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Arctic Cat 660 cc, Service Manual

The Arctic Cat 660 cc Service Manual is essential for anyone looking to properly maintain or repair their vehicle. This manual provides detailed instructions on servicing and troubleshooting, ensuring your Arctic Cat runs smoothly. Download your free manual from manualshive.com today for all the information you need.

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6-3

Testing Handlebar 

Warmer Elements        

(HI/OFF/LO Function)

„

NOTE: During this test, resistance will vary due

to temperature; therefore, this test should be made
at room temperature of 20° C (68°F).

1. Remove the handlebar pad; then disconnect the

handlebar warmer three-wire connector.

2. In the element connector, connect one ohmmeter

lead to the green/white lead; then connect the other
ohmmeter lead to the green lead.

3. The meter must read between 7.2 and 8.8 ohms.

4. In the element connector, connect the ohmmeter

between the green/black and yellow lead wires.

5. The meter must read between 12.6 and 15.4 ohms.

6. Replace any element measuring less than or more

than the specified amount.

„

NOTE: Repeat test for the other element.

7. Connect the leads; then install and secure the

handlebar pad.

Testing Thumb

Warmer Element

(HI/OFF/LO Function)

„

NOTE: During this test, resistance will vary due

to temperature; therefore, this test should be made
at room temperature of 20° C (68°F).

1. Remove the handlebar pad; then disconnect the

thumb warmer three-wire connector.

2. In the element connector, connect one ohmmeter

lead to the green/white lead; then connect the other
ohmmeter lead to the green lead.

3. The meter must read between 3.6 and 4.4 ohms.

4. In the element connector, connect one ohmmeter

lead to the green/black lead; then connect the other
ohmmeter lead to the yellow lead.

5. The meter must read between 10.8 and 13.2 ohms.

„

NOTE: If either test is not within specification,

replace the thumb warmer element.

6. Connect the leads; then install and secure the

handlebar pad.

Testing Handlebar

Warmer Switch

(HI/OFF/LO Function)

1. Remove the handlebar pad.

2. Disconnect the handlebar warmer three-wire

connector.

3. In the switch connector, connect the ohmmeter

leads to the green/white and green lead wires.

4. With the switch in the OFF (middle) position, the

meter must read an open circuit. With the switch
in the HI position, the meter must read 1 ohm or
less resistance.

5. In the switch connector, connect the ohmmeter

leads to the green/black and green leads.

6. With the switch in the OFF (middle) position, the

meter must read an open circuit. With the switch
in the LO position, the meter must read 1 ohm or
less resistance.

7. Connect the leads; then install and secure the

handlebar pad.

Testing Thumb

Warmer Switch

(HI/OFF/LO Function)

1. Remove the handlebar pad.

2. Disconnect the thumb warmer three-wire

connector.

3. In the switch connector, connect one ohmmeter

lead to the green/white lead; then connect the other
ohmmeter lead to the green lead.

4. With the switch in the OFF (middle) position, the

meter must read an open circuit. With the switch
in the HI position, the meter must read 1 ohm or
less resistance.

5. In the switch connector, connect one ohmmeter

lead to the green/black lead; then connect the other
ohmmeter lead to the green lead.

6. With the switch in the OFF (middle) position, the

meter must read an open circuit. With the switch
in the LO position, the meter must read 1 ohm or
less.

7. Connect the leads; then install and secure the

handlebar pad.

6

Summary of Contents for 660 cc

Page 1: ...ile decals display the words Warning Caution and Note to emphasize impor tant information The symbol WARNING identifies personal safety related information Be sure to follow the directive because it d...

Page 2: ...ED TEXT to Go Section Foreword 1 General Information 2 Engine 3 Engine Related Items 4 Fuel Systems 5 Engine Electrical Systems 6 Chassis Electrical Systems 7 Steering and Body 8 Drive Train and Brake...

Page 3: ...ion 120 cc Model 1 3 Tipped Snowmobile 660 cc Models 1 4 Low Oil Pressure Warning Light 660 cc Models 1 4 Check Engine Light 660 cc Models 1 4 Preparation For Storage 1 4 Preparation After Storage 1 5...

Page 4: ...se gasolines containing methanol RECOMMENDED OIL 120 cc The recommended oil to use is a multi grade or single grade engine grade oil calibrated to the ambient tempera ture at which the engine is run S...

Page 5: ...ized Arctic Cat Snowmo bile dealer for a checkup and oil change This service is at the discretion and expense of the snowmobile owner Genuine Parts When replacement of parts is necessary use only genu...

Page 6: ...urned 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 run ning oil pressure has been lost and the engine will auto mati...

Page 7: ...ible 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 snow...

Page 8: ...to the instructions given in this man ual To correct for too much deflection washer s from between the driven pulley sheaves can be removed to tighten the drive belt and allow the belt to return to th...

Page 9: ...this important checkup done R Adjust drive belt deflection R Adjust track tension and alignment R Adjust throttle cable tension R Check engine idle R Check coolant level R Check chain case lubricant l...

Page 10: ...5 31 4 3 51 7 1 71 9 8 91 12 6 12 1 7 32 4 4 52 7 2 72 10 0 92 12 8 13 1 8 33 4 6 53 7 3 73 10 1 93 12 9 14 1 9 34 4 7 54 7 5 74 10 2 94 13 0 15 2 1 35 4 8 55 7 6 75 10 4 95 13 1 16 2 2 36 5 0 56 7 7...

Page 11: ...5 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 No Size of Drill in Inches No Size of Drill in In...

Page 12: ...8 03858 38 1 49606 78 3 07086 19 00748 59 02323 99 03898 39 1 53543 79 3 11023 20 00787 60 02362 1 0 03937 40 1 57480 80 3 14960 21 00827 61 02402 1 03937 41 1 61417 81 3 18897 22 00866 62 02441 2 078...

Page 13: ...s 2 5 Assembly Schematic 660 cc 2 6 Engine 2 9 Removing Engine 120 cc Model 2 9 Removing Engine 660 cc Models 2 10 Disassembling Engine 120 cc Model 2 16 Disassembling Engine 660 cc Models 2 21 Servic...

Page 14: ...e In Piston 18 006 18 014 mm 0 7089 0 7092 in Piston Pin Dia 17 995 18 000 mm 0 7085 0 7087 in Piston Ring Groove Ring Clearance 1st 2nd Oil 0 03 0 07 mm 0 0012 0 0028 in 0 02 0 06 mm 0 0008 0 0024 in...

Page 15: ...30 56 mm 1 189 1 203 in Crank Pin Diameter 25 990 26 000 mm 1 0232 1 0236 in Crankshaft Runout Max 0 100 mm 0 004 in Cylinder Bore Diameter Max 60 25 mm 2 372 in Cylinder Head Distortion Max 0 03 mm 0...

Page 16: ...Torque Patterns 660 cc ENGINE SIZE CYLINDER HEAD CRANKCASE 660 cc 0738 462 0738 513 ENGINE SIZE ENGINE COVER OIL PAN 660 cc MD1630 0738 515 ENGINE SIZE INTAKE MANIFOLD EXHAUST MANIFOLD 660 cc 0738 87...

Page 17: ...Starter 4 8 35 Starter Plate Ring Gear Shield 4 8 35 Tensioner Guide Bracket 1 0 1 2 7 9 Thermostat Housing Outlet Pipe 2 4 17 Throttle Body 1 3 9 5 Throttle Body STD 2 4 17 Timing Chain Tensioner 1...

Page 18: ...2 6 4S ENG04 Assembly Schematic 660 cc...

Page 19: ...2 7 2 4S E RP04 T...

Page 20: ...2 8 4S E C04 T...

Page 21: ...cc Model NOTE The drive chain must be removed in order to remove the engine see Drive Chain and Sprock ets sub section in Section 8 1 Disconnect the choke and throttle cables from the carburetor then...

Page 22: ...d four lock nuts A049 NOTE The front center plug is to access the oil drain plug 13 Place the snowmobile in the upright position then on the left hand side of the engine remove the three cap screws se...

Page 23: ...e pinch off the coolant drain hose and remove the drain plug AO176 7 Using a length of in I D hose slide it over the end of the coolant drain hose then attach the other end to the air silencer drain h...

Page 24: ...support AO183 AO185 13 Remove the two 27 torx head cap screws securing the ECU to the bracket then remove the ECU AO184A 14 On the standard model using Spring Pliers p n 0644 391 or p n 0644 397 remov...

Page 25: ...irpin clip and large hitch pin securing the belt guard in place then remove the belt guard Account for two plastic collars NOTE On turbo models remove the flange nuts securing the intercooler bracket...

Page 26: ...the drive clutch to the PTO adapter then using Clutch Puller p n 0644 207 and a breaker bar and Spanner Wrench p n 0644 136 tighten the puller If the drive clutch will not release sharply strike the h...

Page 27: ...nger AO182 26 Remove the starter solenoid connector and starter motor cable MD1700 27 Remove the two rear engine mount nuts then remove the two front engine mount cap screws AO190 AO199 28 Remove the...

Page 28: ...e NOTE Engine lift points consist of a bracket on the front right side of the exhaust manifold and an integral eye of the alternator adjustment bracket Disassembling Engine 120 cc Model 1 Remove the o...

Page 29: ...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 GF318D 7 Remove the r...

Page 30: ...curing the ignition coil to the crankcase housing GE318D 12 Remove the cylinder head cover GM205D 13 Remove the air breather body assembly from the cylinder head cover Account for a gasket GM206D 14 R...

Page 31: ...n of the dowel pins GM210D GM211D 18 Remove the cap screws securing the crankcase side cover to the crankcase Account for dowel pins and a gasket GM212D GM213D 19 Remove the washer from camshaft and n...

Page 32: ...Note the direction of the arrow on the connecting rod and mark the connecting rod and end cap for reference during installation GM121D GM120D 23 Remove the connecting rod end cap and account for the...

Page 33: ...ap screws holding the grooved belt cover then remove the belt cover Remove the cap screw holding the oil level stick tube in place then remove the tube and the oil level stick 2 Remove the coolant fil...

Page 34: ...1676 6 Remove the intake manifold Account for the gasket and wire loom tab MD1674 7 Remove the coil cover from the cylinder head cover then remove the three 6 mm cap screws that secure the ignition co...

Page 35: ...On turbo models remove the turbo see Section 3 AO269 11 Remove the two cap screws and four lock nuts securing the exhaust manifold to the cylinder head AO268 12 Loosen the 8 mm cap screw and move the...

Page 36: ...eplacement is not necessary 17 Remove the four engine mount brackets 18 Remove the thermostat outlet pipe and thermostat MD1610 MD1609 19 Remove the thermostat housing with the water temperature senso...

Page 37: ...oil pan cap screws and flange nuts NOTE A carefully placed strike with a rubber plastic hammer may be necessary to break the sealant MD1491 24 Remove the three cap screws securing the oil pump strain...

Page 38: ...acket cap screws timing chain guide cap screws and the timing chain tensioner pivot cap screw then remove the timing chain tensioner guide bracket timing chain tensioner and timing chain guide MD1497...

