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Operator`s Manual

1. Reverse Switch Button SN NS CN be os aN A SN 52 nz v 741 438 1 Always warm up the engine for 2 3 minutes prior to shifting into reverse 2 With the engine at idle under 2500 RPM and the snowmobile at a com plete stop press the reverse switch button then release the button E NOTE The snowmobile must be at a complete stop and the engine run ning under 2500 RPM before the sys tem will allow shifting 3 When reverse is engaged a reverse icon will illuminate in the speedom eter tachometer and a reverse alarm will sound CAUTION Never shift into reverse while the snowmobile is moving forward as it is hard on the driven pulley torque bracket and the cam rollers 4 To shift into forward stop the snow mobile and allow the engine to idle under 2500 RPM then press the reverse button and release the button 20 Operating in Reverse 1100 cc Models A WARNING Use caution and minimal speed when operating the snowmobile in reverse Be sure the button is in the desired position 1 When shifting into reverse always wait for the reverse icon to illumi nate and the reverse alarm to sound before backing up W NOTE The reverse function is can celled whenever the engine is shut off 2 After shifting from reverse to for ward or from forward to reverse apply the throttle slowly and evenly to allow the driven pulley to engage properly
2. CAUTION Do not use studs that are more than 9 525 mm 0 375 in longer than the track lug height A WARNING Do not operate a snowmobile with loose studs as they may be thrown from the track Always use a shielded safety stand whenever performing any maintenance or adjustments A WARNING DO NOT stand behind the snowmo bile or near the rotating track NEVER run the track at high speed when the track is suspended Reverse Operation The engine reverse function offers the operator the convenience of being able to back up the snowmobile rather than hav ing to turn the snowmobile around by hand This feature under most situations should not be used to free a stuck snow mobile as it will tend to dig the skis deeper into the snow Always use mini mal speed when operating in reverse and come to a complete stop before shifting from either forward to reverse or reverse to forward Shifting Into Reverse 800 cc Models 741 438A B NOTE Correct drive belt tension deflection is important for the reverse function to operate properly If the belt is too tight difficulty in engaging reverse will be experi enced the reverse function will make up to three attempts to engage into reverse and if the function is not completed after the third attempt the engine will shut down 1 Always warm up the engine for 2 3 minutes prior to shifting into reverse The reverse function is c
3. Check for wear damage and tight connections Exhaust System Weekly 14 Check for damage leakage and obstructions Nuts Bolts Fasteners Weekly Check tightness Recoil Starter Weekly Check rope for wear fraying and proper operation Shock Absorbers Weekly 17 48 Check for fluid leakage and damage and air pres sure Fox Air Shocks Spark Plugs 3500 Mi 35 Check center electrode insulator color carbon and gap Valve Clearance 1100 cc Mod 5000 Mi 36 Check adjust els Seasonal Suspension Weekly 48 Check for damage loose components and proper adjustment Track Tension Alignment Weekly 45 47 Check adjust as necessary Wear Strips Weekly 53 Check for wear and damage Wires amp Cables Weekly Check for wear damage and fraying Fuel System Tank Pump In Weekly Check for damage wear obstructions and leak Line Filter amp Vent Hose age Fuel Filter 1100 cc Models 5000 Mi Replace 2 years Air Silencer 800 cc Models Seasonal Inspect clean Air Cleaner Filter 1100 cc Turbo Weekly 31 Check replace Models Seasonal APV System Monthly 22 Check adjust as necessary Chain Case Daily 28 Check lube level and for leakage Chain Case Lubricant Seasonal Replace Heat Exchangers Monthly Check for wear leakage and damage Drive Clutch Driven Pulley Monthly 16 17 Check for damage binding and wear remove drive belt clean drive clutch driven pull
4. CAUTION After reversing in deep powder snow conditions make sure the snowflap does not become caught up in the track Track and or snowflap damage may occur CAUTION If the snowmobile is equipped with ice scratchers the scratchers must be disengaged or component dam age will occur Access Panel Hood Removing Installing To remove the access panel and hood use the following procedure 800 cc a baer Torx Head Scre Torx Head Screws 7m 0746 793 1100 cc Non Turbo Torx Head Screw Foam Seal I Torx Head Screw Torx Head Screws a 0746 092 1100 cc Turbo Torx Head Scre Sas FY SAS a 7 PA JZ NY dl lt A A A Straps d a Tox Head Screw 0746 091 Torx Head Screws 1 Remove the quarter turn and hairpin clip from the pin located at the front of the access panel Move the panel up and off the pin then swing the panel all the way out and unhinge the panel from the lower console Left Hand Side Shown L Thumb Serew Hairpin Cli Left Side Only airpin Clip 0746 800 2 Remove the two torx head screws securing the hood located on the underside of the hood above the front tube of the upper A arm then remove the two torx head screws from the top side of the hood secur ing the hood to the upper console and the two torx head screws from under the nosepiece of the hood
