Arctic Cat SD-ROM 2005 Service Manual
TABLE OF
CONTENTS
Click on the Green Text to Go!
Section
Foreword
1. General Information (Vol. I)
2. Engine (Vol. I)
2005 Snowmobile
Service Manual CD-ROM
3. Engine-Related Items (Vol. I)
4. Fuel Systems (Vol. I)
5. Engine Electrical Systems (Vol. I)
6. Chassis Electrical Systems (Vol. II)
7. Steering and Body (Vol. II)
8. Drive Train and Brake Systems (Vol. II)
9. Track/Rear Suspension (Vol. II)
FOREWORD
This Arctic Cat Service Manual Volume One contains service and maintenance information for the Model Year 2005
Arctic Cat Snowmobiles. The complete two-volume set is designed to aid service personnel in service-oriented applications.
This volume is divided into sections. The sections cover specific snowmobile components or systems and, in addition
to the standard service procedures, includes assembling, disassembling, and inspecting instructions. When using this
manual as a guide, the technician should use discretion as to how much disassembly is needed to correct any given condition.
The service technician should become familiar with the operation and construction of the components or systems by
carefully studying the complete two-volume set. This will assist the service technician in becoming more aware of and
efficient with servicing procedures. Such efficiency not only helps build consumer confidence but also saves time and
labor.
All Arctic Cat publications and snowmobile decals display the words Warning, Caution, and Note to emphasize important information. The symbol ! WARNING identifies personal safety-related information. Be sure to follow the
directive because it deals with the possibility of severe personal injury or even death. The symbol ! CAUTION
identifies unsafe practices which may result in snowmobile-related damage. Follow the directive because it deals with
the possibility of damaging part or parts of the snowmobile. The symbol NOTE: identifies supplementary information worthy of particular attention.
At the time of publication, all information, photographs, and illustrations were technically correct. Some photographs
and illustrations used in this volume are used for clarity purposes only and are not designed to depict actual conditions.
Because Arctic Cat Inc. constantly refines and improves its products, no retroactive obligation is incurred.
All materials and specifications are subject to change without notice.
Keep this manual accessible in the shop area for reference.
Product Service and Warranty Department
Arctic Cat Inc.
© 2004 Arctic Cat Inc. October 2004
®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN
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SECTION 1 — GENERAL INFORMATION
1
Snowmobile Identification ....................................... 1-2
Recommended Gasoline and Oil ........................... 1-2
Break-In Procedure ................................................ 1-2
Genuine Parts ........................................................ 1-3
High Altitude Operation .......................................... 1-3
Preparation For Storage ......................................... 1-3
Preparation After Storage ....................................... 1-4
After Break-In Checkup (100 Miles) ....................... 1-5
After Break-In Checkup Checklist .......................... 1-6
Torque Conversions ............................................... 1-7
Tightening Torque (General Bolts) ........................ 1-7
Fraction/Decimal Conversion Chart ....................... 1-8
Drill Bit Sizes (Number) Chart ................................ 1-8
MM/In. Conversion Chart ....................................... 1-9
Servicing Symbols ................................................ 1-10
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TABLE OF
CONTENTS
1-1
Snowmobile
Identification
The Arctic Cat Snowmobile has two important identification numbers. The Vehicle Identification Number
(VIN) is stamped into the tunnel near the right-side
footrest. The Engine Serial Number (ESN) is stamped
into the crankcase of the engine.
0726-383
These numbers are required to complete warranty
claims properly. No warranty will be allowed by Arctic
Cat Inc. if the engine serial number or VIN is removed
or mutilated in any way.
RECOMMENDED GASOLINE
(EFI Models)
The recommended gasoline to use in these snowmobiles is 87 minimum octane regular unleaded. In many
areas, oxygenates (either ethanol or MTBE) are added
to the gasoline. Oxygenated gasolines containing up to
10% ethanol or up to 15% MTBE are acceptable gasolines. Do not use gasolines containing methanol.
NOTE: When using the recommended gasoline,
the Fuel Designation Connector (the gray wire at
the ECU) must be connected.
NOTE: When using oxygenated gasolines, the
Fuel Designation Connector (the gray wire at the
ECU) must be disconnected.
! CAUTION
Do not use white gas or gasoline containing
methanol. Only Arctic Cat approved gasoline
additives should be used.
! CAUTION
If oxygenated gasoline is to be used, it is
extremely important that the Fuel Designation
Connector at the ECU is disconnected. If not,
severe engine damage may occur.
NOTE: In order for the ECU to change modes, the
engine must be OFF when connecting or disconnecting the Fuel Designation Connector.
Recommended
Gasoline and Oil
RECOMMENDED GASOLINE
(Carbureted Models)
The recommended gasoline to use in these snowmobiles is 87 minimum octane regular unleaded. In many
areas, oxygenates (either ethanol or MTBE) are added
to the gasoline. Oxygenated gasolines containing up to
10% ethanol or up to 15% MTBE are acceptable gasolines; however, whenever using oxygenated gasolines,
the carburetor main jet must be one size larger than the
main jet required for regular unleaded gasoline. For
example, if a 400 main jet is recommended for regular
unleaded gasoline, a 410 main jet must be installed if
using an oxygenated gasoline.
When using ethanol blended gasoline, it is not necessary to add a gasoline antifreeze since ethanol will prevent the accumulation of moisture in the fuel system.
! CAUTION
Do not use white gas or gasolines containing
methanol. Only Arctic Cat approved gasoline
additives should be used.
RECOMMENDED OIL
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 carbureted model break-in) and meets all of the lubrication
requirements of the Arctic Cat snowmobile engine.
Break-In Procedure
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.
