General Information Troubleshooting Lubrication, Maintenance and Tune-up Adjustments for Special Use
fuel System-Carbureted Models fuel System-fuel Injected Models Exhaust System Electrical Systems Oil Injection System Cooling System Recoil Starter Drive System Brake, Driven Shaft, Dropcase and Driveshaft front Suspension and Steering Track and Rear Suspension Off-season Storage Index Wiring Diagrams
Contents
QUICK REfERENCE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • • • • • • • • • • • • • • • • . . IX
CHAPTER ONE
GENERAL INFORMATION
1
Manual organization . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2 Notes, cautions and warnings. . . . . . . . . . . . . . . . . . . .. 2 Safety first . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2 Service hints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3 Engine and chassis serial numbers . . . . . . . . . . . . . . . .. 5 Engine operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6 Torque specifications. . . . . . . . . . . . . . . . . . . . . . . . . . .. 7 Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 7 Lubricants. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 12 RTV gasket sealant . . . . . . . . . . . . . . . . . . . . . . . . . . .. 13 Threadlock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 13
Gasket remover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Expendable supplies . . . . . . . . . . . . . . . . . . . . . . . . . .. Basic hand tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Precision measuring tools. . . . . . . . . . . . . . . . . . . . . .. Special tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Mechanic's tips. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Ball bearing replacement. . . . . . . . . . . . . . . . . . . . . . .. Seals ........................................ Snowmobile operation. . . . . . . . . . . . . . . . . . . . . . . . .. Snowmobile safety ... . . . . . . . . . . . . . . . . . . . . . . . .. Snowmobile code of ethics. . . . . . . . . . . . . . . . . . . . ..
14 14 14 19 23 25 28 31 32 34 34
CHAPTER TWO TROUBLESHOOTING ......................•.•.•..... Operating requirements. . . . . . . . . . . . . . . . . . . . . . . .. Troubleshooting instruments. . . . . . . . . . . . . . . . . . . .. Testing electrical components . . . . . . . . . . . . . . . . . . .. Engine electrical system troubleshooting ........... Voltage regulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
46 46 46 47 54 54
eo.
•
•
•
•
•
•
•
•
•
•
•
•
•
•
••
55 55 59 61 64 64
Daily maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . .. Weekly maintenance. . . . . . . . . . . . . . . . . . . . . . . . . .. Monthly maintenance. . . . . . . . . . . . . . . . . . . . . . . . .. Non-scheduled maintenance. . . . . . . . . . . . . . . . . . . .. General inspection and maintenance. . . . . . . . . . . . . .. Engine tune-up .... . . . . . . . . . . . . . . . . . . . . . . . . ..
82 85 90 91 98 100
CHAPTER THREE LUBRICATION, MAINTENANCE AND TUNE-UP Pre-ride checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Fluid checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Break-in procedure ............................ Maintenance schedules . . . . . . . . . . . . . . . . . . . . . . . .. Lubrication ................................... Air cooling system ............................. Liquid cooling system. . . . . . . . . . . . . . . . . . . . . . . . ..
72 72 72 73 74 77 79
45
Electronic fuel injection .. . . . . . . . . . . . . . . . . . . . . .. Engine ...................................... Two-stroke pressure testing. . . . . . . . . . . . . . . . . . . . .. Power train. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Skis and steering. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Track assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
72
CHAPTER FOUR ADJUSTMENTS FOR SPECIAL USE
125
Carburetor tuning. . . . . . . . . . . . . . . . . . . . . . . . . . . .. 125 High-altitude clutch tuning. . . . . . . . . . . . . . . . . . . .. 133
Gearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 133 Spring suspension adjustment. . . . . . . . . . . . . . . . . .. 133
CHAPTER FIVE
ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Engine number identification. . . . . . . . . . . . . . . . . .. Engine lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . .. Service precautions. . . . . . . . . . . . . . . . . . . . . . . . . .. Servicing engine in frame . . . . . . . . . . . . . . . . . . . . .. Engine removal .............................. Engine mounts ............................... Engine installation. . . . . . . . . . . . . . . . . . . . . . . . . . .. Engine top end ...............................
149 150 150 151 151 154 156 158
Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Piston, piston pin, and piston rings .. . . . . . . . . . . .. Reed valve assembly (1990-1991 EI Tigre) ........ Reed valve assembly (437.4,497,594 and 599 cc engines). . . . . . . . . . .. Crankcase and crankshaft . . . . . . . . . . . . . . . . . . . . .. Driveshaft for coolant pump and oil injection pump . . . . . . . . . . . . . . . . . . . . . ..