5. 17 Paddle Track XF High Country M Models 17 Track Studs XF F Models 8 Reverse Operation Access Panel Hood Removing Installing 20 Removable Seat 2 ao cm Arctic Power Valve APV System 800 cc Models ese SeT a iee a RR 22 Exhaust Controlled Timing ECT System 800 cc Models sees 23 Operating Instructions 24 27 Starting and Stopping Engine 24 Braking 5 Emergency Stopping Throttle Ignition Monitor Switch Varying Altitude Operation Lubrication Chain Case Rear Suspension Maintenance eee Periodic Maintenance Checklist Air Cleaner Filter 1100 cc Turbo Models Fuel System reete pten te Checking Engine Oil Level 1100 cc Models 32 Changing Engine Oil Filter 1100 cc Models 33 Coolant Level I Spark Plugs Checking Adjusting Valve Clearance 1100 cc Models Checking Adjusting APV Cables 800 cc Models Battery Electric Start F ses tees Brake System Burnishing Brake Pads Drive Belt Track Tension Track Alignment Suspension 48 Lights 51 Ski Wear Bars Adjusting Ski Stance Rail Wear Strips Performance Tips Preparation for Storage Preparation after Storage U S EPA Emission Control Statement Warranty Coverage U S Only Change of Address Ownership or Warranty Mic S 61
6. 3 Place a straightedge on top of the drive belt The straightedge should reach from the driven 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 slack Note the amount of deflection on the ruler at the bottom of the straightedge The deflection should be at 1 1 4 in Drive Belt Driven Pulley Drive Clutch 0746 092 E NOTE Push down on the belt with the ruler only until the bottom of the belt flexes upward then read the amount of deflection 5 To correct drive belt deflection remove the sheave adjuster from the pulley remove or add shim washers to the adjuster and install the adjuster W NOTE Adding shim washers will decrease belt deflection removing shim washers will increase belt deflection 6 Install the belt guard then close the access panel 55 DRIVE CLUTCH AND DRIVEN PULLEY Keeping the drive clutch and driven pulley clean should be the pri mary consideration of the operator The drive clutch and driven pulley can be cleaned of any drive belt accumulation using compressed air The sheaves can be cleaned using a clean cloth and parts cleaning solvent DRIVE CLUTCH DRIVEN PULLEY OFFSET If premature drive belt wear is experienced or if the drive belt turns over offset must be checked Also offset must be checked whenever either the drive clutch or
7. 3 Remove the intake panel below the gauge then locate the hood harness connector located in front of the speedometer and unplug the con nector then move the hood slightly forward and remove the hood E NOTE On the turbo models first unhook the rubber straps securing the air filter housing to the intake plenum of the hood then move the hood slightly forward and remove the hood To install the access panel and hood use the following procedure 1 Position the hood onto the snowmo bile and connect the hood harness connector making sure the harness does not become pinched E NOTE On 800 cc models make sure the hood tabs are seated between the throttle body boot E NOTE On the turbo models prior to securing the hood make sure the air filter is seated properly into the air silencer and secured using the two rubber straps 2 Secure the hood with torx head screws and tighten securely E NOTE Before installing the hood make sure the mounting screw clips are in position E NOTE On the 1100 cc non turbo models make sure the foam seal is in place on the air intake E NOTE On the turbo models make sure the air filter housing is properly connected and secured with the rub ber straps to the intake plenum of the hood and turbocharger 3 Install the access panel onto the lower console then close the access panel and secure with the hairpin clip and quarter turn Install the intake panel Removable S
8. 8 Stand well away from the dead bat tery and start the vehicle with the good battery Allow the vehicle to run for several minutes applying some charge to the dead battery 9 Start the snowmobile with the dead battery and allow it to run for several minutes before disconnecting the jumper cables 10 Remove the jumper cables in oppo site order of hook up 4 3 2 1 Be careful not to short cables against bare metal E NOTE Have the battery and elec trical system checked prior to oper ating the snowmobile again Drive Clutch and Driven Pulley The drive clutch and driven pulley do not require lubrication therefore no special maintenance is required by the snowmo bile owner except for periodical cleaning see the Periodic Maintenance Checklist in the Maintenance section However the drive clutch and driven pul ley should be disassembled cleaned and inspected by an authorized Arctic Cat Snowmobile dealer after every 800 miles of operation or at the end of the snowmo biling season whichever occurs first This service is at the discretion and expense of the snowmobile owner When operating the snowmobile at high altitudes it may be necessary to change certain component parts of the drive clutch and or the driven pulley See an authorized Arctic Cat Snowmobile dealer for further information CAUTION DO NOT attempt to service the drive clutch and driven pulley The drive clutch and driven pulley must
