2007 Snowmobile Operator’s Manual p/n 2257-617
LIMITED WARRANTY Arctic Cat Inc. (hereinafter referred to as Arctic Cat) extends a limited warranty on each new Arctic Cat Snowmobile it manufactures and on each part and accessory manufactured 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.
Table of Contents Limited Warranty.................. Inside Front Cover Foreword.........................................................1 Declaration of Conformity ...............................2 Snowmobile Safety Rules ...............................3 General Information ...................................4-30 Snowmobile Identification...........................4 Control Locations .......................................4 Tipped Snowmobile ....................................7 Gasoline-Oil ...............
REFERENCE INFORMATION Write the appropriate information for your Arctic Cat Snowmobile in the spaces below. Always use these numbers when referring to your snowmobile.
FOREWORD Congratulations! You have chosen a quality Arctic Cat Snowmobile designed and manufactured to give dependable service. Be sure, as the owner/operator of an Arctic Cat Snowmobile, to become thoroughly familiar with its basic operation, maintenance, 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.
DECLARATION OF CONFORMITY Application of council directives: EMC Directive 89/336/EEC EC Machinery Directive 98/37/EC Issued by European Commission.
SNOWMOBILE SAFETY RULES SNOWMOBILE SAFETY RULES 3
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. The Engine Serial Number (ESN) is stamped into the crankcase of the engine. 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.
Z Models 734-268A F-Series/Jaguar Z1 Models 741-375B Crossfire/M-Series Models 741-633A GENERAL INFORMATION 5
T660/Bearcat Wide Track Models 741-632A Bearcat 570 Model 740-586A Panther 570/660 Models 741-634A 6 GENERAL INFORMATION
TIPPED SNOWMOBILE Tipping a snowmobile on its side is sometimes desirable for maintenance purposes; however, on a 660 cc model, Arctic Cat recommends NOT TIPPING IT ON ITS SIDE IN EXCESS OF A 70° ANGLE. ! CAUTION The 660 cc models should not be tipped on their sides in excess of a 70° angle for any reason, as engine oil may seep into the upper engine through the airintake system. Severe engine damage could result if the engine is run with oil in the upper engine.
GASOLINE-OIL Recommended Gasoline (Carbureted Models) The recommended gasoline to use in these snowmobiles is 87 minimum octane regular unleaded. In many areas, oxygenates (either ethanol or MTBE) are added to the gasoline. Oxygenated gasolines containing up to 10% ethanol or up to 15% MTBE are acceptable gasolines; however, whenever using oxygenated gasolines, the carburetor main jet must be one size larger than the main jet required for regular unleaded gasoline.
! CAUTION Any oil used in place of the recommended oil may cause serious damage. 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. ! WARNING OILCHARTD After the engine break-in period, the engine oil should be changed every 2500-3000 miles on standard 660 cc models.
4. Fill the gasoline container with gasoline; then cap the gasoline container and shake the mixture vigorously. 5. Using a fine-mesh screened funnel, pour the fuel mixture from the gasoline container into the snowmobile gas tank. ! WARNING Always fill the gas tank in a wellventilated area. Never add gasoline to the snowmobile gas tank near any open flames or with the engine running. DO NOT SMOKE while mixing fuel or filling the gas tank.
To ensure proper engine break-in on the 1100 cc Z1 and 660 cc models, Arctic Cat recommends that the engine oil and filter be changed after 200-500 miles. This service is at the expense of the snowmobile owner. INDICATOR LIGHTS (Carbureted Models/ Bearcat W/T NonTurbo/Panther 660) Indicator lights are incorporated within the speedometer.
COOLANT TEMPERATURE WARNING LIGHT (Carbureted Models/ Bearcat W/T NonTurbo/Panther 660) If the coolant temperature is at the maximum running temperature, the coolant temperature warning light will flash a warning (alert). If the coolant temperature is above the maximum running temperature, the coolant temperature warning light will cease flashing and will remain constantly illuminated.
Bottom Button By pushing the bottom button once, the readout screen will display hourmeter or trip-meter/odometer; by pushing the button once again, the two functions will be reversed. To reset the trip meter with the trip meter displayed, push and hold the bottom button until the display is cleared. The hour-meter readout will not reset. ZJ001A A. Chassis Control Unit B. Oil Pressure/Low Oil C. High Beam D. Check Engine E.
