1987 Arctic Cat" Kitty Cat,m Illustrated Parts and Service Manual
Contents
1. 30 Gi SOIL 30 Throttle oiii ar 30 kaidi 5 drei urna 222 490 29 3 Slide carburetor off intake studs then disconnect the throttle rod and spring from governor arm Disconnect rod from car buretor Specifications 4 Remove the two nuts and lock washers securing silencer cover then remove cover SETTING Carburetor Model Size Main Jet Pilot Jet Air Jet Pilot Outlet Throttle Valve Pilot Screw turns out 780 5 Remove the two silencer spacers Slide silencer housing off carburetor studs then disconnect choke rod from choke plate Ac count for the gasket between carburetor and silencer housing Fig 3 3 Removal and Disassembly 1 Rotate the fuel shut off valve clockwise to as the off position then disconnect fuel line from the carburetor Wipe spilled fuel 2 Remove the two nuts and lock washers securing carburetor to intake of cylinder 6 eee R pilot air screw then remove the Fig 3 1 Fig 3 4 779 782 2B 7 Remove the bolt and fiber washer securing the float bowl Fig 3 5 8 Lift float bowl off carburetor Remove main jet and main jet ring Fig 3 6 9 Remove float pin then remove float Fig 3 7 A784 785 10 Remove tube and nozzle from carburetor Fig 3 B 787 11 Remove inlet needle seat and gasket Cleaning Wash all meta2. 7 Apply a lightweight petroleum based oil to the steering post bushings Check the lubri cant level in the gear case and add lubricant if necessary B Tighten all screws nuts and bolts making sure that all calibrated nuts and bolts are tightened to specifications 9 Make sure all rivets holding components together are tight Replace all loose rivets 10 Clean and polish the hood console and chassis with an automotive type cleaner wax DO NOT USE SOLVENTS OR SPRAY CLEAN ERS THE PROPELLENT WILL DAMAGE THE FINISH 11 Lightly sand the bottom of the skis then us ing black paint p n 0652 004 paint the entire bottom of the skis 12 If possible store the Kitty Cat indoors Raise the rear of the snowmobile off the floor and block up the rear end Cover the snowmobile with either a machine cover or heavy tarpaulin to protect it from dirt and dust 13 If the Kitty Cat must be stored outdoors block the entire snowmobile off the ground and cover it with either a machine cover or heavy tarpaulin to protect it from dirt dust and rain NOTE Avoid using a plastic cover as moisture will collect on the snowmobile causing rusting Preparation After Storage Taking the snowmobile out of summer storage and correctly preparing it for another season will assure many miles and hours of trouble free snowmobiling Arctco recommends the following procedure to prepare the snowmobile 1 Clean the snowmobile thorough
3. Engine Gasoline The Kitty Cat Snowmobile engine when new or The correct gasoline is 88 minimum octane lead overhauled requires a short break in period ap ed Do not use gaolines containing either meth proximately 10 operating hours or two tankfuls of or more than 5 ethanol a 24 1 fuel mixture before being subjected to heavy load conditions or full throttle operation Strict adherence to the break in procedure will contribute to optimum performance and longevity of the engine Do not use gasolines containing either methanol or more than 5 ethanol Also gasoline ad ditives and white MUST BE USED they will eventually cause engine damage During break in a maximum of 1 2 throttle is re commended however brief full throttle accelera tions and variations in driving speeds contribute to good engine break in 2 NOTE Arctco recommends gasoline however unleaded gasoline of at least 88 minimum octane may be used as a substitute if leaded gasoline is not available Recommended Oil The correct oils to use are either Arctco 50 1 Oil or Arctic Cat 50 1 Oil These oils are specially for mulated to meet the lubrication requirements of the Kitty Cat engine Summer Storage curo Prior to storing the Kitty Cat for the summer it is extremely important that it be properly serviced to prevent rusting and component deterioration Arctco rec
4. and tightening nut to 30 40 n m 22 29 ft Fig 2 43 Ib AT49 14 Apply RTV to both sides of the gear case 11 Install shifter so centrifugal weights are gasket Place gasket against crankcase positioned against shifter arms Fig 2 41 Fig 2 44 750 753 15 Install cover w output shaft Install five 12 Install bearing in gear case housing Apply screws then tighten screws with impact grease to the inner lips of the seal then screwdriver Fill gear case place seal in position Fig 2 42 Fig 2 45 A751 A755 19 Electrical System 4 Make sure flywheel magnets are clean Align keyway of flywheel with key in crankshaft 1 Move ignition coil into position then secure Place flywheel on crankshaft with two screws and lock washers Connect coil lead to lead from magneto 5 nstall flywheel flat washer lock washer Fig 2 46 and nut Using a flywheel holder tighten nut to 4 0 5 0 kg m 29 36 ft Ib Fig 2 49 757 763 2 install magneto baseplate align the scribe marks made during assembly Apply 6 Move fl 3 gels ywheel fan into position Apply Loc Loc Tite to three Screws then tighten Tite to the four mounting screws Install and SSIEWS Securely tighten screws using an impact screwdriver Fig 2 4 Fig 2 50 A764 T Install starter pulley and spacer Secure with three screws and tighten securely Fig 2 48 Fig 2 51 3 Pla
5. lanition 36 5 5 5 ce nic wo 36 pee 31 32 Specifications Spark Plug Spark Plug Gap mm in Ignition System Charge Coil Lighting Coil External Coil Secondary External Coil Primary Spark Plug Cap Lighting System Ignition Timing degrees mm Wiring Diagram NGK BR6HS 0 7 0 028 CDI open circuit 117 ohms 209 1 3 ohms 20 5900 ohms 20 11 000 ohms 15 5000 ohms 20 12V 35W 20 6000 rpm hot 1 728 0 068 Testing Ignition System The ignition system used in the Kitty Kokusan is the open circuit type It is opposite from other ignitions used on all the larger Arc tic models naturally close type and this must be kept in mind when selecting your trouble shootina method Before starting the troubleshooting procedure you must first pinpoint the problem of an engine which won t start to either the electrical system fuel system or the engine inner com ponents To accomplish this first remove the spark plug and inspect its condition ques tionable replace it with a new one Adjust the spark plug gap to 0 5 0 7 mm or 0 020 0 028 Ground the spark plug to a good clean surface turn on the switch and crank the engine over hard using the recoil As the engine is being cranked over observe the firing tip of the sp
6. Examine the crankcase sealing area any nicks or scratches are found in the sealing area correct the surface with the use of a sur face plate covered with 400 grit Wetordry sandpaper Rotate the crankcase in a figure eight motion until a uniform finish is noted Fig 2 30 c ee Crankshaft 1 Thoroughly wash crankshaft w bearing in cleaning solvent 2 Inspect edges of bearing for external wear scoring and scuffing Rotate the bearings by nand to ensure free turning without binding or roughness 3 Check the connecting rod using the same method If binding or roughness is noted the connecting rod bearing and crank pin will have to be replaced 4 Measure the rod small end diameter using a snap gauge Lock the gauge and carefully remove it Fig 2 31 5 Measure the snap gauge with a microme ter The diameter must be 15 99 16 00 mm 0 6295 0 6303 in If diameter is not within specifications the connecting rod must be replaced Fig 2 32 A727 6 Check the crankshaft runout on a setup as shown using a surface plate V blocks and a dial indicator with a mounting base T Support the crankshaft on the bearings or the shaft itself 8 Mount the dial indicator against the crankshaft at the area of the oil seals Be sure that the crankshaft is clean Fig 2 33 AT41 9 Slowly rotate the crankshaft and observe the total crankshaft runout