9. ARCTIC CAT Operator s Manual Crossover Mountain Performance Models F 800 Models M 1100 Turbo Models F 1100 Models XF 800 Models F 1100 Turbo Models XF 1100 Models M 800 Models XF 1100 Turbo Models M 1100 Models Limited Warranty Arctic Cat Inc hereinafter referred to as Arctic Cat extends a limited warranty as described below on each new Arctic Cat Snowmobile it assembles and on each genuine Arctic Cat Snowmobile part and accessory assembled and sold by an authorized Arctic Cat Snowmobile dealer The limited warranty on an Arctic Cat Snowmobile is extended to the original retail purchaser for the time periods described below however the balance of the remaining warranty may be transferred to another party unless the purchase is for commercial use see below Warranty coverage is only available in the country in which the original retail purchase occurs to the original retail purchaser resident in that country or to a transferee resident in that country of the balance of the remaining warranty Arctic Cat warrants only the products it assembles and or sells and does not warrant that other products will function properly when used with an Arctic Cat Snowmobile or will not damage the Arctic Cat Snowmobile Arctic Cat does not assume any liability for incidental or consequential damages Arctic Cat will repair or replace at its option free of charge including any related labor charges any parts that are found to
10. Please read the following information completely Your authorized Arctic Cat snowmobile dealer will repair or replace any defective emission related component at no cost to you during the warranty period You may have non warranty service performed by any repair establishment that uses equivalent components The regulations provide significant civil penalties for tampering that causes your snowmobile to no longer meet U S EPA emission standards Arctic Cat further warrants that the engine and its emission related components are free from defects in materials or workmanship that could cause the engine to fail to comply with applicable regulations during the warranty period If you have any questions about this information or the emission warranty coverage statement contact your local authorized Arctic Cat snowmobile dealer WARRANTY PERIOD The emission warranty period for this snowmobile begins on the same date as the standard warranty coverage and continues for 30 months or 2500 miles whichever comes first COMPONENTS COVERED The emissions warranty covers major emissions control components and emission related components listed as follows Engine Management and Sensors Fuel Air System Barometric Pressure Sensor Fuel Injectors Camshaft Position Sensor Fuel Pressure Regulator Engine Control Unit ECU Fuel Pump Engine Coolant Temperature Sensor Carburetor s Intake Air Temperature Sensor Turbocharger Assembly Manifold Absolute Pressur
11. mobile owner if qualified to do so If the owner does not feel qualified take the snowmobile to an autho rized Arctic Cat Snowmobile dealer for this service This service is at the discretion and expense of the snow mobile owner Removing Drive Belt B NOTE Changing a drive belt can be done by the snowmobile owner if qualified to do so If the owner does not feel qualified take the snowmo bile to an authorized Arctic Cat Snowmobile dealer for this service This service is at the discretion and expense of the snowmobile owner 1 Turn ignition key to the OFF posi tion and wait for all moving parts to stop 2 Set the brake lever lock 3 Open the left side access panel then remove the rear belt guard B NOTE On the 1100 cc models move and secure the rear belt guard up and out of the way or disconnect the ECU wires 4 Remove the cap screw lock washer washer and sheave adjuster from the end of the driven pulley then remove the sheave adjuster from the cap Screw Movable Sheave Drive Belt S Sheave Adjuster DS Shims 0 Ring P cl Driven Clutch Cap Screw Lock Washer Washer 0743 395 E NOTE Verify the shims and O ring are not removed from the adjuster 5 Remove the lock washer and flat washer from the cap screw and reverse the sheave adjuster 6 Install the cap screw into the driven pulley then tighten the cap screw until the movable sheave opens far enough to allo
12. the discretion and expense of the snowmobile owner GASOLINE On the 800 cc and turbo models for optimum performance use 91 octane minimum gasoline Preparation for Storage Prior to storing the snowmobile it must be properly serviced to prevent corrosion and component deterioration An authorized Arctic Cat Snowmobile dealer should per form this service however the owner operator can perform this service if desired This service is at the discretion and expense of the snowmobile owner To prepare the snowmobile for storage Arctic Cat recommends the following procedure 1 Clean the seat cushion with a damp cloth and a 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 B NOTE On the 1100 cc models change the engine oil and replace the air filter if necessary then pro ceed to step 6 CAUTION Do not do steps 3 5 on the 1100 cc models severe engine damage could result 3 Place the rear of the snowmobile up on a shielded safety stand 4 Carefully pry the intake boots partially over the throttle body inlets then start the engine and allow to idle 5 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 Turn