! 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.
DIAGNOSTIC CODES/ CHECK ENGINE (2Stroke Models) ZJ004A NOTE: When air can no longer be heard, purging from oil pump bleed, tighten the bleed bolt to 1.05 kg-m (7.5 ft-lb). 4. Start the engine. The warning light shuld go out within five seconds. If the engine does not start, take the snowmobile to an authorized Arctic Cat Snowmobile dealer. Check Engine Light The Check Engine Light is controlled by the ECU and may illuminate for a number of reasons.
Number of Flashes Trouble 1-2 (Check Engine Light) Failure in ignition coil. 1-6 (Check Engine Light) Incorrect adjustment/ failure in APV cable. 1-7 Failure in exhaust tem(Check perature sensor. Engine Light) 1-8 (Check Engine Light) Failure in servomotor. 2 (Check Engine Light) Failure in injector(s). 2-1 (Check Engine Light) Failure in knock sensor. 2-3 (Check Engine Light) Failure in knock control system. 4 Open or short circuit in (Check barometric pressure Engine Light) sensor.
Number of Flashes Trouble 3 (Check Engine Light) Failure in injector (#1). 4 (Check Engine Light) Failure in barometric pressure sensor. 5 Open or short circuit in (Check Engine intake manifold air temLight) perature sensor. 6 Open or short circuit in (Check Engine water temperature senLight) sor. 2. Adjust the handlebar up or down to operator’s desired tilt; then tighten the lock nuts evenly and securely. Check steering for maximum right/left turning capabilities. 3. Recheck securely.
1. Press inward on the lock pin to release the cam lever and “flip” the cam lever up. 735-501B 2. Adjust the handlebar up or down to operator’s desired tilt, tighten the cap screws evenly to 3.5 kg-m (25 ft-lb), and check steering for maximum right/left turning capabilities. NOTE: Do not adjust the handlebar to a position that allows the brake fluid to be below the low mark on either side of the master cylinder.
4. After the handlebar is “locked” in position, release the cam lever and rotate it one turn clockwise; then press down on the cam lever until it “locks” in place. NOTE: At this point, gently lift the cam lever without pressing in on the lock pin. If the cam lever cannot be lifted, the lock pin is secure. ! CAUTION If at any time the lock pin will not engage into the locked position, do NOT operate the snowmobile. Take the snowmobile to an authorized Arctic Cat dealer for service.
COOLING SYSTEM (Liquid) Some 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 service. If not under warranty, this service is at the discretion and expense of the snowmobile owner.
When operating the snowmobile at high altitudes, it may be necessary to change certain component parts of the drive clutch. 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.
NOTE: If the adjustment bolt will not turn using the fingers (because of dirty threads), use a wrench to loosen the bolt; then using the fingers, adjust the bolt until it is finger-tight. Once the adjustment bolt becomes difficult to turn by hand, the drive chain is properly tensioned. 3. Lock the adjustment by bottoming the jam nut against the chain case. NOTE: When the head of the adjustment bolt bottoms on the jam nut, the drive chain is in need of being replaced.
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 deteriorates (or seems to be deteriorating), take the snowmobile to an authorized Arctic Cat Snowmobile dealer for shock absorber evaluation and/or servicing. This service is at the discretion and expense of the snowmobile owner.
NOTE: Stud installation can be performed 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. For proper installation, use the following procedure: 1. Using Stud Template (p/n 2639903), mark the desired stud pattern to be used. 2. Using the proper-sized stud hole drill bit, drill out the stud holes. 3.
Always use minimal speed when operating in reverse and come to a complete stop before shifting from either forward to reverse or reverse to forward. Once you have shifted to a new gear, apply slight throttle until positive engagement of the shift has been observed. To shift the reverse transmission, use the following procedure: 1. Come to a complete stop. 2. Either push or pull the shift lever to the desired position; then apply slight throttle until positive engagement of the shift has been observed.
When riding single, the backrest should be moved forward to a position comfortable to the operator. Be sure to maintain the backrest pad in a vertical position in all locations. Also, be sure to tighten all retaining knobs securely after adjusting the backrest. 0741-438 NOTE: The system will not shift until the button is released. ! WARNING Moving the backrest forward limits the seating capacity to one person only. 3.