7. Lock Clamp Recoil Starter Ref No Qty 11 3002 318 1 0720 076 Ref No Description Description 9 1 3002 493 1 Recoil Starter Ass y inc 2 12 e E Rin 2 3002 494 1 Recoil 3002 504 1 eGrip Ass y inc 13 3 3002 495 1 Reel Recoil 3002 505 1 eeGrip 4 3002 496 2 ePaw 3010 016 3 Screw 5 3002 497 1 eSpring Recoil 3003 020 3 Washer Lock 6 3002 498 1 Drive 3002 506 1 Pulley Starter 7 3002 499 1 3002 507 1 Spacer 8 3003 317 1 Cover Spring 3002 279 3 Screw 9 3002 501 1 eSpring Return 3003 206 3 Washer Lock 10 3002 502 2 eWasher 94 Related Items Description Part Number Black Metal Paint 0652 004 Headlight Bulb 0609 004 Taillight Bulb 0609 01 1 Arctco 50 1 Oil 55 U S gal 0636 026 Arctco 50 1 Oil 1 at 0636 027 Arctco 20 1 Oil 1 qt 0636 028 Arctco 20 1 Oil 55 U S gal 0636 081 Arctco Engine Preserver 0636 177 Wheel Kit 0134 707 Kitty Cat Machine Cover 0636 035 Kitty Cat Machine Cover 0636 109 Operator s Manual 2254 344 Safety Handbook 2254 347 Tool Kit 0155 619 RTV 732 Sealant 3 oz tube 0134 971 Parts Service Manual 2254 350 Machine Cover 0352 009 Arctic Cat 50 1 Oil 55 U S gal 0352 138 Arctic Cat 50 1 Oil 16 oz 0355 018 Arctic Cat 20 1 Oil 1 at 0134 124 NOTE For a complete list of related items ref
8. Pan 42 Assembly lt lt ve cvy 5 ave Boye 43 Steering Front Frame and Console 44 Seat Tunnel and Taillight 45 Drive Undercarriage and 46 Crankcase and Cylinder 47 Piston and Crankshaft 48 Muffler Cowling and Silencer 49 v esto a bolo aa dem Ra d dis 50 2 52222542 2 55 5 51 52 1 RET 003 53 Km visis rss 54 NOTE The illustrations used are for reference to replacement part numbers only and are not to be used for assembly New part numbers for this year are underlined Service parts may be ordered through either Arc tco Inc or Certified Parts Corporation Mail orders should be addressed to Arctco Inc Certified Parts Corp P O Box 810 1111 West Racine Street Thief River Falls MN 56701 Janesville WI 53545 Attn Parts Dept Phone orders call Arctco Inc Certified Parts Corp 1 800 328 0281 U S 1 800 356 0777 U S 1 800 982 0017 MN 1 800 652 6979 WI 41 0302 128 8011 070 0302 145 8040 366 8061 708 8002 130 8051 242 0302 112 0662 012 0300 200 0302 091 0302 056 0610 008 0302 057 0300 184 0302 061 3003 020 3010 016 Bumper Bolt Carriage Belly Pan Nut Lock Hivet Screw Cap Washer L
9. Part No Description Piston Ring Assembly Pin Bearing Circlip Crankshaft Ass y inc 7 11 s Rod Connecting e Pin 481 3002 482 3003 320 3003 261 3002 462 3002 463 3010 070 e Bearing s Crankshaft Right e Crankshaft Left Bearing Right Bearing Left Oil Seal Right Oil Seal Left Key 0727 253 3003 266 3002 488 3002 436 3003 264 3003 190 3002 491 3002 443 3003 175 3003 023 3002 461 0212 283 3002 492 3002 348 4 RO 2 3 aN Muffler Cowling and Silencer Gasket Bolt Stud Nut Washer Lock Cover Cooling Fan Screw Cap Spark Plug Washer Plug Magneto Inspection Emblem Cowling Screw Ref No 14 3003 206 0217 027 3002 483 3002 484 3002 439 3002 485 3002 689 3002 486 3002 487 3002 458 3003 165 3003 265 2 Description Washer Lock Spark Plug BR 6HS Gasket Insulator Bolt Stud Rod Choke Valve Nut Silencer Ass y inc 25 Gasket Spacer Bolt Stud Grommet 0727 132 Ref No Part No Description 3002 619 3002 509 3002 510 3002 511 3002 684 3002 462 3002 512 3002 615 3003 267 3003 190 3003 020 3002 690 3002 452 3003 321 3002 620 i cR Centrifugal shifter Shaft Throttle Return Plate Throttle Return Screw Seal Oil Lever Throttle Control Spring Bolt Washer Lock Washer Nut Bo
10. This is the dif ference between the highest and lowest readings Maximum runout must not exceed 0 05 mm 0 002 in If runout exceeds specifi cations the crankshaft must be straightened or replaced Assembly Crankcase Gear Case 1 If bearings were removed install bearings into crankcase halves 2 Using a seal installing tool insert seals in crankcase halves NOTE Make sure spring side of seal is positioned toward center of crankshaft 3 Apply grease to the inner lips of the seals 17 Fig 2 34 A744 4 Press crankshaft into magneto side of case Fig 2 35 A742 5 Apply RTV to both halves of the crankcase Fig 2 36 743 6 Install crankcase dowel pins if they were re moved 7 Apply blue Loc Tite to the five screws that secure crankcase assemble cases then tighten screws using an impact screw driver 18 Fig 2 37 745 NOTE Place rubber band over connecting rod to prevent rod from damaging cases if engine is accidently rotated 8 Install a woodruff key in the PTO end of the engine crankshaft Slide drive gear onto crankshaft so the large beveled edge is positioned inward Fig 2 38 A746 9 Place centrifugal onto PTO end of crank shaft making sure notch of centrifugal aligns with keyway of crankshaft Fig 2 39 A747 10 Secure PTO end crankshaft components by 13 Install the primary driven shaft applying Loc Tite to the nut installing the nut
11. a backflush of the filter using parts washing solvent e a CAUTION 1 Drain all fuel from the fuel tank DO NUT force Me air SERE Camy 96 MAY EALS 2 Pull the fuel shut off valve filter from the bot damage to the screw and or seat tem of the fuefTantc 3 Remove fuel line clamp then separate fuel line from valve filter Throttle Cable The correct throttle cable adjustment is when 4 Clean or replace valve filter with the engine stopped the carburetor throt tle is completely open against its limit while 5 Install valve filter into the grommet on the the throttle control lever lightly contacts the fuel tank handlebar grip The throttle arm should also contact the throttle stop screw when the throt 6 Connect fuel line then secure with clamp tle control lever is released 30 SECTION 4 ELECTRICAL SYSTEM TABLE OF CONTENTS ODOCHIGAHOIS Luo res ac ah tane 5 32 Minna 2 vee dios Y eto ao rs os 32 Testing Ignition System 33 Wiring Harness Test 33 Ignition Coil Output Test 34 Charge Coil Output 34 Testing Electrical Resistances 34 Testing Spark Plug 34 Testing External Coil Secondary 34 Testing External Coil Primary Testing Charge 35 Testing Lighting Coil TIRE 22 35
12. 0302 118 0302 079 0300 179 0300 152 0300 181 8070 316 0300 144 8050 277 2081 000 0302 109 0302 104 0300 150 0302 101 0211 916 0300 178 8002 250 0300 180 0302 110 0302 111 0302 108 B051 273 4 Description Flange Bearing Bracket Brake Position Sprocket Track Drive Spacer Idler Wheel Front Pin Spring Driveshaft Washer Adjuster Plate Side Left Spacer Spacer Bogie Wheel Decal Warning Sprocket Idler Screw Cap idler Wheel Rear Axle Axle Rear Plate Side Right Washer Lock 0727 251 Ret No Part No Description i 0 Ono Cn 3002 469 3002 470 3002 454 3003 020 3002 616 3002 472 3002 451 3003 185 3002 012 3003 259 3002 617 Oho Crankcase and Cylinder Ref Head Cylinder Gasket Head Nut Washer Lock Cylinder Gasket Cylinder Bolt Stud Crankcase Ass y inc 9 amp 10 s Pin Dowel Screw Gase Gear 3002 475 3002 445 3002 012 3002 519 3003 260 3002 456 3002 460 3003 188 3010 016 3003 023 M oh Gasket Gear Case Screw Pin Dowel Plug Breather Plug Oil Level Gasket Oil Level Plug Oil Filler Gasket Oil Filler Screw Washer 0720 071 Ref No Part Qty Description 3002 476 3002 477 3002 478 3003 186 3010 264 3002 479 3010 318 3002 480 Piston and Crankshaft Ref No _