13. tion is caused by a too rich con dition too much oil or incorrect spark plugs heat range too cold W NOTE If the center electrode insu lators are light gray white or black and if the oil injection pump synchro nization and ignition timing are cor rect different heat range spark plugs may be necessary Authorized Arctic Cat Snowmobile dealers have detailed spark plug information Consult a dealer before changing spark plugs as incorrect heat range spark plugs could cause poor engine performance or engine damage CAUTION If a spark plug is light gray white or black and another is tan or light brown take the snowmobile to an authorized Arctic Cat Snowmobile dealer for inspection and service If not under warranty this service is at the discretion and expense of the snowmobile owner Checking Adjusting Valve Clearance 1100 cc Models After 5000 miles or prior to seasonal storage valve clearance should be checked and adjusted as necessary E NOTE Take the snowmobile to an authorized Arctic Cat Snowmobile dealer for inspection and service This service is at the discretion and expense of the snowmobile owner CAUTION It is critical that the checking adjust ing valve clearance be done at the recommended intervals or severe engine damage may occur Checking Adjusting APV Cables 800 cc Models Proper cable adjustment is critical to the operation of the APV system Although inspecting cable adjust
14. Brake Lever Headlight Dimmer Switch Thumb Warmer Handlebar Warmer Switches Emergency Stop Switch Reverse Switch Throttle Lever Ignition Switch Gasoline Oil Recommended Gasoline 1100 cc Models The recommended gasoline to use in these snowmobiles is 87 octane regular unleaded In many areas oxygenates are added to the gasoline Oxygenated gaso lines containing up to 10 ethanol are acceptable gasolines ENOTE The turbo models will detect lower octane gasoline and reduced engine performance will result It is recommended that 91 octane minimum gasoline be used in these models When using ethanol blended gasoline it is not necessary to add a gasoline antifreeze since ethanol will prevent the accumula tion of moisture in the fuel system 0745 789 CAUTION If a situation arises wherein 91 octane gasoline is not available 87 octane gasoline can be substituted how ever do not prolong the usage of 87 octane gasoline as it will cause poor engine performance CAUTION Do not use white gas or gasolines containing methanol Only Arctic Cat approved gasoline additives should be used Recommended Gasoline 800 cc Models The only recommended gasoline to use in these snowmobiles is 91 octane mini mum E NOTE For optimum performance use only 91 octane minimum gaso line In many areas oxygenates are added to the gasoline Oxygenated gasolines con
15. Front End Lift p n 5639 151 elevate the front of the snow mobile 2 Remove the lock nuts securing the wear bar to the ski Wear Bar 0743 185 3 Remove the wear bar from the ski Installing Ski Wear Bars 1 Move the wear bar into position on the bottom of the ski B NOTE If installing a double offset wear bar the carbide edge should be directed to the outside of the ski 2 Align the wear bar studs with the holes in the ski then install the lock nuts Tighten to 11 15 ft lb Adjusting Ski Stance B NOTE Local laws and or regula tions as to maximum width of the ski stance on these snowmobiles may be applicable Always comply with the maximum width laws and or reg ulations when adjusting ski stance E NOTE Ski stance can be increased decreased by 2 5 cm 1 0 in 1 Place the front of the snowmobile on a support stand 2 Remove the cotter pin then remove the slotted nut and cap screw secur ing the ski assembly to the spindle Remove the ski Account for the rubber damper inserts and washers 3 To increase ski stance place ski stance spacer to the outside of the spindle and adjust the damper Cotter Pin si Cap Screw 0746 797 4 To decrease ski stance place ski stance spacer to the inside of the spindle and adjust the damper 0746 796 5 Apply an all temperature grease to the non threaded portion of the cap screw then slide the ca
16. NOTE The snowmobile must be on a level surface for this procedure 2 Shut the engine off then remove the right side access panel and verify oil is visible at least halfway up in the sight glass SNO 244A 3 If oil is not visible halfway up in the sight glass add recommended engine oil until oil is visible half way up the sight glass CAUTION Care must be taken not to over fill the reservoir with oil Changing Engine Oil Filter 1100 cc Models A WARNING Care must be taken if a hot drain plug is removed by hand Burning could occur B NOTE Recycle or properly dis pose of the used engine oil B NOTE The access panels and hood must be removed for this pro cedure see Access Panel Hood Removing Installing in the General Information section 1 Park the snowmobile on a level sur face then start the engine and allow it to warm up for 5 10 minutes or if the snowmobile was operated allow the engine to idle for approximately 30 seconds Shut the engine off 2 Remove the torx head screws and the access plate from beneath the snowmobile 3 Place a drain pan beneath the engine oil pan drain plug then remove the plug and allow the oil to drain com pletely PC010A 4 Install the engine oil drain plug with a new gasket then tighten the plug to 16 ft Ib 5 Remove the four torx head screws securing the right side footrest to the tunnel and the su
17. Snowmobile Safety Rules RS 448980 2M ADEM MS COMET Wouoizeu 2669 ip SULOU e og oye mass Q unuioy uuns xrud Bo saabe Bo 0401 9fIoI PIOWIOAG pose euo eoKui BABY ef Treo uoo uo Bets Buruie xb ur suas uoq ap zasn ja sajeso suopepueunuoaa ja 10 xne zesstoqo esuos uouiuo2 osn pue suogtin o puc sme yeso We Aeqo RULL EA ROY E IUU9 0188 eui aessa ojoAo q uasuciBsuapiz 1910 A gui 10104 wefeupt Upega JEINAEES SOUUNY ejopo wosugu amp uepte C opjodssy e691 abg p za og 0 L ee t601Jo og Day naagy aatY maodY LEER aa pebBassed z ouissey tjsod z cojabbossEd OLUISSEIN 0350d L oloGIoA top CZUaIdEo El OEMOSSO 1840098 s1a as 0 ed Jauosied o SHE d eJeyooos siajas ua Ed UOSied ug SHE V uejousedexuolsessed gd wosyiouuddo 42A uecopijo uaBuau uapuex Isyex ueejutexioy A ugeyyqax ueeAggngst ue pu QUY IS WEA vr Efeismiuuony uconuony EJO oumsoBessed uo uoo ot19 eu pteqqna d 76640 se pug eu ptexug v epuexg rejue esugibog XDEGAIN Z E Solopoul oj ins sieBessed xnop uiui d saana sajgpow say uns sabessed un WNWKEN v siaBussed op 9PUTLULUOS2L aiquiou a zejoadse spets dp z uo saapu omy uimuixey A spets drs uo Japu euo uintupceii v Rioedez 40pu JadoJd oAi2sq0 972 7 Ge amp DL EMT 00e DIL dl a A294 MEMOIR LPR E epino Ip erenugi ayuauizjueye 05597 uoxoqpue yoy mug vi940 Bo sa uevjouns esseeddoon gy guu 2ueuiK ef on woodsuorprujsu 7519 420 SET