! CAUTION On models equipped with a seat warmer, disconnect the warmer wiring harness prior to fully removing the seat. 1. Inside the rear storage compartment on the bottom of the seatbase, pull the retaining clips away from locking pins. 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 procedure: 0735-854 To install the rear seat, use the following procedure: 1.
2. Lift up on the back of the seat; then move the front of the seat up or down into one of the seven available positions. ! CAUTION Do not use the adjuster lever to lift the seat. To install the seat, use the following procedure: ! CAUTION Do not use the adjuster lever to lift the seat. 3. Press down on the rear of the seat; then secure the seat by releasing the seat adjuster lever. ! WARNING Make sure the seat is securely locked in place or personal injury may result.
The system consists of an exhaust valve assembly mounted to the exhaust side of each cylinder and connected by adjustable cables to an electronic servo mounted beneath the hood. NOTE: The mounting location of the servo will vary from model to model. 739-152H NOTE: The RPM ranges will vary from model to model. 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.
If a system fault is suspected, use an ohmmeter 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. 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 attempting to start the engine. Also, on carbureted models, be sure the correct carburetor main jet(s) for the operating temperature, altitude, and gasoline are being used.
3. Test the throttle control lever by completely compressing and releasing it several times. The lever MUST return to the idle position quickly and completely. ! CAUTION 740-159A On liquid cooled models, always check the coolant level before starting the engine. 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.
NOTE: On carbureted models when the engine is being started with aid of the choke, DO NOT COMPRESS THE THROTTLE CONTROL LEVER. If the throttle control lever is compressed, the engine will not start because the gas/air mixture will be too lean. To start a warm engine, however, the throttle control lever may have to be compressed slightly. NOTE: On EFI models when the engine is being started, DO NOT COMPRESS THE THROTTLE CONTROL LEVER.
! 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 operated 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 of time. 10.
HIGH RPM OPERATION (660 cc Models) If this occurs, the brake fluid requires a cool-down period before the brakes will again function properly. This cool-down period will vary depending upon the ambient air temperature and the temperature of the brake fluid.
3. Never ride the brake. Even maintaining 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 SNOWMOBILE WITH THE BRAKE LEVER LOCK ENGAGED. ! WARNING The brake lever lock is not a parking brake and should not be applied for periods exceeding 5 minutes.
NOTE: On 660 cc models, ensure that the ignition switch key is in the OFF position when the engine is not running. Leaving the ignition switch in the ON position allows the lights to be on and will drain power from the battery. The engine WILL NOT START without battery power. THROTTLE/IGNITION MONITOR SWITCH (2-Stroke/Jaguar Z1 Models) 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.
NOTE: On fan-cooled models if the throttle control lever operates properly and the engine does not start, either a malfunctioning monitor switch or a misadjusted magnetic carburetor switch (on twin carburetor models) may be the problem. 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.
! WARNING Under no circumstances should disconnection of the throttle control wiring harness be used as a substitute for the monitor switch during normal operation of the snowmobile. Personal 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 snowmobile must be operated with a disconnected throttle control wiring harness, EXTREME CAUTION MUST BE TAKEN.
LUBRICATION STANDARD CHAIN CASE (Every 40 Operating Hours) The recommended amount of transmission lube in the chain case is 236 ml (8 fl oz) for models without reverse and 354 ml (12 fl oz) for models with reverse. Adding more transmission lube to the chain case (above the recommended amount) may result in leakage. To check the transmission lube level, use the following procedure: 1. With the snowmobile level, shut engine off and wait for all moving parts to stop; then open the hood. 2.
ACT DRIVE GEAR CASE (Each Season Prior to Storage) 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 dealer for this service. If not under warranty, this service is at the discretion and expense of the snowmobile owner. It is very important that the gear case be flushed and the lubricant be replaced after each season of use.
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. NOTE: It is critical that the snowmobile is on a level surface to ensure the lubricant drains properly and completely. 6. Secure the snowmobile in this position until the lubricant is completely drained.
15. Tip the snowmobile onto its right side and place a piece of cardboard underneath. 16. Remove the drain plug from the gear case; then install the drain adapter fitting with hose 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.
