2009 arctic cat crossfire 8 sno pro 141 snowmobiles service repair manual by 1639701yu

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 M M/I N. 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

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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 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.

RECOMMENDED GASOLINE (Carbureted Models)

The recommended gasoline to use in these snowmobiles 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 carburetor 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 gasoline antifreeze is not necessary since ethanol will prevent the accumulation of moisture in the fuel system. RECOMMENDED GASOLINE (EFI Models)

VIN

The recommended gasoline to use in these snowmobiles 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.

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 Arctic Cat Inc. if the engine serial number or VIN is removed or mutilated in any way.

Recommended Gasoline and Oil

CAUTION

Do not use white gas or gasolines containing methanol. Only Arctic Cat approved gasoline additives should be used.

-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 carbureted model break-in) and meets all of the lubrication requirements of the Arctic Cat snowmobile engine. RECOMMENDED OIL (120 ee)

The recommended oil to use is a multi-grade oil calibrated to the ambient temperature at which the engine is run. See the viscosity chart for details.

CAUTION

Any oil used in place of the recommended oil may cause serious damage.

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120 ee Multi-Grade

The Arctic Cat engine requires a short break-in period (approximately 10 operating hours) before being subjected to heavy load conditions or full-throttle operation. Strict adherence to the break-in procedure will contribute to optimum performance and longevity of the engine.

SAE #

ENGINE OIL ~c

-35 -29 -23 -18 "12 -7 1 " 10 15 21 21 32 0 10 20 30 40 SO 60 10 80 90

TEMP ~F -30 -.20 -10

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

During break-in, a maximum of 112 throttle is recommended; however, brief full-throttle accelerations and variations in driving speeds contribute to good engine break-in. After the 10 hour break-in period, the snowmobile may be taken to an authorized Arctic Cat Snowmobile dealer for a checkup and oil change at the discretion and expense of the 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 during the break-in period.

ENGINE OIL

____-3_0_-_20_-_10__0__1_0__20__30__4_0~

TEMP~OC

-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 prolonged 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 accelerations and variations in driving speeds contribute to good engine break-in.

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 recommends 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 genuine Arctic Cat parts. They are precision-made to ensure high quality and correct fit.

High Altitude Operation

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 (-26Â°C/-15Â°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.

Operating a snowmobile at varying altitudes requires changes in performance components. These changes affect drive train components and carburetion components (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

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.

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 clutching, engine, suspension, and track. CLUTCHING

As altitude changes, engine horsepower changes with it. As you go up in altitude, the engine loses horsepower. Because of this, the constant velocity transmission (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 engagement 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 of gravity 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 upshift. If the up-shift is too quick, due to a very steep helix, RPM will be pulled down under the peak operating 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.

ENGINE

A normally aspirated engine will generate more horsepower at sea level than it does at higher altitudes. Many reasons for this are possible, but the biggest reason 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 correct 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 of these characteristics will become more evident the higher the altitude. It will be necessary to make changes to the fuel systems (carbureted models) and drive systems that support 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 downstream of the turbocharger thus limiting the compressor 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 diaphragm to the waste-gate control arm.

Carburetor calibration changes for high altitude operation 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

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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 turbocharger 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 of terrain are all factors that affect the suspension at high altitude. Trail riding versus powder snow riding versus combination riding will all require different suspension settings. 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 of the 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 suspension 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 of the snowmobile will improve on the trail but will affect the performance 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. Several 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 tension; ski pressure can be decreased by relaxing spring tension. Springs with different spring rates are available 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 of the snowmobile. On the Sno Pro models with air shocks, they are individually adjustable for the terrain conditions 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 MSeries Sno Pro models. The shocks can be "finetuned" to match the operator's weight, riding style, and terrain conditions. -NOTE: Care should be taken to have equal pressure in the ski shocks before operating the snowmobile.

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 of the 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. Generally, 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.

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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 penetrating 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 riding 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 lubrication, 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 lubricating 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 illuminate each time the ignition switch is turned to RUN or START, and it should go out when the engine starts. If the 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 snowmobile should be on level ground.

2. If the 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 deterioration. To prepare the snowmobile for storage, Arctic Cat recommends the following procedure: 1. Clean the seat cushion with a damp cloth and Arctic 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 of the 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:

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A. Disconnect the high tension leads from the spark plugs; then remove the plugs, connect them to the leads, and ground them on the cylinder 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 petroleumbased 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 tension leads.

9. On carbureted models, drain the gas from each carburetor float chamber. 10. Fill the gas tank to its rated capacity; then add Arctic Cat Fuel Stabilizer to the gas tank following directions on the container for the stabilizer/gasoline 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 pulley. 14. Apply light oil to the shafts of the 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-temperature grease. 15. 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. 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 DAMAGE 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 prolonged 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 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, ventilated tarpaulin to protect it from dirt and dust. 19. 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, ventilated tarpaulin 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 exterior of the snowmobile. 2. Clean the engine. Remove the cloth from the exhaust system. Check exhaust system and air silencer for obstructions.

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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 damaged 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 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 on the 2-stroke models, fill the oil-injection reservoir with the recommended 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 lubrication.

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 carbureted 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 causing 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 tightened to specifications. 10. On the 120 cc, inspect the drive chain and drive chain tightener. Replace if necessary; then lubricate the binding screw drum with WD-40 and the drive chain with a dry, graphite-based chain lubricant. 11. If not done during preparation for storage, lubricate all grease fittings (front and rear suspension, spindles, and upper steering shafts on the Crossfire/MSeries or steering arms on the BearcatlF -Series/Z 11 T-Series) with a low-temperature grease. 12. On liquid cooled models, check the coolant level and all coolant hoses and connections for deterioration 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 system. 15. Inspect the entire brake system, all controls, headlight, taillight, brakelight, ski wear bars, and headlight aim; adjust or replace as necessary. 16. Adjust the track to the proper tension and alignment. 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 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 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, 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 Section 6 of this 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.

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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 (0Â° 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 seizure.