18. System Arctic Cat recommends that the brake system brake lever fluid reservoir hose caliper pads and brake disc be checked daily for fluid leakage wear or damage and for proper operation Also the brake fluid level must be checked every time before starting the engine A WARNING DO NOT operate the snowmobile when the brake lever lock is engaged or when any component in the brake system is damaged worn or adjusted improperly If the snowmo bile is operated and the brake system is not functioning properly severe personal injury could result Checking Adding Brake Fluid 1 With the brake fluid reservoir in a level position and the cover removed check the fluid level The brake fluid level must be at the high barke fluid mark in the reservoir High Brake Fluid Mark Low Brake Fluid Mark gt g El xs 745 817A 2 If the brake fluid is below the high brake fluid mark add Arctic Cat approved DOT 4 brake fluid until the fluid is at the recommended level Install and secure the reservoir cover Do not allow moisture to con taminate the brake system CAUTION Brake fluid is highly corrosive Do not spill brake fluid on any surface of the snowmobile A WARNING Do not overfill the brake fluid reser voir Overfilling the reservoir may cause the brake system to hydrauli cally lock Use only Arctic Cat approved DOT 4 brake fluid Never substitute or mix different types or gra
19. Tunnel Protector Kit p n 6639 118 for the XF models p n 6639 075 for the F models or p n 6639 189 for HCR models must be installed For proper installation use the following procedure 1 Using the appropriate stud template see chart mark the desired stud pattern to be used Stud Template Chart Track Length p n 129 in 6639 143 141 in 4639 991 2 Using the proper sized stud hole drill bit drill out the stud holes 3 Push the stud through the hole from inside the track then place the domed support plate and lock nut on the exposed stud 4 Using a wrench to secure the stud tighten the lock nut on the exposed stud 18 It is also recommended that whenever studs are installed on a track carbide wear bars should be installed on the skis Carbide wear bars complement the track studs to balance steering control under these conditions The length of the car bide on the wear bars should be propor tionate to the number of track studs i e small number of track studs short length of carbide many track studs long length of carbide The proper pro portion between the number of studs and carbide length on the wear bar will main tain steering balance A WARNING Always balance the snowmobile with the proper proportion between the number of studs and carbide length on the wear bars Do not over drive conditions use common sense in all operating conditions
20. Warranty Procedure Owner Responsibility Inside Back Cover Reference Information Write the appropriate information for your Arctic Cat Snowmobile in the spaces below Always use these numbers when referring to your snowmobile Model Date of Purchase Vehicle Identification Number Engine Serial Number Your Arctic Cat Dealer Address Phone A WARNING A snowmobile is a very high performance vehicle Because it does accelerate rapidly and is capable of very high speeds it should not be operated by a nov ice or an inexperienced operator Never accelerate rapidly or drive at high speed beyond the limits of visibility or without being totally familiar with the terrain and what lies in front of you Obey speed limits and never operate at speeds that do not allow adequate maneuvering and stopping distances Read and study the entire Operator s Manual and Safety Handbook Failure to follow this warning could result in personal injury to yourself or others Personal Injury To avoid injury to yourself and others NEVER operate the snowmobile without first reading and understanding this manual and the Snowmobile Safety Hand book then follow the instructions and heed the warnings given USE COMMON SENSE DON T DRINK and DRIVE STAY IN CONTROL at ALL TIMES TELL YOUR FRIENDS If you see a friend operating a snowmobile recklessly at excessive speeds while intoxicated o
21. and access panels see Access Panel Hood Removing Install ing in the General Information section Coolant Level E NOTE Use a good quality ethyl ene glycol based automotive type coolant W NOTE Always check the coolant level with the engine cold 800 cc Models Locate the coolant filler neck behind the left side steering support If the coolant needs to be added fill the coolant hose up to the filler neck then remove 190 ml of fluid The hood must be removed see Access Panel Hood Removing Installing sub section in the Gen eral Information section CAUTION After operating the snowmobile for the initial 5 10 minutes stop the engine allow the engine to cool down and check the coolant level Add coolant as necessary E NOTE On the HCR model if operat ing on ice or hard packed snow the ice scratchers must be engaged to reduce engine overheating 1100 cc Models E NOTE The access panels and hood must be removed for this pro cedure see Access Panel Hood Removing Installing sub section in the General Information section 1 Remove the filler cap from the cool ant reservoir 2 Verify the coolant level is at the bot tom of the tab in the filler neck 0746 117 3 If the coolant is below the tab add coolant to the reservoir until at the tab CAUTION If the coolant is below the tab and if coolant has been added immediately inspect for leakage and or damag