1-2
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During the break-in period, a maximum of 1/2 throttle
is recommended; however, brief full-throttle accelerations 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 oilinjection system to ensure adequate engine
lubrication in extremely cold conditions.
Genuine Parts
1. Clean the seat cushion with a damp cloth and
Arctic Cat Vinyl Protectant (p/n 0638-313).
2. Clean the snowmobile thoroughly by hosing dirt,
oil, grass, and other foreign matter from the skid
frame, tunnel, hood, and belly pan. Allow the
snowmobile to dry thoroughly. DO NOT get water
into any part of the engine.
3. Place the rear of the snowmobile up on a shielded
safety stand.
NOTE: On M-Series and “Laydown” engine mod-
els, the air silencer boot can be pried forward to
access the intake bores. Pry the boot forward;
then proceed to step 7.
NOTE: On some standard models, the air-intake
silencer is a one-piece unit, and the silencer
boot(s) can be removed to access the intake
bore(s). Remove the boots; then proceed to step 7.
1
When replacement of parts is necessary, use only genuine 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 (on all models) and carburetion components (on carbureted models).
High altitude information decal(s) are located beneath
the hood of the snowmobile.
! CAUTION
On carbureted models, carefully follow the Main
Jet Chart recommendations for proper main jet
selection for altitude, temperature, and gasoline
being used.
King Cat and M-Series snowmobiles are initially set up
at the factory for operation between 6000-9000 feet.
Consult the appropriate specifications for this information.
NOTE: On some standard models, the air-intake
silencer includes a cover/tool tray assembly and a
baffle/resonator, and the silencer boot cannot be
removed to access the intake bores. Proceed to
step 4.
4. Open the air-intake silencer cover; then remove
the three screws securing the cover/tool tray
assembly to the silencer.
5. Close the cover; then tip the cover/tool tray
assembly forward and out of its slots and remove
the assembly.
6. Using a large flat-blade screwdriver, remove the
baffle/resonator tabs from the air-intake silencer
slots and remove the baffle/resonator to access the
intake bores.
NOTE: The baffle/resonator can be removed
more easily by removing the back tabs first.
7. Start the engine and allow to idle. With the engine
idling, spray Arctic Cat Engine Storage Preserver
(p/n 0636-177) into the intake(s) until the engine
exhaust starts to smoke heavily or until the engine
starts to drop in RPM. Turn engine off.
NOTE: On M-Series and “Laydown” engine models, secure the air silencer boots onto the intake
bores.
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Preparation
For Storage
Prior to storing the snowmobile, it must be properly
serviced to prevent corrosion and component deterioration. An authorized Arctic Cat Snowmobile dealer
should perform this service; however, the owner/operator can perform this service if desired. To prepare the
snowmobile for storage, Arctic Cat recommends the
following procedure:
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NOTE: On some standard models, install the air-
intake silencer boot(s); on some standard models,
install the baffle/resonator and the cover/tool tray
assembly.
8. Plug the exhaust system outlet with a clean cloth.
9. With the ignition switch in the OFF position:
A. Disconnect the high tension lead(s) from the
spark plug(s); then remove the plug(s), connect
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1-3
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it/them to the lead(s), and ground it/them on the
cylinder head(s).
! CAUTION
Never crank the engine over without grounding
the spark plug(s). Damage to coils and/or CDI
unit 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 plug(s) and connect the high
tension lead(s).
10. On carbureted models, drain the gas from each
carburetor float chamber.
11. Fill the gas tank to its rated capacity; then add
Arctic Cat Fuel Stabilizer (p/n 0638-165) to the
gas tank following directions on the container for
the stabilizer/gasoline ratio. Tighten the gas tank
cap securely.
19. Clean and polish the hood, console, and chassis
with Arctic Cat Hood and Windshield Cleaner/
Polish (p/n 0636-174). DO NOT USE
SOLVENTS OR SPRAY CLEANERS. THE
PRO- PELLENT WILL DAMAGE THE FINISH.
20. On electric start models, disconnect the battery
cables making sure to disconnect the negative
cable first; then clean the battery posts and cables.
21. If possible, store the snowmobile indoors. Raise
the track off the floor by blocking up the back end
making sure the snowmobile is secure. Loosen the
track adjusting bolts to reduce track tension. Cover
the snowmobile with a machine cover or a heavy
tarpaulin to protect it from dirt and dust.
22. If the snowmobile must be stored outdoors,
position the snowmobile out of direct sunlight;
then block the entire snowmobile off the ground
making sure the snowmobile is secure. Loosen the
track adjusting bolts to reduce track tension. Cover
with a machine cover or a heavy tarpaulin to
protect it from dirt, dust, and rain.
12. Drain the chain-case lubricant by removing the
chain-case drain plug located on the backside of
the chain-case assembly. Remove the chain-case
cover and inspect chain, sprockets, chain
tensioner, and rollers for wear and the chain for
proper tension. Install the drain plug, chain-case
cover, and seal; then pour Arctic Cat Transmission
Lube (p/n 0636-817) into the filler hole according
to appropriate specifications.
13. Drain the fluid from the gear case. Install the drain
plug; then pour Arctic Cat ACT Drive Fluid (p/n
4639-027) into the gear case according to
appropriate specifications.
14. Clean and inspect the drive clutch and driven
pulley.
15. 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.
16. Apply light oil to the upper steering post bushing,
ski spindles and bolts, front and rear pivot
bushings of the skid frame, and plungers of the
shock absorbers.
17. Lubricate all grease fittings (front and rear
suspension, spindles, speedometer drive adapter,
and the driven shaft support bearing) with a lowtemperature grease.
