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2009 Arctic Cat Crossfire 8 Sno Pro 141" Snowmobiles Service Repair Manual

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This is the Highly Detailed factory service repair manual for the2009 ARCTIC CAT CROSSFIRE 8 SNO PRO 141” SNOWMOBILES, this Service Manual has detailed illustrations as well as step by step instructions,It is 100 percents complete and intact. they are specifically written for the do-it-yourself-er as well as the experienced mechanic.2009 ARCTIC CAT CROSSFIRE 8 SNO PRO 141” SNOWMOBILES Service Repair Workshop Manual provides step-by-step instructions based on the complete dis-assembly of the machine. It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure. Complete download comes in pdf format which can work under all PC based windows operating system and Mac also, All pages are printable. Using this repair manual is an inexpensive way to keep your vehicle working properly.

Service Repair Manual Covers:
General Information
Engine
Engine-Related Items
Fuel Systems
Electrical Systems
Drive Train / Track / Brake Systems
Rear Suspension
Steering and Body
Wiring Diagrams
File Format: PDF
Compatible: All Versions of Windows & Mac
Language: English
Requirements: Adobe PDF Reader

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2009 Arctic Cat Crossfire 8 Sno Pro 141" Snowmobiles Service Repair Manual

  1. 1. SECTION 1- GENERAL INFORMATION! SPECIFICATIONS TABLE OF CONTENTS General Specifications ............................................ 1-2 Snowmobile Identification ....................................... 1-2 Recommended Gasoline and Oil ............................ 1-2 Break-In Procedure ................................................. 1-3 Genuine Parts ......................................................... 1-3 High Altitude Operation ........................................... 1-3 Drive Chain Lubrication (120 cc) ............................. 1-6 Low Oil Pressure Warning Light (1100 cc).............. 1-6 Preparation For Storage.......................................... 1-6 Preparation After Storage ....................................... 1-7 After Break-In Checkup (100 Miles - 2-Stroke/ 600 Miles - 4-Stroke)............................................ 1-8 After Break-In Checkup Checklist ........................... 1-9 Engine Specifications (2-Stroke) ........................... 1-10 Engine Specifications (4-Stroke) ........................... 1-11 Cylinder Head Volume Specifications (2-Stroke) .. 1-12 Engine Piston Travel Versus Crank Angle Chart (2-Stroke) ......................... ... 1-12 Crankshaft RunoutiRepair Specifications (2-Stroke) ........................................................ ... 1-12 Fraction/Decimal Conversions .............................. 1-13 MM/IN. Conversions.............................................. 1-13 Torque Conversions (ft-Ib/N-m) ............................. 1-14 Tightening Torque (General Bolts) ........................ 1-14 Assembly Schematics/Torque Specifications (Table of Contents)............................................. 1-14 Engine Torque Patterns (1100 cc) ......................... 1-28 Arctic Power Valve (APV) System Specifications (2-Stroke) .................................... 1-30 Oil Consumption Specifications (2-Stroke)............ 1-31 EFI Specifications ................................................. 1-31 Throttle Valve Angle Specifications ....................... 1-31 Fuel Pump Specifications (570 cc) ........................ 1-31 Carburetor Specifications ...................................... 1-31 Electrical Specifications ........................................ 1-32 Ignition Timing Specifications (2-Stroke) ............ ... 1-38 Steering/Body Torque Specifications .................... 1-40 Drive System Specifications.................... .............. 1-41 Drive Clutch/Driven Pulley-Related Specifications ..................................................... 1-41 Arctic Cat Drive Belt Dimensions .......................... 1-41 Drive System Components ................................... 1-41 Gear Case Performance Calibrations ................... 1-42 Drive System Torque Specifications ...................... 1-43 Rear Suspension Torque Specifications ............... 1-43 Track Warranty Guidelines .................................... 1-45 Track Specifications............................................... 1-46 Front Suspension Specifications ........................ ... 1-46 Rear Suspension Specifications ........................... 1-46 Shock Absorber Specifications........................... ... 1-47 Idler Wheel Dimensions ........................................ 1-47 1-1
  2. 2. General Specifications -NOTE: General specifications for each 2009 Arctic Cat Snowmobile can be accessed from the Arctic Cat Cat Tracker Dealer Communication System online. Snovvmobile Identification The Arctic Cat Snowmobile has two important identi- fication 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 ofthe engine. VIN 0726-383 -NOTE: The VIN also appears on a decal beneath the seat (CrossfireIM-Series) or attached to the right-side tunnel (remaining models). The decal also displays pertinent production information. These numbers are required to complete warranty claims properly. No warranty will be allowed by Arc- tic Cat Inc. if the engine serial number or VIN is removed or mutilated in any way. Recommended Gasoline and Oil A CAUTION Do not use white gas or gasolines containing metha- nol. Only Arctic Cat approved gasoline additives should be used. A CAUTION Any oil used in place of the recommended oil may cause serious damage. 1-2 RECOMMENDED GASOLINE (Carbureted Models) The recommended gasoline to use in these snowmo- biles is 87 octane regular unleaded. -NOTE: 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 carbu- retor main jet must be one size larger than the main jet required for regular unleaded gasoline. For example, if a 220 main jet is recommended for regular unleaded gasoline, a 230 main jet must be installed if using an oxygenated gasoline. When using ethanol blended gasoline, adding a gaso- line antifreeze is not necessary since ethanol will pre- vent the accumulation ofmoisture in the fuel system. RECOMMENDED GASOLINE (EFI Models) The recommended gasoline to use in these snowmo- biles is 87 octane regular unleaded. In many areas, oxygenates (either ethanol or MTBE) are added to the gasoline. Oxygenated gasolines containing up to 10% ethanol or up to 15% MTBE are acceptable gasolines. Do not use gasolines containing methanol. -NOTE: For optimum performance, do not exceed the recommended 87 octane gasoline. Using a higher octane gasoline will not increase overall performance. -NOTE: The Z1 Turbo models will detect lower octane gasoline and reduced engine performance will result. 91 octane (minimum) gasoline should be used in these models. RECOMMENDED OIL (2-Stroke) The recommended oil to use in the oil-injection system is Arctic Cat 50: 1 Injection Oil (for standard models) or Arctic Cat Synthetic APV 2-Cycle Oil (for APV models). The oil is specially formulated to be used either as an injection oil or as a pre-mix oil (for carbu- reted model break-in) and meets all of the lubrication requirements ofthe Arctic Cat snowmobile engine. RECOMMENDED OIL (120 ee) The recommended oil to use is a multi-grade oil cali- brated to the ambient temperature at which the engine is run. See the viscosity chart for details. 2009 Arctic Cat Snowmobiles Factory Service Manual - all Models - www.ReadManuals.com
  3. 3. SAE # ENGINE OIL Multi-Grade ~c -35 -29 -23 -18 "12 -7 1 " 10 15 21 21 32 TEMP ~F -30 -.20 -10 0 10 20 30 40 SO 60 10 80 90 GEN-0048 RECOMMENDED OIL (1100 ee) The recommended oil to use is Synthetic Turbo OW-40 Oil in all temperatures and conditions. Multi-Grade Engine Oil ENGINE OIL TEMP~OC____-3_0_-_20_-_10__0__1_0__20__30__4_0~ -22 -4 14 32 50 68 86 104 OILCHARTJ After the engine break-in period, the engine oil should be changed every 2500-3000 miles and before pro- longed storage. Break-In Procedure 2-STROKE The Arctic Cat 2-stroke 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 112 throttle is recommended; however, brief full-throttle accelera- tions and variations in driving speeds contribute to good engine break-in. & 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 operating in extremely cold conditions (-26°C/-15°F or colder), could cause spark plug fouling and excessive carbon buildup. A 100:1 gaS/oil mixture must be used in conjunction with the oil-injection system to ensure adequate engine lubrication in extremely cold conditions. 120 ee The Arctic Cat engine requires a short break-in period (approximately 10 operating hours) before being sub- jected to heavy load conditions or full-throttle opera- tion. Strict adherence to the break-in procedure will contribute to optimum performance and longevity of the engine. During break-in, a maximum of 112 throttle is recom- mended; however, brief full-throttle accelerations and variations in driving speeds contribute to good engine break-in. After the 10 hour break-in period, the snow- mobile may be taken to an authorized Arctic Cat Snowmobile dealer for a checkup and oil change at the discretion and expense ofthe snowmobile owner. 1100 ee The Arctic Cat engine (when new or rebuilt) requires a short break-in period before the engine is subjected to heavy load conditions. This engine does not require any pre-mixed fuel dur- ing the break-in period. & CAUTION DO NOT use premixed fuel in the snowmobile gas tank. Engine damage will occur. To ensure trouble-free operation, careful adherence to the following break-in guidelines will be beneficial. 0-200 miles 1/2 Throttle (45 MPH-max) 200-400 miles 1/2-3/4 Throttle 400-600 miles 1/2-3/4 Throttle * * With occasional full-throttle operation. To ensure proper engine break-in, Arctic Cat recom- mends that the engine oil and filter be changed after 600 miles or after one month, whichever comes first. This service is at the discretion and expense of the snowmobile owner. Genuine Parts When replacement of parts is necessary, use only gen- uine Arctic Cat parts. They are precision-made to ensure high quality and correct fit. High Altitude Operation Operating a snowmobile at varying altitudes requires changes in performance components. These changes affect drive train components and carburetion compo- nents (570 cc). -NOTE: The 120 cc and 1100 cc turbo do not require calibration changes for varying altitudes. 2009 Arctic Cat Snowmobiles Factory Service Manual - all Models - www.ReadManuals.com
