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Operator`s Manual

1. Item Interval Page Remarks Brake System Daily 27 Check for binding leakage and proper operation lever firmness travel caliper disc and pads Cooling System Liquid Daily 10 25 Check for leakage damage obstructions coolant level Oil Injection System Daily Check for leakage damage and injection oil level Stop Switch Daily Check for proper operation Hoses Daily Check for damage leakage and wear Headlight amp Taillight Brakelight Daily 36 37 Check for proper operation and cleanliness Steering System Daily Check for proper operation tightness of bolts and binding Throttle Control System Daily 19 Check for binding sticking proper operation throttle cable tension and wear Drive Belt Daily 30 Check for wear cracks and fraying Monthly Check length and width dimensions Ski Wear Bars Daily 38 Check for wear and damage Electrical Wiring Weekly Check for wear damage and tight connections Exhaust System Weekly 10 Check for damage leakage and obstructions Nuts Bolts Fasteners Weekly Check tightness Recoil Starter Weekly Check rope for wear fraying and proper operation Shock Absorbers Weekly 11 34 Check for fluid leakage and damage and air pres sure Fox Air Shocks Spark Plugs Weekly 25 Check center electrode insulator color carbon and gap Suspension Weekly 34 Check for damage loose components and proper ad
2. 18 Preparation after Storage Removable Seat Crossfire 800 Models 15 U S EPA Emission Control Statement Warranty TOWINQ M iii 2 15 Coverage U S Only sss 46 Arctic Power Valve APV System 15 Change of Address Ownership or Warranty Exhaust Controlled Timing ECT System 16 Transfer aere tete toe notet ets Ces tlt Operating Instructions 17 20 Warranty Procedure Owner Starting and Stopping Engine 17 Responsibility Inside Back Cover Braking iii 18 Reference Information Write the appropriate information for your Arctic Cat Snowmobile in the spaces below Always use these numbers when referring to your snowmobile Model Date of Purchase Vehicle Identification Number Engine Serial Number Your Arctic Cat Dealer Address Phone A WARNING A snowmobile is a very high performance vehicle Because it does acceler ate rapidly and is capable of very high speeds it should not be operated by a novice or an inexperienced operator Never accelerate rapidly or drive at high speed beyond the limits of visibility or without being totally familiar with the terrain and what lies in front of you Obey speed limits and never operate at speeds that do not allow adequate maneuvering and stopping dis tances Read and study the entire Operator s Manual and Safety Handbook Failure to follow th
3. 1 Turn ignition key to the OFF position and wait for all moving parts to stop 2 Set the brake lever lock 3 Open the left side access panel then remove the belt guard 4 Remove the cap screw lock washer washer and sheave adjuster from the end of the driven pulley W NOTE Assure that the shims and O ring are not removed from the adjuster Movable Sheave Drive Belt CI Sheave Adjuster CRI BSS Shims 0 Ring Cap Screw Lock Washer Washer Driven Clutch 0743 395 5 Remove the cap screw w lock washer and washer from the adjuster remove the washer and lock washer from the cap screw turn the adjuster around reverse it and insert the cap screw into the adjuster D 4 3 Movable Sheave rive Belt Sheave Adjuster Z Driven Pulley Cap Screw 0744 551 6 Install the sheave adjuster and cap screw onto the driven pulley then tighten the cap screw until the mov able sheave opens far enough to allow the belt to be removed B NOTE Before installing the drive belt use a suitable cleaning solvent to thoroughly clean the sheaves 7 Remove the drive belt from the driven pulley first then from the drive clutch Installing Drive Belt B NOTE If a new drive belt is being installed see Drive Belt Break In sub section in the General Infor mation section Place the drive belt so the part num ber can be read between the sheaves
4. W NOTE The brake pads may be changed by the snowmobile owner if qualified to do so If the owner does not feel qualified take the snowmo bile to an authorized Arctic Cat Snowmobile dealer for this service This service is at the discretion and expense of the snowmobile owner B NOTE When installing new brake pads always install them as a set Never install just one pad or use brake pads which have been used in another snowmobile 1 Measure the thickness of both brake pads The brake pad thickness must be greater than 5 0 mm 0 20 in If the brake pad thickness is less than specified replacement of both pads is necessary Brake Pads Brake Disc Hydraulic Brake Caliper 0739 269 2 Remove the pin hairpin clip secur ing the brake pads to the caliper assembly 3 Remove the brake fluid reservoir cover then remove most of the brake fluid from the reservoir Install the cover B NOTE The above procedure will allow room for the fluid from the cali per when the pistons are pushed into the caliper for installing new brake pads Replacing the cover will prevent fluid spillage 4 Using a pair of pliers pull one brake pad out of the caliper assembly E NOTE Changing one pad at a time will prevent one piston from pushing out the other piston from the caliper 5 Using a flat blade tool slowly and carefully push the piston into the caliper 6 Position the new brake pads into the caliper
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6. This service is at the discretion and expense of the snowmobile owner Lubrication ACT Drive Gear Case It is very important that the gear case be flushed and the lubricant be replaced after each season of use Arctic Cat rec ommends that the flushing and replacing be done prior to off season storage E NOTE Flushing the gear case and replacing the lubricant can be done by the snowmobile owner if qualified to do so If the owner does not feel qualified take the snowmobile to an authorized Arctic Cat Snowmobile dealer for this service This service is at the discretion and expense of the snowmobile owner To flush the gear case and replace the lubricant use the following procedure 1 Open the left side access panel then remove the panel and the belt guard 2 Remove the drive belt see Drive Belt sub section in the Maintenance sec tion then remove the driven pulley W NOTE If excessive oil deposits are noticed take the snowmobile to an authorized Arctic Cat Snowmobile dealer for service If not under war ranty this service is at the discretion and expense of the snowmobile owner 3 Using Handlebar Stand p n 5639 152 or a suitable substitute tip the snowmobile onto its right side W NOTE It is recommended that the gas tank be nearly empty less than 1 4 full when tipping the snowmobile 4 Remove the drain plug from the gear case then install a drain adapter fit ting with hose into the drain p
7. ing the ski assembly to the spindle Remove the ski Account for the rubber damper inserts and washers 3 To increase ski stance place both ski stance spacers to the outside of the spindle 4 To decrease ski stance place both ski stance spacers to the inside of the spindle 5 Apply an all temperature grease to the non threaded portion of the cap screw then slide the cap screw through the ski accounting for the rub ber damper inserts and washers B NOTE Install the cap screw so the slotted nut will be located to the inside of the ski 6 Apply red Loctite 271 to the threads of the cap screw then tighten the nut to 45 ft Ib 7 Place the cotter pin into the ski cap screw and spread the pin 8 Repeat procedure for the other ski Rail Wear Strips Arctic Cat recommends that the wear strips be checked weekly and replaced as necessary Measure the wear strips at 25 4 cm 10 in intervals Wear strips must be 10 7 mm 0 42 in thick or thicker If wear strip measurements are less than specified replacement of both wear strips is necessary to prevent premature track clip wear and possible track damage Take the snowmobile to an authorized Arctic Cat Snowmobile dealer for this service This service is at the discretion and expense of the snowmobile owner Each time a new set of wear strips are installed they should be tempered Tem per the wear strips by driving the snow mobile for approximately a mile
8. To maintain positive steering characteris tics Arctic Cat recommends that the ski wear bars be checked before each use and replaced if worn beyond 1 2 of the origi nal diameter Ski wear bars are available from an authorized Arctic Cat Snowmo bile dealer A WARNING result in a loss of steering control Removing Ski Wear Bars W NOTE Determine which type of wear bar is being replaced and remove and install accordingly 1 Remove ice and snow buildup from the ski 2 Using a suitable safety stand or lift elevate the front of the snowmobile 3 Remove the lock nuts securing the wear bar to the ski Wear Bar 0743 185 4 Remove the wear bar from the ski Installing Ski Wear Bars 1 Move the wear bar into position on the bottom of the ski 38 B NOTE If installing a double offset wear bar the carbide edge must be directed to the outside of the ski 2 Align the wear bar studs with the holes in the ski then install the lock nuts Tighten to 11 15 ft Ib Adjusting Ski Stance B NOTE Local laws and or regula tions as to maximum width of the ski stance on these snowmobiles may be applicable Always comply with the maximum width laws and or reg ulations when adjusting ski stance E NOTE Ski stance can be increased decreased by 2 5 cm 1 0 in Place the front of the snowmobile on a support stand 2 Remove the cotter pin then remove the slotted nut and cap screw secur
9. oz tua a j AO352A A TAN or LIGHT BROWN insula tor indicates correct spark plugs heat range B LIGHT GRAY or WHITE insula tor indicates over heating of the engine This condition is caused by a too lean condition or incorrect spark plugs heat range too hot C BLACK insulator indicates fuel in the combustion chamber is not burning completely This condi tion is caused by a too rich con dition too much oil or incorrect spark plugs heat range too cold W NOTE If the center electrode insu lators are light gray white or black and if the oil injection pump synchro nization and ignition timing are cor rect different heat range spark plugs may be necessary Authorized Arctic Cat Snowmobile dealers have detailed spark plug information Con sult a dealer before changing spark plugs as incorrect heat range spark plugs could cause poor engine per formance or engine damage CAUTION If a spark plug is light gray white or black and another is tan or light brown take the snowmobile to an authorized Arctic Cat Snowmobile dealer for inspection and service If not under warranty this service is at the discretion and expense of the snowmobile owner 26 Checking Adjusting APV Cables Proper cable adjustment is critical to the operation of the APV system Although inspecting cable adjustment is recom mended every 1000 2000 miles the cable should not need adjustme
10. Arctic Cat Snowmobile dealer for service If not under war ranty this service is at the discre tion and expense of the snowmobile owner Low Oil Warning Icon The Low Oil Warning Icon is designed to alert the snowmobile operator when the oil in the oil injection reservoir gets below a prescribed level however it is highly recommended that a visual verification of the oil level in the reservoir be done prior to operating the snowmobile Once the Low Oil Warning Icon illuminates during operation of the snowmobile the operator must periodically monitor the level of oil in the reservoir and must fill the reservoir the next time gasoline is added to the gas tank The alert level of the Low Oil Warning Icon is approximately equal to tankful of gasoline under normal operat ing conditions Diagnostic Codes Diagnostic codes are activated by the ECU and may be displayed on the read out screen for a number of reasons If a code is displayed while the engine is running the ECU is receiving input that is outside of its established parameters If a code has been activated take the snow mobile to an authorized Arctic Cat Snow mobile dealer for service If not under warranty this service is at the discretion and expense of the snowmobile owner Additional codes are displayed on the readout screen Refer to the following chart for diagnostic codes Code Trouble 2 Failure in injector s 4 Open or short circ
11. be checked Also offset must be checked whenever either the drive clutch or driven pulley is serviced W NOTE For checking offset it is necessary to use Clutch Alignment Bar p n 0644 496 This special tool can be purchased from an autho rized Arctic Cat snowmobile dealer To check offset use the following proce dure 1 Open the left side access panel then remove the belt guard 2 Install the clutch alignment bar between the drive clutch sheaves 3 Allow the bar to rest on the drive clutch shaft and against the outside edge of the driven pulley stationary sheave E NOTE The alignment bar must extend beyond the front edge of the drive clutch 4 With the bar against the outside edge of the driven pulley stationary sheave at points A and B the bar should just clear the inside edge of the stationary sheave of the drive clutch and rest on the stationary shaft at point C with a maximum 0 060 in clearance at point C At this point measurement between points A and C should be 1 507 in with a maximum 0 060 in clear ance If the bar either will not clear the inside edge or is more than the specified amount the offset must be corrected 0745 177 B NOTE If the offset is out of speci fication take the snowmobile to an authorized Arctic Cat Snowmobile dealer for drive system evaluation and or servicing This service is at the discretion and ex
12. in severe engine damage Cooling System These snowmobiles are equipped with a closed liquid cooling system for engine cooling The cooling system should be inspected daily for leakage and damage Also the coolant level should be checked daily If leakage or damage is detected take the snowmobile to an authorized Arctic Cat Snowmobile dealer for ser vice If not under warranty this service is at the discretion and expense of the snowmobile owner When filling the cooling system reser voir use an ethylene glycol based cool ant water mixture which will satisfy the coldest anticipated weather conditions of your area in accordance with the coolant manufacturer s recommendations For checking filling cooling system refer to Coolant Level sub section in the Main tenance section Drive Clutch and Driven Pulley The drive clutch and driven pulley do not require lubrication therefore no special maintenance is required by the snowmo bile owner except for periodical cleaning see the Periodic Maintenance Checklist in the Maintenance section However the drive clutch and driven pul ley should be disassembled cleaned and inspected by an authorized Arctic Cat Snowmobile dealer after every 800 miles of operation or at the end of the snowmo biling season whichever occurs first This service is at the discretion and expense of the snowmobile owner When operating the snowmobile at high altitudes it may be