18. Tighten all nuts, bolts, and cap screws making sure
all calibrated nuts, bolts, and cap screws are
tightened to specifications. Make sure all rivets
holding the components together are tight.
Replace all loose rivets.
! 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 carburetor(s) must be cleaned
before starting the engine.
1. Clean the snowmobile thoroughly. Polish the
exterior of the snowmobile.
2. Clean the engine. Remove the cloth from the
exhaust system. Check exhaust system and airintake silencer/air filter for obstructions.
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. Inspect the drive belt for cracks and tears. Check
belt specifications. Replace if damaged or worn.
Install the drive belt.
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1-4
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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
filter and replace if necessary.
6. Inspect all fuel hoses and oil hoses for
deterioration or cracks; replace if necessary. Make
sure all connections are tight; then fill the oilinjection reservoir with the recommended
injection oil.
NOTE: After prolonged storage, Arctic Cat rec-
ommends one tankful of 100:1 gas/oil mixture be
used in conjunction with the oil-injection system
to ensure proper lubrication.
7. Inspect the entire brake system, all controls,
headlight, taillight, brakelight, ski wear bars, and
headlight aim; adjust or replace as necessary.
8. Inspect each spark plug. Replace, gap, or clean as
necessary.
9. Adjust the track to the proper tension and
alignment. Lock the jam nuts.
10. Adjust the carburetor(s) and choke cable on
carbureted models and throttle cable on all
models.
! WARNING
On VM-style carburetors, 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 causing the piston valve not to
return to the full-closed position.
11. Tighten all nuts, bolts, and cap screws making sure
all calibrated nuts, bolts, and cap screws are
tightened to specifications.
12. Lubricate all grease fittings (rear suspension,
spindles, speedometer drive adapter, and the
driven shaft support bearing) with a lowtemperature grease.
13. On liquid cooled models, check the coolant level
and all coolant hoses and connections for
deterioration or cracks. Add properly mixed
coolant as necessary.
14. On fan cooled models, clean the engine cooling
fins and all vents.
15. On electric start models, charge the battery; then
connect the battery cables making sure to connect
the positive cable first. Test the electric start
system.
After Break-In Checkup
(100 Miles)
The 100 mile checkup offered by some dealerships
reduces problems and warranty costs. A program of
this kind should be offered by all dealerships. Many
dealerships have added the price of the checkup into
the selling price of the snowmobile, and others offer it
as a bonus to the customers who purchase snowmobiles
from their dealership.
There are three areas that require adjustment after the
break-in period in order to obtain peak performance.
These areas are the following.
A. Carburetor jetting
B. Drive belt deflection/Break-In
C. Track tension and alignment
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 altitude, oxygenated gasoline usage, and temperature.
DRIVE BELT DEFLECTION — Drive belt deflection is very important to the snowmobile. Even if it is
checked and is correct when the snowmobile is set up,
it does change (more so during the break-in period).
This is because the rubber engine mounts and the rubber snubber on the torque link will all take a “set” during the first 100 miles, which allows the distance
between the drive clutch 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. This all leads to a
low-end performance problem and, if not corrected,
causes premature drive belt wear.
After the break-in period, drive belt deflection should
be checked according to the instructions given in this
manual. To correct for too much deflection, washer(s)
from between the driven pulley sheaves can be
removed to “tighten the drive belt” and allow the belt to
return to the proper ratio for drive clutch engagement.
DRIVE BELT BREAK-IN — It is critical for maximum drive belt life to 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 1/2
throttle or lower. This will allow 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, it is possible to destroy
a new drive belt in less than 50 miles. This should be
explained to customers at the time of drive belt sales.
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To increase the life of a drive belt, it is very important
that the belt be warmed up before subjecting it to any
type of use. In cold temperature (0° or below), the
engine should be allowed to idle for a period of 8 to 10
minutes. This will allow 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 seizure.
Each operator should be instructed to drive the snowmobile for several minutes at a low throttle setting to
warm the belt up before using wide-open-throttle. This
practice should be followed on all models for maximum belt life.
After Break-In
Checkup Checklist
Below is a recommended list of items to check after
the break-in period. By performing this inspection,
warranty cost can be reduced and customer satisfaction can be increased.
The recommended mileage for this inspection is
between 100 and 300 miles. Please encourage the customers to have this important checkup done.
In addition to instructing each operator about these
drive belt break-in procedures, Arctic Cat also recommends that the operators be informed that a drive belt
(like brake pads, wear strips, etc.) is considered a normal wear item and is listed as an exclusion on the Arctic Cat Limited Warranty.
TRACK TENSION AND ALIGNMENT — There is
a certain amount of stretch 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 thereafter. If
these adjustments aren’t performed, the track may
“derail” which leads to track and slide rail damage.
Along with these three major areas, there are also other
areas that should be checked and adjusted during the
“After Break-In Checkup.” A checklist to assist you
with this service follows. Not only will the customer be
happier, but it also gets the customer back into your
dealership, which in many cases will mean additional
sales in accessories, belts, oil, etc.