  4. 4. High altitude information decal(s) are located beneath the hood ofthe snowmobile. A CAUTION On carbureted models, carefully follow the Main Jet Chart recommendations for proper main jet selection for altitude, temperature, and gasoline being used. The M-Series snowmobiles are initially set up at the factory for operation between 6000-9000 feet. Consult the appropriate specifications for this information. Following are basic high altitude theories for clutch- ing, engine, suspension, and track. CLUTCHING As altitude changes, engine horsepower changes with it. As you go up in altitude, the engine loses horse- power. Because ofthis, the constant velocity transmis- sion (CVT) system needs to be changed to compensate for the horsepower loss. At altitudes above 5000 ft, clutch engagement RPM is normally higher than the standard setting due to the horsepower loss at altitude as opposed to what would be seen for horsepower at sea level. The engine will lose peak horsepower but will also lose horsepower at engagement speed. For this reason, higher engagement speeds are usually needed at altitude in order to attain acceptable acceleration. This higher engagement speed can be attained several ways. Some of the methods will affect other characteristics of CVT operation, so you must be careful what you change. Drive clutch springs are the most common way to increase engage- ment speed; however, by simply changing the cam arms to a lighter weight from the heavier sea level cam arm, you will gain some engagement speed. Other more complicated methods exist such as engagement notches and changing the position of the cam arm center ofgravity in relation to the roller. This is called "tucking the weight" and can be used, but, like the engagement notch, it can hurt belt life. The driven clutch will also playa part in CVT tuning for high altitude operation. A steeper helix (torque bracket) angle in the driven clutch will mean a quicker up-shift. A shallower angle will mean a slower up- shift. If the up-shift is too quick, due to a very steep helix, RPM will be pulled down under the peak operat- ing RPM of the engine (where the horsepower is) and performance will suffer. The engine may even bog. If you have a helix that is too shallow, the engine may over-rev or have poor acceleration. Usually, angles shallower than the sea level calibrations work best. The driven spring will also affect driven clutch tuning. Tighten the spring, and RPM will increase. Loosen the spring, and RPM will decrease. The spring should be used to fine-tune and complement the helix selection. Carburetor calibration changes for high altitude opera- tion will have an effect on the CVT system and how it operates. Understanding the basics of CVT operation is important in order to make the correct high altitude CVT calibration changes. 1-4 ENGINE A normally aspirated engine will generate more horse- power at sea level than it does at higher altitudes. Many reasons for this are possible, but the biggest rea- son is that the higher you go, less oxygen is available for the engine to use during its combustion process. Less oxygen means it needs less fuel to obtain the cor- rect air/fuel ratio to operate properly. This is why the fuel ratio has to be recalibrated. High altitude engines operate as though they have a lower compression ratio. This, along with less oxygen and less fuel, means that the engine generates less horsepower. The carbureted models will also have lower pressure applied to the float chamber because of pressure changes in the atmosphere between high altitude and sea level. All ofthese characteristics will become more evident the higher the altitude. It will be necessary to make changes to the fuel sys- tems (carbureted models) and drive systems that sup- port engine operation as altitude changes. TURBOCHARGING Turbocharging is one method of compensating for loss of air density that works extremely well when applied to four-cycle internal combustion engines. Exhaust gasses are directed through the turbocharger turbine wheel which is attached to the compressor through a common shaft. As the exhaust gasses spin the turbine, the compressor is spun at very high RPM. Inlet air is drawn into the compressor, compressed, and routed to the intake manifold of the engine. Intake pressure, therefore, is maintained at the optimum level as altitude or temperature increases. The turbocharger output must be regulated to maintain the optimum manifold pressure throughout the designed operating range. This is accomplished by regulating the volume of exhaust gasses passing through the turbine by controlling a diverter valve (waste-gate) at the turbocharger turbine inlet. At lower altitudes/temperatures, excessive exhaust gasses are diverted past the turbine and into the exhaust down- stream of the turbocharger thus limiting the compres- sor output to maintain correct manifold pressure. As altitude increases, the manifold pressure is held constant by diverting less exhaust past the turbine, thus increasing compressor speed. This will continue until the waste-gate is completely closed at which time manifold pressure will start to decrease much the same as a normally aspirated engine. The waste-gate is controlled by a spring/diaphragm mechanism that is connected to the intake manifold by an air line. A mechanical linkage connects the dia- phragm to the waste-gate control arm. 2009 Arctic Cat Snowmobiles Factory Service Manual - all Models - www.ReadManuals.com
  5. 5. Air is heated by friction and compression through the turbocharger and air density is lost by heating the air; therefore, an after-cooler is installed between the tur- bocharger compressor and the intake manifold. This is an air-to-air after-cooler that uses outside air directed through a radiator-type cooler to cool the compressed air prior to entering the intake manifold. SUSPENSION The different riding styles of the individual operator, the varying snow conditions, and the type ofterrain are all factors that affect the suspension at high altitude. Trail riding versus powder snow riding versus combi- nation riding will all require different suspension set- tings. The normal setting for front ski suspension is as little spring pre-load tension as possible for powder snow riding allowing the skis to float across the snow with the least amount of resistance. Trail riding will require more spring tension to carry the varying load more effectively. Many different settings and spring tensions to consider exist when adjusting for riding style and snow conditions. The rear suspension has a number of spring settings that produce different riding characteristics. The front arm spring and shock will also affect the ride and handling when either on a trail or in powder snow. A strong spring setting on this shock will cause the snowmobile to tend to "dig" more when riding in the powder snow rather than climbing up on top of the snow. But, it will work more effectively when riding on a trail. A softer spring setting will allow the front of the rear suspension to collapse much quicker and change the angle of the track to the snow. A more gradual angle will tend to raise the snowmobile up on the snow rather than digging into it. Many possible variables and adjustments to the rear suspension exist depending on snow conditions, riding style, and type of terrain. These adjustments can be made to individualize the snowmobile to the riding style ofthe operator. M-Series/Crossfire As snow cover and riding conditions change, several different adjustments can be made to change the ride and handling characteristics for operator preference. Located on the front suspension arm are limiter straps. They limit the amount of "fallout" the front arm can have. These straps may be adjusted in or out due to conditions and riding style. The more the straps are brought up, the more steering power the operator has due to the amount of ski pressure. Another adjustment that can be made on the rear sus- pension is the front arm shock spring tension. As trail conditions change, the spring pre-load may be used to decrease the chance of the front end "bottoming out." With a stiffer spring pre-load, the ride ofthe snowmo- bile will improve on the trail but will affect the perfor- mance in the deep powder snow. In deep powder snow, the stiffer spring pre-load will cause the front-end to "dig" and possibly take longer for it to plane off. Sev- eral different-rate springs are available for different riding styles and terrain conditions. On the standard models, the front shock springs are also 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. Additional ski pressure can be obtained by tightening the spring ten- sion; ski pressure can be decreased by relaxing spring tension. Springs with different spring rates are avail- able for operator choice and snow conditions. A limit exists as to how far you can pre-load the springs before "coil bind" takes effect where the wire on the spring actually runs into itself and causes binding. Equal adjustments should be maintained on both sides ofthe snowmobile. On the Sno Pro models with air shocks, they are individually adjustable for the terrain condi- tions and driving style of the operator. The ski shocks are preset at 4.6 kg/cm2 (65 psi) as an initial setting on the Crossfire Sno Pro models or at 4.2 kg/cm2 (60 psi) on the M-Series Sno Pro models. The rear arm shock is preset at 9.8 kg/cm2 (140 psi) on the Crossfire and M- Series Sno Pro models. The shocks can be "fine- tuned" to match the operator's weight, riding style, and terrain conditions. -NOTE: Care should be taken to have equal pres- sure in the ski shocks before operating the snow- mobile. Finally, track tension should be looked at to make sure that it is within recommended specifications to affect the efficiency of the snowmobile. On models with the torque sensing link, the track is actually tightening as the suspension moves through its range of motion causing the track to sag in the middle and rub on the top part ofthe rear suspension arm. TRACK Carefully matching the riding requirements to the type of track will ensure the maximum use of all available engine power. Lug height and track durometer are the two main concerns when selecting a track for various riding styles. Tracks exist with lug heights from 0.750 in. up to 2.25 in. to accommodate various snow conditions. Gener- ally, the deeper the snow, the taller the lug. It must be noted that the installation of any deep-lug track may reduce top end speed and promote premature wear strip wear in marginal snow conditions. 2009 Arctic Cat Snowmobiles Factory Service Manual - all Models - www.ReadManuals.com 1-5