Page 39: ...er head cap screws then remove the cylinder head Account for the two dowel pins and discard the gasket NOTE Always install a new head gasket NOTE Care should be taken not to tip the cylin der head ups...

Page 40: ...ely cracked or damaged in any way replacement is necessary CYLINDER HEAD VALVE ASSEMBLY NOTE Remove the valves by pressing down on the spring retainer and removing the valve keeper Account for valve s...

Page 41: ...indicator ATV1082A 3 Rotate the valve in the V blocks 4 Maximum runout must not exceed specifications Replacing Valve Guide NOTE If a valve guide is worn or damaged it must be replaced 1 If a valve g...

Page 42: ...e freely in the guide use a standard valve guide reamer and handle to remove all burrs and tight areas that may remain in each valve guide GEN 0022 ATV 0107 Measuring Valve Guide Valve Stem Clearance...

Page 43: ...turns using a T handle 2 Remove the pilot shaft and cutter then coat the valve seat with a blueing compound and insert the valve into the valve guide Rotate the valve while tapping the valve head then...

Page 44: ...or scuffing is detected the piston must be replaced 4 Inspect the perimeter of each piston for signs of excessive blowby Excessive blowby indicates worn piston rings or an out of round cylinder Removi...

Page 45: ...next oversize by using a boring machine or replace the cylinder GEN 0032 2 Measure the corresponding piston diameter at a point 14 mm 0 551 in above the piston skirt at a right angle to the piston pi...

Page 46: ...not exceed specifications GM130D Cleaning Inspecting Measuring Cylinder 1 Wash the cylinder in parts cleaning solvent 2 Check the gasket surface of the cylinder for distortion with a straightedge and...

Page 47: ...arked for identification purposes ATV 1068 CAM LOBE WEAR Worn cam lobes result in reduced power output The limit of cam lobe wear is specified for both intake and exhaust lobes in terms of cam height...

Page 48: ...be within specifications GEN 0037 3 Measure the connecting rod big end inside diameter 4 Measurement must be within specifications GEN 0038 5 Measure the crank pin connecting rod clearance 6 Measureme...

Page 49: ...ve each ring by working it toward the dome of the piston while rotating it out of the groove NOTE If the existing rings will not be replaced with new ones note the location of each ring for proper ins...

Page 50: ...ations GEN 0033 3 Piston skirt to cylinder clearance must be within specifications NOTE If a cylinder is out of specification and needs to be bored all the cylinders must be bored to obtain uniformity...

Page 51: ...ocations If distortion limit is exceeded correct surface with a surface plate and abrasive paper of about 400 grit AO349 4 Place paper on and over surface plate and rub surface against paper to grind...

Page 52: ...g replacing will be necessary MEASURING CONNECTING ROD BIG END SIDE CLEARANCE 1 Check big end of connecting rod for side clearance with rod fitted and connected to its crank pin in the normal manner 2...

Page 53: ...haft or the engine block has been replaced or if the bearings are out of specification 1 Locate the four numbers on the PTO side of the engine block on the oil pan sealing surface AO350 2 Locate the f...

Page 54: ...e piston rings and install the piston and connecting rod assembly taking care not to damage the crankshaft with the connecting rod studs NOTE When installing the piston rotate the crankshaft until the...

Page 55: ...ead to the cylinder with the cap screws Tighten to 2 8 kg m 20 ft lb GM210D 11 Apply lightweight oil to the ends of the push rods then install the rods GM209D 12 Loosely secure the rocker arms to the...

Page 56: ...cap screws GE318D 17 Connect the ignition coil wire NOTE The spark plug should be removed and cleaned or replaced Adjust gap to specification and tighten the plug to 2 5 2 8 kg m 18 20 ft lb 18 Connec...

Page 57: ...ll the rod and spring onto the carburetor GF208D 24 Install the gasket onto the mounting studs then install the air cleaner housing onto the carburetor Install the air breather hose onto the air clean...

Page 58: ...l holes in the bearings line up with the notches and oil pas sages in the upper and lower crankcase halves MD1471 MD1551A 2 Lay the crankshaft into position and place a small piece about the width of...

Page 59: ...the lower crankcase half bearing faces liberally with engine oil taking care not to get oil on the crankcase bearing journals AO319 NOTE Take care not to get sealant on the bear ing surfaces Sealant...

Page 60: ...p screws and 1 7 kg m 12 ft lb for step one and 2 4 kg m 17 ft lb for step two for the 8 mm cap screws MD1573 0738 513 12 Install one piston pin circlip into one of the pistons making sure the open en...

Page 61: ...Remove the protective hoses from the connecting rod studs then seat the connecting rods over the connecting rod journals NOTE Make sure the tabs and the oil holes in the connecting rod bearings are al...

Page 62: ...onnecting rod caps NOTE Make sure the identification numbers stamped on the side of the connecting rod caps and the V arrow on the connecting rod caps are facing the timing chain end of the crankcase...

Page 63: ...NOTE The large camshaft cap mounts are posi tioned at the camshaft sprocket end of the cylinder head All other camshaft caps have identification numbers designating intake side I 1 I 2 and I 3 or exha...

Page 64: ...end Arrows on each cap need to face toward the sprocket end of the camshaft MD1521 MD1522 34 Install the timing chain tensioner and cap screws Tighten the cap screws to 1 0 1 2 kg m 7 9 ft lb MD1588 3...

Page 65: ...tensioner guide and cap screws Tighten the cap screws to 1 8 2 8 kg m 13 20 ft lb AO326 AO327 39 While holding in the tab on the timing chain tensioner plunger install the timing chain tensioner guide...

Page 66: ...s to 1 7 kg m 12 ft lb Install the intake cam timing sensor onto the timing chain cover AO329A MD1490 NOTE Use blue Loctite 242 on the two center cap screws NOTE Note the position of the alternator ad...

Page 67: ...o position on the cylinder head Install six cap screws Using the pattern shown tighten the cap screws to 1 1 kg m 8 ft lb AO332 NOTE All three of the inner gaskets have an alignment tab but only the t...

Page 68: ...cap screw and tighten to 10 kg m 72 ft lb MD1661 49 Install the starter mounting plate and secure it in place with the bottom cap screw and nut then install the ring gear shield and the remaining thr...

Page 69: ...tall the cap screw and the two lock nuts Tighten to 2 4 kg m 17 ft lb AO336 54 Install the four engine mount brackets Tighten all mounting cap screws coated with blue Loctite 242 Tighten the left rear...

Page 70: ...e grooved belt over the crankshaft pulley water pump and alternator Using a prying tool wedge the alternator out to obtain a belt deflection of 8 9 mm 0 31 0 35 in for a new belt or 12 15 mm 0 47 0 59...

Page 71: ...NOTE A small amount of Anti Seize Thread Compound p n 0678 146 applied to the threads of the sensor will aid in future removal 60 Install the exhaust heat shield and four cap screws then tighten the c...

Page 72: ...d injectors Tighten the two cap screws to 1 3 kg m 9 5 ft lb MD1676 MD1450 64 Install the air intake manifold support bracket and all wiring loom tabs and brackets Tighten to 2 3 kg m 16 5 ft lb MD145...

Page 73: ...with blue Loctite 243 securing the engine and brake bracket to the front end DO NOT TIGHTEN AT THIS TIME A050A 3 Align the engine with the scribed line made during removing then measure the distance...

Page 74: ...ith the bearing retainer cap screws and lock nuts A023A 14 Position the choke and throttle cables in the bracket then connect them to the carburetor A046A 15 Tighten the adjustment jam nuts securely N...

Page 75: ...ten the front mounts to 2 6 kg m 19 ft lb and the rear mounts to 4 8 kg m 35 ft lb NOTE At this point if the torque bumper was turned in return it to the original position AO190 MD1698 8 Connect the s...

Page 76: ...shers are properly positioned 12 Secure the driven pulley by installing any alignment washers the washer and cap screw coated with blue Loctite 242 Tighten the cap screw to 2 6 3 3 kg m 19 24 ft lb MD...

Page 77: ...hen carefully thread the sheave adjuster back into the driven pulley Tighten the adjuster securely using the deflection tool E Close the belt guard then install the driven pulley plug 18 With the two...

Page 78: ...p n 0644 397 install the two springs securing the muffler to the support brackets then install the two springs to the exhaust manifold AO180 AO267 29 Install the ECU to the bracket in the chassis and...

Page 79: ...hose then secure with the hold down plate Connect the positive cable and then the negative cable NOTE There is no vent hose on turbo model battery 36 If the engine oil was drained remove the filler c...

Page 80: ...lace throttle body assembly 5 Clean replace spark plugs 6 Turn ignition switch ON and OFF listen for stepping motor operation 7 Replace ECU 8 Replace sensor Problem Engine Does Not Start No Fuel at Cy...

Page 81: ...4 Fuel pressure regulator faulty 5 Air intake silencer obstructed 1 Service replace problem component 2 Adjust throttle cable to specifications 3 Replace injector s 4 Replace regulator hose 5 Clean a...

Page 82: ...Engine Stops Suddenly Condition Remedy 1 Gas tank empty 2 Spark absent 3 Check Engine light illuminated 4 Fuel filter s obstructed 5 Fuel pressure low 6 Fuel pump faulty 7 Fuel pump relay faulty 8 Ga...

Page 83: ...Checking Compression 3 10 Removing Installing Spark Plugs 3 11 Servicing Valves 3 12 Ignition Timing 3 17 Servicing Oil Filter 3 18 Testing Oil Pressure 3 19 Oil Flow Chart 3 20 Replacing Water Pump...

Page 84: ...to remove the engine to access the recoil starter see Section 2 REMOVING DISASSEMBLING 1 Remove the cap screws securing the recoil starter GR304D 2 Pull the rope out of the housing and align with the...

Page 85: ...y way replacement is necessary 1 Inspect the spring retaining notch in the recoil housing GR113D 2 Inspect the loop of the recoil spring for wear or cracking GR114D NOTE Note the orientation of the re...

Page 86: ...Install the reel assembly with rope wound in the appropriate direction GR507D GR111D 3 Install the springs and ratchets GR506D GR505D 4 Install the plate and secure it with the screw GR503D WARNING Ex...

Page 87: ...he cap screws securing the belt guard to the engine then remove the belt guard from the engine compartment 3 Inspect the belt for cracks wear and proper tension 4 Using the thumb check the tension tig...

Page 88: ...e pan in front of the chain case 2 Locate and disconnect the air silencer drain hose from the fitting at the bottom of the belly pan in front of the chain case then cut the cable tie that secures the...

Page 89: ...he system with a pressure tester to help purge air from the system INSPECTING COOLANT HOSES AND CLAMPS All coolant hoses and connections should be checked annually for deterioration cracks and wear Al...

Page 90: ...resentative of the dif ferent styles of 4 stroke cooling systems in the 2004 Arctic Cat snowmobiles Some components may vary from model to model therefore the technician should use discretion and soun...