13. 1987 Arctic Cat Kitty Cat Illustrated Parts and Service Manual ARCTIC TABLE OF CONTENTS Page 1 General Information 1 8 2 Engine 9 23 3 Fuel System 25 30 4 Electrical System 31 36 5 Recoil Starter 37 40 6 Service Parts 41 54 SECTION 1 GENERAL INFORMATION TABLE OF CONTENTS SPECITIGOLONS cnn 2 Exo Beak Ss oa 2 Recommended Gasoline 2 Recommended Oll cse uou ence veh eens 4 4 Summer Storage 2 2 22422 94 Preparation After 5 3 L bricatigft ii ats 4 2584 5 Track TENSION 2 i uz 02 12 0 2l131 2 2 5 TACK AHnfiBllt 1225522 ua ERA 6 6 steering Alignment Ctr eye 7 ua A 7 7 Specifications Drive Clutch Centrifugal Brake 25 4 10 mE Length around Track Tension range 20 25 mm 3 4 1 in Spark Plug A BR6HS ED Spark Plug Gar Ignition Timing 20 BTDC 1 728 mm 0 068 in MISCELLANY Ignition Type Track Width leghwSHs T Specifications subject to change without notice Gear Case Lubricant SAE 10W 30 Recommended
14. 24 ft Ib 7 Field test the track under actual conditions then verify correct track alignment NOTE After adjusting track alignment be sure correct track tension has been tained Ski Alignment Checking Ski Alignment 1 Turnthe handlebar to the straight ahead posi tion 2 Measure the distances to the outside edges of the leaf springs Make sure the measure ments are taken behind the front mount bracket and ahead of the rear mount bracket Right Spindle Crank Steering Left Spindle Crank NOTE Ski alignment is correct when the skis are parallel to each other equal measurements front and rear or when the skis have a maximum of 6 mm 1 4 in toe out front measurement 6 mm 1 4 in more than rear measurement 3 ski alignment is not as specified the snowmobile will have a tendency to wander and may be difficult to control therefore an adjustment is necessary Adjusting Ski Alignment 1 Make sure the ignition key is in the OFF posi tion 2 Visually examine to determine which ski is out of alignment with respect to the handle bar then make adjustment to that ski 3 Open the hood and loosen the front tie rod jam nut of the ski to be aligned 4 Remove the lock nut securing the front tie rod ball joint to the spindle crank then separate the ball joint from the spindle crank Front Tie Rod Ball Joint Steering Tie Rod Ball Joint Spindle Crank RIGHT SIDE VI
15. 27 250 0302 143 8040 366 8002 070 8051 273 8002 250 0123 534 0116 074 8060 306 0117 860 0606 022 0300 168 8061 708 8061 710 Tunnel Nut Lock Screw Cap Washer Lock Screw Cap Nut Snap in Snap Rivet Reflector Plate Rear Bumper Rivet Rivet 0611 025 0300 173 8050 157 0302 131 0302 157 0116 378 0611 196 0623 012 0609 008 0609 011 8040 276 0115 588 Decal Handle Handle Washer Pad Foam Cover Seat inc 19 eSnap Tape Reflective 23 roll Screw Self Tapping Taillamp Assembly inc 23 s Bulb Taillight Nut Lock Tape 0727 128 Ref No CO N C Cn ch 46 ranno ov 1 0302 060 0300 208 0300 230 0300 229 0300 129 8051 272 8002 220 0300 153 8050 217 0300 151 0302 081 8050 242 0300 162 0302 086 0123 439 0123 765 6051 212 8004 037 0300 156 0300 167 0300 122 2204 001 8070 376 Drive Undercarriage and Track Guard Chain Screw Self Tapping Pin Brake Pin Hair Bracket Brake Washer Lock Screw Cap Spring Idler Washer Spacer Brake Tightener Chain Washer Band Brake Clutch Washer Washer Cup Washer Lock Screw Cap Sprocket Drive 42T Track Chain Ass y inc 22 e Link Connecting Pin Spring Description Ref No 24 0300 138
16. 8 788 Inspect starter plunger and seat for wear or damage Check carburetor mounting gaskets for damage Place carburetor insulator on a surface plate covered with 400 grit Wetordry emery paper Move the insulator over the surface plate using a figure 8 motion The motion should produce an even wear pattern over the entire sealing area Fig 3 10 cauno air leak between the carburetor and engine will cause severe engine Assembly and Installation Fig 3 11 KEY 1 Carb Assy 10 Throttle Adjusting Screw 2 Tube 11 Spring 3 Main Jet 12 Bolt 4 Ring 13 Washer 5 Float 14 Nozzle 6 Float Pin 15 Float Chamber Gasket 7 Needle Valve Assy 16 Pilot Adjusting Screw 8 Washer 17 Spring 9 Pilot Jet No 35 1 Install the inlet needle seat and gasket 2 Install the nozzle and nozzle tube 3 Place the float in position then secure with float pin 4 Invert the carburetor so the float is posi tioned upward Using a calipers measure the distance from the edge of the float to the float bowl base Correct float height should be 16 5 17 8 mm 0 65 0 70 in If an adjustment is necessary bend the float arm actuating tab to establish correct float height Fig 3 12 A789 5 Install the main jet and main jet ring 6 Make sure float bowl O ring is correctly positioned then install float bowl Secure bowl with bolt and fiber washer 7 Slide spri
17. EW 5 Align the ski then rotate the ball joint until the ball joint stud aligns with the hole in the spindle crank and insert the ball joint stud in to the spindle crank amp Install the lock nut on the ball joint stud and secure 7 Tighten the front tie rod jam nut and affirm the correct alignment NOTE There should be approximately an equal number of threads showing on both ends of the front tie rod more threads are show ing on one end than on the other the jam nuts can be loosened and the tie rod rotated until thread equality is attained this process will not affect ski alignment Tighten the jam nuts securely Steering Alignment Visually examine the steering alignment by plac ing the handlebar in the straight ahead position and checking to be sure the skis are pointing straight ahead If the skis are not pointing straight ahead adjust using the following procedure 1 Open the hood and loosen the steering tie rod jam nut 2 Remove the lock nut securing the steering tie rod ball joint to the spindle crank Separate the steering tie rod and ball joint from the spindle crank 3 Place the handlebar and skis in the straight ahead position 4 Rotate the ball joint until the ball joint stud aligns with the hole in the spindle crank then secure the ball joint to spindle crank with the lock nut NOTE There should be approximately an equal number of threads showing on both ends of the steeri
18. any carbon buildup which has col lected in the combustion chamber Use a non metallic tool to prevent scratching and scoring 01 the combustion chamber 2 horoughly clean the cylinder head in clean ing solvent 3 Inspect spark plug threaded area for any damage 4 Place the cylinder head on a surface plate covered with 400 grit Wetordry sandpaper Move the head in a figure eight motion to check sealing area for trueness High spots can be noted by evidence of a shiny portion on one area of thesealing area Theentire surface must have a uniform appearance 14 Fig 2 21 tM e al s X x 409 AUAM Cylinder 1 Remove carbon buildup from the exhaust port NOTE Use a non metallic carbon removal tool 2 Wash the cylinder in clean solvent 3 Inspect cylinder for pitting scoring scuff ing or corrosion Replace if damaged 4 To remove minor imperfections or marks in the cylinder use a flex hone with 500 grit stones to clean the bore Use honing oil for lubrication Move hone back and forth so a crosshatch pattern will result 5 Inspect all threaded areas for damaged or stripped threads 6 Insert an inside micrometer cylinder gauge or snap gauge into the cylinder bore and take six measurements of the bore Measure front to back and side to side at points below in take port above exhaust port and 1 cm 0 375 in below the to