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 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. 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 performance is experienced, the drive clutch/driven pulley alignment must be checked. TRACK TENSION AND ALIGNMENT - A certain 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 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, 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 o o o o o o o o o o o o o o o

Jet carburetors according to average temperature, type of gasoline being used, and altitude (570 cc) Check drive belt deflection - drive clutch/driven pulley alignment and parallelism (800/1000/ 1100cc) Adjust track tension and alignment Check throttle cable tension Check oil-injection pump adjustment (2-stroke) Check engine idle Check coolant level Check gear case lubricant level Check engine oil (4-stroke) Check lights (high/low beam, brakelight) Check safety switch operation Check engine compartment 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

2009 Arctic Cat Snowmobiles Factory Service Manual - all Models - www.ReadManuals.com

1-9

Engine Specifications (2-Stroke) 500 cc

ITEM Engine Model Number

570 cc

600 cc

800 cc

1000 cc

AX50L7

AA56A8

AJ60L6

AB80L3

AB10L3

Displacement

499 cc

565 cc

599 cc

794 cc

999 cc

No. of Cylinders

Bore x Stroke

71 x 63

73.8 x 66

73.8 x 70

85 x 70

90.3 x 78 6.41 :1

Compression Ratio

6.38:1

6.41 :1

6.46:1

6.39:1

Cooling System

Liquid

Fan

Liquid

Fuel Mixture

Oil Injection

Ignition Timing (Engine Warm)

12° @ 2000 RPM 0.034 in.

20° @ 2000 RPM 0.099 in.

15° @ 2000 RPM 0.059 in.

25° @ 3250 RPM 0.162 in.

20° @ 3750 @ 1800 RPM* RPM** 0.113 in. 0.057 in.

Spark Plug (NGK)

BR9EYA

Spark Plug Gap

0.028-0.031 in.

Piston Skirt/Cylinder Clearance

0.0030-0.0041 in.

0.0033-0.0045 in.

0.0030-0.0041 in.

Piston Ring End Gap

0.008-0.016 in.

0.012-0.0196 in.

Cylinder Trueness Limit

0.004 in.

Piston Pin Diameter

0.8659-0.8661 in.

0.7085-0.7087 in.

0.8659-0.8661 in.

0.9447-0.9449 in.

Piston Pin Bore Diameter

0.8661-0.8665 in.

0.7087-0.7091 in.

0.8661-0.8665 in.

0.9450-0.9453 in.

Connecting Rod Small End Bore

1.0631-1.0634 in.

0.9056-0.9059 in.

1.0631-1.0634 in.

1.1418-1.1422 in.

Connecting Rod Radial Play

0.0001-0.0008 in.

Crankshaft Runout (t.i.r.)

0.002 in.

Crankshaft End Play

0.002-0.004 in.

Reed Stopper Height

0.315 in.

0.236 in.

0.433 in.

0.512 in.

* F-Series ** Crossfire/M-Series

1-10

2009 Arctic Cat Snowmobiles Factory Service Manual - all Models - www.ReadManuals.com

Engine Specifications

(120 ee)

(1100 ee) 120 cc

ITEM Engine Model Number

AA12A2

Displacement

119 cc

No. of Cylinders

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) (Exh)

0.0032 in. 0.0039 in.

1100 cc

ITEM Engine Model Number

AA11L1

Displacement

1056 cc

No. of Cylinders

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 (Non-Turbo)

0.0004-0.0010 in.

Piston Pin/Connecting Rod Small End Clearance (Turbo)

0.0004-0.0009 in.

Piston Ring End Gap

0.0059-0.0138 in. 0.0118-0.0177 in. 0.0078-0.0275 in.

Piston Ring/Groove Clearance

(1st) (2nd) (Oil) (1st - Top) (1st - Bottom) (2nd) (Oil)

0.0059-0.0074 0.0008-0.0035 0.0008-0.0024 0.0024-0.0059

in. in. in. in.

Piston Diameter (10 mm from skirt edge) (Non-Turbo)

3.8568-3.8574 in.

Piston Diameter (10 mm from skirt edge) (Turbo)

3.8574-3.8580 in.

Valve Guide Bore Diameter

0.4409-0.4416 in.

Cylinder/Head Distortion (max)

0.002 in.

Valve Face Width

0.032-0.039 in.

0.866-0.867 in.

Valve Face Runout (max)

0.0012 in.

Connecting Rod Small End Bore Inside Diameter (Non-Turbo)

Valve Clearance - Cold (59째_77째 F)

(IntlExh)

0.030-0.070 in.

Connecting Rod Small End Bore Inside Diameter (Turbo)

0.945-0.946 in.

Valve Seat Contact Width

(IntlExh)

0.032-0.039 in.

Cam Lobe Height (Non-Turbo)

(Int)

1.487-1.489 in.

Valve Stem Diameter

(IntlExh)

0.2150-0.2156 in.

Cam Lobe Height (Turbo)

(Int)

1.436-1.437 in.

Valve Stem Runout (max)

0.002 in.

Cam Lobe Height (Non-Turbo)

(Exh)

1.432-1.433 in.

Valve Spring Free Length (max)

1.22 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. 0.2165-0.2170 in.

Valve Guide Inside Diameter Valve Guide/Stem Clearance (max)

(Int) (Exh)

0.0015 in. 0.0022 in.

Valve Face Width

0.0197 in.

Valve Clearance - Cold (59째_77째 F) (Int) (Exh - Non-Turbo) (Exh - Turbo)

0.0039-0.0078 in. 0.0078-0.0118 in. 0.0118-0.0157 in.

Valve Seat Contact Width

(IntlExh)

0.0354-0.0433 in.

(Int) (Exh)

0.2155-0.2161 in. 0.2147-0.2153 in.

Valve Stem Diameter

2009 Arctic Cat Snowmobiles Factory Service Manual - all Models - www.ReadManuals.com

1-11

Cylinder Head Volume Specifications (2-Stroke) -NOTE: For cylinder head volume tests, see appropriate Measuring Critical Components subsection in Section 2. ENGINE TYPE

-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

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.

iB-1

------

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.

728-144A

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 stroke

70mm stroke

66mm stroke

78mm stroke

Degrees BTDC

BTDC

0.034 in.

0.038 in.

0.036 in.

0.042 in.

0.053 in.

0.059 in.

0.056 in.

0.065 in.

0.076 in.

0.085 in.

0.081 in.

0.093 in.

0.094 in.

0.105 in.

0.099 in.

0.113 in.

570 cc 73.8 x 66

in.

600 cc 73.8 x 70

in.

800 cc 85 x 70

in.

1000 cc 90.3 x 78

in.