Page 91: ...29 Hose 30 Hose 31 Filler Neck 32 Filler Neck Cap 33 Heat Exchanger 34 Rivet 35 Clamp 36 Hose Protector KEY 1 Coolant Tank 2 Cap 3 Machine Screw 4 Lock Nut 5 Vent Fitting 6 Vent Hose 7 Decal 8 Teflon...

Page 92: ...certain the battery is fully charged 4 Install the compression tester gauge with adapter into the spark plug hole then with the throttle valve in the full open position crank the engine over to get t...

Page 93: ...r then remove the ignition coils noting the coil with the green tubing is for the 1 cylinder A0205 A0206 738 478A 3 Using a 3 8 in drive ratchet adapter and a 5 8 in spark plug socket carefully remove...

Page 94: ...the four 6 mm cap screws Tighten only until snug A0204 Servicing Valves ADJUSTING VALVES 1 Remove the two cap screws securing the coolant tube to the valve cover AO223 2 Remove the three cap screws se...

Page 95: ...Be careful so the inner spark plug hole gaskets don t fall into the engine 7 Remove the air silencer see appropriate Servicing Air Silencer in this section AO215 8 Carefully remove the water pump alt...

Page 96: ...clearance checks should be done prior to any adjusting or shimming there fore record each valve clearance value in the sequence for reference 11 Check clearance for 1 and 6 record the clearances 12 Ch...

Page 97: ...ve clearance is in between shim sizes always adjust to the looser side of the spec ification 5 After the new shim has been selected install the shim into the bucket with the number side of the shim fa...

Page 98: ...n 10 Install the water pump alternator belt cover and secure with the two cap screws one lock nut and washer 11 Connect the coolant tube to the valve cover and secure with the two cap screws AO223 12...

Page 99: ...ine and allow it to idle then observe the timing marks with the timing light Timing should be 5 1 BTDC 1150 RPM AO242 7 If the timing is out of specification verify that the engine idle is within spec...

Page 100: ...om the engine AO257 NOTE Prior to installing the new oil filter first apply a thin film of oil to the filter O ring AO258 6 Install the filter then hand tighten until the filter is seated to the gaske...

Page 101: ...d tighten securely AO264 4 Start the engine run at 4000 RPM and observe the oil pressure The engine oil specification is 2 74 kg cm 39 psi 20 NOTE This test must be done with the engine at room temper...

Page 102: ...STON PIN CAMSHAFT HOUSING ROD BEARING CYLINDER HEAD VENTURI VALVE CHAIN TENSIONER ADJUSTER CRANKSHAFT CRANKSHAFT JOURNAL CYLINDER BLOCK LOWER CRANKCASE OIL COOLER OIL FILTER LOWER CRANKCASE OIL PUMP O...

Page 103: ...r alternator cap screws then push the alternator toward the engine and remove the belt AO265 AO266 5 Remove the springs securing the muffler to the exhaust manifold and chassis then unplug the oxygen...

Page 104: ...xhaust manifold heat shield and secure with the three 6 mm cap screws Tighten to 1 1 kg m 8 ft lb AO279 13 Secure the muffler to exhaust manifold and chassis with the springs then connect the oxygen s...

Page 105: ...g the breather hose to the top of the air silencer then remove the hose 4 Disconnect the harness plug in connector from the air temperature sensor AO214 5 Remove the lower drain hose from the bottom o...

Page 106: ...p and water Dry the air silencer thoroughly prior to installing INSTALLING 1 Install the air temperature sensor into the air silencer AO217 2 Position the air silencer into the engine compartment then...

Page 107: ...from the air silencer and turbo inlet 2 Remove the four 8 mm cap screws from the air silencer cover and remove the air filter AO354 3 Inspect the air silencer and filter thoroughly for foreign materi...

Page 108: ...or dance with the manufacturer s recommendations CAUTION Do not drop the turbocharger It it is dropped it must be replaced CAUTION Do not touch rotating parts as damage to turbine or compressor blades...

Page 109: ...ble clamping device clamp off the two coolant hoses then loosen the hose clamps and disconnect the coolant hoses from the turbo 10 Remove the three 8 mm lock nuts and two 8 mm cap screws from the turb...

Page 110: ...oil feed pipe with the banjo bolt and the two copper washers Tighten to 1 5 kg m 11 ft lb AO368 3 With the gasket in place secure the turbo outlet to the turbo with the two 8 mm cap screws and the thr...

Page 111: ...low the engine to idle for at least two minutes before increasing RPM to allow for proper lubrication of the turbo shaft and bearings 13 After running the engine with the coolant tank on and tight ope...

Page 112: ...e specification is 0 07 0 12 mm 0 003 0 005 in AO311 4 Using a feeler gauge measure the oil pump rotor set radial clearance The clearance specification is 0 10 mm 0 17 mm 0 004 0 007 in AO312 5 Remove...

Page 113: ...ghten the screws to 0 8 1 1 kg m 6 8 ft lb AO310A 10 Install the timing cover oil pan and valve cover see Section 2 PRESSURE RELIEF VALVE NOTE The engine must be removed for this pro cedure 1 Remove t...

Page 114: ...120 cc 4 3 Cleaning Carburetor 120 cc 4 5 Inspecting Carburetor 120 cc 4 5 Assembling Carburetor 120 cc 4 5 Installing Carburetor 120 cc 4 7 Adjusting Carburetor 120 cc 4 8 Throttle Cable 120 cc 4 9 T...

Page 115: ...ould be performed Many times what appears to be a serious problem is only a minor one 1 Make sure the gas tank shut off valve was in the OPEN position 2 Turn the shut off valve to the CLOSED position...

Page 116: ...the carburetor Account for the gasket A001 4 Turn the gas tank shut off valve to the CLOSED position 5 Remove the fuel supply hose 6 Disconnect the rod and spring from the carburetor GF317D 7 Slide t...

Page 117: ...rburetor GF321D 4 Remove the splash ring from the carburetor tower GF322D 5 Remove the pin securing the float to the carburetor body then remove the float and needle valve assembly GF323D GF324D 6 Rem...

Page 118: ...ons or damage 6 Inspect the carburetor mounting flange for damage and tightness 7 Place the carburetor insulator on a surface plate covered with 400 grit wet or dry sandpaper Move the insulator over t...

Page 119: ...splash ring onto the carburetor tower GF322D 4 Secure the float chamber to the carburetor with the drain bolt GF321D 5 Install the pilot jet GF320D 6 Install the high speed adjuster screw and rotate...

Page 120: ...he gasket and air cleaner housing into position on the carburetor then install the air breather hose GF316D A001 5 Place the air cleaner housing and carburetor on the engine and secure with the flange...

Page 121: ...le cable adjustment is when with the engine OFF the carburetor throttle is completely open against its limit while the throttle lever lightly con tacts the handlebar grip The throttle arm on the carbu...

Page 122: ...bar pad and cut the cable tie securing the throttle cable to the steering post NOTE Note the location of the cable tie for assembly 5 Loosen the throttle cable binding screw then loosen the throttle c...

Page 123: ...he hand grip The throttle arm on the carburetor should also contact the throttle stop screw when the throttle control is released Adjust by using the following procedure 2 Loosen the throttle cable wi...

Page 124: ...o mark the coolant hoses for assembling purposes 6 Remove the throttle body from the intake plenum NOTE Remove the throttle body ISC bowl before using any type of cleaners to clean the throttle body 7...

Page 125: ...ll the air silencer see appropriate Servicing Air Silencer in Section 3 Fuel Filter 660 cc NOTE The fuel filter should be replaced every 5000 miles NOTE Before removing the fuel filter take note of th...

Page 126: ...tunnel 4 On the Touring Trail lift the seat up and backward enough to access the fuel pump connections and wiring NOTE On the Bearcat to access the wiring and gasline connections it will be necessary...

Page 127: ...5 On the Touring Trail move the seat forward and secure the rear of the seat to the tunnel with existing hardware NOTE On the Bearcat secure the gas tank to the seat base with existing hardware and in...

Page 128: ...the console then slide the cable forward and out of the console A043 4 Pull the recoil starter rope out approximately 60 cm 24 in then tie a slip knot in the starter rope below the console and allow...

Page 129: ...and secure with two lock nuts then using a screw coated with blue Loctite 243 secure the choke knob to the end of the cable 7 Slide the ignition switch into position on the console then secure with th...

Page 130: ...the specific sub section accordingly 0738 785 WARNING Whenever any maintenance is performed on the fuel system there should be no welding smoking open flames etc in the area KEY 1 Gas Tank Assy 2 Vent...

Page 131: ...am 28 Cover 29 Extension 30 Plate 31 Seat Base 32 Mount 33 Seat Wire 34 Retainer Knob KEY 1 Seat Assy Front 2 Gas Tank Seat Base Assy 3 Teflon Tape 4 Plug 5 Grommet 6 Vent 7 Tank Cap 8 Seal 9 Foam 10...

Page 132: ...pump Secure with clamps NOTE The fuel hoses must be connected to their respective fittings and tightened securely or leakage will result 4 Attach the wiring harness to the fuel pump 5 Secure the seat...

Page 133: ...ce the gas tank in position on the tunnel 2 Connect the vent hose to the gas tank 3 Connect the fuel supply and return hoses to the fuel pump Secure with clamps NOTE The fuel hoses must be connected t...

Page 134: ...5 2 Troubleshooting Ignition System 120 cc 5 3 Testing Main Wiring Harness 120 cc 5 3 Testing Electrical Resistances 120 cc 5 4 Testing Ignition Key Switch 5 4 Testing Electric Fuel Pump 660 cc 5 4 I...

Page 135: ...gnition coil makes the transistor TR1 conduct through the resistor R and forms the primary circuit indicated by dashed lines As the flywheel turns faster the primary current increases and the terminal...

Page 136: ...ive ignition switch B Defective emergency stop switch C Defective wiring harness D Defective tether Testing Main Wiring Harness 120 cc NOTE The main wiring harness test can be made using the Fluke Mod...

Page 137: ...ad less than 1 ohm of resistance 3 With the switch in the ON position the meter must read OL infinite resistance Testing Electric Fuel Pump 660 cc 1 Remove the hardware securing the console to the gas...

Page 138: ...s securing the solenoid to the starter motor AO282 3 Tip the solenoid back and unhook the pinion lever then pull the solenoid out and away from the starter motor AO283 4 Remove the two through bolts s...

Page 139: ...springs 5 Inspect the commutator cap bushing for wear 6 Inspect the brass commutator end of the armature for any burned spots or damage If the commutator is slightly burned or damaged the armature mu...

Page 140: ...ty between each segment 3 Check for continuity between the commutator segments and the armature body If there is continuity between the armature body and the commutator segments the armature is faulty...

Page 141: ...mmutator case making sure the alignment marks made during disassembling align AO287 5 Install the end cap and secure with existing through bolts Tighten securely AO285 AO284 6 Install the pinion lever...