  6. 6. Durometer is a measurement of how hard a rubber is. The lugs on most tracks range between 60 and 80 durometer. On the durometer scale, the higher the number, the harder the lugs. For riding in deep powder snow, a softer 60 durometer track works best. The softer rubber allows the track to "give" a little and pack the snow creating lift rather than digging its way straight down. When hill-climbing, the harder lug of an 80 durometer track works the best due to penetrat- ing the hard snow creating more bite. Some tracks come with a dual durometer rating, such as a track with a 80/60 durometer rating. The lugs on this track are 80% 80 durometer rubber, and the top 20% is made of the softer 60 durometer rubber. This track is designed to be a good all-around track for rid- ing mostly in deep powder snow but can climb the occasional hard snow hill. Drive Chain Lubrication (120 ee) The drive chain should be lubricated every 20 operating hours with a dry, graphite-based chain lubricant. By using a dry, graphite-based chain lubricant, dirt buildup on the drive chain will be minimized. Before each lubri- cation, inspect the drive chain for dirt accumulation. To lubricate the drive chain, shut the engine off and wait for all moving parts to stop, remove the drive chain guard, and lubricate the drive chain. After lubri- cating the drive chain, install the drive chain guard. If the drive chain is excessively dirty, it should be removed and cleaned prior to being lubricated (see Drive Chain and Sprockets (120 cc) in Section 6). -NOTE: If a dry, graphite-based chain lubricant is not available, lubricate the drive chain with several drops of petroleum-based oil. If the snowmobile is operated in the summer with the optional wheel kit, the drive chain should be lubricated more frequently. Lovv Oil Pressure Warning Light (1100 ee) The Low Oil Pressure Warning Light indicates engine oil pressure, not the oil level; however, if the oil level is low, it may affect oil pressure. The light should illu- minate each time the ignition switch is turned to RUN or START, and it should go out when the engine starts. Ifthe light stays illuminated or it illuminates while the engine is running, oil pressure has been lost and the engine will automatically shut off. -NOTE: The following oil check procedures are valid only if the oil pressure warning light has activated. If oil pressure is lost, use the following procedure: 1-6 1. With the engine off, remove the engine oil level stick and wipe it clean. Without screwing it in, set the stick back in the oil tank. Remove it and observe the oil level on the stick. -NOTE: To ensure an accurate reading, the snow- mobile should be on level ground. 2. Ifthe oil level is at or below the ADD mark on the oil level stick, add only enough recommended oil to raise the level to the NORMAL range. DO NOT overfill the reservoir with oil. 3. After adding oil if the engine starts, oil pressure should be normal. Preparation For Storage Prior to storing the snowmobile, it must be properly serviced to prevent corrosion and component deterio- ration. To prepare the snowmobile for storage, Arctic Cat recommends the following procedure: 1. Clean the seat cushion with a damp cloth and Arc- tic Cat 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 ofthe engine. 3. On the 4-stroke models, change the engine oil; then on the 120 cc and turbo models, clean the air filter (see Section 3). 4. On the 2-stroke models, place the rear of the snowmobile up on a shielded safety stand. 5. On the 500/600/800/1000 cc engine models, start the engine and allow to idle. With the engine idling, pry the intake boot forward; then spray an Engine Storage Preserver into the intakes until the engine exhaust starts to smoke heavily or until the engine starts to drop in RPM. Tum engine off. Install the intake boot. 6. On the 570 cc engine models, carefully pry the intake boots partially over the carburetor inlets; then start the engine and allow to idle. With the engine idling, spray an Engine Storage Preserver into the intakes until the engine exhaust starts to smoke heavily or until the engine starts to drop in RPM. Tum engine off. Install the intake boots. & CAUTION Do not run the engine without the belt guard in place and secured. 7. Plug the exhaust system outlet with a clean cloth. 8. On the 2-stroke models with the ignition switch in the OFF position: 2009 Arctic Cat Snowmobiles Factory Service Manual - all Models - www.ReadManuals.com
  7. 7. A. Disconnect the high tension leads from the spark plugs; then remove the plugs, connect them to the leads, and ground them on the cyl- inder heads. & CAUTION Never crank the engine over without grounding the spark plugs. Damage to ignition system may result. 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 connect the high ten- sion leads. 9. On carbureted models, drain the gas from each carburetor float chamber. 10. Fill the gas tank to its rated capacity; then add Arc- tic Cat Fuel Stabilizer to the gas tank following directions on the container for the stabilizer/gaso- line ratio. Tighten the gas tank cap securely. 11. Flush the gear case and change the lubricant (see Section 6). 12. Remove the drive belt from the drive clutch/driven pulley. Lay the belt on a flat surface or slide it into a cardboard sleeve to prevent warping or distortion during storage; then clean and inspect the drive clutch and driven pulley. -NOTE: For removing drive belt, see Removing! Installing Drive Belt in Section 6 of this manual. 13. Clean and inspect the drive clutch and driven pul- ley. 14. Apply light oil to the shafts ofthe shock absorbers; then lubricate all grease fittings (front and rear suspension, spindles, and upper steering shafts on the CrossfirelM-Series or steering arms on the Bearcat/F-Series/ZliT-Series) with a low-tempera- ture grease. 15. Tighten all nuts, bolts, and cap screws making sure all calibrated nuts, bolts, and cap screws are tight- ened to specifications. Make sure all rivets holding the components together are tight. Replace all loose rivets. 16. Clean and polish the hood, console, and chassis with Arctic Cat Hood and Windshield Cleaner/ Polish. DO NOT USE SOLVENTS OR SPRAY CLEANERS. THE PROPELLENT WILL DAM- AGE THE FINISH. 17. On electric start models, disconnect the battery cables making sure to disconnect the negative cable first; then clean the battery posts and cables. & CAUTION Batteries require charging if left for extended non-start periods. Arctic Cat recommends trickle charging once a month. Follow the manufacturer's instructions and cautions. & CAUTION On models with remote start, make sure to leave the battery cables disconnected. Failure to disconnect the battery cables when storing the snowmobile for a pro- longed period of time (six weeks or more) will result in a discharged or damaged battery. 18. If possible, store the snowmobile indoors. Raise the track offthe 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, ventilated tarpaulin to protect it from dirt and dust. 19. If the snowmobile must be stored outdoors, posi- tion the snowmobile out of direct sunlight; then block the entire snowmobile off the ground mak- ing sure the snowmobile is secure. Loosen the track adjusting bolts to reduce track tension. Cover with a machine cover or a heavy, ventilated tar- paulin 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 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 carburetors must be cleaned before starting the engine. 1. Clean the snowmobile thoroughly. Polish the exte- rior ofthe snowmobile. 2. Clean the engine. Remove the cloth from the exhaust system. Check exhaust system and air silencer for obstructions. 2009 Arctic Cat Snowmobiles Factory Service Manual - all Models - www.ReadManuals.com 1-7
  8. 8. 3. 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. 4. Remove and inspect the drive belt for cracks and tears. Check belt specifications. Replace if dam- aged or worn. Install the drive belt. -NOTE: For installing drive belt, see Removing! Installing Drive Belt in Section 6 of this manual. -NOTE: If the old belt is worn but in reasonable condition, retain it with the snowmobile as a spare in case of emergency. 5. On carbureted models, inspect the in-line fuel fil- ter and replace ifnecessary. 6. Inspect all fuel hoses and oil hoses for deteriora- tion or cracks; replace if necessary. Make sure all connections are tight; then on the 2-stroke models, fill the oil-injection reservoir with the recom- mended injection oil. -NOTE: On the 2-stroke models 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 lubrica- tion. 7. On the 2-stroke models, inspect each spark plug. Replace, gap, or clean as necessary. 8. Adjust the carburetor(s) and choke cable on carbu- reted models and throttle cable on all models. & WARNING On carbureted models, be sure to tighten the swivel adapter jam nuts securely. If a jam nut isn't tightened, the adjuster can rotate out of the carburetor cap caus- ing the piston valve not to return to the full-closed position. 9. Tighten all nuts, bolts, and cap screws making sure all calibrated nuts, bolts, and cap screws are tight- ened to specifications. 10. On the 120 cc, inspect the drive chain and drive chain tightener. Replace if necessary; then lubri- cate the binding screw drum with WD-40 and the drive chain with a dry, graphite-based chain lubri- cant. 11. Ifnot done during preparation for storage, lubricate all grease fittings (front and rear suspension, spin- dles, and upper steering shafts on the Crossfire/M- Series or steering arms on the BearcatlF-Series/Z11 T-Series) with a low-temperature grease. 12. On liquid cooled models, check the coolant level and all coolant hoses and connections for deterio- ration or cracks. Add properly mixed coolant as necessary. 1-8 13. On fan cooled models, clean the engine cooling fins and all shrouding. 14. On electric start models, charge the battery; then connect the battery cables making sure to connect the positive cable first. Test the electric start sys- tem. 15. Inspect the entire brake system, all controls, head- light, taillight, brakelight, ski wear bars, and head- light aim; adjust or replace as necessary. 16. Adjust the track to the proper tension and align- ment. Lock the jam nuts. After Break-In Checkup (100 Miles - 2-Strokel 600 Miles - 4-Stroke) Certain areas require adjustment after the break-in period in order to obtain peak performance. These areas are the following. CARBURETOR JETTING (Carbureted Models) - Altitude, temperature, and the use of oxygenated gasoline affect the carburetion needed for optimum engine performance. The carburetor main jets must be changed in conjunction with changes in operating alti- tude, oxygenated gasoline usage, and temperature. DRIVE BELT DEFLECTION - Drive belt deflec- tion is very important to the snowmobile. Even if it is checked and is correct when the snowmobile is set up, it does change (more so during the break-in period). This is because the rubber engine mounts and the rub- ber snubber on the torque link will all take a "set" dur- ing the first 100 miles allowing the distance between the drive clutch and driven pulley to shorten. When this happens, the snowmobile will appear to have a too long drive belt. To add to this, the drive belt itself wears and stretches somewhat leading to a low-end performance problem and, ifnot corrected, causes pre- mature drive belt wear. After the break-in period, drive belt deflection should be checked according to the instructions given in Sec- tion 6 ofthis manual. DRIVE BELT BREAK-IN - For maximum drive belt life, allow the belt to break in before subjecting it to hard use such as wide-open-throttle operation or hill climbing. The first 20 miles on the drive belt should be at 112 throttle or lower allowing the belt to gain its optimum flexibility and will extend belt life. Do not exceed 50 MPH during the first 20 miles. If this procedure isn't followed, a new drive belt can be destroyed in less than 50 miles. 2009 Arctic Cat Snowmobiles Factory Service Manual - all Models - www.ReadManuals.com