-NOTE: Measure in from the shaft end the specified amount when checking runout at points D and F. When checking runout in the center, place indicator on center of bearing as shown at point E. Maximum runout at any of the three measuring points is Âą 0.002 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

2009 Arctic Cat Snowmobiles Factory Service Manual - all Models - www.ReadManuals.com

Fraction/Decimal Conversions 8ths

16ths

32nds

64ths

MM/IN. Conversions

64ths

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

2009 Arctic Cat Snowmobiles Factory Service Manual - all Models - www.ReadManuals.com

1-13

Torque Conversions (ft-lb/N-m)

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 special instructions and other important information necessary 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

~_ID'

DESCRIPTION Torque control required

243 - apply blue Loctite #243 271 - apply red Loctite #271

Tightening Torque (General Bolts)

Type of Bolt

Thread Diameter A (mm)

Tightening Torque

(Conventional or 4 Marked Bolt)

12-36 in.-Ib

® ~~ ','1"1 , '

36-60 in.-Ib

T · ' I.I.,

(7 Marked Bolt)

wmmtll«

1-14

.qj

Lubricate with Arctic Cat 50:1 Injection Oil - Non-APV Engines Lubricate with Arctic Cat Synthetic APV 2-Cycle Oil - APV Engines

7-11 ft-Ib

16-25 ft-Ib

24-48 in.-Ib

6-8 ft-Ib

13-20 ft-Ib

29-43 ft-Ib

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

120 cc

. t

96 in.-Ib

' P

@@~

20 ft-Ib

""\~ 20 ft-Ib

96 in.-Ib

18 ft-Ib

15 ft-Ib

120-ENG09

2009 Arctic Cat Snowmobiles Factory Service Manual - all Models - www.ReadManuals.com1-15

570 cc

~ 96 in.-Ib

~ 7

IJJ

(i)

c€

8 11 4

210

570-ENG09

1-16

2009 Arctic Cat Snowmobiles Factory Service Manual - all Models - www.ReadManuals.com

28 ft-Ib

48 in.-Ib

15 ft-Ib

fJIJ-~~-Â· 48 in.-Ib

96 in.-Ib ..... . .-

570ENG09

. Manual - all Mod esI 2009 Arctic Cat Sn owmobiles Factory S ervlce wwwR . eadManuals.com

1-17

500 cc

-~<D

\ ~ 96in.·lb

~ 108 in.·lb 500CC1A09

1-18

2009 Arctic Cat Snowmobiles Factory Service Manual - all Models - www.ReadManuals.com

96 in.-Ib

crossfire..:

(A)

, f;!i!J~ 15ft.O._:

/ 4fC

20ft-lb

(A)

<lll- "

(A)

22 ft-Ib

(B)

""-------~',"

• ~

/~ .-

24 ft-Ib

F5/T500 /

~ 50 ft-Ib

/ 3~~

~ ." ~ ~ -~ ~ :,,;r:::: " ;~/

23ft-lb

25ft-lb

", <lll-,

15 ft-Ib

2009 Arctic Cat Snowmobiles Factory Service Manual - all Models - www.ReadManuals.com

1-19

600 cc

ill (Do(D

0 @

1>-48 in.·lb

\ >--

~----1

0 CD

(J)

ill

(!)

ill

>--/ 48 in.·lb

96 in.·lb

>-96 in.·lb

1-20

. Manual - all Models - www. ReadManuals.com 2009 Arctic Cat Snowmobiles Factory Service

96 in.·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)

1· i..'1"- -o'k '©J ;.1..1 I

~/o ~ j

lk-

II _II

(A) ~I ~'~ (A) ~ -~I"-:''-@I 81J8 'l:Jttt:J (A)

(A)

(C)Coolant Temperature Sensor 18 I t . l b .

20ft·lb

16ft·lb

F-Series ~

~,.-

50 ft . Ib \

\ 25f! .lb ; '

~ 15ft·lb

.~~'~~.v~ ~ "'<:J 23 ft· lb

~...,

j~ @:j~

25 ft·lb

~ '

...

2009 Arctic Cat Snowmobiles Factory Service Manual - all Models - www.ReadManuals.com

48 in.·lb

1-21

800 cc

* 9 513

I I

® @

ill

* Accessible from Top Side

(A) 10 mm Step 1: 13 ft-Ib Step 2: 31 ft·lb (8) 8 mm 25 ft-Ib (C) 6 mm

• 19ft·lb

17 ft·lb

(Knock Sensor)

96 in.-Ib

(D) Coolant Temperature Sensor 18 ft·lb . .

96in.·lb

•

800 09 1

1-22

2009 Arctic Cat Snowmobiles Factory Service Manual - all Models - www.ReadManuals.com

96 in.-Ib

30 ft-Ib

•

F-Series

:J.

:J. 50 ft-Ib

--~

\ 25 ft-~ Ib _\

f'J Ai .,~~ 23 ft-Ib

:J 17ft-lb -

•

19 ft·lb

•

96 in.-Ib

800 09 2

2009 Arctic Cat Snowmobiles Factory Service Manual - all Models - www.ReadManuals.com

1-23

1000 cc

0 0

/~ ~

ill

0 0

ill ill

ill

* 14

18 ft·lb

(8 )

(8 ) 6 mm

96 in.·lb

(A)

* Accessible from Top Side ~

19 ft·lb

____ J

-~ ~ / ~ 48in.·lb

c(;<::e /

0:>

96 in.·lb

,.'~' .

( .