13. ing upon the ambient air temperature and the temperature of the brake fluid If loss of brakes has occurred because of high fluid temperatures do not operate the snowmobile until the cool down period has expired and brake lever firmness has returned A WARNING Excessive repetitive use of the hydraulic brake for high speed stops will cause overheating of the brake fluid and premature brake pad wear which will result in an unexpected loss of brakes 2 Be sure to maintain the brake fluid at the proper level and take care not to get any moisture in the system as moisture in the brake fluid lowers the boiling point If the brake fluid is ever boiled by high speed stops or repeti tive use or if moisture is allowed to enter the system it must be changed Never substitute or mix different types or grades of brake fluid A WARNING Use only Arctic Cat approved brake fluid Never substitute or mix differ ent types or grades of brake fluid Brake loss can result Check brake fluid level and pad wear before each use Brake loss can result in severe injury or even death 3 Never ride the brake Even main taining minimal pressure on the brake lever will cause the brake pads to drag on the disc and may overheat the brake fluid 4 The brake lever lock is not a parking brake and should not be applied for periods exceeding 5 minutes NEVER OPERATE THE SNOW MOBILE WITH THE BRAKE LEVER LOCK ENGAGED A WARNIN
14. must be checked every time before starting the engine The brake fluid must be visible in the sight glass A WARNING DO NOT operate the snowmobile when the brake lever lock is engaged or when any component in the brake system is damaged worn or adjusted improperly If the snowmo bile is operated and the brake sys tem is not functioning properly severe personal injury could result Checking Adding Brake Fluid 1 With sight glass reservoir in a level position check the fluid level The brake fluid level must be visible in the sight glass B NOTE If the sight glass appears dark there is a sufficient amount of fluid in the reservoir 27 Sight Glass Ke 4 v9 Brake Fluid Reservoir 741 328A 2 If the brake fluid is not visible in the sight glass remove the reservoir cover and add Arctic Cat approved brake fluid until the fluid is at the recom mended level Install and secure the reservoir cover Do not allow moisture to contaminate the brake system CAUTION Brake fluid is highly corrosive Do not spill brake fluid on any surface of the snowmobile A WARNING Do not overfill the brake fluid reser voir Overfilling the reservoir may cause the brake system to hydrauli cally lock Use only Arctic Cat approved brake fluid Never substi tute or mix different types or grades of brake fluid Brake loss can result Brake loss can result in severe injury or even deat
15. necessary to change certain component parts of the drive clutch and or the driven pulley See an authorized Arctic Cat Snowmobile dealer for further information CAUTION DO NOT attempt to service the drive clutch and driven pulley The drive clutch and driven pulley must be serviced by an authorized Arctic Cat Snowmobile dealer only Drive Clutch Driven Pulley Alignment The parallelism and the offset between the drive clutch and driven pulley are set at the factory Normally no adjustment is necessary as long as neither the drive clutch nor the driven pulley is removed or disassembled However if premature drive belt wear is experienced or if the drive belt turns over the drive clutch driven pulley alignment must be checked Take the snowmobile to an authorized Arctic Cat Snowmobile dealer for this service If not under warranty this service is at the discretion and expense of the snowmobile owner Fuel Pump The fuel pump is designed to provide adequate amount of gas to the injectors at all throttle settings If a fuel delivery problem is suspected take the snowmo bile to an authorized Arctic Cat Snowmo bile dealer If not under warranty this service is at the discretion and expense of the snowmobile owner Shock Absorbers Standard Gas Each shock absorber should be visibly checked weekly for fluid leakage cracks or breaks in the lower case or a bent plunger If any one of these conditions is
16. or similar surface B NOTE There should be an aver age operating load on the snowmo bile 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 4 Make a vertical mark which inter sects the horizontal mark on the aim ing surface directly in front of the headlight 5 Engage the brake lever lock and start the engine Move the headlight dim mer switch to the HIGH beam posi tion DO NOT USE LOW BEAM 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 mark on the aiming surface Aiming Surface 8 m 25 ft A AS reme i E 5 cm 2 in up A Fg lD Intense OA 740 153A 7 Adjust the headlight using the adjustment knobs until correct aim is obtained Shut the engine off then disengage the brake lever lock 37 Ski Wear Bars 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 turn ing 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 min imal however if the snowmobile is oper ated on terrain where the snow cover is minimal the ski wear bar will wear faster
17. questions about this information or the emission warranty coverage statement contact your local authorized Arctic Cat snowmobile dealer WARRANTY PERIOD The emission warranty period for this snowmobile begins on the same date as the standard warranty coverage and continues for 30 months or 2500 miles whichever comes first COMPONENTS COVERED The emissions warranty covers major emissions control components and emission related components listed as follows Engine Management and Sensors Fuel Air System Barometric Pressure Sensor Fuel Injectors Camshaft Position Sensor Fuel Pressure Regulator Engine Control Unit ECU Fuel Pump Engine Coolant Temperature Sensor Carburetor s Intake Air Temperature Sensor Turbocharger Assembly Manifold Absolute Pressure Sensor Air Bypass Valve Oxygen Sensor Turbo Waste Gate Control Valve Throttle Position Sensor Crankcase Ventilation System ISC Valve Ignition System Miscellaneous Items Used in Aforementioned Systems Ignition Coil Connectors Knock Sensor System Switches Crankshaft Position Sensor Grommets Exhaust Temperature Sensor Clamps Capacitive Discharge Ignition CDI Module Hoses Magneto Pick Up Ties Gaskets Wiring OWNER S RESPONSIBILITIES The owner of any snowmobile warranted under this Arctic Cat Emission Control Statement is responsible for the proper maintenance and use of the snowmobile as stated in the Operator s Manual Proper maintenance generally includes replacement a
18. specification the snowmobile will bog and lack power at engagement and will have a slower maximum speed For good perfor mance proper belt deflection is critical To correct this condition first determine if the drive belt is within specifications see Drive Belt sub section and replace if worn or too long Always run the drive belt in the same direction Installing the drive belt so the part number can be read will ensure that the drive belt is always run the same direction DRIVE BELT DEFLECTION Drive belt length condition and deflection are all important for peak performance To check and adjust drive belt deflection remove the belt guard then use the fol lowing procedure E NOTE lt may be necessary to remove a shim washer from between the driven pulley sheaves to allow the driven pulley to close tighter Adding shim washers will decrease belt deflection and removing shim wash ers will increase belt deflection Avail able shim washers from Arctic Cat are p n 0648 714 0 090 in one included in the tool kit p n 0648 715 0 030 in and p n 0648 716 0 060 in 40 E NOTE Removing adding shim washers may be done by the snow mobile owner if qualified to do so If the owner does not feel qualified take the snowmobile to an autho rized Arctic Cat Snowmobile dealer for this service This service is at the discretion and expense of the snow mobile owner 1 Turn the engine off then open the access pane
19. standard mph or metric kph With RPM displayed on the readout screen by pushing and holding the incre ment button maximum RPM will be dis played on the readout screen The maximum RPM readout will reset when the decrement button is pushed while maximum RPM is displayed Odometer Trip Meter 1 Trip Meter 2 Hour Meter By pushing the decrement button the readout screen will display odometer trip meter 1 trip meter 2 and hour meter To reset the trip meter with the trip meter displayed push and hold the decre ment button until the display is cleared The hour meter readout will not reset Altimeter By pushing the select button the readout screen will display altimeter and maxi mum altimeter The altimeter readout is based off baro metric pressure and may require calibra tion as weather conditions change To calibrate the altimeter to an estab lished altitude with altimeter selected on the display screen by pushing and hold ing the select button for a minimum of two seconds the acronym CAL will be displayed on the readout screen for one second then the altitude value will flash Push the increment button to increase the displayed altitude push the decrement button to decrease the displayed altitude Pushing and holding a button will accel erate the number display W NOTE If MPH has been selected in the speed readout the altitude value will be displayed in feet If kph has been selected in the s
20. the monitor switch during normal operation of the snowmobile Per sonal injury and damage could occur if the throttle system malfunctions or if the operator is unable to stop the engine in an emergency If the snow mobile must be operated with a dis connected throttle control wiring harness EXTREME CAUTION MUST BE TAKEN NEVER EXCEED 10 MPH WITH THE THROTTLE CONTROL WIRING HARNESS DISCONNECTED B NOTE The monitor switch is now bypassed All other ignition electrical features ignition switch emergency stop switch headlight taillight and brakelight will operate properly Varying Altitude Operation Operating a snowmobile at varying alti tudes requires changes in performance components These changes affect drive train components The altitude information decal is located beneath the hood of the snowmobile B NOTE Just as important as cali brating the snowmobile for higher altitudes is recalibrating the snow mobile when going to lower alti tudes Always consult the altitude decal beneath the hood of the snow mobile Crossfire models are initially set up at the factory for operation between 0 3000 feet M Series models are initially set up at the factory for operation between 6000 9000 feet B NOTE Drive train changes can be made by the snowmobile owner if qualified to do so If the owner does not feel qualified take the snowmo bile to an authorized Arctic Cat Snowmobile dealer for this service
21. this service This service is at the discretion and expense of the snowmobile owner Exhaust Controlled Timing ECT System This system automatically adjusts the ignition timing to provide maximum per formance through a variety of operating conditions The ECU receives input on engine RPM demand and exhaust pipe temperature engine condition and adjusts the ignition timing accordingly This system is not adjustable and is main tenance free 16 If a system fault is suspected use an ohm meter to check continuity of the exhaust pipe temperature sensor located in the expansion chamber A reading of either 0 ohm or infinity indicates a failed sensor Exhaust Pipe Temperature Sensor 0737 314 B NOTE A disabled ECT system WILL NOT cause engine damage however a failed ECT system will have slower throttle response and may produce slightly less top end performance Operating Instructions Starting and Stopping Engine It is imperative that the brake system be checked for wear and proper operation and that all safety checks found in the accompanying Snowmobile Safety Handbook be performed before attempt ing to start the engine After the engine has been started check the headlights high and low beam taillight and brake light to be sure they are working properly and adjusted correctly Make sure all lights are clean to provide maximum illu mination The headlight and taillight must be clean and mu
22. tighten the left side mounting bolts followed by the front and right top rear bolts Re check the parallelism If still out of specifi cation repeat correction procedure GASOLINE On the 600 1000 cc models for optimum performance do not exceed the recommended 87 octane gaso line Using a higher octane gasoline will not increase overall performance On the 800 cc models for optimum performance use 91 octane minimum gasoline Preparation for Storage Prior to storing the snowmobile it must be properly serviced to prevent corrosion and component deterioration An autho rized Arctic Cat Snowmobile dealer should perform this service however the owner operator can perform this service if desired This service is at the discretion and expense of the snowmobile owner To prepare the snowmobile for storage Arctic Cat recommends the following procedure 1 Clean the seat cushion with a damp cloth and a Vinyl Protectant 2 Clean the snowmobile thoroughly by hosing dirt oil grass and other foreign matter from the skid frame tunnel hood and belly pan Allow the snowmobile to dry thoroughly DO NOT get water into any part of the engine 3 Place the rear of the snowmobile up on a shielded safety stand 4 Start the engine and allow to idle then pry the intake boot forward 5 Spray an Engine Storage Preserver into the intakes until the engine exhaust starts to smoke heavily or until the engine starts to drop i
23. 7 Repeat steps 4 6 for the other pad then secure the pads with the pin hairpin clip 29 8 Remove the reservoir cover and remove the remaining fluid then fill the reservoir with fresh fluid and install the cover 9 Pump the brake lever to ensure cor rect positioning of the brake pads then release 10 Remove the reservoir cover and fill the reservoir to the proper level with fresh brake fluid then install the cover E NOTE When new brake pads are installed a burnishing process is required Drive the snowmobile slowly and compress the brake lever several times until the pads just start to warm up then allow them to cool down This procedure stabilizes the pad material and extends the life of the pads Drive Belt The drive belt transfers power from the drive clutch to the driven pulley If the belt is worn cracked or stretched maxi mum power will not be transmitted and the belt could also fail and therefore must be replaced Periodic checks at least once a month under normal usage of two drive belt specifications are essential 1 Measure the outside circumference of the drive belt The belt should be within the recommended range in circumference 2 Measure the outside width of the drive belt The belt should be within the recommended range in width 3 Check the belt for cracking fraying etc If any of the specifications or conditions are unsatisfactory replace the drive belt E NOTE Dr
