm
Sensing Link (3/4-1 in.) (1-1 1/4 in.)
4. Elevate the rear of the skid frame and the track
into position in the tunnel. FasTrack w/Torque 32-38 mm 38-44 mm
Sensing Link (1 1/4-1 1/2 in.) (1 1/2-1 3/4 in.)
(121 in. Track)
5. Align the offset pivot idler arm assembly with the
appropriate hole in the tunnel. Secure the offset FasTrack w/Torque 38-44 mm 50.8-57.2 mm
Sensing Link (1 1/2-1 3/4 in.) (2-2 1/4 in.)
pivot idler arm assembly with a cap screw (coated (136 in. Track)
with red Loctite #271), lock washer, and flat
washer. DO NOT TIGHTEN AT THIS TIME.
NOTE: Do not install the short legs of the rear
springs onto the adjusting cams at this time.
6. At this time, tighten all four skid frame mounting

cap screws to 3.2 kg-m (23 ft-lb).
311), install the short legs of the rear springs onto
the adjusting cams making sure the cams are in the
same adjustment positions.
NOTE: On models with remote adjuster, guide
the adjuster reservoir hose through the hole in the 729-429A
left-side tunnel panel. Route the hose through the
clamp attached to the speedometer drive; then NOTE: If the track is new, it will stretch slightly
attach to the quick-coupler. and take a “set” within the first 300 to 500 miles of
9
operation.
8. Tighten the two track tension adjusting bolt evenly
until track deflection is within specifications; then ADJUSTING DEFLECTION
lock the jam nuts to secure the adjustment.
1. Place the snowmobile up on a shielded safety
9. Check track tension deflection and alignment; stand. Check to make sure the track is 2-3 in. off
adjust if necessary (see Track Tension and Track the floor.
Alignment in this sub-section).
2. If the measurement is not as specified, loosen the
jam nuts of the adjusting bolts.
9-81
Track Alignment
NOTE: Proper track alignment is when the rear

idler wheels are equidistant from the inner drive
lugs on the inside surface of the track.
CHECKING
1. Using a shielded safety stand, raise the rear of the

snowmobile off the floor making sure the track is
free to rotate.
0727-456
3. If the measurement obtained in step 2 is more than ! WARNING

specified, tighten the adjusting bolts. If the mea- The tips of the skis must be positioned against a
surement obtained is less than specified, loosen wall or similar object for safety. Keep hands, feet,
the adjusting bolts. When the measurement is and clothing away from moving components.
within specification range, lock the adjustment by
bottoming the jam nuts against the axle housings. 2. Start the engine and accelerate slightly. Use only
enough throttle to rotate the track several revolu-
NOTE: Vigorously push the underside of the tions. SHUT THE ENGINE OFF.
track up and down. Track must not hit the top of
the tunnel or slap the skid frame. NOTE: Allow the track to coast to a stop. Do not
apply the brake because it could produce inaccu-
4. After correct track tension is obtained, check track rate alignment conditions.
alignment (see Track Alignment in this sub-sec-
tion). 3. When the track stops rotating, check the relation-
ship of the rear idler wheels and the inner track
NOTE: Track tension and track alignment are drive lugs. If the distance from the idler wheels to
interrelated; always check both even if only one the inner drive lugs is the same on both sides, no
adjustment seems necessary. Always establish adjustment is necessary.
correct track tension before checking and/or
adjusting alignment.
725-070A
4. On the side of the track which has the inner drive

lugs closer to the rear idler wheel, loosen the
adjusting bolt jam nut; then rotate the adjusting
bolt clockwise 1-1 1/2 turns.
5. Continue to check the track alignment and make
the necessary adjustments until proper alignment
is obtained.
6. After proper track alignment is obtained, lock the
jam nut against the axle housing.
NOTE: Make sure correct track tension is main-
tained after adjusting track alignment.
NOTE: Field test the track under actual condi-

tions and, after the field test, check track align-
ment and track tension; adjust as necessary.
9-82
This Track/Rear Suspension sub-section (Repair Pro-
completed individually and efficiently. Each sub-sec-
Cleaning and Inspecting, Assembling, and Installing
sound judgment when removing and installing compo- AG671D
nents.
tions.
Wear Strips
REMOVING
NOTE: It is possible to remove and install a wear

Removing strip without removing the skid frame. To do this,
Skid Frame remove the machine screw and lock nut securing
the wear strip at the front of the slide rail; then
NOTE: Many service procedures can be per- track and drive it rearward off the slide rail. Apply
formed without removing the skid frame. Closely low-temperature grease to the new wear strip and
observe the note introducing each sub-section for slide rail; then align the wear strip with openings
this important information. (windows) in the track and drive it forward onto the
nut.
1. Loosen the jam nuts and two track-tension adjust-
ing bolts. NOTE: The skid frame should be removed for
this procedure (see Removing Skid Frame in this
sub-section).

AG670D 9
while holding the flared bushing, remove the rear
cap screws securing the skid frame to the tunnel.
Account for lock washers and flat washers.
AG504D
NOTE: The support stand should hold the snow- 2. Using a pipe wrench and starting from either end,
mobile level but not raised off the floor.
3. Remove the front cap screws securing the skid rail. Move the pipe wrench 7.5 cm (3 in.) and
frame to the tunnel. Account for a flat washer and again twist the wear strip off the rail. Repeat this
a lock washer. procedure until the wear strip is free of the rail.
4. Remove the support stand; then tip the snow- NOTE: The wear strip can also be driven off the
mobile onto one side using a piece of cardboard to slide rail; however, it is quicker to use a pipe
protect against scratching. Remove the skid frame. wrench.
9-83
AG505D AG536D
CLEANING AND INSPECTING INSTALLING
NOTE: Whenever a part is worn excessively, NOTE: Apply a light coat of grease to the slide
cracked, or damaged in any way, replacement is rail surface to aid in installing a new wear strip. If
necessary. there are any sharp edges on the lower portion of
and compressed air.
! WARNING

AG534D
the wear strip forward into position.
AG529D

AG535D

9-84
End Caps

REMOVING
1. Remove the lock nut, washers, and cap screw

AG508D
gravel.
! WARNING

AG506D
bling.
2. Using a hammer, tap the end cap off the rail.
INSTALLING
1. Position the end cap on the slide rail; then align the
NOTE: Whenever a part is worn excessively, hole in the end cap with the hole in the slide rail.
necessary. 2. Secure with a cap screw, washers, and lock nut.
and wear.
Shock Pads

REMOVING
1. Using a 3/16-in. drill bit drill out the rivets secur-

ing the shock pad to the slide rail. Account for the
retaining brackets.
9
AG507D

wear.
AG476D
9-85
2. Remove the shock pad.
INSPECTING

necessary.
1. Inspect the pad and retaining brackets for damage

or wear.
2. Inspect the rivet holes in the slide rail for damage
or elongation.
INSTALLING AG686D
1. Place the pad and retaining brackets into position 2. Note the locations of the flat washers for assembly
on the slide rail. purposes. The washers are to be installed next to
the idler wheels.
2. Secure the pad assembly with rivets.
AG622D
AG531D

Front Outer necessary.
Idler Wheels 1. Clean the bearing with a clean cloth.

2. Inspect each idler wheel and each plastic hub for
NOTE: The skid frame does not have to be cracks or damage.
REMOVING inspect for binding or roughness.
1. Remove the cap screws and lock nuts securing the 4. If a bearing must be replaced, use this procedure.
front outer idler wheel and the idler wheel mount-
ing block. Account for flat washers and an axle. ! CAUTION
removal.

from the inside of the wheel.
the idler wheel.
AG678D
9-86
AG538D AG686D
D. Install the snap ring making sure the “sharp 2. Place the idler wheel and axle against the mount-
side” is directed away from the bearing. ing block making sure there is a flat washer on
both sides of the idler wheel.
AG539D
AG622D
AG623D
9
AG540D
3. Secure the idler wheel assembly with a cap screw
INSTALLING and a lock nut. Tighten cap screws to 3.2 kg-m
(23 ft-lb).
1. Secure the mounting block on the slide rail with a
cap screw and lock nut. Tighten to 3.2 kg-m
(23 ft-lb).
9-87
NOTE: The large, thick washer must be installed
next to the idler wheel. The small, thin washer
must be installed against the slide rail.
AG618D
Rear Inner AG674D
Idler Wheels CLEANING AND INSPECTING

NOTE: The skid frame does not have to be necessary.
REMOVING
1. Remove the cap screws and lock washers securing or damage.
the rear inner idler wheel and the idler wheel
mounting block. Account for a flat washer and an 3. Rotate the idler wheel bearings (by hand) and
axle. inspect for binding or roughness.
! CAUTION
removal.

AG672D C. Press the new bearing (on its outer race) into
the idler wheel.
AG673D
AG538D
2. Note the locations of the flat washers for assembly
purposes. D. Install the snap ring making sure the “sharp
9-88
AG539D AG674D
AG672D
AG540D
INSTALLING
Rear Upper Idler
1. Secure the mounting block on the slide rail with a
cap screw and lock nut. Tighten to 3.2 kg-m Wheels/Rear Springs
(23 ft-lb).
section).
REMOVING

! WARNING
Care must be taken when removing the spring or
damage or injury could result. 9
AG673D
2. Place the idler wheel and axle into position against

the mounting block making sure there is a flat
washer on the inside of the idler wheel. Tighten to
3.2 kg-m (23 ft-lb).
AG624DA
9-89
2. Mark the offset pivot idler and the idler arm for
assembly purposes.
AG678D

AG675D the spring slide to the rail. Account for a slide
block and washer.
3. Remove the cap screws, washers, and lock nuts
securing the offset pivot idler to the upper idler
wheel; then remove the offset pivot idler assem-
bly.
4. Remove the spacer.
AG679D
AG677D
NOTE: It may be necessary to use the Idler

Wheel Puller Kit (p/n 0644-122) to remove the
wheel.
AG680D
7. Remove the spring and sleeve from the idler arm.
AG461D

securing the front outer idler wheel; then remove
the idler wheel.
AG681D
9-90
NOTE: Use the same procedure for the other E. Install the insert.
side.
INSPECTING

necessary.

or damage.
inspect for binding or roughness. AG540D
4. If a bearing must be replaced, use this procedure. 5. Inspect the spring, spring slide, sleeve, washers,
slide block insert, and shaft area for wear.
! CAUTION 6. Inspect the adjusting cams and arms for cracks.

Do not remove the bearing unless it is absolutely INSTALLING
removal. 1. Slide the sleeve and spring onto the idler arm.
the idler wheel.
AG681D
2. Place the spring slide and slide block (with spring

in slide block) into position on the slide rail.
Secure with a cap screw (coated with red Loctite
#271) and washer. Tighten to 3.2 kg-m (23 ft-lb).
NOTE: Make sure the spring is located above the
AG538D spring slide mounting bolt.

side” is directed away from the bearing. 9
AG680D
AG539D
9-91
AG679D AG545D
3. Install the front outer idler wheel; then secure with 6. Making sure the marks made during disassembly
the cap screw, washer, and lock nut. Tighten to are aligned, install the offset pivot idler to the idler
3.2 kg-m (23 ft-lb). arm and secure with the cap screws, washers, and
lock nuts. Tighten to 2.6 kg-m (19 ft-lb).
AG678D
AG675D
4. Install the spacer.
7. Place the short spring leg onto the adjusting cam
using the rear suspension spring tool.
AG677D
5. Install the rear upper idler wheel on the idler arm. AG624DA
9-92
Rear Axle and
Idler Wheels

section).
DISASSEMBLING
1. Remove the insert from the idler wheel; then

remove the cap screw and large flat washer secur- AG628D
ing the outer rear idler wheel. Remove the outer
idler wheel from the shaft. 3. Carefully slide the shaft out from the inner idler
wheels and note the position of the spacers and
washers.
AG626D
NOTE: The large flat side of the wheel insert is

AG805D
positioned next to the inner plastic adjuster bush-
ing. The idler wheel must be installed with the CLEANING AND INSPECTING
wheel insert properly positioned.
2. Loosen the track adjusting bolts. Slide the outer cracked, or damaged in any way, replacement is
adjuster bushings off the axle. necessary.

2. Inspect all idler wheel inserts (inner and outer) for
any cracks.
for cracks and poor bonding.
4. Inspect the plastic insert of each idler wheel for
cracks.
5. Inspect the shaft for wear and damaged threads.
9
AG627D
6. Inspect all idler wheel bearings. Turn each bearing
(by hand) and if any roughness or binding is noted,
! CAUTION
removal.
9-93
1. In order from the right-hand side, slide the axle
C. Press the new bearing (on its outer race) into through the slide rail axle bracket; then place a flat
the idler wheel. washer, short spacer with bushings, inner idler
wheel with insert, long spacer with bushings, and
flat washer on the axle. Slide the axle through the
opposite slide rail axle bracket. Place the plastic
adjuster bushings on the axle (on the outside of
each axle bracket). Make sure the hole in the
adjuster bushing is aligned directly with the
adjusting bolt.
AG538D

AG805D
AG539D
AG551D
2. Place the outer idler wheels on the axle (with the

large flat of the insert directed inward) and secure
with two cap screws (coated with red Loctite
#271) and large flat washers. Tighten cap screws
to 3.2 kg-m (23 ft-lb); then install the inserts.
AG540D
AG626D
3. Adjust track alignment (see Track Alignment in

this sub-section).
9-94
4. Adjust track tension deflection (see Track Tension
in this sub-section).
Idler Arm

section).
DISASSEMBLING
AG553D
1. Remove the rear upper idler wheels and springs NOTE: Mark the hole that the upper shock links
(see Rear Upper Idler Wheels/Rear Springs in this are mounted in for assembly purposes.
sub-section).
AG554D
AG545D
2. Remove the cap screw and lock nut securing the upper shock links to the idler arm. Account for a
upper shock eyelet to the idler arm. Account for a lock nut, spacer, flat washers, and axle links.
spacer, lock nut, and bushings.
9
AG682D
AG467D
AG556D
9-95
NOTE: Note the mounting hole from which the
rear arm was removed for assembly purposes.
AG477D
AG683D

rear arm to the slide rail. Account for the serrated
axles and axle tube.
AG561D

necessary.
AG558D
2. Inspect each idler wheel for cracks or damage.
4. Inspect all welds and the tubing of the upper arm
for cracks or unusual bends.
5. Inspect the two adjusting cams for damage.
check for binding or roughness.
AG560D 7. If a bearing must be replaced, use this procedure.
rear arm to the idler arm. Account for the alumi- ! CAUTION
num axle and bushing assemblies. Do not remove the bearing unless it is absolutely
removal.

the idler wheel.
9-96
1. Install the rear arm onto the idler arm with an alu-
minum axle, bushing assemblies, cap screw, and a
AG538D

AG477D
NOTE: Install the rear arm assembly into the

appropriate mounting hole as noted during disas-
sembly.
AG539D
AG683D
2. Place the rear arm assembly into position (with the

brace facing towards the front). Secure with a cap
screw and lock nut. Tighten to 3.2 kg-m (23 ft-lb).
9
AG540D
ASSEMBLING
AG558D

insert the cap screw with washer through the eye-
lets. Secure with a cap screw, washer, and lock
AG562D nut. Tighten to 3.2 kg-m (23 ft-lb).
9-97
6. Install the rear upper idler wheels, rear springs,
and offset pivot idler (see Rear Upper Idler
Wheels/Rear Springs in this sub-section).
Front Arm/Front Shock

Absorber/Front Inner
Idler Wheels
AG556D
section), and the rear springs must be removed
from the adjusting cams.
REMOVING
1. Remove the lower cap screws and lock nuts secur-

ing the limiter straps to the rail support. Account
for flat washers.
AG682D
4. Place the upper shock eyelet with bushings

between the idler arm brackets making sure the
spacer is properly positioned between the brack-
ets. Secure with a cap screw and lock nut. Tighten
to 3.2 kg-m (23 ft-lb).
AG632D

upper front shock absorber eyelet to the front arm.
Pull the shock eyelet free of the bracket. Account
for a serrated axle.
AG467D

cap screw as the shock eyelet must be free to
pivot.
5. Grease the idler arm and rear arm grease fittings

with a low-temperature grease.
AG582D

front arm to the front arm mounting brackets.
9-98
AG633D AG688D
4. Remove the front arm and account for an axle tube 6. Remove the cap screw securing the front shock
and serrated axles. mounting bracket to the rear shock pivot. Account
for an axle.
AG685D
AG689D
5. Remove the cap screw securing the front inner
idler wheels to the slide rails. Account for one
small washer, two spacers, four large flat washers,
a lock washer, and a lock nut.
AG690D
7. Remove the cap screw securing the front shock to

the mounting bracket.
9
AG687D
AG691D
9-99
INSPECTING 2. Secure the front shock mounting bracket and axle
assembly to the rear shock pivot.
necessary.

unusual bends.
2. Closely inspect all tubing for cracks or unusual
bends.
3. Inspect the bearings, bushings, and front arm spac-
ers for wear or damage.
4. Inspect the two rear track guide bumpers. If worn,
drill out the rivets securing the bumpers to the arm
AG690D
and replace with new bumpers.
AG689D
AG486D
3. Slide the front idler wheel axle through the slide
5. Inspect the shock absorber for any signs of oil rail; then install a spacer, large washer, idler
leakage especially at the point where the shock wheel, large washer, rear shock pivot, large
shaft enters the shock body. washer, idler wheel, large washer, and a spacer.
end) for any cracks, signs of separation, or for
unthreading.
7. Inspect the shock absorber for damage.
INSTALLING
1. Secure the shock eyelet to the front shock

mounting bracket. Tighten to 3.2 kg-m (23 ft-lb).
AG688D
4. Secure the front inner idler wheel assembly with a

cap screw, flat washer, lock washer, and a lock
5. Position the front arm with spacers, an axle tube,
and serrated axles to the mounting brackets.
Secure with the cap screw and lock nut. Tighten to
4.2 kg-m (30 ft-lb).
AG691D
9-100
Rear Shock Absorber
and Shock Links

section).
DISASSEMBLING

AG685D
6. Position the upper shock eyelet and serrated axle

in the front arm. Secure with a cap screw and lock
AG624DA
! WARNING
Care must be taken when removing the spring from
AG582D
the adjusting cam or damage or injury could result.
cap screw as the shock eyelet must be free to 2. Remove the cap screw securing the lower shock
pivot. eyelet and shock links. Account for shock sleeves,
axle links, and a lock nut.
7. Secure the limiter straps with cap screws, washers,
9
AG692D
AG632D
NOTE: Lay components out in order as they are
removed.

shock absorber at the upper eyelet and remove the
shock absorber. Account for a sleeve and bush-
ings.
9-101
the idler wheel.
AG634D
4. Mark the hole that the upper shock links are

mounted in for assembly purposes; then remove AG538D
the cap screw and lock nut securing the shock
links to the upper arm bracket. Account for all D. Install the snap ring making sure the “sharp
mounting hardware. side” is directed away from the bearing.