. '-'"

~~~~U

'J..' /

il~

50ft.lb

48 in.·lb

1000 09 2

1-24

2009 Arctic Cat Snowmobiles Factory Service Manual - all Models - www.ReadManuals.com

F-Series

96 in.-Ib - -~/6 ' 9Yo'

501t-lb

( 501t.lb ~

(!PeP

25 It-Ib

iCa ~

50 It-Ib

â&#x20AC;¢ ~

108 in.-Ib

2009 Arctic Cat S nowmobiles Facto ry Service Ma nual - all Models - www.ReadManuals.com

1-25

1100 cc

Engine Case Torque Va lue 15 ft-Ib Qty 4 - 96 in.-Ib â&#x20AC;¢ 6 mm Cap Screw S 1 120 in -Ib at 18 - Step tep . .. 8 mm Cap Screw y 2 19 ft-Ib

... 10 mm Cap Screw Oty

6 - Step 1 13 ft -Ib Step 2 33 ft-Ib

1100ccJAG09

1-26

- Manual - all Models - www.ReadManuals.com 2009 Arctic Cat Snowmobiles Factory Service

84 in.-Ib

60 in.-Ib

84 in.-Ib

30 ft-Ib

1100ccZ1RV09

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1-27

Engine Torque Patterns (1100 ee) Engine Case

Oil Separator Plates

741-582A

Oil Pan Plate

741-737A

Oil Pan

741-738A

741-584A

Cylinder Head

741-617A

1-28

2009 Arctic Cat Snowmobiles Factory Service Manual - all Models - www.ReadManuals.com

Camshaft Cover

Engine Cover

741-624A

Magneto Cover

741-580A

Exhaust Manifold

741-583A

744-0038

2009 Arctic Cat Snowmobiles Factory Service Manual - all Models - www.ReadManuals.com

1-29

Crossfire/M-Series (800/1000 ee)

Arctic Povver Valve (APV) System Specifications

Servomotor

(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 742-209A

ENGINE

VALVE POSITION

CYCLE RPM

600 cc

Full-Open

73-7400 (Low/High All)

800 cc

Mid-Open Full-Open

60-6500 (Low/High All) 78-8100 (Low/High All)

ENGINE

CENTER ± 0.039 in.

600 cc

1.417 in.

Mid-Open Full-Open

6300 (Low/High All) 6500 (Low/High All)

800 cc

1.377 in.

1000 cc

1.319 in.

1000 cc

APV CABLE LENGTH

-NOTE: The 800 cc and 1000 cc have a three-stage exhaust valve system. The stages are closed, midopen, 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 (CrossfirelFSeries) or at 6270 RPM (M-Series). F-Series

• 0735-516

Servomotor

741-635A

Crossfire/M-Series (600 ee) Support Tube -"... Steering Post

739-715A

1-30

2009 Arctic Cat Snowmobiles Factory Service Manual - all Models - www.ReadManuals.com

Oil Consumption Specifications

Fuel Pump Specifications

(2-Stroke)

(570 ee)

ENGINE

RPM

FULL-CLOSED (Idle) 3 Minutes

FULL-OPEN 2 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

RPM 1000-2000

3.0-3.5

0.21-0.25

4.5-5.5

0.32-0.39

Carburetor Specifications

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

PILOT AIR FLOAT HEIGHT MAIN PILOT THROTTLE SCREW SETTING (TURNS OUT) (mm) AIR JET OUTLET VALVE 1 1/2

TPSTOOL (DC VOLTS)

ANALYZER TOOL (DC VOLTS)

Idle

0.710-0.818

Full-Open

3.472-4.048

3.470-4.046

Idle

0.646-0.754

Full-Open

3.472-4.485

3.470-4.046

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°

Idle

1.100-1.140

8.5°

4.300-4.500

90°

500 cc 600 cc

KG/CM 2

3000-4000

EFI Specifications Fuel Pressure (2-Stroke)

PSI

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.

DIAGNOSTIC TOOL

1100 cc Non-Turbo

Full-Open 1100 cc Turbo Idle Full-Open

0.690-1.110

10°

4.000-4.200

90°

-NOTE: Breaking the seal on the idle screw jam nut or the screws on the TPS will void warranty.

2009 Arctic Cat Snowmobiles Factory Service Manual - all Models - www.ReadManuals.com

1-31

Electrical Specifications (570 ee) -NOTE: The ignition system is a Normally Open Ignition (NOI). Resistance Test Test Value

Description Ignition Coil Primary (External) Secondary

0.26-0.35 ohm 6800-10,200 ohms

Charge Coil (1) Charge Coil (2)

+ Test Connections orange high tension wire

black/white high tension wire

12-18 ohms

black/red

green/red

12-18 ohms

brown/white

green/red

Ignition Timing Sensor

148-222 ohms

green/white

brown

Lighting Coil

0.12-0.18 ohm

yellow

Spark-Plug Cap

4000-6000 ohms

cap end

Description

cap end

+ Test Connections -

Test Value

Voltage Regulator/Rectifier

11-14 AC volts

yellow

brown

Low Oil-Light Sending Unit

Less than 1 ohm (float end down)

terminal

Ignition Switch

Less than 1 ohm (key in OFF position)

terminal

Description

+ Test Connections -

Peak Voltage Test

Primary Coil (External)

254-266V

orange

black/white

Charge Coil (1)

13.7-15.4V

black/red

green/red green/red

Charge Coil (2)

14.5-15.7V

brown/white

Ignition Timing Sensor

4.8-6.4V

green/white

brown

Lighting Coil

6.5-7.0V

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

Electrical Specifications (500 ee) -NOTE: The ignition system is a Normally Open Ignition (NOI). Resistance Test Test Value

Description

+ Test Connections -

Ignition Coil Primary Secondary

0.24-0.36 ohm 6800-10,200 ohms

orange/black high tension wire

orange/red high tension wire

Charge Coil (1)

7.2-10.8 ohms

black/red

green/red

Charge Coil (2)

7.2-10.8 ohms

brown/white

green/red

Lighting Coil

0.08-0.12 ohm

yellow

Ignition Timing Sensor

80.8-121 ohms

green/white

brown/green

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 Connections -

Test Value

Chassis Control Unit* (Crossfire/F-Series)

10-15 DC Volts

red/blue (low power) red/black (high power)

black (low power) black (high power)

Voltage Regulator/Rectifier (T500)

10-15 DC Volts 11-14 AC Volts

red/blue yellow

black black

Low Oil-Light Sending Unit

Less than 1 ohm (float end down)

terminal

Ignition Switch

Less than 1 ohm (key in OFF position)

terminal

Description

terminal

+ Test Connections -

Peak Voltage Test

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

Ignition Timing Sensor

4.8V

green/white

brown/green

Injection Coil

13.2V

blue/white

Fuel Pump Coil

12.8V

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 Multimeter (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.

2009 Arctic Cat Snowmobiles Factory Service Manual - all Models - www.ReadManuals.com

1-33