24. 8 F Use a U L approved 22 7 1 6 U S gal gasoline container for mixing the gasoline and oil To properly mix the fuel at a 100 1 ratio use the following procedure CAUTION Never mix oil and gasoline in the snowmobile gas tank 1 Pour gasoline into the gasoline con tainer until approximately half full 2 Pour 236 ml 8 fl oz of the recom mended 2 cycle oil into the gasoline container 3 Install cap on gasoline container and shake the mixture vigorously 4 Fill the gasoline container with gaso line then cap the gasoline container and shake the mixture vigorously 5 Using a fine mesh screened funnel pour the fuel mixture from the gaso line container into the snowmobile gas tank A WARNING Always fill the gas tank in a well ven tilated area Never add gasoline to the snowmobile gas tank near any open flames or with the engine run ning DO NOT SMOKE while mixing fuel or filling the gas tank Engine Break In The Arctic Cat engine when new or rebuilt requires a short break in period before the engine is subjected to heavy load conditions Arctic Cat requires that the first tankful of fuel be premixed at a 100 1 ratio in all oil injection models During the break in period a maximum of 1 2 throttle is recommended however brief full throttle accelerations and varia tions in driving speeds contribute to good engine break in After one 1 tankful break in per
25. Crossfire 600 Crossfire 800 Sno Pro LTD MG M amp 8 Sno Pro LTD M8 HER M1000 Sno Pro ARCTIC CAT SHARE OUR PASSION Limited Warranty Arctic Cat Inc hereinafter referred to as Arctic Cat extends a limited warranty on each new Arctic Cat Snowmobile it assembles and on each part and accessory assembled or sold by Arctic Cat The warranty is extended to the original retail purchaser only on parts and accessories sold through an authorized Arctic Cat Snowmobile dealer Warranty on snowmobiles is extended to the original retail purchaser however the balance of the unused warranty may be transferred to another party Warranty coverage is only available in the country in which the original retail purchase occurs to the original retail purchaser resident in that country or to a transferee resident in that country of the balance of the unused warranty Arctic Cat warrants only the products it assembles and or sells and does not warrant that other products will function properly when used with an Arctic Cat Snowmobile or will not damage the Arctic Cat Snowmobile Arctic Cat does not assume any liability for incidental or consequential damages Arctic Cat will repair or replace at its option free of charge including any related labor charges any parts that are found to be warrantable in material or workmanship This repair work MUST be done by an authorized Arctic Cat Snowmobile dealer No transportation charges rental char
26. G The brake lever lock is not a parking brake and should not be applied for periods exceeding 5 minutes The brake lever lock maintains the brake lever in the compressed position and maintains pressure against the brake disc however after a period of time the pressure applied to the brake disc may relax below the amount required to hold the snow mobile stationary 5 Pumping the brake lever is permissi ble however if pumping the brake lever more than twice is necessary to obtain the necessary stopping power immediately take the snowmobile to an authorized Arctic Cat Snowmo bile dealer for service If not under warranty this service is at the discre tion and expense of the snowmobile owner 6 When new brake pads are installed a burnishing process is required Drive the snowmobile slowly and compress the brake lever several times until the pads just start to heat up then allow them to thoroughly cool down This process stabilizes the pad material and extends the life of the pads Emergency Stopping There are several methods of stopping or slowing the snowmobile under a variety of situations Identified in the following chart are the ways a snowmobile may be brought to a stop and the effectiveness under normal conditions Item Function Condition Emergency interrupts igni ALL Stop Switch tion circuit Throttle Ignition interrupts igni ALL Monitor Switch tion circuit I
27. MPRESS THE THROTTLE CONTROL LEVER If the throttle control lever is com pressed the engine will not start because the fuel air mixture will be too lean B NOTE When a warm engine is being started the throttle control lever may have to be compressed slightly 6 On manual start models pull the recoil handle slowly until resistance is felt then give a short quick pull Repeat until the engine starts ENOTE On large displacement engines in extremely cold weather pull the recoil handle slowly two to three times to begin the starting procedure 17 CAUTION To avoid damaging the recoil starter DO NOT pull the recoil rope to its limit or release the recoil handle from an extended position Allow the rope to rewind slowly 7 When the engine starts allow it to warm up properly Idle the engine several minutes until the engine has reached normal operating tempera ture Do not idle the engine for excessively long periods of time CAUTION It is extremely important that the engine is properly warmed up before subjecting the engine to high speed operation or heavy loads The engine should be allowed to idle at least 3 4 minutes before it is oper ated at more than 1 2 throttle In extremely cold conditions the warm up time will be longer Cold seizure and piston scuffing caused by insufficient warm up will not be covered by warranty Also do not idle the engine for excessively long periods o
28. N ojes oq sofesnoous put SISIOPUI 3 amp 2 INI snna AL34YS 31I80WMONS General Information Snowmobile Identification The Arctic Cat Snowmobile has two important identification numbers The Vehicle Identification Number VIN is stamped into the tunnel near the right side footrest and on a decal beneath the seat The decal also displays pertinent production information The Engine Serial Number ESN is stamped into the crankcase of the engine VIN 0726 383 These numbers are required by the dealer to complete warranty claims properly No warranty will be allowed by Arctic Cat Inc if the engine serial number or VIN is removed or mutilated in any way Always provide the snowmobile name VIN and ESN when contacting an autho rized Arctic Cat Snowmobile dealer for parts service accessories or warranty If the complete engine must be replaced ask the dealer to notify Arctic Cat for correct registration information Control Locations Shown are the typical control locations for Arctic Cat snowmobiles Location of a specific control will vary according to model Handlebar Warmer Switch Emergency Stop Switch Thumb bak bed 2 UM Throttle Lever A AES ha TINI SUI Brake Lever X IN Headlight Dimmer VQ GSN Switch pt yc Gi Reverse Switch Brake Lever Lock Nu F Ignition Switch A maj 741 633A Gasoline Oil CAUTION Recommended Gasoline 600 1000 cc Models The recommended
29. ON After reversing in deep powder snow conditions make sure the snowflap does not become caught up in the track Track and or snowflap dam age may occur 14 Crossfire 600 IVIG Models The reverse transmission function offers the operator the convenience of being able to back up the snowmobile rather than having to turn the snowmobile around by hand This feature under most situations should not be used to free a stuck snow mobile as it will tend to dig the skis deeper into the snow Always use minimal speed when operating in reverse and come to a complete stop before shifting from either forward to reverse or reverse to for ward To shift the reverse transmission use the following procedure 1 Come to a complete stop B NOTE The snowmobile must be at a complete stop and the engine run ning under 3000 RPM before the sys tem will allow shifting 2 With the engine at idle under 3000 RPM press the reverse switch but ton then release the button The reverse selection will be complete Reverse Switch Button 741 438A B NOTE The system will not shift until the button is released 3 To shift into forward stop the snow mobile and allow the engine to idle under 3000 RPM then press the button and release The forward selection will be complete A WARNING Use caution and minimal speed when operating the snowmobile in reverse Be sure the button is in the desired posi
30. Pump grease into the spindle grease fit ting both sides until grease is noted coming out of the top and bottom of the spindle Wipe excess grease from the spindle Lubrication ra Point On Spindle a 0737 294 Pump grease into the upper steering shaft grease fitting located on each side of the snowmobile directly below the inner cap screw securing the upper A arm to the chassis until grease is noted coming out of the bottom of the shaft Wipe excess grease from the shaft xd n Grease Fitting 0743 219 Rear Suspension This procedure should be done every 40 operating hours B NOTE Arctic Cat recommends that Arctic Cat All Temp Grease p n 4639 365 be used for this proce dure B NOTE Illustrated are the general locations of grease fittings Actual locations will vary from model to model 1 Shut engine off and wait for all mov ing parts to stop 2 With the gas tank nearly empty less than 1 4 full and using Handlebar Stand p n 5639 152 or a suitable substitute lay the snowmobile on its left side 3 Remove ice and snow buildup from the skid frame to expose the grease fittings e A Front Arm Grease Fitting f 3 4 t X NE 74M 275 9 IBY HA amp Sa Aa Pd Rear Arm Grease Fittings ir i 0741 376 4 Lubricate the grease fittings with all temperature grease 23 Maintenance Periodic Maintenance Checklist
31. RODUCT SERVICE AND WARRANTY DEPT P O BOX 810 Fold Back Once Place Stamp Here THIEF RIVER FALLS MN 56701 NOTES 49 50 NOTES Warranty Procedure Owner Responsibility At the time of sale an Owner Registration form is to be completed by the selling dealer and consumer The receipt of the registration form by Arctic Cat is a condi tion precedent to warranty coverage It is the selling dealer s responsibility to retain and or submit the appropriate copies of the form to the appropriate place s to initi ate warranty coverage The dealer will furnish to the consumer a signed copy of the form which must be presented to the dealer when requesting warranty service The registration form is the consumer s proof of ownership and warranty eligibility The form is used by the dealer to validate the warranty claim Retain your copy of the form and keep it in a safe place When warranty repair is suspected the snowmobile should be taken to the selling dealer who has the primary responsibility to perform warranty repairs Subject to the limitations set forth in the Limited Warranty in the event the selling dealer has ceased to do business you have moved or you are in a location away from your selling dealer warranty may be performed by any authorized Arctic Cat Snowmo bile dealer The authorized Arctic Cat Snowmobile dealer will examine the snowmobile or part to determine if in his opinion a warrantabl
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33. WARNING DO NOT attempt to check or adjust track tension with engine running Turn ignition key to the OFF position Personal injury could result from contact with a rotating track 1 Remove excess ice and snow buildup from the track track drive sprockets and the inside of the skid frame 2 Elevate the snowmobile on a shielded safety stand high enough to use a spring scale 32 3 At mid point of the track on the bottom side hook a spring scale around a track clip then pull down on the scale to the recommended pressure Measure the deflection distance between the bottom of the wear strip and the inside surface of the track clip Compare the measure ment with the chart Setup After Break Tension In Tension All Models 20 Ib 44 51 mm 51 57 mm 1 3 4 2 in 2 2 1 4 in Deflection i x 20919 0743 188 B NOTE On the M Series models measurement is from the bottom of the wear strip at the point of the shock pad on the slide rail Adjusting Track Tension E NOTE To ensure proper track ten sion adjustment perform all adjust ments on both sides of the snowmobile 1 Loosen the rear idler wheel adjust ing bolt jam nuts Rear Idler T Wheels 7 Track Adjuster Adjusting Bolt Jam Nut 739 636B 2 If the deflection distance between the bottom of the wear strip and the inside of the track exceeds specifi cations tighten
34. ance throughout the RPM range The recommended engine oil to use The system consists of an exhaust valve assembly mounted to the exhaust side of each cylinder and connected by adjust able cables to an electronic servo mounted beneath the hood E NOTE The mounting location of the servo will vary from model to model N ce A Actuating Cable gt NN py KK E Return Spring o il 4 ad NAT Exhaust Valve 4 UK NUN 739 152F At low RPM the exhaust valves are held in the DOWN position by return springs This gives the engine a low port exhaust design calibrated to provide maximum low RPM power and improve fuel economy at trail speeds n Down A Position C Exhaust Flow 739 152G At high RPM the exhaust valves are raised This creates a high port exhaust design calibrated to provide maximum performance at high RPM Up A Position ne A SY oy tA A A a Lr _ PS gt Exhaust Flow N N 7 HP 739 152H B NOTE The RPM ranges will vary from model to model 15 W NOTE If the servomotor cycles three times and then shuts down the exhaust valve cables are not adjusted correctly The exhaust valves may also be sticking E NOTE APV cleaning may be done by the snowmobile owner if qualified to do so If the owner does not feel qualified take the snowmobile to an authorized Arctic Cat Snowmobile dealer for
35. and steering arms with all tem perature grease Tighten all nuts bolts and cap screws making sure all nuts bolts and cap screws are tightened securely Make sure all rivets hold ing the components together are tight Replace all loose rivets Clean and polish the hood console and chassis with Arctic Cat Hood and Windshield Cleaner Polish p n 4639 559 DO NOT USE SOL VENTS OR SPRAY CLEANERS THE PROPELLANT WILL DAM AGE THE FINISH If possible store the snowmobile indoors Raise the track off the floor by blocking up the back end making sure the snowmobile is secure Loosen the track adjusting bolts to reduce track tension Cover the snowmobile with a machine cover or a heavy tarpaulin to protect it from dirt and dust 43 17 If the snowmobile must be stored out 44 doors position the snowmobile out of direct sunlight then block the entire snowmobile off the ground making sure the snowmobile is secure Loosen the track adjusting bolts to reduce track tension Cover with a machine cover or a heavy tarpaulin to protect it from dirt dust and rain CAUTION Avoid storing in direct sunlight and using a plastic cover as moisture may collect on the snowmobile causing corrosion Preparation after Storage Taking the snowmobile out of storage and correctly preparing it for another sea son will assure many miles and hours of trouble free snowmobiling Arctic Cat recommends the following proced
36. ar ranty E NOTE Stud installation can be per formed by the snowmobile owner if qualified to do so If the owner does not feel qualified take the snowmo bile to an authorized Arctic Cat Snow mobile dealer for this service This service is at the discretion and expense of the snowmobile owner 12 A WARNING When installing studs on a single ply track it is important to use Arctic Cat approved studs proper head diameter If approved studs proper head diameter are not used studs could tear free of the track causing possible injury or even death Con sult an authorized Arctic Cat Snow mobile dealer for information CAUTION If installing studs a short Snowflap p n 5639 232 must be installed or component damage will occur B NOTE To prevent tunnel damage from the studs Tunnel Protector Kit p n 4639 968 must be installed For proper installation use the following procedure 1 Using the stud template see chart mark the desired stud pattern to be used Stud Template Chart Track Length p n 141 in 4639 991 2 Using the proper sized stud hole drill bit drill out the stud holes 3 Push the stud through the hole from inside the track then place the domed support plate and lock nut on the exposed stud 4 Using a wrench to secure the stud tighten the lock nut on the exposed stud It is also recommended that whenever studs are installed on a track