22. ately take the snowmobile to an autho rized Arctic Cat Snowmobile dealer for service If not under warranty this ser vice is at the discretion and expense of the snowmobile owner 6 When new brake pads are installed a burnishing process is required see Brake System in the Mainte nance section of this manual 26 Emergency Stopping There are several methods of stopping or slowing the snowmobile under a variety of situations Identified in the following chart are the ways a snowmobile may be brought to a stop and the effectiveness under normal conditions Item Function Condition Emergency interrupts igni ALL Stop Switch tion circuit Throttle Ignition interrupts igni ALL Monitor Switch tion circuit Ignition Switch interrupts igni ALL tion circuit Brake slows the drive ALL system Tether HCR interrupts igni ALL and RR models tion circuit Throttle Ignition Monitor Switch The throttle control is equipped with a monitor switch for safety purposes which will stop the engine when a loss of return spring force occurs If ice forms in the throttle system or if there is some other malfunction of the throttle system result ing in a loss of return spring force the monitor switch will stop the engine when the throttle control lever is released A WARNING If any malfunction of the throttle sys tem occurs such as freezing in fluffy snow and the monitor switch does not s
23. can damage the turbocharger engine 1 Remove the left side access panel then remove the air filter from the housing 2 Inspect the air filter for dirt or dam age CAUTION Do not use compressed air in an attempt to clean the filter Damage to the filter may occur If the filter is dirty it must be replaced CAUTION A torn air filter can cause damage to the turbocharger engine Contami nants may get inside the turbo charger engine if the filter is torn Carefully examine the filter for holes or tears Replace the filter with a new one if it is torn 3 Clean any debris from inside the air intake plenum 4 Place the new filter 1f necessary into the housing then install the left side access panel CAUTION Do not run the engine without the air filter installed Severe damage to the turbocharger engine will occur Fuel System A WARNING Whenever any maintenance or inspection is made on the fuel system in which there may be fuel leakage there should be no welding smoking open flames etc in the area In Line Fuel Filter 1100 cc Models Arctic Cat recommends that the in line fuel filter be replaced every 5000 miles The filter must be clean to allow the fuel hose to transmit the amount of gasoline required If the in line fuel filter is obstructed gas oline flow will be restricted therefore the filter must be replaced To re
24. charge the battery an additional 1 5 hours then retest The battery is ready for service 9 Place the battery into position in the snowmobile then coat the battery posts and cable ends with a light coat of multi purpose grease CAUTION Before installing the battery make sure the ignition switch is in the OFF position 10 Secure the red positive cable to the positive terminal on the battery using a cap screw lock washer and a flat washer Tighten securely 11 Secure the main black negative cable and the small black negative cable to the battery using a cap screw lock washer and a flat washer Tighten securely CAUTION Connecting cables in reverse posi tive to negative and negative to posi tive can cause serious damage to the electrical system W NOTE Ensure the harness wires and cables are routed properly as noted during removing battery procedure 12 Install the battery bracket solenoid and tighten the two screws and lock nuts to 105 in lb then install the seat and secure with the torx head screw Tighten securely 39 E NOTE On the LXR models prior to lowering and securing the seat con nect the seat heater harness connector Fuses Fuses protect the snowmobile electrical system from overloading If electrical parts in the snowmobile are not working the system may have been overloaded and caused a blown fuse Before repairing or replacing any electrical
25. crankshaft position sensor 11 Failure in speed sensor 12 Failure in coil MAG 13 Failure in coil PTO 14 Failure in ISC valve 15 Failure in oxygen sensor 19 Failure in camshaft position sensor 21 Open or short circuit in or loose knock sensor 22 Failure in injector PTO secondary 23 Failure in injector MAG secondary 25 Failure in shifting system gear posi tion switch 26 Malfunction in air pressure sensor 29 Malfunction in shift control switch OCTN Low octane gasoline Turbo models Handlebar Height Tilt M 800 Sno Pro LTD HCR XF 800 High Country Models To adjust handlebar height use the fol lowing procedure 1 From each side of the steering post compress the locking tabs to unlock the handlebar 0745 843 2 With the tabs compressed adjust the handlebar up or down to the desired position then release the tabs to lock the handlebar in place W NOTE When the desired height is found make sure that the lock collar is seated in the grooves by lifting up and pressing down on the handlebar To adjust handlebar tilt use the following procedure 1 Loosen the four cap screws and tilt the handlebar to the desired position 13 S bes 0745 845 2 Tighten the four cap screws evenly to 15 ft Ib A WARNING Tighten the cap screws according to specifications to prevent unexpected moveme