Electrical Specifications (600 ee) -NOTE: The ignition system is a Normally Open Ignition (NOI). Resistance Test Test Value

Description

+ Test Connections -

Ignition Coil Primary Secondary

0.24-0.36 ohm 6800-10,200 ohms

orange/black high tension wire

orange/red high tension wire

Charge Coil (1)

7.2-10.8 ohms

black/red

green/red

Charge Coil (2)

7.2-10.8 ohms

brown/white

green/red

Lighting Coil

0.08-0.12 ohm

yellow

Ignition Timing Sensor

80.8-121 ohms

green/white

brown/green

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 Chassis Control Unit*

+ Test Connections -

Test Value 10-15 DC Volts

red/blue (low power) red/black (high power)

black (low power) black (high power)

Low Oil-Light Sending Unit

Less than 1 ohm (float end down)

terminal

Servomotor

12 DC Volts

red/black (counterclockwise) black/red (clockwise)

black/red (counterclockwise) red/black (clockwise)

terminal

Ignition Switch

Less than 1 ohm (key in OFF position)

Description

+ Test Connections -

Peak Voltage Test

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

Ignition Timing Sensor

4.8V

green/white

brown/green

Injection Coil

13.2V

blue/white

Fuel Pump Coil

12.8V

orange

Lighting Coil

14.8-22.2V (@ 2000 RPM)

yellow

brown

* Harness plugged III -NOTE: To test the coolant temperature sensor, see Section 5.

1-34

2009 Arctic Cat Snowmobiles Factory Service Manual - all Models - www.ReadManuals.com

Electrical Specifications (800 ee) -NOTE: The ignition system is a Normally Open Ignition (NOI). Resistance Test Test Value

Description

+ Test Connections -

Ignition Coil Primary Secondary

0.24-0.36 ohm 5040-7560 ohms

black/white high tension wire

white/blue high tension wire

Charge Coil (1)

7.2-10.8 ohms

black/red

green/red

Charge Coil (2)

7.2-10.8 ohms

brown/white

green/red

Lighting Coil

0.08-0.12 ohm

yellow

Ignition Timing Sensor (1)

148-222 ohms

blue/white

brown/green

Ignition Timing Sensor (2)

148-222 ohms

green/white

brown/green

Injection Coil

15.2-22.8 ohms

blue/white

Fuel Pump Coil

1.52-2.28 ohms

orange

Spark-Plug Cap

4000-6000 ohms

Description

cap end

+ Test Connections -

Test Value

Voltage Regulator/Rectifier* (F-Series)

10-15 DC Volts

red/violet

black

Voltage Regulator/Rectifier* (Crossfire/M-Series)

10-15 DC Volts 11-14 AC Volts

red/blue yellow

black black

Low Oil-Light Sending Unit

Less than 1 ohm (float end down)

terminal

Servomotor

12 DC Volts

red/black (counterclockwise) black/red (clockwise)

black/red (counterclockwise) red/black (clockwise)

terminal

Ignition Switch

Less than 1 ohm (key in OFF position)

Description

+ Test Connections -

Peak Voltage Test

MAG Primary Coil (Harness Sider

125-137V

orange/red

PTa Primary Coil (Harness Sider

126-139V

white/red

white/black

Charge Coil (1)

13.6-14.8V

black/red

green/red

orange/black

Charge Coil (2)

13.5-14.6V

brown/white

green/red

Lighting Coil

5.4-5.8V

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

Fuel Pump Coil

12.3V

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 Multimeter (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.

2009 Arctic Cat Snowmobiles Factory Service Manual - all Models - www.ReadManuals.com

1-35

Electrical Specifications (1000 ee) -NOTE: The ignition system is a Normally Open Ignition (NOI). Resistance Test Test Value

Description

+ Test Connections -

Ignition Coil Primary Secondary

0.24-0.36 ohm 5040-7560 ohms

black/white high tension wire

white/blue high tension wire

Charge Coil (1)

7.2-10.8 ohms

black/red

green/red

Charge Coil (2)

7.2-10.8 ohms

brown/white

green/red

Lighting Coil

0.08-0.12 ohm

yellow

Ignition Timing Sensor (1)

148-222 ohms

blue/white

brown/green

Ignition Timing Sensor (2)

148-222 ohms

green/white

brown/green

Injection Coil

15.2-22.8 ohms

blue/white

Fuel Pump Coil

1.52-2.28 ohms

orange

Spark-Plug Cap

4000-6000 ohms

Description

cap end

+ Test Connections -

Test Value

Voltage Regulator/Rectifier* (F-Series)

10-15 DC Volts

red/violet

black

Voltage Regulator/Rectifier* (Crossfire/M-Series)

10-15 DC Volts 11-14 AC Volts

red/blue yellow

black black

Low Oil-Light Sending Unit

Less than 1 ohm (float end down)

terminal

Servomotor

12 DC Volts

red/black (counterclockwise) black/red (clockwise)

black/red (counterclockwise) red/black (clockwise)

terminal

Ignition Switch

Less than 1 ohm (key in OFF position)

Description

+ Test Connections -

Peak Voltage Test

MAG Primary Coil (Harness Sider

125-137V

orange/red

PTa Primary Coil (Harness Sider

126-139V

white/red

white/black

Charge Coil (1)

13.6-14.8V

black/red

green/red

orange/black

Charge Coil (2)

13.5-14.6V

brown/white

green/red

Lighting Coil

5.4-5.8V

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

Fuel Pump Coil

12.3V

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.

1-36

2009 Arctic Cat Snowmobiles Factory Service Manual - all Models - www.ReadManuals.com

Electrical Specifications (1100 ee) -NOTE: The ignition system is a Normally Open Ignition (NOI). Resistance Test Test Value

Description

+ Test Connections -

Magneto Coil (three tests)

0.2-0.4 ohm

yellow

Coil (1)

1.4 ohms

red/green

gray/green brown/green

Coil (2)

1.4 ohms

red/green

Crankshaft Position Sensor

173-211 ohms

green

blue

Coolant Temperature Sensor

2.3k-2.6k ohms

yellow/black

ground

Injection Coil Starter Relay

3.6 ohms

black/yellow

black

Spark-Plug Cap

4000-6000 ohms

cap end

Description

Test Value

+ Test Connections -

-NOTE: To test the coolant temperature sensor, see Section 5.

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/rectifier 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

600 cc Ignition Timing - Engine Warm BTDC - 15°/2000 RPM - 0.059 in. Not Adjustable

Ignition Timing Specifications (2-Stroke)