19. ar rearward PAN WARNING PAN 00 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 Slide the wear bar rearward until it is possible to insert the rear of the wear bar into the hole at the rear of ihe ski 3 Center the wear bar bolt in its hole and install the washer and lock nut 4 Tighten lock nut securely SECTION 2 ENGINE TABLE OF CONTENTS 1450292525 2 102 IIEG 3255454 10 Xo vi 436v oV aV im UV o Vr i 10 Cleaning and Inspection 14 AGBOITIDIV Va adden ES Sar 17 Goat date 23 Crankshaft End Play Range Specifications GENERAL Model Type No of Cylinders Lubrication Starter System Bore x Stroke Displacement Compression Ratio Piston Ring End Gap Range mm in Piston Skirt Cylinder Clearance Range in Piston Pin Diameter Range mm in Piston Pin Bore Diameter Range in Connecting Rod Small End Diameter Crankshaft Runout mm in mm in mm in cu TORQUE Cylinder Head Nut Crankcase Bolts Flywheel Nut Intake and Exhaust Nuts Disassembly Fan Power Head 1 Hemove gas tank then disconnect fuel lines from carburetor 2 the nuts and lock washers securing carbu
20. ark plug If no spark is present disconnect the main engine wiring harness and repeat the test If there is now spark present with the main harness disconnected the problem lies in the safety switch or the wiring harness If no spark is present the problem is in the ignition system To troubleshoot these components the following procedure is recommended i NOTE To test the ignition system use either an ohmmeter or CDI tester Wiring Harness Test Procedure 1 Disconnect the wiring harness at the engine Fig 4 2 Engine Wiring Harness Perform test at the main harness four pro ng connector Connect one ohmmeter lead to the black wire in the connector Attach the red ohmmeter lead to the brown wire in the connector With both the ignition and safety switch in the position the meter must register OPEN If the tester reads CLOSED disconnect the ignition switch from the main wiring harness lf the tester now reads OPEN replace the ignition switch 0725 704 If the meter remains in the CLOSED posi tion with the ignition switch disconnected disconnect the safety switch If the meter now reads OPEN replace the safety Switch If the meter remains in the CLOSED posi tion with both switches disconnected replace the wiring harness 33 Ignition Coll Output Test 1 Remove the resistor spark plug and spark plug cap from the engine Next instal
21. ce flywheel key in position 766 20 Power Head Fan 1 Place the bearing in the connecting rod small end Apply engine assembly oil to the bearing Fig 2 52 767 2 Install the piston rings The letter near the ring end must be positioned upward Make sure ring ends are positioned correctly over piston ring keepers Fig 2 53 4 Install piston pin Secure piston pin with circlips Fig 2 55 769 NOTE Make sure open end of both circlips is directed toward either the piston top or bottom 5 Apply athin coat of RTV to both sides of the cylinder base gasket then install base gasket Fig 2 56 3 Place the piston assembly onto the con necting rod Make sure arrow on dome of piston points to the exhaust side of the engine Fig 2 54 768 6 Using a piston holder to square the piston compress the piston rings and in stall the cylinder Do not force cylinder If cylinder binds remove check piston rings and install Fig 2 57 7 Place head gasket in position Fig 2 58 8 Place cylinder head in position Head must be positioned so the cooling air flow is parallel to fin pattern 9 Tighten cylinder head nuts to 8 12 n m 6 9 ft Ib Fig 2 59 10 Install head cowling and fasten securely Fig 2 60 22 11 Install fan cover and secure with four screws Make sure high tension coil lead is secured by upper rear scr
22. e nut to set up the brake 3 Ensure correct brake lever travel distance then tighten the rearward flange nut to secure the adjustment Track Tension NOTE Track tension and track alignment are interrelated therefore always check both even if only one adjustment seems necessary Track tension is directly related to the overall per formance of the snowmobile If the track is too loose it may slap against the tunnel causing wear or it may ratchet on the track drive sprockets the track is too tight track drive sprocket wear will result In addition a track that has improper tension will prevent the snowmobile from reaching optimum performance Checking Track Tension warning AN DO attempt to check or adjust track tension with engine running Turn ignition key to OFF position Personal injury could result from con with rotating track 1 Before checking track tension remove ex cess ice and snow buildup from the track and from the track drive sprockets 2 Raise the rear of the snowmobile off the floor eee Sure the track is not contacting the loor 3 Exert moderate downward pressure at mid span of the lower track section Measure the distance between the bottom of the rear bogie wheels and the inside surface of the track The measurement must be within a 5 range of 20 25 mm 3 4 1 in If the measure ment is not as specified an adjustment is necessary Adjus
23. e the following procedure Adjusting 1 Loosen the throttle cable wire binding screw Fig 3 16 The Kitty Cat is equipped with a Mikuni car buretor that has been adjusted at the factory However altitude temperature and wear may Wire cause changes to the carburetor y Binding gt 7 Three external adjustments can be performed on the Mikuni carburetor the throttle stop screw the air screw and throttle cable Screw 0726 195 2 Pull all slack from the throttle cable wire and exert slight tension on the wire 3 Tighten the throttle cable wire binding screw 4 Fi LI X N warning A 0725 571 DO NOT operate the snowmobile when com Throttle Stop Screw ponent in the throttle system is damaged frayed The throttle stop screw controls the seating kinked worn or improperly adjusted position of the throttle valve which determines the proper idle speed Turn clockwise to in crease the engine idle speed and counter clockwise to decrease engine idle speed Ait Screw Fuel Filter The air screw determines the air fuel mixture for idling When the air screw is turned clockwise the amount of air is reduced and the mixture is enriched When the air screw is turned counter clockwise the amount of air is increased and A fuel filter is incorporated in the fuel shut off the mixture is leaned valve located in the bottom of the fuel tank The only cleaning is