37. carbide wear bars should be installed on the skis Carbide wear bars complement the track studs to balance steering control under these conditions The length of the car bide on the wear bars should be propor tionate to the number of track studs i e small number of track studs short length of carbide many track studs long length of carbide The proper pro portion between the number of studs and carbide length on the wear bar will main tain steering balance A WARNING Always balance the snowmobile with the proper proportion between the number of studs and carbide length on the wear bars Do not over drive conditions use common sense in all operating conditions CAUTION Do not use studs that are more than 9 525 mm 0 375 in longer than the track lug height A WARNING Do not operate a snowmobile with loose studs as they may be thrown from the track Always use a shielded safety stand whenever performing any maintenance or adjustments A WARNING DO NOT stand behind the snowmo bile or near the rotating track NEVER run the track at high speed when the track is suspended Reverse Operation Crossfire 800 M8 M1000 Models The engine reverse function offers the operator the convenience of being able to back up the snowmobile rather than hav ing to turn the snowmobile around by hand This feature under most situations should not be used to free a stuck snow mobile as it
38. ctic Cat s warranty 1 Failure to perform the proper break in procedure and all related maintenance storage procedures if stored for extended periods and or service as recommended in the Operators Manual Repairs and or adjustments by anyone other than an authorized Arctic Cat Snowmobile dealer Use of an improper fuel mixture ratio Use of improper carburetor main jets Use of improper gasoline lubricating oils or spark plugs An accident or subjecting the snowmobile to misuse abuse or negligent operation Any modification addition or removal of parts unless instructed to do so by Arctic Cat Use of the snowmobile in any way for racing purposes 9 Removal of the engine for use in another vehicle 10 Removal or mutilation of the Vehicle Identification Number or Engine Serial Number 11 Use of parts not sold or approved by Arctic Cat 12 Track and tunnel damage resulting from either ice stud or hooker plate installation 13 Damage due to improper transportation In consideration of the foregoing any implied warranty is limited in duration to the various warranty periods set forth This warranty gives you specific legal rights and you may also have other rights which vary from state province to state province and country to country Some jurisdictions do not allow limitations on how long an implied warranty lasts so the above limitations may not apply to you ONOnNRWD Table of Contents Limited Warranty Insi
39. de Front Cover Emergency Stopping FOleWOIGQ erotic thet ce dessen c ees ada 1 Throttle Ignition Monitor Switch Declaration of Conformity 2 Varying Altitude Operation Snowmobile Safety Rules 9 Lubrication General Information 4 16 ACT Drive Gear Case Snowmobile Identification 4 Front Suspension Control Locations 4 Rear Suspension Gasoline Oil 4 Maintenance Engine Break In 5 Periodic Maintenance Checklist 6 6 Drive Belt Break In Fuel System Speedometer Tachometer Coolant Level Diagnostic CodesS iii 9 Spark Plugs Telescopic Handlebar Sno Pro Sno Pro LTD Checking Adjusting APV Cables Models 9 Brake System Handlebar Tilt 9 Drive Belt 10 Track Tension Exhaust System 10 Track Alignment Air Intake Silencer Cooling System Drive Clutch and Driven Pulley Drive Clutch Driven Pulley Alignment ve Fuel PUmp ineo te eta 11 Adjusting Ski Stance Shock Absorbers 11 Rail Wear Strips Deep Lug Track 12 Performance Tips Track Studs Crossfire Models 12 Preparation for Storage ina Reverse Operation
40. detected replacement is necessary Take the snowmobile to an authorized Arctic Cat Snowmobile dealer for this service If not under warranty this service is at the discretion and expense of the snow mobile owner B NOTE When the snowmobile is operated in extremely cold weather 23 C 10 F or colder a small amount of leakage may be present Unless the leakage is excessive replacement is not necessary Rebuildable Gas B NOTE The presence of a FOX identifier decal or embossed on a shock absorber body indicates a rebuildable shock absorber B NOTE The frequency of servicing rebuildable shock absorbers will vary according to the types of conditions and terrain the snowmobile has been subjected to If riding quality deterio rates or seems to be deteriorating take the snowmobile to an authorized Arctic Cat Snowmobile dealer for shock absorber evaluation and or ser vicing This service is at the discre tion and expense of the snowmobile owner Servicing rebuildable shock absorbers is considered normal maintenance and is the responsibility of the owner Take the snowmobile to an authorized Arctic Cat Snowmobile dealer for this service This service is at the discretion and expense of the snowmobile owner Kits are available to either stiffen or soften gas shock valv ing If changes in shock valving are desired see an authorized Arctic Cat Snowmobile dealer This service is at the discretion and expense of
41. e Check the coolant level and all cool ant hoses and connections for deteri oration or cracks Add properly mixed coolant as necessary Inspect the entire brake system all controls headlight taillight brake light ski wear bars and headlight aim adjust or replace as necessary Adjust the track to the proper ten sion and alignment see Track Ten sion and Track Alignment sub sections in the Maintenance sec tion 45 U S EPA Emission Control Statement Warranty Coverage U S Only STATEMENT WARRANTY Arctic Cat warrants to the original retail purchaser and each subsequent purchaser that all U S EPA certified Arctic Cat snowmobiles are designed built and equipped to conform to all U S EPA Emission Control Regulations Please read the following information completely Your authorized Arctic Cat snowmobile dealer will repair or replace any defective emission related component at no cost to you during the warranty period You may have non warranty service performed by any repair establishment that uses equivalent components The regulations provide significant civil penalties for tampering that causes your snowmobile to no longer meet U S EPA emission standards Arctic Cat further warrants that the engine and its emission related components are free from defects in materials or workmanship that could cause the engine to fail to comply with applicable regulations during the warranty period If you have any
42. e condition exists If a warrantable con dition appears to exist the dealer will repair or replace at Arctic Cat s option free of charge including any related labor costs all parts that are found to be warrant able and any other parts which the warrantable part caused to be damaged You the consumer will then be asked to sign a warranty form to ensure Arctic Cat that the warranty work was actually performed It is the consumer s responsibility to maintain and service the snowmobile in accor dance with Arctic Cat s recommendations in the Operator s Manual To protect yourself and your snowmobile follow all safety and service tips Arctic Cat will NOT warrant repairs required as a result of not performing standard operator maintenance storage procedures and service as outlined in the Operator s Manual Should you have any questions concerning the warranty contact an authorized Arc tic Cat Snowmobile dealer Arctic Cat Inc P O Box 810 Thief River Falls MN 56701 218 681 8558 CN 7 ma C CN ARCTIC CAT Printed in U S A Trademarks of Arctic Cat Inc Thief River Falls MN 56701 p n 2258 798 Phone 218 681 9851 U S 204 982 1656 Canada
43. e into the drain plug hole 17 Tip the snowmobile back to the upright position then place a drain pan on the floor next to the drain hose and tip the snowmobile toward its left side far enough to allow the flush fluid to drain from the gear case into the drain pan 18 Secure the snowmobile in this posi tion until the flush fluid is com pletely drained drive system 20 Pour 12 fl oz 600 cc models or 15 fl oz remaining models of recom mended gear case fluid into the check fill hole then install the plug Tighten securely CAUTION Do not add more or less than the recommended amount of lubricant to the gear case or damage to the gear case will occur Oil level should be at the Oil Fill Level on the gear CAUTION It is critical that all of the flush fluid be drained from the gear case prior to filling with new lubricant 22 case cover 21 Install the driven pulley then install the drive belt see Drive Belt sub section in the Maintenance section and the belt guard 22 Install the left side access panel then close the access panel Front Suspension B NOTE Arctic Cat recommends that Arctic Cat All Temp Grease p n 4639 365 be used for this proce dure It is very important that the front suspen sion is greased on a monthly basis using all temperature grease The front suspen sion should also be greased after traile ring the snowmobile on an open trailer
44. e sure as the owner operator of an Arctic Cat Snowmobile to become thoroughly familiar with its basic operation mainte nance and off season storage procedures Read this manual and the accompanying Snowmobile Safety Handbook before operating the snowmobile to learn safe and proper use of your new Arctic Cat Snowmobile Always operate the snowmobile within your level of skill and current terrain conditions The Operator s Manual Snowmobile Safety Handbook and Snowmobile Decals display the words Warning Caution and Note to emphasize important information The symbol WARNING identifies personal safety related information Be sure to follow the directive because it deals with the possibility of serious personal injury or even death A CAUTION identifies unsafe practices which may result in snowmobile related damage Follow the directive because it deals with the possi bility of damaging part or parts of the snowmobile The symbol BE NOTE identi fies supplementary information worthy of particular attention This manual covers operator related maintenance operating instructions and off season storage instructions If major repair or service is ever required contact an authorized Arctic Cat Snowmobile dealer for professional service At the time of publication all information and illustrations were technically cor rect Some illustrations used in this manual are used for clarity purposes only and are not designed to depict actual condi
45. ed Arctic Cat Snowmobile dealer for service If not under warranty this service is at the discretion and expense of the snow mobile owner Spark Plugs BM NOTE Always use the recom mended spark plugs in the engine See the appropriate specifications chart for correct spark plug gap Varying terrain conditions and operating usage may require spark plugs of a differ ent heat range For example sustained cross country riding will usually require colder heat range spark plugs while trail riding or other continual slow speed operation will usually require hotter heat range spark plugs Removing Installing Spark Plugs 1 Remove the springs securing the expansion chamber to the exhaust manifold and resonator 2 Move the expansion chamber out of the way to access the spark plugs 3 Remove the spark plug caps from the plugs 4 Using a spark plug wrench remove the plugs 5 Install the plugs and finger tighten 6 Tighten the spark plugs to 19 ft lb then install the spark plug caps 7 Place the expansion chamber into position and secure to the exhaust manifold and resonator with the springs 25 Checking Spark Plugs To see if the spark plugs being used are of the proper heat range after the snowmo bile has been operated under normal driv ing conditions remove the spark plugs and examine the condition of the center electrode insulator of each spark plug Center Electrode a Insulator
46. ed cable from the cable housing to the end of the cable cable drum APV CABLE LENGTH ENGINE CENTER 0 039 in 600 cc 1 417 in 800 cc 1 377 in 1000 cc 1 319 in y O _ SSS 0735 516 E NOTE The two cable measure ments must be equal in length or less than 0 5 mm 0 020 in differ ence in length from each other W NOTE Repeat steps 4 and 5 for each cable then compare the mea surements to the APV Cable Length chart E NOTE The measurements must be within the specifications from the chart If the measurements are within specifications no adjustment is necessary proceed to step 8 If they are not within specifications proceed to step 6 6 Loosen the jam nut on the cable to be adjusted then using the adjusting nuts lengthen or shorten the housing as needed 7 Once the proper length has been attained hold the adjusting nut in place and tighten the jam nut securely 8 Place the cable housings into position in the servomotor Secure the cable housings with the cable holder and retaining clip 800 1000 cc models CAUTION Assure the cables are rotated and secured properly to avoid contact ing exhaust components Brake System Arctic Cat recommends that the brake system brake lever fluid reservoir hose caliper pads and brake disc be checked daily for fluid leakage wear or damage and for proper operation Also the brake fluid level
47. equally and do not over adjust the limiter straps to adversely affect steering and operator control of the snowmobile Some experimentation may be required until the proper adjustment for the opera tor s individual style is obtained E NOTE If the limiter straps are adjusted it is highly recommended that at least a minimum of 1 8 in preload on the shock spring be maintained 35 A WARNING Do not adjust the front arm limiter straps to a point at which steering and operator control of the snowmo bile are adversely affected Adjusting Skid Frame Rear Arm Shock Spring Proper adjustment of rear arm shock absorber spring pre load is necessary to get the most desirable ride The rear arm shock spring is adjustable for the terrain conditions and driving style and weight of the operator The spring adjuster nut has been set at the fac tory so the correct amount of threads are exposed between the adjuster nut and the threaded shock body as an initial setting Rear spring pre load adjustment is accomplished by loosening the adjuster nut locking collar B from the adjuster nut A and using the Spring Adjuster Tool from the tool kit rotating the adjuster nut in whichever direction is desired Tighten the locking collar against the adjuster nut 7 Threaded Shock Body 0745 159 Lights For the correct headlight bulb and or tail light brakelight LED see the appropriate specifications sheet Removing a