  9. 9. To increase the life of a drive belt, the belt must be warmed up before subjecting it to any type of use. In cold temperature (0° or below), the engine should be allowed to idle for a period of 8 to 10 minutes allowing heat from the engine compartment to soften the drive belt. Not only will this procedure increase belt life but will also help prevent engine damage from cold sei- zure. & WARNING When following this procedure, the operator must not leave the snowmobile unattended during the warm-up period. Each operator should be instructed to drive the snow- mobile for several minutes at a low throttle setting to warm the belt up before using wide-open-throttle. This practice should be followed on all models for maxi- mum belt life. DRIVE CLUTCHIDRIVEN PULLEY ALIGNMENT - The parallelism and the offset between the drive clutch and driven pulley are set at the factory. Normally, no adjustment is necessary; however, if premature drive belt wear or poor perfor- mance is experienced, the drive clutch/driven pulley alignment must be checked. TRACK TENSION AND ALIGNMENT - A cer- tain amount of stretch occurs on all tracks during the first 500 miles. The track must be adjusted after the first 50 to 100 miles to the specifications given in the Setup and Pre-Delivery Manual and periodically there- after. If these adjustments aren't performed, the track may "derail" which leads to track and slide rail dam- age. Along with these three major areas, other areas should be checked and adjusted during the "After Break-In Checkup." A checklist to assist you with this service follows. After Break-In Checkup Checklist Below is a recommended list of items to check after the break-in period. The recommended mileage for this inspection is between 100 and 300 miles. o Jet carburetors according to average tempera- ture, type of gasoline being used, and altitude (570 cc) o Check drive belt deflection - drive clutch/driven pulley alignment and parallelism (800/1000/ 1100cc) o Adjust track tension and alignment o Check throttle cable tension o Check oil-injection pump adjustment (2-stroke) o Check engine idle o Check coolant level o Check gear case lubricant level o Check engine oil (4-stroke) o Check lights (high/low beam, brakelight) o Check safety switch operation o Check engine compartment for any rubbing components o Check steering hardware for tightness o Check skid frame and A-arm mounting hard- ware for tightness o Check brake lever travel and adjustment o Grease all lubrication points 2009 Arctic Cat Snowmobiles Factory Service Manual - all Models - www.ReadManuals.com 1-9
  10. 10. Engine Specifications (2-Stroke) ITEM 500 cc 570 cc Engine Model Number AX50L7 AA56A8 Displacement 499 cc 565 cc No. of Cylinders 2 2 Bore x Stroke 71 x 63 73.8 x 66 Compression Ratio 6.38:1 6.41 :1 Cooling System Liquid Fan Fuel Mixture Oil Injection Oil Injection Ignition Timing (Engine Warm) 12° @ 2000 RPM 20° @ 2000 RPM 0.034 in. 0.099 in. Spark Plug (NGK) BR9EYA BR9EYA Spark Plug Gap 0.028-0.031 in. 0.028-0.031 in. Piston Skirt/Cylinder Clearance 0.0030-0.0041 in. 0.0033-0.0045 in. Piston Ring End Gap 0.008-0.016 in. 0.012-0.0196 in. Cylinder Trueness Limit 0.004 in. 0.004 in. Piston Pin Diameter 0.8659-0.8661 in. 0.7085-0.7087 in. Piston Pin Bore Diameter 0.8661-0.8665 in. 0.7087-0.7091 in. Connecting Rod Small End Bore 1.0631-1.0634 in. 0.9056-0.9059 in. Connecting Rod Radial Play 0.0001-0.0008 in. 0.0001-0.0008 in. Crankshaft Runout (t.i.r.) 0.002 in. 0.002 in. Crankshaft End Play 0.002-0.004 in. 0.002-0.004 in. Reed Stopper Height 0.315 in. 0.236 in. * F-Series ** Crossfire/M-Series 1-10 600 cc 800 cc 1000 cc AJ60L6 AB80L3 AB10L3 599 cc 794 cc 999 cc 2 2 2 73.8 x 70 85 x 70 90.3 x 78 6.46:1 6.39:1 6.41 :1 Liquid Liquid Liquid Oil Injection Oil Injection Oil Injection 15° @ 2000 RPM 25° @ 3250 RPM 20° @ 3750 ro@ 1800 0.059 in. 0.162 in. RPM* RPM** 0.113 in. 0.057 in. BR9EYA BR9EYA BR9EYA 0.028-0.031 in. 0.028-0.031 in. 0.028-0.031 in. 0.0030-0.0041 in. 0.0030-0.0041 in. 0.0030-0.0041 in. 0.012-0.0196 in. 0.012-0.0196 in. 0.012-0.0196 in. 0.004 in. 0.004 in. 0.004 in. 0.8659-0.8661 in. 0.8659-0.8661 in. 0.9447-0.9449 in. 0.8661-0.8665 in. 0.8661-0.8665 in. 0.9450-0.9453 in. 1.0631-1.0634 in. 1.0631-1.0634 in. 1.1418-1.1422 in. 0.0001-0.0008 in. 0.0001-0.0008 in. 0.0001-0.0008 in. 0.002 in. 0.002 in. 0.002 in. 0.002-0.004 in. 0.002-0.004 in. 0.002-0.004 in. 0.433 in. 0.433 in. 0.512 in. 2009 Arctic Cat Snowmobiles Factory Service Manual - all Models - www.ReadManuals.com
  11. 11. Engine Specifications (120 ee) ITEM 120 cc Engine Model Number AA12A2 Displacement 119 cc No. of Cylinders 1 Bore x Stroke 60 x 42 Cooling System Air Spark Plug (NGK) BPR6ES Spark Plug Gap 0.028-0.031 in. Piston SkirtiCylinder Clearance 0.0008-0.0047 in. Piston Pin Diameter 0.5898-0.5904 in. Piston Pin Bore Diameter 0.5908-0.5917 in. Piston Pin/Connecting Rod Small End Clearance 0.0002-0.0020 in. Piston Ring End Gap (1 stl2nd) 0.0079-0.0280 in. Piston Ring/Groove Clearance (1 stl2nd) 0.0012-0.0039 in. Piston Ring Thickness 0.058-0.059 in. Piston Diameter (10 mm from skirt edge) 2.3575-2.3618 in. Cylinder/Head Distortion (max) 0.0012 in. Connecting Rod Small End Bore Inside Diameter 0.5908-0.5917 in. Connecting Rod Big End Inside Diameter 1.0242-1.0246 in. Connecting Rod Big End Side Clearance 0.0079-0.0472 in. Cam Lobe Height (min) 1.189 in. Crank Pin Diameter 1.0232-1.0236 in. Crank Pin/Connecting Rod Clearance 0.0006-0.0028 in. Crankshaft Rod Journal (Out-of-Round/Taper) 0.004 in. Crankshaft Runout (t.i.r.) 0.004 in. Valve Guide Inside Diameter 0.2165-0.2170 in. Valve Guide/Stem Clearance (max) (Int) 0.0032 in. (Exh) 0.0039 in. Valve Guide Bore Diameter 0.4409-0.4416 in. Valve Face Width 0.032-0.039 in. Valve Face Runout (max) 0.0012 in. Valve Clearance - Cold (59°_77° F) (IntlExh) 0.030-0.070 in. Valve Seat Contact Width (IntlExh) 0.032-0.039 in. Valve Stem Diameter (IntlExh) 0.2150-0.2156 in. Valve Stem Runout (max) 0.002 in. Valve Spring Free Length (max) 1.22 in. Engine Specifications (1100 ee) ITEM 1100 cc Engine Model Number AA11L1 Displacement 1056 cc No. of Cylinders 2 Bore x Stroke 98 x 70 Cooling System Liquid Spark Plug (NGK) - Non-Turbo CR8EIB-9 Spark Plug (NGK) - Turbo MR8AI-9 Spark Plug Gap - Non-Turbo 0.031-0.035 in. Spark Plug Gap - Turbo 0.035 in. Piston SkirtiCylinder Clearance (Non-Turbo) 0.0011-0.0016 in. Piston SkirtiCylinder Clearance (Turbo) 0.0006-0.0010 in. Piston Pin Diameter (Non-Turbo) 0.8658-0.8661 in. Piston Pin Diameter (Turbo) 0.9447-0.9449 in. Piston Pin Bore Diameter (Non-Turbo) 0.8662-0.8664 in. Piston Pin Bore Diameter (Turbo) 0.9449-0.9451 in. Piston Pin/Connecting Rod Small End Clearance 0.0004-0.0010 in. (Non-Turbo) Piston Pin/Connecting Rod Small End Clearance 0.0004-0.0009 in. (Turbo) Piston Ring End Gap (1st) 0.0059-0.0138 in. (2nd) 0.0118-0.0177 in. (Oil) 0.0078-0.0275 in. Piston Ring/Groove Clearance (1st - Top) 0.0059-0.0074 in. (1st - Bottom) 0.0008-0.0035 in. (2nd) 0.0008-0.0024 in. (Oil) 0.0024-0.0059 in. Piston Diameter (10 mm from skirt edge) 3.8568-3.8574 in. (Non-Turbo) Piston Diameter (10 mm from skirt edge) (Turbo) 3.8574-3.8580 in. Cylinder/Head Distortion (max) 0.002 in. Connecting Rod Small End Bore Inside Diameter 0.866-0.867 in. (Non-Turbo) Connecting Rod Small End Bore Inside Diameter 0.945-0.946 in. (Turbo) Cam Lobe Height (Non-Turbo) (Int) 1.487-1.489 in. Cam Lobe Height (Turbo) (Int) 1.436-1.437 in. Cam Lobe Height (Non-Turbo) (Exh) 1.432-1.433 in. Cam Lobe Height (Turbo) (Exh) 1.417-1.418 in. Camshaft Journal Outside Diameter 0.8650-0.8658 in. Camshaft Journal Bore Diameter 0.8666-0.8670 in. Camshaft Journal Clearance 0.0007-0.0020 in. Crank Pin Diameter 1.7707-1.7720 in. Crankshaft Runout 0.002 in. Crankshaft Main Bearing Clearance 0.0006-0.0016 in. Crankshaft Thrust Runout (max) 0.0043 in. Crankshaft Main/Rod Journals (Bearing Surfaces) 0.0012 in. Valve Guide Inside Diameter 0.2165-0.2170 in. Valve Guide/Stem Clearance (max) (Int) 0.0015 in. (Exh) 0.0022 in. Valve Face Width 0.0197 in. Valve Clearance - Cold (59°_77° F) (Int) 0.0039-0.0078 in. (Exh - Non-Turbo) 0.0078-0.0118 in. (Exh - Turbo) 0.0118-0.0157 in. Valve Seat Contact Width (IntlExh) 0.0354-0.0433 in. Valve Stem Diameter (Int) 0.2155-0.2161 in. (Exh) 0.2147-0.2153 in. 2009 Arctic Cat Snowmobiles Factory Service Manual - all Models - www.ReadManuals.com 1-11
  12. 12. Cylinder Head Volume Specifications (2-Stroke) -NOTE: For cylinder head volume tests, see appropriate Measuring Critical Components sub- section in Section 2. ENGINE TYPE SQUISH - GAP 500 cc 0.059 in. 570 cc 0.066 in. 600 cc 0.059 in. 800 cc 0.059 in. 1000 cc 0.058 in. A CAUTION These specifications are not intended to be used for engine modification. Reducing the head volume to a smaller specification could cause piston detonation problems which is not a warranty situation. Engine Piston Travel Versus Crank Angle (2-Stroke) -NOTE: When using the chart below, first know the engine stroke and timing in degrees; then read across from the degree figure to find timing. 500 cc 6001800 cc 570 cc 1000 cc 63mm 70mm 66mm 78mm stroke stroke stroke stroke Degrees BTDC BTDC BTDC BTDC BTDC 12 0.034 in. 0.038 in. 0.036 in. 0.042 in. 15 0.053 in. 0.059 in. 0.056 in. 0.065 in. 18 0.076 in. 0.085 in. 0.081 in. 0.093 in. 20 0.094 in. 0.105 in. 0.099 in. 0.113 in. Crankshaft Runoutl Repair Specifications (2-Stroke) For those who have crankshaft work sent out to another shop, provide them with this information. To use the specifications, first refer to the drawing; then find the letter which indicates the specification and refer to the chart below the illustration. Be sure to note the proper engine row. 1-12 -NOTE: We have given the proper location for checking crankshaft runout as the very edge of the straight portion of the shaft where the oil seal makes contact. From the illustration, note that three check points are called out: at either end, out on the taper as shown, and also on the center bearing race. The crankshaft is still supported on the outer bearings using V blocks. --A-I iB-1- - - - - - 728-144A 570 cc in. 73.8 x 66 600 cc in. 73.8 x 70 800 cc in. 85 x 70 1000 cc in. 90.3 x 78 -NOTE: Measure in from the shaft end the speci- fied amount when checking runout at points D and F. When checking runout in the center, place indi- cator on center of bearing as shown at point E. Maximum runout at any of the three measuring points is ± 0.002 in. 2009 Arctic Cat Snowmobiles Factory Service Manual - all Models - www.ReadManuals.com
  13. 13. 8ths 1/8 = .125 1/4 = .250 3/8 = .375 1/2 = .500 5/8 = .625 3/4 = .750 7/8 = .875 - - - - - - - - - Fraction/Decimal Conversions 16ths 32nds 64ths 64ths 1/16 = .0625 1/32 = .03125 1/64 = .015625 33/64 = .515625 3/16 = .1875 3/32 = .09375 3/64 = .046875 35/64 = .546875 5/16 = .3125 5/32 = .15625 5/64 = .078125 37/64 = .578125 7/16 = .4375 7/32 = .21875 7/64= .109375 39/64 = .609375 9/16 = .5625 9/32 = .28125 9/64 = .140625 41 /64 = .640625 11/16 = .6875 11/32 = 11/64 = 43/64 = .671875 .34375 .171875 13/16 = .8125 13/32 = 13/64 = 45/64 = .703125 .40625 .203125 15/16 = .9375 15/32 = 15/64 = 47/64 = .734375 .46875 .234370 - 17/32 = 17/64 = 49/64 = .765625 .53125 .265625 - 19/32 = 19/64 = 51/64 = .796875 .59375 .296875 - 21/32 = 21/64 = 53/64 = .828125 .65625 .328125 - 23/32 = 23/64 = 55/64 = .859375 .71875 .359375 - 25/32 = 25/64 = 57/64 = .890625 .78125 .390625 - 27/32 = 27/64 = 59/64 = .921875 .84375 .421875 - 29/32 = 29/64 = 61/64 = .953125 .90625 .453125 - 31/32 = 31/64= 63/64 = .984375 .96875 .484375 MM/IN. Conversions 2009 Arctic Cat Snowmobiles Factory Service Manual - all Models - www.ReadManuals.com 1-13