24. egin removing spring one turn at a time by alternately using thumbs to guide spring off reel 3 While exerting downward pressure on the drive plate remove the E ring and notched washer securing recoil components Fig 5 3 3 10 If the recoil rope must be replaced remove the recoil handle from the end of the rope then guide rope through the recoil reel 792 38 Fig 5 6 A798 Cleaning and Inspection NOTE Whenever a part is worn excessive ly cracked defective or damaged way replacement is necessary 1 Clean all recoil components with cleaning solvent Dry components with compressed air Fig 5 7 ABOO 2 Inspect all springs shims washers pawls and drive plate for excessive wear or damage 3 Inspect the recoil reel and housing for cracks or damage Check the center hub for cracks and excessive wear Fig 5 99 4 Check the recoil rope for breaks fraying 5 Inspect the main spring for cracks crystal lization and abnormal bends Fig 5 9 797 6 Inspect the starter handle and end piece for damage cracks or deterioration Assembly and Installation 1 Hook the end of the recoil spring around the mounting lug of the recoil reel 2 to insert the recoil spring winding in a clockwise direction Insert windings one at a time until the complete recoil spr ing is installed NOTE spring must seat
25. er to the Accessories and Options Manual
26. evenly on the recoil housing to ensure correct in stallation 39 If a recoil rope is to be installed secure a knot in one end of the rope and insert the rope through the hole in the recoil reel then wrap rope counterclockwise around reel leaving 50 cm 20 in of rope free of roller Align the hook in the end of the recoil spring with the notch in the recoil housing NOTE At this time a light oil may be used 5 to lubricate both the spring and reel hub Carefully slide the recoil reel over the hub and hook spring on the hub NOTE To ensure correct spring installa tion rotate reel clockwise until slight spring tension is felt 6 Slide two notched washers onto the recoil shaft 7 return spring to the hole in the recoil reel 8 Install compression spring and cover 9 Install starter pawls Fig 5 10 794 10 Use a hooked wire to guide the return 11 12 13 14 40 spring when installing the drive plate Rotate the plate until spring is in position Press drive plate onto shaft then secure with a notched washer and E ring Place recoil in position on fan housing then install screws Pull the recoil rope until pawls engage with recoil pulley This will center the recoil on the housing Tighten the three screws securing the re coil Check recoil for correct operation SECTION 6 SERVICE PARTS TABLE OF CONTENTS Ski Engine and Belly
27. ew Fig 2 61 ATTS 12 Install recoil starter Just before tightening Screws pull recoil rope and hold to center recoil then tighten screws securely Fig 2 62 13 Install exhaust gasket then place muffler onto exhaust studs Secure muffler with two nuts and lock washers tighten nuts to 8 11 6 8 ft Ib Fig 2 63 AFTE gt 14 Install spark plug then tighten to 25 28 n m 18 20 ft lb 15 In order place a gasket insulator and gasket onto the intake studs Fig 2 64 ATTT 16 Connect carburetor rod and rod spring to the throttle control lever and the carburetor throttle plate 17 Slide carburetor onto the intake studs then secure with two nuts and lock washers Tighten nuts to 8 11 n m 6 8 ft Ib Fig 2 65 Fill Gear Case 1 Remove the oil fill plug located on the top of the gear case cover 2 Remove the oil level screw from the lower side of the gear case cover 3 Add SAE 10W 30 lubricant until fluid flows out oil level hole 4 Install the oil level screw 5 Install the oil fill plug 23 SECTION 3 FUEL SYSTEM TABLE OF CONTENTS y Ags Reda pras 26 Removal and Disassembly TEMPS CAB BING dean b e 27 ERIT 28 Assembly and Installation 28 ACTUSUNG eter ater sade 92564 30 Throttle Stop
28. hut the engine off and wait for all moving parts to stop remove the drive chain shield and lubricate the drive chain After lubricating the drive chain install the drive chain shield 4 If excessive dirt is present on the drive chain clean using the following procedure 1 Remove the drive chain shield 2 Remove the master link from the drive chain then remove the chain 3 Washthe drive chain in parts cleaning solvent and dry using compressed air 4 Place the chain into position on the clutch sprocket loop the chain over the driven sprocket and install the master link making sure that the clip open end is directed away from the direction of drive chain rotation and that the clip is seated properly NOTE Make sure the chain is resting on the chain tensioner and proper chain tension is maintained 5 Lubricate the drive chain with dry graphite based chain lubricant 6 Install the drive chain shield NOTE If a dry graphite based chain lubri cant is not available lubricate the drive chain with several drops of petroleum based oil the Kitty Cat is operated in the summer with the optional wheel kit the drive chain should be lubricated more frequently STEERING POST BUSHINGS Apply a lightweight petroleum based oil to the upper and lower steering post bushings every 40 operating hours GEAR CASE Every 40 operating hours the lubricant level should be checked in the gear case To check the lubr
29. icant level remove the oil level screw from the lower side of the gear case The lubricant must be at the point of overflowing in the oil level hole If lubricant is not present add SAE 10W 30 through the oil fill hole until it flows out of the oil level hole e _ QURE Fill Oil Level Screw 0726 156 Checking Brake Lever Travel 1 Compress the brake lever fully 2 Check the distance between the brake lever and the lever stop The distance must be within the specified range of 6 13 mm 1 4 1 2 In Fig 1 2 1 4 1 2 in 3 travel distance is not as specified adjust the brake Adjusting Brake Lever Travel To adjust the brake lever travel use the following procedure 1 Remove the drive chain shield 2 Loosen the jam nut on the retaining pin then tighten the retaining pin to set up the brake Fig 1 3 Forward Flange Nut Rearward Flange Nut Retaining Pin 3 Check the brake lever travel distance periodically while tightening the retaining pin When the distance is within the specified range of 6 13 mm 1 4 1 2 in tighten the jam nut on the retaining pin to secure the adjust ment NOTE The brake band should lock tightly when the brake lever is compressed and should disengage when the lever is released additional adjustment is necessary use the following steps 1 Loosen the rearward flange nut on the brake cable 2 Tighten the forward flang
30. l a non resistor type spark plug and cap 2 the mm 1 adapter to the spark plug wire Attach the yellow tester lead to the mm 1 connector Connect the red tester lead to a good ground on the engine Fig 4 6 Yellow gt Red 10 Ground 3 Set the tester selector knob 85 Set the high low switch in the high scale position 4 Crank the engine over quickly If the tester light illuminates output is satisfactory If the tester light fails to illuminate proceed to testing the charge coil output Test 3 times for conclusive results Charge Coil Output Test The new Kitty Cat ignition has incorporated the CDI unit and external coil into one component Because of this we will proceed directly to the charge coil test after testing the external coil output 1 Disconnect the small single black lead from the external coil to the main wiring harness 2 Using a adapter wire from the tester kit connect the red tester lead to the single wire connector of the main engine wiring harness Connect the yellow tester lead to a good ground on the engine 3 Set the tester selector knob on 55 high Scale 4 Crank the engine over quickly If the tester light illuminates output is satifactory and this would pinpoint the external coil and CDI unit as being defective 34 5 the tester light fails to illuminate during the charge coil test replace the charge coil Repeat the te