❏ Jet carburetor(s) according to average
temperature, type of gasoline being used, and
altitude
❏ Adjust drive belt deflection
❏ Adjust track tension and alignment
❏ Adjust throttle cable tension
❏ Check oil-injection pump adjustment
❏ Check engine idle
❏ Check coolant level
❏ Check chain case lubricant level
❏ Check lights (high/low beam, brakelight)
❏ Check safety switch operation
❏ Check driveshaft area for any rubbing
components
❏ Check steering hardware for tightness
❏ Check skid frame and A-arm mounting
hardware for tightness
❏ Check brake lever travel and adjustment
❏ Grease all lubrication points
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Torque Conversions
ft-lb kg-m ft-lb kg-m ft-lb kg-m ft-lb kg-m ft-lb kg-m
1 0.1212.941 5.7618.481 11.2
2 0.3223.042 5.8628.682 11.3
3 0.4233.243 5.8638.783 11.5
4 0.6243.344 6.1648.984 11.6
5 0.7253.545 6.2659.085 11.8
6 0.8263.646 6.4669.186 11.9
7 1.0273.747 6.5679.387 12.0
8 1.1283.948 6.6689.488 12.2
9 1.2294.049 6.8699.589 12.3
10 1.4304.250 6.9709.790 12.5
11 1.5314.351 7.1719.891 12.6
12 1.7324.452 7.2 72 10.0 92 12.8
13 1.8334.653 7.3 73 10.1 93 12.9
14 1.9344.754 7.5 74 10.2 94 13.0
15 2.1354.855 7.6 75 10.4 95 13.1
16 2.2365.056 7.7 76 10.5 96 13.3
17 2.4375.157 7.9 77 10.7 97 13.4
18 2.5385.358 8.0 78 10.8 98 13.6
19 2.6395.459 8.2 79 10.9 99 13.7
20 2.8405.560 8.3 80 11.1 100 13.8
1
Tightening Torque
(General Bolts)
Type of Bolt
(Conventional or
4 Marked Bolt)
(7 Marked Bolt) 5 0.3-0.6 2.0-4.5
Thread
Diameter
A (mm)
5 0.2-0.4 1.5-3.0
6 0.4-0.7 3.0-5.0
8 1.0-1.6 7.0-11.5
10 2.2-3.5 16.0-25.5
6 0.8-1.2 6.0-8.5
8 1.8-2.8 13.0-20.0
10 4.0-6.0 29.0-43.5
Tightening Torque
kg-m ft-lb
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Fraction/Decimal
ft-lb x 0.1383 = kg-m
Conversion Chart
8ths 16ths 32nds 64ths 64ths (cont)
1/8 = .125 1/16 = .0625 1/32 = .03125 1/64 = .015625 33/64 = .515625
1/4 = .250 3/16 = .1875 3/32 = .09375 3/64 = .046875 35/64 = .546875
3/8 = .375 5/16 = .3125 5/32 = .15625 5/64 = .078125 37/64 = .578125
1/2 = .500 7/16 = .4375 7/32 = .21875 7/64 = .109375 39/64 = .609375
5/8 = .625 9/16 = .5625 9/32 = .28125 9/64 = .140625 41/64 = .640625
3/4 = .750 11/16 = .6875 11/32 = .34375 11/64 = .171875 43/64 = .671875
7/8 = .875 13/16 = .8125 13/32 = .40625 13/64 = .203125 45/64 = .703125
— 15/16 = .9375 15/32 = .46875 15/64 = .234370 47/64 = .734375
— — 17/32 = .53125 17/64 = .265625 49/64 = .765625
— — 19/32 = .59375 19/64 = .296875 51/64 = .796875
— — 21/32 = .65625 21/64 = .328125 53/64 = .828125
— — 23/32 = .71875 23/64 = .359375 55/64 = .859375
— — 25/32 = .78125 25/64 = .390625 57/64 = .890625
— — 27/32 = .84375 27/64 = .421875 59/64 = .921875
— — 29/32 = .90625 29/64 = .453125 61/64 = .953125
— — 31/32 = .96875 31/64 = .484375 63/64 = .984375
kg-m x 7.235 = ft-lb
Drill Bit Sizes
(Number) Chart
No.
1 .2280 21 .1590 41 .0960 61 .0390
2 .2210 22 .1570 42 .0935 62 .0380
3 .2130 23 .1540 43 .0890 63 .0370
4 .2090 24 .1520 44 .0860 64 .0360
5 .2055 25 .1495 45 .0820 65 .0350
6 .2040 26 .1470 46 .0810 66 .0330
7 .2010 27 .1440 47 .0785 67 .0320
8 .1990 28 .1405 48 .0760 68 .0310
9 .1960 29 .1360 49 .0730 69 .0292
10 .1935 30 .1285 50 .0700 70 .0280
11 .1910 31 .1200 51 .0670 71 .0260
12 .1890 32 .1160 52 .0635 72 .0250
13 .1850 33 .1130 53 .0595 73 .0240
14 .1820 34 .1110 54 .0550 74 .0225
15 .1800 35 .1100 55 .0520 75 .0210
16 .1770 36 .1065 56 .0465 76 .0200
17 .1730 37 .1040 57 .0430 77 .0180
18 .1695 38 .1015 58 .0420 78 .0160
19 .1660 39 .0995 59 .0410 79 .0145
20 .1610 40 .0980 60 .0400 80 .0135
Size of Drill
in Inches
No.
Size of Drill
in Inches
No.
Size of Drill
in Inches
No.
Size of Drill in
Inches
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MM/IN. Conversion
Chart
mm in. mm in. mm in. mm in. mm in.