necessary.
1. Clean shock pivot and idler wheel axle in part-

cleaning solvent. Dry with compressed air.
! WARNING
AG539D
2. Clean the idler wheel bearings with a clean cloth.
3. Closely inspect the idler wheel axle for wear,
bends, or damaged threads at either end. 7. Inspect the shock absorber for any signs of oil
4. Inspect the idler wheels for signs of cracking, shaft enters the shock body.
wear, or outer rubber separation from plastic
wheel. 8. Inspect the rubber shock bushings located in the
shock absorber eyelets for cracks or deterioration.
inspect for any signs of binding or roughness. 9. Inspect the shock absorber eyelet welds (at each
! CAUTION links for cracks or signs of separation. Either weld
the eyelet or replace the shock link.
necessary. The bearing will be damaged during 11. Inspect the axle surfaces for any signs of corro-
removal. sion. If corrosion is found, lightly buff the surface
A. Remove the wheel insert and the snap ring. apply a light coat of grease.
9-102
ASSEMBLING
1. Secure the shock eyelet to the idler arm with Slide Rails
bushings, sleeve, lock nut, and a cap screw.
NOTE: The skid frame must be removed for this pro-
cedure (see Removing Skid Frame in this sub-section).
REMOVING
NOTE: When it is necessary to replace one or

will then hold the crossbraces, axles, and brackets
in their correct assembly order. Always mark the
mounting hole locations during disassembly to
speed up the assembly process and to prevent any
damage. This method is much quicker than to
completely disassemble the entire skid frame. To
replace either rail, use the following procedure.
AG634D
1. Remove the end cap from the slide rail. Account
2. Secure the rear shock links and the lower shock for a cap screw, lock nut, and two flat washers.
absorber eyelet to the shock pivot bracket by plac-
ing the bushings and shock sleeve into the shock
eyelet; then install the axle links into the rear
shock links. Secure the assembly by installing a
cap screw and thin flat washer through the shock
link assembly, thick flat washer, shock pivot
bracket and shock eyelet assembly, thick flat
washer, shock link assembly, and a thin flat
washer. Secure the assembly with a lock nut.
AG506D

AG692D
9
insert the cap screw with washer through the eye- AG509D
lets. Secure with a cap screw, washer, and lock
nut. Tighten to 3.2 kg-m (23 ft-lb). 3. Using a pipe wrench and starting from either end,
slide rail; however, it is quicker to use the pipe
wrench.
9-103
6. Remove the cap screw and lock washer securing
the front inner idler wheel.
AG510D
4. Remove the cap screws securing the crossbraces to

the slide rail. AG687D
7. Remove the short spring leg from the adjusting

cam.
AG511D

front outer idler wheel and the idler wheel mount- AG624DA
ing block. Account for flat washers and an axle.
the spring slide to the rail. Account for a spacer
and the slide block.
AG678D
AG679D
AG686D
9-104
AG680D AG693D
9. Mark the mounting position of the front arm 12. Remove the cap screws and lock nut securing the
mounting bracket. rear inner idler wheels and mounting block.
AG637D AG672D
10. Remove the cap screws securing the front arm

mounting bracket. Account for lock nuts.
AG673D
9
13. Mark the mounting position of the rear arm limiter
AG638D and rear arm.
11. Mark the mounting position of the rear inner idler

wheels.
AG683D
9-105
14. Remove the cap screw, lock washer, and lock nut
from the rear arm limiter shaft.
AG628D
NOTE: The adjusting bolt may have to be loos-

AG639D ened to remove the adjuster bushing.
rear arm to the rail.
AG525D
NOTE: At this point, the slide rail should be free

AG694D of the skid frame components and can be
removed.
16. Remove the idler wheel insert; then remove the
cap screw and flat washer securing the rear idler 17. Remove the cap screws and lock nuts securing the
wheel. Remove the idler wheel; then remove the track adjuster bracket.
adjuster bushing.
AG527D
AG626D
18. Using a drill and a 3/16-in. drill bit, drill out the
rivets and remove the shock pads. Note the shock
pad location for installation. Account for the
retaining brackets.
9-106
AG528D 0727-726
INSPECTING INSTALLING
NOTE: Whenever a part is worn excessively, 1. Install the shock pads and retaining brackets; then
cracked, or damaged in any way, replacement is secure with rivets.
necessary.
AG531D
2. Secure the track adjuster bracket with the cap

AG529D screws and lock nuts. Tighten to 1.5 kg-m
(11 ft-lb).
9
AG527D
3. Place the rail into position; then install the adjuster

bushing and rear idler wheel. Secure with a cap
AG530D screw (coated with red Loctite #271) and flat
washer. Tighten to 3.2 kg-m (23 ft-lb); then install
the wheel insert.
9-107
AG628D AG673D
AG626D AG693D
4. Install the rear arm limiter cap screw (coated with

red Loctite #271) in the appropriate hole (as noted
during disassembly) and tighten to 3.2 kg-m
(23 ft-lb).
AG672D
6. Secure the front arm mounting bracket with the

cap screws (coated with red Loctite #271) and lock
AG639D
5. Install the rear inner idler wheels in the appropri-

ate hole as noted during disassembly and secure
with cap screws (coated with red Loctite #271)
AG638D
9-108
7. Place the spring into the slide blocks; then place
the spring slide and slide block assembly into posi-
tion on the slide rail. Secure with a cap screw
(coated with red Loctite #271) and washer.
AG686D
10. Secure the outer idler wheel to the mounting block

with a cap screw, flat washers, idler wheel, axle,
and a lock nut. Tighten to 3.2 kg-m (23 ft-lb).
AG680D
AG678D
AG679D 11. Secure the crossbraces with cap screws (coated

with red Loctite #271). Tighten to 1.5 kg-m
8. Secure the front inner idler wheel axle with a cap (11 ft-lb).
screw (coated with green Loctite #609) and lock
washer. Tighten to 3.2 kg-m (23 ft-lb).
9
AG511D
AG687D 12. Install the rear arm in the appropriate hole as noted
during disassembly; then secure with a cap screw
9. Secure the outer idler wheel mounting block with (coated with red Loctite #271) and lock nut.
the cap screw and lock nut. Tighten to 3.2 kg-m Tighten to 3.2 kg-m (23 ft-lb).
(23 ft-lb).
9-109
14. Secure the end cap onto the slide rail using a cap
screw, flat washers, and a lock nut. Tighten to
1.1 kg-m (8 ft-lb).
AG694D
NOTE: Apply a light coat of grease to the slide

rail surface to aid in installing a new wear strip. If
there are any sharp edges on the lower portion of AG506D
15. Install the short spring leg onto the adjusting cam.
AG534D
AG516DA
then using a block of wood and a hammer, drive 16. Adjust suspension.
the wear strip forward into position. Secure with a
machine screw and lock nut. Tighten to 1.1 kg-m 17. After the skid frame has been installed, adjust
(8 ft-lb). track tension deflection (see Track Tension in this
sub-section) and track alignment (see Track Align-
ment in this sub-section).
AG509D
9-110

one side. Deactivate all switches.
1. Tip the snowmobile on its side.
3. Position the front of the skid frame into the tunnel
and align the front arm with the appropriate 2. Hook a spring scale around a track clip at mid-
mounting hole in the tunnel. Insert the cap screw span; then pull the track down with the scale to 9
with washers through the tunnel mounting hole kg (20 lb) and measure the distance between the
and through the front arm. DO NOT TIGHTEN bottom of the wear strip and the inside surface of
AT THIS TIME. Repeat this procedure on the the track. Track deflection must be within specifi-
other side. cations.
NOTE: To aid in centering the front arm with the Rear Suspension Setup After Break-In
hole in the tunnel, position the skid frame and Style Tension Tension
FasTrack w/o Torque 19-25 mm 25-32 mm
4. Elevate the rear of the skid frame and the track
into position in the tunnel. FasTrack w/Torque 32-38 mm 38-44 mm
Sensing Link 1 1/4-1 1/2 in.) (1 1/2-1 3/4 in.)
(121 in. Track)
5. Align the offset pivot idler arm assembly with the
appropriate hole in the tunnel. Secure the offset FasTrack w/Torque 38-44 mm 50.8-57.2 mm
Sensing Link (1 1/2-1 3/4 in.) (2-2 1/4 in.)
pivot idler arm assembly with a cap screw (coated (136 in. Track)
with red Loctite #271), lock washer, and flat
washer. DO NOT TIGHTEN AT THIS TIME.
NOTE: Do not install the short legs of the rear
springs onto the adjusting cams at this time.
6. At this time, tighten all four skid frame mounting

cap screws to 3.2 kg-m (23 ft-lb).
311), install the short legs of the rear springs onto
the adjusting cams making sure the cams are in the
same adjustment positions.
8. Tighten the two track tension adjusting bolt evenly
until track deflection is within specifications; then 729-429A
lock the jam nuts to secure the adjustment.
NOTE: If the track is new, it will stretch slightly
9. Check track tension deflection and alignment; and take a “set” within the first 300 to 500 miles of
9
adjust if necessary (see Track Tension and Track operation.
Alignment in this sub-section).
ADJUSTING DEFLECTION
1. Place the snowmobile up on a shielded safety

stand. Check to make sure the track is 2-3 in. off
the floor.
2. If the measurement is not as specified, loosen the
jam nuts of the adjusting bolts.
9-111
Track Alignment

idler wheels are equidistant from the inner drive
lugs on the inside surface of the track.
CHECKING
1. Using a shielded safety stand, raise the rear of the

free to rotate.
0727-456
3. If the measurement obtained in step 2 is more than ! WARNING

specified, tighten the adjusting bolts. If the mea- The tips of the skis must be positioned against a
surement obtained is less than specified, loosen wall or similar object for safety. Keep hands, feet,
the adjusting bolts. When the measurement is and clothing away from moving components.
within specification range, lock the adjustment by
bottoming the jam nuts against the axle housings. 2. Start the engine and accelerate slightly. Use only
enough throttle to rotate the track several revolu-
NOTE: Vigorously push the underside of the tions. SHUT THE ENGINE OFF.
track up and down. Track must not hit the top of
the tunnel or slap the skid frame. NOTE: Allow the track to coast to a stop. Do not
apply the brake because it could produce inaccu-
4. After correct track tension is obtained, check track rate alignment conditions.
alignment (see Track Alignment in this sub-sec-
tion). 3. When the track stops rotating, check the relation-
NOTE: Track tension and track alignment are drive lugs. If the distance from the idler wheels to
interrelated; always check both even if only one the inner drive lugs is the same on both sides, no
adjustment seems necessary. Always establish adjustment is necessary.
correct track tension before checking and/or
adjusting alignment.
725-070A
4. On the side of the track, which has the inner drive

lugs closer to the rear idler wheel, loosen the
adjusting bolt jam nut; then rotate the adjusting
bolt clockwise 1-1 1/2 turns.
is obtained.
jam nut against the axle housing.
NOTE: Make sure correct track tension is main-
tained after adjusting track alignment.
NOTE: Field test the track under actual condi-

tions and after the field test, check track alignment
and track tension; adjust as necessary.
9-112
Repair Procedure 4 - End Cap
This Track/Rear Suspension sub-section (Repair Pro- removed for this procedure.
completed individually and efficiently. Each sub-sec- REMOVING
Cleaning and Inspecting, Assembling, and Installing 1. Remove the lock nut, washer, and cap screw
procedures. Some components may vary from model securing the end cap.
sound judgment when removing and installing compo-
nents.
tions.
Removing
Skid Frame AG297D
2. Using a hammer, tap the end cap off the rail.

NOTE: Many service procedures can be per-
formed without removing the skid frame. Closely CLEANING AND INSPECTING
observe the note introducing each subsequent
sub-section for this important information. NOTE: Whenever a part is worn excessively,
1. Loosen the jam nuts and the two track tension necessary.
adjusting bolts.
and wear.
wear.
gravel.
! WARNING
9
pressed air.
0727-456
2. Place a support stand under the rear bumper; then damaged threads. Use a new lock nut when assem-
remove the four cap screws securing the skid bling.
frame to the tunnel.
INSTALLING
NOTE: The support stand should hold the snow-
mobile level and not raised off the floor. 1. Position the end cap on the slide rail; then align the
hole in the end cap with the hole in the slide rail.
3. Remove the support stand; then tip the snowmo-
bile onto one side using a piece of cardboard to 2. Secure with a cap screw and new lock nut. Tighten
protect against scratching. Remove the skid frame. to 1.1 kg-m (8 ft-lb).
9-113
Wear Strip hook the edge of the wear strip with the pipe
NOTE: The skid frame should be removed for again twist the wear strip off the rail. Repeat this
this procedure. procedure until the wear strip is free of the rail.
NOTE: Prior to removing the wear strips, inspect NOTE: The wear strip can also be driven off the
each wear strip for wear. The wear strip must be
10.7 mm (0.42 in.) thick or thicker. If the wear strip wrench.
measurement is less than specified, replacement
of both wear strips is necessary. CLEANING AND INSPECTING

necessary.

and compressed air.
! WARNING
Always wear safety glasses while using com-
pressed air.

0727-726
NOTE: It is possible to remove and install a wear unusual bends. Place the straightedge along the
remove the machine screw and lock nut securing bottom surface of the slide rail. If the rail is found
the wear strip at the front of the slide rail; then to be bent, it must be replaced.
track and drive it rearward off the slide rail. Apply 4. Place the straightedge along the side of the slide
low-temperature grease to the new wear strip and rail. If rail is found to be bent, it must be replaced.
slide rail; then align the wear strip with openings
(windows) in the track and drive it forward onto the INSTALLING
nut tightened to 1.1 kg-m (8 ft-lb). NOTE: Apply a light coat of grease to the slide
rail surface to aid in installing new wear strips.
the wear strip to the front of the slide rail. 1. Starting from the back, start the wear strip onto the
rail; then using a block of wood and a hammer,
drive the wear strip forward into position.
AG298D
AG070
2. Secure with a machine screw (coated with red

Loctite #271) and lock nut. Tighten to 1.1 kg-m
(8 ft-lb).
9-114
ASSEMBLING
Rear Spring 1. Slide the spring and plastic sleeve onto the rear
arm.
NOTE: The skid frame must be removed for this 2. Position the long spring leg into the spring slide.
procedure (see Removing Skid Frame in this sub- Make sure the spring is located above the spring
section)
slide mounting bolt.
DISASSEMBLING
1. Remove the set screw from the lock collar secur-

ing the upper idler wheel to the rear arm; then
remove the lock collar and idler wheel.
0727-896
3. Install the idler wheel with the snap ring facing

inward on the rear arm and secure with a lock col-
lar and set screw.
AG307D
4. Repeat steps 1-3 for the other rear spring.
NOTE: It may be necessary to use the Idler NOTE: When installing the opposite side spring,
Wheel Puller Kit (p/n 0644-122). make sure the adjusting cam (spring adjuster
block) is set in the same position.
2. Slide the spring and the plastic sleeve off the rear
arm.
Rear Arm
NOTE: The skid frame must be removed for this pro-

cedure (see Removing Skid Frame in this sub-section).
DISASSEMBLING
1. Remove the set screw from the lock collar secur-

ing the upper idler wheel to the rear arm; then
remove lock collar and idler wheel.
AG308D
9
3. Repeat steps 1-2 for the other rear spring.
INSPECTING

necessary.
1. Inspect the spring slide, washers, and shaft area for

wear.
2. Inspect the spring adjusting cams (spring adjuster AG625D
blocks) for cracks.
NOTE: If an idler wheel is tight on the rear arm,
use the Idler Wheel Puller Kit (p/n 0644-122) to
remove the idler wheel.
9-115
2. Remove the cap screw and lock nut securing the 6. Remove the lock nut, washer, and cap screw
upper shock eyelet to the rear arm. securing the limiter strap to the rear arm. Remove
the limiter strap.
7. Remove the lock nut and cap screw securing the
lower arm to the slide rails. Twist the arm forward
and from between the slide rails.
AG309

upper shock link to the rear arm.
AG083
AG310
4. Remove the cap screw and large flat washer secur- AG084
ing the center pivot idler wheels; then remove the
wheels. CLEANING AND INSPECTING

necessary.

or damage.
AG600
5. Remove the lock nut and cap screw securing the 5. Inspect all welds and the tubing of the upper arm
rear arm at its center pivot point. Account for two for cracks or unusual bends.
axles and a center tube. 6. Inspect the two adjusting cams (spring adjuster
blocks) for damage.
9-116
ASSEMBLING 5. Place the limiter strap into position around the
upper and lower arm tubes and secure with cap
1. Apply grease to the bushings and axles; then place screw, washers, and lock nut. Tighten to 1.1 kg-m
the axle tube and the two axles into position in the (8 ft-lb).
lower arm.
6. Position the shock links into the upper hole of the
rear arm bracket. Place a spacer between the cen-
ter of the brackets and push the cap screw through
the shock link, spacer, bracket, and remaining
shock link. Secure with a washer and lock nut.
AG084
2. Place the lower rear arm into position between the

slide rails; then secure with a cap screw (coated
with red Loctite #271) and lock nut. Tighten to
3.2 kg-m (23 ft-lb).
AG310
7. Place the shock eyelet between the upper idler arm

brackets and secure with a cap screw and lock nut.
NOTE: Do not over-tighten the shock cap screws
as the shock eyelets must be free to pivot.
8. Grease the pivot tubes of the upper and lower

arms.
Front Arm
AG083
3. Place the center pivot idler wheels into position

and secure each with a large flat washer and cap
screw. Tighten to 3.2 kg-m (23 ft-lb). NOTE: The skid frame must be removed for this
procedure.
DISASSEMBLING
1. Remove the cap screw securing the upper shock

absorber eyelet to the front arm. Pull the shock
eyelet free of the bracket.
9
AG600
4. Position the upper arm with axles into the lower

arm; then secure with a cap screw and lock nut.
AG303
9-117
2. Remove the upper cap screw, washer, and lock nut INSPECTING
securing each limiter strap to the front arm.
necessary.

unusual bends.
2. Inspect all tubing (square and round) for cracks or
unusual bends.
3. Inspect the bushings and axles for wear or dam-
age.
4. Inspect the track bumpers (upper and lower). If
worn, drill out the rivets securing the bumpers to
AG300
the arm and replace with new bumpers.
3. Remove the cap screws and washers securing the
ASSEMBLING
outer idler wheels; then slide the idler wheels from
the shaft. 1. Apply a light coat of grease to the axles and bush-
ing areas. Position the front arm into the mounting
brackets (upper holes) and secure with two cap
screws and lock nuts. Position the lock nuts to the
inside of the brackets. Tighten to 4.2 kg-m
(30 ft-lb).
AG322D

the front arm to the slide rail brackets.
AG305
AG304
5. Remove the front arm and account for the axles.

AG304
2. Wrap the limiter straps around the front arm and

align the holes. Secure each strap with a cap
screw, washers (one on each side of the strap), and
9-118
Front Idler Wheels
and Bracket, Front
Shock Bracket, and
Front Arm Bracket

procedure.
DISASSEMBLING
AG300
1. Remove the lock nut, washer, and cap screw
3. Install the outer idler wheels on the idler wheel securing the end cap; then remove the end cap.
shaft and secure with flat washers and cap screws
(coated with red Loctite #271). Tighten to
2.4 kg-m (17 ft-lb).
AG297
2. Remove the lock nut securing the wear strip to the

slide rail.
AG322D
4. Position the shock eyelet with bushing into the

bracket and secure with a cap screw and lock nut.
9
AG298
3. Remove the four cap screws securing both front

crossbraces; then remove the crossbraces.
AG303

as the shock eyelets must be free to pivot.
9-119
front arm to the front arm bracket.
AG301
4. Remove the push nut and pin securing the rubber

shock pad and remove the pad. AG304
5. Remove the cap screws and flat washers securing 11. Remove the cap screws and lock nuts securing the
the front idler wheels to the front arm bracket. front arm bracket to the slide rail; then slide the
front arm bracket forward off the slide rail.
lower shock eyelet to the front shock bracket. INSPECTING
Swing the shock forward and out of the bracket.
Account for a bushing. NOTE: Whenever a part is worn excessively,
necessary.
1. Inspect all weldments for cracks or unusual bends.