26. engine off Install the intake boots CAUTION Do not run the engine without the belt guard in place and secured 6 Plug the exhaust system outlet with a clean cloth CAUTION Do not do step 7 on the 1100 cc mod els severe engine damage could result 7 With the ignition switch in the OFF position 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 coils and ECU may result B Pour 29 5 ml 1 fl oz of SAE 30 petroleum based oil into each spark plug hole and pull the recoil starter handle slowly about 10 times C Install the spark plugs and con nect the high tension leads 8 Fill the gas tank to its rated capacity then add Arctic Cat Fuel Stabilizer p n 0436 907 to the gas tank fol lowing directions on the container for the stabilizer gasoline ratio Tighten the gas tank cap securely 9 With the snowmobile level check the lubricant level in the chain case If low add chain lube through the fill plug hole 10 Remove the drive belt from the drive clutch driven pulley Lay the belt on a flat surface or slide it into a card board sleeve to prevent warping or distortion during storage 11 Clean and inspect the drive clutch and driven pulley 12 Apply light oil to the uppe
27. get any moisture in the system as moisture in the brake fluid lowers the boiling point If the brake fluid is ever boiled by high speed stops or repetitive use or if mois ture is allowed to enter the system it must be changed Never substitute or mix different types or grades of brake fluid A WARNING Use only Arctic Cat approved DOT 4 brake fluid Never substitute or mix different types or grades of brake fluid Brake loss can result Check brake fluid level and pad wear before each use Brake loss can result in severe injury or even death 3 Never ride the brake Even main taining minimal pressure on the brake lever will cause the brake pads to drag on the disc and may overheat the brake fluid 4 The brake lever lock is not a parking brake and should not be applied for periods exceeding 5 minutes NEVER OPERATE THE SNOW MOBILE WITH THE BRAKE LEVER LOCK ENGAGED A WARNING The brake lever lock is not a parking brake and should not be applied for periods exceeding 5 minutes The brake lever lock maintains the brake lever in the compressed position and maintains pressure against the brake disc however after a period of time the pressure applied to the brake disc may relax below the amount required to hold the snowmobile stationary 5 Pumping the brake lever is permissible however if pumping the brake lever more than twice is necessary to obtain the necessary stopping power immedi
28. in the Limited Warranty in the event the selling dealer has ceased to do business you have moved or you are in a location away from your selling dealer warranty may be performed by any authorized Arctic Cat Snowmo bile dealer The authorized Arctic Cat Snowmobile dealer will examine the snowmobile or part to determine if in his opinion a warrantable condition exists If a warrantable con dition appears to exist the dealer will repair or replace at Arctic Cat s option free of charge including any related labor costs all parts that are found to be warrant able and any other parts which the warrantable part caused to be damaged You the consumer will then be asked to sign a warranty form to ensure Arctic Cat that the warranty work was actually performed It is the consumer s responsibility to maintain and service the snowmobile in accor dance with Arctic Cat s recommendations in the Operator s Manual To protect yourself and your snowmobile follow all safety and service tips Arctic Cat will NOT warrant repairs required as a result of not performing standard operator maintenance storage procedures and service as outlined in the Operator s Manual Should you have any questions concerning the warranty contact an authorized Arc tic Cat Snowmobile dealer Arctic Cat Inc P O Box 810 Thief River Falls MN 56701 218 681 8558 ARCTIC CAT Printed in U S A Trademarks of Arctic Cat Inc Thief Riv
29. part check the appropriate fuses If a fuse blows opens a circuit all the parts of the snowmobile that use that circuit will not work Once which fuse to check has been deter mined perform the following steps 1 Locate the fuse block and remove the fuse block cover E NOTE To locate the fuse block on the 1100 cc models open the left side access panel the fuse block is on the belt guard On the 800 cc models open the right side access panel the fuse block is on the upper spar PC020A B NOTE There are spare fuses beneath the fuse block cover 2 Remove the suspected fuse B NOTE Fuse function desciptions are next to the fuse contacts in the fuse block 40 3 Look through the clear side of the fuse to see if the element inside is burned or separated If it is the fuse is blown and should be replaced with a fuse of the correct amperage rating A WARNING Always replace a fuse with one hav ing the same specified amperage rat ing Using a fuse with a higher rating can cause severe wire damage and could start a fire 4 Install the fuse block cover and close the access panel Even after replacing a fuse it may con tinue to blow if the cause of the overload is not determined If the fuse continues to blow take the snowmobile to an autho rized Arctic Cat Snowmobile dealer for service If not under warranty this ser vice is at the discretion and expense of the snowmobile owner Brake