500 cc Ignition Timing - Engine Warm BTDC - 12°/2000 RPM - 0.034 in. Not Adjustable

ROTATING DIRECTION

I~~:::~i, i!!~~ ~_j-C_BT_DC_2_40

740-130A

_ _ _---,

800 cc -NOTE: For timing verification, use a dial indicator and scribe a mark on the flywheel for 25° BTDC.

•

Rotating Direction 0742-218

570 cc Ignition Timing - Engine Warm BTDC - 20°/2000 RPM - 0.099 in. Not Adjustable

Ignition Timing - Engine Warm BTDC - 25°/3250 RPM - 0.162 in. Not Adjustable

~ 'Y~

BlDC 18°

Q,'"lrl/" II

~/I

/.' J BlDC 21l" BlDC 2T

:::;I~~_ I::~ ~3J(BlOC BlDC 16° 14" BlDC IT

- BlDC 24°

•

Rotating Direction

0742-217

1-38

2009 Arctic Cat Snowmobiles Factory Service Manual - all Models - www.ReadManuals.com

0744-033

1000 cc (F-Series)

1000 cc (Crossfire/M-Series)

Ignition Timing - Engine Warm BTDC - 20°/3750 RPM - 0.113 in. Not Adjustable

Ignition Timing - Engine Warm BTDC - 14°/1800 RPM - 0.057 in. Not Adjustable

: :::~~ ifI i~::~

BTDC 15" BTDC 14" BlDC

i i

BlDC 16" BTDCIII" BTDC 20" BTDC 22"

8"~_Ir=BlDC211" I

•

Rotating Direction 0744-035 0744-034

2009 Arctic Cat Snowmobiles Factory Service Manual - all Models - www.ReadManuals.com

1-39

Steering/Body Torque Specifications 120 Sno Pro Item

Torque ft-Ib

BearcatIF-SerieslT-SerieslZ1 Item

Torque ft-Ib

Ski

Spindle Arm/Spindle**

Suspension Arm/Spindle

Front Suspension Arm (Upper)

Front Suspension Arm (Lower)

Tie Rod End (Spindle)*

Steering Arm/Spindle*

Inner Tie Rod End/Steering*

Steering Arm/Suspension Mounting Bracket

40 20 120 in.-Ib

Ski Shock/Shock Mount

Sway Bar Mounting Bracket/Suspension Mounting Bracket

A-Arm/Spindle

Tie Rod Jam Nut**

A-Arm/Chassis

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*

Ski/Spindle

CrossfirelM-Series Ski

Handlebar Adjuster Block/Post (Standard)

120 in.-Ib

Handlebar Adjuster (Sno Pro)

Steering Post Mounting Block

96 in.-Ib

Drag Link/Steering Arm (Bearcat/F-SerieslT-Series)**

12 120 in.-Ib

Steering Post/Stop*

Drag Link/Steering Arm (Z1)**

Steering Tie Rod/Shaft Arm*

30 30

Shock Absorber/Shock Mounting Frame (Bearcat/F-SerieslT-Series)

Steering ArmlTie Rod Steering PostlTie Rod*

Shock Absorber/Shock Mounting Frame (Z1)

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)

96 in.-Ib

Shock Absorber/Spindle

Front Suspension Arm/Chassis* (Upper)

Front Suspension Arm/Chassis* (Lower)

Bearing Cap/Spindle** Upper Bearing Bracket/Support Plate** Shock Absorber/Spindle Suspension Mounting Bracket/Chassis (Lower) Suspension Mounting Bracket/Chassis (Upper)

13 96 in.-Ib 32 96 in.-Ib 20

Steering Support Plate/Steering Support

96 in.-Ib

Shock Mount Frame/Suspension Mounting Bracket

96 in.-Ib

Shock Mount Frame/Front Upper Frame

Spindle Retainer/Spindle**

Front Bumper (Bearcat)

Steering Post/Chassis*

Steering Support/Chassis**

Rear Bumper/Heat Exchanger** (Bearcat/F-SerieslT-Series)

Rear Bumper/Heat Exchanger** (Upper) (Z1)

96 in.-Ib

Rear Bumper/Heat Exchanger** (Lower) (Z1)

Rear RacklTunnel (Bearcat XT)

Center Steering Link/Steering Arm* Gas Tank/Steering Support

* w/Green Loctite #609 ** w/Blue Loctite #243

1-40

* w/Green Loctlte #609 ** w/Blue Loctite #243

2009 Arctic Cat Snowmobiles Factory Service Manual - all Models - www.ReadManuals.com

Drive System Specifications

Drive Clutch/Driven Pulley-Related Specifications

Arctic Cat Drive Belt Dimensions

ALIGNMENT BAR MODEL

CENTEROFFSET TO-CENTER OFFSET FLOAT PIN 0644-427

11.50"

1.655"

None

Z1ITZ1 /Bearcat Z1 XT 0644-727

10.20"

1.655"

None

Bearcat 570/F-Series/ T-Series

11.50"

1.507"

None

Crossfire/M-Series

0644-496

Parallelism

800 eel 1 000 ee/11 00 ee

--r0.040 in.

0.060 in.

;9 C

LENGTH

WIDTH

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

CAUTION

Do not allow the driven pulley to "float" on the output shaft or damage to the driven pulley will occur.

---'---~---

BELT PIN *0627-046

0743-410

-NOTE: The difference between Drive Belt (pIn 0627-046) and Drive Belt (pIn 0627-060) is the hardness. The Drive Belt (pIn 0627-060) is more flexible, and if used in place of Drive Belt (pIn 0627046), the engine will run at a lower RPM.

Drive System Components A list of Arctic Drive Clutch and Driven Pulley components that are available through the Arctic Cat Service Parts Department can be found in the Quick Reference Guide. This information will be useful when doing any fine-tuning on the drive system.

-NOTE: See Section 6 in this manual for alignment and parallelism procedures. 2009 Arctic Cat Snowmobiles Factory Service Manual - all Models - www.ReadManuals.com

1-41

Gear Case Performance Calibrations Drive Sprocket

9 Tooth (2.52" pitch)

10 Tooth (2.52" pitch)

8 Tooth (3.0" pitch)

Gear Ratio 66 65 64 63 62 61 60 59 58 57 56 55 54 66 65 64 63 62 61 60 59 58 57 56 55 54 66 65 64 63 62 61 60 59 58 57 56 55 54

54 55 56 57 58 59 60 61 62 63 64 65 66 54 55 56 57 58 59 60 61 62 63 64 65 66 54 55 56 57 58 59 60 61 62 63 64 65 66

Engine RPM 6200 6400 6600 6800 7000 7200 7400 7600 7800 Vehicle Speed (mph) 91 94 97 100 103 106 109 112 114 88 91 94 96 99 102 105 108 111 85 88 91 93 96 99 102 104 107 82 85 88 90 93 96 98 101 103 80 82 85 87 90 92 95 98 100 77 79 82 84 87 89 92 94 97 74 77 79 82 84 86 89 91 94 72 74 77 79 81 84 86 88 91 70 72 74 76 79 81 83 85 88 67 70 72 74 76 78 80 83 85 65 67 69 71 74 76 78 80 82 63 65 67 69 71 73 75 77 79 61 63 65 67 69 71 73 75 77 101 104 108 111 114 117 121 124 127 98 101 104 107 110 113 117 120 123 95 98 101 104 107 110 113 116 119 91 94 97 100 103 106 109 112 115 88 91 94 97 100 103 106 108 111 85 88 91 94 97 99 102 105 108 83 85 88 91 93 96 99 101 104 80 83 85 88 90 93 95 98 101 77 80 82 85 87 90 92 95 97 75 77 80 82 84 87 89 92 94 72 75 77 79 82 84 86 89 91 70 72 74 77 79 81 84 86 88 68 70 72 74 76 79 81 83 85 96 99 102 106 109 112 115 118 121 93 96 99 102 105 108 111 114 117 90 93 96 99 102 105 107 110 113 87 90 93 95 98 101 104 107 110 84 87 90 92 95 98 100 103 106 81 84 87 89 92 95 97 100 102 79 81 84 86 89 91 94 97 99 76 79 81 84 86 88 91 93 96 74 76 78 81 83 86 88 90 93 71 74 76 78 80 83 85 87 90 69 71 73 76 78 80 82 84 87 67 69 71 73 75 77 80 82 84 64 67 69 71 73 75 77 79 81