149 166 170 180 182 184 198
CHAPTER SIX FUEL SYSTEM-CARBURETED MODELS. • • • . • . . . . . . . . . . . • . • • . . • . . . • . . • • . . .. Air silencer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 211 Fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 220 Altitude compensator. . . . . . . . . . . . . . . . . . . . . . . . .. 220
CHAPTER SEVEN FUEL SYSTEM-FUEL INJECTED MODELS • . . . . . . . . . . • • . . . . . . . . . . . . . . . . • • . . .. Fuel injection system components ............... 229 Testing and troubleshooting (EFI powered by battery). . . . . . . . . . . . . . . . . . . .. 232
21 1
Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 221 Throttle cable replacement . . . . . . . . . . . . . . . . . . . .. 222
227
Testing and troubleshooting (EFI system magneto-powered). . . . . . . . . . . . . . .. 242 Component service. . . . . . . . . . . . . . . . . . . . . . . . . .. 246 Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 254
CHAPTER EIGHT EXHAUST SYSTEM. • . . . . . . . . . • • • • • • • • • . • • . . . . • • • • • • • • • • • • • • . . . . . . . . . ..
262
Exhaust system repair. . . . . . . . . . . . . . . . . . . . . . . .. 266
CHAPTER NINE ELECTRICAL SYSTEM. • . • • • • • • • • • • • • • . . . . . . . . • . • • • . . . . . . . . . . . . • . . • • . . •• Flywheel and stator assembly. . . . . . . . . . . . . . . . . .. Ignition coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. cm unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Voltage regulator. . . . . . . . . . . . . . . . . . . . . . . . . . . .. Lighting system. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Instrument assembly . . . . . . . . . . . . . . . . . . . . . . . . ..
268 282 283 284 284 285
Warning lamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Fuel level sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Oil level gauge ............................... Electric starting motor. . . . . . . . . . . . . . . . . . . . . . . .. Wiring diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
CHAPTER TEN OIL INJECTION SYSTEM. • . • . • . . • • . • • • • • • • • • • • • • • • • . • . . . . . . . . . . . . . . . . • .. System components. . . . . . . . . . . . . . . . . . . . . . . . . .. 295 Oil pump service . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 295
268 286 287 289 289 289 293
295
Component replacement. . . . . . . . . . . . . . . . . . . . . .. 296 Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 297
CHAPTER ELEVEN COOLING SYSTEMS. . . • • . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • .. Fan-cooled models ............................ 300
Liquid-cooled models ....................... "
300 303
CHAPTER TWELVE RECOIL STARTER .••. . . . . • • • • • . . . . . . • • • • • • . . . . . . . . • . • • • . . . . . . • • • • . . .•
3 t4
CHAPTER THIRTEEN DRIVE SYSTEM . . . • . . . . . . . • • . . . . . . . . . • • • • . . . . . . . . • • . • • . . . . . . . • • • • . . ..
324
Drive unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 324 Drive pulley assembly. . . . . . . . . . . . . . . . . . . . . . . .. 325 Driven pulley. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 328
Drive belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 330 Drive pulley service. . . . . . . . . . . . . . . . . . . . . . . . . .. 334 Driven pulley service. . . . . . . . . . . . . . . . . . . . . . . . .. 345
CHAPTER fOURTEEN BRAKE, DRIVEN SHAfT, DROPCASE AND DRIVESHAfT . . . . . • • • • • • • . . . . . • • • • . .. Drive chain and sprockets (models without reverse) ...................... 370 Drive chain and sprockets (models with reverse) .... 374 External chain tensioner . . . . . . . . . . . . . . . . . . . . . .. 380
Driven shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Driveshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Mechanical brake system . . . . . . . . . . . . . . . . . . . . .. Hydraulic brake system ........................
370 38 I 384 387 393
CHAPTER fifTEEN fRONT SUSPENSION AND STEERING. . . . . . . . . . . . . . . . . . • • • • . . . . . . . . . . • • • • .. 401 Skis ....................................... 401 Front suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 406
Steering assembly .......................... " 422 Steering adjustment. . . . . . . . . . . . . . . . . . . . . . . . . .. 428
CHAPTER SIXTEEN TRACK AND REAR SUSPENSION. . . . . . . . . . • • • . . . . • • . . . . . . . . . . . . . . . . . . . • .. Rear suspension. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Wear strips. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. End caps .................................... Shock absorbers .............................. Front arm spring ....... . . . . . . . . . . . . . . . . . . . . .. Rear spring ..................................