2. Inspect all tubing (square and round) for cracks or
unusual bends.
3. Inspect the bushings and axles for wear or dam-
age.
4. Inspect the track bumpers (upper and lower). If
worn, remove the rivets securing the bumpers to
the arm and replace with new bumpers.
AG317
ASSEMBLING
7. Slide the idler wheel axle out of the front arm 1. Slide the front arm bracket on the slide rail. Install
brackets and idler wheels; then remove the idler the cap screws (coated with red Loctite #271) and
wheels. Account for spacers. lock nuts. Tighten to 2.4 kg-m (17 ft-lb).
8. Remove the cap screw and flat washer securing 2. Position the front arm into the front arm bracket.
the outer idler wheel. Remove the outer idler Install the cap screw and lock nut. Tighten to
wheel and account for two spacer washers. 4.2 kg-m (30 ft-lb).
AG321
AG304
9. Slide the inner axles out of the front arm brackets;

then remove the front shock bracket.
9-120
3. Align the front shock bracket between the front
arm brackets; then slide the inner axle through the
brackets. Install the spacers and outer idler wheels
on the inner axle and secure with flat washer and
cap screw (coated with red Loctite #271). Tighten
to 2.4 kg-m (17 ft-lb).
AG301
NOTE: Be sure to place the forward crossbrace

through the limiter straps.
9. Install the lock nut (threads coated with red Loctite

#271) securing the wear strip to the slide rail.
AG322D Tighten to 1.1 kg-m (8 ft-lb).
4. Place the front idler wheels and spacers into posi-
tion and slide the idler wheel axle through the idler
wheels and front shock bracket.
5. Secure the front idler wheels to the front arm
bracket with flat washers and cap screws. Tighten
to 3.2 kg-m (23 ft-lb).
6. Install the bushing into the lower shock eyelet and
place the lower shock eyelet into the front shock
bracket. Install the cap screw and lock nut. Tighten
to 3.2 kg-m (23 ft-lb).
AG298D
10. Place the end cap onto the rail and secure with cap
screw, washers, and lock nut. Tighten to 1.1 kg-m
(8 ft-lb).
AG317
7. Install the rubber shock pad on the slide rail and

9
secure with push pin and a new push nut.
8. Place both front crossbraces between the slide rails
and secure with four cap screws (coated with red AG297
Loctite #271). Tighten to 2.4 kg-m (17 ft-lb).
9-121
ASSEMBLING
Front Arm Shock 1. Apply a light coat of grease to both bushings and
Absorber install the bushings into the shock absorber eye-
lets.

procedure.
DISASSEMBLING

upper shock absorber eyelet to the front arm.
Account for a bushing.
AG318
2. Position the lower shock absorber eyelet into the

crossbrace bracket and secure with a cap screw
and lock nut. Tighten to 3.2 kg-m (23 ft-lb).
3. Position the upper shock absorber eyelet into the
front arm bracket and secure with a cap screw
(coated with red Loctite #271) and lock nut.
AG306 Tighten to 3.2 kg-m (23 ft-lb).
2. Remove the cap screw and lock nut securing the NOTE: Do not over-tighten the shock cap screws
lower shock eyelet to the front shock bracket. as the shock eyelets must be free to pivot.
Remove the shock absorber and account for a
bushing.
Rear Arm
Shock Absorber
And Shock Links

procedure.
DISASSEMBLING

lower shock absorber eyelet and shock links to the
AG317
pivot tube bracket. Account for the two shock link
3. Slide the rubber shock boot off the shock absorber. axles.
INSPECTING

necessary.

shaft enters the shock body.
AG314
9-122
2. Remove the cap screw and lock nut securing the 3. Inspect the shock absorber eyelet welds (at each
upper shock absorber eyelet to the rear arm end) for any cracks or signs of separation.
bracket. Remove the shock absorber.
links for cracks or signs of separation. Either weld
the eyelet or replace the shock link assembly.
5. Inspect the axle surfaces for any signs of corro-
sion. If corrosion is found, lightly buff the surface
apply a light coat of grease.
ASSEMBLING
1. Apply a thin coat of grease to the upper shock

absorber eyelet. Position the eyelet into the upper
arm bracket and secure with a cap screw and lock
AG309

shock links to the upper arm bracket. Account for
the spacer, two shock link axles, and washers.
AG309
2. Apply a thin coat of grease to the outer surface of

the shock link axles and slide the axles into the
AG310
shock link eyelets.
3. Place the shock link eyelets on each side of the
upper arm bracket and place a spacer into the
bracket. Secure the shock links and spacer to the
upper arm bracket using a cap screw, washers (on
the outside of each eyelet), and lock nut. Tighten
lock nut to 3.2 kg-m (23 ft-lb).
NOTE: When installing shock links, the longest
side of the shock eyelet must be positioned toward
the shock absorber.
9
AG316
INSPECTING

necessary.

shaft enter the shock body.
AG313
2. Inspect the rubber shock bushings located in the
shock absorber eyelets for cracks or deterioration.
9-123
4. Place the lower shock absorber eyelet into the rear CLEANING AND INSPECTING
pivot bracket; then place the lower shock link eye-
let with bushings into position and secure the NOTE: Whenever a part is worn excessively,
lower shock link eyelet and the shock absorber to cracked, or damaged in any way, replacement is
the rear pivot bracket with a cap screw, two wash- necessary.
ers, and lock nut. Tighten to 3.2 kg-m (23 ft-lb).
1. Clean all shock pivot components.
as the shock eyelets must be free to pivot. 2. Inspect all axles for wear or damage.
3. Inspect idler wheel and hub for cracks or damage.
4. Inspect rear pivot for damage.
ASSEMBLING
1. Align the rear shock pivot with the spacers, idler

wheels, and washers installed between the pivot
arm brackets; then slide the pivot axle through the
brackets.
2. Place the lower shock absorber eyelet into the rear
pivot bracket; then place the lower shock link eye-
lets with bushings into position and secure the
AG314 lower shock link eyelets and the shock absorber to
the rear pivot bracket with a cap screw, two wash-
ers, and lock nut. Tighten to 3.2 kg-m (23 ft-lb).
Rear Shock Pivot as the shock eyelets must be free to pivot.

procedure.
Center Inner
DISASSEMBLING
Idler Wheels
lower shock absorber eyelet and shock links to the
pivot tube bracket. Account for the two shock link NOTE: The skid frame does not have to be
axles. removed for this procedure.
REMOVING
1. Remove the cap screws and flat washers securing

the idler wheels and spring slides to the center
idler wheel brackets.
AG314

the pivot arm axle to the pivot arm mounting
bracket.
3. Slide the inner axle out of the pivot arm bracket far AG403
enough to remove the rear shock pivot and account
for a spacer axle. 2. Slide the inner axle out of the center idler wheel
brackets and remove the idler wheels. Account for
two spacer axles and six washers.
9-124
INSPECTING
NOTE: Whenever a part is worn excessively, Slide Rail

necessary.
1. Inspect each idler wheel and plastic hub for cracks procedure.
or damage.
REMOVING
inspect for binding or roughness. NOTE: When it is necessary to replace one or
INSTALLING will then hold the crossbraces and brackets in
their correct assembly order. This method is much
1. Position the idler wheels with spacers and spacer quicker than to completely disassemble the entire
washers (one on each side of idler wheel) between skid frame.
the center idler wheel brackets.
2. Slide the inner axle through the idler wheel brack- securing the end cap to the slide rail. Remove the
ets, idler wheels, spacers, and spacer washers. end cap from the slide rail.
3. Place the spring slides onto the springs and idler
wheel brackets; then secure with two flat washers
and cap screws (coated with red Loctite #271).
AG297D
2. Remove the four cap screws securing both front

crossbraces between the slide rails; then remove
the crossbraces.
AG403
9
AG301
3. Remove the push nuts and pins securing the rubber

shock pads; then remove the shock pads.
the outer idler wheel to the front arm bracket.
9-125
AG322D AG600
5. Remove the three cap screws and lock nuts secur- 8. Remove the two cap screws and lock nuts securing
ing the front arm bracket to the slide rail. the auxiliary wheel bracket.
9. Remove the cap screw, lock nut, and two washers
securing the spring block.
10. Remove the long cap screw securing the lower
rear arm assembly to the slide rails.
AG323

the center inner idler wheel bracket to the slide
rail.
AG332D
11. Remove two cap screws securing each of the artic-

ulating frame brackets; then remove the articulat-
ing skid frame. Account for spacers.
AG390
7. Remove the cap screws and large flat washers

securing the center pivot idler wheels; then
remove the idler wheels.
AG611D
12. Remove the cap screw and nut securing the spring
tension block to the slide rail. Account for the
washers.
13. With all bracket hardware removed, pull the slide
rail slowly forward and out of all brackets.
9-126
INSPECTING 6. Align the auxiliary wheel bracket, center idler
wheel bracket, front arm bracket, and front idler
NOTE: Whenever a part is worn excessively, wheel bracket with the appropriate holes in the
cracked, or damaged in any way, replacement is skid frame. Secure each with cap screws and lock
necessary. nuts. Tighten to 2.4 kg-m (17 ft-lb).
1. Inspect the slide rail for cracks or unusual bends. 7. Install the outer idler wheel on the front arm
bracket. Secure with a cap screw (coated with red
2. Inspect the wear strip for wear. The wear strip Loctite #271) and lock nut. Tighten to 2.4 kg-m
must be 10.7 mm (0.42 in.) thick or thicker. If the (17 ft-lb).
AG322D
0727-726 8. Place the shock pads into position and secure with
pins and push nuts.
INSTALLING
9. Install both front crossbraces between the slide
1. Starting in front, place the back end of the slide rails. Secure with four cap screws (coated with red
rail into the first bracket and slowly work it back Loctite #271). Tighten to 2.4 kg-m (17 ft-lb).
through all brackets. Install the cap screws and
lock nuts securing the slide rail to the brackets. NOTE: Be sure to place the forward crossbrace
Tighten all slide rail hardware to the recom- tube through the limiter straps.
mended torque specifications.
2. Place the spring tension block into position on the
slide rail and secure with a cap screw, two wash-
ers, and a lock nut. Tighten securely ensuring free
movement of the spring tension block.
3. Place the articulating skid frame into position,
install spacers, and secure with four cap screws
4. Secure the lower rear arm assembly with the long
cap screw, lock nut (threads coated with red Loc-
tite #271), and washers. Tighten to 3.2 kg-m
(23 ft-lb).
AG301 9
5. Place the center pivot idler wheels into position 10. Place the end cap onto the rail and secure with the
and secure each with a large flat washer and cap cap screw, washer, and lock nut. Tighten to
screw. Tighten to 3.2 kg-m (23 ft-lb). 1.1 kg-m (8 ft-lb).
9-127

one side. Turn all switches to the OFF position.
Slide the inner axles through the upper and rear 1. Tip the snowmobile on its side.
arms of the skid frame.
2. Hook a spring scale around a track clip at mid-
NOTE: The proper front arm tunnel mounting span; then pull the track down with the scale to 9
hole to use will depend on which position the front kg (20 lb) and measure the distance between the
arm brackets are mounted in on the slide rails. If bottom of the wear strip and the inside surface of
the front arm brackets are positioned in the rear the track clip. Track deflection must be within
rail mounting holes, use the upper rear mounting specifications.
holes.
Rear Suspension Setup After Break-In
3. Position the front of the skid frame into the tunnel Style Tension Tension
and align the front arm with the appropriate
mounting hole in the tunnel. Slide the lock washer FasTrack w/o Torque 19-25 mm 25-32 mm
onto the cap screw; then secure the front arm to the
tunnel with the cap screw and lock washer. Thread FasTrack w/Torque 32-38 mm 38-44 mm
the cap screw in only half way. DO NOT Sensing Link (1 1/4-1 1/2 in.) (1 1/2-1 3/4 in.)
(121 in. Track)
TIGHTEN AT THIS TIME.
FasTrack w/Torque 38-44 mm 50.8-57.2 mm
NOTE: To aid in centering the front arm with the Sensing Link (1 1/2-1 3/4 in.) (2-2 1/4 in.)
holes in the tunnel, position the skid frame and (136 in. Track)
4. Slide the skid frame and track into the tunnel.

5. Tip the snowmobile onto the opposite side and
install the remaining front arm cap screw and lock
washer. Use the same procedure as step 3.
6. Align the rear arm with the forward mounting hole
in the bracket. Secure the rear arm with a cap
screw and lock washer. DO NOT TIGHTEN AT
THIS TIME.
NOTE: Do not tighten any of the four cap screws
until all have been started. To obtain proper align- 729-429A
ment of the rear arm, pry the arm in the proper
direction until alignment is obtained. NOTE: If the track is new, it will stretch slightly
and take a “set” within the first 300 to 500 miles of
7. Again tip the snowmobile onto the opposite side operation.
and install the remaining rear arm cap screw and
lock washer. Follow the same procedure as in step ADJUSTING DEFLECTION
6.
1. Place the snowmobile on a shielded safety stand.
8. Tighten all four skid frame mounting cap screws Check to make sure the track is 2-3 in. off the
to 3.2 kg-m (23 ft-lb). floor.
9. Check track tension; adjust as necessary (see 2. If the measurement is not as specified, loosen the
Track Tension in this sub-section). jam nuts of the adjusting bolts.
10. Check track alignment; adjust as necessary (see
Track Alignment in this sub-section).
9-128
NOTE: Allow the track to coast to a stop. DO
NOT apply the brake because it could produce
inaccurate alignment conditions.
3. When the track stops rotating, check the relation-

drive lugs. If the distance from the idler wheels to
the inner track drive lugs is the same on both sides,
no adjustment is necessary.
0727-456
3. If the measurement is more than specified, tighten

the adjusting bolts. If the measurement is less than
specified, loosen the adjusting bolts. When the
measurement is within specification range, lock
the adjustment by bottoming the jam nuts against
the axle housings.
NOTE: Vigorously push the underside of the
track up and down. Track must not hit the top of 725-070A
the tunnel or slap the skid frame.
NOTE: If the distance from the idler wheels to
4. After correct track tension is obtained, check track the inner track drive lugs is not the same on both
alignment (see Track Alignment in this sub-sec- sides, an adjustment is necessary.
tion).
ADJUSTING
NOTE: Track tension and track alignment are
interrelated; always check both even if only one 1. On the side of the track which has the inner drive
adjustment seems necessary. Always establish lugs closer to the rear idler wheel, loosen the
correct track tension before checking and/or adjusting bolt jam nut; then rotate the adjusting
adjusting alignment. bolt clockwise 1-1 1/2 turns.
is obtained.
Track Alignment
adjusting bolt jam nut against the axle housing.
idler wheels are equidistant from the inner drive NOTE: Make sure correct track tension is main-
lugs on the inside surface of the track. tained after adjusting track alignment.
CHECKING NOTE: Field test the track under actual condi-
tions and, after the field test, recheck track align-
1. Using a shielded safety stand, raise the rear of the ment and track tension; adjust as necessary.
free to rotate. 9
! WARNING
Overload Springs
The tips of the skis must be positioned against a
wall or similar object for safety. Keep hands, feet,
and clothing away from moving components. To either engage or disengage the spring tension
blocks, use the Spring Block Tool, a spark plug socket,
2. Start the engine and accelerate slightly. Use only and a screwdriver and rotate the spring block to the
enough throttle to rotate the track several revolu- desired position. Both spring blocks must be in the
tions. SHUT THE ENGINE OFF. same position (either engaged or disengaged).
9-129
DRIVE SPROCKET LOCATION
The following illustrations will provide all necessary When pressing new sprockets on the driveshaft,
information to relocate sprockets on the driveshaft. remember to align the sprocket alignment marks or the
sprockets won’t be timed correctly. See illustration
When information is required to assemble the drive- below.
shaft, refer to the parts manual for model being worked
on; then refer to the following illustrations using the
part number listed in the parts manual as a reference.
0728-351
0727-829
727-829A
9-130
0728-001
0000-004
0728-002
0000-004
0728-004
0000-006
9-131
0728-006
0000-007
0728-007
0000-008
0728-008
0000-009
9-132
0728-009
0000-007
0728-010 — 0728-019
0000-011
0728-011
0000-012
9-133
0728-012
0000-013
0728-013
0000-013
0728-015
0000-015
9-134
0728-016
0000-016
0728-017
0000-017
0728-018
0000-018
9-135
0728-021
0000-087
0728-022
0000-018
0728-023
0000-089
9-136
0728-024
0000-090
0728-025
0000-091
0728-026
0000-092
9-137
0728-027
0000-017
0728-028
0000-020
0728-029
0000-021
9-138
0728-030
0000-022
0728-031
0000-023
0728-032
0000-038
9-139
0728-033
0000-093
0728-035
0000-094
0728-036
0000-095
9-140
0728-037
0000-096
0728-038
0000-097
0728-039
0735-365
0728-040
9
0728-040
9-141
0728-041
0735-366
0728-042
0728-042
0728-043
0728-043
0728-047
0728-047
9-142
0728-048
0728-048
0728-049
0728-049
0728-050
0728-050
9-143
DRIVE TRACK USAGE CHART
Below is a listing of drive tracks for Arctic Cat snowmobiles. This chart lists each track with its specifications such
as length, pitch, width, rail centers, and bar grip design.
From the information provided in this chart, note what other tracks can be substituted as a replacement track if a
recommended track isn’t available. Pay close attention to all critical specifications when choosing an alternative
track. Do not select a track with a lower rating than the track being replaced.
# Lugs in
P/N Length Width Rail Center Center Belt Bar Design Rating Lug Height
0602-153 115” 16” 8.84” Two Full Block 2 .850”
0602-249 131” 15” N/A N/A N/A 2
0602-754/755 136” 15” 8.84” Four Full Block 2 .725”
0602-725 156” 16” 8.84” Four Full Block 2 .725”
0602-680 136” 15” 8.84” Four Conical Stud 4 1.25”
0602-758 136” 15” 8.84” Four Wave 3 .920”
0602-677 121” 15” 8.84” Four Full Block 4 .725”
0602-752/753 121” 15” 8.84” Four Full Block 2 .725”
0602-756 136” 15” 8.84” Four Full Block 4 .725”
0602-759 136” 15” 8.84” Four Wave 4 .920”
0602-762 156” 16” 8.84” Four Full Block 2 .725”
0602-798 121” 15” 8.84” Four Full Block 4 .725”
0602-805 136” 15” 8.84” Four Deep Lug 2 1.40”
0602-925 121” 15” 8.84” Four Deep Lug 4 1.60”
0602-942 121” 15” 8.84” Four Wave 4 1.25”
0602-861 156” 20” 13.50” Four Full Block 4 .850”
0602-868 121” 15” 8.84” Four Full Block 2 .725”
0602-869 136” 15” 8.64” Four Deep Lug 4 1.40”
0602-904 136” 15” 8.84” Four Deep Lug 4 1.60”
0602-905 136” 15” 8.84” Four Deep Lug 4 2.00”
0602-921/922 121” 15” 8.84” Four Full Block 4 .725”
0602-824 121” 15” 8.84” Four N/A 4 1.40”
0602-923 121” 15” 8.84” Four Full Block 4 .850”
0602-928 121” 15” 8.84” Four Full Block 4 .725”
0602-962 156” 20” 13.50” Four Full Block 4 1.00”
0602-935 156” 16” 8.84” Four Full Block 4 1.00”
1602-004/005 121” 15” 8.84” Four Full Block 4 .850”
1602-033 121” 15” 8.84” Four Full Block 4 .850”
1602-008 121” 15” 8.84” Four Aggressive Wave 4 1.25”
1602-238 128” 13.5” 8.84” Four Aggressive Wave 4 1.375”
1602-015 68” 11” 8.84” Four Wave 2 .690”
1602-093 136” 15” 8.84” Four Full Block 2 .850”
1602-089 121” 15” 8.84” Four Full Block 3 .850”
1602-124 121” 15” 8.84” Four Full Block 4 .850”
1602-141 121” 15” 8.84” Four Full Block 3 .850”
1602-137 144” 15” 8.84” Four Deep Lug 4 2.00”
1602-080 144” 15” 8.84” Four Deep Lug 4 2.00”
1602-130 144” 15” 8.84” Four Full Block 4 1.25”
1602-135 156” 15” 8.84” Four Deep Lug 4 2.00”
1602-136 151” 15” 8.84” Four Deep Lug 4 2.00”
1602-139 151” 15” 8.84” Four Deep Lug 4 2.00”
1602-149 121” 15” 8.84” Four Wave 4 .850”
1602-160 136” 15” 8.84” Four Deep Lug 4 1.375”
1602-176 121” 15” 8.84” Four Full Block 4 .850”
9-144
DRIVE TRACK USAGE CHART (Cont)
P/N Length Width Rail Center # Lugs in Bar Design Rating Lug Height
Center Belt
1602-188 136” 15” 8.84” Four Wave 2 .725”
1602-321 121” 15” 8.84” Four Full Block 2 .850”
1602-236 144” 15” 8.84” Four Deep Lug 4 2.00”
1602-237 151” 15” 8.84” Four Deep Lug 4 2.00”
1602-258 128” 13.5” 8.84” Four Full Block 4 1.00”
1602-330 128” 13.5” 8.84” Four Full Block 4 .725”
6799-800 136” 15” 8.84” Four Wave 4 1.50”
6799-841* 121” 15” 8.84” Four Deep Lug 4 2.00”
6799-842 136” 15” 8.84” Four Deep Lug 4 2.00”
6909-819 136” 15” 8.84” Four Wave 4 1.25”
* This track can only be used on AWS V chassis with a Torque Sensing Link Rear Suspension.
9-145
DRIVE TRACK LUG PATTERNS
Below are illustrations of the lug patterns available on Arctic Cat drive tracks. These patterns are representative
samples only, and the actual patterns may vary.
Aggressive Wave Full Block