  14. 14. Torque Conversions (ft-lb/N-m) Tightening Torque (General Bolts) Thread TighteningType of Bolt Diameter A (mm) Torque (Conventional or 4 Marked Bolt) 5 12-36 in.-Ib ~~ .qj 6 36-60 in.-Ib ® ','1"1 , ' T · ' I.I., - 8 7-11 ft-Ib 10 16-25 ft-Ib (7 Marked Bolt) 5 24-48 in.-Ib wmmtll« (j 6 6-8 ft-Ib 8 13-20 ft-Ib 10 29-43 ft-Ib 1-14 Assembly Schematicsl Torque Specifications (Table of Contents) Servicing Symbols................................................. 1-14 120 cc.................................................................... 1-15 570 cc.................................................................... 1-16 500 cc.................................................................... 1-18 OOO~.................................................................... 1~0 800 cc.................................................................... 1-22 1000 cc.................................................................. 1-24 1100 cc.................................................................. 1-26 Servicing Symbols Listed in the table below are symbols indicating spe- cial instructions and other important information nec- essary for proper servicing. Please note the definition for each symbol. -NOTE: Before engine assembly, ensure all threaded areas are clean to assure an accurate torque value is achieved. & CAUTION Torque values have a range of + or - 20%. SYMBOL DESCRIPTION ~_ID' Torque control required 243 - apply blue Loctite #243 271 - apply red Loctite #271 Lubricate with Arctic Cat 50:1 Injection Oil - Non-APV Engines Lubricate with Arctic Cat Synthetic APV 2-Cycle Oil - APV Engines Lubricate with Arctic Cat Low-Temp Grease 3B - Three Bond Sealant HT - High-Temp Sealant AS - Anti-Seize Thread Compound 2009 Arctic Cat Snowmobiles Factory Service Manual - all Models - www.ReadManuals.com
  15. 15. 120 cc ~ . t e ~ 96 in.-Ib ~ : . / 20 ft-Ib .~ ' P @@~ ""~ 20 ft-Ib ~ I 96 in.-Ib 18 ft-Ib ~ 15 ft-Ib 120-ENG09 2009 Arctic Cat Snowmobiles Factory Service Manual - all Models - www.ReadManuals.com1-15
  16. 16. 570 cc ~ 96 in.-Ib @ ® ~ © (i) IJJ ~y c€@ 7 ® ® Q) 0 8 11 4 210 570-ENG09 1-16 2009 Arctic Cat Snowmobiles Factory Service Manual - all Models - www.ReadManuals.com
  17. 17. ~ 28 ft-Ib ~ 48 in.-Ib ~ 15 ft-Ib fJIJ-~~-·96 in.-Ib 48 in.-Ib ....~...- 570ENG09 2009 Arctic Cat Snowmobiles Factory S .ervlce Manual - all Mod Ies- wwwR. eadManuals.com 1-17
  18. 18. 500 cc <D 0 -~<D ~ < 96in.·lb ~ 108 in.·lb 500CC1A09 1-18 2009 Arctic Cat Snowmobiles Factory Service Manual - all Models - www.ReadManuals.com
  19. 19. ~ 96 in.-Ib (C) 6 mm 96 in.-Ib (D) Coolant Temperature Sensor 18 ft-Ib • ~ 20ft-lb ~ crossfire..: , f;!i!J~ 15ft.O._: / 4fC <lll- " "~ (A) (A) . '- (A) ~ 22 ft-Ib ""-------~'," ~- G @. /~ .- 5 •~ 24 ft-Ib ~ F5/T500 / 50 ft-Ib ~ 0 /3~~ ~ ~."~ 25ft-lb~ -~ :,,;r:::: 23ft-lb " ;~/ ", <lll-, ~ 15 ft-Ib 2009 Arctic Cat Snowmobiles Factory Service Manual - all Models - www.ReadManuals.com (B) 1-19
  20. 20. 1-20 600 cc 1>-- 48 in.·lb ® @ 0 @ (J) >-- 96 in.·lb ill ~----1ill(Do(D 0 CD (!) @ ill -- >--/ 48 in.·lb >--96 in.·lb 2009 Arctic Cat Snow . Manual - all Models - www.mobiles Factory Service ReadManuals.com
  21. 21. ~ 96 in.·lb ~ 20ft·lb 16ft·lb F-Series ~ ~,.- 50 ft Ib 25f! ; '.lb ~. 15ft·lb ~ .~~'~~.v~~ "'<:J 23 ft·lb '- ~..., '. ~ 25 ft·lb '.... (A) 10 mm Step 1: 13 ft-Ib Step 2: 31 It-Ib (8) 6 mm 96In.·lb (8) (A) (8) (A)(C) (8) (A) 1·i..'1"- -o'k'©Jlk- ;.1..1 Vl II I ~/o ~ j _ I I (A) ~ -~I"-:''-@I ~I~'(A) 81J8 'l:Jttt:J ~ (A) (A) (A) (C)Coolant Temperature Sensor 18 I t . l b . j~@:j~~~ @ , ~ 48 in.·lb 2009 Arctic Cat Snowmobiles Factory Service Manual - all Models - www.ReadManuals.com 1-21
  22. 22. 1-22 800 cc :J ·(A) 10 mm Step 1: 13 ft-Ib Step 2: 31 ft·lb (8) 8 mm 25 ft-Ib (C) 6 mm 96 in.-Ib (D) Coolant Temperature Sensor 18 ft·lb . . :J · / 96in.·lb a @ <D ill @ 0 ill @ ill *9 513 II ® 0 ® 0 @ ® * Accessible from Top Side :J :J• 19ft·lb 17 ft·lb (Knock Sensor) • 800 09 1 2009 Arctic Cat Snowmobiles Factory Service Manual - all Models - www.ReadManuals.com
  23. 23. :J 96 in.-Ib 30 ft-Ib • F-Series :J. :J. 50 ft-Ib 25 ft-~Ib :J--~ _ 17ft-lb f'JAi .,~~ " 23 ft-Ib - • 19 ft·lb • 96 in.-Ib 800 09 2 2009 Arctic Cat Snowmobiles Factory Service Manual - all Models - www.ReadManuals.com 1-23
  24. 24. 1000 cc /~ '" ~ 18 ft·lb :J - (8) (8) 6 mm 96 in.·lb (A) ~ ..~ ____J -~ ~ /~ 48in.·lb 96 in.·lb 0:> c(;<::e / ( ,.'~' . t? . ' . .'-'" 'J..' ~~~~U ..~~ / ~ il~ 50ft.lb ~ 48 in.·lb 1-24 ® ill <D @ 0 ill ill 0 0 0 ill @ ® ill *14 I * Accessible from Top Side ~ 19 ft·lb ~~ 2009 Arctic Cat Snowmobiles Factory Service Manual - all Models - www.ReadManuals.com @ @ 7 1000 09 2
  25. 25. ~ F-Series 501t-lb . ( ~ 501t.lb ~QP ~ 25 It-Ib / .'(!PeP iCa~ 50 It-Ib •~ 108 in.-Ib 2009 Arctic Cat Snowmobiles Facto 96 in.-Ib- - 69' Yo' ,~~/ " 0J, ~ ry Service Manual - all Models - www.ReadManuals.com 1-25
  26. 26. 1100 cc EngineCase Torque Value 15 ft-Ib Qty 4- 96 in.-Ib • 6 mm Cap Screw S 1 120in -Ib at 18 - tep . .. 8 mm Cap Screw y Step 2 19 ft-Ib Oty 6- Step 1 13 ft-Ib ... 10 mm Cap Screw Step 2 33 ft-Ib 1100ccJAG09 1-26 2009 Arctic Cat Snow - Manual - all Models -mobiles Factory Service www.ReadManuals.com
  27. 27. 84 in.-Ib 60 in.-Ib 60 in.-Ib 30 ft-Ib 2009 Arctic Cat Snowmobiles Facto .ry Service Manual - all Models - www.ReadManuals.com ,'~ 84 in.-Ib 1100ccZ1RV09 1-27
  28. 28. Engine Torque Patterns (1100 ee) Engine Case Oil Separator Plates 741-582A 741-737A Oil Pan Plate Oil Pan 741-738A 741-584A Cylinder Head 741-617A 1-28 2009 Arctic Cat Snowmobiles Factory Service Manual - all Models - www.ReadManuals.com
  29. 29. Camshaft Cover Engine Cover 741-624A 741-580A Magneto Cover Exhaust Manifold 741-583A 744-0038 2009 Arctic Cat Snowmobiles Factory Service Manual - all Models - www.ReadManuals.com 1-29
  30. 30. Arctic Povver Valve (APV) System Specifications (2-Stroke) -NOTE: The servo will activate once at APV cycle RPM. If the servo cycles three times, cable length adjustment or valve inspection is required. APV Position/RPM ENGINE VALVE POSITION CYCLE RPM 600 cc Full-Open 73-7400 (Low/High All) 800 cc Mid-Open 60-6500 (Low/High All) Full-Open 78-8100 (Low/High All) 1000 cc Mid-Open 6300 (Low/High All) Full-Open 6500 (Low/High All) -NOTE: The 800 cc and 1000 cc have a three-stage exhaust valve system. The stages are closed, mid- open, and full-open. Each model has a designated RPM at which the system is synchronized and checked by the ECU for proper operation occuring once each time the engine is started. The 800 cc system is checked at 4800 RPM and the 1000 cc system is checked at 6100 RPM (CrossfirelF- Series) or at 6270 RPM (M-Series). F-Series Servomotor 741-635A Crossfire/M-Series (600 ee) Support Tube -"... Steering Post 739-715A 1-30 ENGINE 600 cc 800 cc 1000 cc Crossfire/M-Series (800/1000 ee) Servomotor / 742-209A APV CABLE LENGTH CENTER ± 0.039 in. 1.417 in. 1.377 in. 1.319 in. •0735-516 2009 Arctic Cat Snowmobiles Factory Service Manual - all Models - www.ReadManuals.com
  31. 31. Oil Consumption Specifications (2-Stroke) FULL-CLOSED FULL-OPEN ENGINE RPM (Idle) 2 Minutes 3 Minutes 500 cc 1833 1.0-2.5 cc 7.4-10.3 cc 570 cc 2000 1.4-2.2 cc 6.9-9.4 cc 600 cc 1833 1.3-3.2 cc 10.9-15.2 cc 800 cc 1833 1.32-3.48 cc 8.74-10.8 cc 1000 cc 1833 1.96-3.57 cc 8.96-10.72 cc EFI Specifications Fuel Pressure (2-Stroke) 42.8-47.3 psi Fuel Pressure (1100 cc Non-Turbo) 43.5 psi Fuel Pressure (1100 cc Turbo) 36.0 psi - Idle 55.0 psi - Full Boost Throttle Valve Angle Specifications TPSTOOL ANALYZER TOOL (DC VOLTS) (DC VOLTS) 500 cc Idle 0.710-0.818 0.710-0.818 Full-Open 3.472-4.048 3.470-4.046 600 cc Idle 0.646-0.754 0.646-0.754 Full-Open 3.472-4.485 3.470-4.046 DIAGNOSTIC TOOL 800 cc Idle 0.646-0.754 3.99° -6.66° Full-Open 3.472-4.485 74.97"-89.37" 1000 cc Idle 0.591-0.699 4.75°-7.55° Full-Open 3.477-4.054 77.39°-91.66° 1100 cc Idle 1.100-1.140 8.5° Non-Turbo Full-Open 4.300-4.500 90° 1100 cc Turbo Idle 0.690-1.110 10° Full-Open 4.000-4.200 90° -NOTE: Breaking the seal on the idle screw jam nut or the screws on the TPS will void warranty. Fuel Pump Specifications (570 ee) RPM PSI KG/CM2 1000-2000 3000-4000 3.0-3.5 0.21-0.25 4.5-5.5 0.32-0.39 Carburetor Specifications PILOT AIR FLOAT HEIGHT MAIN PILOT THROTTLE SCREW SETTING (TURNS OUT) (mm) AIR JET OUTLET VALVE 1 1/2 22-24 -NOTE: The above specifications are production settings. For high altitude jetting and settings, refer to the jet chart beneath the snowmobile hood. For optional tuning components, see the Quick Reference Guide. 2009 Arctic Cat Snowmobiles Factory Service Manual - all Models - www.ReadManuals.com 1-31
  32. 32. Electrical Specifications (570 ee) -NOTE: The ignition system is a Normally Open Ignition (NOI). Description Resistance Test Test Value Ignition Coil Primary (External) 0.26-0.35 ohm orange Secondary 6800-10,200 ohms high tension wire Charge Coil (1) 12-18 ohms black/red Charge Coil (2) 12-18 ohms brown/white Ignition Timing Sensor 148-222 ohms green/white Lighting Coil 0.12-0.18 ohm yellow Spark-Plug Cap 4000-6000 ohms cap end Description Test Value Voltage Regulator/Rectifier 11-14 AC volts yellow Low Oil-Light Sending Unit Less than 1 ohm (float end down) terminal Ignition Switch Less than 1 ohm (key in OFF posi- terminal tion) Description Peak Voltage Test Primary Coil (External) 254-266V orange Charge Coil (1) 13.7-15.4V black/red Charge Coil (2) 14.5-15.7V brown/white Ignition Timing Sensor 4.8-6.4V green/white Lighting Coil 6.5-7.0V yellow + Test Connections - black/white high tension wire green/red green/red brown yellow cap end + Test Connections - brown terminal terminal + Test Connections - black/white green/red green/red brown yellow Peak Voltage Tests were made with the Fluke Model 73 Multimeter (pin 0644-191) set to the DC Volt scale and the Peak Voltage Reading Adapter (pin 0644-307) with the main harness connectors plugged in (except on the primary coil/CCU tests), spark plugs removed and grounded, and by pulling the recoil starter rope briskly. -NOTE: Lighting coil output is unregulated voltage. A WARNING Most voltages generated by the ignition system are sufficient to interrupt pacemakers! All technicians, especially those using pacemakers, must avoid contact with all electrical connections when pulling the recoil starter rope or after the engine has been started. 1-32 2009 Arctic Cat Snowmobiles Factory Service Manual - all Models - www.ReadManuals.com
  33. 33. Electrical Specifications (500 ee) -NOTE: The ignition system is a Normally Open Ignition (NOI). Description Resistance Test Test Value Ignition Coil Primary 0.24-0.36 ohm orange/black Secondary 6800-10,200 ohms high tension wire Charge Coil (1) 7.2-10.8 ohms black/red Charge Coil (2) 7.2-10.8 ohms brown/white Lighting Coil 0.08-0.12 ohm yellow Ignition Timing Sensor 80.8-121 ohms green/white Injection Coil 15.2-22.8 ohms blue/white Fuel Pump Coil 1.52-2.28 ohms orange Spark-Plug Cap 4000-6000 ohms cap end Description Test Value Chassis Control Unit* 10-15 DC Volts red/blue (low power) + Test Connections - orange/red high tension wire green/red green/red yellow brown/green blue/white orange cap end + Test Connections - black (low power) (Crossfire/F-Series) red/black (high power) black (high power) Voltage Regulator/Rectifier 10-15 DC Volts red/blue black (T500) 11-14 AC Volts yellow black Low Oil-Light Sending Unit Less than 1 ohm (float end down) terminal terminal Ignition Switch Less than 1 ohm (key in OFF position) terminal terminal Description Peak Voltage Test + Test Connections - Primary Coil* 104V orange/black orange/red Charge Coil (1) 13.2-14.1V black/red green/red Charge Coil (2) 13.6-14.2V brown/white green/red Lighting Coil 8.3V yellow yellow Ignition Timing Sensor 4.8V green/white brown/green Injection Coil 13.2V blue/white blue/white Fuel Pump Coil 12.8V orange orange Lighting Coil 14.8-22.2V (@ 2000 RPM) yellow brown * Harness plugged III -NOTE: To test the coolant temperature sensor, see Section 5. Peak Voltage Tests were made at room temperature with the MaxiClips (pin 0744-041), Fluke Model 73 Multime- ter (pin 0644-191) set to the DC Volt scale, and the Peak Voltage Reading Adapter (pin 0644-307). Also, the main harness connectors must be unplugged (except on the primary coil/CCU tests), the spark plugs removed and grounded, and by pulling the recoil starter rope briskly. -NOTE: Lighting coil output is unregulated voltage. A WARNING Most voltages generated by the ignition system are sufficient to interrupt pacemakers! All technicians, especially those using pacemakers, must avoid contact with all electrical connections when pulling the recoil starter rope or after the engine has been started. 2009 Arctic Cat Snowmobiles Factory Service Manual - all Models - www.ReadManuals.com 1-33