F-Series/Jaguar Z1 0739-724 F-Series/Jaguar Z1 0741-440 SPEEDOMETER DRIVE ADAPTER - Bearcat W/T Non-Turbo/ Bearcat 570/Panther/ Z Models (SemiAnnually) 741-335A On the Crossfire/F-Series/M-Series/ Jaguar Z1 models, pump grease into the upper steering shaft grease fitting (located on the right-side of the snowmobile directly above the forward part of the upper A-arm) until grease is noted coming out of the bottom of the shaft. Wipe excess grease from the shaft.
REAR SUSPENSION (Every 40 Operating Hours) NOTE: Arctic Cat recommends that Arctic Cat Low-Temp Grease (p/n 0636-593) be used for this procedure. NOTE: Determine which style rear suspension is being lubricated and locate the grease fittings accordingly. ! CAUTION The 660 cc models should not be tipped on their sides for any reason, as engine oil may seep into the upper engine through the airintake system. Severe engine damage could result if the engine is run with oil in the upper engine. 3.
MAINTENANCE PERIODIC MAINTENANCE CHECKLIST ITEM INTERVAL PAGE 2000 miles/ Seasonal __ Replace Brake System (Hydraulic) Daily 68 Check for binding, leakage, and proper operation; lever firmness, travel, caliper, disc, and pads Brake System (Mechanical) Daily 66 Check for binding, sticking, and proper operation; lever travel, cable, spring, caliper, and disc Air Filter (660 cc Turbo) Cooling System - Liquid REMARKS Daily 20 Check for leakage, damage, obstructions, coolant level Cooling Sys
The longevity and safety of the snowmobile can be increased by making periodic checks of the items in the preceding checklist. If, at any time, abnormal noises, vibrations, 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.
3. Install the in-line fuel filter in the fuel hose so the arrow on the filter points toward the fuel pump. Make sure the fuel hoses fit tightly on the filter. If a fuel hose does not fit tightly, cut 6 mm (1/4 in.) from the end of the fuel hose; then install on the filter. ! WARNING The fuel hoses must fit tightly on the fuel filter. If the fuel hose length doesn’t permit this procedure, replace the fuel hose.
NOTE: It takes 800 ml (27 fl oz) to raise the oil level from the lower mark to the upper mark on the bottom end of the stick. CHECKING ENGINE OIL LEVEL (Jaguar Z1) 1. Park the snowmobile on a level surface; then start the engine and allow it to warm up for 10-15 minutes, or if the snowmobile was operated, allow the engine to idle for approximately 30 seconds. 0741-490 NOTE: To attain an accurate oil level reading, do not thread the stick into the reservoir. 4.
2. Place a drain pan beneath the belly pan plug hole; then remove the oil drain plug and washer from the underside of the crankcase. 3. Remove the oil fill cap from the top of the engine. 4. After the oil has drained completely, install the oil drain plug and washer and tighten to 2.3 kgm (16.5 ft-lb). 2. Park the snowmobile on a level surface; then start the engine and allow it to warm up for 10-15 minutes, or if the snowmobile was operated, allow the engine to idle for approximately 30 seconds. 3.
7. Using Oil Filter Wrench (p/n 0644-389), loosen (but do not remove) the oil filter and allow the oil to drain from the filter; then remove the filter. NOTE: If the warning light does not illuminate, take the snowmobile to an authorized Arctic Cat Snowmobile dealer for service. 8. Apply a light coat of fresh engine oil to the seal of the new oil filter. 13. If the warning light illuminates (from step 12), start the engine. The warning light should go out within five seconds.
ADJUSTING CARBURETOR (Single) The carburetor has been calibrated at the factory for average riding conditions; however, altitude, temperature, and general wear may necessitate certain carburetor adjustments. Be sure the correct carburetor main jet for the operating temperature, altitude, and type of gasoline is being used (see Selecting Carburetor Main Jet(s) section).
0727-156 2. Loosen the jam nut securing the throttle cable swivel adapter; then rotate the swivel adapter clockwise until the piston valve bottoms in the piston valve bore. 3. Place a finger lightly against the side of the valve; then rotate the carburetor swivel adapter counterclockwise until slight upward movement of the valve is noted. 4. Place a finger against the valve. Rotate the idle speed screw clockwise until it contacts the valve. 5.