48. eved by increase ing or decreasing the air pressure in the rear arm air shock absorber 34 Adjusting Front Ski Shock Springs STD E NOTE On some models the front ski shock springs are not adjust able The front ski shock springs are individ ually adjustable for the terrain conditions and driving style of the operator The spring adjuster nut has been set at the fac tory so the correct amount of threads are exposed between the adjuster nut and the threaded shock body as an initial setting Additional ski pressure can be obtained by tightening the spring tension ski pres sure can be decreased by relaxing spring tension B NOTE Equal adjustments should be maintained on both sides of the snowmobile Front ski shock spring pre load adjust ment is accomplished by loosening the adjuster nut locking collar B from the adjuster nut A and using the Spring Adjuster Tool from the tool kit rotating the adjuster nut in whichever direction is desired Tighten the locking collar against the adjuster nut Threaded Shock Body 0745 159 Adjusting Fox Air Shocks B NOTE It is recommended to moni tor the air pressure in the air shocks once every month B NOTE Adjusting air shocks may be done by the snowmobile owner if qualified to do so If the owner does not feel qualified take the snowmo bile to an authorized Arctic Cat Snowmobile dealer for this service This service is at the discretio
49. f the snowmobile owner Low Oil Warning Icon The Low Oil Warning Icon is designed to alert the snowmobile operator when the oil in the oil injection reservoir gets below a prescribed level however it is highly recommended that a visual verifi cation of the oil level in the reservoir be done prior to operating the snowmobile Once the Low Oil Warning Icon illumi nates during operation of the snowmo bile the operator must periodically monitor the level of oil in the reservoir and must fill the reservoir the next time gasoline is added to the gas tank The alert level of the Low Oil Warning Icon is approximately equal to 1 tankful of gasoline under normal operating condi tions Indicator Icons Deluxe Gauge Certain models are equipped with a deluxe gauge combination speedometer tachometer Indicator icons are incorpo rated within the speedometer tachometer Also incorporated into the speedometer tachometer is a digital readout screen FZ001E High Beam Oil Pressure Low Oil Coolant Temperature Increment Button Select Button THA Decrement Button G Service RPM MPH kph By pushing the increment button once the RPM and MPH will be displayed one on the readout screen and one with the needle By pushing the button once again the functions will be reversed By pushing the increment button with speed being displayed for more than two seconds the display will change between
50. f time 8 Flooding If the engine does not start but seems ready to start engage the brake lever lock then compress the throttle control lever fully and try to start the engine When the engine starts release the throttle control lever immediately After the warm up release the brake lever lock E NOTE If the engine fails to start during the attempt with the throttle control lever compressed remove the spark plugs and clean and dry them thoroughly or install a new set of properly gapped recommended spark plugs 9 To shut off the engine turn the igni tion key to the OFF position or push the emergency stop switch to the DOWN position 18 Braking The following items are items that the operator must be familiar with when operating this snowmobile and its hydraulic brake system Important addi tional information on the proper mainte nance of the brake system is found in the Maintenance section 1 Use the brakes wisely Each time the brakes are applied in all hydraulic brake systems including automotive applications heat is transferred to the brake fluid The amount of heat transferred during high speed stops and or repetitive use may be high enough to boil the brake fluid and cause the brakes to either fade or may cause an unexpected loss of brakes If this occurs the brake fluid requires a cool down period before the brakes will again function properly This cool down period will vary depend
51. gasoline to use in these snowmobiles is 87 octane regular unleaded In many areas oxygenates either ethanol or MTBE are added to the gasoline Oxygenated gasolines con taining up to 1096 ethanol or up to 1596 MTBE are acceptable gasolines When using ethanol blended gasoline it is not necessary to add a gasoline anti freeze since ethanol will prevent the accumulation of moisture in the fuel sys tem Do not use white gas or gasolines containing methanol Only Arctic Cat approved gasoline additives should be used B NOTE For optimum performance do not exceed the recommended 87 octane gasoline Using a higher octane gasoline will not increase overall performance Recommended Gasoline 800 cc Models The only recommended gasoline to use in these snowmobiles is 91 octane minimum E NOTE For optimum performance use only 91 octane minimum gasoline CAUTION If a situation arises wherein 91 octane gasoline is not available 87 octane gasoline can be substituted however do not prolong the usage of 87 octane gasoline as it will cause poor engine performance In many areas oxygenates either ethanol or MTBE are added to the gasoline Oxygenated gasolines containing up to 10 ethanol or up to 15 MTBE are acceptable gasoline Do not use gasolines containing methanol CAUTION Do not use white gas or gasoline containing methanol Only Arctic Cat approved gasoline additives shou
52. general inspection and for off season storage servicing This inspection and servicing is at the expense of the snow mobile owner Fuel System A WARNING Whenever any maintenance or inspection is made on the fuel sys tem in which there may be fuel leak age there should be no welding smoking open flames etc in the area Gasoline Additives Fuel de icer can be used for all models Also periodic use of an injector cleaner is recommended especially in the last tank of gasoline before storage Arctic Cat Fuel Stabilizer p n 0436 907 should also be added to the last tank of gasoline before storage Fuel Pickup Valves All models are equipped with fuel pickup valves in the gas tank If ever there is a restricted fuel flow and a pickup valve is suspected take the snowmobile to an authorized Arctic Cat Snowmobile dealer for this service If not under warranty this service is at the discretion and expense of the snowmobile owner Coolant Level E NOTE Use a good quality ethyl ene glycol based automotive type coolant B NOTE Always check the coolant level with the engine cold Locate the appropriate FULL mark on the coolant reservoir If coolant is below the FULL mark add coolant to the FULL mark CAUTION If the coolant is below the FULL COLD mark and if coolant has been added immediately inspect for leak age and or damage If leakage or damage is detected take the snow mobile to an authoriz
53. ges or inconvenience costs will be paid by Arctic Cat The warranty is validated upon examination of said parts by Arctic Cat or an authorized Arctic Cat Snowmobile dealer Arctic Cat reserves the right to inspect such parts at its factory for final determination if warranty should apply The warranty periods are as follows 1 For snowmobiles used for recreational purposes lf purchased between May 1 and November 30 warranty expires ONE 1 YEAR from December 1 of the current year lf purchased between December 1 and April 30 ONE 1 YEAR from the date of sale 2 For snowmobiles used for commercial purposes including rental operations ONE 1 YEAR from the date of invoice and or 5000 MILES whichever comes first non transferable 3 THIRTY 30 DAYS from date of sale of snowmobile on Arctic Cat supplied batteries 4 THIRTY 30 DAYS from date of sale for all dealer installed genuine Arctic Cat service parts and accessories 5 UNTIL EXPIRATION OF THE NEW PRODUCT WARRANTY paragraphs 1 and 2 above for all eligible replacement parts on new product Exclusions to this warranty include normal wear abuse i e a track run on marginal snow conditions without proper lubrication or additional idler wheels and the following parts Fuel Filter Light Bulbs Windshield Torn or Punctured Upholstery Drive Belt Wear Bars Water Pump Belt Brake Pads Fan Belt Spark Plugs Wear Strips Drive Clutch Driven Pulley Wear Parts The following will VOID Ar
54. ghtly approximately 1 8 throttle and try starting the engine If the engine now starts and stops when the throttle lever is released take the snowmobile to an autho rized Arctic Cat Snowmobile dealer for service If not under warranty this service is at the discretion and expense of the snowmobile owner A WARNING If the throttle control lever does not work properly DO NOT ATTEMPT TO START THE ENGINE 4 If the throttle control lever operates properly rotate the ignition key to the RUN position and go through normal starting procedures E NOTE If the throttle control lever operates properly and the engine does not start a malfunctioning monitor switch may be the problem Take the snowmobile to an autho rized Arctic Cat Snowmobile dealer for service If not under warranty this service is at the discretion and expense of the snowmobile owner However if a dire emergency exists wherein the engine must be started disconnect the throttle monitor switch located in the right side han dlebar control W NOTE If disconnection of the throttle monitor switch is needed to start the engine take the snowmo bile to an authorized Arctic Cat Snowmobile dealer for service as soon as possible If not under war ranty this service is at the discretion and expense of the snowmobile owner 20 A WARNING Under no circumstances should dis connection of the throttle control wir ing harness be used as a substitute for
55. gnition Switch interrupts igni ALL tion circuit Brake slows the ACT ALL drive Throttle Ignition Monitor Switch The throttle control is equipped with a monitor switch for safety purposes which will stop the engine when a loss of return spring force occurs If ice forms in the throttle system or if there is some other malfunction of the throttle system result ing in a loss of return spring force the monitor switch will stop the engine when the throttle control lever is released A WARNING If any malfunction of the throttle sys tem occurs such as freezing in fluffy snow and the monitor switch does not shut off the engine press down on the emergency stop switch IMME DIATELY to stop the engine DO NOT start the engine until the malfunction in the throttle system has been located and corrected If the snowmobile engine stops abruptly when the throttle control lever is released and the activation of the monitor switch is suspected use the following procedure 1 Rotate the ignition key to the OFF position 2 Remove ice and snow from the throttle system and wait 5 10 min utes for the engine heat to thaw ice from the throttle system 19 3 Test the throttle control lever by compressing and releasing it several times The lever MUST return to the idle position quickly and completely E NOTE If the throttle control lever operates properly and the engine does not start compress the throttle lever sli
56. h Changing Brake Fluid The brake fluid must be changed on a reg ular basis and whenever the brake fluid has been overheated or contaminated The brake fluid should be changed every 1000 miles or at the end of the snowmobiling season whichever occurs first Take the snowmobile to an authorized Arctic Cat Snowmobile dealer for this service This service is at the discretion and expense of the snowmobile owner Checking Brake Lever Travel Before each use check the brake lever travel using the following procedure 1 Compress the brake lever fully W NOTE Do not pump the brake lever as it will produce an inaccurate reading 28 2 Measure the distance between the brake lever and the handlebar The distance must be greater than 2 54 cm 1 in i vi F 7 x v 7 2 54 cm 1 in 741 328B 3 If the resultant distance is less than specified take the snowmobile to an authorized Arctic Cat Snowmobile dealer for service If not under war ranty this service is at the discretion and expense of the snowmobile owner A WARNING Do not operate the snowmobile if the compressed distance between the brake lever and the handlebar is less than 2 54 cm 1 in Brake loss may occur Brake loss can result in severe personal injury Bleeding Brake System If the brake lever feels spongy when applied the brake system may need to be bled To bleed the brake use the follow ing
57. he hood then remove the O rings securing the air silencer ple num to the hood and remove the air silencer plenum to access the bulbs 4 Remove the bulb from the headlight housing and disconnect the wiring harness from the bulb Headlight Bulb i pP E f Oe D nails 233 E il rd lt Hood Harness Headlight Bulb 0740 462 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 1 Plug the wiring harness into the headlight bulb 2 Insert the bulb into the headlight housing 3 Press the air silencer plenum into place on the hood and secure with the O rings then close the hood 4 Carefully push the headlight lenses rearward far enough to install the torx head screws Tighten the screws securely 5 Tighten the headlight adjustment knobs 6 Check headlight aim see Adjusting Headlight Aim in this sub section A WARNING Do not operate the snowmobile unless headlight beam is adjusted incorrectly adjusted properly An beam will not provide the operator the optimum amount of light Adjusting Headlight Aim The headlight can be adjusted for vertical aim of the HIGH LOW beam The geo metric center of HIGH beam zone is to be used for vertical aiming 1 Position the snowmobile on a level floor so the headlight is approxi mately 8 m 25 ft from an aiming surface wall
58. hould reach from the drive clutch to the top of the driven pulley B NOTE Make sure the drive belt is all the way out in the driven pulley before checking drive belt fit 2 Using a stiff ruler centered between the drive clutch and driven pulley push down on the drive belt just enough to remove all slack and note the amount of deflection The deflec tion should be within the range of 28 5 31 8 mm 1 1 8 1 1 4 in 3 To correct drive belt deflection remove the sheave adjuster from the pulley remove or add shim washers to the adjuster and install the adjuster W NOTE Adding shim washers will decrease belt deflection and remov ing shim washers will increase belt deflection Available shim washers from Arctic Cat are p n 0648 714 0 090 in one included in the tool kit p n 0648 715 0 030 in and p n 0648 716 0 060 in E NOTE Removing adding shim washers may be done by the snow mobile owner if qualified to do so If the owner does not feel qualified take the snowmobile to an autho rized Arctic Cat Snowmobile dealer for this service This service is at the discretion and expense of the snow mobile owner Removing Drive Belt E NOTE Changing a drive belt can be done by the snowmobile owner if qualified to do so If the owner does not feel qualified take the snowmo bile to an authorized Arctic Cat Snowmobile dealer for this service This service is at the discretion and expense of the snowmobile owner