0735-731 0735-737
Conical Stud Wave

0736-242 0736-250
Deep Lug
0736-258
9-146
IDLER WHEEL SELECTION CHART
P/N Diameter I.D. Insert Part Number Width Color Spoke
0114-209 4.25 in. 0.625 in. 0104-340 0104-341 0.75 in. Not spoked
0604-225 5.35 in. 0.625 in. 0104-340 0104-341 1.12 in. Chrome
0604-226 5.35 in. 0.625 in. 0604-220 1.33 in. Chrome
0604-227 5.35 in. 0.625 in. 0604-220 1.33 in. Gold
0604-235 5.35 in. 0.625 in. 0104-340 0104-341 1.12 in. Gold
0604-332 5.35 in. 0.625 in. 0104-304 0104-341 1.12 in. Black
0604-334 5.35 in. 0.625 in. 0604-220 1.33 in. Black
0604-205 5.63 in. 0.984 in. NONE 1.00 in. Not spoked - has hole for wrench
0604-234 5.63 in. 0.625 in. 0604-220 1.33 in. Gold
0604-239 5.63 in. 0.625 in. 0104-340 0104-341 1.12 in. Gold
0604-240 5.63 in. 0.625 in. 0104-340 0104-341 1.12 in. Chrome
0604-281 5.63 in. 0.625 in. 0604-220 1.33 in. Silver
0604-327 5.63 in. 0.625 in. 0604-220 1.12 in. Chrome
0604-328 5.63 in. 0.625 in. 0604-220 1.12 in. Gold
0604-333 5.63 in. 0.625 in. 0604-220 1.12 in. Black
0604-374 5.63 in. 0.984 in. NONE 1.00 in. Not spoked - S/A 0604-205 w/o hole
0604-450 5.63 in. 0.625 in. 0104-340 0104-341 0.875 in. Not spoked - aluminum center
0604-981 5.63 in. 0.625 in. 0104-340 0104-341 1.12 in. Green
0638-550 5.63 in. 0.625 in. 0104-340 0104-341 1.12 in. Purple
0114-206 6.38 in. 0.625 in. 0104-340 0104-341 0.875 in. Not spoked - aluminum center
0604-222 6.38 in. 0.750 in. 0604-224 1.46 in. Chrome
0604-223 6.38 in. 0.750 in. 0604-224 1.46 in. Gold
0604-237 6.38 in. 0.625 in. 0604-220 1.46 in. Gold
0604-238 6.38 in. 0.625 in. 0604-220 1.46 in. Chrome
0604-331 6.38 in. 0.750 in. 0604-224 1.46 in. Black
0604-670 6.38 in. 0.625 in. 0604-220 1.12 in. Black
0604-969 6.38 in. 0.625 in. 0604-220 1.00 in. Not spoked
0604-980 6.38 in. 0.625 in. 0604-220 1.12 in. Green
0638-431 6.38 in. 0.750 in. 0604-224 1.46 in. Purple
0104-298
0604-275
7.125 in.
7.125 in.
0.750 in.
0.625 in.
0104-342
0604-220
0104-343 0.95 in.
1.46 in.
Not spoked
Silver
9
0604-276 7.125 in. 0.625 in. 0604-220 1.46 in. Gold
1604-837 5.630 in. 0.787 in. None Not spoked
9-147
Torque Specifications
ITEM TORQUE
End Caps ft-lb 8
kg-m 1.1
Wear Strip/Rail ft-lb 8
kg-m 1.1
Idler Wheels (5/16-in. cap screw) ft-lb 17
kg-m 2.4
Idler Wheels (3/8-in. cap screw) ft-lb 23
kg-m 3.2
Mounting Block/Rail ft-lb 23
kg-m 3.2
Spring Slide Block/Rail ft-lb 23
kg-m 3.2
Offset Pivot Idler/Idler Arm ft-lb 19
kg-m 2.6
Rear Arm/Rail ft-lb 23
kg-m 3.2
Front Arm Mounting Bracket/ ft-lb 17
Rail kg-m 2.4
Front Arm/Mounting Brackets ft-lb 30
kg-m 4.2
Limiter Straps ft-lb 8
kg-m 1.1
Crossbrace/Rail ft-lb 11
kg-m 1.5
Shock Links ft-lb 23
kg-m 3.2
Shock Eyelets ft-lb 23
kg-m 3.2
Rear Arm/Idler Arm ft-lb 23
kg-m 3.2
Track Adjuster Bracket/Rail ft-lb 11
kg-m 1.5
Rear Arm Limiter/Rail ft-lb 23
kg-m 3.2
Skid Frame/Tunnel ft-lb 23
kg-m 3.2
9-148
REBUILDABLE SHOCK ABSORBER USAGE GUIDE
REAR SUSPENSION FRONT ARM
Extended Collapsed
Length Length Part No. Year Model
10.10 7.06 0604-767 1996 580ZR

10.10 7.43 1604-006 1996 600 ZRT, 800 ZRT
10.10 7.06 1604-036 1996 440 ZR*, ZR 580 E.T.T.*
11.03 7.98 1604-163 1997 ZRT 800
11.03 7.98 1604-163 1997 ZRT 600
11.03 7.98 1604-163 1997 ZR 580 EFI
11.40 7.98 1604-113 1997 ZR 440*
11.40 7.98 1604-113 1998 ZR 440* (Consumer Model)
11.22 7.97 1604-379 1998 ZR 500
11.22 7.97 1604-379 1998 ZR 600, ZR 600 EFI
11.22 7.97 1604-379 1998 ZRT 600
11.22 7.97 1604-379 1998 ZRT 800
11.22 7.97 1604-379 1998 Thundercat, Thundercat M/C
11.22 7.97 1604-379 1998 Powder Special 600 EFI LE
11.40 7.98 1604-113 1998 ZR 600 EFI C.C.*
11.22 7.97 0704-384 1999 Powder Special 600 EFI LE, 700, 700 LE,
ZRT 600, ZRT 800, Thundercat, ZR 500,
ZR 500 EFI, ZR 600, ZR 600 EFI, ZR 700
11.40 7.98 1604-385 1999 ZR 500 LE*, ZR 500 EFI LE*, ZR 600 LE*,
ZR 600 EFI LE*
11.22 7.97 0704-467 2000 Thundercat, Thundercat M/C, ZRT 600, ZRT 800,
ZR 500, ZR 500 EFI, ZR 600, ZR 600 EFI,
ZR 600 EFI LE (Reverse), ZR 700,
ZR 700 LE (Reverse), Powder Special Models
11.47 7.98 0704-470 2000 ZR 600 EFI LE (Clicker)*, ZR 700 LE (Clicker)*
11.40 7.98 0704-531 2001 Mountain Cat 600 EFI LE*, Mountain Cat 800 LE*
11.22 7.97 0704-467 2001 Mountain Cat 800, Mountain Cat 1000, Thundercat,
ZR 500, ZR 500 EFI, ZR 600, ZR 600 EFI
11.40 7.98 0704-470 2001 ZR 600 EFI LE*
11.22 7.97 0704-575 2001 ZR 800
11.40 7.98 0704-577 2001 ZR 800 LE*
11.22 7.97 0704-528 2001 ZRT 600, ZRT 800
11.40 7.98 0704-556 2001 ZRT 600 LE*, ZRT 800 LE*
* Remote Reservoir 9
9-149
REAR SUSPENSION REAR ARM
Extended Collapsed Part No. Year Model
Length Length
14.55 9.80 0604-768 1996 580ZR
14.73 9.88 1604-007 1996 600ZRT, 800ZRT
14.18 9.80 1604-035 1996 440ZR, ZR580 E.T.T.
14.35 9.88 1604-164 1997 ZRT 800
14.35 9.88 1604-164 1997 ZRT 600
14.35 9.88 1604-164 1997 ZR 580 EFI
14.28 10.03 1604-186 1997 ZR 440
14.28 10.03 1604-186 1998 ZR 440 (Consumer Model)
14.35 9.88 1604-382 1998 ZR 500
14.35 9.88 1604-382 1998 ZR 600, ZR 600 EFI
14.35 9.88 1604-382 1998 ZRT 600
14.35 9.88 1604-382 1998 ZRT 800
14.35 9.88 1604-382 1998 Powder Special 600 EFI LE
14.28 10.03 1604-186 1998 ZR 600 EFI C.C.
14.35 9.88 0704-435 1999 Powder Special 600 EFI LE, 700, 700 LE,
ZRT 600, ZR 500, ZR 500 LE, ZR 500 EFI,
ZR 500 EFI LE, ZR 600, ZR 600 LE,
ZR 600 EFI, ZR 600 EFI LE, ZR 700
14.28 10.30 0704-450 1999 ZRT 800, Thundercat
14.35 9.88 0704-468 2000 ZRT 600, ZR 500, ZR 500 EFI, ZR 600,
ZR 600 EFI, ZR 600 EFI LE (Reverse), ZR 700,
ZR 700 LE (Reverse), Powder Special Models
14.35 9.88 0704-469 2000 Thundercat, Thundercat M/C, ZRT 800
14.48 9.88 0704-475 2000 ZR 600 EFI LE (Clicker), ZR 700 LE (Clicker)
14.36 9.98 0704-529 2001 Mountain Cat 600 EFI LE, Mountain Cat 800,
Mountain Cat 800 LE, Mountain Cat 1000
14.35 9.88 0704-469 2001 Thundercat, ZR 800
14.35 9.88 0704-468 2001 ZR 500, ZR 500 EFI, ZR 600, ZR 600 EFI
14.48 9.88 0704-475 2001 ZR 600 EFI LE, ZR 800 LE
14.35 9.88 0704-530 2001 ZRT 600, ZRT 600 LE, ZRT 800, ZRT 800 LE
9-150
SKI SUSPENSION SHOCKS
Extended Collapsed Part No. Year Model
Length Length
13.10 8.97 0603-708 1996 800 ZRT
14.36 9.62 0603-685 1996 600 ZRT
16.40 10.40 0603-717 1996 440 ZR*
14.02 8.87 0603-735 1996 ZR 580 E.T.T.
14.36 9.62 0603-896 1997 ZRT 800
14.36 9.62 0603-896 1997 ZRT 600
14.36 9.62 0603-896 1997 ZR 580 EFI
16.40 10.40 0603-717 1997 ZR 440*
16.40 10.40 0603-717 1998 ZR 440* (Consumer Model)
16.40 10.97 1603-027 1998 ZR 500
16.40 10.97 1603-027 1998 ZR 600, ZR 600 EFI
14.36 9.52 1603-176 1998 ZRT 600
14.36 9.52 1603-176 1998 ZRT 800
16.40 10.97 1603-027 1998 Powder Special 600 EFI L.E.
16.40 10.40 0603-717 1998 ZR 600 EFI C.C.*
16.40 10.97 1603-027 1999 Powder Special 600 EFI LE, 700 LE
14.30 9.96 1603-218 1999 Powder Special 700
16.40 10.97 1603-027 1999 ZRT 600, ZRT 800, Thundercat, ZR 500
16.40 10.97 1603-027 1999 ZR 500 EFI, ZR 600, ZR 600 EFI, ZR 700
16.40 10.40 1603-193 1999 ZR 500 LE*, ZR 500 EFI LE*, ZR 600 LE*
16.40 10.40 1603-193 1999 ZR 600 EFI LE*
17.95 11.47 0703-666 2000 Thundercat, ZRT 600, ZRT 800, ZR 500, ZR 500 EFI,
ZR 600, ZR 600 EFI, ZR 600 EFI LE (Reverse),
ZR 700, ZR 700 LE (Reverse)
14.30 9.90 0703-672 2000 Powder Special 500 EFI LE, Powder Special 600
EFI LE, Powder Special 700, Powder Special 700 LE
16.40 10.97 0703-679 2000 Thundercat M/C
16.94 10.47 0703-714 (R)/ 2001 Mountain Cat 600 EFI LE*, Mountain Cat 800 LE*
0703-715 (L)
9
15.30 10.30 0703-756 2001 Mountain Cat 800, Mountain Cat 1000
17.95 11.48 0703-753 2001 Thundercat, ZRT 600, ZRT 800
17.95 11.48 0703-666 2001 ZR 500, ZR 500 EFI, ZR 600, ZR 600 EFI, ZR 800
17.99 11.47 0703-716 (R)/ 2001 ZR 600 EFI LE*
0703-717 (L)
17.99 11.47 0703-824 (R)/ 2001 ZR 800 LE*
0703-825 (L)
17.99 11.47 0703-798 (R)/ 2001 ZRT 600 LE*, ZRT 800 LE*
0703-800 (L)
* Remote Reservoir w/Clicker
9-151
REBUILDABLE SHOCK ACCESSORY PART
NUMBERS
1991 & Newer Shocks
P/N DESC. P/N DESC.

0603-348 Valve, Shock 1.300 Dia. x .006 in. Thk 0603-204 Piston .041 in. Orifice
0603-345 Valve, Shock 1.250 Dia. x .006 in. Thk 0603-388* Piston .070 in. Orifice
0603-892 Valve, Shock 1.100 DIa. x .004 in. Thk 0603-551 Piston .125 in. Orifice
0603-893 Valve, Shock 1.000 Dia. x .004 in. Thk
0603-339 Valve, Shock 1.000 Dia. x .006 in. Thk NOTE: Shock Oil (p/n 1639-245) is available from
0603-340 Valve, Shock 1.000 Dia. x .008 in. Thk Arctic Cat Parts Department.
0603-894 Valve, Shock .900 Dia. x .004 in. Thk
9-152
SHOCK ABSORBER USAGE GUIDE
Below is a list of shock absorbers used on the front and rear suspensions of many Arctic Cat snowmobiles.
Specifications given for each shock absorber include collapsed and extended length, stroke, and both rebound and
compression valving ratings.
When using the shock absorber guide, always select a shock absorber with the same length, both collapsed and
extended. Shock valving selection will depend on personal preference.
P/N Collapsed Extended Stroke Rebound Compression

Length Length Valving Valving
0604-217 10.190” 16.250” 6.06” 3 1
0604-464 10.190” 16.250” 6.06” 2 3
0604-591 10.170” 16.250” 6.06” 1 2
0604-308 9.580” 15.020” 5.45” 1 2
0604-311 9.580” 15.020” 5.45” 4 3
0604-402 9.580” 15.020” 5.45” 3 4
0604-659 9.580” 15.020” 5.45” 2 1
0604-737 9.580” 15.020” 5.44” 2 2
0604-763 9.580” 15.020” 5.44” 4 3
0604-923 9.580” 15.020” 5.44” 1 1
0604-404 9.700” 15.020” 5.32” 3 3
0604-453 9.700” 15.020” 5.32” 2 2
0604-462 9.700” 15.020” 5.32” 1 1
0604-664 9.590” 14.020” 4.61” 2 2
0604-665 9.590” 14.020” 4.61” 1 1
0603-420 9.380” 14.280” 4.95” 2 3
0603-555 9.410” 13.540” 4.13” 1 1
0603-645 9.290” 13.050” 3.76” 2 2
0604-755 7.060” 10.100” 3.04” 3 1
0604-533 7.060” 9.710” 2.65” 2 3
0604-599 7.060” 10.100” 3.04” 1 2
0603-792 9.830” 15.290” 5.46” 1 2
1604-102 9.560” 15.010” 5.45” 1 1
1604-101 7.670” 11.420” 3.75” 3 1
1604-196 7.670” 11.370” 3.70” 3 1
0603-117
1604-093
7.060”
7.670”
10.030”
11.370”
2.97”
3.70”
1
3
1
2
9
0603-758 9.830” 15.290” 5.47” 2 2
1604-369 8.420” 12.490” 4.07” 2 2
0703-997 11.470” 17.990” 6.52” — —
0703-996 11.470” 17.990” — — —
0703-929 11.470” 17.990” 6.52” — —
0703-825 11.470” 17.990” 6.52” — —
0703-824 11.470” 17.990” — — —
0703-810 11.470” 16.900” 5.43” — —
0703-756 10.300” 15.300” 5.00” — —
0703-753 11.470” 17.990” 6.52” — —
1703-056 11.470” 17.990” 6.52” — —
9-153
SHOCK ABSORBER USAGE GUIDE (Cont)

