Arctic Cat Snowmobile Tool Catalog
Special
Tools
Catalog
Effective Date:
February, 2008
SNOWMOBILE
FOREWORD
This publication is designed to help authorized Arctic Cat Snowmobile dealers in identifying the special tools available from Arctic Cat Inc. Each of these special tools is identified by part number and by name. A brief function
description is also included for each special tool.
In several cases, two or more tools of those listed will serve the same purpose. Determine which of the tools will
best suit your needs and order accordingly. If additional information is required about any of the special tools, call
the Service Parts Department at Arctic Cat Inc.
Order all special tools using any of the following methods:
A. Cat Tracker Online
B. For Phone Orders, call our WATS line (7 a.m. to 6 p.m. Central Time) - U.S. 1-800-279-2281
C. For Telefax Orders, call (24 hours a day, 7 days a week - after hours voice mail) 800-279-1916
D. For Mail Orders, address to ARCTIC CAT INC.
P.O. Box 810
Thief River Falls, MN 56701
ATTN: Service Parts Department
Pickup Orders require 24-hour notice. Pickup Orders will automatically be shipped 3 days after processing unless
a special pickup date is requested.
Remember to include Dealer Name
Dealer Number
Purchase Order Number
Method of Shipment (1 day or 2 day service is available)
Specify if Emergency Service Processing (ESP) is desired
1
TABLE OF CONTENTS
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Angle Finder . . . . . . . . . . . . . . . . . . . . . . . . (p/n 0644-097). . . 3
Ball Hone
. . . . (p/n 0644-290, 291, 292, 293, 294, 531, 532, 533). . . 3
Coolant Cap (Non-Pressurized) . . . . . . . . . (p/n 0644-156). . . 3
Fan Spanner Wrench (Suzuki) . . . . . . . . . . (p/n 0644-340). . . 3
Flywheel Spanner Wrench . . . . . . . . . . . . . (p/n 0144-007). . . 3
Duck-Foot T-Handle Wrench (8 mm) . . . . . (p/n 0644-332). . . 4
EFI Throttle Cable Jam Nut/
Oil-Injection Pump Jam Nut Wrench . . . . . (p/n 0644-242). . . 4
Exhaust Spring Pliers . . . . . . . . . . . . . .(p/n 0644-391,397). . . 4
Crankshaft Protector Cap . . . . . . . . . . . . . . (p/n 0644-234). . . 4
Flywheel Puller . . . . . . . . . . . . . . . . . . . . . . (p/n 0744-040). . . 4
Flywheel Puller . . . . . . . . . . . . . . . . . . . . . . (p/n 0644-480). . . 5
Flywheel Puller Insert . . . . . . . . . . . . . . . . . (p/n 0644-179). . . 5
Crankshaft Bearing Remover . . . . . . . . . . . (p/n 0144-302). . . 5
Idle Speed Screw Jam Nut Wrench . . . . . . (p/n 0644-311). . . 5
Linkage Wrench (8 mm) . . . . . . . . . . . . . . . (p/n 0644-333). . . 5
Oil Filter Wrench (Adjustable). . . . . . . . . . . (p/n 0644-389). . . 5
Oil Injection Usage Tool . . . . . . . . . . . . . . . (p/n 0644-007). . . 6
Oil Seal Protector Tool . . . . . . . . . . . . . . . . (p/n 0644-219). . . 6
Blind-Hole Bearing Puller . . . . . . . . . . . . . . (p/n 0644-500). . . 6
Piston Pin Puller . . . . . . . . . . . . . . . . . . . . . (p/n 0644-328). . . 6
Rigid Hone Stone Set (2.7-4.1 in.) . . . . . . . (p/n 0644-043). . . 6
Ring Compressor . . . . . . . . . . . . . . . . . . . . (p/n 0644-378). . . 6
Spring Tool . . . . . . . . . . . . . . . . . . . . . . . . . (p/n 0644-072). . . 7
Starter Assembly Tool. . . . . . . . . . . . . . . . . (p/n 0644-052). . . 7
Stud Runner (6, 8, & 10 mm) . . . . (p/n 0644-018,019,020). . . 7