59. ilities W NOTE Do not adjust the handlebar to a position that allows air to enter the brake system 3 Recheck lock nuts cap screws tighten securely E NOTE Recommended torque value of lock nuts is 18 ft Ib Recom mended torque value for the Allen head cap screws on models with a telescoping handlebar is 20 ft Ib A WARNING Tighten lock nuts cap screws according to specifications to pre vent unexpected movement of the handlebar during operation over rough terrain DO NOT position han dlebar so steering maximum right left turning capabilities or throttle and brake controls are affected Exhaust System The exhaust system is designed to reduce noise and to improve the total perfor mance of the engine If any exhaust sys tem component is removed from the engine and the engine is run severe engine damage will result 10 Air Intake Silencer Used in conjunction with the fuel intake system is a specially designed air intake silencer The purpose of the silencer is to quiet the intake of fresh air Since the fuel intake system is calibrated with the air intake silencer in place the engine must never be run with the silencer removed Performance will not be improved if the air intake silencer is removed In con trast severe engine damage will occur CAUTION These snowmobiles are not designed to be operated in dusty conditions Operating the snowmo bile in dusty conditions will result
60. iod the snowmobile may be taken to an authorized Arctic Cat Snow mobile dealer for a checkup This checkup is at the discretion and the expense of the snowmobile owner CAUTION DO NOT exceed the one 1 tankful limitation of a 100 1 gas oil break in mixture Continuous use of a gas oil mixture unless consistently operat ing in extremely cold conditions 26 C 15 F or colder could cause spark plug fouling and excessive carbon buildup A 100 1 gas oil mix ture must be used in conjunction with the oil injection system to ensure adequate engine lubrication in extremely cold conditions Drive Belt Break In Drive belts require a break in period of approximately 25 miles Drive the snow mobile for 25 miles at 3 4 throttle or less By revving the engine up and down but not exceeding 60 mph the exposed cord on the side of a new belt will be worn down This will allow the drive belt to gain its optimum flexibility and will extend drive belt life E NOTE Before starting the snowmo bile in extremely cold temperatures the drive belt should be removed and warmed up to room temperature Once the drive belt is at room temper ature install the drive belt see Drive Belt sub section in the Maintenance section CAUTION Never run the engine with the drive belt removed Excessive revving of the engine could result in serious engine damage and drive clutch fail ure Speedometer Tachomete
61. is warning could result in personal injury to yourself or others Personal Injury To avoid injury to yourself and others NEVER operate the snowmobile without first reading and understanding this manual and the Snowmobile Safety Hand book then follow the instructions and heed the warnings given USE COMMON SENSE DON T DRINK and DRIVE STAY IN CONTROL at ALL TIMES TELL YOUR FRIENDS If you see a friend operating a snowmobile recklessly at excessive speeds while intoxicated or in other unsafe ways don t wait until it is too late to warn of the consequences of snowmobile misuse Such conduct endangers everyone TAKE AN ACTIVE ROLE IN THE SAFETY OF YOUR SELF AND OTHERS Parts and Accessories When in need of replacement parts oil or accessories for your Arctic Cat Snowmo bile be sure to only use GENUINE ARCTIC CAT PARTS OIL AND ACCESSO RIES Only genuine Arctic Cat parts oil and accessories are engineered to meet the standards and requirements of your Arctic Cat Snowmobile For a complete list of accessories refer to the current Arctic Cat Accessory Catalog To aid in service and maintenance procedures on these snowmobiles an Illustrated Parts Manual and a Service Manual are available through your local Arctic Cat Snowmobile dealer Foreword Congratulations You have chosen a quality Arctic Cat Snowmobile designed and assembled to give dependable service B
62. ive 89 336 EEC EC Machinery Directive 98 37 EC S2011M8HSPUSW S2011M8HLEUSG S2011M8HHCUSG S2011M1LSEUSW 2011CFHSPUSO 2011CFHLEUSG Standards to which conformity is declared EMC MACHINERY Manufacturer if not issuing agent EN 55012 EN 61000 6 0 EN 292 1 EN 292 2 EN 953 EN 1050 EN 954 1 Arctic Cat Inc 601 Brooks Ave S Thief River Falls MN 56701 USA Fi ef 429 RUN AE E BE too pth 29 OE MBAR ICRA AA KR 166essedopens sessanta 1191 ezuoprud eyes souumpeeueee weluosaa sassy np su qwroo Ja A Oey pop eanqosqossods oye Quay ood uen eines se uon yefe ung uouerosta IO uuega pode es vu 20 ddo og Beauet Ger sesso np seu EPESI JA efoqueas ef evel efoxproq oA 40 0p SUNWON sop ys uapea yoddoyst uum 20 ddn og sanos sep TOSIOAER snoa onbruo quopnid TOADS neo p snos sap 39 oumu 990 6 UF TOAD NOLI URA Peos Gurssas9 uom LOH MED OSN sagem uodo 92 ung 20 PNO YIIEM weuerzeu ofa 19 0uu6u 0 OH OPELOSEE umor uuns yua Bo yanasa Go 10404 60 HOI PEWAG qox MOAI to us quas ef prex pagpusuyoeeed ef fore Ere GEPON unu yuns pugauy J51905uA TE 2294 k eNWrTMLETA yE LAND ID enung oye maet 0650 bi wexoapugureenag vytuoj Bo se pierre med n ueeyoues vssenddoon Ty poru guspuua el eer 9164 BUONE PULLALODII J9 spo XNE 70981900 i L 29009 UOUAIOI zZ osn pue suoprintia pue sse peso We A900 Snowmobile Safety Rules U2 422420 3590 K uuayorD eui euo vto 60400 Wesuo SJ0p
63. ive belts should be pur chased from an authorized Arctic Cat Snowmobile dealer as Arctic Cat drive belts are made to exact specifi cations and of quality material Belts made by other manufacturers may not be of the same specifications or quality and therefore usage could result in poor performance and pre mature belt failure 30 E NOTE Before starting the snowmo bile in extremely cold temperatures the drive belt should be removed and warmed up to room temperature Once the drive belt is at room temper ature install the drive belt Also new drive belts have a break in period of approximately 25 miles After installing a new drive belt drive the snowmobile for 25 miles at 3 4 throttle or less By revving the engine up and down but not exceeding 60 mph the exposed cord on the side of a new belt will be worn down This will allow the drive belt to gain its optimum flexibility and will extend drive belt life CAUTION Never run the engine with the drive belt removed Excessive revving of the engine could result in serious engine damage and drive clutch failure Checking Adjusting Drive Belt Deflection Deflection TZ Drive Clutch Drive Belt Driven Clutch 0743 319 The drive belt must have the proper fit in the drive clutch and driven pulley To check for proper drive belt fit use the following procedure 1 Place a straightedge on the top of the drive belt The straightedge s
64. justment Track Tension Alignment Weekly 32 33 Check adjust as necessary Wear Strips Weekly 38 Check for wear and damage Wires amp Cables Weekly Check for wear damage and fraying Fuel System Tank Pump In Weekly Check for damage wear obstructions and leak Line Filter amp Vent Hose age Air Silencer Seasonal nspect Clean APV System Monthly 15 Check adjust as necessary ACT Drive Gear Case Seasonal 21 Flush and change drive fluid prior to storage Heat Exchangers Monthly Check for wear leakage and damage Drive Clutch Driven Pulley Monthly 10 11 Check for damage binding and wear remove drive belt clean drive clutch driven pulley with compressed air and clean sheaves with suitable parts cleaning solvent Front amp Rear Suspension Monthly 22 23 Grease 24 The longevity and safety of the snowmo bile can be increased by making periodic checks of the items in the preceding checklist If at any time abnormal noises vibra tions or improper working conditions of any component of this snowmobile are detected DO NOT OPERATE THE SNOWMOBILE Take the snowmobile to an authorized Arctic Cat Snowmobile dealer for inspection and adjustment or repair If not under warranty this service is at the discretion and expense of the snowmobile owner The snowmobile should be taken to an authorized Arctic Cat Snowmobile dealer at the end of each snowmobiling season for
65. l 2 Make sure the drive belt is sitting at the top of the driven pulley sheaves 3 Place a straightedge on top of the drive belt The straightedge should reach from the driven clutch to the top of the driven pulley 4 Using a stiff ruler centered between the drive clutch and driven pulley push down on the drive belt just enough to remove all slack Note the amount of deflection on the ruler at the bottom of the straightedge The deflection should be at 1 1 4 in Deflection Drive Clutch Driven Clutch 0743 319 E NOTE Push down on the belt with the ruler only until the bottom of the belt flexes upward then read the amount of deflection 5 To correct drive belt deflection remove the sheave adjuster from the pulley remove or add shim washers to the adjuster and install the adjuster B NOTE Adding shim washers will decrease belt deflection removing shim washers will increase belt deflection 6 Install the belt guard then close the access panel DRIVE CLUTCH AND DRIVEN PULLEY Keeping the drive clutch and driven pulley clean should be the pri mary consideration of the operator The drive clutch and driven pulley can be cleaned of any drive belt accumulation using compressed air The sheaves can be cleaned using a clean cloth and parts cleaning solvent DRIVE CLUTCH DRIVEN PULLEY OFFSET If premature drive belt wear is experienced or if the drive belt turns over offset must
66. ld be used Recommended Injection Oil The recommended oil to use in the oil injection system is either Arctic Cat APV Synthetic 2 Cycle Oil p n 4639 349 qt or p n 5639 469 gal or Formula SS Semi Synthetic Oil p n 5639 470 qt or p n 5639 471 gal This oil is specially formulated to be used either as an injec tion oil or as a pre mix oil for break in and meets all of the lubrication require ments of the Arctic Cat snowmobile engine CAUTION Any oil used in place of the recom mended oil could cause serious engine damage Filling Gas Tank Since gasoline expands as its temperature increases the gas tank must be filled to its rated capacity only Expansion room must be maintained in the tank particu larly if the tank is filled with cold gaso line and then moved to a warm area Also if the snowmobile is to remain on a trailer after filling the gas tank the bed of the trailer must be maintained level to prevent gasoline from draining out through the gas tank vent hose A WARNING Always fill the gas tank in a well ven tilated area Never add gasoline to the snowmobile gas tank near any open flames or with the engine run ning DO NOT SMOKE while filling the gas tank Do not sit on the snow mobile without first installing the gas tank cap Break In Gas Oil Mixing Instructions Before mixing gasoline and oil make sure the oil is at room temperature 20 C 6
67. lower gauge pres sure 0 14 3 52 kg cm 2 5 psi 3 To decrease air pressure in the shock press the black bleed valve button half way down and hold until desired pressure is attained B NOTE Pressing the button fully down and releasing it will allow only a small amount of air to escape micro adjust 4 To increase air pressure in the shock pump until desired pressure is attained 5 Remove the pump valve from the shock air valve B NOTE As the pump valve is being removed from the shock the sound of air loss is from the pump hose not from the shock 6 Install the air valve cap onto the shock Adjusting Skid Frame Front Arm The skid frame front arm shock spring tension and the limiter straps are adjust able However Arctic Cat recommends that the shock spring be maintained at the factory preset of 1 8 1 4 in preload Tightening the skid frame front arm shock spring may cause improper bal ance and may ruin the handling features of the snowmobile The length adjustment of the front arm limiter straps determines the weight dis tribution between the front of the skid frame and the skis Tightening the limiter strap shortening the strap will pull up on the front of the skid frame and will increase ski pressure Loosening the lim iter strap lengthening the strap lowers the front of the skid frame and decreases ski pressure When customizing the amount of ski pressure be sure to adjust both straps
68. lug hole od Oil Fill Level gt Drain Plug SO a JO Plug 744 133D O CheckFill B NOTE To aid in draining the lubri cant it is advisable to fashion a drain adapter by acquiring a fitting Gear Case Drain Fitting p n 0644 552 and a length of 3 8 in hose 5 Tip the snowmobile back to the upright position then place a drain pan on the floor next to the drain hose and tip the snowmobile toward its left side far enough to allow the lubricant to drain from the gear case into the drain pan E NOTE It is critical that the snow mobile is on a level surface to ensure the lubricant drains properly and completely 6 Secure the snowmobile in this posi tion until the lubricant is completely drained CAUTION It is critical that all of the old lubri cant be drained from the gear case prior to flushing the gear case 7 When the lubricant has completely drained from the gear case tip the snowmobile back to the upright posi tion remove the drain adapter and install and securely tighten the drain plug then remove the check fill plug 8 Pour Arctic Cat ACT Drive Flush Fluid p n 4639 333 into the check fill hole then install the plug Tighten securely CAUTION Do not add more or less than the recommended amount 6 fl oz of flush fluid to the gear case 9 Install the driven pulley then install the drive belt see Drive Belt sub section in the Mainte
69. mpleted after the third attempt the engine will shut down CAUTION Never shift into reverse while the snowmobile is moving forward as it is hard on the driven pulley torque bracket and the cam rollers Operating in Reverse CAUTION Never engage the electric starter or pull the recoil starter rope when the engine is running or when operating in reverse Damage to the engine and or either the electric start or recoil start system will occur 13 1 When reverse is engaged a reverse icon will illuminate in the speedom eter tachometer and a reverse alarm will sound 2 If the throttle lever is compressed before complete reverse engage ment the engine may shut down Always wait for the reverse icon to illuminate and the reverse alarm to sound before backing up 3 Ifreverse is used for longer than five minutes continuously the engine will shut down A WARNING Do not use high speed when backing up Control could be lost and injury could occur CAUTION Do not use high speed when back ing up Damage to the drive belt and driven pulley components may occur E NOTE While operating in reverse a rev limiter will activate at 6000 RPM 4 After shifting from reverse to for ward or from forward to reverse apply the throttle slowly and evenly to allow the driven pulley to engage properly 5 The reverse function is cancelled whenever the engine is shut off CAUTI