.01 .00039 .41 .01614 .81 .03189 21 .82677 61 2.40157
.02 .00079 .42 .01654 .82 .03228 22 .86614 62 2.44094
.03 .00118 .43 .01693 .83 .03268 23 .90551 63 2.48031
.04 .00157 .44 .01732 .84 .03307 24 .94488 64 2.51968
.05 .00197 .45 .01772 .85 .03346 25 .98425 65 2.55905
.06 .00236 .46 .01811 .86 .03386 26 1.02362 66 2.59842
.07 .00276 .47 .01850 .87 .03425 27 1.06299 67 2.63779
.08 .00315 .48 .01890 .88 .03465 28 1.10236 68 2.67716
.09 .00354 .49 .01929 .89 .03504 29 1.14173 69 2.71653
.10 .00394 .50 .01969 .90 .03543 30 1.18110 70 2.75590
.11 .00433 .51 .02008 .91 .03583 31 1.22047 71 2.79527
.12 .00472 .52 .02047 .92 .03622 32 1.25984 72 2.83464
.13 .00512 .53 .02087 .93 .03661 33 1.29921 73 2.87401
.14 .00551 .54 .02126 .94 .03701 34 1.33858 74 2.91338
.15 .00591 .55 .02165 .95 .03740 35 1.37795 75 2.95275
.16 .00630 .56 .02205 .96 .03780 36 1.41732 76 2.99212
.17 .00669 .57 .02244 .97 .03819 37 1.45669 77 3.03149
.18 .00709 .58 .02283 .98 .03858 38 1.49606 78 3.07086
.19 .00748 .59 .02323 .99 .03898 39 1.53543 79 3.11023
.20 .00787 .60 .02362 1.0 .03937 40 1.57480 80 3.14960
.21 .00827 .61 .02402 1 .03937 41 1.61417 81 3.18897
.22 .00866 .62 .02441 2 .07874 42 1.65354 82 3.22834
.23 .00906 .63 .02480 3 .11811 43 1.69291 83 3.26771
.24 .00945 .64 .02520 4 .15748 44 1.73228 84 3.30708
.25 .00984 .65 .02559 5 .19685 45 1.77165 85 3.34645
.26 .01024 .66 .02598 6 .23622 46 1.81102 86 3.38582
.27 .01063 .67 .02638 7 .27559 47 1.85039 87 3.42519
.28 .01102 .68 .02677 8 .31496 48 1.88976 88 3.46456
.29 .01142 .69 .02717 9 .35433 49 1.92913 89 3.50393
.30 .01181 .70 .02756 10 .39370 50 1.96850 90 3.54330
.31 .01220 .71 .02795 11 .43307 51 2.00787 91 3.58267
.32 .01260 .72 .02835 12 .47244 52 2.04724 92 3.62204
.33 .01299 .73 .02874 13 .51181 53 2.08661 93 3.66141
.34 .01339 .74 .02913 14 .55118 54 2.12598 94 3.70078
.35 .01378 .75 .02953 15 .59055 55 2.16535 95 3.74015
.36 .01417 .76 .02992 16 .62992 56 2.20472 96 3.77952
.37 .01457 .77 .03032 17 .66929 57 2.24409 97 3.81889
.38 .01496 .78 .03071 18 .70866 58 2.28346 98 3.85826
.39 .01535 .79 .03110 19 .74803 59 2.32283 99 3.89763
.40 .01575 .80 .03150 20 .78740 60 2.36220 100 3.93700
1
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1-9
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Servicing Symbols
Listed in the table below are symbols indicating special
instructions and other important information necessary
for proper servicing. Please note the definition for each
symbol. These symbols are used throughout this twovolume set.
SYMBOL DESCRIPTION
Torque control required
242 - apply blue Loctite #242 (p/n 1639-815)
243 - apply blue Loctite #243 (p/n 1639-413)
270 - apply green Loctite #270 (p/n 1639-817)
271 - apply red Loctite #271 (p/n 1639-820)
609 - apply green Loctite #609 (p/n 1639-821)
Lubricate with Arctic Cat 50:1 Injection Oil (p/n 0636-286)
Lubricate with Arctic Cat Extreme 50:1 Injection Oil (p/n 0639-112)
Lubricate with Arctic Cat Low-Temp Grease (p/n 0636-593)
3B - Three Bond Sealant (p/n 0636-070)
HT - High-Temp Sealant (p/n 0636-069)
AS - Anti-Seize Thread Compound (p/n 0678-146)
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1-10
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SECTION 2 — ENGINE
2
Arctic Cat Engine Specifications ............................. 2-2
Torque Conversions ................................................ 2-3
Piston Replacement Guide ..................................... 2-4
Assembly Schematics (Table of Contents).............. 2-4
Engine Piston Travel Versus Crank Angle Chart ... 2-22
Cylinder Head Volume Specifications ................... 2-23
Crankshaft Runout Specifications ......................... 2-23
Engine ................................................................... 2-24
Removing Engine (Table of Contents)................... 2-24
Disassembling Engine (Table of Contents) ........... 2-34
Servicing Top-Side Components
(500/600/700 cc “Laydown” Engine Models) ..... 2-62
Cleaning and Inspecting Engine ........................... 2-66
Measuring Critical Components ............................ 2-70