432 434 435 435 457 457
Front arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Rear arm and lower arm . . . . . . . . . . . . . . . . . . . . . .. Idler wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Track ... , ..................................
CHAPTER SEVENTEEN OFF-SEASON STORAGE. . . . . • • • . . . . . • • • • • . . . • • • • • . . . . . . . . • . . • . . • • • . . . ..
432 459 460 461 461 462
467
INDEX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 47 t
WIRING DIAGRAMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 473
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DRIVE·· BELT. 'PECIFICATIONS(contin~ed) Model
Part No.
1997 EXT 580 EFI
0627-012
Powder SpeciaiEFI
0627-012 0621-010 0627*010
ZRT600
Powder Extreme·
0627-010 0621-010
34-36
t2~121
(1.3~1H·417')
(47.2447.64) 120-121· (47.24-41.64)
34..36 (1.339-1.417) 34-36 .. .(1.339..1.411) 34~36
(1.339-1.417) 34-36 (1.339-1.417) 34-36 (1.339~1.417)
1998 Z440
0621-012
ZL440
0627-021
ZR440
0621-020
Panther 440
0627~1
34-36 (1.339"1.417) 34-36 (1.339-1.417) 34-36 (1.339~1.417)
ZLSOO
0621·020
Cougar
0621~021
Panther 550 Pantera
EXT 580 EFI
0621"021 0621"021 • 0621-021
POWder special EFt
0621-020.
ZR600
0621·020
·E){T600
0621-029
ZRt600
0627-020
34..36 (1.339-1 ;417) 34-36 (1.339-1.417) 34-36 (1.339-1.41.7)
12~121
.. (47;2441.64) 120-121 (47.24-41.64) 120-121 (47.2447;64) 120-121 (47.2447.64) 120':121 (47.24-47.64)· . 12~121
(47.2447;64) .. 120-121· ... (47.24-41.64) 12~121
(47.24-41.64)
34~36
12~121
{1.339-1.417}
(47,2441.64) . 120-121 (47.2447.64)
34~36
(1.339-1.417) 34-36 (1.339-1.417) 34-36 (1.339~1.417)
Powder Extreme
120~t21
(41.2447.$4) 120;;121 . (47.2441.64) •
34·36 (1.339-10417) 34*36
12~121
(47.2447.64) 120...121·· (47.24-47.64) t2~121
(47:2441.64) 12~121 ..
(1~339-1.417) .
(47~24-41.64)
34-36 (1.339-1;417) 34..36. (1.339-1.417)
(47;24-47.64) 12Q:121 ..... (47.2447.64)
12~t21
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Chapter One
General Information
This Clymer shop manual covers the 1990-1998 Arctic Cat Prowler, Cougar, Panther 440, Panther 550, EXT 550, EXT 580, EXT 600, Z 440, ZL 440, ZR 440, ZR 580, ZR 600, ZRT 600, Powder Special and Powder Extreme models. Troubleshooting, tune-up, maintenance and repair are not difficult if you know what tools and equipment to use, as well as the proper procedures. Step-by-step instructions guide you through jobs ranging from simple maintenance to complete engine and suspension overhaul. This manual can be used by anyone from a first time do-it-yourselfer to a professional mechanic. Detailed drawings and clear photographs give you all the information you need to do the work right. Some of the procedures in this manual require the use of special tools. The resourceful mechanic can, in many cases, think of acceptable substitutes for special tools. This can be as simple as using a few pieces of threaded rod, washers and nuts to remove a bearing or fabricating a
tool from scrap material. However, using a substitute for a special tool is not recommended as it could damage the part. If you find that a tool can be designed and safely made, but will require some type of machine work, you may want to search out a local community college or high school that has a machine shop curriculum. Industrial arts instructors sometimes welcome outside work that can be used as practical shop applications for advanced students. Tables appearing at the end ofthis chapter provide useful general information for service. Tables 1-8 are at the end of the chapter. Table 1 lists model number coverage and engine displacement. General dimensions are listed in Table 2. Table 3 lists vehicle weight. Metric and u.S. standards are used throughout this manual. U.S. to metric conversion is given in Table 4. Critical torque specifications are found in table form at the end of each chapter (as required). The general torque specifications listed in Table 5 can be used when a torque specification is not listed for a specific component or assembly.