70. n RPM Turn engine off Install the intake boot CAUTION Do not run the engine without the belt guard in place and secured 6 Plug the exhaust system outlet with a clean cloth 7 With the ignition switch in the OFF position A Disconnect the high tension leads from the spark plugs then remove the plugs connect them to the leads and ground them on the cylinder heads CAUTION Never crank the engine over without grounding the spark plugs Damage to coils and or ECU may result 10 11 12 13 14 15 16 B Pour 29 5 ml 1 fl oz of SAE 30 petroleum based oil into each spark plug hole and pull the recoil starter handle slowly about 10 times C Install the spark plugs and con nect the high tension leads Fill the gas tank to its rated capacity then add Arctic Cat Fuel Stabilizer p n 0436 907 to the gas tank fol lowing directions on the container for the stabilizer gasoline ratio Tighten the gas tank cap securely Flush the gear case and replace the lubricant see Lubrication section Remove the drive belt from the drive clutch driven pulley Lay the belt on a flat surface or slide it into a card board sleeve to prevent warping or distortion during storage Clean and inspect the drive clutch and driven pulley Apply light oil to the upper steering post bushing and shafts of the shock absorbers Lubricate the rear suspension spin dles
71. n and expense of the snowmobile owner The air shocks are individually adjustable for the terrain conditions and driving style of the operator The shocks are preset at the factory see chart as an initial setting however it is possible to fine tune the shocks to match the operator s weight riding style and terrain conditions Checking and adjusting air pressure must be done at riding temperature outside Also it is advisable to check air pressure when the outside temperature varies more than 25 Initial Setting Chart Front Shock Rear Arm Model Ski Shock Sno Pro 4 2 kg cm 9 5 10 2 kg cm Models 60 psi 135 145 psi W NOTE Care should be taken to have equal pressure in the front ski shocks before operating the snow mobile To increase or decrease air pressure use the following procedure W NOTE When adjusting air pres sure all weight must be removed from the suspension and the shock absorbers must be fully extended W NOTE Adding air pressure will increase the air spring force reduc ing air pressure will decrease air spring force A WARNING Do not exceed 10 5 kg cm 150 psi in the shock 1 Remove the air valve cap from the shock 2 Thread the valve of Shock Absorber Air Pump p n 2603 614 onto the shock air valve approximately six rotations W NOTE As the pump is being attached to the shock the hose will fill with air This will result in a
72. nance section and the belt guard 10 Install the left side access panel then close the access panel 21 11 Position the tips of the skis against a wall then using a shielded safety stand raise the rear of the snowmo bile off the floor making sure the track is free to rotate A WARNING The tips of the skis must be posi tioned against a wall or similar object 19 When the fluid has completely drained from the gear case tip the snowmobile back to the upright position remove the drain adapter and install and securely tighten the drain plug then remove the check fill plug CAUTION A WARNING DO NOT stand behind the snowmo bile or near the rotating track NEVER run the track at high speed when the track is suspended The correct lubricant to use in the gear case is Arctic Cat Synthetic ACT Gear Case Fluid Any substitute may cause serious damage to the 12 Start the engine and accelerate slightly Use only enough throttle to turn the track several revolutions SHUT ENGINE OFF 13 Open the left side access panel then remove the panel and the belt guard 14 Remove the drive belt see Drive Belt sub section in the Maintenance sec tion then remove the driven pulley 15 Using Handlebar Stand p n 5639 152 or a suitable substitute tip the snowmobile onto its right side 16 Remove the drain plug from the gear case then install the drain adapter fit ting with hos
73. nd Installing Taillight Brakelight These models are equipped with an LED taillight brakelight If the LED fails it must be replaced To remove and install the LED use the following procedure 36 E NOTE To access the harness con nector and the two self tapping screws securing the taillight to the snowflap compress the two flanged tabs located on the under side of the tunnel and carefully pry up on the front of the taillight snowflap 1 Flanged Tabs 0744 462 1 Disconnect the taillight harness con nector 2 Remove the two self tapping screws securing the taillight to the snowflap 3 Secure the taillight to the snowflap with the two self tapping screws then connect the taillight connector 4 Secure the front of the snowflap to the tunnel by carefully tapping the snowflap until the two flanged tabs snap into place Removing Headlight Bulb E NOTE The bulb portion of headlight is fragile HANDLE WITH CARE When replacing the headlight bulb the bulb assembly must first be removed from the housing Do not touch the glass portion of the bulb If the glass is touched it must be cleaned with a dry cloth before installing To access the headlight bulbs use the fol lowing procedure 1 With the hood closed loosen the headlight adjustment knobs 2 Carefully push the headlight lenses rearward far enough to remove the torx head screws securing the air silencer plenum to the hood 3 Open t
74. nd hold the right button until the display is cleared The hour meter readout will not reset Service Icon The icon should briefly illuminate each time the engine is started then it should go out If the icon illuminates while the engine is running the system is receiving input that is outside of its established parameters If the icon illuminates indicat ing an error take the snowmobile to an authorized Arctic Cat Snowmobile dealer for service If not under warranty this ser vice is at the discretion and expense of the snowmobile owner Coolant Temperature Warning Icon If the coolant temperature is at or above 80 C 176 F the coolant temperature warning icon will flash a warning alert If the coolant temperature is at or above 93 C 200 F the coolant temperature warning icon will cease flashing and will remain constantly illuminated Temperature Icon Above 80 C 176 F Steady Flash Coolant Coolant Temperature Constant On Coolant Temperature Icon Coolant Temperature Above 93 C 200 F CAUTION At this point take precautionary measures such as changing to loose snow terrain shutting the engine off allowing the engine to cool down and checking coolant level If unable to either determine or remedy the problem take the snowmobile to an authorized Arctic Cat Snowmobile dealer for service If not under war ranty this service is at the discre tion and expense o
75. nd service at the owner s choosing such items as air filter oil and oil filter or any other part item or device related to emissions control as specified in the Operator s Manual It is the owner s responsibility to ensure that the snowmobile is used in a manner for which it was designed 46 Change of Address Ownership or Warranty Transfer Arctic Cat Inc keeps on file the current name and address of the owner of this snowmobile This will allow Arctic Cat to reach the current owner with any important safety information which may be necessary to protect customers from personal injury or property damage Please make sure a copy of this form is completed and returned to Arctic Cat Inc if you move or if the snowmobile is sold to another party This form may also be used to transfer the unused portion of the original warranty to a second party In order to transfer warranty fill out this form completely then return a copy of this form to Arctic Cat Inc Arctic Cat will then process the application and issue warranty for the balance of the time remaining of the original warranty L Address Change L Ownership Change L Warranty Transfer CHANGE OF ADDRESS OWNERSHIP WARRANTY TRANSFER TO Name Address City State Province Zip Code Postal Code Phone Year and Model Snowmobile Vehicle Identification Number VIN CHANGE OF ADDRESS OWNERSHIP ARCTIC CAT INC P
76. ng bolt jam nut then rotate the adjusting bolt clockwise 1 to 1 1 2 turns 33 Rear Idler Wheels 7 Track Adjuster Adjusting Bolt 739 636B 2 Check track alignment and continue adjustment until proper alignment is obtained E NOTE Make sure correct track tension is maintained after adjust ing track alignment see Track Ten sion sub section in this section 3 After proper track alignment is obtained tighten the adjusting bolt jam nut against the axle housing A WARNING If a jam nut is not tightened properly the adjusting bolt could loosen causing the track to become dangerously loose 4 Field test the track under actual con ditions 5 After the field test check the align ment of the track If additional adjust ment is necessary repeat Adjusting Track Alignment procedure Suspension The suspension should be adjusted for the operational needs and riding prefer ence of the operator The front shock springs determine the amount of ski pressure and the reaction of the front suspension to rough terrain The amount of ski pressure can also be changed by adjusting the length of the skid frame front arm limiter straps On standard models the rear arm shock absorber spring influences the load carry ing capability of the snowmobile and should be adjusted for the weight and rid ing preference of the operator W NOTE On Sno Pro models this adjustment is achi
77. nt Personal injury could result if contact is made with a rotating track Remove excess ice and snow buildup from the track track drive sprockets and the inside of the skid frame 2 Position the tips of the skis against a wall then using a shielded safety stand raise the rear of the snowmo bile off the floor making sure the track is free to rotate A WARNING The tips of the skis must be posi tioned against a wall or similar object A WARNING DO NOT stand behind the snowmo bile or near the rotating track NEVER run the track at high speed when the track is suspended 3 Start the engine and accelerate slightly Use only enough throttle to turn the track several revolutions SHUT ENGINE OFF B NOTE Allow the track to coast to a stop DO NOT apply the brake because it could produce an inaccu rate alignment condition 4 When the track stops rotating check the relationship of the rear idler wheels and the inner track drive lugs If the rear idler wheels are centered between the inner track drive lugs no adjustment is necessary Rear Idler Wheels E Inner Track Drive a S centered between Drive Lugs 725 070A 5 If the idler wheels are not centered between the inner track drive lugs an adjustment is necessary Adjusting Track Alignment 1 On the side of the track which has the inner track drive lugs closer to the rear idler wheel loosen the adjusti
78. nt often To check the cable adjustment use the fol lowing procedure WWE Servomotor Adjusting Nut Jam Nut Left Side Adjusting Nut Footrest 742 209A 1 Using a small needle nose pliers remove the servomotor retaining clip 800 1000 cc models and the cable holder Retaining Clip Cable Holder Exhaust Valve Cables 0744 489 2 Using an adjustable wrench rotate the servomotor actuator counter clockwise to loosen the cable then pull the cable housings down and out of the servomotor CAUTION Do not use the nut securing the pul ley to the servomotor to rotate the actuator B NOTE For installing purposes note the side that the servomotor cables are installed on 3 Slide each cable drum out of the slot of the servomotor actuator 4 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 W NOTE If the cable exhaust valve does not move freely the exhaust valve assembly will need to be removed for further inspection Take the snowmobile to an authorized Arctic Cat Snowmobile dealer for this service ENOTE When measuring the cables they are to be routed as close to their installed position as possible 5 While holding the cable housing lightly pull on one cable end to remove any slack then measure the amount of expos
79. of the drive clutch first then between the sheaves of the driven pulley 2 Remove the sheave adjuster and install it in its original position beveled side out then install the cap screw lock washer washer and sheave adjuster back into the driven pulley Tighten the cap screw to 32 ft lb CAUTION Do not apply Loctite to the driven pulley cap screw or component damage may occur 3 Install the belt guard then close the left side access panel 31 A WARNING Never operate the snowmobile with out the belt guard access panel secured in place 4 Release the brake lever lock Track Tension Track tension is directly related to the overall performance 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 If extremely loose the idler wheels may climb over the track lugs forcing the track against the tunnel causing the track to lock Arctic Cat recommends that the track tension be checked daily during the first 300 miles of operation and once a week thereafter and adjusted according to need The track will stretch and take a set during break in Track deflection must be maintained within the recom mended range A WARNING Track tension must be properly maintained Personal injury could result if a track is allowed to become excessively loose Checking Track Tension A
80. on a hard pack trail then immediately drive into deep snow and allow the wear strips to cool Repeat the procedure warming up the wear strips then cooling them down two or three times E NOTE The rail wear strips will wear rapidly if the snowmobile is operated on terrain on which the snow cover is minimal Loose snow is required to cool and lubricate the wear strips and prevent accelerated wear Minimum Thickness 0 42 in ge ad A ue a didi SRS j DA JE Me ja e alte WE ows 30 Iz OG OC ai sii eem 0743 189 39 Performance Tips Operating a high performance snowmo bile requires a special attention that is not required by a low performance snowmo bile Often a minor adjustment will result in a large increase in performance This section is intended to highlight minor conditions that adversely affect performance and the adjustments needed to correct them Be sure however to thoroughly read and understand this entire manual especially the section on spark plugs track tension and alignment and suspension DRIVE BELT This link between the engine and drive train is often the most neglected component The drive belt must have the proper fit in the drive clutch and driven pulley Proper fit is when the top surface of the drive belt is flush with the top or up to 1 16 in higher than the driven pulley sheaves with the sheaves fully closed If drive belt deflection is above
81. peed readout the alti tude value will be displayed in meters To reset the maximum altimeter readout with the maximum altimeter displayed push and hold the select button for a min imum of two seconds Service Icon The icon should briefly illuminate each time the engine is started then it should go out If the icon illuminates while the engine is running the system is receiving input that is outside of its established parameters If the icon illuminates indi cating an error take the snowmobile to an authorized Arctic Cat Snowmobile dealer for service If not under warranty this service is at the discretion and expense of the snowmobile owner Coolant Temperature Warning Icon If the coolant temperature is at or above 80 C 176 F the coolant temperature warning icon will flash a warning alert If the coolant temperature is at or above 93 C 200 F the coolant temperature warning icon will cease flashing and will remain constantly illuminated Steady Flash Coolant Temperature Icon Coolant Temperature Above 80 C 176 F Constant On Coolant Coolant Temperature Temperature Icon Above 93 C 200 F CAUTION At this point take precautionary measures such as changing to loose snow terrain shutting the engine off allowing the engine to cool down and checking coolant level If unable to either determine or remedy the problem take the snowmobile to an authorized