Adjusting Engine Idle Speed 1. With the snowmobile on a shielded safety stand, start the engine, release the parking brake, and thoroughly warm up. “Finetune” the idle speed screw and the pilot air screw until the engine idles smoothly at the desired RPM (1500 RPM is recommended). ! WARNING DO NOT stand behind the snowmobile or near the rotating track. NEVER run the track at high speed when the track is suspended.
NOTE: Carburetor adjustments and changing main jets 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 this service. This expense is at the discretion and expense of the snowmobile owner. ! CAUTION Make sure to perform these adjustment/synchronization procedures on all carburetors. 3. Slowly rotate one choke cable adjuster counterclockwise while checking the choke lever for freeplay.
NOTE: On some models, the air-intake silencer includes a cover/tool tray assembly and a baffle/resonator, and the silencer boot cannot be removed to access the intake bores. Proceed to step 1. 1. Open the air-intake silencer cover; then remove the screws securing the cover/tool tray assembly to the silencer. 2. Close the cover; then tip the cover/tool tray assembly forward and out of its slots and remove the assembly. 3.
! WARNING Be sure to tighten the swivel adapter jam nuts securely. If a swivel adapter jam nut is not tightened, the adjuster can rotate out of the carburetor cap causing the piston valve not to return to the full-closed position. 9. In turn on each carburetor, place a finger against the piston valve. Rotate the idle speed screw clockwise until it contacts the valve. 10. Compress the throttle lever to the full-open position; then rotate each idle speed screw clockwise 2 complete turns.
5. With the snowmobile on a shielded safety stand, start the engine, release the brake lever lock, and thoroughly warm up. ! WARNING DO NOT stand behind the snowmobile or near the rotating track. NEVER run the track at high speed when the track is suspended. NOTE: Make engine idle adjustment only after the engine has reached running temperature. Since the idle speed screws have not been finetuned, slight throttle pressure may be necessary to keep the engine running.
! CAUTION Use only GENUINE Mikuni brass main jets. Also, if using an oxygenated gasoline (up to 10% ethanol or up to 15% MTBE), the carburetor main jet must be one size larger than the main jet required for regular unleaded gasoline. NOTE: Carburetor main jet(s) may be changed 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.
Varying terrain conditions and operating usage may require spark plugs of a different 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 (Crossfire/M-Series) 1.
3. Install the plugs and fingertighten. 4. Tighten the spark plugs to 2.5-2.8 kg-m (18-20 ft-lb); then install the spark plug caps. Removing/Installing Spark Plugs (660 cc Models) 1. Remove the spark plug/coil cover. 2. Remove the cap screws securing the spark plug coils to the engine; then remove the coils. 3. Using a spark plug wrench, remove the plugs. 4. Install the plugs and fingertighten. 5. Tighten the spark plugs to 2.
! 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. CHECKING/ ADJUSTING VALVE CLEARANCE (660 cc/ 1100 cc Z1) After 3500 miles (660 cc)/5000 miles (1100 cc Z1) or prior to seasonal storage, valve clearance should be checked and adjusted as necessary.
! WARNING ! CAUTION Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the state of California to cause cancer and reproductive harm. Wash hands after handling. Before installing the battery, make sure the ignition switch is in the OFF position. 1. Remove the negative battery cable; then remove the positive cable and the battery vent tube. Remove the battery from the snowmobile. Care should be taken not to damage the vent tube.
Sealed with Cap Strip ! CAUTION This maintenance-free battery requires periodic charging to prevent sulfiding. If the snowmobile will be idle for extended periods of time, trickle charge from time to time. If the battery completely discharges, permanent damage will occur requiring replacement. ! WARNING Always wear safety glasses when connecting or disconnecting a battery charger. Do not smoke or allow open flames near a charging battery.
2. Remove the suspected fuse. 3. Look through the clear side of the fuse to see if the metal wire inside is separated. If it is, the fuse is blown and should be replaced with a fuse of the correct amperage rating. ! WARNING Always replace a fuse with one having the same specified amperage rating. Using a fuse with a higher rating can cause severe wire damage and could start a fire. 4. Install the fuse panel cover. 736-448A Once which fuse to check has been determined, perform the following steps: 1.
1. Open the right-side access panel; then remove the fuse panel cover. The fuse panel is located behind the battery. ZJ005A NOTE: There are spare fuses inside the fuse panel. 2. Remove the suspected fuse. 3. Look through the clear side of the fuse to see if the metal wire inside is separated. If it is, the fuse is blown and should be replaced with a fuse of the correct amperage rating. ! WARNING Always replace a fuse with one having the same specified amperage rating.