Page 142: ...ng the alternator compo nents DISASSEMBLING 1 Using a 3 8 in impact wrench and a 22 mm socket remove the alternator pulley nut then remove the pulley and spacer AO295 AO296 2 Remove the positive lead...

Page 143: ...he covers make sure to make corresponding alignment marks on the covers for assembling purposes AO303A NOTE Be sure to take note of the location of the wave washer which is positioned in the alternato...

Page 144: ...egative Test 1 Using an ohmmeter connect the positive tester probe to the negative terminal and the negative tester probe to each of the rectifier terminals Take note of which terminals register conti...

Page 145: ...install the rotor assembly into the alternator housing 3 Make sure the wave washer is properly positioned in the alternator housing outside the bearing then place the two alternator covers together m...

Page 146: ...h component 7 Install the dust cover using the existing screws Tighten securely AO298 8 Install the positive lead nut and insulator AO297 9 Properly position the alternator pulley spacer then install...

Page 147: ...correctly 1 Check wiring against wiring diagram Problem Starter Does Not Turn Over Condition Remedy 1 Battery discharged 2 Connection loose 3 Grounding improper 4 Fuse blown not installed 1 Check char...

Page 148: ...Wiring Diagram Ignition 660 cc Turbo Harness p n 3006 843 0739 280 5 15...

Page 149: ...Wiring Diagram Ignition 660 cc STD Harness p n 3006 606 0738 189 5 16...

Page 150: ...Wiring Diagram Ignition 120 cc Harness p n 0686 684 0737 331 5 17...

Page 151: ...lebar Warmer Elements HI OFF LO Function 6 3 Testing Thumb Warmer Element HI OFF LO Function 6 3 Testing Handlebar Warmer Switch HI OFF LO Function 6 3 Testing Thumb Warmer Switch HI OFF LO Function 6...

Page 152: ...h harness to the main wiring harness Position the wires so they will not be either pinched or come in contact with any moving components Start the engine and check the switch for proper operation Head...

Page 153: ...f either test is not within specification replace the thumb warmer element 6 Connect the leads then install and secure the handlebar pad Testing Handlebar Warmer Switch HI OFF LO Function 1 Remove the...

Page 154: ...on the meter must read less than 1 ohm of resistance Testing Passenger Handwarmer Elements NOTE During this test resistance will vary due to temperature therefore this test should be made at room temp...

Page 155: ...Wiring Diagram Main Trail Turbo Harness p n 0686 975 Touring Turbo Harness p n 0686 977 Touring Harness p n 0686 979 0738 973 6 5...

Page 156: ...Wiring Diagram Main Bearcat W T Harness p n 0686 804 0738 150 6 6...

Page 157: ...Wiring Diagram Hood Trail Turbo Harness p n 0686 879 Touring Turbo Harness p n 0686 879 Touring Harness p n 0686 879 0739 115 6 7...

Page 158: ...Wiring Diagram Hood Bearcat W T Harness p n 0686 868 0738 175 6 8...

Page 159: ...Wiring Diagram Main Hood 120 cc Harness p n 0686 684 0737 331 6 9...

Page 160: ...120 cc Model 7 19 Front Suspension Arms 7 20 Front Suspension Ski Shock Absorber 7 22 Sway Bar 7 23 Console 7 24 Belly Pan 120 cc Model 7 24 Belly Pan 7 25 Gas Tank Seat Assembly 7 31 Seat Cushion Ta...

Page 161: ...handlebar pad 2 Remove the C clips securing the brake and throttle lever pins in the brake housing and throttle control then remove the pins and levers A979 A998 3 Disconnect the brake and throttle ca...

Page 162: ...emove the retainer and bearing INSPECTING NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is necessary 1 Inspect all welded areas for cracks or deteriora tion 2 Insp...

Page 163: ...ck all fasteners to ensure they are tight Turn the handlebar full left and full right sev eral times to ensure free movement 6 Apply Handlebar Adhesive p n 0636 071 to the bore of the handlebar grip t...

Page 164: ...the skid plate AL144D 2 Remove the cotter pin cap screw and lock nut securing the tie rod to the steering post AL146D 3 Remove the two cap screws and lock nuts securing the lower steering post bracket...

Page 165: ...he chassis Be careful not to hook any wires or hoses INSPECTING NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is necessary 1 Inspect all welded areas for cracks or...

Page 166: ...to 2 5 kg m 18 ft lb AL147D 5 Secure the handlebar pad AL136D 6 Tip the snowmobile on its side then place the tie rod into position Secure with a cap screw coated with green Loctite 609 and lock nut...

Page 167: ...ski for abnormal bends or cracks INSTALLING 0737 548 1 Place the ski the ski into position on the spindle then secure with a cap screw two washers and a lock nut 2 Tighten the lock nut securely making...

Page 168: ...d to the underside of the ski The purpose of the wear bar is to assist in turning the snowmobile to minimize ski wear and to maintain good steering control If the snowmobile is operated primarily in d...

Page 169: ...ich the drag link will be removed remove the self tapping screws securing the steering boot to the front end NOTE To access the MAG side drag link mount ing bolt it will be necessary to remove the MAG...

Page 170: ...nstall the MAG side rubber engine mount to the chassis with the two cap screws Tighten cap screws to 3 5 kg m 25 ft lb Install the cap screw securing the engine mount bracket to the rubber engine moun...

Page 171: ...d on one end of the tie rod The right hand thread is the inside ball joint and jam nut 2 Secure the tie rod to the steering post Tighten to 2 5 2 8 kg m 18 20 ft lb 3 Secure the steering post to the f...

Page 172: ...read therefore each can only be installed on one end of the tie rod The right hand thread is the inside ball joint and jam nut 2 Secure the tie rod to the ball joint on the forked end of the drag link...

Page 173: ...e and counterclockwise The movement should be smooth and free If the spindle movement is rough or binding grease the spindle with a good low temperature grease Rotate the spindle If the movement remai...

Page 174: ...ect the tie rod ball joint in place If damage wear or unusual bends are noted loosen the jam nut then remove the ball joint from the tie rod INSPECTING NOTE Whenever a part is worn excessively cracked...

Page 175: ...s securing the skid plate then remove the skid plate NOTE The front machine screw on some mod els is secured with a washer and lock nut AL144D 2 Remove the cotter pins cap screws and slotted nuts secu...

Page 176: ...measurements front and rear or when the skis have up to a maximum of 6 mm 1 4 in toe out front measurement 6 mm 1 4 in more than rear measurement 3 If ski alignment is not as specified the snowmo bile...

Page 177: ...pply blue Loctite 242 to the jam nut threaded area and tighten to 1 7 2 1 kg m 12 15 ft lb Tighten both jam nuts against the steering tie rod 3 With the handlebar in the straight ahead position secure...

Page 178: ...easurement from in front of the spindle to the outer edge of the wear bar bolts without using the straightedge must not exceed the rear measurement by more than 1 6 6 4 mm 1 16 1 4 in toe out 0734 408...

Page 179: ...s or any signs of deterioration 2 Inspect the axles for wear or damage 3 Inspect the tubing for signs of being twisted or bent INSTALLING 0737 549 1 Slide the A arms onto the cap screws and swing them...

Page 180: ...front end 8 Remove the cap screws and lock nuts securing the suspension arms to the front end then remove the arms INSPECTING NOTE Whenever a part is worn excessively cracked or damaged in any way rep...

Page 181: ...re with cap screw and lock nut 5 Accounting for mounting hardware install the spindle onto the suspension arm with the cap screws and lock washers FS086A 6 Place the shock absorber into position and s...

Page 182: ...itial setting 3 Install the bushings sleeves and spacers into each shock end then place the shock absorber into position Install both cap screws from the front Tighten the lock nuts to 2 8 kg m 20 ft...

Page 183: ...llips head screws securing the belly pan to the footrest supports A040 4 Using a piece of cardboard to protect the finish tip the snowmobile on the right side and using a 20 drill bit drill out the be...

Page 184: ...ood Belly Pan NOTE The following procedure is for a typical Arctic Cat snowmobile belly pan Some compo nents will vary from model to model The techni cian should use discretion and sound judgment REMO...

Page 185: ...shock mount AL179D 11 Remove the front belly pan to nosepiece Phillips head screws AL181D 12 Remove the front belly pan to nosepiece torx head screws AL182D 13 Remove the belly pan assembly from the...

Page 186: ...s securing the belly pan underneath the shock mount AL179D 5 Install the shock absorber bolt Tighten to 2 8 kg m 20 ft lb AL178D 6 Install the left side steering tie rod boot Secure with the screws AL...

Page 187: ...drive and close the belt guard 10 Install the left side cap screw securing the bumper to the air intake silencer plenum AL172D 11 Insert the left side louver foam AL171D 12 Install the left side louve...

Page 188: ...on the left side then remove the right side belly pan torx head screws from the center belly pan and tunnel AL188D 6 Remove the screws securing the right side steering tie rod boot then remove the boo...

Page 189: ...d shape INSTALLING RIGHT SIDE 1 Place the belly pan assembly in position in the frame 2 Install the nosepiece torx head screws to the front belly pan AL182D 3 Install the nosepiece Phillips head screw...

Page 190: ...per to the air intake silencer plenum AL186D 9 Insert the right side louver foam 8 AL185D 10 Install the right side louver AL184D 11 Install the right side front belly pan cap screw washer and lock nu...

Page 191: ...n 2 Remove the two cap screws washers and lock nuts securing the gas tank to the seat base 3 Remove the vent hose from the gas tank 4 Disconnect the wiring harness from the fuel pump Label the fuel ho...

Page 192: ...or two washers 9 Raise the rear of the seat assembly high enough to disconnect the taillight wiring harness then disconnect the taillight from the main wiring harness A045 10 Remove the seat assembly...

Page 193: ...ttom edge of the plastic seat base Position the staples in the same area as the original staples were located NOTE Note the cushion fit If any wrinkles are noted remove by pulling the cushion material...

Page 194: ...e the windshield INSTALLING 1 Place the windshield into position and install the O rings 2 Secure the windshield to the hood with screws w snaps Install the caps Backrest Rack Taillight Assembly NOTE...

Page 195: ...he tunnel KEY 1 Backrest 2 Cover 3 Axle 4 Cup Washer 5 Tension Block 6 Machine Screw 7 Adjuster Arm 8 Spacer 9 Machine Screw 10 Retaining Screw 11 Lens 12 Gasket 13 Bulb 14 Housing 15 Cover 16 Washer...

Page 196: ...refer to the appropriate illustration for component details then remove disassemble and assemble install accordingly Some components will vary from model to model The technician should use discretion...

Page 197: ...hine Screw 18 Machine Screw 19 Washer 20 Lock Nut 21 Washer 22 Snowflap 23 Machine Screw 24 Decal Touring KEY 1 Tunnel Assy 2 Plate 3 Rivet 4 Bracket 5 Rivet 6 Mounting Plate 7 Tunnel Roll 8 Rear Bump...