Assembling Engine (Table of Contents) ................ 2-72
Installing Engine (Table of Contents)................... 2-107
Troubleshooting Engine (Carbureted Models)..... 2-118
Troubleshooting Engine (EFI Models) ................. 2-121
Engine Information (Table of Contents)............... 2-125
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TABLE OF
CONTENTS
2-1
600 cc “Laydown”
700 cc Carb 700 cc EFI 900 cc Carb 900 cc EFI
0.075-0.105
0.0029-0.0041
0.30-0.50
0.012-0.020
0.1
0.004
23.995-24.000
23f*
3.775
0.149
0.7-0.8
0.082
0.038
0.038
0.059
0.133
0.081
0.258
0.028-0.031
0.075-0.105
0.0029-0.0041
0.30-0.50
0.075-0.105
0.075-0.105
0.075-0.105
0.083-0.150
0.095-0.150
0.095-0.150
0.0029-0.0041
0.0029-0.0041
0.0029-0.0041
0.0033-0.0059
0.0037-0.0059
0.0037-0.0059
0.012-0.020
0.30-0.50
0.012-0.0196
0.30-0.50
0.012-0.0196
0.30-0.50
0.012-0.0196
0.20-0.83
0.008-0.033
0.20-0.83
0.008-0.033
0.20-0.83
0.008-0.033
0.7-0.8
0.028-0.031
0.7-0.8
0.028-0.031
0.7-0.8
0.028-0.031
0.7-0.8
0.028-0.031
0.7-0.8
0.028-0.031
0.7-0.8
0.028-0.031
0.7-0.8
0.028-0.031
862
52.6
85
3.346
76
2.992
17e*
862
52.6
85
3.346
76
2.992
698
42.59
79.7
3.145
70
2.755
698
42.59
79.7
3.145
70
2.755
EFI
599
36.54
73.8
2.906
70
2.755
599
36.54
78
3.071
62.7
2.469
565
34.5
73.8
2.910
66
2.598
550
33.56
73.4
2.890
65
2.559
2.082
12j*
0.969
12i*
0.969
15d*
1.509
24h*
3.390
18e*
2.049
33e*
6.556
0.9447-0.9449
24.002-24.010
0.9450-0.9453
29.003-29.011
1.1410-1.1420
0.003-0.020
0.1
0.004
23.995-24.000
0.9447-0.9449
24.002-24.010
0.9450-0.9453
29.003-29.011
1.1410-1.1420
0.003-0.020
0.8665
0.1
0.004
21.995-22.000
0.8659-0.8661
22.002-22.010
0.8662-
27.003-27.011
1.0631-1.0634
0.003-0.020
0.1
0.004
21.995-22.000
0.8659-0.8661
22.002-22.010
0.8662-0.8665
27.003-27.011
1.0631-1.0634
0.003-0.020
0.1
0.004
21.995-22.000
0.8659-0.8661
22.002-22.010
0.8662-0.8665
27.003-27.011
1.0631-1.0634
0.003-0.020
0.1
0.004
19.995-20.000
0.7872-0.7874
20.002-20.010
0.7875-0.7878
26.003-26.011
1.0237-1.0241
0.02-0.03
0.1
0.004
17.995-18.000
0.7085-0.7087
17.998-18.006
0.7086-0.7089
23.003-23.011
0.9056-0.9059
0.02-0.03
0.1
0.004
19.995-20.000
0.7872-0.7874
20.002-20.010
0.7875-0.7878
26.003-26.011
1.0237-1.0241
0.02-0.03
0.0001-0.0008
0.0001-0.0008
0.0001-0.0007
0.0001-0.0007
0.0001-0.0007
0.0008-0.0012
0.0008-0.0012
0.0008-0.0012
0.05-0.10
0.002-0.004
11.0
0.05
0.002
0.05
0.002
0.05
0.002
0.05
0.002
0.05
0.002
0.05
0.002
0.05
0.002
0.05
0.002
0.433
0.05-0.10
0.002-0.004
11.0
0.433
0.05-0.10
0.002-0.004
11.0
0.433
0.05-0.10
0.002-0.004
11.0
0.433
0.05-0.10
0.002-0.004
11.0
0.433
0.05-0.10
0.002-0.004
9.4 - 9.8
0.370 - 0.385
0.05-0.10
0.002-0.004
0.236
0.004
N/A 6.0
0.05-0.10
0.002-
e*
5.258
0.207
0.7-0.8
0.145
0.028-0.031
0.7-0.8
0.028-0.031
499
30.4
71
2.795
63
2.480
499
30.4
71
2.795
63
2.480
30
25d*
3.692
0.075-0.105
0.0029-0.0041
0.20-0.40
0.008-0.016
0.1
0.004
21.995-22.000
0.8659-0.8661
0.075-0.105
0.0029-0.0041
0.20-0.40
0.008-0.016
0.1
0.004
21.995-22.000
0.8659-0.8661
Arctic Cat Engine Specifications
0.080-0.150
0.0031-0.0059
0.15-0.83
0.006-0.033
0.1
0.004
15.995-16.000
0.1
0.004
— mm
— in.
Cylinder Trueness
Limit (max)
17.995-18.000
— mm
Piston Pin
0.6297-0.6299
0.7085-0.7087
— in.
Diameter Range
0.7-0.8
431
26.3
65
2.559
65
2.559
AA37A7 AS44A8 AW50L4 AV50L4 ACB55L6 AA56A4 AD60L9 AJ60L2 AE70L3 AD70L3 AA86L4 AB86L4
367
22.41
60
2.362
65
2.559
— cu in.
— in.
— in.
ITEM 370 cc 440 cc 500 cc w/o APV 500 cc w/ APV 550 cc 570 cc 600 cc STD
Engine Model
Number
D i s p l a c e m e n t — c c
No. of Cylinders 2 2 2 2 2 2 2 2 2 2 2 2
Bore — mm
Stroke — mm
Compression Ratio 6.3:1 6.5:1 6.34:1 6.30:1 6.6:1 6.4:1 6.26:1 6.46:1 6.49:1 6.49:1 6.41:1 6.41:1
Cooling System Fan Cooled Fan Cooled Liquid Cooled Liquid Cooled Liquid Cooled Fan Cooled Liquid Cooled Liquid Cooled Liquid Cooled Liquid Cooled Liquid Cooled Liquid Cooled
18e*
2.012
87 87 87 87 87 87 87 87 87 87 87 87
18e*
2.012
— mm
Gasoline Octane
(min)
Fuel Mixture Oil Injection Oil Injection Oil Injection Oil Injection Oil Injection Oil Injection Oil Injection Oil Injection Oil Injection Oil Injection Oil Injection Oil Injection
Ignition Timing degrees
0.079
0.079
— in.