0704-760 10.050” 14.450” 4.40” — —
0704-758 8.070” 11.270” 3.20” — —
0704-743 9.890” 14.490” 4.60” — —
0704-738 7.970” 11.220” 3.25” — —
0704-712 7.990” 11.650” 3.66” — —
0704-635 7.340” 10.860” 3.52” — —
0704-617 7.970” 11.220” 3.25” — —
0704-530 9.880” 14.350” 4.47” — —
0704-529 9.880” 14.350” 4.47” — —
0704-519 8.070” 11.270” 3.20” — —
0704-518 10.050” 14.450” 4.40” — —
0704-512 9.890” 14.490” 4.60” — —
NOTE: Rebound and compression valving is rated on a scale of 1-4 (1 being the stiffest and 4 being the
softest).
9-154
Ryde FX

0604-756 9.590” 14.200” 4.61” 3 3
0604-757 9.590” 14.200” 4.61” 2 2
0604-758 9.590” 14.200” 4.61” 1 2
0604-909 9.550” 14.570” 5.02” 2 1
0603-649 9.560” 13.100” 3.84” 2 1
1604-001 9.550” 14.570” 5.02” 1 1
1604-011 9.550” 14.570” 5.02” 3 3
1604-092 9.580” 14.700” 5.12” 1 1
0604-997 7.490” 10.110” 2.87” 3 1
1604-085 10.590” 16.710” 6.12” 1 1
0603-843 9.460” 14.300” 4.85” 2 2
1604-176 9.540” 14.660” 5.12” 1 2
1604-212 9.540” 14.660” 5.12” 1 2
1604-218 10.570” 16.640” 6.07” 2 1
0603-901 9.940” 15.170” 5.24” 2 2
1603-172 9.960” 14.300” 4.35” 2 3
1603-173 9.080” 13.790” 4.47” 2 3
1603-174 10.460” 16.300” 5.85” 2 3
1603-175 11.330” 17.060” 5.73” 2 3
1604-368 8.380” 12.110” 3.74” 1 1
1604-370 10.550” 16.670” 6.12” 1 1
1604-371 9.550” 14.670” 5.12” 1 1
1604-372 9.550” 14.670” 5.12” 1 1
1603-200 9.080” 13.790” 4.47” 2 3
1603-201 9.960” 14.300” 4.35” 2 3
1604-460 10.550” 16.670” 6.12” — —
1604-369 8.420” 12.490” 4.07” — —
1603-597 11.360” 17.060” 5.70” — —
1604-995 8.420” 12.490” 4.07” — —
1603-436 9.990” 15.310” 5.32” — —
1604-730 10.550” 16.670” 6.12” — —
1603-614 9.990” 15.310” 5.32” — —
9
NOTE: Rebound and compression valving is rated on a scale of 1-4 (1 being the stiffest and 4 being the
softest).
9-155
REAR SUSPENSION SPRING SELECTION CHART
Below is a list of rear suspension springs and specifi-
cations. This chart was compiled to assist technicians
in fine-tuning the Arctic Cat rear suspension when the
original springs are not satisfactory and a softer or
firmer ride is desired.
A longer spring in areas (D) and (E) can be selected if
cut off to match the original spring. The replacement
spring must match the original spring in areas (D) and
(E).
0730-218
Wire Diameter Angle Number of Coil Width Length Length

P/N
(A) (B) Coils (C) (D) (E)
0604-054/053 .406 65° 7.75 3.88 17.50 4.50
0604-118/117 .460 45° 9.00 4.75 17.50 4.50
0604-132/133* .437 85° 9.00 5.03 16.50 5.75
0604-134/135* .468 85° 9.00 5.03 16.50 5.75
0604-272/273 .437 90° 9.00 4.80 17.50 5.50
0604-282/283 .437 75° 9.00 4.80 17.50 5.50
0604-288/289 .460 60° 9.00 4.75 17.50 4.50
0604-290/291 .490 60° 9.00 5.02 17.50 4.50
0604-314/315** .460 90° 9.00 5.03 17.50 5.50
0604-400/401 .406 90° 8.75 4.32 17.50 5.50
0604-454/455* .437 90° 9.00 4.80 17.50 4.50
0604-474/475 .406 90° 7.75 3.88 17.50 4.50
0604-492/493 .406 90° 8.75 4.32 15.75 5.50
0604-584/585 .406 90° 8.75 4.32 18.10 5.70
0604-592/593 .460 83° 8.75 4.80 15.75 5.50
0604-654/655** .437 90° 8.75 4.59 20.00 5.70
0604-660/661** .437 90° 8.75 4.59 18.10 5.70
0604-746/747 .390 90° 8.75 4.32 19.75 5.70
0604-774/775* .421 90° 8.75 4.43 18.10 5.70
0604-970/971* .421 90° 8.75 4.43 15.90 5.70
1604-050/051** .437 83° 8.75 4.59 16.00 5.70
1604-076/077** .460 97° 9.00 4.53 16.00 5.70
1604-078/079** .437 83° 8.75 4.56 21.00 5.70
1604-178/179** .421 77° 8.75 4.52 20.00 6.00
1604-194/195** .460 90° 8.75 4.53 16.00 6.70
1604-060/061** .460 77° 8.75 4.85 20.00 5.50
1604-062/063** .437 75° 8.75 4.60 18.00 5.50
1604-224/225** .460 83° 8.75 4.53 21.00 5.70
1604-388/389** .452 75° 8.75 4.60 18.00 5.50
1604-442/443 .452 90° 8.75 4.53 16.00 5.70
1604-067/066 .460 75° 8.75 4.83 18.00 5.50
1604-065/064 .421 75° 8.75 4.45 18.00 5.50
1604-608/609 .437 83° 8.75 4.59 20.75 5.70
1604-149/148*** .460 77° 8.75 4.84 22.00 8.00
1604-381/380*** .452 77° 8.75 4.97 22.00 8.00
1604-146/147*** .421 77° 8.75 4.52 22.00 8.00
1604-144/145*** .437 77° 8.75 4.52 22.00 8.00
1604-600/601**** .359 90° 5.75 3.00 15.62 5.12
1604-616/617**** .375 90° 5.75 3.00 15.62 5.12
1604-604/605** .452 75° 8.75 4.62 18.75 5.50
1604-818/819**** .405 75° 8.75 4.32 19.00 5.50
1604-739/740** .437 75° 8.75 4.60 16.00 5.50
2604-044/045 .452 90° 8.75 4.68 18.75 5.50
*Long leg of spring is bent inward **Short leg of spring is bent inward ***Must be cut to correct length ****Square wire
NOTE: The wire diameter and length of the spring have a large influence over the valving of the shocks.
9-156
FRONT SUSPENSION SKI SPRINGS - AWS Models
PART WIRE FREE LENGTH RATE LB/INCH # OF COILS TAB

NUMBER DIAMETER INCHES
0603-019 .315 5.25 520 7 NO
0603-020 .312 1.75 750 3 NO
0603-090 .331 10.5 110 11 YES
0603-132 .312 7.25 350 8 NO
0603-160 .312 2.0 880 3 NO
0603-173 .312 2.0 750 3 NO
0603-279 .281 9.25 40 10.0 YES
0603-152 .281 11.35 43-53 Variable 13.5 YES
0603-550 .312 11.75 60 12.5 YES
0603-260 .312 11.35 70 13.5 YES
0603-425 .312 11.35 70 13.5 NO
0603-277 .312 8.75 70-83 Variable 9.0 YES
0603-400 .281 11.35 43-53 Variable 13.5 YES
0603-426 .331 11.35 80 13.5 NO
0603-430 .331 11.35 80 13.5 YES
0603-278 .328 8.25 85-100 Variable 9.0 YES
0603-090 .331 10.50 110 11.0 YES
0603-548 .420 10.50 110 12.0 NO
0603-6652 .331 10.50 110 11.0 YES
0603-709 .330 9.50 110 10.0 YES
0603-626 .307 9.14 115 9.0 YES
0603-650 .330 9.14 150 9.0 YES
0603-663 .331 10.5 110 11 YES
0603-860 .312 9.50 110 7.5 YES
1603-891 .312 9.50 110 8.5 YES
0703-4822 .312 9.50 110 7.5 YES
0603-8362 .306 11.50 80-125 Dual Rate 14.0 YES
0603-837 .306 11.50 80-125 Dual Rate 14.0 YES
0603-760 .313 9.15 110 10.0 NO
0603-602 .280 11.40 70 13.0 YES
0703-5792 .312 8.38 90 9.0 YES
0703-5882 .312 11.50 96 13.0 YES
0703-5922 .331 10.50 90 7.5 YES
0703-5972 .331 9.50 110 10.5 YES
0703-5992 .312 8.38 90 9.0 YES
1603-170 .331 10.50 90 7.5 YES
1603-254 .331 9.50 110 10.0 NO
0703-6302 .331 9.50 110 10.0 NO
0603-718 .312 11.30 110 14.0 YES
1603-197 .312 8.38 90 9.5 YES
1603-225 .312 12.25 95 14.9 YES
1603-239 .281 10.5 90 11.34 YES
1603-2402 .312 11.30 110 14.0 YES
0703-6202 .281 10.50 90 11.3 YES
0703-6192 .312 12.25 95 14.9 YES
1603-2753 .312 12.61 80-120 Dual Rate 14.9 YES
0703-6202 .281 10.50 90 11.3 YES
0603-7662 .312 11.30 110 15.5 YES
1603-2842 .312 12.61 80-120 Dual Rate 14.9 YES
1603-293 .343 10.50 110 8.5 YES
1603-391
1603-3922
1603-4102
.312
.312
.312
14.13
14.13
9.5
80-120 Dual Rate
80-120 Dual Rate
110
17.0
17.0
13
YES
YES
YES
9
1603-425 .331 13.0 130 12.44*/14.44** NO
1603-459 .243 8.00 85 11.0 NO
1603-5064 .295 12.61 80/120 11.11*/13.11** YES
1603-527/892 .295 9.00 110 9.8*/11.8** YES
1603-577 — — — — —
1603-599 .306 13.0 110 14 YES
1603-6024 .306 11.5 77/205 14*/16** YES
1603-6041 .312 14.125 121 15*/17** YES
1603-6114 .331 11.4 60/175 11*/14** YES
1603-6122 .331 11.4 60/175 11*/14** YES
1603-859 .312 13.00 110 14.2 YES
1603-8602 .306 13.0 110 14 YES
1603-865 .295 9.00 110 11.8 YES
1603-871 .336 10.50 110 10.0 YES
1603-8745 .312 14.21 80/120 Dual Rate 18.5 YES
1603-876 .306 12.50 110 11.2*/13.2** YES
9-157
FRONT SUSPENSION SKI SPRINGS - AWS Models (cont)
PART WIRE FREE LENGTH RATE LB/INCH # OF COILS TAB

NUMBER DIAMETER INCHES
1603-892/527 .295 9.00 110 9.8*/11.8** YES
1603-8932 .312 14.125 60/120 Dual Rate 16.0 YES
0703-418 .312 9.14 110 10.0 YES
0703-744 .331 13.00 120 14.4 NO
0703-7452 .120 2.0 20 1.787*/3.787** NO
0703-8122 .295 9.0 110 12 YES
0703-821 .331 10.5 90 8 YES
0703-8724 .331 10.5 90 8 YES
0703-8944 .331 9.5 110 10 NO
0703-9374 .343 10.5 110 9 YES
1703-0044 .336 10.5 110 12 YES
1703-0142 .312 9.36 90 6.5*/8.5** NO
1703-0154 .312 9.36 90 6.5*/8.5** NO
1703-037 .306 12.50 110 11.2*/13.2** YES
1703-0424 .331 10.50 90 8.0 YES
1703-0452 .331 10.50 90 8.0 YES
1703-046/0044 .336 10.50 110 12.0 YES
1703-0876 .331 13.0 120 12.44*/14.44** NO
1 Orange Color * Active Coils
2 Green Color ** Total Coils
3 White Color
4 Platinum Color
5 Silver Color
6 Yellow Color
AFS MODELS
PART NUMBER FREE LENGTH INCHES RATE LB/INCH
0603-196 2.75 250
0603-021 2.25 350
0603-132 7.25 375
0603-203 2.75 380
0603-127 7.25 420
0603-197 5.35 430
0603-019 5.25 520
0603-020 1.75 750
0603-173 2.00 750
0603-160 2.00 880
FRONT SUSPENSION SWAY BAR

PART NUMBER DESCRIPTION APPLICATION
0703-185 3/8” diameter Powder Special 600 EFI L.E.
0703-202 7/16” diameter All 1998 Models except Powder Special 600 EFI L.E., Cougar
Models, and Panther 550
0703-193 1/2” diameter 1998 Cougar Models and Panther 550
0703-194 5/8” diameter (Same as 0603-423)
0703-190 Chrome Moly AWS
0603-024* 5/8 hex AFS Models
0603-422* 1/2” diameter 1999-2000 Panther 550
0603-254* 7/16” diameter All 1999-2000 Models (AWS)
0603-423* 5/8” diameter AWS Models I-V (Heavy duty)
0703-202 7/16” diameter All 2001-2002 Models
* Unpainted
9-158
REAR SUSPENSION (Front Arm Springs)
PART NUMBER FREE LENGTH INCHES RATE LB/INCH

0604-216 7.8 100
0604-624* 5.0 130
0604-534 7.0 130
0604-413* 7.0 130
0604-740 7.0 170
0604-658* 7.0 170
0604-587 7.0 250
0604-697 7.1 275
0604-776 6.0 290
0604-0051 14 20
0604-1711 15 25
0604-0061 12 150
1604-125 7.0 220
1604-197 7.0 190
0603-860* 9.5 110
1603-018* 9.5 90
1603-267 8.5 110
1604-509** 7.0 160 (.343 wire dia.)
1604-445** 7.0 180 (.360 wire dia.)
1603-171 8.4 90
1604-619 8.0 110
1604-741 8.0 110
1604-667 7.0 170
0704-523 8.0 110
1603-891/860 9.5 110
1604-788 7.0 110
* Tab on Bottom
1 AFS Models
**This spring only fits shock (p/n 1604-480), non-adjuster sleeve shock
9-159
Standard Shock & Spring Chart - 2002 Models
Front Suspension Rear Suspension
Models Ski Ski Front Arm Front Arm Rear Arm Rear Arm Sway Bar
Shock Shock Spring Shock Shock Shock Spring
(Right/Left) Spring (Right/Left)
BEARCAT W/T 1603-393 1703-046 0603-117 0604-587 0604-766 1604-608/609 N/A
PANTERA 550 1603-174 0703-872 1604-369 0603-860 1604-460 1604-604/605 0703-202
PANTERA 600 EFI/800 1603-175 0703-872/ 1604-369 1603-891 1604-460 1604-604/605 0703-202
EFI 1703-042
PANTHER 440 1603-253 0703-894 1604-369 0603-860 1604-460 1604-604/605 N/A
PANTHER 570 esr/570 r 1603-253 1703-051 1604-369 1603-891 1604-460 1604-604/605 0703-202
MOUNTAIN CAT 500 1603-436 1603-891 1604-369 1603-018 1604-730 1604-062/063 N/A
MOUNTAIN CAT 570 1603-614 1603-891 1604-369 1603-018 1604-730 1604-062/063 0703-202
MOUNTAIN CAT 600 EFI 1603-436 0603-860 1604-369 1603-018 1604-730 1604-062/063 N/A
MOUNTAIN CAT 800 LE/ 0703-810 1603-599 0704-617 0704-523 0704-529 2604-044/045 0703-202
800 EFI LE
MOUNTAIN CAT 1000 0703-756 1603-892 0704-617 0704-523 0704-529 2604-044/045 N/A
MOUNTAIN CAT 800/800 0703-756 1603-892 0704-617 0704-523 0704-529 2604-044/045 N/A
EFI
MOUNTAIN CAT 600 EFI 0703-810 1603-599 0704-617 0704-523 0704-529 2604-044/045 0703-202
LE
0703-894 (es)
Z 370/370 es 1603-253 0703-630 1604-101 1603-171 1604-455 0604-654/655 N/A
1703-043 (es)
Z 440/440 es 1603-253 0703-630 1604-101 1603-171 1604-455 0604-654/655 N/A
1703-015 (esr)
Z 570/570 esr 1603-253 1703-014 1604-101 1603-171 1604-455 0604-654/655 0703-202
Z 570 SS 1603-174 0703-592 0704-758 1604-788 0704-760 1604-818/819 0703-202

ZL 500 1603-175 1703-045 1604-369 1603-018 1604-372 1604-062/063 0703-202
ZL 550/550 esr 1603-597 1703-045 1604-995 1603-018 1604-372 1604-062/063 0703-202
1703-042 (esr)
ZL 600 EFI/600 EFI esr 1603-175 1703-045 1604-369 1603-018 1604-372 1604-062/063 0703-202
ZL 800 EFI esr 1603-175 1703-042 1604-369 1603-018 1604-372 1604-062/063 0703-202
ZL 600 EFI SS (Black/ 0703-829 1603-612 (G)/ 0704-758 1604-788 0704-760 1604-818/819 0703-202
Orange) 1603-611 (PT)
ZL 600 EFI SS (EB) 0703-829 1603-602 0704-519 1604-788 0704-518 1604-818/819 0703-202
ZL 800 EFI SS (Black/ 0703-829 1603-612 (G)/ 0704-758 1604-788 0704-760 1604-818/819 0703-202
Orange) 1603-611 (PT)
ZR 120 1603-458 0703-802 N/A N/A N/A 1604-706/707 N/A
ZR 500 0703-929 1603-612 0704-738 0704-523 0704-580 1604-818/819 0703-202
1603-893 (G)
ZR 500 CC 0703-996/997 1603-604 (OR) 0704-712 1604-197 0704-743 1604-442/443 0703-202
ZR 500 LE (EB) 0703-824/825 1603-392 0704-635 1604-445 0704-512 1604-442/443 0703-202

ZR 600/600 EFI 0703-929 1603-612 0704-738 1604-523 0704-530 1604-818/819 0703-202
1603-893 (G)
ZR 600 EFI CC 0703-996/997 1603-604 (OR) 0704-712 1604-197 0704-743 1604-442/443 0703-202
ZR 800/800 EFI 0703-929 1603-612 0704-738 0704-523 0704-530 1604-818/819 0703-202

1603-893 (G)
ZR 800 CC/800 EFI CC 0703-996/997
1603-604 (OR)
0704-712 1604-197 0704-743 1604-442/443 0703-202
ZRT 600 1703-056 1603-506 0704-738 0704-523 0704-530 1604-740/739 0703-202

THUNDERCAT 0703-753 1603-874 0704-758 1604-788 0704-760 1604-818/819 0703-202
9-160
OPTIONAL REAR ARM SPRING CHART - 2002 Models
NOTE: Optional rear arm springs (L = Light; H = Heavy) marked with the * must have the legs cut to size.
Always cut the optional spring legs to the same length as the standard spring legs.
Rear Arm Spring Rear Arm