8000 8200 8400 8600 8800 9000 117 113 110 106 103 99 96 93 90 87 84 81 79 130 126 122 118 114 110 107 103 100 97 93 90 87 124 120 116 112 109 105 102 98 95 92 89 86 83

120 116 112 109 105 102 98 95 92 89 86 83 81 134 129 125 121 117 113 109 106 102 99 96 93 89 127 123 119 115 111 108 104 101 97 94 91 88 85

123 119 115 111 108 104 101 98 94 91 88 85 83 137 132 128 124 120 116 112 108 105 101 98 95 92 130 126 122 118 114 110 107 103 100 97 93 90 87

Shaded rows indicate existing tooled gear ratios

1-42

2009 Arctic Cat Snowmobiles Factory Service Manual - all Models - www.ReadManuals.com

126 122 118 114 110 107 103 100 97 93 90 87 84 140 136 131 127 123 119 115 111 107 104 100 97 94 134 129 125 121 117 113 109 106 102 99 96 92 89

129 125 121 117 113 109 106 102 99 96 92 89 86 143 139 134 130 125 121 117 114 110 106 103 99 96 137 132 128 124 119 116 112 108 105 101 98 95 91

132 128 123 119 115 112 108 104 101 98 95 91 88 147 142 137 133 128 124 120 116 112 109 105 102 98 140 135 131 126 122 118 114 111 107 103 100 97 94

Drive System Torque Specifications 120 Sno Pro Item

Torque ft-Ib

Centrifugal Clutch**

Secondary Sprocket**

Drive Sprocket Bearing/Chassis

BearcatIF-SerieslM-SerieslCrossfireIT-SeriesIZ1

Bearcat XT Item

Torque ft-Ib

Wear Strip/Rail

50 in.-Ib

End Cap/Rail

80 in.-Ib

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

Drive Clutch

Idler Wheel/Pivot Assembly - Rail

Spider*

250

Rear Arm Shock Pivot Axle/Rail

Spider Retainer Nut*

Front Arm Shock Bracket Axle/Rail

Drive Clutch Cover**

120 in.-Ib

Rear Arm Limiter/Rail*

Front Rail Support/Rail*

20 120 in.-Ib

Cam Arm Pin Lock Nut Cam Arm Set Screw*

19 in.-Ib

Limiter Strap/Rail Support

Drive Clutch/Ring Gear*

Spring Slide Block/Rail

Driven Pulley

Outer Idler Wheel Mounting Block/Rail

Driven Shaft Jam Nut

Articulating Skid Frame/Rail

RaillTunnel

66 in.-Ib

Torque Bracket Brakeline Fitting/Caliper

Crossfire/Crossfire R

10.5 Wear Strip/Rail

50 in.-Ib

Torque Bracket Cover

72 in.-Ib

End Cap/Rail

80 in.-Ib

Movable Sheave

72 in.-Ib

Mounting Block/Rail

Idler Wheel/Mounting Block

Brakeline/Master Cylinder

Speedometer Sensor Bracket

Gear Case/Chassis

Brake Caliper Housing/Chassis

Outside Caliper Housing/Inside Caliper Housing

Gear Case Cover

12.5

Spring Slide/Slide Block - Rail (Standard)

Spring Slide/Slide Block - Rail (R)

Pivot Arm/Idler Arm (R)

Idler Wheel Axle/Rail

Rear Arm/Rail

Gear Case Drain Plug

Rear Arm Limiter/Rail*

Driveshaft/Output Shaft Cap Screw**

Front Arm Mounting Bracket/Rail (R)

120

Rear Shock Pivot/Inner Idler Wheel - Rail

Driveshaft/Brake Disc Retaining Nut

41 in.-Ib

Shift Actuator/Gear Case

*w/Green Loctite #620 **w/Blue Loctite #243

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)

Rear Suspension Torque Specifications 120 Sno Pro Item

78 in.-Ib

End Cap/Rail

120 in.-Ib

Pivot Assembly/Rail

40 120 in.-Ib

Track Adjuster Bracket/Rail Rear Rail Support/Rail

Inner Idler Wheel/Rail

40 40

RaillTunnel

Torque ft-Ib

Limiter Strap/Rail Support

M-Series Wear Strip/Rail

50 in.-Ib

End Cap/Rail

80 in.-Ib

Axle Housing/Rail

Mounting Block/Rail

Rear Arm/Bracket*

Inner Idler Wheel/Mounting Block

Rear Wheel Axle*

Idler Wheel Axle/Rail

Cross-Brace Axle/Rail*

Rear Arm/Rail

Idler AxlelTunnel*

Idler Arm/Rear Arm

Rear Arm Limiter/Rail Support

* w/Blue Loctite #243

Front Arm Shock Axle/Rail

Front Rail Support/Rail

Outer Idler Wheel/Mounting Block

Limiter Strap/Rail Support

40 120 in.-Ib

Track Adjuster Bracket/Rail

120 in.-Ib

Front Arm/Rail

RaillTunnel

* w/Blue Loctite #243 2009 Arctic Cat Snowmobiles Factory Service Manual - all Models - www.ReadManuals.com

1-43

F-SerieslZ1 Item

Bearcat 5701T-Series 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

Idler Wheel/Mounting Block

Rear Arm/Rail

Rear Arm/Idler Arm

Spring Slide/Slide Block - Rail

Shock Pivot/Idler Wheel - Rail

Pivot Arm/Idler Arm

Spring Slide Block/Rail

Idler Wheel Axle/Rail

Pivot Arm/Idler Arm

Front Arm Shock Axle/Rail

Idler Wheel Axle/Rail

Front Arm/Rail

Front Arm Shock Axle/Rail

Rear Shock Pivot/Front Arm

Front Arm/Rail

Limiter Strap/Front Arm

120 in.-Ib

Rear Shock Pivot/Rail

Track Adjuster Bracket/Rail

120 in.-Ib

Rear Arm Limiter/Rail

Rear Arm Limiter/Rail*

Rail Support/Rail

RaillTunnel

Limiter Strap/Rail Support

120 in.-Ib

RaillTunnel

* w/Blue Loctlte #243

1-44

2009 Arctic Cat Snowmobiles Factory Service Manual - all Models - www.ReadManuals.com

50 20 120 in.-Ib 40

Track Warranty Guidelines Failure Mode

Description

Cause

Warranty

Delamination (A)

Condition in which the track fabric cleanly separates or spreads apart from the rubber.

Result of poor adhesion between fabric and rubber material

Covered

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.

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.

Covered Rods out of center. If a rod is positioned off-center during track manufacturing, tearing along the side of the track may occur Âą 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.). pull-through as well as track clips that are torn off. Internal Lug Damage

Condition in which internal lugs are torn, worn, or Result of contact being made with a foreign object. cracked. Track derailment can also cause this damage.

Not Covered

Broken Rods/ Missing Clip (D)

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 of the Track or Air which may include air bubbles/pockets/voids Bubbles within the track.

Manufacturing flaw.

Lugs Torn Off Outer Belt (B)