  34. 34. Electrical Specifications (600 ee) -NOTE: The ignition system is a Normally Open Ignition (NOI). Description Resistance Test Test Value Ignition Coil Primary 0.24-0.36 ohm orange/black Secondary 6800-10,200 ohms high tension wire Charge Coil (1) 7.2-10.8 ohms black/red Charge Coil (2) 7.2-10.8 ohms brown/white Lighting Coil 0.08-0.12 ohm yellow Ignition Timing Sensor 80.8-121 ohms green/white Injection Coil 15.2-22.8 ohms blue/white Fuel Pump Coil 1.52-2.28 ohms orange Spark-Plug Cap 4000-6000 ohms cap end Description Test Value Chassis Control Unit* 10-15 DC Volts red/blue (low power) + Test Connections - orange/red high tension wire green/red green/red yellow brown/green blue/white orange cap end + Test Connections - black (low power) red/black (high power) black (high power) Low Oil-Light Sending Unit Less than 1 ohm (float end down) terminal terminal Servomotor 12 DC Volts red/black (counterclockwise) black/red (counterclockwise) black/red (clockwise) red/black (clockwise) Ignition Switch Less than 1 ohm (key in OFF position) terminal terminal Description Peak Voltage Test + Test Connections - Primary Coil* 104V orange/black orange/red Charge Coil (1) 13.2-14.1V black/red green/red Charge Coil (2) 13.6-14.2V brown/white green/red Lighting Coil 8.3V yellow yellow Ignition Timing Sensor 4.8V green/white brown/green Injection Coil 13.2V blue/white blue/white Fuel Pump Coil 12.8V orange orange Lighting Coil 14.8-22.2V (@ 2000 RPM) yellow brown * Harness plugged III -NOTE: To test the coolant temperature sensor, see Section 5. Peak Voltage Tests were made at room temperature with the MaxiClips (pin 0744-041), Fluke Model 73 Multime- ter (pin 0644-191) set to the DC Volt scale, and the Peak Voltage Reading Adapter (pin 0644-307). Also, the main harness connectors must be unplugged (except on the primary coil/CCU tests), the spark plugs removed and grounded, and by pulling the recoil starter rope briskly. -NOTE: Lighting coil output is unregulated voltage. A WARNING Most voltages generated by the ignition system are sufficient to interrupt pacemakers! All technicians, especially those using pacemakers, must avoid contact with all electrical connections when pulling the recoil starter rope or after the engine has been started. 1-34 2009 Arctic Cat Snowmobiles Factory Service Manual - all Models - www.ReadManuals.com
  35. 35. Electrical Specifications (800 ee) -NOTE: The ignition system is a Normally Open Ignition (NOI). Description Resistance Test Test Value Ignition Coil Primary 0.24-0.36 ohm black/white Secondary 5040-7560 ohms high tension wire Charge Coil (1) 7.2-10.8 ohms black/red Charge Coil (2) 7.2-10.8 ohms brown/white Lighting Coil 0.08-0.12 ohm yellow Ignition Timing Sensor (1) 148-222 ohms blue/white Ignition Timing Sensor (2) 148-222 ohms green/white Injection Coil 15.2-22.8 ohms blue/white Fuel Pump Coil 1.52-2.28 ohms orange Spark-Plug Cap 4000-6000 ohms cap end Description Test Value Voltage Regulator/Rectifier* 10-15 DC Volts red/violet (F-Series) Voltage Regulator/Rectifier* 10-15 DC Volts red/blue (Crossfire/M-Series) 11-14 AC Volts yellow Low Oil-Light Sending Unit Less than 1 ohm (float end down) terminal Servomotor 12 DC Volts red/black (counter- clockwise) + Test Connections - white/blue high tension wire green/red green/red yellow brown/green brown/green blue/white orange cap end + Test Connections - black black black terminal black/red (counter- clockwise) black/red (clockwise) red/black (clockwise) Ignition Switch Less than 1 ohm (key in OFF position) terminal terminal Description Peak Voltage Test + Test Connections - MAG Primary Coil (Harness Sider 125-137V orange/red orange/black PTa Primary Coil (Harness Sider 126-139V white/red white/black Charge Coil (1) 13.6-14.8V black/red green/red Charge Coil (2) 13.5-14.6V brown/white green/red Lighting Coil 5.4-5.8V yellow yellow Ignition Timing Sensor (1) 4.3V blue/white brown/green Ignition Timing Sensor (2) 4.4V green/white brown/green Injection Coil 6.8-7.3V blue/white blue/white Fuel Pump Coil 12.3V orange orange Lighting Coil 14.8-22.2V (@ 2000 RPM) yellow brown * Malll harness plugged III -NOTE: To test the coolant temperature sensor, see Section 5. Peak Voltage Tests were made at room temperature with the MaxiClips (p/n 0744-041), Fluke Model 73 Multime- ter (p/n 0644-191) set to the DC Volt scale, and the Peak Voltage Reading Adapter (p/n 0644-307). Also, the main harness connectors must be unplugged (except on the primary coil and voltage regulator/rectifier tests), the spark plugs removed and grounded, and by pulling the recoil starter rope briskly. -NOTE: Lighting coil output is unregulated voltage. A WARNING Most voltages generated by the ignition system are sufficient to interrupt pacemakers! All technicians, especially those using pacemakers, must avoid contact with all electrical connections when pulling the recoil starter rope or after the engine has been started. 2009 Arctic Cat Snowmobiles Factory Service Manual - all Models - www.ReadManuals.com 1-35
  36. 36. Electrical Specifications (1000 ee) -NOTE: The ignition system is a Normally Open Ignition (NOI). Description Resistance Test Test Value Ignition Coil Primary 0.24-0.36 ohm black/white Secondary 5040-7560 ohms high tension wire Charge Coil (1) 7.2-10.8 ohms black/red Charge Coil (2) 7.2-10.8 ohms brown/white Lighting Coil 0.08-0.12 ohm yellow Ignition Timing Sensor (1) 148-222 ohms blue/white Ignition Timing Sensor (2) 148-222 ohms green/white Injection Coil 15.2-22.8 ohms blue/white Fuel Pump Coil 1.52-2.28 ohms orange Spark-Plug Cap 4000-6000 ohms cap end Description Test Value Voltage Regulator/Rectifier* 10-15 DC Volts red/violet (F-Series) Voltage Regulator/Rectifier* 10-15 DC Volts red/blue (Crossfire/M-Series) 11-14 AC Volts yellow Low Oil-Light Sending Unit Less than 1 ohm (float end down) terminal Servomotor 12 DC Volts red/black (counter- clockwise) + Test Connections - white/blue high tension wire green/red green/red yellow brown/green brown/green blue/white orange cap end + Test Connections - black black black terminal black/red (counter- clockwise) black/red (clockwise) red/black (clockwise) Ignition Switch Less than 1 ohm (key in OFF position) terminal terminal Description Peak Voltage Test + Test Connections - MAG Primary Coil (Harness Sider 125-137V orange/red orange/black PTa Primary Coil (Harness Sider 126-139V white/red white/black Charge Coil (1) 13.6-14.8V black/red green/red Charge Coil (2) 13.5-14.6V brown/white green/red Lighting Coil 5.4-5.8V yellow yellow Ignition Timing Sensor (1) 4.3V blue/white brown/green Ignition Timing Sensor (2) 4.4V green/white brown/green Injection Coil 6.8-7.3V blue/white blue/white Fuel Pump Coil 12.3V orange orange Lighting Coil 14.8-22.2V (@ 2000 RPM) yellow brown * Malll harness plugged III -NOTE: To test the coolant temperature sensor, see Section 5. Peak Voltage Tests were made at room temperature with the MaxiClips (p/n 0744-041), Fluke Model 73 Multime- ter (p/n 0644-191) set to the DC Volt scale, and the Peak Voltage Reading Adapter (p/n 0644-307). Also, the main harness connectors must be unplugged (except on the primary coil and voltage regulator/rectifier tests), the spark plugs removed and grounded, and by pulling the recoil starter rope briskly. -NOTE: Lighting coil output is unregulated voltage. A WARNING Most voltages generated by the ignition system are sufficient to interrupt pacemakers! All technicians, especially those using pacemakers, must avoid contact with all electrical connections when pulling the recoil starter rope or after the engine has been started. 1-36 2009 Arctic Cat Snowmobiles Factory Service Manual - all Models - www.ReadManuals.com
  37. 37. Electrical Specifications (1100 ee) -NOTE: The ignition system is a Normally Open Ignition (NOI). Description Resistance Test Test Value Magneto Coil (three tests) 0.2-0.4 ohm yellow Coil (1) 1.4 ohms red/green Coil (2) 1.4 ohms red/green Crankshaft Position Sensor 173-211 ohms green Coolant Temperature Sensor 2.3k-2.6k ohms yellow/black Injection Coil Starter Relay 3.6 ohms black/yellow Spark-Plug Cap 4000-6000 ohms cap end Description Test Value -NOTE: To test the coolant temperature sensor, see Section 5. + Test Connections - yellow gray/green brown/green blue ground black cap end + Test Connections - These tests were made at room temperature with the MaxiClips (pin 0744-041), Fluke Model 73 Multimeter (pin 0644-191), and the Peak Voltage Reading Adapter (pin 0644-307). For ignition coil peak voltage test, the battery must be fully charged. Also, the main harness connectors must be unplugged (except on the voltage regulator/recti- fier test). & WARNING Most voltages generated by the ignition system are sufficient to interrupt pacemakers! All technicians, especially those using pacemakers, must avoid contact with all electrical connections when pulling the recoil starter rope or after the engine has been started. 2009 Arctic Cat Snowmobiles Factory Service Manual - all Models - www.ReadManuals.com 1-37
  38. 38. 500 cc Ignition Timing Specifications (2-Stroke) Ignition Timing - Engine Warm BTDC - 12°/2000 RPM - 0.034 in. Not Adjustable I~~:::~i, i!!~~~_j-C_BT_DC_2_40___---, •Rotating Direction 570 cc Ignition Timing - Engine Warm BTDC - 20°/2000 RPM - 0.099 in. Not Adjustable 0742-218 Q,'"lrl/"II ~/I ~ 0742-217 1-38 600 cc Ignition Timing - Engine Warm BTDC - 15°/2000 RPM - 0.059 in. Not Adjustable ROTATING DIRECTION 800 cc 740-130A -NOTE: For timing verification, use a dial indicator and scribe a mark on the flywheel for 25° BTDC. Ignition Timing - Engine Warm BTDC - 25°/3250 RPM - 0.162 in. Not Adjustable ~ 'Y~ BlDC 18° BlDC 14" . BlDC 2T BlDC IT ! - BlDC 24° BlOC 16° /J' BlDC 21l" :::;I~~_I::~~3J(- •Rotating Direction 0744-033 2009 Arctic Cat Snowmobiles Factory Service Manual - all Models - www.ReadManuals.com
  39. 39. 1000 cc (Crossfire/M-Series) Ignition Timing - Engine Warm BTDC - 14°/1800 RPM - 0.057 in. Not Adjustable 0744-034 1000 cc (F-Series) Ignition Timing - Engine Warm BTDC - 20°/3750 RPM - 0.113 in. Not Adjustable BlDC 16" ifI : BTDCIII" BTDC 15" i BTDC 20" BTDC 14" i BTDC 22" :::~~ i~::~BlDC 8"~_Ir=BlDC211" I •Rotating Direction 2009 Arctic Cat Snowmobiles Factory Service Manual - all Models - www.ReadManuals.com 0744-035 1-39