Surface Plate . . . . . . . . . . . . . . . . . . . . . . . (p/n 0644-016). . . 7
V Blocks (Large) . . . . . . . . . . . . . . . . . . . . . (p/n 0644-535). . . 7
V Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . (p/n 0644-022). . . 7
Valve and Spring Retainer Tool . . . . . . . . . (p/n 0644-448). . . 8
Valve Spring Compressor Tool . . . . . . . . . . (p/n 0444-197). . . 8
Hose Clamp Installation Tool . . . . . . . . . . . (p/n 0444-120). . . 8
Fuel Hose Clamp Tool . . . . . . . . . . . . . . . . (p/n 0644-545). . . 8
Water Pump Bearing & Seal Tool Kit . . . . . (p/n 0644-502). . . 8
Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
Battery Charger (1.5 Amp) . . . . . . . . . . . . . (p/n 0436-634). . . 8
Oil Pressure Test Kit . . . . . . . . . . . . . . . . . . (p/n 0644-495). . . 9
Compression Tester Kit . . . . . . . . . . . . . . . (p/n 0444-213). . . 9
Fuel Pressure Test Kit . . . . . . . . . . . . . . . . (p/n 0644-493). . . 9
Engine Leak-Down Test Kit. . . . . . . . . . . . . (p/n 0644-522). . . 9
Engine Pressure Test Kit . . . . . . . . . . . . . . (p/n 0744-051). . . 9
EFI Analyzer . . . . . . . . . . . . . . . . . . . . . . . . (p/n 0744-049). . . 9
EFI Analyzer Update Kit . . . . . . . . . . . . . . . (p/n 0744-047). . 10
EFI Analyzer Test Harness . . . . . . . . . . . . . (p/n 0644-181). . 10
Laptop Diagnostic Test Kit . . . . . . . . . . . . . (p/n 0744-050). . 10
CCU Diagnostic Test Kit . . . . . . . . . . . . . . . (p/n 0644-517). . 10
EFI Analyzer Test Harness . . . . . . . . . . . . . (p/n 0639-624). . 10
Engine Timing Gauge. . . . . . . . . . . . . . . . . (p/n 0144-009). . 10
Ignition Test Plug . . . . . . . . . . . . . . . . . . . . (p/n 0144-306). . 10
Multimeter (Fluke Model 73 w/Case) . . . . . (p/n 0644-191). . 11
Peak Voltage Reading Adapter. . . . . . . . . . (p/n 0644-307). . 11
MaxiClips . . . . . . . . . . . . . . . . . . . . . . . . . . (p/n 0744-041). . 11
Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . (p/n 0644-275). . 11
Timing Light . . . . . . . . . . . . . . . . . . . . . . . . (p/n 0644-296). . 11
Vacuum Test Pump. . . . . . . . . . . . . . . . . . . (p/n 0644-131). . 11
Shift Actuator Test Harness . . . . . . . . . . . . (p/n 0744-058). . 12
Laptop Diagnostic Tool . . . . . . . . . . . . . . . . (p/n 0744-048). . 12
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-13
Carburetor Adjustment Screwdriver (90°). . (p/n 0644-289). . 12
Synchronizer Repair Kit . . . . . . . . . . . . . . . (p/n 0644-062). . 12
Carburetor Synchronizing Tool Adapter . . . (p/n 0644-023). . 12
Chip Puller . . . . . . . . . . . . . . . . . . . . . . . . . (p/n 0644-188). . 12
Fuel Pump Socket Wrench. . . . . . . . . . . . . (p/n 0644-364). . 13
Gas Gauge Removal Tool. . . . . . . . . . . . . . (p/n 0644-357). . 13
Throttle Position Sensor (TPS)
Adjustment Tool Kit . . . . . . . . . . . . . . . . . . . (p/n 3639-891). . 13
90° Hex Driver (1/4 in.) . . . . . . . . . . . . . . . . (p/n 0644-550). . 13
Drive System/Track . . . . . . . . . . . . . . . . . . . . . 13-20
Air Pressure Test Kit - Gear Case. . . . . . . . (p/n 0644-530). . 13
Bearing Removal Tool. . . . . . . . . . . . . . . . . (p/n 0644-421). . 14
Bearing Removal and Installation Tool . . . . (p/n 0644-167) . . 14
Brake Disc Socket Wrench (ACT Drive) . . . (p/n 0644-415) . . 14