Page 198: ...rubber headlight socket cap then push in and turn the headlight socket counter clockwise and remove it from the headlight housing 2 Remove the caps covering the four headlight adjustment screws then r...

Page 199: ...ximately 8 m 25 ft from an aiming surface wall or similar surface NOTE There should be an average operating load on the snowmobile when adjusting headlight aim 2 Measure the distance from the floor to...

Page 200: ...lb kg m 30 4 2 Tie Rod Jam Nuts ft lb kg m 12 15 1 7 2 1 Shock Absorber Chassis ft lb kg m 20 2 8 Suspension Arms Spindle ft lb kg m 30 4 2 Shock Absorber Spindle ft lb kg m 20 2 8 Front Suspension Ar...

Page 201: ...Adjuster 8 45 Brake System 120 cc 8 49 Brake System 8 51 Brake Lever Master Cylinder Assembly 8 56 Drive System Specifications 8 60 Chain Case Performance Specifications With Tension Pad Tightener Sy...

Page 202: ...muffler hold down spring from the muffler and support bracket A018 3 Remove the two nuts securing the muffler to the engine A019 4 Press down on the muffler and pull it to the side until the muffler f...

Page 203: ...or stripped threads 4 Inspect the keyways in the driveshaft chain sprocket and clutch for wear or damage 5 Inspect the chain and chain sprocket for wear or damage 6 Inspect the driveshaft sprockets fo...

Page 204: ...ginally matched A too short drive belt will cause a loss in performance and a bog on engagement NOTE A drive belt that is worn thin may produce the same effect as one that is too long Drive belt const...

Page 205: ...arm pins one at a time then remove the cam arm with bushing and account for the washers NOTE When installing cam arms always use new lock nuts Make sure the head of each cam arm pin is positioned tow...

Page 206: ...ion of drive clutch rotation NOTE The drive clutch rotates counterclock wise 8 With the cam arm pin alignment notch properly positioned to the cam arm set screw install the new cam arm set screws pre...

Page 207: ...t in this section 2 Remove the bolt and lock washer securing the drive clutch to the crankshaft FC002A 3 Using Clutch Compressor p n 0644 420 compress the movable sheave inward then insert the compres...

Page 208: ...ap screw and lock washer from the cover then while firmly holding the cover remove the four remaining screws and lock washers equally AM059D FC054 2 Remove the cover and spring AM061D FC055 3 Position...

Page 209: ...tyle after the lock nuts and set screws have been removed remove the cam arm pins one at a time noting the position of the alignment notches for assembly purposes Account for the O rings 0739 038 7 On...

Page 210: ...holder using the clutch puller and the same procedure as pulling the drive clutch from the crankshaft 11 Remove the spider spacer washers and movable sheave 12 Using a pair of pliers remove the six s...

Page 211: ...less than 0 20 mm 0 008 in If cover bushing is not within specifications replace the cover AM078D FC087 AM077D 6 Inspect the bushing in the movable sheave for wear damage or cracks Measure the inside...

Page 212: ...g marks 5 Place the movable sheave spacer washers and spider into position on the stationary sheave hub Make sure all threads are clean and free of oily residue Apply green Loctite 620 to the entire t...

Page 213: ...each cam arm pin positioned towards the direction of the drive clutch rotation install the cam arms NOTE The drive clutch rotates counterclock wise 9 On the 6 post style with the cam arm pin properly...

Page 214: ...12 point 1 2 in socket and the drive clutch spanner wrench tighten the clutch bolt to 6 9 7 6 kg m 50 55 ft lb AF477D FC002 4 Check alignment between the drive clutch and driven pulley see Drive Clutc...

Page 215: ...jaws just enough to allow room for the bushing to pass between 2 Position the cam arm over the spread jaws AM094 3 Slide a new bushing onto one of the cam arm pins then position the pin through the ca...

Page 216: ...ected upward SC002D NOTE To aid in driven pulley servicing use a roll of duct tape as a work fixture The work fixture will increase the stability of the pulley during the repair procedure 3 Remove the...

Page 217: ...e the plate drive the roller pin out of the plate Account for the pin thrust washer and roller SC006D SC007D CLEANING AND INSPECTING NOTE Whenever a part is worn excessively cracked or damaged in any...

Page 218: ...ance between the shaft and the respective bearing must not exceed 0 5 mm 0 020 in If the clearance exceeds the specification the bearing must be replaced B466D B467 REMOVING BEARINGS To remove driven...

Page 219: ...the bracket aligns with the part number on the stationary sheave Install the three socket head screws and lock washers DO NOT tighten at this time AI062 4 Place any thrust washers as noted during dis...

Page 220: ...without binding 11 Rotate the torque bracket cam until it is tight then using a long hex wrench tighten the three socket head cap screws securing the bracket SC011D INSTALLING 1 Slide the alignment w...

Page 221: ...iven pulley retrieve the cap screw washer from inside the pulley bore then account for and remove any alignment wash ers These washers must be used during install ing DISASSEMBLING 1 Prior to disassem...

Page 222: ...nd strike each screw with a hammer FS091 FS092 5 Release the compression of the spring by removing the wing nut then remove the movable sheave Account for the spacer retainer FS093 FS094 NOTE Note the...

Page 223: ...FS096 FS097 NOTE Premature wear will result if the plastic washer is not installed during assembling 8 Remove the three torx head screws securing the cover to the torque bracket FS098 9 Using Driven P...

Page 224: ...ect spring for distortion crystallization or breaks 6 Inspect the rollers pins and spring mounting holes for cracks damage or wear 7 Inspect the cover and movable sheave bearings for wear For each res...

Page 225: ...ing then secure with the snap ring REPLACING ROLLERS 1 Drive the spring pins out of the stationary sheave FS101 NOTE Once a spring pin is exposed it may be necessary to remove the pin using a pair of...

Page 226: ...ack into place FS107 ASSEMBLING 1 Using Driven Pulley Spring Adjustment Tool p n 0644 413 install the spring adjuster FS099 2 Install the torque bracket cover and secure with three torx head screws Ti...

Page 227: ...during disassembling place the stationary sheave onto the torque bracket FS095 5 Place the spacer retainer into position on the stationary sheave noting the proper location of the holes from disassemb...

Page 228: ...n to 2 6 3 3 kg m 19 24 ft lb 4 Install the drive belt NOTE For installing drive belt on models with the ACT Roller Driven Pulley see Removing Installing Drive Belt in this section Drive Clutch Driven...

Page 229: ...4 Install the driven pulley and secure with a cap screw and washers Tighten the cap screw to 2 6 3 3 kg m 19 24 ft lb CHECKING PARALLELISM 1 Check parallelism of the drive clutch driven pulley using t...

Page 230: ...dge should reach from the drive clutch to the top of the driven pulley 4 Using a stiff ruler centered between the drive clutch and driven pulley push down on the drive belt just enough to remove all s...

Page 231: ...se Gear 13 Thrust Washer 14 Thrust Bearing 15 Retaining Ring 16 Cap Screw 17 Tab Lock Washer 18 Washer 19 Shaft Retainer 20 Spring Pin 21 Spring 22 Reverse Idler Spacer 23 Reverse Shaft 24 Reverse Idl...

Page 232: ...ter 39 Cap Screw 40 Washer T660 Touring KEY 1 Track Drive Assy 2 Driveshaft 3 Drive Sprocket 4 Drive Sprocket 5 Idler 6 Drive Bushing 7 Flange Plate Bearing Assy 8 Carriage Bolt 9 Flange Plate 10 Bear...

Page 233: ...on 36 Brake Pad Set 37 Retaining Pin 38 O Ring 39 Housing 40 Adapter Fitting 41 Cap Screw 42 Washer 43 Cap Screw T660 Touring Turbo KEY 1 Track Drive Assy 2 Drive Sprocket 3 Driveshaft 4 Magnet 5 Flan...

Page 234: ...Level Stick 35 Tube 36 Bracket 37 Lock Nut 38 Cap Screw 39 Nut 40 Washer 41 Roller Arm 42 Cap Screw 43 Lock Nut 44 Roller Shaft 45 Roller 46 Bearing 47 Washer 48 Guard 49 Carriage Bolt 50 Lock Nut 51...

Page 235: ...ift Pivot 6 Bushing 7 Axle 8 Washer 9 Washer 10 External Tooth Lock Washer 11 Cap Screw 12 Bracket 13 Switch Boot 14 Alarm Switch 15 Reverse Alarm 16 Retaining Ring 17 Lock Nut 18 Shift Linkage Assy 1...

Page 236: ...iven shaft then remove the driven pulley from the engine compartment Account for the key stub shaft on the Bearcat and T660 Touring and alignment washers NOTE On the Bearcat and T660 Touring if the dr...

Page 237: ...rom the face of the inner idler sprocket and place in safe location until assembly AF439 13 Remove the lock nut securing the top sprocket AF432 14 Remove the spring washer in front of the top sprocket...

Page 238: ...m sprocket and spacer washer AF427 19 Check the idler gear shaft If the shaft surface is rough remove the shaft using a pair of vise grip pliers Rotate the shaft counterclockwise 20 Remove the shoulde...

Page 239: ...e lock nuts securing the driveshaft flange bearing assembly and cable adapter On the Bearcat remove the adapter and speedometer cable AF053 NOTE On the Touring Trail models remove the three lock nuts...

Page 240: ...ings Rotate the inner bearings by hand Check each sprocket tooth for any signs of chipping and wear 15 Closely inspect the drive chain for broken links 16 Inspect the reverse gear Inspect the teeth fo...

Page 241: ...the tunnel Install the driveshaft with the splined end through its mounting hole in the chain case 4 Place the PTO side of the driveshaft into position by sliding the bolts of the flange bearing asse...

Page 242: ...lar at this time Secure the PTO side bearing and flange plates with two carriage bolts and lock nuts Tighten to 2 2 2 5 kg m 16 18 ft lb 9 On the MAG side driven shaft install the bearing O ring and f...

Page 243: ...g and shaft Tighten the collar set screw 15 Place the rubber alignment pin into position in the idler sprocket then slide the outer idler gear on the shaft Install shim washer on the shaft AF436 16 If...

Page 244: ...e collar in the direction of rotation until tight and tighten the collar set screw AF054 28 Install the skid frame see Section 9 29 Place the intake plenum into position and secure with the torx head...

Page 245: ...4 0 381 mm 0 010 0 015 in Lock the adjustment by tightening the jam nuts securely against the tie rod ends NOTE To adjust the linkage rod the shift lever must be moved to the forward position 5 Instal...

Page 246: ...ecure the spring using a cable tie AF421 9 Remove the set screw from the adjuster housing then remove the adjuster socket from the housing by pulling it free of the adjuster bolt AF422 10 Rotate the a...

Page 247: ...all an 8 32 set screw AF403 AF425 4 Install the bent tab of the spring into the slot of the adjuster socket with the outer hooked end of the spring positioned in the clockwise direction AF406 5 With t...

Page 248: ...and place the spring into position in the end of the adjuster bolt AF401 10 Use a thin coat of grease on the stem shaft to hold it in position then place the stem into the end of the adjuster bolt AF4...