  40. 40. Steering/Body Torque Specifications 120 Sno Pro Item Tie Rod End (Spindle)* Inner Tie Rod End/Steering* Ski Shock/Shock Mount A-Arm/Spindle A-Arm/Chassis Ski/Spindle CrossfirelM-Series Ski Handlebar Adjuster Block/Post (Standard) Handlebar Adjuster (Sno Pro) Steering Post Mounting Block Steering Post/Stop* Steering Tie Rod/Shaft Arm* Steering ArmlTie Rod Steering PostlTie Rod* Steering Link/Steering Arm Spindle ArmlTie Rod Suspension Arm/Spindle (Upper) Suspension Arm/Spindle (Lower) (Crossfire) Suspension Arm/Spindle (Lower) (M-Series) Sway Bar Link/Front Arm (Crossfire) Shock Absorber/Spindle Front Suspension Arm/Chassis* (Upper) Front Suspension Arm/Chassis* (Lower) Steering Post/Chassis* Steering Support/Chassis** Center Steering Link/Steering Arm* Gas Tank/Steering Support * w/Green Loctite #609 ** w/Blue Loctite #243 1-40 Torque ft-Ib 15 20 20 30 30 20 35 120 in.-Ib 20 96 in.-Ib 30 30 30 30 20 30 30 40 30 96 in.-Ib 20 30 30 30 20 20 96 in.-Ib BearcatIF-SerieslT-SerieslZ1 Item Ski Spindle Arm/Spindle** Suspension Arm/Spindle Front Suspension Arm (Upper) Front Suspension Arm (Lower) Steering Arm/Spindle* Steering Arm/Suspension Mounting Bracket Sway Bar Mounting Bracket/Suspension Mounting Bracket Tie Rod Jam Nut** Spindle Arm and Steering ArmlTie Rod* Steering Post/Chassis* Steering Post/Steering Tie Rod* Steering Tie Rod/Steering Arm Drag Link/Steering and Spindle Tie Rods* Steering Post/Suspension Mounting Bracket* Drag Link/Steering Arm (Bearcat/F-SerieslT-Series)** Drag Link/Steering Arm (Z1)** Shock Absorber/Shock Mounting Frame (Bearcat/F-SerieslT-Series) Shock Absorber/Shock Mounting Frame (Z1) Bearing Cap/Spindle** Upper Bearing Bracket/Support Plate** Shock Absorber/Spindle Suspension Mounting Bracket/Chassis (Lower) Suspension Mounting Bracket/Chassis (Upper) Steering Support Plate/Steering Support Shock Mount Frame/Suspension Mounting Bracket Shock Mount Frame/Front Upper Frame Spindle Retainer/Spindle** Front Bumper (Bearcat) Rear Bumper/Heat Exchanger** (Bearcat/F-SerieslT-Series) Rear Bumper/Heat Exchanger** (Upper) (Z1) Rear Bumper/Heat Exchanger** (Lower) (Z1) Rear RacklTunnel (Bearcat XT) * w/Green Loctlte #609 ** w/Blue Loctite #243 2009 Arctic Cat Snowmobiles Factory Service Manual - all Models - www.ReadManuals.com Torque ft-Ib 26 30 32 32 32 40 20 120 in.-Ib 13 30 35 35 30 35 35 12 120 in.-Ib 32 32 13 96 in.-Ib 32 96 in.-Ib 20 96 in.-Ib 96 in.-Ib 20 13 32 25 25 20 20
  41. 41. Drive System Specifications Drive Clutch/Driven Pulley-Related Specifications ALIGNMENT BAR MODEL OFFSET CENTER- PIN TO-CENTER OFFSET FLOAT Crossfire/M-Series 0644-427 11.50" 1.655" None Z1ITZ1 /Bearcat Z1 XT 0644-727 10.20" 1.655" None Bearcat 570/F-Series/ 0644-496 11.50" 1.507" None T-Series & CAUTION Do not allow the driven pulley to "float" on the output shaft or damage to the driven pulley will occur. Parallelism 800 eel1 000 ee/11 00 ee =---'---~--- C J ;9 C ~ --r-0.060 in. ~ 0.040 in. 0743-410 -NOTE: See Section 6 in this manual for alignment and parallelism procedures. Arctic Cat Drive Belt Dimensions BELT PIN LENGTH WIDTH *0627-046 46 ± 3/16 inch 1 29/64 inch *0627-047 4317/32 ± 3/16 inch 1 29/64 inch **0627-060 46 ± 3/16 inch 1 29/64 inch **0627-066 43 17/32 ± 3/16 inch 1 29/64 inch **0627-067 45 13/32 ± 3/16 inch 1 13/32 inch *Double-Cog High Performance Belt w/Hard Compound **Double-Cog High Performance Belt w/High COF Compound -NOTE: The difference between Drive Belt (pIn 0627-046) and Drive Belt (pIn 0627-060) is the hard- ness. The Drive Belt (pIn 0627-060) is more flexi- ble, and if used in place of Drive Belt (pIn 0627- 046), the engine will run at a lower RPM. Drive System Components A list of Arctic Drive Clutch and Driven Pulley com- ponents that are available through the Arctic Cat Ser- vice Parts Department can be found in the Quick Reference Guide. This information will be useful when doing any fine-tuning on the drive system. 2009 Arctic Cat Snowmobiles Factory Service Manual - all Models - www.ReadManuals.com 1-41
  42. 42. Gear Case Performance Calibrations Engine RPM Drive Gear Ratio 6200 6400 6600 6800 7000 7200 7400 7600 7800 8000 8200 8400 8600 8800 9000Sprocket Vehicle Speed (mph) 66 54 91 94 97 100 103 106 109 112 114 117 120 123 126 129 132 65 55 88 91 94 96 99 102 105 108 111 113 116 119 122 125 128 64 56 85 88 91 93 96 99 102 104 107 110 112 115 118 121 123 63 57 82 85 88 90 93 96 98 101 103 106 109 111 114 117 119 62 58 80 82 85 87 90 92 95 98 100 103 105 108 110 113 115 61 59 77 79 82 84 87 89 92 94 97 99 102 104 107 109 112 9 Tooth 60 60 74 77 79 82 84 86 89 91 94 96 98 101 103 106 108(2.52" pitch) 59 61 72 74 77 79 81 84 86 88 91 93 95 98 100 102 104 58 62 70 72 74 76 79 81 83 85 88 90 92 94 97 99 101 57 63 67 70 72 74 76 78 80 83 85 87 89 91 93 96 98 56 64 65 67 69 71 74 76 78 80 82 84 86 88 90 92 95 55 65 63 65 67 69 71 73 75 77 79 81 83 85 87 89 91 54 66 61 63 65 67 69 71 73 75 77 79 81 83 84 86 88 66 54 101 104 108 111 114 117 121 124 127 130 134 137 140 143 147 65 55 98 101 104 107 110 113 117 120 123 126 129 132 136 139 142 64 56 95 98 101 104 107 110 113 116 119 122 125 128 131 134 137 63 57 91 94 97 100 103 106 109 112 115 118 121 124 127 130 133 62 58 88 91 94 97 100 103 106 108 111 114 117 120 123 125 128 61 59 85 88 91 94 97 99 102 105 108 110 113 116 119 121 124 10 Tooth 60 60 83 85 88 91 93 96 99 101 104 107 109 112 115 117 120(2.52" pitch) 59 61 80 83 85 88 90 93 95 98 101 103 106 108 111 114 116 58 62 77 80 82 85 87 90 92 95 97 100 102 105 107 110 112 57 63 75 77 80 82 84 87 89 92 94 97 99 101 104 106 109 56 64 72 75 77 79 82 84 86 89 91 93 96 98 100 103 105 55 65 70 72 74 77 79 81 84 86 88 90 93 95 97 99 102 54 66 68 70 72 74 76 79 81 83 85 87 89 92 94 96 98 66 54 96 99 102 106 109 112 115 118 121 124 127 130 134 137 140 65 55 93 96 99 102 105 108 111 114 117 120 123 126 129 132 135 64 56 90 93 96 99 102 105 107 110 113 116 119 122 125 128 131 63 57 87 90 93 95 98 101 104 107 110 112 115 118 121 124 126 62 58 84 87 90 92 95 98 100 103 106 109 111 114 117 119 122 61 59 81 84 87 89 92 95 97 100 102 105 108 110 113 116 118 8 Tooth 60 60 79 81 84 86 89 91 94 97 99 102 104 107 109 112 114(3.0" pitch) 59 61 76 79 81 84 86 88 91 93 96 98 101 103 106 108 111 58 62 74 76 78 81 83 86 88 90 93 95 97 100 102 105 107 57 63 71 74 76 78 80 83 85 87 90 92 94 97 99 101 103 56 64 69 71 73 76 78 80 82 84 87 89 91 93 96 98 100 55 65 67 69 71 73 75 77 80 82 84 86 88 90 92 95 97 54 66 64 67 69 71 73 75 77 79 81 83 85 87 89 91 94 Shaded rows indicate existing tooled gear ratios 1-42 2009 Arctic Cat Snowmobiles Factory Service Manual - all Models - www.ReadManuals.com
  43. 43. Drive System Torque Specifications 120 Sno Pro Item Torque ft-Ib Centrifugal Clutch** 20 Secondary Sprocket** 20 Drive Sprocket Bearing/Chassis 20 BearcatIF-SerieslM-SerieslCrossfireIT-SeriesIZ1 Drive Clutch Spider* Spider Retainer Nut* Drive Clutch Cover** Cam Arm Pin Lock Nut Cam Arm Set Screw* Drive Clutch/Ring Gear* Driven Pulley Driven Shaft Jam Nut Torque Bracket Brakeline Fitting/Caliper Brakeline/Master Cylinder Torque Bracket Cover Movable Sheave Speedometer Sensor Bracket Gear Case/Chassis Brake Caliper Housing/Chassis Outside Caliper Housing/Inside Caliper Housing Gear Case Cover Gear Case Drain Plug Driveshaft/Output Shaft Cap Screw** Driveshaft/Brake Disc Retaining Nut Shift Actuator/Gear Case *w/Green Loctite #620 **w/Blue Loctite #243 55 250 85 120 in.-Ib 11 19 in.-Ib 22 32 40 66 in.-Ib 10.5 21 72 in.-Ib 72 in.-Ib 17 20 20 17 12.5 12 70 120 41 in.-Ib Rear Suspension Torque Specifications 120 Sno Pro Item Torque ft-Ib End Cap/Rail 78 in.-Ib Axle Housing/Rail 20 Rear Arm/Bracket* 20 Rear Wheel Axle* 20 Cross-Brace Axle/Rail* 20 Idler AxlelTunnel* 20 * w/Blue Loctite #243 Bearcat XT Item Wear Strip/Rail End Cap/Rail Mounting Block/Rail Idler Wheel/Mounting Block Slide Block/Rail Pivot Arm/Idler Arm Rear Arm/Rail Rear Arm/Idler Arm Front Arm/Rail Idler Wheel/Shock Bracket - Rail Idler Wheel/Pivot Assembly - Rail Rear Arm Shock Pivot Axle/Rail Front Arm Shock Bracket Axle/Rail Rear Arm Limiter/Rail* Front Rail Support/Rail* Limiter Strap/Rail Support Spring Slide Block/Rail Outer Idler Wheel Mounting Block/Rail Articulating Skid Frame/Rail RaillTunnel Crossfire/Crossfire R Wear Strip/Rail End Cap/Rail Mounting Block/Rail Idler Wheel/Mounting Block Spring Slide/Slide Block - Rail (Standard) Spring Slide/Slide Block - Rail (R) Pivot Arm/Idler Arm (R) Idler Wheel Axle/Rail Rear Arm/Rail Rear Arm Limiter/Rail* Front Arm Mounting Bracket/Rail (R) Rear Shock Pivot/Inner Idler Wheel - Rail Front Arm Shock Axle/Rail Front Rail Support/Rail* (Standard/Sno Pro) Front Rail Support/Rail* (R) Front Arm/Rail (Standard/Sno Pro) Front Arm/Mounting Bracket (R) Limiter Strap/Rail Support Pivot Assembly/Rail Track Adjuster Bracket/Rail Rear Rail Support/Rail Inner Idler Wheel/Rail RaillTunnel M-Series Wear Strip/Rail End Cap/Rail Mounting Block/Rail Inner Idler Wheel/Mounting Block Idler Wheel Axle/Rail Rear Arm/Rail Idler Arm/Rear Arm Rear Arm Limiter/Rail Support Front Arm Shock Axle/Rail Front Rail Support/Rail Outer Idler Wheel/Mounting Block Front Arm/Rail Limiter Strap/Rail Support Track Adjuster Bracket/Rail RaillTunnel * w/Blue Loctite #243 2009 Arctic Cat Snowmobiles Factory Service Manual - all Models - www.ReadManuals.com Torque ft-Ib 50 in.-Ib 80 in.-Ib 20 20 20 20 40 40 40 40 40 40 40 40 20 120 in.-Ib 20 20 20 40 50 in.-Ib 80 in.-Ib 20 20 40 34 20 40 40 40 20 40 40 20 30 40 40 120 in.-Ib 40 120 in.-Ib 20 40 40 50 in.-Ib 80 in.-Ib 20 20 40 40 34 20 40 20 20 40 120 in.-Ib 120 in.-Ib 40 1-43
  44. 44. F-SerieslZ1 Bearcat 5701T-Series Item Torque ft-Ib Item Torque ft-Ib Wear Strip/Rail 50 in.-Ib Wear Strip/Rail 50 in.-Ib End Cap/Rail 80 in.-Ib End Cap 80 in.-Ib Mounting Block/Rail 20 Mounting Block/Rail 20 Idler Wheel/Mounting Block 20 Idler Wheel/Mounting Block 20 Rear Arm/Rail 40 Rear Arm/Rail 40 Rear Arm/Idler Arm 40 Rear Arm/Idler Arm 40 Spring Slide/Slide Block - Rail 20 Shock Pivot/Idler Wheel - Rail 20 Pivot Arm/Idler Arm 20 Spring Slide Block/Rail 20 Idler Wheel Axle/Rail 20 Pivot Arm/Idler Arm 20 Front Arm Shock Axle/Rail 40 Idler Wheel Axle/Rail 20 Front Arm/Rail 40 Front Arm Shock Axle/Rail 40 Rear Shock Pivot/Front Arm 20 Front Arm/Rail 40 Limiter Strap/Rail Support 120 in.-Ib Limiter Strap/Front Arm 120 in.-Ib Rear Shock Pivot/Rail 40 Track Adjuster Bracket/Rail 120 in.-Ib Rear Arm Limiter/Rail 50 Rear Arm Limiter/Rail* 50 Rail Support/Rail 20 Rail Support/Rail 20 RaillTunnel 40 Limiter Strap/Rail Support 120 in.-Ib RaillTunnel 40 * w/Blue Loctlte #243 1-44 2009 Arctic Cat Snowmobiles Factory Service Manual - all Models - www.ReadManuals.com