2. At the point where the disc is locked, check the distance between the brake lever and the lever stop. The distance must be within a range of 6-13 mm (1/4-1/ 2 in.). NOTE: If the brake adjustment knob has reached its maximum adjustment (cannot be rotated any further clockwise), both brake pads must be replaced. ! WARNING DO NOT attempt to adjust the brake with the flange nuts on the brake cable bracket. Incorrect brake adjustment may occur causing possible brake failure. 727-451A 3.
NOTE: When adjusting the brake, do not accidentally close the gas tank shut-off valve. 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. Checking/Adding Brake Fluid 1. With the fluid reservoir/sight glass reservoir in a level position, check the fluid level.
! CAUTION Brake fluid is highly corrosive. Do not spill brake fluid on any surface of the snowmobile. 2. Measure the distance between the brake lever and the handlebar. The distance must be greater than 2.54 cm (1 in.). ! WARNING Do not overfill the brake fluid reservoir. Overfilling the reservoir may cause the brake system to hydraulically lock. Use only Arctic Cat approved brake fluid. Never substitute or mix different types or grades of brake fluid. Brake loss can result.
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 following procedure: 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 snowmobile to an authorized Arctic Cat Snowmobile dealer for this service. This service is at the discretion and expense of the snowmobile owner. 1.
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: 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 snowmobile to an authorized Arctic Cat Snowmobile dealer for this service. This service is at the discretion and expense of the snowmobile owner.
5. Using a flat-blade tool, slowly and carefully push the piston into the caliper. 6. Position the new brake pads into the caliper. 7. Repeat steps 4-6 for the other pad; then secure the pads with the pin/ hairpin clip. 8. Remove the reservoir cover and remove the remaining fluid; then fill the reservoir with fresh fluid. 9. Pump the brake lever to ensure correct positioning of the brake pads; then release. 10. Fill the reservoir to the proper level with fresh brake fluid.
Also, drive belts have a break-in period of approximately 20 miles. After installing a new drive belt, drive the snowmobile for 20 miles at 1/2 throttle or less. This will allow the drive belt to gain its optimum flexibility and will extend drive belt life. NOTE: On the ACT roller driven pulley, adding shim washers will decrease belt deflection and removing shim washers will increase belt deflection. Available shim washers from Arctic Cat are p/n 0648714 (0.090 in.), p/n 0648-715 (0.030 in.
4. After the belt is installed properly, close and secure the belt guard and the hood. ! WARNING Never operate the snowmobile without the belt guard secured in place. 5. Release the brake lever lock. Removing Drive Belt (ACT Roller Driven Pulley) 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 snowmobile to an authorized Arctic Cat Snowmobile dealer for this service.
Installing Drive Belt (ACT Roller Driven Pulley) 741-721B 7. On Style A with the O-ring and shim washers removed, carefully thread the sheave adjuster back into the driven pulley; then tighten the adjuster with the deflection tool/screwdriver/spark plug wrench assembly until it bottoms against the driven shaft. NOTE: By bottoming the sheave adjuster against the driven shaft, the sheaves of the driven pulley will spread far enough to allow the removal of the drive belt. 8.
! WARNING Never operate the snowmobile without the belt guard/access panel secured in place. 5. 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.
739-636B 729-429A Model Setup Tension After BreakIn Tension Z Models @ 20 lb 38-44 mm (1 1/2-1 3/4 in.) 44-51 mm (1 3/4-2 in.) Panther Models @ 20 lb 44-51 mm (1 3/4-2 in.) 51-57 mm (2-2 1/4 in.) T660 Touring/ Turbo Touring @ 20 lb 44-51 mm (1 3/4-2 in.) 51-57 mm (2-2 1/4 in.) Turbo Trail @ 20 lb 38-44 mm (1 1/2-1 3/4 in.) 44-51 mm (1 3/4-2 in.) Bearcat Models @ 20 lb 44-51 mm (1 3/4-2 in.) 51-57 mm (2-2 1/4 in.) F-Series Models @ 20 lb 44-51 mm (1 3/4-2 in.) 51-57 mm (2-2 1/4 in.