Page 249: ...nect the brake cable from the lever then slide the brake cable out of the lever A999 7 Remove the handlebar pad and cut the cable tie securing the brake cable to the steering post NOTE Note the locati...

Page 250: ...f the brake cable to the bracket with the jam nuts A005 6 Secure the brake cable to the steering post with a cable tie then install the handlebar pad CHECKING BRAKE LEVER TRAVEL 1 Compress the brake l...

Page 251: ...igh mark Install and secure the reservoir cover DO NOT allow moisture to contaminate the brake system CHANGING BRAKE FLUID The brake fluid must be changed on a regular basis and or whenever the brake...

Page 252: ...high mark with approved brake fluid 2 Slide a piece of flexible tubing over the ball of the bleeder valve and direct the other end into a container 0730 434 3 Slowly compress the brake lever and hold...

Page 253: ...bile slowly and compress the brake lever repeatedly until the pads just start to heat up then allow them to cool down This process stabilizes the pad material and extends the life of the pads REMOVING...

Page 254: ...cessively cracked or damaged in any way replacement is necessary 1 Inspect the brake pistons for gouges cracks pitting scuffing or corrosion If any of these conditions exist replace the piston 2 Clean...

Page 255: ...a new O ring when assem bling the brake caliper 2 In each caliper half apply approved brake fluid to the brake piston then while twisting install the piston with the open side facing out AF266 AF269...

Page 256: ...This process stabilizes the pad material and extends the life of the pads Brake Lever Master Cylinder Assembly REMOVING 1 Slide a piece of flexible tubing over the ball of the bleeder valve and direct...

Page 257: ...the master cylinder 4 Compress the locking tabs of the reservoir and remove the reservoir from the master cylinder Account for an O ring seal AF205 INSPECTING NOTE Whenever a part is worn excessively...

Page 258: ...on the handlebar Secure with two torx head machine screws and clamp tighten securely 2 Install the hose on the master cylinder Tighten securely KEY 1 Brake Assy 2 Brake Lever 3 Lever Mounting Screw 4...

Page 259: ...e the brakelight switch into the brake control until the self locking tabs snap into position Lightly pull on the switch to make sure it is properly secured 4 Bleed the brake system see Brake System H...

Page 260: ...147 Yellow Green 9 Over T660 Trail Turbo 0 5000 0725 384 0646 149 Red 0646 671 69 5 0726 166 0648 662 Platinum 5 9000 0646 147 Yellow Green 9 Over MODEL ALTITUDE TORQUE BRACKET GEAR RATIO CHAIN DRIVE...

Page 261: ...104 4 18 37 0 486 68 62 4 72 8 83 2 93 6 104 0 16 33 0 484 66 62 1 72 5 82 8 93 2 103 5 19 41 0 463 72 59 4 69 3 79 2 89 1 99 0 18 39 0 461 70 59 1 69 0 78 9 88 7 98 6 17 37 0 459 68 58 9 68 7 78 5 88...

Page 262: ...47 0648 024 55 53 0648 107 57 50 0648 125 51 49 0648 126 53 51 0648 656 62 54 0648 679 50 36 0648 681 62 50 0648 682 58 52 0648 683 58 50 0648 696 66 50 0 27 66 52 0 27 0648 719 68 42 0 34 68 44 0 32...

Page 263: ...41 0 grams 39 5 grams 44 5 grams 45 0 grams 46 5 grams 46 5 grams 47 0 grams 0746 533 47 5 grams 0746 527 50 5 grams 53 5 grams 49 5 grams 54 0 grams 53 0 grams 49 5 grams 48 5 grams 52 5 grams 51 5...

Page 264: ...8 64 ARCTIC CAT CAM ARMS 99 CAM 0746 642 50 5 grams 0746 653 63 5 grams 0746 640 71 5 grams 0746 655 56 5 grams 0746 645 646 647 52 57 49 grams...

Page 265: ...8 65 8 ARCTIC CAM ARMS 04 CAM...

Page 266: ...07 358 68 0107 215 70 0107 216 70 0602 371 72 0107 372 WIDE CHAIN 13 Link PITCH P N 68 0602 495 70 1602 041 72 1602 042 WIDE CHAIN 15 Link 68 1602 036 70 0602 968 72 0602 972 74 1602 037 WIDE SPROCKET...

Page 267: ...010 49 3 16 inch 1 1 4 inch 0227 011 44 3 16 inch 1 1 4 inch 0227 014 45 1 2 3 16 inch 1 1 4 inch 0227 016 45 1 16 3 16 inch 1 1 4 inch 0227 017 42 13 16 3 16 inch 1 1 4 inch 0227 019 43 1 4 3 16 inc...

Page 268: ...Touring 600 0627 020 Powder Special 500 EFI 0627 020 Powder Special 600 Models 0627 020 Powder Special 700 0627 020 Thundercat Thundercat M C 0627 020 Z 370 0627 021 Z 440 0627 021 ZL 440 0627 021 ZL...

Page 269: ...ring Super Jag EXT Wildcat EFI 25 9 10 200 34 67 1 365 Wildcat AWS 28 9 11 375 34 67 1 365 1993 Lynx Jag Panther Cougar Pantera Prowler Cheetah Touring EXT Models 25 9 10 200 34 67 1 365 Wildcat AWS M...

Page 270: ...m 5 5 0 75 Movable Sheave ACT ft lb kg m 5 5 0 75 Driven Pulley Cap Screw ft lb kg m 19 24 2 6 3 3 Chain Tensioner ft lb Shoulder Nut kg m 4 5 0 6 0 7 Voltage Regulator ft lb Speedometer Pick Up kg m...

Page 271: ...ring movable sheave Problem Excessive Belt Deposits Condition Remedy 1 Offset adjusted incorrectly 2 Drive clutch driven pulley sheaves rough damaged dirty 3 Driven pulley movable sheave travel impair...

Page 272: ...3 Polish replace cam arms 4 Replace buttons 5 Clean sheaves Problem Drive Belt Glazed Condition Remedy 1 Drive belt does not meet measurement specifications 2 Drive clutch spring tension inadequate 3...

Page 273: ...ake Condition Remedy 1 Brake fluid overheated contaminated 2 Master cylinder damaged faulty 3 Caliper brake hose leaking 4 Air ducts obstructed missing 5 Brake lever linkage damaged 1 Replace fluid 2...

Page 274: ...ng Marks Location 9 86 Drive Track Usage Chart 9 102 Drive Track Lug Patterns 9 104 Track Warranty Guidelines 9 105 Idler Wheel Selection Chart 9 106 Torque Specifications 9 108 Shock Absorber Usage G...

Page 275: ...ion system works think of the entire system in terms of three points the skid frame rear axle center the skid frame front arm and the ski saddle center Assume that the front arm functions as a station...

Page 276: ...two limiter straps on AWS models can be short ened if desired This adjustment must be made to suit driving style and some test driving time With the rear arm in its present mounting location no advant...

Page 277: ...nd some travel is lost NOTE When making any changes to the front or rear suspension the change should be made at both ends to keep the suspension balanced For example installing stiffer springs in fro...

Page 278: ...make sure arms are parallel 8 Tighten the four bolts securing the two arms on each side to 9 7 kg m 70 ft lb 9 Install the shock absorber making sure to tighten the two mounting bolts NOTE The above p...

Page 279: ...mmended by Arctic Cat Inc that when disassembling and assembling the suspension all stock mounting locations be used as shown in the following illustra tions 0739 214 CAUTION It is extremely important...

Page 280: ...9 7 9 735 315A 0739 320 T660 Touring Models IDLER WHEEL MTG HOLE Pantera 800 EFI Bearcat Wide Track...

Page 281: ...snowmobile model from the list and follow the chart to attain schematic designation and repair procedure Snowmobile Models Slide Rail Style Front Arm Style Rear Arm Style Idler Wheels Style Articulat...

Page 282: ...Spacer 24 Axle Housing 25 Track Adjuster 26 Bushing 27 Cap Screw 28 Washer 29 Cap Screw 30 Cap Screw 31 Nut 32 Lock Washer Style A 33 Spacer 34 Pad 35 Solid Rivet 36 Track Assy 37 Guide Clip KEY 1 For...

Page 283: ...Nut 19 Pad 20 Screw 21 Cap Screw 22 Rear Arm 23 Cap Screw 24 Washer 25 Coupler Block 26 Bushing 27 Lock Nut 28 Cap Screw 29 Adjuster 30 Track Assy 31 Guide Clip 32 Wear Clip Style C KEY 1 Formed Rail...

Page 284: ...er 34 Spacer 35 Adjuster Style E 36 Cap Screw 37 Cap Screw 38 Lock Nut 39 Bumper 40 Spacer 41 Washer 42 Bushing 43 Axle 44 Idler Wheel 45 Bushing 46 Idler Wheel 47 Insert KEY 1 Formed Rail 2 Support 3...

Page 285: ...ck Cover 21 Limiter Strap 22 Lock Nut 23 Washer 24 Cap Screw 25 Axle 26 Washer 27 Lock Washer 28 Cap Screw Style A KEY 1 Front Arm 2 Grease Fitting 3 Bushing 4 Bearing 5 Axle Tube 6 Axle 7 Cap Screw 8...

Page 286: ...ng 19 Spacer 20 Axle 21 Washer 22 Arm 23 Bushing 24 Cap Screw 25 Lock Nut 26 Washer 27 Lock Washer 28 Cap Screw 29 Cap Screw 30 Axle 31 Link 32 Spacer 33 Cap Screw 34 Shock Absorber 35 Sleeve 36 Bushi...

Page 287: ...asher 30 Lock Washer 31 Cap Screw 32 Cap Screw 33 Link Axle 34 Shock Link 35 Cap Screw 36 Spacer 37 Shock Absorber 38 Bushing 39 Sleeve Style C KEY 1 Idler Arm 2 Bushing 3 Grease Fitting 4 Rear Arm 5...

Page 288: ...Washer 27 Spring 28 Wear Block 29 Rivet 30 Washer 31 Retaining Clip Style A KEY 1 Formed Rail 2 Wear Strip 3 Lock Nut 4 Cap Screw 5 Washer 6 End Cap 7 Machine Screw 8 Cap Screw 9 Washer 10 Crossbrace...

Page 289: ...Washer 35 Nut Style C 36 Cap Screw 37 Idler Wheel 38 Cap Screw 39 Cap KEY 1 Cap Screw 2 Washer 3 Idler Wheel 4 Bearing 5 Retaining Ring 6 Mounting Block 7 Cap Screw 8 Lock Nut 9 Cap Screw 10 Washer 11...

Page 290: ...Loosen the jam nuts and the two track tension adjusting bolts 0735 454 2 Place a support stand under the rear bumper then remove the two cap screws securing the upper idler wheel assembly to the tunne...

Page 291: ...h openings windows in the track and drive it forward onto the slide rail Secure with the machine screw and lock nut 1 Remove the machine screw and lock nut securing the wear strip to the front of the...