31. llic carburetor parts with a good quality carburetor cleaner DO NOT place any of the non metallic parts in car buretor cleaner because damage or de terioration will result After all metallic parts have been washed place the parts in a wire basket and sub merse in carburetor cleaner the parts for about 30 minutes then rinse with fresh carburetor cleaner Dry the components with compressed air only making sure all holes orifices and channels are unobstructed DO NOT use wire or small drill bits to clean car buretor orifices holes or channels Distorted or damaged orifices holes or channels can result in poor carburetor operation The carburetor must be cleaned with carburetor cleaner only 27 Inspection NOTE Whenever a part is worn exces sively cracked defective or damaged any way replacement is necessary 1 Examine the carburetor body float bowl and mixing chamber for cracks nicks stripped threads and any other imperfec tions in the casting Examine the throttle and choke plates for any bends or damage Check condition of the throttle return spring Inspect float for holes or damage Inspect all gaskets and O rings for distor tion tears or noticeable damage Inspect nozzle and tube for damaged holes or threads Inspect tip of inlet needle valve Replace valve if tip is worn or grooved Fig 3 9 8 10 2
32. lt Bearing Left Lever Throttle Cable Governor 3002 702 3002 459 3003 320 3002 518 3002 455 3002 468 3002 621 3003 268 3002 689 3002 515 3002 466 3002 516 3002 736 3002 517 3002 912 Ref Bolt Spacer Bearing Right Shaft Primary Driven Washer Spring Bracket Throttle Cable Bolt Adjuster Nut Adjuster Rod Carburetor Spring Carburetor Rod Gear Primary Drive Nut Gear Primary Driven Washer Lock C 1 Ehn Carburetor Ref 6505 294 e Screw Throttle Ad justing 6505 289 e Spring 3003 262 e Bolt 6505 013 e Washer 6505 284 e Nozzle 6505 286 e Gasket Float Chamber 3003 263 Screw Pilot Adjusting 6505 291 e Spring 0720 072 Ref No Part No Qty Description 3002 618 Carburetor Ass y inc 2 17 6505 285 Tube 3003 189 e Main Jet 6505 292 e 6505 287 s Float 6505 288 s Pin Float 6505 293 Needle Valve Ass y 6505 244 a Gasket 6505 297 e Pilot Jet No 35 CO Ch Cn a D727 133 00 J C Cn i oop 3003 150 3003 146 3003 147 3002 711 3003 097 3003 270 3003 145 3002 453 3002 490 Q9 o stator inc 2 5 e Coil Lighting a Coil Primary e Screw Washer Lock e Screw Rotor Screw Fan 18 3002 446 3002 664 3002 450 3003 053 3002 464 3003 191 3002 349 3003 020 3002 465 Screw Nut Washer Washer Lock Clamp Coil Ass y Screw Washer
33. ly Polish the exterior of the snowmobile using an automo tive type cleaner wax 2 Clean the engine cooling fins and the recoil starter vents Remove the cloth from the muf fler 3 Check all control wires and cables for signs of wear or fraying Replace if necessary Use cable ties or tape to route wires and cables away from hot or rotating parts 4 Inspect the drive chain and drive chain ten sioner Replace if necessary 5 Lubricate the drive chain and steering post bushings 6 Check brake lever travel distance all con trols ski alignment track tension track align ment brake band and ski wear bars adjust or replace as necessary 7 Examine the fuel filter and clean or replace if necessary 8 Fill the fuel tank with properly mixed fuel 9 Clean and install the seat cushion 10 Check the spark plug clean or replace as necessary then start the engine and ensure proper carburetor adjustments Lubrication The drive chain and steering post bushings must be properly lubricated to ensure efficient opera tion Also the gear case lubricant must be main tained at the proper level DRIVE CHAIN The drive chain should be lubricated every 20 operating hours with a dry graphite based chain lubricant By using a dry graphite based chain lubricant dirt buildup on the drive chain will be minimized Before each lubrication inspect the drive chain for dirt accumulation To lubricate the drive chain s
34. lywheel puller remove the fly 18 Remove the screws securing ignition coil wheel Account for the flywheel key then remove coil Fig 2 11 Fig 2 14 A761 A756 16 Scribe a line on the stator plate and the crankcase Use these marks during assembly 12 Gear Case Crankcase 1 Using an impact screwdriver remove the screws securing gear case cover Lift cover off crankcase Fig 2 15 755 2 Remove cover gasket 3 Remove primary driven shaft and gear from gear case Fig 2 16 A752 4 Remove shifter from end of engine crank shaft 5 Remove the nut securing primary drive gear and centrifugal to the crankshaft Fig 2 17 A748 6 In order remove the centrifugal weight assembly primary drive gear and key from the crankshaft Fig 2 18 go ATAT 7 Using an impact screwdriver remove the five screws securing crankcase halves Fig 2 19 745 8 Carefully separate the crankcase halves 00 OT ve ch ree or any ter instruments 10 pry cases apart Any damage to the crankcase sealing area will an air leak resulting in severe engine damage 13 Fig 2 20 742 9 the crankshaft from the crankcase 10 Thoroughly wash all engine components Cleaning and inspection NOTE Whenever a part is worn exces sively cracked defective or damaged in any way replacement is necessary Cylinder Head 1 Remove
35. ng onto pilot air screw then care fully tighten screw until lightly seated From the seated position rotate the pilot air screw one turn counterclockwise 8 Install the pilot jet 9 Place the small air silencer gasket onto the carburetor studs 10 Thread choke rod through hole in silencer housing then connect choke rod to choke plate Slide air silencer onto mounting studs 11 Slide the two spacers onto the mounting studs 12 Make sure silencer gasket is positioned on outer cover then install cover and secure with two cap screws and lock washers Fig 3 13 13 780 In order place gasket insulator and gasket onto the cylinder intake studs Fig 3 14 14 15 16 17 ATTT Connect carburetor and carburetor rod spring to both the throttle control lever and the throttle plate Sfide carburetor onto the cylinder intake mounting studs Secure with two lock washers and nuts Connect fuel line to the carburetor Rotate the fuel shut off valve counterclockwise Check throttle cable operation Throttle system must work smoothly and must not stick or bind If throttle does not operate smoothly replace necessary parts N WARNING 44 DO NOT operate the Kitty Cat if any component of the throttle system binds or sticks Faulty throt tle operation could result in personal injury or property damage 18 Start engine and test run 29 To adjust the throttle cable us
36. ng tie rod If more threads are showing on one end than on the other the jam nuts can be loosened and the tie rod rotated until thread equally is attained this process will not af fect steering alignment Tighten the jam nuts securely 5 Tighten the steering tie rod jam nut 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 snowmobile is operated on terrain where the snow cover is minimal the ski wear bar will wear faster Removing Ski Wear Bar 1 ice and snow buildup from the ski 2 With the fuel tank nearly empty less than 1 4 full lay the snowmobile on its side A piece of cardboard should be used to protect the finish on the hood 3 Remove the lock nut and washer securing the wear bar to the ski 0725 071 4 Either pry or pull the center of the wear bar away from the ski until the wear bar bolt is clear of the ski then slide the wear bar for ward as far as possible and pull the rear of the wear bar from the hole in the rear of the ski 5 Remove the wear bar from the hole in the front of the ski Installing Ski Wear Bar 1 Insert the front of the wear bar into the hole at the front of the ski and swing the wear b