Model (Right/Left) Spring
Type
Bearcat W/T L 1604-146/147* Round
H 1604-381-380*
Pantera Models
Panther Models L 1604-144/145* Round
Mountain Cat 600 EFI LE/800/800 EFI/1000 H 1604-149/148*
Mountain Cat 500/570/600 EFI L 1604-064/065 Round
ZL 500/550/600 EFI H 1604-066/067
Z Models L 1604-178/179* Round
H 1604-144/145*
ZR 500/600/600 EFI/800/800 EFI L 1604-144/145* Square
H 1604-381/380*
ZL 800 EFI esr L 0604-970/971 Round
H 1604-194/195
ZR 500 CC L 1604-050/051 Round
H 1604-149/148*
ZR 500 LE (EB)/600 EFI CC/800 CC/800 EFI CC L 1604-050/051 Round
H 1604-194/195
ZRT 600 L 0604-774/775* Round
H 1604-604/605*
* These springs must be cut off or damage to the track may occur
9-161
REBUILDABLE SHOCK PISTON DEPTH CHART
Model Front Suspension Ski Rear Suspension Front Rear Suspension Rear
Arm Arm
1997 ZRT 800 0.800" (20.32 mm) 0.600" (15.24 mm) 0.720" (18.29 mm)
1998 ZR 440 (Consumer Model) 1.360" (34.54 mm) 3.0-3.5" (76.20-88.90 mm) 0.720" (18.29 mm)
1998 ZR 500 0.950" (24.13 mm) 0.650" (16.51 mm) 0.720" (18.29 mm)
1998 ZR 600 0.950" (24.13 mm) 0.650" (16.51 mm) 0.720" (18.29 mm)
1998 ZRT 600 0.800" (20.32 mm) 0.650" (16.51 mm) 0.720" (18.29 mm)
1998 ZRT 800 0.800" (20.32 mm) 0.650" (16.51 mm) 0.720" (18.29 mm)
1998 Thundercat 0.800" (20.32 mm) 0.650" (16.51 mm) 0.720" (18.29 mm)
1998 Thundercat M/C 0.800" (20.32 mm) 0.650" (16.51 mm) 0.720" (18.29 mm)
1998 Powder Special EFI L.E. 0.950" (24.13 mm) 0.650" (16.51 mm) 0.720" (18.29 mm)
1998 ZR 600 EFI C.C. 1.360" (34.54 mm) 3.0-3.5" (76.20-88.90 mm) 0.720" (18.29 mm)
1999 Powder Special 600 EFI LE 0.950" (24.13 mm) 0.650" (16.51 mm) 0.720" (18.29 mm)
1999 Powder Special 700 LE 0.950" (24.13 mm) 0.650" (16.51 mm) 0.720" (18.29 mm)
1999 ZR 500 0.950" (24.13 mm) 0.650" (16.51 mm) 0.720" (18.29 mm)
1999 ZR 500 EFI 0.950" (24.13 mm) 0.650" (16.51 mm) 0.720" (18.29 mm)
1999 ZR 600 0.950" (24.13 mm) 0.650" (16.51 mm) 0.720" (18.29 mm)
1999 ZR 600 EFI 0.950" (24.13 mm) 0.650" (16.51 mm) 0.720" (18.29 mm)
1999 ZR 700 0.950" (24.13 mm) 0.650" (16.51 mm) 0.720" (18.29 mm)
1999 ZRT 600 0.950" (24.13 mm) 0.650" (16.51 mm) 0.720" (18.29 mm)
1999 Powder Special 700 0.950" (24.13 mm) 0.650" (16.51 mm) 0.720" (18.29 mm)
1999 ZRT 800 0.950" (24.13 mm) 0.650" (16.51 mm) 0.720" (18.29 mm)
1999 ZR 500 LE 1.360" (34.54 mm) 3.0-3.5" (76.20-88.90 mm) 0.720" (18.29 mm)
1999 ZR 500 EFI LE 1.360" (34.54 mm) 3.0-3.5" (76.20-88.90 mm) 0.720" (18.29 mm)
1999 ZR 600 LE 1.360" (34.54 mm) 3.0-3.5" (76.20-88.90 mm) 0.720" (18.29 mm)
1999 ZR 600 EFI LE 1.360" (34.54 mm) 3.0-3.5" (76.20-88.90 mm) 0.720" (18.29 mm)
2000 Powder Special 500 EFI LE/ 0.950" (24.13 mm) 0.650" (16.51 mm) 0.800" (20.32 mm)
600 EFI LE
2000 Powder Special 700 0.950" (24.13 mm) 0.650" (16.51 mm) 0.800" (20.32 mm)
2000 Powder Special 700 LE 0.900" (22.86 mm) 0.650" (16.51 mm) 0.800" (20.32 mm)
2000 ZR 500 1.250" (31.75 mm) 0.650" (16.51 mm) 0.800" (20.32 mm)
2000 ZR 500 EFI 1.250" (31.75 mm) 0.650" (16.51 mm) 0.800" (20.32 mm)
2000 ZR 600 1.250" (31.75 mm) 0.650" (16.51 mm) 0.800" (20.32 mm)
2000 ZR 600 EFI/600 EFI LE (R) 1.250" (31.75 mm) 0.650" (16.51 mm) 0.800" (20.32 mm)
2000 ZR 700/700 LE (R) 1.250" (31.75 mm) 0.650" (16.51 mm) 0.800" (20.32 mm)
2000 ZRT 600 1.250" (31.75 mm) 0.650" (16.51 mm) 0.800" (20.32 mm)
2000 Thundercat M/C 0.950" (24.13 mm) 0.650" (16.51 mm) 0.800" (20.32 mm)
2000 ZRT 800 1.250" (31.75 mm) 0.650" (16.51 mm) 0.800" (20.32 mm)
2000 ZR 700 LE (C) 1.365" (34.67 mm) 3.000" (76.20 mm) 0.800" (20.32 mm)
2000 ZR 600 VEV 1.250" (31.75 mm) 0.650" (16.51 mm) 0.800" (20.32 mm)
2000 ZR 600 SE 1.365" (34.67 mm) 3.000" (76.20 mm) 0.800" (20.32 mm)
2000 ZR 600 EFI LE (C) 1.365" (34.67 mm) 3.000" (76.20 mm) 0.800" (20.32 mm)
2001 Mountain Cat 600 EFI LE 1.365" (34.67 mm) 3.000" (76.20 mm) 0.800" (20.32 mm)
2001 Mountain Cat 800 0.900" (22.86 mm) 0.650" (16.51 mm) 0.800" (20.32 mm)
2001 Mountain Cat 800 LE 1.365" (34.67 mm) 3.000" (76.20 mm) 0.800" (20.32 mm)
2001 Mountain Cat 1000 0.900" (22.86 mm) 0.650" (16.51 mm) 0.800" (20.32 mm)
2001 ZR 500/500 EFI/600/600 EFI 1.250" (31.75 mm) 0.650" (16.51 mm) 0.800" (20.32 mm)
2001 ZR 600 EFI LE 1.365" (34.67 mm) 3.000" (76.20 mm) 0.800" (20.32 mm)
2001 ZR 800 1.250" (31.75 mm) 0.650" (16.51 mm) 0.800" (20.32 mm)
2001 ZR 800 LE 1.365" (34.67 mm) 3.000" (76.20 mm) 0.800" (20.32 mm)
9-162
REBUILDABLE SHOCK PISTON DEPTH CHART
(cont)
Model Front Suspension Ski Rear Suspension Front Rear Suspension Rear
Arm Arm
2001 ZRT 600 1.250" (31.75 mm) 0.650" (16.51 mm) 0.800" (20.32 mm)
2001 ZRT 600 LE 1.365" (34.67 mm) 3.000" (76.20 mm) 0.800" (20.32 mm)
2001 ZRT 800 1.250" (31.75 mm) 0.650" (16.51 mm) 0.800" (20.32 mm)
2001 ZRT 800 LE 1.365" (34.67 mm) 3.000" (76.20 mm) 0.800" (20.32 mm)
2002 Mountain Cat 600 EFI LE 1.250” (31.75 mm) 0.650” (16.51 mm) 0.800” (20.32 mm)
2002 Mountain Cat 800/800 EFI 0.900” (22.86 mm) 0.650” (16.51 mm) 0.800” (20.32 mm)
2002 Mountain Cat 800 LE/800 EFI LE 1.250” (31.75 mm) 0.650” (16.51 mm) 0.800” (20.32 mm)
2002 Mountain Cat 1000 0.900” (22.86 mm) 0.650” (16.51 mm) 0.800” (20.32 mm)
2002 Thundercat 1.250” (31.75 mm) 2.400” (60.96 mm) 2.700” (68.58 mm)
2002 ZL 600 EFI SS N/A 2.400” (60.96 mm) 2.700” (68.58 mm)
2002 ZL 600 EFI SS (EB) N/A 2.400” (60.96 mm) 2.700” (68.58 mm)
2002 ZR 500 LE (EB) 1.365” (34.67 mm) 1.365” (34.67 mm) 1.365” (34.67 mm)
2002 ZR Models 1.250” (31.75 mm) 0.650” (16.51 mm) 0.800” (20.32 mm)
2002 ZR CC Models 3.000” (76.20 mm) 3.000” (76.20 mm) 1.365” (34.67 mm)
2002 ZRT 600 1.250” (31.75 mm) 0.650” (16.51 mm) 0.800” (20.32 mm)
REBUILDABLE SHOCK TOOLS REQUIRED

0644-268 Shock Bearing Cap Installation Tool
0644-057 Shock Spring Removal Tool
0644-158 Shock Inflation Needle
0644-142 Gas Shock Retaining Blocks
0644-162 Replacement Needle
0644-169 Shock Piston Location Tool
0644-151 Nitrogen Regulator
0644-277 Shock Rod Clamping Tool
REBUILDABLE SHOCK REBUILD KITS

1639-769 IFP
1639-770 Front Arm Quick-Adjust
1639-771 Clicker Shock
9-163
2002 VALVE STACKS
Standard Ski Shock (p/n 0703-929) Standard Ski Shock
(p/n 0703-810)
ZR 500/ZR 600/
ZR 600 EFI/ZR 800/ZR 800 EFI Mountain Cat 600 EFI LE/Mountain Cat 800 LE
Compression: Rebound: Compression: Rebound:
10. 1.300 x .006 1. 1.250 x .006 10. 1.300 x .008 1. 1.250 x .006
9. 1.100 x .006 2. 1.250 x .006 9. 1.100 x .006 2. 1.250 x .008
8. .900 x .006 3. .900 x .006 8. .900 x .010 3. 1.250 x .006
7. .700 x .008 4. 1.250 x .008 7. .800 x .010 4. 1.250 x .008
6. 1.250 x .006 5. 1.250 x .008 6. 1.250 x .008 5. 1.100 x .008
5. 1.250 x .006 6. 1.100 x .010 5. 1.250 x .006 6. 1.000 x .010
4. 1.100 x .008 7. 1.000 x .010 4. 1.100 x .008 7. .900 x .010
3. 1.000 x .008 8. .900 x .010 3. 1.000 x .010 8. .800 x .010
2. .900 x .010 9. .800 x .010 2. .900 x .010
1. .800 x .010 1. .800 x .010
Piston Depth 1.250 in./Piston Orifice .093 in. Piston Depth 1.250 in./Piston Orifice .093 in.
Standard Ski Shock Standard Ski Shock

(p/n 1703-056) (p/n 0703-824-R/0703-825-L)
ZRT 600 ZR 500 LE (EB)
10. 1.300 x .006 1. 1.250 x .006 10. 1.300 x .006 1. 1.250 x .006
9. 1.000 x .006 2. 1.250 x .006 9. 1.000 x .006 2. 1.250 x .006
8. .900 x .006 3. .900 x .006 8. .900 x .006 3. 1.250 x .008
7. .700 x .008 4. 1.250 x .008 7. .700 x .008 4. 1.250 x .008
6. 1.250 x .008 5. 1.250 x .008 6. 1.250 x .006 5. 1.100 x .010
5. 1.250 x .008 6. 1.100 x .010 5. 1.250 x .006 6. 1.000 x .010
4. 1.100 x .008 7. 1.000 x .010 4. 1.100 x .008 7. .900 x .010
3. 1.000 x .008 8. .900 x .010 3. 1.000 x .008 8. .800 x .010
2. .900 x .010 9. .800 x .010 2. .900 x .010
1. .800 x .010 1. .800 x .010
Piston Depth 1.250 in./Piston Orifice .093 in. Piston Depth 1.365 in./Piston Orifice .081 in.
Standard Ski Shock (p/n 0703-753) Remote Reservoir Ski Shock

(p/n 0703-996-R/0703-997-L)
Thundercat
Compression: Rebound: ZR CC Models
10. 1.300 x .006 1. 1.250 x .006 Compression: Rebound:
9. 1.000 x .006 2. 1.250 x .006 10. 1.300 x .006 1. 1.250 x .006
8. .900 x .006 3. .900 x .006 9. 1.100 x .006 2. 1.250 x .006
7. .700 x .008 4. 1.250 x .008 8. .900 x .006 3. 1.250 x .008
6. 1.250 x .008 5. 1.250 x .008 7. .700 x .008 4. 1.250 x .008
5. 1.250 x .008 6. 1.100 x .010 6. 1.250 x .006 5. 1.100 x .010
4. 1.100 x .008 7. 1.000 x .010 5. 1.250 x .006 6. 1.000 x .010
3. 1.000 x .008 8. .900 x .010 4. 1.100 x .008 7. .900 x .010
2. .900 x .010 9. .800 x .010 3. 1.000 x .008 8. .800 x .010
1. .800 x .010 2. .900 x .010
Piston Depth 1.250 in./Piston Orifice .093 in. 1. .800 x .010
Piston Depth 3.000 in./Piston Orifice .081 in.
Standard Ski Shock (p/n 0703-756)
Standard Front Arm Shock (p/n 0704-519)
Mountain Cat 800/Mountain Cat 1000
Compression: Rebound: ZL 600 EFI SS (EB)
9. 1.100 x .006 2. 1.250 x .008 8. 1.300 x .008 1. 1.300 x .010
8. .900 x .010 3. 1.250 x .006 7. .700 x .008 2. .700 x .006
7. .800 x .010 4. 1.250 x .008 6. 1.300 x .015 3. 1.300 x .010
6. 1.250 x .008 5. 1.100 x .008 5. 1.300 x .015 4. 1.250 x .010
5. 1.250 x .006 6. 1.000 x .010 4. 1.300 x .015 5. 1.100 x .010
4. 1.100 x .008 7. .900 x .010 3. 1.250 x .015 6. 1.000 x .010
3. 1.000 x .010 8. .800 x .010 2. 1.100 x .012 7. .900 x .010
2. .900 x .010 1. 1.000 x .010 8. .800 x .010
1. .800 x .010 Piston Depth 2.400 in./Piston Orifice N/A
Piston Depth .900 in./Piston Orifice .093 in.
Standard Front Arm Shock (p/n 0704-738)
ZR Models (Standard)/ZRT 600
Compression: Rebound:
6. 1.300 x .012 1. 1.250 x .010
5. 1.100 x .012 2. 1.100 x .010
4. 1.000 x .012 3. 1.000 x .010
3. .900 x .010 4. .900 x .010
2. .800 x .010 5. .800 x .010
1. 1.250 x .010
9-164
Front Arm Clicker Shock Standard Rear Arm Shock (p/n 0704-743)
(p/n 0704-635)
ZR CC Models
ZR 500 LE (EB) Compression: Rebound:
Compression: Rebound: 8. 1.300 x .008 1. 1.250 x .010
6. 1.300 x .012 1. 1.250 x .010 7. 1.000 x .010 2. 1.250 x .010
5. 1.100 x .012 2. 1.250 x .010 6. .900 x .008 3. 1.250 x .010
4. 1.000 x .012 3. 1.100 x .010 5. .700 x .006 4. 1.100 x .010
3. .900 x .010 4. 1.000 x .010 4. 1.250 x .010 5. 1.000 x .010
2. .800 x .010 5. .900 x .010 3. 1.100 x .010 6. .900 x .010
1. 1.250 x .010 6. .800 x .010 2. 1.000 x .010 7. .800 x .010
Piston Depth 1.365 in./Piston Orifice .041 in.
Front Arm Smart Shock
(p/n 0704-758) Rear Arm Smart Shock (p/n 0704-760)
ZL SS Models/Thundercat ZL SS Models/Thundercat
8. 1.300 x .008 1. 1.300 x .010 8. 1.300 x .008 1. 1.300 x .012
7. .700 x .008 2. .700 x .006 7. .007 x .008 2. .900 x .006
6. 1.300 x .015 3. 1.300 x .010 6. 1.300 x .015 3. 1.300 x .010
5. 1.300 x .015 4. 1.250 x .010 5. 1.300 x .015 4. 1.250 x .010
4. 1.300 x .015 5. 1.100 x .010 4. 1.300 x .015 5. 1.100 x .010
3. 1.250 x .015 6. 1.000 x .010 3. 1.250 x .015 6. 1.000 x .010
2. 1.100 x .012 7. .900 x .010 2. 1.100 x .012 7. .900 x .010
1. 1.000 x .010 8. .800 x .010 1. 1.000 x .010 8. .800 x .010
Piston Depth 2.400 in./Piston Orifice N/A Piston Depth 2.700 in./Piston Orifice N/A
Standard Front Arm Shock Standard Rear Arm Shock (p/n 0704-529)
(p/n 0704-617)
Mountain Cat 600 EFI LE/Mountain Cat 800 LE/
Mountain Cat 600 EFI LE/Mountain Cat 800 Models/ Mountain Cat 1000
800 EFI Models Compression: Rebound:
6. 1.300 x .012 1. 1.250 x .010 6. 1.100 x .010 2. 1.250 x .015
5. 1.100 x .012 2. 1.100 x .010 5. .900 x .004 3. 1.250 x .010
4. 1.000 x .012 3. 1.000 x .010 4. 1.250 x .010 4. 1.250 x .010
3. .900 x .010 4. 1.000 x .010 3. 1.100 x .015 5. 1.100 x .010
2. .800 x .010 5. .900 x .010 2. 1.000 x .015 6. 1.000 x .010
1. 1.250 x .010 6. .800 x .010 1. .900 x .010 7. .900 x .010
7. .700 x .010 8. .800 x .010
Piston Depth .650 in./Piston Orifice .059 in. Piston Depth .800 in./Piston Orifice .039 in.
Standard Front Arm Shock Standard Rear Arm Shock (p/n 0704-530)
(p/n 0704-712)
ZR Models (Standard)/ZRT 600
ZR CC Models Compression: Rebound:
6. 1.250 x .010 1. 1.250 x .010 8. 1.100 x .006 2. 1.100 x .010
5. .800 x .010 2. 1.100 x .010 7. .900 x .008 3. 1.000 x .010
4. .900 x .010 3. 1.000 x .010 6. .800 x .008 4. .900 x .010
3. 1.000 x .012 4. 1.000 x .010 5. 1.250 x .010 5. .800 x .010
2. 1.100 x .012 5. .900 x .010 4. 1.100 x .010 6. .700 x .010
1. 1.300 x .012 6. .800 x .010 3. 1.000 x .010
7. .700 x .010 2. .900 x .010
Standard Rear Arm Shock (p/n 0704-592)
Standard Rear Arm Shock (p/n 0704-518)
ZR 500 LE (EB)
ZL 600 EFI SS (EB)
Compression: Rebound:
8. 1.300 x .008 1. 1.300 x .012
9
6. 1.000 x .010 2. 1.250 x .010
5. .900 x .010 3. 1.250 x .010 7. .700 x .008 2. .900 x .006
4. 1.250 x .010 4. 1.100 x .010 6. 1.300 x .015 3. 1.300 x .010
3. 1.100 x .010 5. 1.000 x .010 5. 1.300 x .015 4. 1.250 x .010
2. 1.000 x .010 6. .900 x .010 4. 1.300 x .015 5. 1.100 x .010
1. .900 x .010 7. .800 x .010 3. 1.250 x .015 6. 1.000 x .010
Piston Depth 1.365 in./Piston Orifice .041 in. 2. 1.100 x .012 7. .900 x .010
1. 1.000 x .010 8. .800 x .010
Piston Depth 2.700 in./Piston Orifice N/A
9-165
4. Remove the screw from the bladder housing on the
Servicing I.F.P. bottom of the shock. Discharge all the pressure
from the shock using the Shock Inflation Needle
Style Shocks (p/n 0644-158). Open the valve in filler handle
until all pressure is released.