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CHAPTER ONE
2
A list of technical abbreviations are given in Table 6. Metric tap drill sizes can be found in Table 7. Table 8 lists wind chill factors. MANUAL ORGANIZATION This chapter provides general information useful to snowmobile owners and mechanics. In addition, information in this chapter discusses the tools and techniques for preventive maintenance, troubleshooting and repair. Chapter Two contains methods and suggestions for quick and accurate diagnosis and repair of problems. Troubleshooting procedures discuss typical symptoms and logical methods to pinpoint the trouble. Chapter Three explains all the periodic lubrication and routine maintenance necessary to keep your snowmobile operating well. Chapter Three also includes recommended tune-up procedures, eliminating the need to frequently consult other chapters on the various assemblies. Subsequent chapters describe specific systems, providing disassembly, repair, assembly and adjustment procedures in simple step-bystep form. If a repair is impractical for a home mechanic, it is indicated. It is usually faster and less expensive to take such repairs to a dealership or competent repair shop. Specifications concerning a specific system are included at the end of the appropriate chapter.
CAUTION could cause permanent mechanical damage; however, personal injury is unlikely. A WARNING emphasizes an area where personal injury or even death could result from negligence. Mechanical damage may also occur. WARNINGS are to be taken seriously. In some cases, serious injury and death have resulted from disregarding similar warnings. SAFETY FIRST Professional mechanics can work for years and never sustain a serious injury. If you observe a few rules of common sense and safety, you can enjoy many safe hours servicing your own machine. If you ignore these rules you can hurt yourself or damage the equipment. 1. Never use gasoline as a cleaning solvent. 2. Never smoke or use a torch in the vicinity of flammable liquids, such as cleaning solvent, in open containers. 3. If welding or brazing is required on the snowmobile, remove the fuel tank to a safe distance, at least 50 feet away. 4. Use the properly sized wrenches to avoid damage to fasteners and injury to yourself. 5. When loosening a tight or stuck nut, be guided by what would happen if the wrench should slip. Be careful and protect yourself accordingly.
NOTES, CAUTIONS AND WARNINGS The terms NOTE, CAUTION and WARNING have specific meanings in this manual. A NOTE provides additional information to make a step or procedure easier or clearer. Disregarding a NOTE could cause inconvenience, but it would not cause damage or personal injury. A CAUTION emphasizes an area where equipment damage could occur. Disregarding a
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GENERAL INFORMATION
6. When replacing a fastener, make sure you use one with the same measurements and strength as the old one. Incorrect or mismatched fasteners can result in damage to the snowmobile and possible personal injury. Beware of fastener kits that are filled with inexpensive and poorly made nuts, bolts, washers and cotter pins. Refer to Fasteners in this chapter for additional information. 7. Keep all hand and power tools in good condition. Wipe greasy and oily tools after using
them. They are difficult to hold and can cause injury. Replace or repair worn or damaged tools. 8. Keep your work area clean and uncluttered. 9. Wear safety goggles during all operations involving drilling, grinding, using a cold chisel or anytime you feel unsure about the safety of your eyes. Wear safety goggles anytime you clean parts using solvent or compressed air. 10. Keep an approved fire extinguisher (Figure 1) nearby. Be sure it is rated for gasoline (Class B) and electrical (Class C) fires. 11. If drying bearings or other rotating parts with compressed air, never allow the air jet to rotate the bearing or part. The air jet is capable of rotating them at speeds far in excess of those for which they were designed. The bearing or rotating part is very likely to disintegrate and cause serious injury and damage. To prevent bearing damage when using compressed air, hold the inner bearing race (Figure 2) with your hand.
SERVICE HINTS
.. Left
FRONT
REAR
... Right
Most of the service procedures covered in this book are straightforward and can be performed by anyone reasonably handy with tools. It is suggested, however, that you consider your own capabilities carefully before attempting any operation involving major disassembly. 1. Front, as used in this manual, refers to the front of the snowmobile; the front of any component is the end closest to the front of the snowmobile. The left and right sides refer to the position of the parts as viewed by a rider sitting and facing forward. For example, the throttle control is on the right side. These rules are simple, but confusion can cause a major inconvenience during service (Figure 3). 2. When disassembling any engine or drive component, mark the parts for location and mark all parts that mate together. Small parts, such as bolts, can be identified by placing them in plastic
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4
sandwich bags (Figure 4). Seal the bags and label them with masking tape and a marking pen. 3. Finished surfaces should be protected from physical damage or corrosion. Keep fuel off painted surfaces. 4. Use penetrating oil on frozen or tight bolts to help loosen them, then strike the bolt head a few times with a hammer and punch (use a screwdriver on screws). Avoid the use of heat where possible, as it can warp, melt or affect the temper of parts. Heat also ruins finishes, especially paint and plastics. 5. No parts removed or installed, other than bushings and bearings, in the procedures given in this manual should require unusual force during disassembly or assembly. If a part is difficult to remove or install, find out why before proceeding. 6. Cover all openings after removing parts or components to prevent the entrance of debris or small objects. 7. Read each procedure completely while looking at the actual parts before starting a job. Make sure you thoroughly understand what is to be done and then carefully follow the procedure, step by step.