Brake Disc Socket Wrench (ACT Drive) . . . (p/n 0644-481) . . 14
Gear Case Drain Fitting . . . . . . . . . . . (p/n 0644-504,508) . . 14
Clutch Alignment Bar . . . . . . . . . . . . . . . . . (p/n 0644-320) . . 14
Clutch Alignment Bar . . . . . . (p/n 0644-246,428,427,496) . . 15
Gear Case Seal Installation Tool . . . . . . . . . (p/n 0644-537) . . 15
Clutch Alignment Bar
(Drive/Driven Parallelism) . . . . . . . . . . . . (p/n 0644-509) . . 15
Clutch Compressor (6-Post) . . . . . . . . . . . . (p/n 0644-420) . . 16
Clutch Compressor (9-Post) . . . . . . . . . . . . (p/n 0644-245) . . 16
Clutch Compressor (Comet) . . . . . . . . . . . . (p/n 0644-123) . . 16
Drive Clutch Bolt Tool (4-Roller) . . . . . . . . . (p/n 0644-281) . . 16
Clutch Puller (Arctic) . . . . . . . . . . . . . . . . . . (p/n 0644-207) . . 16
Clutch Puller (Comet) . . . . . . . . . . . . . . . . . (p/n 0644-096) . . 16
Clutch Puller (Comet) . . . . . . . . . . . . . . . . . (p/n 0644-100) . . 17
Clutch Puller . . . . . . . . . . . . . . . . . . . . . . . . (p/n 0744-052) . . 17
Drive Belt Deflection Tool . . . . . . . . . . . . . . (p/n 0644-412) . . 17
Drive Belt Deflection Tool . . . . . . . . . . . . . . (p/n 0644-424) . . 17
Drive Belt Gauge. . . . . . . . . . . . . . . . . . . . . (p/n 0644-443) . . 17
Drive Belt Replacement Tool . . . . . . . . . . . . (p/n 0644-435) . . 17
Drive Clutch Spanner Wrench. . . . . . . . . . . (p/n 0644-136) . . 18
Driven Pulley Puller. . . . . . . . . . . . . . . . . . . (p/n 0744-023) . . 18
Driven Pulley Puller - ACT. . . . . . . . . . (p/n 0644-469,468) . . 18
Driven Shaft Bearing Spanner
Wrench Kit. . . . . . . . . . . . . . . . . . . . . . . . (p/n 0744-054) . . 18
Driven Pulley Compressor Tool . . . . . . . . . . (p/n 0644-444) . . 18
Driven Pulley Spring Adjustment Tool . . . . . (p/n 0644-413) . . 19
Reverse Gear Adjustment Gauge . . . . . . . . (p/n 0644-244) . . 19
Roller Pin Removal Tool . . . . . . . . . . . . . . . (p/n 0644-276) . . 19
Spider Removal Kit . . . . . . . . . . . . . . . . . . . (p/n 0644-449) . . 19
Spider Removal Kit (4-Roller) . . . . . . . . . . . (p/n 0644-505) . . 19
Track Clip Installation Tool . . . . . . . . . . . . . . (p/n 0644-194) . . 20
Track Stud Hole Drill (7 mm) . . . . . . . . . . . . (p/n 1639-629) . . 20
Chassis/Suspension . . . . . . . . . . . . . . . . . . . . . 20-24
Ball Joint Fork . . . . . . . . . . . . . . . . . . . . . . .(p/n 0644-098) . . 20
Idler Wheel Alignment Tool . . . . . . . . . . . . . (p/n 0644-228) . . 20
Idler Wheel Puller Kit. . . . . . . . . . . . . . (p/n 0644-122,400) . . 20
Bearing Cap Seal
Protector . . . . . . . . . . . . . . (p/n 0644-268,403,404,542) . . 21
Floating Piston Location Gauge . . . . . . . . . (p/n 0644-350) . . 21
Bellcrank Centering Tool . . . . . . . . . . . . . . . (p/n 0644-541) . . 21
Floating Piston Removal Tool . . . . . . . . . . . (p/n 0644-348) . . 21
Floating Piston Installation/Location
Tool Kit. . . . . . . . . . . . . . . . . . . . . . . . . . .(p/n 0644-402) . . 21
Gas Shock Retaining Blocks (Zero Pro) . . . (p/n 0644-486) . . 21
Gas Shock Rod/Body Clamping Tool . . . . .(p/n 0644-425) . . 22
Inflation Needle . . . . . . . . . . . . . . . . . . . . . .(p/n 0744-020) . . 22
Inflation Needle Replacement. . . . . . . . . . . (p/n 0644-544) . . 22
Inflation Needle Replacement Tip. . . . . . . . (p/n 0644-539) . . 22