in the following sub-sections are used for clarity
purposes and are not designed to depict actual
conditions.
! WARNING
Before servicing a gas shock absorber, first dis-
charge all pressure from the shock. Remove the
screw from the bottom of the shock and insert the
Shock Inflation Needle (p/n 0644-158). Open valve
until all pressure is released. Failure to do this may
cause personal injury.
DISASSEMBLING AG335
1. Remove the shock from the snowmobile. 5. Using a 9/16-in. wrench, remove the brass bladder
housing from the lower end cap. Account for an
2. Wash the shock body in parts cleaner; then dry O-ring.
with compressed air to remove sand and dirt.
! WARNING
When using compressed air to dry components,
always wear safety glasses.
3. Place the shock into the Gas Shock Retaining

Blocks (p/n 0644-142); then remove shock eyelet
mounting axle and bushings from end cap.
! CAUTION
It is important that the Gas Shock Retaining
Blocks (p/n 0644-142) are used during both AP014
disassembly and assembly. Any other method of
securing the shock body during these 6. Using a large adjustable wrench (12-in. or 14-in.),
procedures may deform the shock body cylinder. remove the end cap.
NOTE: A paper shop towel between the shock NOTE: 1994 and older shocks have Loctite on
body and retaining blocks will help prevent scuff- the lower end cap. Heating the lower end cap may
ing of the shock body. be necessary. Use care not to overheat.
AP110DA AP016DA
7. Using a 1-in. open end wrench, loosen the shock

shaft bearing cap a couple of turns.
9-166
NOTE: Do not remove the bearing cap at this NOTE: Do not lay shock parts on a rag as it may
time. transfer lint to the parts causing internal shock
problems.
! WARNING
13. Remove the piston ring from the piston. Loosen

(but do not remove) the lock nut from the bottom
of the shock shaft; then clean the piston area with
clean parts-cleaning solvent to remove dirt or for-
eign material from between the valves. Dry the
piston and valves completely using compressed
air.
AP026
! WARNING
8. Turn the shock so that the open end is up. Then
remove the Allen-head screw located in the center When using compressed air to dry components,
of the floating piston. Account for a small O-ring. always wear safety glasses.
NOTE: If for some reason the piston must be

removed from the shock shaft, it must be installed
with its large seven slots located next to the lock
nut side of the shock shaft.
AP022
9. Using a pair of pliers, pull the floating piston

assembly out of the shock body. Account for a pis-
ton ring and an O-ring.
AP051
10. Pour the oil out of the shock body.
11. Unscrew the shaft bearing cap and lift the shaft
assemble from the shock body.
AP028
NOTE: If shock valving must be removed for

cleaning, remove all valving as a complete assem-
AP027 bly and place on a 5/16 x 3-in. cap screw to keep in
proper order. Note which side is the top side for
12. Clean the inside of the shock body using clean assembly purposes.
parts-cleaning solvent. Blow dry using com-
pressed air.
9-167
ASSEMBLING
1. Place the shock shaft eyelet into the vise; then

assemble valves and piston and tighten the lock
nut to 2.1-2.8 kg-m (15-20 ft-lb).
! CAUTION
DO NOT OVER-TIGHTEN. If excessive torque is
applied, damage to the piston and valves will
occur.
2. Place the shock body between the two Gas Shock

AP032
Retaining Blocks (p/n 0644-142) and secure in a
vise.
14. Items to inspect:
A. Shock shaft for straightness, nicks, or burrs. ! CAUTION
B. Shaft bearing end cap — clean, inspect, or It is important that the Gas Shock Retaining
replace. Blocks (p/n 0644-142) are used during both
disassembly and assembly. Any other method of
C. Inside of shock body for scratches, burrs, or securing the shock body during these
excessive wear. procedures may deform the shock body cylinder.
D. Piston rings for cuts, chipped or nicked edges, 3. Apply a light coat of oil on the O-ring and piston
or excessive wear. ring and install piston into shock body.
E. O-rings for nicks, cuts, or cracks.

F. Valves for kinks or waves.
G. Rubber damper (ski shocks only) for chipping,
cracking, or being missing.
15. Items to replace:
A. Bleed screw O-ring on the floating piston.
B. Shock shaft bearing cap if any signs of oil leaks
or damage.
AP033
C. Any part worn or damaged.
4. Place the shaft bearing cap into the body and
NOTE: For shaft, shaft eyelets, or shaft bearing tighten securely.
cap replacement, see Shaft Eyelet or Bearing Cap
and Shaft Seal sub-section.
AP026
5. Loosen vise and reposition the shock body and

retaining blocks so the bottom of the shock body is
“up” and in a vertical position. Extend the shock
shaft fully and fill the shock body with Shock Oil
(p/n 1639-245) to within 1-1 1/2-in. from the top.
9-168
6. Slowly move the shock shaft up and down a few
times keeping the piston under oil at all times.
This is to remove the air from under the piston.
Extend the shock shaft fully; then fill the shock
body with oil to within 1/2-3/4-in. from the top.
NOTE: After filling the shock body with oil, allow
5 minutes for all air bubbles to rise to the top.
7. Apply a light coat of oil on the floating piston ring

and O-ring and install the floating piston in the
shock body.
AG339
9. Using the tool as a handle, push the piston down

into the shock body until the adjustment knob
comes in contact with the shock body. Give the
tool a quarter turn to free it from the piston. The
piston should now be located correctly.
AP023
NOTE: Depending on which shock absorber is

being worked on, adjust the piston location tool to
the specification indicated in the Rebuildable
Shock Piston Depth Chart in this section.
729-085C
NOTE: As the floating piston is pushed into the

shock absorber body, air and excess oil will come
out through the hole in the piston. If no oil comes
out through the hole in the piston, remove the pis-
ton and add more oil to the shock body.
10. Install the Allen-head screw and O-ring into the

bottom of the floating piston. While securing the
piston with a 9/16-in. wrench, tighten the Allen-
head screw.
AP050
9
8. Attach the Shock Piston Location Tool (p/n 0644-
169) to the piston by placing its slotted end over
the flats on the top of the piston and giving the tool
a quarter turn. Pull gently on the tool to make sure
it is secure to the piston.
AP020
11. Pour out the excess oil from the shock body.
12. Install the lower end cap on the shock body.
9-169
13. Using Shock Retaining Blocks (p/n 0644-142) to NOTE: When removing the shock from the snow-
hold the shock in place and using an adjustable mobile, it will be necessary to disconnect the
wrench, tighten the end cap securely. adjuster assembly. Before disconnecting the
adjuster, the adjustment knob must be turned
completely open (counterclockwise) so there is no
pressure on the line. To prevent oil spillage, place
a protective cap on the hose end.
2. Wash the shock body in parts-cleaning solvent;

then dry with compressed air to remove sand and
dirt.
AP016DA
14. Apply a light coat of oil on the bladder housing O-

ring; then install the brass bladder housing into the
lower end cap. Tighten securely.
AG807
! WARNING
DISASSEMBLING
! WARNING
Before any work can be performed on the gas
AP014 shock absorber, first discharge all pressure from
the shock remote reservoir. Remove the valve
15. Pressurize the shock (see Pressurizing Rebuildable screw from the pressure valve and insert the Shock
Shocks section). After shock has been pressurized, Inflation Needle (p/n 0644-158). Open valve until all
install screw into bladder housing. Tighten pressure is released. Failure to do this may cause
securely. personal injury.
16. Install shock eyelet bushings and axle. 1. Using the Shock Retaining Blocks (p/n 0644-142),
place the remote reservoir in a vise.
Servicing Front Arm

Quick-Adjust Shock
REMOVING
1. Remove the shock from the snowmobile.
AG808
2. Remove the valve screw from the pressure valve.
9-170
AG809 AG812
3. Discharge all pressure from the remote reservoir

using the Shock Inflation Needle (p/n 0644-158).
Open the valve in the filler handle until all pres-
sure is released.
AG813
6. Secure the shock body eyelet in a vise; then loosen

the shock end cap and carefully remove the shock
rod with valving assembly.
AG810
NOTE: If the shock body turns with the upper
4. Reattach the adjustment knob assembly to the end cap, the shock body can be removed from the
shock adjuster hose. lower end cap; then remove the outer sleeve and
place the shock body in the shock blocks. Remove
the upper end cap.
9
AG811
5. Push the remote reservoir end cap in; then use a AG814
sharp tool to remove the circlip. Remove the
remote reservoir end cap.
9-171
9. Using a long needle-nose pliers, remove the float-
ing piston from the remote reservoir; then pour out
the excess oil from the remote reservoir.
AG815
NOTE: If for some reason the piston must be

removed from the shock shaft, it must be installed
with the “Rebound Side” located next to the lock AG818
nut of the shock shaft.
NOTE: Do not remove the lock nut from the bot-

tom of the shock rod as it is very important the
valving on either side of the piston stay in its
proper position. If shock valving must be removed
for cleaning, remove all valving as a complete
assembly and place on a 5/16 x 3-in. cap screw to
keep in the proper order. Note which side is the
top side for assembly purposes.
7. Remove the spiral retaining ring from the shock

body; then remove the outer threaded sleeve.
AG819
10. Clean the shock body, reservoir, and the outer

threaded sleeve with parts cleaner.
DISASSEMBLING/CLEANING/
ASSEMBLING ADJUSTER BODY
1. Disconnect the quick coupler.

2. While securing the adjuster body in a vise with
Shock Retaining Blocks (p/n 0644-142), remove
the adjuster end cap; then remove the Allen-head
AG816 screw from the center of the floating piston.
AG817 AG820
9-172
AG821 AG823
3. Using a long needle-nose pliers, remove the float- 8. Adjust the piston location tool (see Rebuildable
ing piston from the adjuster assembly. Shock Piston Depth Chart in this section).
AG822 AG824
4. Pour out the oil from the adjuster body. 9. Using a good low-temperature grease, lightly
grease the O-ring of the floating piston.
5. Clean all components thoroughly; then use com-
pressed air to dry. 10. Using a long needle-nose pliers, insert the floating
piston into the adjuster body until the piston is
flush with the top of the body.
! WARNING 11. Using the piston location tool as a handle, push the
When using compressed air, always wear a good piston down into the adjuster body until the adjust-
pair of safety glasses. ment stop of the tool comes in contact with the
adjuster body. The piston should now be located
6. Using the retaining blocks, secure the adjuster correctly.
body in a vise.
7. Pour oil into the adjuster body until it reaches the
bottom of the threads; then using a suitable tool,
push in on the spring-loaded valve in the coupler
assembly to remove any air in the coupler fitting
9
and hose. Add oil to reach the bottom of the
threads. Allow time for air bubbles to dissipate.
AG825
12. Install the Allen-head screw with a new O-ring

into the floating piston; then tighten securely.
9-173
AG826 AG829
AG827 AG830
13. Pour out the excess oil from the adjuster assembly; 15. There must be a 1/4 to 1 turn of free-play on the
then grease the tip of the floating piston adjuster handle. If handle free-play is not within specifica-
screw using a good quality grease. tions, repeat steps 7-11.
1. Inspect all hoses for cracks, kinks, or signs of

damage; then clean all hoses and shock compo-
nents of any contaminated oil.
2. Inspect all shock and reservoir surfaces for signs
of damage.
NOTE: All cleaning fluids must be removed com-
pletely before assembling to avoid contamination
of the oil.
3. Inspect all O-rings for cracks or damage. It is rec-

AG828
ommended that all O-rings be replaced with new
14. Install the adjuster handle making sure the handle O-rings any time the shock is disassembled.
is turned out (counterclockwise) completely.
Tighten securely. 4. Clean all parts; then lay all parts on a clean news-
paper.
ASSEMBLING SHOCK AND
REMOTE RESERVOIR
NOTE: When assembling the shock, it is recom-

mended to replace old O-rings with new O-rings.
There is a Shock Rebuild Kit (p/n 1639-770) that
contains all the necessary O-rings for rebuilding
the front arm quick-adjust shock.
1. Secure the shock body in a vise by the lower end

cap eyelet.
9-174
2. Lightly grease the shock body and the O-rings on
the outer threaded sleeve; then install the outer
threaded sleeve making sure the fitting on the
outer threaded sleeve aligns with the fitting on the
shock body.
AG834
5. Position the remote reservoir below the shock

body; then fill the remote reservoir to the top with
new shock oil. Allow time for air bubbles to dissi-
pate.
AG831
6. Install the floating piston with the Allen-head
screw installed in piston. Push piston in until flush
with top of reservoir body; then let reservoir and
hose hang down from shock for a few minutes to
let any air work up and out of the shock. Push the
floating piston all the way into the reservoir. The
shock may overflow with oil. Pull the floating pis-
ton back 2 inches and push back down a couple of
times while keeping the open end of the reservoir
down and below the shock body. This will remove
all the air from the reservoir and hose.
AG832
AG849
NOTE: Assembling this shock results in oil over-

AG833
flowing several times. This is necessary to remove
air from the system. 9
3. Install the spiral retainer on the shock body mak- 7. With the floating piston pushed to the bottom of
ing sure the retainer seats in the retainer groove. the reservoir, finish filling the shock body with
new shock oil to the bottom of the threads. Allow
4. While holding the remote reservoir above the time for all air bubbles to dissipate; then angle the
shock body with the hose free of any low spots, fill shock body slightly in the vise.
the remote reservoir with new shock oil until oil
flows free of air bubbles into the shock body. 8. Lightly grease the threads of the shock body and
the piston adjuster O-ring.
NOTE: You may proceed with a few small air
bubbles coming from the orifices near the top of
the shock.
9. Set the adjuster piston 1 to 1 1/2 in. from valving

piston while holding the end cap at the top.
9-175
AG835 AG838
10. To install the shock rod, align the valve piston NOTE: When installing the adjuster piston, push
wear ring end gap with the low-speed orifice cut- down only on the adjuster piston. Do not push
away positioning the cutaway so it faces the down on the shock eyelet.
upward angle of the shock body which will allow
air to escape. Install the valving piston by pushing 12. Pour oil into the coupler female end; then connect
on the shaft eyelet while guiding the piston ring hose from the shock body to the adjuster assem-
into the shock body. Push the piston to bottom of bly.
the threads on the inside shock body.
AG839
AG836
13. While keeping the adjuster and hose below the
11. Allow air to dissipate; then stand shock straight up shock, turn the adjuster knob in (clockwise) until
and fill with oil. Install adjuster piston by pushing oil reaches the top of the shock body free of air
down on adjuster piston until it is just past the ori- bubbles; then back the adjuster knob off.
fice in the shock body.
NOTE: The adjuster knob must remain con-
nected and backed out through the remaining pro-
cedure until the shock has been pressurized;
otherwise, the oil will be trapped on top of the
adjuster piston and the shock rod will appear to be
short and the shock will not function properly.
AG837
AG840
9-176
14. While holding the shock eyelet to prevent the NOTE: The shock must be pressurized and de-
shock rod from moving, SLOWLY push down on pressurized before an accurate piston depth mea-
the shock rod end cap; then slowly screw in shock surement can be taken.
rod end cap to allow air and oil to escape past the
threads of the end cap. Tighten securely.
AG844
AG841 17. Test the shock by pushing down on the shock shaft
until it bottoms; then release the shaft. The shaft
15. Install the reservoir end cap into the remote reser- should return smoothly to the extended position.
voir; then install circlip. Pull out on the reservoir
end cap to ensure that the circlip has been properly NOTE: If a soft spot or a mushy area is felt as the
seated in its groove. shaft is pushed down, this would indicate air in the
shock body. If there is air in the shock body,
repeat the entire disassembly and assembly pro-
cedure.
18. Clamp the remote reservoir upright in the shock

blocks. Discharge all pressure from the reservoir.
Push the remote reservoir end cap in and remove
the circlip. Remove the remote reservoir end cap.
19. Measure the piston depth from the top of the reser-
voir body to the top of floating piston. Measure-
ment should be within specification (see
Rebuildable Shock Piston Depth Chart in this sec-
tion). If measurement is not correct, pour 1 inch of
AG842
shock oil on top of the piston. Remove the Allen-
head screw; then move the piston to the proper
depth and install Allen-head screw with O-ring.
20. Pour out excess oil. Reinstall the end cap and cir-
clips; then pressurize the shock.
21. Install the valve screw in the end of the remote res-
ervoir.
22. Disconnect the adjuster reservoir; then refill the
adjuster reservoir.
9
FILLING ADJUSTER RESERVOIR
1. Remove the adjuster end cap; then remove the