Page 292: ...r arm to the skid frame then remove the rear arm Account for and note the location of all hardware AO159 2 Remove the rear springs and sleeves from the rear arm INSPECTING NOTE Whenever part is worn e...

Page 293: ...r wheel bearings Rotate each bear ing by hand and if any roughness or binding is noted replace the idler wheel assembly 3 Inspect all idler wheel inserts inner and outer for any cracks 4 Inspect the o...

Page 294: ...he idler wheel axle assembly into position in the tunnel and secure with cap screws coated with blue Loctite 243 Tighten securely Slide Rail NOTE The skid frame must be removed for this procedure see...

Page 295: ...ock pad to the slide rail Remove the shock pad AO161 8 Remove the slide rail from the skid frame INSPECTING NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is necess...

Page 296: ...re the rear suspension arm bracket and back ing plate to the slide rail with cap screws and lock nuts Tighten securely AO162 4 Secure the rear suspension arm to the bracket with existing hardware Tigh...

Page 297: ...e side until the muffler flange clears the engine exhaust studs then remove the muffler from the engine compartment Account for the exhaust gasket 5 Compress and hold the brake lever then remove the c...

Page 298: ...ALLING 737 161B 1 Position the key on the rear driveshaft then slide the chain sprocket clutch drive chain assembly into position 2 Secure the clutch with a pair of channel lock pliers at the outer cl...

Page 299: ...t be removed for this procedure see Removing Skid Frame in this sub section REMOVING 1 Remove the five machine screws securing the rear chain guard then remove the guard A017A 2 Compress and hold the...

Page 300: ...l A022 2 Slide the driveshaft assembly into position in the tunnel then secure with carriage bolts and lock nuts Tighten securely A021 3 Place the upper idler wheel assembly into position in the tunne...

Page 301: ...ounting cap screws securely 7 Check track tension adjust as necessary see Track Tension in this sub section Track Tension NOTE Track tension and track alignment are interrelated therefore always check...

Page 302: ...tension is adjusted CHECKING 1 Remove excess ice and snow buildup from the track track drive sprockets and the inside of the skid frame 2 Position the tips of the skis against a wall then using a shi...

Page 303: ...ions and photographs used in this sub section are used for clarity purposes only and are not designed to depict actual condi tions Removing Skid Frame NOTE Many service procedures can be per formed wi...

Page 304: ...g a pipe wrench and starting from either end hook the edge of the wear strip with the pipe wrench jaw and twist the wear strip off the slide rail Move the pipe wrench 7 5 cm 3 in and again twist the w...

Page 305: ...ion AG535D 2 Secure with a machine screw and lock nut Tighten to 1 1 kg m 8 ft lb End Caps NOTE The skid frame does not have to be removed for this procedure REMOVING 1 Remove the lock nut washers and...

Page 306: ...ck pads 2 Remove the shock pads INSPECTING NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is necessary 1 Inspect the pads for damage or wear 2 Inspect the rivet hol...

Page 307: ...ulic press press the bearing out from the inside of the wheel C Press the new bearing on its outer race into the idler wheel AG538D D Install the snap ring making sure the sharp side is directed away...

Page 308: ...the spring from the adjusting cam AG624DA 2 Mark the offset pivot idler and the idler arm for assembly purposes AG675D 3 Remove the cap screws securing the offset pivot idler to the upper idler wheel...

Page 309: ...el and plastic hub for cracks or damage 3 Rotate the idler wheel bearings by hand and inspect for binding or roughness 4 If a bearing must be replaced use this procedure A Remove the wheel insert if a...

Page 310: ...idler wheel on the idler arm AG545D 4 Install the spacer collar onto the idler arm AG677D 5 Place the flanged axle with a thin flat washer through the notched side of the offset pivot idler arm assem...

Page 311: ...at side of the wheel insert is positioned next to the inner plastic adjuster bush ing The idler wheel must be installed with the wheel insert properly positioned 2 Loosen the track adjusting bolts Sli...

Page 312: ...he insert if applicable AG540D ASSEMBLING 1 In order from the right hand side slide the axle through the slide rail axle bracket then place a flat washer short spacer with bushings inner idler wheel w...

Page 313: ...rear upper idler wheels and springs see Rear Upper Idler Wheels Rear Springs in this sub section AG545D 2 Remove the cap screw and lock nut securing the upper shock eyelet to the idler arm Account for...

Page 314: ...Clean the bearings with a clean cloth 2 Inspect each idler wheel for cracks or damage 3 Inspect the bushings located in the arm pivot area for wear or damage 4 Inspect all welds and the tubing of the...

Page 315: ...side between the slide rails Secure with a cap screw and lock nut Tighten to 4 7 kg m 34 ft lb FS083D NOTE Install the rear arm assembly into the appropriate mounting hole as noted during disas sembl...

Page 316: ...dler see Rear Upper Idler Wheels Rear Springs in this sub section Front Arm Front Shock Absorber Front Inner Idler Wheels NOTE The skid frame must be removed for this procedure see Removing Skid Frame...

Page 317: ...ler wheels to the slide rails Account for one small washer two spacers four large flat washers a lock washer and a lock nut AG687D AG688D 6 Remove the cap screw securing the front shock mounting brack...

Page 318: ...t welds at each end for any cracks signs of separation or for unthreading 7 Inspect the shock absorber for damage INSTALLING 1 Secure the shock eyelet to the front shock mounting bracket Tighten to 3...

Page 319: ...or this procedure see Removing Skid Frame in this sub section DISASSEMBLING 1 Using the Rear Suspension Spring Tool p n 0144 311 remove the spring from the adjusting cam AG624DA 2 Remove the cap screw...

Page 320: ...aring on its outer race into the idler wheel AG538D D Install the snap ring making sure the sharp side is directed away from the bearing AG539D E Install the insert if applicable 7 Inspect the shock a...

Page 321: ...ary to replace one or both slide rails it is recommended that one slide rail be removed at a time The remaining slide rail will then hold the crossbraces axles and brackets in their correct assembly o...

Page 322: ...the adjusting cam AG624DA 8 Remove the cap screw and flat washer securing the spring slide to the rail Account for a spacer and the slide block AG515D 9 Mark the mounting position of the front arm mo...

Page 323: ...hing cap screw and lock nut AG672D 13 Mark the mounting positions of the rear arm lim iter A and rear arm B then remove the cap screws lock washers and lock nuts from the rear arm limiter and rear arm...

Page 324: ...1 Inspect the slide rail for cracks or unusual bends AG529D 2 Inspect the wear strip for wear The wear strip must be 10 7 mm 0 42 in thick or thicker If the wear strip measurement is less than specifi...

Page 325: ...coupler block with bushing Secure with cap screw and lock nut Tighten to 2 1 kg m 15 ft lb 6 Install the rear inner idler wheel mounting block in the appropriate hole as noted during disassembly and...

Page 326: ...h cap screws coated with blue Loctite 243 Tighten to 6 9 kg m 50 ft lb FS051 NOTE Apply a light coat of grease to the slide rail surface to aid in installing a new wear strip If there are any sharp ed...

Page 327: ...ngle to the bottom of the tunnel 4 Elevate the rear of the skid frame and the track into position in the tunnel 5 Align the offset pivot idler arm assembly with the appropriate hole in the tunnel Secu...

Page 328: ...or slap the skid frame 4 After correct track tension is obtained check track alignment see Track Alignment in this sub sec tion NOTE Track tension and track alignment are interrelated always check bo...

Page 329: ...r disengaged Repair Procedure 3 Track Rear Suspension This Track Rear Suspension sub section Repair Pro cedure 3 has been organized so each procedure can be completed individually and efficiently Each...

Page 330: ...d slide rail then align the wear strip with openings windows in the track and drive it forward onto the slide rail Secure with the machine screw and lock nut NOTE The skid frame should be removed for...

Page 331: ...534D 1 From the back start the wear strip onto the rail then using a block of wood and a hammer drive the wear strip forward into position AG535D 2 Secure with a machine screw and lock nut Tighten to...

Page 332: ...en to 1 1 kg m 8 ft lb Shock Pads NOTE The skid frame does not have to be removed for this procedure REMOVING NOTE The shock pads should be removed only if being replaced 1 Twist the push nuts off the...

Page 333: ...ment is necessary 1 Clean the bearing with a clean cloth 2 Inspect each idler wheel and each plastic hub for cracks or damage 3 Rotate the idler wheel bearing by hand and inspect for binding or roughn...

Page 334: ...washer on both sides of the idler wheel AG622D AG623D 3 Secure the idler wheel assembly with a cap screw and a lock nut Tighten cap screws to 3 2 kg m 23 ft lb AG618D Rear Inner Idler Wheels NOTE The...

Page 335: ...lastic hub for cracks or damage 3 Rotate the idler wheel bearings by hand and inspect for binding or roughness 4 If a bearing must be replaced use this procedure A Remove the wheel insert if applicabl...

Page 336: ...rings NOTE The skid frame must be removed for this procedure see Removing Skid Frame in this sub section REMOVING 1 Using the Rear Suspension Spring Tool p n 0144 311 remove the spring from the adjust...

Page 337: ...ail Account for a slide block and washer AG679D AG680D 7 Remove the spring and sleeve from the idler arm AG681D NOTE Use the same procedure for the other side INSPECTING NOTE Whenever a part is worn e...

Page 338: ...ear 6 Inspect the adjusting cams and arms for cracks INSTALLING 1 Slide the sleeve and spring onto the idler arm AG681D 2 Place the spring slide and slide block with spring in slide block into positio...

Page 339: ...ening the pivot idler arm lock nuts tighten the lower lock nut first or binding may occur AG675D 7 Place the short spring leg onto the adjusting cam using the rear suspension spring tool AG624DA Rear...

Page 340: ...ny cracks 3 Inspect the outer rubber portion of the idler wheels for cracks and poor bonding 4 Inspect the plastic insert of each idler wheel for cracks 5 Inspect the shaft for wear and damaged thread...

Page 341: ...e the outer idler wheels on the axle with the large flat of the insert directed inward and secure with two cap screws coated with red Loctite 271 and large flat washers Tighten cap screws to 3 2 kg m...

Page 342: ...shock links to the idler arm Account for a lock nut spacer flat washers and axle links AG682D AG556D 4 Remove the cap screw and lock nut securing the rear arm to the slide rail Account for the serrat...

Page 343: ...cams for damage 6 Rotate the idler wheel bearings by hand and check for binding or roughness 7 If a bearing must be replaced use this procedure A Remove the wheel insert if applicable and the snap rin...

Page 344: ...cure with a cap screw washer and lock nut Tighten to 3 2 kg m 23 ft lb AG556D AG682D 4 Place the upper shock eyelet with bushings between the idler arm brackets making sure the spacer is properly posi...

Page 345: ...ng the front arm to the front arm mounting brackets AG633D 4 Remove the front arm and account for an axle tube and serrated axles AG685D 5 Remove the cap screw securing the front inner idler wheels to...