37. nnect the single external coil lead from the main wiring harness Set the Multitester selector in the X1K posi tion Touch the two tester leads together and zero the meter Touch the red tester lead to the single black lead of the external coil Touch the black tester lead to the metal center post of the coil Fig 4 8 The meter should read 11 000 ohms 20 Testing Charge Coil 1 Disconnect the small single black lead of the external coil from the main engine wir ing harness 4 Set the Multitester selector knob in the X100 position Touch the tester leads to gether and zero the meter Touch the red tester lead to the single con nector of the main engine wiring harness Touch the black tester lead to a good ground on the engine Resistance of the charge coil must meas ure 117 ohms zx 20 Fig 4 9 Testing Lighting Coil 1 Disconnect the main wiring harness at the engine 2 Set the Multitester selector in the X1 posi tion and touch the two tester leads to gether Zero the meter 3 Touch the two testers leads to the two yellow wires in the engine wiring harness connector 4 Lighting coil resistance must measure 1 3 ohm 20 Fig 4 10 39 Ignition Timing NOTE Engine timing can only be checked I with the engine running at 6000 rpm using a good quality timing light Before checking the timing allow the engine to run and warm up for 5 min Checking 1 Remo
38. ock Plate Engine Engine 06 8 Strap Cap Gas Tank Gas Hose Fuel 25 Filter Shut Off Pad Bracket Fuel Tank Washer Spring Screw 0300 133 8002 140 0123 425 0300 158 8040 426 0300 154 0300 187 8002 142 8050 247 8040 396 0300 124 0300 126 0300 189 0109 413 3003 023 8050 217 0123 498 8050 217 TIUS SPEI Screw Clamp Saddle Nut Lock Spring Cover Saddle Screw Cap Washer Nut Lock Ski Skag Tip Ski Bushing Washer Washer Clamp Washer 0727 248 Ref No 1 0300 176 0302 072 0609 005 0609 004 0609 006 0123 616 0123 614 0124 054 0302 066 0123 636 0123 149 0123 788 B041 126 Fo Ohh ao Hood Assembly 1 Hood Bezel Headlight Housing Head Lamp Bulb Head Lamp Socket w Rubber Cap Screw Adjusting Spring Adjusting Snap amp Cap Harness Wiring Screw Machine Washer Backing Cable Tie Nut Lock Thin 0123 010 0123 549 0212 549 0211 951 0302 150 0302 151 0302 152 0302 153 0211 950 0611 195 0606 097 0300 155 0300 185 8 nO PO fO 00 Nut Expansion Screw Machine Decal Arctic Cat Decal Front Stripe Decal Side Right Decal Side Left Decal Rear Side Right Decal Rear Side Left Decal Kitty Cat Tape Reflective Windshield Hook Latch Latch Rubber 0727 249 Ref No Par
39. ometer or snap gauge to the cylinder just above the intake port Take measurement from front to back Fig 2 26 A729 2 Measure the piston skirt 1 cm 0 375 in above the bottom of the piston skirt 15 Fig 2 27 AT31 3 Subtract the measurement in step 2 from measurement in step 1 The difference is the piston skirt clearance and must be 0 05 0 13 mm 0 0020 0 005 in UT NOTE If the clearance exceeds the wear limit the piston must be replaced to bring clearance into acceptable range However if clearance is still excessive the cylinder will have to be replaced Piston Ring End Gap 1 Insert the piston ring about 1 cm 0 375 in in to the top of the cylinder bore Position the ring horizontally in cylinder by pressing the dome of the piston against the ring 2 Slide a feeler gauge between the ends of the ring Fig 2 28 AT35 3 Piston ring end gap must be 0 20 0 80 mm 0 008 0 031 in Since the amount of wear at the ends and center of the piston ring af fects the end gap replace the ring set if the ring end gap is excessive 16 Crankcase Halves 1 Thoroughly wash halves using cleaning sol vent 2 Inspect halves for scoring pitting scuffing or any imperfections in the casting 3 Inspect all threaded areas for damaged or stripped threads Fig 2 29 AT21 4 Check the bearing areas for signs of cracking or bearing movement then check dowel pins for wear 5
40. ommends the following procedure to prepare the snowmobile for summer storage 1 Hemove the seat cushion from the tunnel wash with a damp cloth and store in a dry place 2 Clean the snowmobile thoroughly by hosing dirt oil grass and other foreign matter from the underframe tunnel hood and belly Allow the snowmobile to dry thoroughly DO NOT get water into any part of the engine 3 Drain all fuel from the fuel tank Close the fuel shut of valve by rotating it clockwise then remove the air intake cover Start the engine and allow it to idle then using a rust prevent ative oil rapidly inject the oil into the car buretor air intake for a period of 10 to 20 seconds until all fuel in the carburetor float bowl is used and the engine stops This pro cedure will coat the crankshaft with a protec tive coating of oil Install the air intake cover and the fuel tank cap if it was removed 4 Plugthe hole in the muffler with a clean cloth 9 Disconnect the high tension wire from the spark plug then remove the spark plug Pour 15 ml 1 2 fl oz of petroleum based oil into the spark plug hole then pull the recoil starter handle slowly about ten times Install the spark plug and connect the high tension wire 6 Remove the drive chain and clean thoroughly in a solvent Install drive chain and lubricate with a dry araphite based chain lubricant NOTE The drive chain is equipped with a master link for servicing
41. openings in the face of the flywheel Using a long screwdriver loosen the three screws and rotate the stator clockwise or counterclockwise to correct timing Tight en screws reassemble engine and recheck timing for accuracy NOTE The Kitty Cat engine runs counter clockwise so to advance timing rotate the stator plate clockwise To retard timing rotate the stator plate counterclockwise SECTION 5 RECOIL STARTER TABLE OF CONTENTS Removal and Disassembly seid 38 Cleaning and 39 Assembly and Installation 40 4 Lift drive plate free of hooked portion of return spring then remove drive plate from Removal and recoil shaft Disassembly 5 Remove spring cover and spring from recoil shaft then remove recoil pawls Fig 5 4 1 Remove the three screws and lock washers securing recoil to magneto housing Fig 5 1 Lr A794 6 Disconnect return spring from recoil reel H then remove spring Fig 5 5 2 Pull the recoil rope about two feet Using a hook guide the recoil rope into the notch of the recoil reel Grasp recoil reel and 4 slowly allow the recoil reel to unwind until all spring tension is released Fig 5 2 795 7 Remove two keyed washers from recoil shaft 8 Carefully lift the recoil reel w main spring off the recoil shaft AT93 9 If the recoil main spring must be replaced b