! WARNING If jam nuts are not tightened properly, 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 personal injury could result. TRACK ALIGNMENT Proper track alignment is obtained when the rear idler wheels are equal distance from the inner track drive lugs.
2. Check track alignment and continue adjustment until proper alignment is obtained. NOTE: Make sure correct track tension is maintained after adjusting track alignment (see Track Tension section). 0727-729 3. After proper track alignment is obtained, tighten the adjusting bolt jam nut against the axle housing. ! WARNING 0739-637 5. If the idler wheels are not centered between the inner track drive lugs, an adjustment is necessary. Adjusting Track Alignment 1.
Adjusting Front Shock Springs (STD) NOTE: On some models, the front shock springs are not adjustable. The front shock springs are individually adjustable for the terrain conditions and driving style of the operator. The spring adjuster has been set at the factory so the correct amount of threads are exposed between the spring adjuster and the shock housing as an initial setting.
To increase or decrease air pressure, use the following procedure. 5. Remove the pump valve from the shock air valve. NOTE: When adjusting air pressure, all weight must be removed from the front suspension, and the shock absorbers must be fully extended. 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. NOTE: Adding air pressure will increase the air spring force; reducing air pressure will decrease air spring force.
! WARNING Do not adjust the front arm limiter straps to a point at which steering and operator control of the snowmobile are adversely affected. NOTE: These cam position settings are suggestions only. Personal riding style will greatly influence cam position settings. Spend time to determine setting preferences. Rear spring pre-load adjustment is accomplished by rotating the adjusting cams. Position 3 provides the stiffest ride, and position 1 is for the light driver or slow-speed trail riding.
Articulating Skid Fame (Bearcat Wide Track Models) The rear articulating portion of the skid frame has two adjusters which control the amount of travel in the rear suspension. 0739-625 These two adjusters have been pre-set at the factory and should require no further adjustment. If adjustment is ever required, rotate the two adjusters equally to permit 12.5-25 mm (1/2-1 in.) travel of the articulating portion of the suspension.
2. Push in on the bulb and rotate it counterclockwise to remove it from the socket. 3. Push in on the socket and rotate it counterclockwise to remove it from the housing. 3. Install the new bulb in the socket by pushing it in and rotating it clockwise. 4. Remove the old bulb by pulling it straight out of the socket. 4. Install the lens and secure with the screws. Removing and Installing Taillight/ Brakelight Bulb (F-Series/Jaguar Z1) 1. Remove the two screws securing the taillight cover. 2.
2. Rotate the headlight bulb base counterclockwise and remove the bulb from the headlight housing. Installing Headlight Bulb (3-Bulb Style) ! 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. Removing Headlight Bulb (Bearcat W/T Turbo/T660 Models) NOTE: The bulb portion of the headlight is fragile. HANDLE WITH CARE. When replacing the headlight bulb, the bulb assembly must first be removed from the housing. 1.
! WARNING Do not operate the snowmobile unless headlight beam is adjusted properly. An incorrectly adjusted beam will not provide the operator the optimum amount of light. Removing Headlight Bulb (Crossfire/MSeries Models) 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.
! WARNING Do not operate the snowmobile unless headlight beam is adjusted properly. An incorrectly adjusted beam will not provide the operator the optimum amount of light. Removing Headlight Bulb (F-Series/ Jaguar Z1) 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.
Installing Headlight Bulb (F-Series/ Jaguar Z1) ! 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. Lift the front of the console enough to allow the headlight housing to be installed; then install the housing making sure the forks of the housing go into the grommets on top of the airintake silencer.
4. Make a vertical mark which intersects the horizontal mark on the aiming surface directly in front of the headlight. 5. Engage the brake lever lock and start the engine. Move the headlight dimmer switch to the HIGH beam position. 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.
! CAUTION The 660 cc models should not be tipped on their sides in excess of a 70° angle for any reason, as the engine oil may seep into the upper engine through the airintake system. Severe engine damage could result if the engine is run with oil in the upper engine. 3. Remove the lock nuts and washers (if applicable) securing the wear bar to the ski. 0739-016 4. Remove the wear bar from the ski and account for the location of the bushings (if applicable). Installing Ski Wear Bars 1.