Page 346: ...ct the two rear track guide bumpers If worn drill out the rivets securing the bumpers to the arm and replace with new bumpers AG486D 5 Inspect the shock absorber for any signs of oil leakage especiall...

Page 347: ...2 kg m 23 ft lb 5 Position the front arm with spacers axle tube and serrated axle into the mounting brackets Secure with cap screws and lock nuts Tighten to 4 2 kg m 30 ft lb AG685D 6 Position the upp...

Page 348: ...ement is necessary 1 Clean shock pivot and idler wheel axle in part cleaning solvent Dry with compressed air 2 Clean the idler wheel bearings with a clean cloth 3 Closely inspect the idler wheel axle...

Page 349: ...link assembly thick flat washer shock pivot bracket and shock eyelet assembly thick flat washer shock link assembly and a thin flat washer Secure the assembly with a lock nut Tighten to 3 2 kg m 23 f...

Page 350: ...he wear strip off the rail Repeat this procedure until the wear strip is free of the rail NOTE The wear strip can also be driven off the slide rail however it is quicker to use the pipe wrench AG510D...

Page 351: ...r and the slide block AG679D AG680D 9 Mark the mounting position of the front arm mounting bracket AG637D 10 Remove the cap screws securing the front arm mounting bracket Account for lock nuts AG638D...

Page 352: ...hen remove the cap screw and flat washer securing the rear idler wheel Remove the idler wheel then remove the adjuster bushing FC194 AG628D NOTE The adjusting bolt may have to be loos ened to remove t...

Page 353: ...ld be removed only if being replaced INSPECTING NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is necessary 1 Inspect the slide rail for cracks or unusual bends AG5...

Page 354: ...sher Tighten to 3 2 kg m 23 ft lb then install the wheel cap AG628D FC194 4 If applicable install coupler block w bushing Secure with cap screws and lock nuts Tighten to 2 1 kg m 15 ft lb FS083C 5 Ins...

Page 355: ...cket with the cap screws coated with red Loctite 271 and lock nuts Tighten to 2 4 kg m 17 ft lb AG638D 9 Place the spring into the slide blocks then place the spring slide and slide block assembly int...

Page 356: ...ghten to 1 5 kg m 11 ft lb AG511D NOTE Apply a light coat of grease to the slide rail surface to aid in installing a new wear strip If there are any sharp edges on the lower portion of the rail use a...

Page 357: ...NOT TIGHTEN AT THIS TIME NOTE Do not install the short legs of the rear springs onto the adjusting cams at this time 6 At this time tighten all four skid frame mounting cap screws to 3 2 kg m 23 ft l...

Page 358: ...k CHECKING 1 Using a shielded safety stand raise the rear of the snowmobile off the floor making sure the track is free to rotate 2 Start the engine and accelerate slightly Use only enough throttle to...

Page 359: ...rive shaft refer to the parts manual for model being worked on then refer to the following illustrations using the part number listed in the parts manual as a reference When pressing new sprockets on...

Page 360: ...9 87 9 0728 001 0000 004 0728 002 0000 004 0728 004 0000 006...

Page 361: ...9 88 0728 006 0000 007 0728 007 0000 008 0728 008 0000 009...

Page 362: ...9 89 9 0728 009 0000 007 0728 010 0728 019 0000 011 0728 011 0000 012...

Page 363: ...9 90 0728 012 0000 013 0728 013 0000 013 0728 015 0000 015...

Page 364: ...9 91 9 0728 016 0000 016 0728 017 0000 017 0728 018 0000 018...

Page 365: ...9 92 0728 021 0000 087 0728 022 0000 018 0728 023 0000 089...

Page 366: ...9 93 9 0728 024 0000 090 0728 025 0000 091 0728 026 0000 092...

Page 367: ...9 94 0728 027 0000 017 0728 028 0000 020 0728 029 0000 021...

Page 368: ...9 95 9 0728 030 0000 022 0728 031 0000 023 0728 032 0000 038...

Page 369: ...9 96 0728 033 0000 093 0728 035 0000 094 0728 036 0000 095...

Page 370: ...9 97 9 0728 037 0000 096 0728 038 0000 097 0728 039 0735 365 0728 040 0728 040...

Page 371: ...9 98 0728 041 0735 366 0728 042 0728 042 0728 043 0728 043 0728 047 0728 047...

Page 372: ...9 99 9 0728 048 0738 017 0728 049 0738 018 0728 050 0738 019 0728 065 0738 355...

Page 373: ...9 100 0728 067 0738 356 0728 072 0738 357 0728 076 0738 358 0728 081 0738 359...

Page 374: ...9 101 9 0728 083 0738 360 0728 084 0738 361 0728 116 0739 222 0728 117 0739 223...

Page 375: ...20 13 50 Four Full Block 4 850 0602 868 121 15 8 84 Four Full Block 2 725 0602 869 136 15 8 64 Four Deep Lug 4 1 40 0602 904 136 15 8 84 Four Deep Lug 4 1 60 0602 905 136 15 8 84 Four Deep Lug 4 2 00...

Page 376: ...1 15 8 84 Four Aggressive Wave 4 2 00 1602 330 128 13 5 8 84 Four Full Block 4 725 1602 336 159 15 8 84 Four Aggressive Wave 4 2 00 1602 410 128 13 5 8 84 Four Deep Lug 4 1 50 1602 411 128 13 5 8 84 F...

Page 377: ...9 104 DRIVE TRACK LUG PATTERNS Below are illustrations of the lug patterns available on Arctic Cat drive tracks These patterns are representative samples only and the actual patterns may vary...

Page 378: ...ice metal gravel etc Not Covered Internal Lug Damage Condition in which internal lugs are torn worn or cracked Result of contact being made with a foreign object Track derailment can also cause this d...

Page 379: ...4 205 w o hole 0604 450 5 63 in 0 625 in 0104 340 0104 341 0 875 in Not spoked aluminum center 0604 459 5 63 in 0 625 in 0104 340 0104 341 1 00 in Not spoked 0604 981 5 63 in 0 625 in 0104 340 0104 34...

Page 380: ...1 00 in 1 22 in Orange 2604 117 7 125 in 0 984 in 1 07 in Not spoked Black 2604 122 5 630 in 0 625 in 1604 772 1604 773 1 22 in Yellow 2604 123 6 380 in 0 625 in 1604 774 1 44 in Yellow 2604 124 7 12...

Page 381: ...ting Bracket ft lb Rail kg m 45 6 2 Front Arm Mounting Brackets ft lb kg m 30 4 2 Limiter Straps ft lb kg m 8 1 1 Crossbrace Rail ft lb kg m 50 6 9 Shock Links ft lb kg m 23 3 2 Shock Eyelets ft lb kg...

Page 382: ...0 2 97 1603 253 10 840 16 300 5 46 1604 455 9 560 15 010 5 45 1604 369 8 420 12 490 4 07 0703 997 11 470 17 990 6 52 0703 996 11 470 17 990 6 52 0703 929 11 470 17 990 6 52 0703 825 11 470 17 990 6 52...

Page 383: ...3 24 0704 802 9 900 14 390 4 49 0704 797 9 900 14 390 4 49 0704 852 9 970 14 630 4 66 1703 449 12 620 9 030 6 68 1703 484 12 660 18 860 6 20 1703 485 12 660 18 860 6 20 1703 449 12 620 19 300 6 68 17...

Page 384: ...01 9 940 15 170 5 24 1603 172 9 960 14 300 4 35 1603 173 9 080 13 790 4 47 1603 174 10 460 16 300 5 85 1603 175 11 330 17 060 5 73 1604 368 8 380 12 110 3 74 1604 370 10 550 16 670 6 12 1604 371 9 550...

Page 385: ...9 00 4 80 17 50 5 50 0604 282 283 437 75 9 00 4 80 17 50 5 50 0604 288 289 460 60 9 00 4 75 17 50 4 50 0604 290 291 490 60 9 00 5 02 17 50 4 50 0604 314 315 460 90 9 00 5 03 17 50 5 50 0604 400 401 40...

Page 386: ...50 5 50 0704 890 891 359 90 5 75 3 00 15 62 5 12 0704 892 893 405 75 8 75 4 32 19 00 5 50 0704 938 939 452 90 8 75 4 53 16 00 5 70 0704 944 945 452 75 8 75 4 62 18 75 5 50 0704 986 987 406 90 8 75 4 3...

Page 387: ...Dual Rate 17 0 YES 1603 5064 295 12 61 80 120 11 11 13 11 YES 1603 5812 306 12 50 110 11 2 13 2 YES 1603 599 306 13 00 110 14 YES 1603 6024 306 11 50 77 205 14 16 YES 1603 6041 312 14 125 121 15 17 Y...

Page 388: ...9 8 11 8 YES 1703 2016 312 14 25 50 17 19 YES 1703 2162 306 10 00 110 9 7 11 7 YES 1703 2256 306 13 00 110 11 1 13 1 YES 1703 2572 312 9 50 110 9 1 11 1 YES 1703 2587 312 9 50 110 9 1 11 1 YES 1703 26...

Page 389: ...9 5 90 1603 267 8 5 110 1604 509 7 0 160 343 wire dia 1604 445 7 0 180 360 wire dia 1603 171 8 4 90 0704 960 8 0 110 0704 936 7 0 170 0704 1781 15 25 0704 855 7 0 180 360 wire dia 0704 523 8 0 110 16...

Page 390: ...H 1604 066 067 Round Problem Track Edge Frayed Drive Lugs Worn Condition Remedy 1 Track alignment adjusted incorrectly 1 Align replace track Problem Track Worn Adjacent to Outer Drive Lugs Condition R...

Page 391: ...000 x 010 3 1 000 x 010 4 900 x 010 2 900 x 010 5 800 x 010 1 800 x 010 6 700 x 010 0644 268 Shock Bearing Cap Installation Tool 0644 057 Shock Spring Removal Tool 0644 158 Shock Inflation Needle 064...

Page 392: ...ntil all pressure is released FS081 FS052 FS053 2 Using a 1 in wrench loosen the end cap and remove the shock rod and valve assembly from the shock body FS054 FS055 3 Pour the oil from the shock body...

Page 393: ...end cap clean inspect or replace C Inside of shock body for scratches burrs or excessive wear D Piston strap for cuts chipped or nicked edges or excessive wear E O rings for nicks cuts or cracks F Va...

Page 394: ...he floating piston into shock until flush with the top of the body FS063 FS064 3 Install IFP tool onto floating piston then press floating piston into shock body 5 90 in FS065 FS066 4 Install bladder...

Page 395: ...FS072 7 Install the set screw and tighten to 1 0 kg m 7 ft lb FS073 8 Install shock rod piston assembly into body NOTE End cap should be down to piston assembly rod fully extended FS074 9 While holdin...

Page 396: ...Rebuildable Shocks sub section FS078 12 Install the set screw with O ring into the bladder housing FS079 13 Test operation of the shock NOTE Shock should feel soft on compression constant on rebound F...

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