AG843 Allen-head screw from the center of the floating
piston.
16. Pressurize the shock (refer to Pressurizing
Rebuildable Shocks in this section).
9-177
4. Adjust the piston location tool (see Rebuildable
Shock Piston Depth Chart in this section).
AG845
AG824
5. Using a good low-temperature grease, lightly

grease the O-ring of the floating piston.
6. Using a long needle-nose pliers, insert the floating
piston into the adjuster body until the piston is
flush with the top of the body.
7. Using the piston location tool as a handle, push the
piston down into the adjuster body until the adjust-
ment stop of the tool comes in contact with the
AG846 adjuster body. The piston should now be located
correctly.
2. Remove the floating piston from the adjuster
assembly.
AG825
AG847 8. Install the Allen-head screw with a new O-ring

into the floating piston; then while securing the
3. Pour oil into the adjuster body until it reaches the piston with a 9/16-in. wrench, tighten the Allen-
bottom of the threads. Allow time for all air bub- head screw.
bles to dissipate.
AG826
AG848
9-178
AG827 AG830
9. Pour out the excess oil from the adjuster assembly; 11. There must be a 1/4 to 1 turn of free-play on the
then grease the tip of the floating piston adjuster knob. If handle free-play is not within specifica-
screw using a good quality grease. tions, repeat steps 1-10.
Installing Internal
Travel Limiting Spacers
These spacers are used to shorten the travel of the
shock absorber to fine tune the suspension to the oper-
ator's driving style.
If installing the spacers in the internal floating piston
shock absorbers, follow these steps.
AG828
1. Disassemble the shock absorber as covered in this
10. Install the adjuster knob making sure the knob is manual.
turned out (counterclockwise) completely. Tighten
securely. 2. Place the shock shaft eyelet into a vise and remove
the nut securing the piston to the shock shaft.
9
AG829
AP028
3. Carefully remove the piston and its valving plates

stacked on either side of the piston from the end of
the shock shaft.
NOTE: When removing the piston and valve
plates from the shock shaft, place the piston
assembly on a 5/16 x 3-in. cap screw and secure
with a nut to keep the assembly in its proper order.
9-179
6. Install the heavy spacer washer and then the piston
with valve plates located on either side onto the
shock shaft. Check to make sure the piston has
been installed with its large slots positioned next
to the lock nut which secures the assembly to the
shaft.
7. Install the lock nut and tighten to 2.1-2.8 kg-m
(15-20 ft-lb).
AP032
NOTE: If the piston assembly should become

mixed, the large slots of the piston must be
located next to the lock nut of the shaft. Refer to
the appropriate Illustrated Parts Manual for valve
plate location.
NOTE: If a rubber washer is found on the shock

shaft next to the bottom side of the bearing cap, it
must be removed before installing the limiting AP055
spacers. The rubber washer must not be used with
the spacers installed.
! CAUTION
4. Measure the length of the limiting spacer(s) that Do not over-tighten the lock nut. If excess torque
are being installed on the shock shaft. Write down is applied, damage to the piston and valves will
this measurement as it will be required to properly occur.
calculate the floating piston depth later in the
assembly process. NOTE: For installing spacers on an IFP shock,
proceed to step 8. For installing spacers on a
remote reservoir shock, proceed to the appropri-
ate assembly procedure for the type of shock
being serviced.
8. Apply a light coat of oil on the O-ring and piston

ring. Install piston and the shock shaft assembly
into the shock body.
AP053
5. Install the desired number of limiting spacers on

the shock shaft.
AP033
9. Place the shaft bearing cap into the shock body

and tighten securely.
AP054
9-180
12. Apply a light coat of oil on the floating piston ring
and O-ring and install the floating piston in the
shock body.
AP026
10. Remove the shock body from the vise and reposi-
tion the shock body and holding blocks in the vise
so its open end is “up.” Extend the shock shaft AG850
fully out; then fill the shock body with Shock Oil
(p/n 1639-245) to within 1-in. from the top. 13. Using a long needle-nose pliers, insert the floating
Slowly stroke the shaft up and down to remove air piston into the adjuster body until the piston is
from under the piston. Oil may need to be added to flush with the top of the body; then using the pis-
keep the shock full. Fill shock to within 1/4-in. ton location tool as a handle, push the piston down
from the top. Allow 5 minutes for all air bubbles to into the adjuster body until the adjustment stop of
rise to the top. the tool comes in contact with the adjuster body.
The piston should now be located correctly.
NOTE: Before installing the internal floating pis-
ton, refer to the illustration below and calculate the
new piston depth using the measurement taken
earlier of the spacer(s) installed and the formula
provided in the illustration.
When using shock internal travel limiting

spacers on rebuildable shocks with IFP’s
(Internal Floating Piston), the IFP depth
setting must be reduced to compensate for
the spacer height. Use the following formula to
adjust your shock depth setting. AG339
Example:
Spacer height = .500 in. NOTE: As the floating piston is pushed into the
Old IFP depth = .750 in. shock absorber body, air and excess oil will come
IFP Depth Adjustment = .1165 x .500 = .058 in.
New IFP depth = .750 - .058 = .692 in. out through the hole in the piston. If no oil comes
0730-266 out through the hole in the piston, remove the pis-
ton and add more oil to the shock body.
11. After calculating the new piston depth, measure
14. Install the Allen-head screw and O-ring into the
9
out this distance on the shock piston location tool;
then adjust and secure the location knob. bottom of the floating piston. Tighten the Allen-
head screw.
16. Install the lower end cap on the shock body.
17. Using Retaining Blocks (p/n 0644-142), hold the
shock body in place and tighten the end cap using
an adjustable wrench. Pressurize the shock follow-
ing the shock pressurizing procedure.
AP050
9-181
4. Clamp the shock body eyelet in a vise; then using
Servicing Rebuildable a 1-in. wrench, unscrew the shaft bearing cover.
Shocks & Remote NOTE: If the shock body turns in lower end cap,
Reservoir w/Clicker use shock blocks to hold the shock.
! WARNING
Before servicing a gas shock absorber, first dis-
charge all pressure from the reservoir. Remove the
screw from the top of the reservoir and insert the
Shock Inflation Needle (p/n 0644-158). Open valve
until all pressure is released. Failure to do this may
cause personal injury.
1. Remove the shock absorber from the snowmobile.

Remove the mounting bushings and bearings from AG852
the shock.
5. With the bearing cover loosened, lift the shaft
2. Wash the shock body and reservoir in parts-clean- assembly from the shock body.
ing solvent; then dry with compressed air to
remove sand and dirt.
! WARNING
! WARNING
When working with Shock Inflation Needle (p/n
0644-158), use extreme care. Misuse of this tool
may cause personal injury or death. Avoid punctur-
ing skin with needle. Pressurized air injected
through the skin may be fatal. Do not release safety
mechanism unless red nose piece is inserted in AG853
shock absorber air valve.
6. Remove the piston ring from the piston.
3. Remove the screw from the bladder housing on
bottom of shock reservoir; then discharge all pres- 7. Loosen (BUT DO NOT REMOVE) the self-lock-
sure from the shock reservoir using Shock Infla- ing nut from the bottom of the shock shaft; then
tion Needle (p/n 0644-158). Open valve in filler clean the piston area with clean parts cleaner to
handle until all pressure is released. remove any dirt or foreign material from between
the valves. Dry the piston and valves completely
using compressed air. Tighten self-locking nut to
2.1-2.8 kg-m (15-20 ft-lb). Do not over-tighten! If
excess torque is applied, the piston and valves will
be damaged.
AG851
! WARNING
Failure to remove pressure from shock reservoir
may result in personal injury. AG280
9-182
NOTE: Do not remove the self-locking nut from NOTE: If the clicker adjustment assembly
the bottom of the shock rod unless piston or pis- located at the opposite end of the reservoir shows
ton valve changes are needed as it is very impor- no signs of oil leakage, removal of the assembly
tant the valving on either side of the piston stay in won’t be necessary.
the proper position.
8. Install the piston ring on the piston.

9. Push down on the reservoir end cap compressing it
2.5 cm (1 in.) into the reservoir; then remove the
reservoir cap retainer ring. Use care not to scratch
the inside of the reservoir.
AG856
NOTE: When servicing the clicker remote reser-

voir only, use new shock oil to flush out the shock
and reservoir bodies; otherwise, residual parts-
cleaning solvent may be trapped in the reservoir
causing oil contamination.
AG854 12. Pour the oil out of the shock and reservoir; then
clean the inside of the reservoir and shock body
NOTE: With the retainer ring removed, wipe the using clean parts washer solvent. Blow dry using
ring area clean to remove any foreign materials. compressed air.
10. Remove the reservoir end cap by grasping the ! WARNING

bladder housing with a pliers and pulling the cap
slowly out of the reservoir body. When using compressed air to dry components,
NOTE: If the shock bearing cap does not show

signs of leakage or damage, do not remove from
the shaft.
13. Inspect shock shaft for straightness, nicks, or

burrs. Inspect shock and reservoir bodies for dents
or scratches. Inspect piston valves for bending or
cracking. Inspect all O-rings and seals for nicks,
cuts, or cracking. Inspect rubber bottom-out
bumpers for wear or damage. Replace any worn or
damaged parts.
NOTE: If changing or removing shock shaft seal,
9
AG855
bearing cap, eyelet, or bottom-out bumper, refer to
11. Remove the Allen-head screw and O-ring from the those sub-sections.
center of the piston. Remove the piston from the
reservoir by grasping the raised area of the piston ASSEMBLING
using a pliers. Pull the piston from the reservoir
and account for the piston ring. 1. Place the shock into a vise at a slight angle and fill
the shock reservoir with Shock Oil (p/n 1639-
245).
9-183
AG857 AP108
NOTE: If filling shock with a remote reservoir, NOTE: The oil in the reservoir will remove any air
hold the reservoir lower than the shock. By hold- in the hose or passageway between the reservoir
ing the reservoir low as oil is added to the reser- and shock body.
voir, air in the hose will be forced into the shock
body and out of the system. 5. Once all air has been removed from the reservoir
body, bottom the piston in the reservoir and then
2. With the Allen-head screw and O-ring installed in pull the piston upward approximately 1/8 in.
the reservoir piston and the reservoir full of shock Rotate the clicker knob to number eight; then
oil, compress the piston ring into position with fin- allow the reservoir to hang down below the shock
gers and slowly push the piston down into the res- absorber in the vise to permit any air that might
ervoir until the O-ring is down in the reservoir remain in the reservoir to rise into the shock body.
housing.
AG859
AG858
6. Install the reservoir end cap and O-ring down into
3. Let the reservoir hang down for a few minutes to the reservoir approximately 2.5 cm (1 in.). Install
let air bubbles rise to the top and into shock body. the retainer ring making sure it is firmly in place.
4. Rotate the clicker adjustment to the number one
position; then using a clean pair of pliers, grasp the
hex area at the center of the piston and slowly push
the piston down into the reservoir until it bottoms
in the reservoir. Once the piston has bottomed out
in the reservoir, slowly pull up on the piston
approximately ½ in. Next, slowly push the piston
back down until it once again bottoms. Repeat this
procedure several times until no air bubbles are
seen rising in the oil in the shock body.
AP011
7. Grasp the bladder housing with a pliers and pull it

up into place against the retainer ring.
9-184
8. Slowly pour oil into the shock body until it is 1/4 13. Install the end cap very slowly to allow excess air
in. from the top of the shock body. Again, allow and oil to come out the threads; then using a 1-in.
five minutes to elapse before proceeding. wrench, tighten the bearing cap firmly down in
place. Do not push down on the shock shaft until
9. Space the bottom edge of the bearing cap approxi- the reservoir has been pressurized. Pressurize the
mately 1/2 to 1 in. away from the piston assembly. reservoir.
10. To install the shock rod, align the valve piston
wear ring end gap with the low-speed orifice cut-
away positioning the cutaway so it faces the
upward angle of the shock body which will allow
air to escape.
AG852
14. Discharge all pressure from the shock reservoir

using Shock Inflation Needle (p/n 0644-158).
Open valve in filler handle until all pressure is
released.
AG860
15. Push down on the reservoir end cap compressing it
11. Compress the piston ring into position with fingers 2.5 cm (1 in.) into the reservoir; then remove the
and slowly start the piston assembly down into the reservoir cap retainer ring. Use care not to scratch
shock body. the inside of the reservoir.
16. Measure the piston depth from the top of the reser-
voir body to the top of the floating piston. Mea-
surement should be within specification (see
Rebuildable Shock Piston Depth Chart in this sec-
tion). If measurement is not correct, pour 1 inch of
shock oil on top of the piston. Remove the Allen-
head screw; then move the piston to the proper
depth and install Allen-head screw with O-ring.
17. Install the reservoir end cap and O-ring down into
the reservoir approximately 2.5 cm (1 in.). Install
the retainer ring making sure it is firmly in place.
AG853 18. Pressurize the reservoir.

12. Give the end of the shock rod a few light taps with 19. Install the shock mounting bushings and bearings
in eyelets. If clicker shocks, set back to desired
9
the palm of the hand to help release air bubbles
from the piston valves. setting.
NOTE: Be careful not to damage the piston ring
and watch that the piston ring ends are overlapped
and in place as the piston is installed.
9-185
Bearing Cap
and Shaft Seal
1. With shaft assembly removed from shock body,

clamp shaft eyelet in vise and remove the lock nut.
AG257
5. Using a small paper clip bent on one end, remove

the inner O-ring.
AP028
2. Lift the piston valve assembly.

NOTE: When removing the piston and valve
plates from the shock shaft, place the piston
assembly on a 5/16 x 3-in. cap screw and secure
with a nut to keep the assembly in its proper order.
AG258
1. Install new O-ring and inner rubber wiper into the

shaft bearing cap; then install outer plastic wiper.
AP032
3. Remove the bearing cap (on front arm adjuster

shocks, remove the adjuster piston and a spacer
washer first).
AG259
4. Remove the outer plastic wiper; then remove the
inner rubber wiper from the bearing cap. 2. Inspect the shoulder or step of the shaft for sharp
edges or a burr. Smooth up with #400 grit sand
paper or emery cloth.
3. Put Bearing Cap Installation Tool (p/n 0644-268)
over the threaded end of the shaft.
9-186
Shaft Eyelet
REMOVING
1. Using Shock Rod Clamping Tool (p/n 0644-277)

to prevent damage to the shaft surface, place the
shock shaft into a vise.
2. Heat the shaft eyelet with a torch to soften the
Loctite.
AP114DA
4. Put a small amount of light grease on the seal and

slide the bearing cap over the tool and onto the
shaft.
AG260
NOTE: The eyelet must be heated up to 300° for

the Loctite to soften.
3. Using a wrench, unscrew the eyelet from the shaft.

AP115DA
5. On a front arm adjuster shock, install the spacer

washer on shaft and install adjuster piston in the
same manner as bearing cap; then remove the
installation tool.
6. Install piston valve assembly. Tighten the self-
locking nut to 2.1-2.8 kg-m (15-20 ft-lb).
AG261
INSTALLING
1. Clean shaft threads and eyelet threads.

9
2. Apply red Loctite to both threads, install the eye-
let, and tighten securely.
AG280
9-187
Ski Shocks
Bottom-Out Bumper
Bottom-out bumper can be replaced by removing
shock eyelet or by removing piston valving assembly
and bearing cap.
Pressurizing
Rebuildable Shocks
AG335
2. Turn the nitrogen tank valve open and slowly

rotate the regulator T-handle inward until the
To pressurize the gas shock absorber, a regulator sys- gauge reads 200 lb of pressure; then close filler
tem and a nitrogen tank will be needed. valve and remove inflation needle.
NOTE: On remote reservoir shocks, use a needle
nose vise grips to hold the bladder housing to
keep the end cap from pushing into the reservoir
when inserting the inflation needle.
AG271
! WARNING
Never have a nitrogen bottle in the area without
having it chained or secured. If the bottle should tip AG851
over and the regulator break off, the gas inside it is
under 1800 lb of pressure and personal injury may
result. 3. Install the screw into the bladder housing and
tighten securely.
! WARNING 4. With the reservoir pressurized, push down on the
shock shaft until it nearly bottoms and release it.
Always rotate the regulator T-handle to its loose The shaft should return to its extended position
position each time when finished using the system.
Each time before the nitrogen tank valve is opened, smoothly.
check to make sure the regulator T-handle is turned
out. When opening the nitrogen tank valve, never NOTE: If a soft spot or a mushy area is felt as the
stand in front of the regulator in case there should shaft is pushed down, this would indicate air in the
be a problem. shock body. If there is air in the shock body, dis-
charge the reservoir gas pressure. Disassemble
NOTE: Before inserting the needle into the blad- the shock to the point that the “filling with oil” and
der, lubricate the needle with light oil to make the “bleeding air” procedures can be redone.
installation easier. Assemble and repeat the pressurizing procedure.
To test the shock absorber for nitrogen gas leaks,
submerge in water.
1. Insert the Shock Inflation Needle (p/n 0644-158)
into the shock bladder; then open the valve on the
filler handle.
9-188
Troubleshooting
Track
Problem: Track Edge Frayed — Drive Lugs Worn

Condition Remedy
1. Track alignment adjusted incorrectly 1. Align — replace track
Problem: Track Worn Adjacent to Outer Drive Lugs
Condition Remedy
1. Track tension adjusted incorrectly 1. Adjust track tension
2. Rear idler wheels dirty — damaged 2. Clean — replace idler wheels
Problem: Track Ratchets — Slaps Tunnel
Condition Remedy
1. Track tension adjusted incorrectly (too loose) 1. Adjust track tension (tighten)
2. Drive sprockets misaligned — damaged 2. Align — replace sprockets
Problem: Wear-Strip Wear Excessive
Condition Remedy
1. Slide rail bent — broken — damaged 1. Repair — replace slide rail
2. Track alignment adjusted incorrectly 2. Adjust track alignment
9-189
NOTES
9-190

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SERVICE MANUAL CD-ROM

Click BLACK text to go!!

The Arctic Cat 4-stroke engine (when new or rebuilt)

Break-In Procedure To ensure trouble-free operation, careful adherence to the

When replacement of parts is necessary, use only genuine

! CAUTION 1. Clean the seat cushion with a damp cloth and

3. Place the rear of the snowmobile up on a shielded

Each operator should be instructed to drive the snowmo-

Thread Tightening Torque

8ths 16ths 32nds 64ths 64ths (cont)

Drill Bit Sizes

mm in. mm in. mm in. mm in. mm in.

Listed in the table below are symbols indicating special

242 - apply blue Loctite #242 (p/n 1639-815)

Lubricate with Arctic Cat 50:1 Injection Oil (p/n 0636-286)

Lubricate with Arctic Cat Low-Temp Grease (p/n 0636-593)

3B - Three Bond Sealant (p/n 0636-070)

 NOTE: The drive chain must be removed in order

6. Turn the gas tank shut-off valve to the CLOSED

7. Disconnect the fuel hose from the carburetor.

8. Pull the recoil starter rope out approximately 60

 NOTE: If equipped with electric start, disconnect

1. Turn the gas tank shut-off valve to the CLOSED

8. Remove the springs securing the expansion

5. Remove the clutch from the engine compartment.

10. Disconnect the four-prong main wiring harness

1. Turn the gas tank shut-off valve to the CLOSED

5. Remove the cap screw and washer securing the

17. Remove the cap screws, washers, and lock

 NOTE: Steps 6 through 12 are for APV equipped

6. Remove the two cap screws securing the

10. Remove the screw securing the servomotor

7. Using a small screwdriver, pry off the cable

8. Rotate the servomotor actuator counterclockwise

13. If applicable, remove the machine screw and

24. Loosen the clamp securing the supply hose to the

25. Lift the engine with mounting brackets out of the

AN385D 26. Remove the cap screws securing the engine

1. Disconnect the battery cables making sure to

9. Remove the cap screw and washer securing the

7. Open the belt guard: then remove the drive belt.

 NOTE: If the driven pulley is tight on the driven

10. Loosen the flange clamp securing each carburetor

8. Using a ½-in. twelve-point socket, remove the bolt

20. Lift the engine with mounting brackets out of the

21. Remove the engine mounting brackets.

 NOTE: On the Pantera 550, account for the

18. Support the hood; then remove the hood cable

2. Secure the hood with a hold-down strap; then

10. Using a small screwdriver, pry off the cable

6. Open the belt guard; then remove the drive belt.

8. Remove the cap screw securing the driven pulley;

16. Label the carburetors. Loosen the flange clamp

2. Remove the wing nut securing the air cleaner end

25. Lift the engine with engine mounting brackets out

7. Remove the recoil starter/fan housing assembly.

5. Mark the locations of the springs for assembly; GM201D

12. Remove the cylinder head cover.

9. Using a flywheel puller, remove the flywheel. GM205D

13. Remove the air breather body assembly from the

NOTE: The drive chain must be removed in order

NOTE: If equipped with electric start, disconnect

NOTE: Steps 6 through 12 are for APV equipped

NOTE: If the driven pulley is tight on the driven

NOTE: On the Pantera 550, account for the

NOTE: For further servicing of the axial fan com-

NOTE: To ensure the cleanliness of the flywheel

NOTE: The metal cylinder base gaskets may be

NOTE: Do not replace the inner seals unless the

NOTE: Cap screws securing the front and rear

NOTE: Keep the special mounting hardware with

NOTE: To ensure the cleanliness of the flywheel

NOTE: If the existing rings will not be replaced O-Ring

NOTE: To ensure the cleanliness of the flywheel

NOTE: A suitable substitute protective cap can

NOTE: Place rubber bands over the connecting

NOTE: For proper assembly, keep all MAG-side

NOTE: Do not remove the water pump impeller

NOTE: On EFI models, the magneto case must

NOTE: Do not replace the inner seals unless the AN327D