2. Remove the cotter pin; then remove the slotted nut and cap screw securing the ski assembly to the spindle. Remove the ski. Account for the rubber damper, inserts, and washers. 3. To increase ski stance 2.5 cm (1 in.), place both ski stance spacers to the outside of the spindle. 4. To decrease ski stance 2.5 cm (1 in.), place both ski stance spacers to the inside of the spindle. 5. Position the ski over the saddle. 6.
1. Be sure ignition key is in the OFF position. ! WARNING DO NOT inspect the axial fan belt while the engine is running. Contact with the axial fan belt, fan blades, or other moving parts may cause personal injury. 2. Lift the hood and remove the screws securing the fan cover; then remove the fan cover. 3. Inspect axial fan belt for cracks, wear, and proper tension. ACCESSORY BELT (660 cc Models) Arctic Cat recommends that the condition of the accessory belt be inspected monthly.
Adjusting Belt Tension 1. Remove the bolts securing the belt guard to the engine; then remove the belt guard from the engine compartment. 2. On the alternator, loosen, but do not remove, the tension bolt (A) and the pivot bolt (B). 4. When the accessory belt is tensioned properly (see Accessory Belt in this sub-section), tighten the tension bolt (A) to 2.4 kg-m (17 ft-lb). 5. Tighten the pivot bolt (B) to 5.1 kg-m (37 ft-lb). 6. Place the belt guard into position and secure with the bolts. 7.
PERFORMANCE TIPS Operating a high performance snowmobile requires a special attention that is not required by a low performance snowmobile. 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.
PREPARATION FOR STORAGE Prior to storing the snowmobile, it must be properly serviced to prevent corrosion and component deterioration. An authorized 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.
8. Start the engine and allow to idle. With the engine idling, spray Arctic Cat Engine Storage Preserver (p/n 0636-177) into the intake(s) until the engine exhaust starts to smoke heavily or until the engine starts to drop in RPM. Turn engine off. NOTE: On some models, install the air-intake silencer boot(s); on some models, install the baffle/ resonator and the cover/tool tray assembly. 9. Plug the exhaust system outlet with a clean cloth.
17. Apply light oil to the upper steering post bushing, ski spindles and bolts, front and rear pivot bushings of the skid frame, and plungers of the shock absorbers. 18. Lubricate the rear suspension, spindles, speedometer drive adapter, and driven shaft support bearing with a low-temperature grease. 19. Tighten all nuts, bolts, and cap screws making sure all calibrated nuts, bolts, and cap screws are tightened to specifications. Make sure all rivets holding the components together are tight.
PREPARATION AFTER STORAGE Taking the snowmobile out of storage and correctly preparing it for another season will assure many miles and hours of trouble-free snowmobiling. Arctic Cat recommends the following procedure: ! CAUTION On carbureted models if the gas in each carburetor float chamber was not drained prior to storage, the carburetor(s) must be cleaned before starting the engine. 1. Clean the snowmobile thoroughly. Polish the exterior of the snowmobile. 2. Clean the engine.
10. Lubricate the rear suspension, spindles, speedometer drive adapter, and driven shaft support bearing with a low-temperature grease. 11. On liquid cooled models, check the coolant level and all coolant hoses and connections for deterioration or cracks. Add properly mixed coolant as necessary. 12. On fan cooled models, clean the engine cooling fins and vents. 13. On 2-stroke models, place the rear of the snowmobile on a shielded safety stand; then start the engine.
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. EPAcertified Arctic Cat snowmobiles are designed, built, and equipped to conform to all U.S. EPA Emission Control Regulations. Please read the following information completely.
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.
Fold Back Once Place Stamp Here CHANGE OF ADDRESS/OWNERSHIP ARCTIC CAT INC. PRODUCT SERVICE AND WARRANTY DEPT. P.O.
WARRANTY PROCEDURE/OWNER RESPONSIBILITY At the time of sale, an Owner Registration form (included with each new snowmobile) is to be completed by the selling dealer and consumer. The receipt of the registration form by Arctic Cat is a condition 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 initiate warranty coverage.
MAINTENANCE RECORD DATE 104 MILEAGE SERVICE PERFORMED/NOTES
MAINTENANCE RECORD DATE MILEAGE SERVICE PERFORMED/NOTES 105
MAINTENANCE RECORD DATE 106 MILEAGE SERVICE PERFORMED/NOTES
ARCTIC CAT Printed in U.S.A. ®TM ® Trademarks of Arctic Cat Inc.