Nitrogen Regulator . . . . . . . . . . . . . . . . . . . (p/n 0644-151) . . 22
Piston Location Tool . . . . . . . . . . . . . . . . . . (p/n 0644-169) . . 22
Shock Absorber Air Pump. . . . . . . . . . . . . . (p/n 2603-614) . . 23
Rear Shock Adjuster . . . . . . . . . . . . . . . . . . (p/n 0644-015) . . 23
Shock Spanner Wrench . . . . . . . . . . . . . . . (p/n 0644-447) . . 23
Gas Shock Shaft Clamping Tool . . . . . . . . . (p/n 0644-543) . . 23
Shock Spanner Wrench . . . . . . . . . . . . . . . (p/n 0644-305) . . 23
Shock Spring Removal Tool . . . . . . . . . . . .(p/n 0644-057) . . 23
Spanner Wrench - Fox Float Shock . . . . . . (p/n 0644-453) . . 24
Rear Axle Nut Socket . . . . . . . . . . . . . . . . . (p/n 0644-399) . . 24
Axle Nut Spanner Wrench. . . . . . . . . . . . . . (p/n 0644-454) . . 24
Ski Alignment Tool. . . . . . . . . . . . . . . . . . . . (p/n 0644-457) . . 24
Rear Suspension Spring Tool . . . . . . . . . . . (p/n 0144-311) . . 24
Miscellany . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-26
Hex Bits (1/4 in. Hex Drive) . . . . . . . . . (p/n 0644-317,316) . . 24
Insert Holder (5/16 in.) . . . . . . . . . . . . . . . .(p/n 0644-315) . . 25
Jack Stand. . . . . . . . . . . . . . . . . .(p/n 0644-076/2639-799) . . 25
Phillips-Head Bits (1/4 in. Hex Drive) . (p/n 0644-319,318) . . 25
Quick-Disconnect Coupler. . . . . . . . . . . . . .(p/n 0644-308) . . 25
Replacement Bolt (Side) . . . . . . . . . . . . . . . (p/n 0644-101) . . 25
Replacement Rivnuts . . . . . . (p/n 0623-557,582/627,581)
. . . . . . . . . . . . . . . . . . . . . . . (p/n 0623-699,874,529/779) . . 25
Rivnut Tool . . . . . . . . . . . . . . . . . . . . . . . . . (p/n 0644-232) . . 26
Rivnut Tool Insert Bit . . . . . . . (p/n 0644-233,405,430,431) . . 26
T-Handle Wrench. . . . . . . . . . (p/n 0644-257,024,025,026) . . 26
T Wrench. . . . . . . . . . . . . . . . . . . . . . . . . . . (p/n 0644-021) . . 26
Torx Bit Insert (5/16 in. Hex Drive) . . . . . . . (p/n 0644-314) . . 26
Torx Bits (1/4 in. Hex Drive). . (p/n 0644-312,393,215,313) . . 26
2
ENGINE
Angle Finder
p/n: 0644-097
Usage: Identify levelness and pitch.
Coolant Cap (Non-Pressurized)
p/n: 0644-156
Usage: Fill cooling system on models equipped with
pressurized coolant cap.
0644-156
0644-097
Ball Hone
p/n: 0644-290 (60-64 mm)
p/n: 0644-291 (65-70 mm)
p/n: 0644-292 (72-74 mm)
p/n: 0644-293 (76-83 mm)
p/n: 0644-294 (83-88 mm)
p/n: 0644-531 (90-95 mm)
p/n: 0644-532 (96-101 mm)
p/n: 0644-533 (102-108 mm)
Usage: Deglaze Nicosil plated cylinders. All are 320 grit
and are recommended for reconditioning all Arctic Cat
snowmobile engine cylinders (1976-2008).
Fan Spanner Wrench (Suzuki)
p/n: 0644-340
Usage: Hold axial fan in place during disassembly and
assembly.
0644-340
Flywheel Spanner Wrench
p/n: 0144-007
Usage: Hold starter cup while removing/installing fly-
wheel nut.
0644-291
0144-007
3
Duck-Foot T-Handle Wrench (8 mm)
p/n: 0644-332
Usage: Adjust oil-injection pump mechanical linkage.
Exhaust Spring Pliers (90°)
p/n: 0644-397
Usage: Remove/install exhaust springs.
0644-332
EFI Throttle Cable Jam Nut/
Oil-Injection Pump Jam Nut Wrench
(10 mm)
p/n: 0644-242
Usage: Loosen and tighten jam nuts on both the oil-injec-
tion pump and EFI throttle cable.
0644-242
Exhaust Spring Pliers (0°)
p/n: 0644-391
Usage: Remove/install exhaust springs.