  45. 45. Track Warranty Guidelines Failure Mode Description Cause Warranty Delamination (A) Condition in which the track fabric cleanly sepa- Result of poor adhesion between fabric and rubber material rates or spreads apart from the rubber. Tread/External Lug Damage (B) Condition in which the lugs are torn, cracked, worn, or separated. Most often a result of riding/spinning on rugged terrain... -rocks, -jagged ice, -metal objects, -gravel roads. High speed running with poor lubrication may produce gummy external track lugs leading to separation. Covered Not Covered Edge Tearing (C) A track failure that occurs along the side of the track in which tearing occurs either parallel or perpendicular to the track edge. Rods out of center. If a rod is positioned off-center during track Covered manufacturing, tearing along the side of the track may occur ± 1/2 in. from the edge. Traction Product Cutting that occurs where a stud or pick is Often the result of contact having been made with a solid or jag- Not Covered and Clip Damage attached to the track including tearing due to stud ged object (e.g. rocks, ice, metal, gravel, etc.). Internal Lug Damage Broken Rods/ Missing Clip (D) pull-through as well as track clips that are torn off. Condition in which internal lugs are torn, worn, or Result of contact being made with a foreign object. Not Covered cracked. Track derailment can also cause this damage. Condition in which tracks are found to have bro- Typically, results from track impacts and overheating. Not Covered ken rods. Gummy tread sometimes accompanies broken rods. Overheating of the rod can result from friction buildup due to poor lubrication or riding at high continuous speeds for long periods of Wear clip and rod section broken out and miss- time in minimal snow conditions. ing. Gummy tread and brown or dark brown rod color at the center sometimes accompanies this failure. Signs of wear strip material melted and sticking to the edges of the wear clip. Also, wear clips that have started to turn blue in color from overheating are all signs of operating the snowmobile on minimal snow. Large Deformities Condition in which a track has large deformities Manufacturing flaw. of the Track or Air which may include air bubbles/pockets/voids Covered Bubbles within the track. Lugs Torn Off Outer Belt (B) B Condition normally found on deep lug tracks. LugfTread Damage A Lug/ Tread Damag@ Typically, the result of operating a deep lug track on minimal snow Not Covered at high rates of speed. This track is designed for deep snow mountainous areas only. c 734-522C D Broken Rod/Missing Clip 734-5228 734-522D 2009 Arctic Cat Snowmobiles Factory Service Manual - all Models - www.ReadManuals.com 1-45
  46. 46. Track Specifications Below is a listing of drive tracks for Arctic Cat snow- mobiles with its specifications. -NOTE: On the M-Series, measurement is from the bottom of the wear strip at the point of the shock pad on the slide rail. All tracks are 15 in. wide except for 120 Sno Pro (11 in.), Crossfire R (14 in.), and Bearcat XT (20 in.). All models at 20 Ib except M-Series (10 Ib). Front Suspension Specifications SWAVBARS SKI SHOCK SPRINGS -NOTE: All springs have a 0.331" wire diameter except 120 Sno Pro (0.235") and Z1m1 (0.343"). Model Free Rate LBI # of Coils Tab Length Inch F5fT500fT570 11.25" 90 6.2*18.2** NO M6/M8/M1000 (STO) 12.50" 120 12.75 YES F 570 9.36" 90 8.5 NO Bearcat 5701 10.10" 110 8.4 NO Bearcat 570 XT F8 (STO) 12.50" 95 14 YES Crossfire (STO) 13.50" 120 12 NO Z1fTZ1 10.50" 110 9.0 YES 120 Sno Pro 6.97" 85 9.0 NO Crossfire R 13.00" 125 11.5 NO Bearcat Z1 XT 10.10" 90 9.6 NO *Active Coils ** Total Coils 1-46 Rear Suspension Specifications FRONT ARM SPRINGS Model Free Length Rate LBllnch Bearcat 570 9.5" 110 Bearcat XT 9.5" 140 F 570 9.5" 90 F5fT500fT570lZ1 fTZ1 7.75" 110 Crossfire/M-Series 7.75" 135 Crossfire R 8.0" 190 F8 8.25" 90/250 F-Series Sno ProlZ1 Turbo Sno Pro 8.25" 100/250 REAR ARM SPRINGS 0730-218 * Square wire -NOTE: The wire diameter and length of the spring have a large influence over the valving of the shocks. A longer spring in areas (0) and (E) can be selected if cut off to match the original spring. Replacement springs must match the original spring in areas (0) and (E). 2009 Arctic Cat Snowmobiles Factory Service Manual - all Models - www.ReadManuals.com
  47. 47. Shock Absorber Specifications Below is a list of shock absorbers used on the front and rear suspensions of Arctic Cat snowmobiles. Specifi- cations given for each shock absorber include col- lapsed and extended length, stroke, and piston depth (if applicable). If replacing a shock absorber, always select a shock absorber with the same length, both col- lapsed and extended. SKI SHOCK Model Collapsed Extended Stroke Piston Length Length Depth Bearcat 570/F5/F 5701 11.55" 17.50" 5.95" N/A T500fT570 Crossfire 500 12.55" 18.75" 6.20" N/A 120 Sno Pro 7.78" 9.49" 1.71" N/A Bearcat XT 10.67" 16.00" 5.33" N/A Z1 fTZ1 fTZ1 Turbo 11.55" 17.50" 5.90" N/A Crossfire 600/800/1 000 12.13" 18.72" 6.59" 1.40" (STO)/Crossfire R Crossfire Sno Pro 12.60" 18.80" 6.20" 6.97" F8 (STO)/F8 LXR 11.47" 16.70" 5.21" 6.50" F-Series Sno Prol 12.30" 16.75" 4.45" 7.00" Z1 Turbo Sno Pro M-Series (STO) 11.56" 17.55" 5.99" 1.25" M-Series Sno Pro 12.00" 17.55" 5.55" 6.68" FRONT ARM SHOCK Model Collapsed Extended Stroke Piston Length Length Depth Bearcat XT 8.42" 12.49" 4.07" N/A F5/F 570lZ1 8.43" 12.53" 4.10" N/A Bearcat 5701 8.09" 11.78" 3.69" N/A Crossfire 500fT-Series Crossfire R 8.17" 11.76" 3.59" 0.58" F8 (STO)/F8 LXR 8.55" 12.49" 3.94" 4.85" Crossfire 600/800/1 000 8.54" 12.51" 3.97" 0.62" (STO)I F-Series Sno Pro/Z1 Turbo Sno Pro M-Series 8.11" 11.25" 3.14" 0.58" REAR ARM SHOCK Model Collapsed Extended Stroke Piston Length Length Depth Bearcat 570fT-Series 10.91" 16.69" 5.78" N/A Crossfire 500 9.89" 14.50" 4.61" N/A F5 10.00" 15.00" 4.61" N/A F 570 9.92" 15.00" 5.08" N/A Bearcat XT 10.89" 16.67" 5.78" N/A Z1 9.87" 14.51" 4.61" N/A Crossfire (STO)I 9.88" 14.37" 4.48" 0.90" Crossfire R Crossfire Sno Pro/M- 11.10" 16.00" 4.90" 5.77" Series F8 (STO)/F8 LXR 9.89" 14.53" 4.64" 5.80" F-Series Sno ProlZ1 10.13" 14.53" 4.40" 5.70" Turbo Sno Pro Idler Wheel Dimensions Model Location 0.0. Bearing 1.0. All Inside Rails 5.63 in. 0.787 in. All Idler Arm 7.12 in. 1.181 in. AII** Inside Rear Axle 7.12 in. 0.787 in. F-Seriesl Outside Front 5.63 in. 0.787 in. T-Series/Z1 F-Seriesl Outside Rear Axle 7.12 in. 0.787 in. T-Series/Z1 M-Series* Inside Rear Axle 8.00 in. 0.787 in. M-Series* Outside Rear Axle 8.00 in. 0.787 in. Bearcat XT Rear Axle 6.38 in. 0.787 in. * 8.00 in. idler wheel cannot be used with standard slide rails. ** Except M-Series 2009 Arctic Cat Snowmobiles Factory Service Manual - all Models - www.ReadManuals.com 1-47
  48. 48. SECTION 2- ENGINE TABLE OF CONTENTS Engine - 120 Sno Pro .............................................. 2-2 Engine - Bearcat 570/F 5701T570 ......................... 2-22 Engine - Crossfire 500/600 - M-Series 600 ........... 2-47 Engine - Crossfire 800/1000 - M-Series 800/1 000............................................. 2-76 Engine - F-Series 500/600 - T-Series 500 ........... 2-109 Engine - F-Series 800/1000 ................................ 2-137 Engine - Bearcat Z1 XTITZ1/Z1 .......................... 2-167 Troubleshooting Engine (2-Stroke Carbureted Models) ......................................... 2-203 Troubleshooting Engine (2-Stroke EFI Models) ... 2-205 Troubleshooting Engine (4-Stroke) ...................... 2-209 2009 Arctic Cat Snowmobiles Factory Service Manual - all Models - www.ReadManuals.com 2-1
  49. 49. Engine - 1 20 Sno Pro This engine section has been organized into sub-sec- tions showing a progression for the complete servicing of the Arctic Cat 120 cc (120 Sno Pro) engine. For consistency purposes, this section shows a complete and thorough progression; however, for efficiency it may be preferable to remove and disassemble only those components needing to be addressed and to ser- vice only those components. Also, some components may vary from model to model. The technician should use discretion and sound judgment. For engine-related servicing procedures, see Section 3 of this manual. -NOTE: Some illustrations and photographs used in this section are used for clarity purposes only and are not designed to depict actual conditions. -NOTE: Critical torque specifications are located in Section 1 of this manual. SPECIAL TOOLS A number of special tools must be available to the technician when servicing the engine. Description pIn V Blocks 0644-022 Surface Plate 0644-016 Ball Hone 0644-290 -NOTE: Special tools are available from the Arctic Cat Service Parts Department. Table of Contents Removing ................................................................ 2-2 Disassembling ......................................................... 2-3 Servicing Components ............................................ 2-8 Assembling............................................................ 2-16 Installing ................................................................ 2-21 Removing Engine -NOTE: The drive chain must be removed in order to remove the engine (see Drive Chain and Sprock- ets sub-section in Section 6). 1. Disconnect the choke and throttle cables from the carburetor; then on each cable, loosen the adjust- ment jam nut closest to the carburetor and remove the cables from the bracket. Route the cables out of the way. A046A 2. Remove the two cap screws securing the steering post to the steering post support. Account for two bearing halves, two lock nuts, and a bearing retainer. A023A 3. Pull the steering post up and back and then out of the lower steering post bearing. 4. Remove the two lock nuts securing the tie rods to the steering post; then remove the tie rods from the steering post. Place the steering post out of the way on the right-hand side of the engine compart- ment. A024 5. Cut the cable tie; then disconnect all wires (a total of four) at the front of the engine. Route them out of the way. 2-2 2009 Arctic Cat Snowmobiles Factory Service Manual - all Models - www.ReadManuals.com
  50. 50. 6. Turn the gas tank shut-off valve to the CLOSED position. & WARNING Whenever any maintenance or inspection is made on a fuel system when there may be fuel leakage, there should be no welding, smoking, open flames, etc., in the area. 7. Disconnect the fuel hose from the carburetor. -NOTE: Be prepared to wipe up any fuel spillage. 8. Pull the recoil starter rope out approximately 60 em (24 in.); then tie a slip-knot in the starter rope below the console and allow the rope to slowly retract against the starter case. 9. Remove the knot at the handle and remove the handle; then thread the rope through the bushing in the console. 10. At this point, scribe a line at the front of the engine and measure the distance between the crankshaft and the driveshaft. Record the measurement for installing purposes. 11. Lay the snowmobile on its side. -NOTE: A piece of cardboard should be used to protect the finish. 12. Using a flat-blade screwdriver, remove the four belly pan plugs covering the engine mounting cap screws; then remove the cap screws. Account for eight washers and four lock nuts. A049 -NOTE: The front center plug is to access the oil drain plug. 13. Place the snowmobile in the upright position; then on the left-hand side of the engine, remove the three cap screws securing the engine and brake bracket to the front end. 14. Remove the engine from the engine compartment. Disassembling Engine 1. Remove the oil drain plug and drain the oil; then install the oil plug and tighten securely. GM300D 2. Remove the wing nut securing the air cleaner end cap to the air cleaner housing. 2009 Arctic Cat Snowmobiles Factory Service Manual - all Models - www.ReadManuals.com
  51. 51. 3. Remove the cap screw and flange nuts securing the air cleaner housing to the carburetor and engine. GF314D 4. Remove the air breather hose from the air cleaner housing; then remove the air cleaner housing from the carburetor. Account for the gasket. A001 GF316D 5. Mark the locations of the springs for assembly; then disconnect the rod and spring from the carbu- retor. GF208D 6. Slide the carburetor off the mounting studs. Account for a gasket, insulator block, and a gas- ket. 7. Remove the recoil starter/fan housing assembly. GM201E 8. Remove the screws securing the recoil starter pul- ley to the flywheel; then remove the nut securing the flywheel to the crankshaft. 2-4 2009 Arctic Cat Snowmobiles Factory Service Manual - all Models - www.ReadManuals.com
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