0.028-0.031
0.060-0.150
0.0024-0.0059
0.15-0.80
— mm
— in.
Piston Skirt/Cylinder
Clearance Range
— mm
Piston Ring End
0.006-0.031
— in.
Gap Range
0.7-0.8
0.028-0.031
— in.
Spark Plug (NGK) BR9EYA BR9EYA BR9EYA BR9EYA BR9EYA BR9EYA BR9EYA BR9EYA BR9EYA BR9EYA B R9EYA BR9EYA
Spark Plug Gap — mm
Lighting Coil Output 12V/185W 12V/185W 12V/156W 12V/156W 12V/180W 12V/210W 12V/190W 12V/190W 12V/156W 12V/190W 12V/156W 12V/190W
Ignition Type CDI/NOI CDI/NOI CDI/NOI CDI/NOI CDI/NOI CDI/NOI CDI/NOI CD/NOI CDI/NOI CDI/NOI CDI/NOI CDI/NOI
22.002-22.010
0.8662-0.8665
22.002-22.010
0.8662-0.8665
15.996-16.004
0.6298-0.6301
17.998-18.006
0.7086-0.7089
— mm
— in.
Piston Pin Bore
Diameter Range
27.003-27.011
1.0631-1.0634
27.003-27.011
1.0631-1.0634
21.003-21.011
0.8269-0.8272
23.003-23.011
0.9056-0.9059
— mm
— in.
Connecting Rod
Small End Bore
8.0
0.003-0.020
0.0001-0.0007
0.05
0.002
0.003-0.020
0.0001-0.0007
0.05
0.002
0.02-0.03
0.0008-0.0012
0.05
0.002
0.02-0.03
0.0008-0.0012
0.05
0.002
— mm
— in.
— mm
— in.
Diameter Range
Connecting Rod
Radial Play Range
Crankshaft Runout
(t.i.r.)
0.05-0.10
0.002-0.004
0.05-0.10
0.002-0.004
0.05-0.10
0.002-0.004
0.05-0.10
0.002-0.004
— mm
— in.
Crankshaft End
Play Range
0.315
0.315
N/A N/A 8.0
— mm
— in.
Reed Stopper
Height
d @ 1800 RPM h @ 3500 RPM
c @ 1400 RPM g @ 3200 RPM
e @ 2000 RPM i @ 4000 RPM
f @ 2500 RPM j @ 4350 RPM
*Engine Warm
2-2
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Torque Conversions
ft-lb kg-m ft-lb kg-m ft-lb kg-m ft-lb kg-m ft-lb kg-m
1 0.1 21 2.9 41 5.7 61 8.4 81 11.2
2 0.3
3 0.4
4 0.6
5 0.7
6 0.8
7 1.0
8 1.1
9 1.2
10 1.4
11 1.5
12 1.7
13 1.8
14 1.9
15 2.1
16 2.2
17 2.4
18 2.5
19 2.6
20 2.8
22 3.0 42 5.8 62 8.6 82 11.3
23 3.2 43 5.8 63 8.7 83 11.5
24 3.3 44 6.1 64 8.9 84 11.6
25 3.5 45 6.2 65 9.0 85 11.8
26 3.6 46 6.4 66 9.1 86 11.9
27 3.7 47 6.5 67 9.3 87 12.0
28 3.9 48 6.6 68 9.4 88 12.2
29 4.0 49 6.8 69 9.5 89 12.3
30 4.2 50 6.9 70 9.7 90 12.5
31 4.3 51 7.1 71 9.8 91 12.6
32 4.4 52 7.2 72 10.0 92 12.8
33 4.6 53 7.3 73 10.1 92 12.9
34 4.7 54 7.5 74 10.2 94 13.0
35 4.8 55 7.6 75 10.4 95 13.1
36 5.0 56 7.7 76 10.5 96 13.3
37 5.1 57 7.9 77 10.7 97 13.4
38 5.3 58 8.0 78 10.8 98 13.6
39 5.4 59 8.2 79 10.9 99 13.7
40 5.5 60 8.3 80 11.1 100 13.8
2
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2-3
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Piston Replacement
Guide
ENGINE SIZE YEAR PISTON RING PISTON & RING SET
370 cc 2005 * 3004-825 3005-913
440 cc 2005 * 3006-413 3005-920
500 cc w/APV 2005 * 3005-828 3006-427
500 cc w/o APV 2005 * 3005-828 3006-746
550 cc 2005 * 3003-760 3006-685
570 cc 2005 * 3006-004 3006-528
600 cc (STD) 2005 * 3005-714 3005-748
600 cc (“Laydown”) 2005 * 3006-004 3006-645
900 cc 2005 * 3006-394 3006-393
700 cc 2005 * 3006-500 3006-499
* Not a Service Part
Assembly Schematics
Table of Contents
370/440 cc .............................................................. 2-6
550 cc ..................................................................... 2-8
570 cc ................................................................... 2-10
600 cc (STD)......................................................... 2-12
900 cc ................................................................... 2-14
500 cc “Laydown” Engine Model (w/APV)............. 2-16
500 cc “Laydown” Engine Model (w/o APV).......... 2-18
600/700 cc “Laydown” Engine Models .................. 2-20
SYMBOL DESCRIPTION
Torque control required
242 - apply blue Loctite #242 (p/n 1639-815)
243 - apply blue Loctite #243 (p/n 1639-413)
270 - apply green Loctite #270 (p/n 1639-817)
271 - apply red Loctite #271 (p/n 1639-820)
609 - apply green Loctite #609 (p/n 1639-821)
Lubricate with Arctic Cat 50:1 Injection Oil (p/n 0636-286)
Lubricate with Arctic Cat Extreme 50:1 Injection Oil (p/n 0639-112)
Listed in the table below are symbols indicating special
instructions and other important information necessary
for proper servicing. Pl ease note the definition for each
symbol. These symbols are used throughout this twovolume set.