82. pense of the snowmobile owner DRIVE CLUTCH DRIVEN PULLEY PARALLELISM If premature drive belt wear is experienced or if the drive belt turns over parallelism must be checked Also parallelism must be checked whenever either the drive clutch or driven pulley is serviced E NOTE For checking parallelism it is necessary to use Clutch Align ment Bar p n 0644 509 This special tool can be purchased from an authorized Arctic Cat Snowmobile dealer To check parallelism use the following procedure 1 Remove the drive belt then open the driven sheaves and place clutch alignment bar between the sheaves Release the sheaves 2 Check the parallelism of the drive clutch driven pulley using the paral lelism bar and reference points X and Y with the parallelism bar between the driven sheaves Using a caliper or a machinist s scale mea sure X and Y from the back side of the parallelism bar to the back side of the drive clutch sheave Measure ment Y must be 0 060 in 0 020 in more than measurement X but Y must not exceed measurement X by more than 0 100 in 41 Y Y 1 5 mm 1 0 mm lt 0 060 in 0 020 in 4 i q 42 3 If parallelism is not within specifica tions the parallelism must be cor rected by first loosening all the engine mounting bolts left side front and right top rear Then pry the front of the engine towards the MAG side of the engine compart ment Next
83. procedure B NOTE The brake system may be bled by the snowmobile owner if qualified to do so If the owner does not feel qualified take the snowmo bile to an authorized Arctic Cat Snowmobile dealer for this service This service is at the discretion and expense of the snowmobile owner 1 Remove the reservoir cover and fill the reservoir with Arctic Cat approved brake fluid CAUTION Brake fluid is highly corrosive Do not spill brake fluid on any surface of the snowmobile A WARNING Use only Arctic Cat approved brake fluid Any substitute may result in a loss of brakes 2 Slide a piece of flexible tubing over the ball of the bleeder valve and direct the other end into a container er T7 739 269B 3 Slowly compress the brake lever and hold Open the bleeder valve to release the fluid and air When the fluid stops close the bleeder valve then release the brake lever 4 Repeat step 3 until the brake fluid flows free of air bubbles E NOTE It may be necessary to refill the reservoir during the bleeding process 5 When the brake fluid is free of all air and the brake lever feels firm when compressed fill the reservoir then install and secure the cover Remove the tube from the bleeder valve Checking Changing Brake Pads The condition of the brake pads must be checked daily and changed if worn or damaged To check and change the brake pads use the following procedure
84. r These snowmobiles are equipped with different speedometer tachometer styles Determine which style your model is equipped with and use the appropriate following information Indicator Icons Standard Gauge Certain models are equipped with a stan dard gauge combination speedometer tachometer Indicator icons are incorpo rated within the speedometer tachometer Also incorporated into the speedometer tachometer is a digital readout screen FZ003D Oil Pressure Low Oil Coolant Temperature Low Fuel Fuel Level mOOUU Service High Beam RPM MPH kph By pushing the left button once the RPM and MPH will be displayed one on the readout screen and one with the needle By pushing the button once again the functions will be reversed By pushing the left button with speed being displayed for more than two sec onds the display will change between standard mph or metric kph Release the button when desired display appears With RPM displayed on the readout screen by pushing and holding the left button max imum RPM will be displayed on the readout screen The maximum RPM readout will reset when the right button is pushed while maximum RPM is displayed Odometer Trip Meter 1 Trip Meter 2 Hour Meter By pushing the right button the readout screen will display odometer trip meter 1 trip meter 2 and hour meter To reset the trip meter with the trip meter displayed push a
85. st be illuminated whenever the engine is running 1 Test the operation of the brake sys tem by compressing the brake lever The brake lever must feel firm when compressed then while holding the brake lever in the compressed posi tion measure the distance between the brake lever and the handlebar The distance must be greater than 2 54 cm 1 in 1in 741 328C 2 Check the fluid level in the reservoir The brake fluid level must be visible in the sight glass Add Arctic Cat approved brake fluid as necessary Sight Glass Ke 1 Brake Fluid Reservoir 741 328A B NOTE If the sight glass appears dark there is a sufficient amount of fluid in the reservoir A WARNING Do not start the engine if the brake system is not functioning properly Service the brake system or have it properly repaired prior to operating the snowmobile Serious personal injury or even death may occur if the brake system is not operating properly 3 Test the throttle control lever by completely compressing and releas ing it several times The lever MUST return to the idle position quickly and completely CAUTION Always check the coolant before starting the engine level 4 Move the emergency stop switch to the UP or RUN position 5 Insert key into ignition switch then rotate key to the RUN position B NOTE When a cold engine is being started DO NOT CO
86. the adjusting bolts to take up excessive slack in the track 3 If the distance between the bottom of the wear strip and the inside surface of the track is less than specified loosen the adjusting bolts to increase the slack in the track 4 Check track alignment see Track Alignment sub section in this sec tion 5 When proper track tension is obtained tighten the adjusting bolt jam nuts against the axle housings W NOTE Since track tension and track alignment are interrelated always check both even if only one adjustment seems necessary A WARNING If jam nuts are not tightened prop erly the adjusting bolts could loosen causing the track to become extremely loose and under some operating conditions 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 operation severe per sonal injury could result Track Alignment Proper track alignment is obtained when the rear idler 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 Track Alignment A WARNING Make sure the ignition key is in the OFF position and the track is not rotating before checking or adjusting track alignme
87. the snowmo bile owner 11 Each shock absorber should be visibly checked weekly for fluid leakage cracks or breaks in the lower case or a bent plunger If any one of these conditions is detected replacement is necessary Take the snowmobile to an authorized Arctic Cat Snowmobile dealer for this service If not under warranty this service is at the discretion and expense of the snow mobile owner E NOTE When the snowmobile is operated in extremely cold weather 23 C 10 F or colder a small amount of leakage may be present Unless the leakage is excessive replacement is not necessary Deep Lug Track Some models are equipped with a deep lug track which is specially designed for use in powder snow riding conditions When the deep lug track is operated in hard packed snow conditions it will run slightly slower than a standard lug track and it will accelerate wear strip wear To decrease the amount of wear strip wear slower speeds must be maintained when operating on hard packed trails Acceler ated wear strip wear caused by operating a deep lug track on hard packed snow conditions is NOT covered under Arctic Cat Inc warranty policy E NOTE If operating on ice or hard packed snow conditions it is recom mended that Ice Scratchers p n 4639 958 be installed to reduce wear strip and engine overheating Track Studs Crossfire Models E NOTE Stud or hooker plate instal lation will void track and tunnel w
88. tion B NOTE An alarm will sound when the snowmobile is operated in reverse Removable Seat Crossfire 800 Models These snowmobiles are equipped with a removable seat To remove the seat use the following procedure 1 Inside the rear storage compartment on the bottom of the seat base rotate the latch cover away from the right side locking pin 2 Lift on the back of the seat and move it rearward to remove it from the tunnel To install the seat use the following pro cedure 1 Slide the front of the seat into posi tion on the tunnel then lower the rear of the seat onto the locking pins 2 Press down on the rear of the seat until the retaining clips snap into place on the locking pins then rotate the latch cover until it snaps into place on the right side locking pin A WARNING Make sure the seat is securely locked in place or personal injury may result Towing If the snowmobile is to be towed by another snowmobile do not tow using the loops in the skis The tow rope should be attached to the spindles Arctic Power Valve APV System CAUTION is either Arctic Cat APV Synthetic 2 Cycle Oil or Formula SS Semi Syn thetic Oil see Gasoline Oil Recom mended Injection Oil sub section in this section Any substitute may cause an APV malfunction This RPM controlled servomotor servo actuated system adjusts the size of the exhaust ports to provide peak perfor m
89. tions Because Arctic Cat Inc constantly refines and improves its products no retroactive obligation is incurred This Operator s Manual should be considered a permanent part of the snowmobile and must remain with the snowmobile at the time of resale If the snowmobile changes ownership more than once contact Arctic Cat Inc Service Department P O Box 810 Thief River Falls MN 56701 for proper registration information This manual was prepared by the Product Service and Warranty Department of Arctic Cat Inc Every Arctic Cat Snowmobile meets or exceeds the standards of the Snowmobile Safety and Certification Committee and displays the SSCC decal Arctic Cat Inc endorses and encourages the safe use of all snowmobiles Always wear a helmet and eye protection Drive with caution observe all state and local regulations and respect the rights of others ISMA members like Arctic Cat do their part to improve trails sponsor events and generally support the sport of snowmobiling As a mem ber of the National Snowmobile Foundation Arctic Cat Inc promotes snowmobil ing through education charity and research programs 2010 Arctic Cat Inc Printed in U S A Declaration of Conformity Application of council directives Issued by European Commission Type of Equipment Snowmobile Brand Name Arctic Cat Model Numbers S2011M6D3EUSB S2011M8H3EUSB S2011M8HEKUSB S2011M8HSEUSW S2011CFD1EUSB S2011CFH1EUSB S2011CFHSEUSG EMC Direct
90. uit in barometric pressure sensor 5 Open or short circuit in intake air tem perature sensor 6 Openor short circuit in water temper ature sensor 7 Open or short circuit in throttle posi tion sensor 12 Failure in ignition coil 16 Incorrect adjustment failure in APV cable 17 Failure in exhaust temperature sen Sor 18 Failure in servomotor 21 Failure in knock sensor OCTN Low octane gasoline On certain models Telescopic Handlebar Sno Pro Sno Pro LTD Models 1 From each side of the steering post compress the locking tabs to unlock the handlebar 0743 463 2 With the tabs compressed adjust the handlebar up or down to the desired position then release the tabs to lock the handlebar in place Handlebar Tilt The handlebar can be adjusted to the position providing the operator with the most comfort To adjust the handlebar use the following procedure B NOTE It may be necessary to remove the handlebar cover for this procedure 1 Loosen the four lock nuts Allen head cap screws on models with a telescoping handlebar securing the handlebar caps and block to the steering post Lock Nut 743 442A Allen Head Cap Screw 0743 467 2 Adjust the handlebar to operator s desired tilt then tighten the lock nuts cap screws evenly and securely Check steering for maximum right left turning capab
91. ure 1 2 Clean the snowmobile thoroughly Polish the exterior of the snowmobile Clean the engine Remove the cloth from the exhaust system Check exhaust system and air intake silencer for obstructions Inspect 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 Inspect the drive belt for cracks and tears Check belt specifications Replace if damaged or worn Install the drive belt E NOTE If the old belt is worn but in reasonable condition retain it with the snowmobile as a spare in case of emergency 5 Inspect all fuel hoses and oil hoses for deterioration or cracks replace if necessary Make sure all connections are tight then fill the oil injection reservoir with the recommended 2 cycle oil see Gasoline Oil Recom mended Injection Oil sub section in the General Information section B NOTE After prolonged storage Arctic Cat recommends one tankful of 100 1 gas oil mixture be used in conjunction with the oil injection system to ensure proper lubrication 6 7 10 11 Inspect the spark plugs Replace gap or clean as necessary Tighten all nuts bolts and cap screws making sure all nuts bolts and cap screws are tightened securely If not done during preparation for storage lubricate the rear suspen sion spindles and steering arms with all temperature greas
92. will tend to dig the skis deeper into the snow Always use mini mal speed when operating in reverse and come to a complete stop before shifting from either forward to reverse or reverse to forward Shifting Into Reverse Reverse Switch Button 741 438A B NOTE Correct drive belt tension deflection is important for the reverse function to operate properly If the belt is too tight difficulty in engaging reverse will be experi enced the reverse function will make up to three attempts to engage into reverse and if the function is not completed after the third attempt the engine will shut down 1 Always warm up the engine for 2 3 minutes prior to shifting into reverse The reverse function is can celled when engine temperature is below 22 F 30 C or above 176 F 80 C 2 Shift only with the engine at idle RPM and the snowmobile com pletely stopped The reverse func tion will not engage if engine speed is above 4000 RPM B NOTE If attempting to shift into reverse at too high engine RPM above 4000 RPM the reverse func tion will be cancelled and the coolant temperature warning icon will flash This indicates the reverse switch button was pressed at too high RPM The operator must reduce engine RPM below 4000 and press the but ton a second time 3 Upon pressing the reverse switch button the reverse function will make up to three attempts to engage into reverse If the function is not co

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