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.

Condition normally found on deep lug tracks.

Covered

734-522C

Lug/ Tread Damag@

Broken Rod/Miss ing Clip LugfTread Damage

734-5228

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734-522D

1-45

Track Specifications

Rear Suspension Specifications

Below is a listing of drive tracks for Arctic Cat snowmobiles with its specifications.

FRONT ARM SPRINGS Free Length

Rate LBllnch

Bearcat 570

Model

9.5"

110

Bearcat XT

9.5"

140

F 570

9.5"

F5fT500fT570lZ1 fTZ1

7.75"

110

Crossfire/M-Series

7.75"

135

8.0"

190

8.25"

90/250

F-Series Sno ProlZ1 Turbo Sno Pro

8.25"

100/250

Crossfire R

REAR ARM SPRINGS

-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 0730-218

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 Length

Rate LBI Inch

# of Coils

Tab

F5fT500fT570

11.25"

6.2* 18 .2**

M6/M8/M1000 (STO)

12.50"

120

12.75

YES

F 570

9.36"

8.5

Bearcat 5701 Bearcat 570 XT

10.10"

110

8.4

NO NO YES

F8 (STO)

12.50"

Crossfire (STO)

13.50"

120

Z1fTZ1

10.50"

110

9.0

YES

NO NO NO

120 Sno Pro

6.97"

9.0

Crossfire R

13.00"

125

11.5

Bearcat Z1 XT

10.10"

9.6

* 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).

* Active Coils ** Total Coils

1-46

2009 Arctic Cat Snowmobiles Factory Service Manual - all Models - www.ReadManuals.com

REAR ARM SHOCK

Shock Absorber Specifications

Model

Below is a list of shock absorbers used on the front and rear suspensions of Arctic Cat snowmobiles. Specifications given for each shock absorber include collapsed and extended length, stroke, and piston depth (if applicable). If replacing a shock absorber, always select a shock absorber with the same length, both collapsed and extended. SKI SHOCK Collapsed Length

Extended Length

Stroke

Piston Depth

Bearcat 570/F5/F 5701 T500fT570

11.55"

17.50"

5.95"

N/A

Crossfire 500

12.55"

18.75"

6.20"

N/A

Model

Collapsed Length

Extended Length

Stroke

Piston Depth

Bearcat 570fT-Series

10.91"

16.69"

5.78"

N/A

Crossfire 500

9.89"

14.50"

4.61"

N/A

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

9.87"

14.51"

4.61"

N/A

Crossfire (STO)I Crossfire R

9.88"

14.37"

4.48"

0.90"

Crossfire Sno Pro/MSeries

11.10"

16.00"

4.90"

5.77"

F8 (STO)/F8 LXR

9.89"

14.53"

4.64"

5.80"

F-Series Sno ProlZ1 Turbo Sno Pro

10.13"

14.53"

4.40"

5.70"

Idler Wheel Dimensions

120 Sno Pro

7.78"

9.49"

1.71"

N/A

Bearcat XT

10.67"

16.00"

5.33"

N/A

Model

0.0.

Bearing 1.0.

Z1 fTZ1 fTZ1 Turbo

11.55"

17.50"

5.90"

N/A

All

Inside Rails

5.63 in.

0.787 in.

Crossfire 600/800/1 000 (STO)/Crossfire R

12.13"

18.72"

6.59"

1.40"

All

Idler Arm

7.12 in.

1.181 in.

Inside Rear Axle

7.12 in.

0.787 in.

F-Seriesl T-Series/Z1

Outside Front

5.63 in.

0.787 in.

Outside Rear Axle

7.12 in.

0.787 in.

AII**

Location

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 Z1 Turbo Sno Pro

12.30"

16.75"

4.45"

7.00"

F-Seriesl T-Series/Z1

M-Series (STO)

11.56"

17.55"

5.99"

1.25"

M-Series*

Inside Rear Axle

8.00 in.

0.787 in.

M-Series Sno Pro

12.00"

17.55"

5.55"

6.68"

M-Series*

Outside Rear Axle

8.00 in.

0.787 in.

Rear Axle

6.38 in.

0.787 in.

Bearcat XT

FRONT ARM SHOCK Model

Collapsed Length

Extended Length

Stroke

Piston Depth

Bearcat XT

8.42"

12.49"

4.07"

N/A

F5/F 570lZ1

8.43"

12.53"

4.10"

N/A

Bearcat 5701 Crossfire 500fT-Series

8.09"

11.78"

3.69"

N/A

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"

8.11"

11.25"

3.14"

0.58"

* 8.00 in. idler wheel cannot be used with standard slide rails. ** Except M-Series

(STO)I

F-Series Sno Pro/Z1 Turbo Sno Pro M-Series

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1-47

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

Engine - 1 20 Sno Pro This engine section has been organized into sub-sections 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 service 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.

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.

-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

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

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 compartment.

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 Sprockets sub-section in Section 6).

1. Disconnect the choke and throttle cables from the carburetor; then on each cable, loosen the adjustment jam nut closest to the carburetor and remove the cables from the bracket. Route the cables out of the way.

2-2

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.

2009 Arctic Cat Snowmobiles Factory Service Manual - all Models - www.ReadManuals.com

A049

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.

-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.

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.

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.

11. Lay the snowmobile on its side. -NOTE: A piece of cardboard should be used to protect the finish. GM300D

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.

2. Remove the wing nut securing the air cleaner end cap to the air cleaner housing.

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3. Remove the cap screw and flange nuts securing the air cleaner housing to the carburetor and engine.

5. Mark the locations of the springs for assembly; then disconnect the rod and spring from the carburetor.

GF208D

6. Slide the carburetor off the mounting studs. Account for a gasket, insulator block, and a gasket.

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. 7. Remove the recoil starter/fan housing assembly.

A001 GM201E

8. Remove the screws securing the recoil starter pulley to the flywheel; then remove the nut securing the flywheel to the crankshaft.

GF316D

2-4

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