0644-397
Crankshaft Protector Cap
p/n: 0644-234
Usage: Protect the crankshaft end during flywheel
removal.
0644-234
Flywheel Puller
p/n: 0744-040 (Complete Set)
p/n: 0643-086 (Body)
p/n: 0643-087 (Bolt)
p/n: 0423-482 (6 mm Cap Screw)
p/n: 0423-483 (8 mm Cap Screw)
Usage: Pull flywheel off crankshaft on all Arctic Cat 2-
stroke models.
0644-391
0744-040
4
Flywheel Puller
p/n: 0644-480 (Complete Set)
p/n: 0644-122 (Wrench)
p/n: 0644-133 (Bolt)
Usage: Pull flywheel off crankshaft on Z1 engine.
0644-480
Flywheel Puller Insert
p/n: 0644-179
Usage: Protect the crankshaft end on the 900 cc engine
during flywheel removal.
Idle Speed Screw Jam Nut Wrench
p/n: 0644-311
Usage: Loosen/tighten idle speed screw jam nut on bat-
teryless EFI system.
0644-311
Linkage Wrench (8 mm)
p/n: 0644-333
Usage: Adjust oil-injection pump mechanical linkage.
Crankshaft Bearing Remover
p/n: 0144-302
Usage: Remove crankshaft bearings.
0644-179
0144-302
0644-333
Oil Filter Wrench (Adjustable)
p/n: 0644-389
Usage: Remove oil filters from 4-stroke engines. Fea-
tures adjustments between 62-96 mm.
0644-389
5
Oil Injection Usage Tool
p/n: 0644-007
Usage: Measure exact amount of oil used by the oil injec-
tion pump during a given time period.
0644-007
Oil Seal Protector Tool
p/n: 0644-219
Usage: Protect the oil seal when installing the water
pump driveshaft on liquid cooled 2-stroke Arctic Cat
engines.
Piston Pin Puller
p/n: 0644-328 (Complete Set)
p/n: 0643-073 (Extractor Nut Only-Small)
p/n: 0643-074 (Extractor Nut Only-Medium)
p/n: 0643-075 (Extractor Nut Only-Large)
p/n: 0643-072 (Threaded T-Handle)
Usage: Remove piston pins.
0644-328
Rigid Hone Stone Set (2.7-4.1 in.)
p/n: 0644-043
Usage: Replacement stones for Cylinder Hone Set (p/n
0644-041).
0644-219
Blind-Hole Bearing Puller
p/n: 0644-500
Usage: Remove bearing from water pump on 1100 cc
engine.
AE152D
0644-043
Ring Compressor
p/n: 0644-378
Usage: Compress piston rings for cylinder installation.
Features a quick-release function for removing tool from
underside of piston.
0644-378
6
Spring Tool
p/n: 0644-072
Usage: Remove/install exhaust springs.
Surface Plate
p/n: 0644-016
Usage: True sealing surfaces.
0644-072
Starter Assembly Tool
p/n: 0644-052
Usage: Hold brushes for assembling UTC brand starter
motor.
0644-052
Stud Runner
p/n: 0644-018 (6 mm)
p/n: 0644-019 (8 mm)
p/n: 0644-020 (10 mm)
Usage: Install studs on cylinders and crankcase.
0644-016
V Blocks (Large)
p/n: 0644-535
Usage: Check crankshaft runout.
0644-535
V Blocks
p/n: 0644-022
Usage: Check crankshaft runout.
0644-020
0644-022
7
Valve and Spring Retainer Tool
p/n: 0644-448
Usage: Adjust intake valve and exhaust valve “lash clear-
ance” (2003-2008 660 cc 4-stroke engines).
Fuel Hose Clamp Tool
p/n: 0644-545
Usage: Install/tighten gasline hose clamps on 2007 and
newer models.
Valve Spring Compressor Tool
p/n: 0444-197
Usage: Remove/install valve springs on all 4-stroke
engines.
Hose Clamp Installation Tool
p/n: 0444-120
Usage: Install crimp clamps on cooling systems.
0644-448
0444-197
0644-545
Water Pump Bearing & Seal Tool Kit
p/n: 0644-502
Usage: Remove/install crankcase water pump bearings
and seals.
0644-502
DIAGNOSTICS
Battery Charger (1.5 Amp)
p/n: 0436-634
Usage: Charge sealed, maintenance-free 12 V batteries.
0444-120
0436-634
8
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