42. p of the cylinder If meas urements vary by more than 0 05 mm 002 the cylinder is tapered or out of round and must be replaced Piston 1 Remove carbon buildup from dome of piston using a non metallic carbon removal tool 2 Examine the sides of the piston for evidence of excessive blow by Excessive blow by will indicate worn piston rings or an out of round cylinder 3 Check the sides and skirts for evidence of scuffing To remove minor marks use 400 grit Wetordry sandpaper and lightly sand the affected area Fig 2 23 3 A732 4 Check the pistons for signs of cracks in the piston pin and skirt areas Replace piston if damage is found 5 Use a piece of an old ring to clean the ring grooves Make sure ring retaining pin is rectly positioned and is in good condition 6 Insert an inside snap gauge about 6 mm 0 250 in from the outside of the piston pin bore Carefully remove the snap gauge Fig 2 24 gt A733 7 Measure the snap gauge with a micrometer Piston pin bore must be 12 00 12 01 mm 0 4724 0 4728 in 8 Measure the piston pin approximately 6 mm 0 250 in from each end Piston pin diam eter must be between 11 99 12 00 mm 0 4720 0 4724 in Fig 2 25 73 re A734 il NOTE piston pin is not within specifica tions replace the piston pin and bearing as a set Piston Skirt Clearance 1 Insert an inside micr
43. retor Slide carburetor off intake studs Fig 2 1 779 10 SPECIFICATION AA06A8 2 Cycle Air Cooled 1 Gas Oil Mix Manual 41 x 45 1 614 x 1 772 59 3 60 6 6 1 0 20 0 80 0 008 0 031 0 05 0 13 0 0020 0 005 11 990 12 000 0 4720 0 4724 12 000 12 010 0 4724 0 4728 15 99 16 00 0 6295 0 6303 0 05 0 002 0 05 0 10 0 002 0 004 then disconnect carburetor rod and rod spring 3 Slide gasket insulator and gasket off intake studs 4 Remove the nuts and lock washers securing muffler Slide muffler off exhaust studs then remove exhaust gasket Fig 2 2 778 5 Remove recoil starter 6 screws securing fan cover then remove cover Fig 2 6 ATTS 1 11 Remove piston pin circlips Remove piston 7 Remove cylinder head cowling pin using the Arctic piston pin puller Fig 2 4 Fig 2 7 8 Remove the cylinder head nuts and washers lift head off cylinder studs 12 Remove recoil starter pulley and spacer 9 Slide head gasket off cylinder studs Fig 2 5 Fig 2 8 ATT2 AT66 10 Slide cylinder straight upward until free of 13 Remove four countersunk screws securing piston Remove base gasket fan then remove fan 11 Fig 2 9 A764 14 Using a flywheel holder or equivalent remove the flywheel nut 17 Remove the three screws securing stator plate to crankcase Fig 2 10 A762 15 Using a f
44. st 3 times for conclusive results Push the reset button between each test NOTE Before replacing any ignition com ponents make sure none of the connectors are corroded or loose Testing Electrical Resistances NOTE resistance tests on the Kitty Cat ignition can be made using the Arctic Multitester p n 0144 053 The following test procedure starts by testing the resistance of the spark plug cap and working back to the charge coil under the flywheel Replace any component that does not have a test value within specification given Testing Spark Plug Cap 1 Remove the spark plug cap from the high tension lead by rotating counterclockwise 2 Set the Multitester selector knob on the X1K position Touch the tester together and zero the meter 3 Touch the two tester leads to either end of the spark plug cap making good contact with its metal contacts 4 Spark plug cap resistance must measure 5000 ohms 20 Testing External Coil Secondary 1 Remove the spark plug cap from the high tension wire of the external coil 2 Set the Multitester selector knob in the X1K position Touch the tester leads together and zero the meter 3 Touch the red lead of tester to the high ten sion lead making good contact with its in ternal wire Touch the yellow tester lead to a good ground Fig 4 7 4 Secondary resistance must measure 5900 ohms 20 Testing External Coil Primary 1 Disco
45. t No P Description oA eh eo OM Ul 4 OO 00 Oi DOROSS 0302 119 8002 220 8050 272 8060 306 0123 534 0300 215 0300 210 0123 406 0302 093 0123 231 0302 085 0123 230 0302 147 8070 318 0302 045 0300 208 0109 822 0302 155 0116 065 0611 166 0211 849 0211 847 0302 092 8070 222 0302 165 0123 191 wwe nded4 Front End Screw Cap Washer Rivet Nut Snap In Nut Jam Nut Adjusting Nut Flange Cable Brake Ring Retaining Lever Pin Grip Left Pin Spring Console Screw Self Tapping Switch Ignition Decal Dash Key Decal Caution Decal Choke Decal Throttle Cable Throttle Pin Spring Grip Right Nut Jam 0302 084 0123 788 8040 366 8002 070 0300 159 0300 140 0609 007 0706 034 0123 790 0302 082 8051 278 0123 851 0300 123 0302 162 8041 516 0302 080 8012 130 0611 022 0124 061 0300 211 0302 054 0302 088 8050 217 0123 397 8060 430 0109 960 Handle Steering Cable Tie Nut Lock Screw Cap Bracket Steering Clamp Steering Switch Stop Pad Handlebar Nut Knurled Tie Rod Washer Lock Washer Int Lock Ball Joint Crank Spindle Nut Lock Thin Tie Rod Front Screw Cap Decal Stop Switch Washer Pyramidal Nut Lock Harness Bushing Washer Clamp Cable Rivet Cap Handlebar 07
46. ting Track Tension 1 Loosen the axle bolts on both ends of the ax le 7 Tensioner Axle Bolt 2 Adjust the tensioner lock nuts on both sides of the track until the proper track tension is attained Make sure to adjust both lock nuts equally 3 When track tension is correct tighten axle bolts to 2 8 3 3 kg m 20 24 ft Ib Track Alignment Proper track alignment is obtained when the rear track drive sprockets are centered in the track cutouts If the track runs to the right or left center an adjustment is necessary Adjusting Track Alignment 1 Before adjusting track alignment remove ex cess ice and snow buildup from the track and track drive sprockets 2 Raise the rear of the snowmobile off the floor making sure the track is free to rotate If the track runs to the right loosen the right side axle bolt and tighten the right side ten sioner lock nut one revolution If the track runs to the left loosen the left side axle bolt and tighten the left side tensioner lock nut one revolution 4 Start the engine and accelerate only enough to rotate the track several revolutions SHUT ENGINE OFF NOTE Allow the track to coast to a stop DO NOT apply the brake because it could pro duce an inaccurate alignment condition 5 When the track stops rotating check the track alignment and continue adjusting until proper alignment is attained 6 Tighten the axle bolt to 2 8 3 3 kg m 20
47. ve the rubber plug located on the in take side of the fan housing Remove the spark plug from the cylinder and install the Arctic dial indicator p n 0144 009 in the spark plug hole using the adapter provided Fig 4 11 36 POS Rotate the engine to top dead center TDC Set the dial of the indicator to the zero posi tion and rotate the flywheel back and forth to check accuracy of zero position Needle must change direction exactly at zero on dial From the TDC position rotate the flywheel clockwise 1 728 mm 0 068 in Holding the flywhee in this position scribe a mark on the flywheel in alignment with the sta tionary pointer found by looking down into the timing hole of the fan housing Connect a timing light and tachometer to the engine Using a shielded safety stand raise the rear of the machine off the floor and start the engine Allow the engine to run for 5 min at a fast idle Gradually increase the engine rpm the scribed mark on the flywheel should align with the stationary pointer of the fan housing at 6000 rpm 7 If the timing is not correct adjust timing Adjusting 1 Remove the screws securing the housing to the engine 2 Remove the three screws securing the starter pulley to the flywheel then remove the four countersunk screws securing the fan to the flywheel Remove pulley and fan 3 Rotate the flywheel until the screws secur ing the stator plate can be viewed through the
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