Back
2-4
Lubricate with Arctic Cat Low-Temp Grease (p/n 0636-593)
3B - Three Bond Sealant (p/n 0636-070)
HT - High-Temp Sealant (p/n 0636-069)
AS - Anti-Seize Thread Compound (p/n 0678-146)
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370/440 cc
2.5-2.8 kg-m
(18-20 ft-lb)
1.8-2.8 kg-m
(13-20 ft-lb)
3B
2.8 kg-m
(20 ft-lb)
2.8-3.5 kg-m
(20-25 ft-lb)
1.1 kg-m
(8 ft-lb)
2.8-3.5 kg-m
(20-25 ft-lb)
1.8-2.2 kg-m
(13-16 ft-lb)
2.8 kg-m
(20 ft-lb)
6.9-7.6 kg-m
(50-55 ft-lb)
2.5-4 kg-m
(18-29 ft-lb)
0.4-0.7 kg-m
(3-5 ft-lb)
0.4-0.7 kg-m
(3-5 ft-lb)
Back
2-6
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3744-ENG
Next
271
0.8-1.2 kg-m
(6-9 ft-lb)
271
1.1 kg-m
(8 ft-lb)
7-9 kg-m
(50.5-65 ft-lb)
1.8-2.2 kg-m
(13-16 ft-lb)
271
2.6-3.3 kg-m
271
HT
HT
HT
1.8-2.2 kg-m
(13-16 ft-lb)
1.8-2.2 kg-m
(13-16 ft-lb)
6 mm 0.8-1.2 kg-m
(6-9 ft-lb)
8 mm 1.8-2.8 kg-m
(13-20 ft-lb)
(19-24 ft-lb)
2
Back
1.8-2.2 kg-m
(13-16 ft-lb)
271
271
HT
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0.7 kg-m
(5 ft-lb)
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3744ENG2
2-7
Next
550 cc
HT
2.4 kg-m
(17 ft-lb)
2.8-3.5 kg-m
(20-25 ft-lb)
2.8-3.5 kg-m
(20-25 ft-lb)
2.4 kg-m
(17 ft-lb)
1.4 kg-m
(10 ft-lb)
6.9-7.6 kg-m
(50-55 ft-lb)
8 mm
1.8-2.8 kg-m
(13-20 ft-lb)
6 mm
0.8-1.2 kg-m
(6-9 ft-lb)
242
Back
2-8
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550-ENG
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1.8-2.8 kg-m
(13-20 ft-lb)
2.5-2.8 kg-m
(18-20 ft-lb)
0.7-1 kg-m
(5-7 ft-lb)
1.8-2.2 kg-m
(13-16 ft-lb)
HT
4-6 kg-m
(29-43.5 ft-lb)
1 kg-m
(7 ft-lb)
2
242
271
7-9 kg-m
(50.5-65 ft-lb)
Back
0.8-1.2 kg-m
(6-9 ft-lb)
242
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HT
0.7-1 kg-m
(5-7 ft-lb)
Back to Section TOC
2.6-3.3 kg-m
(19-24 ft-lb)
550ENG2
2-9
Next
570 cc
Back
2-10
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570-ENG
Next
0.8-1.2 kg-m
(6-9 ft-lb)
HT
HT
1.1 kg-m
(8 ft-lb)
1.8-2.2 kg-m
(13-16 ft-lb)
4.6 kg-m
(29-43.5 ft-lb)
0.8-2.1 kg-m
(6-9 ft-lb)
609*
1.8-2.8 kg-m
(13-20 ft-lb)
*Must be used in conjunction
with Loctite Primer #7471.
2
271
1.8-2.2 kg-m
(13-16 ft-lb)
0.7-1.0 kg-m
(5-7 ft-lb)
0.8-1.2 kg-m
(6-9 ft-lb)
271
0.8-1.2 kg-m
(6-9 ft-lb)
271
8-8.7 kg-m
(58-63 ft-lb)
271
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570ENG2
2-11
Next
600 cc (STD)
242
242
242
2.8-3.5 kg-m
(20-25 ft-lb)
HT
1.1 kg-m
(8 ft-lb)
8 mm 1.8-2.8 kg-m
(13-20 ft-lb)
10 mm 4-6 kg-m
(29-43.5 ft-lb)
2.4 kg-m
(17 ft-lb)
242
Back
2.4 kg-m
(17 ft-lb)
2-12
2.8-3.5 kg-m
(20-25 ft-lb)
Back to TOC
2.4 kg-m
(17 ft-lb)
0.7 kg-m
(5 ft-lb)
6.9-7.6 kg-m
(50-55 ft-lb)
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5&6-ENG
Next
2
Back
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5&6ENG04
2-13
Next
900 cc
Back
2-14
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900-ENG
Next
2
Back
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900-ENG2
2-15
Next
500 cc (“Laydown” w/APV)
Back
2-16
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500CC1
Next
242
2.5-2.8 kg-m
(18-20 ft-lb)
2.5-2.8 kg-m
(18-20 ft-lb)
0.7 kg-m
(5 ft-lb)
242
10 mm
4.2-4.8 kg-m
(30-35 ft-lb)
242
2
Back
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2.5-2.8 kg-m
(18-20 ft-lb)
6.9-7.6 kg-m
(50-55 ft-lb)
Back to Section TOC
500CC2
2-17
Next
500 cc (“Laydown” w/o APV)
Back
2-18
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500CC1A
Next
2
Back
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500CC2A
2-19
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