CHAPTER ONE
11. Repairs go much faster and easier if your machine is clean before you begin work. There are many special cleaners on the market, like Bel-Ray Degreaser, for washing the engine and related parts. Follow the manufacturer's directions on the container for the best results. Clean all oily or greasy parts with cleaning solvent as you remove them. WARNING Never use gasoline as a cleaning agent. It presents an extreme fire hazard. Be sure to work in a well-ventilated area when using cleaning solvent. Keep a fire extinguisher, rated for gasoline fires, handy in any case.
12. Much of the labor charges for repairs made by dealers are for the time involved during the removal, disassembly, assembly, and reinstallation of other parts in order to reach the defective
8. Recommendations are occasionally made to refer service or maintenance to a snowmobile dealer or a specialist in a particular field. In these cases, the work will be done more quickly and economically than if you performed the job yourself. 9. In procedural steps, the term replace means to discard a defective part and replace it with a new or exchange unit. Overhaul means to remove, disassemble, inspect, measure, repair or replace defective parts, reassemble and install major systems or parts. 10. Some operations require the use of a hydraulic press. It is wiser to have these operations performed by a shop equipped for such work, than to try to do the job yourself with makeshift equipment that may damage your machine.
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5
GENERAL INFORMATION
part. It is frequently possible to perform the preliminary operations yourself and then take the defective unit to the dealer for repair at considerable savings. 13. If special tools are required, make arrangements to get them before you start. It is frustrating and time-consuming to get partly into a job and then be unable to complete it. 14. Make diagrams (take a video or Polaroid picture) wherever similar-appearing parts are found or parts must be installed in a certain order or location. For instance, crankcase bolts may have differing lengths. A faulty memory can result in costly mistakes. Laying out parts in their proper order is a good practice, but if the parts are disturbed the exercise is a waste of time. 15. When assembling parts, be sure all shims and washers are replaced exactly as they came out. 16. Whenever a rotating part butts against a stationary part, look for a shim or washer. Use new gaskets if there is any doubt about the condition of the old ones. A thin coat of silicone sealant on non-pressure type gaskets may help them seal more effectively. 17. If it is necessary to make a cover gasket and you do not have a suitable old gasket to use as a guide, you can use the outline of the cover and gasket material to make a new gasket. Apply engine oil to the cover gasket surface. Then place the cover on the new gasket material and apply
pressure with your hands. The oil will leave a very accurate outline on the gasket material that can be cut around. CAUTION If purchasing gasket material, measure the thickness of the old gasket (at an uncompressed point) and purchase gasket material with the same approximate thickness.
18. Heavy grease can be used to hold small parts in place if they tend to fall out during assembly. Be sure to keep grease and oil away from electrical components. 19. A carburetor is best cleaned by disassembling it and cleaning the parts in hot soap and water. Never soak gaskets and rubber parts in commercial carburetor cleaners. Never use wire to clean out jets and air passages because that will damage them easily. Use compressed air to blowout the carburetor only if the float has been removed first. 20. Take your time and do the job right. Do not forget that a newly rebuilt engine must be broken in just like a new one. ENGINE AND CHASSIS SERIAL NUMBERS
Arctic Cat snowmobiles are identified by frame and engine identification numbers. The frame or Vehicle Identification Number (VIN) is stamped on the right side of the tunnel just below the front of the seat (Figure 5). The engine number is stamped on the side of the crankcase as shown in Figure 6. The engine model number is also listed on a decal located on the fan or magneto housing as shown in Figure 7. Write all the serial numbers and model numbers applicable to your machine in the front of this book. Take the serial numbers and model numbers with you when you order parts from the dealer. Always order parts by year and engine and machine numbers. If possible, compare the
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