30. replace for defective or leaking shock corroded or pitted shaft peeling chrome Limited to one 1 year or 1000 miles of normal riding conditions rebuild for leaking shock warranted replace for defective shock corroded or pitted shaft peeling chrome The following will VOID Arctic Cat s warranty 1 Failure to perform the proper break in procedure and all related maintenance storage procedures if stored for extended periods and or service as recommended in the Operator s Manual Repairs and or adjustments by anyone other than an authorized Arctic Cat Snowmobile dealer Use of an improper fuel mixture ratio Use of improper carburetor jets Use of improper gasoline lubricating oils or spark plugs An accident or subjecting the snowmobile to misuse abuse or negligent operation Any modification addition or removal of parts unless instructed to do so by Arctic Cat Use of the snowmobile in any way for racing purposes 9 Removal of the engine for use in another vehicle 10 Removal or mutilation of the Vehicle Identification Number or Engine Serial Number 11 Use of parts not sold or approved by Arctic Cat 12 Track and tunnel damage resulting from either ice stud or hooker plate installation 13 Damage due to improper transportation ONDARON Arctic Cat shall not be responsible for and this limited warranty excludes recovery of economic punitive consequential and incidental damages lost profits and loss of use S
31. taining up to 10 ethanol are acceptable gasoline Do not use gasolines containing methanol CAUTION Do not use white gas or gasoline con taining methanol Only Arctic Cat approved gasoline additives should be used Recommended Injection Oil 800 cc Models The recommended oil to use in the oil injection system is either Arctic Cat APV Synthetic 2 Cycle Oil p n 4639 349 qt or p n 5639 469 gal or Formula SS Semi Synthetic Oil p n 5639 470 qt or p n 5639 471 gal These oils are spe cially formulated to be used either as an injection oil or as a pre mix oil for break in and meets all of the lubrication requirements of the Arctic Cat snowmo bile engine CAUTION Any oil used in place of the recom mended oil could cause serious engine damage Recommended Engine Oil 1100 cc Models The recommended oil to use is Synthetic OW 40 Oil p n 5639 172 qt or p n 5639 173 gal After the engine break in period the engine oil should be changed every 2500 3000 miles on the non turbo models or 1500 2000 miles on the turbo models and before prolonged storage Filling Gas Tank Since gasoline expands as its temperature increases the gas tank must be filled to its rated capacity only Expansion room must be maintained in the tank particu larly if the tank is filled with cold gaso line and then moved to a warm area Also if the snowmobile is to remain on a trailer
32. wear strips will wear rapidly if the snowmobile is Operated on terrain on which the snow cover is minimal Loose snow is required to cool and lubricate the wear strips and prevent accelerated wear W NOTE Two Wheel Kit p n 6639 184 and Four Wheel Kit p n 5639 995 are available to reduce wear strip wear E NOTE If operating on ice or hard packed snow conditions it is recom mended that Ice Scratchers p n 5639 897 be installed to reduce wear strip wear and engine overheat ing Performance Tips Operating a high performance snowmo bile requires a special attention that is not required by a low performance snowmo bile Often a minor adjustment will result in a large increase in performance This section is intended to highlight minor conditions that adversely affect performance and the adjustments needed to correct them Be sure however to thoroughly read and understand this entire manual especially the section on spark plugs track tension and alignment and suspension DRIVE BELT This link between the engine and drive train is often the most neglected component The drive belt must have the proper fit in the drive clutch and driven pulley Proper fit is when the top surface of the drive belt is flush with the top or up to 1 16 in higher than the driven pulley sheaves with the sheaves fully closed If drive belt deflection is above specification the snowmobile will bog and lack power at engagement and
33. will have a slower maximum speed For good perfor mance proper belt deflection is critical To correct this condition first determine if the drive belt is within specifications see Drive Belt sub section and replace if worn or too long Always run the drive belt in the same direction Installing the drive belt so the part number can be read will ensure that the drive belt is always run the same direction DRIVE BELT DEFLECTION Drive belt length condition and deflection are all important for peak performance To check and adjust drive belt deflection remove the belt guard then use the fol lowing procedure B NOTE It may be necessary to remove a shim washer from between the driven pulley sheaves to allow the driven pulley to close tighter Adding shim washers will decrease belt deflection and removing shim washers will increase belt deflection Available shim washers from Arctic Cat are p n 0648 714 0 090 in one included in the tool kit p n 0648 715 Sa in and p n 0648 716 0 060 in E NOTE Removing adding shim washers may be done by the snow mobile owner if qualified to do so If the owner does not feel qualified take the snowmobile to an autho rized Arctic Cat Snowmobile dealer for this service This service is at the discretion and expense of the snow mobile owner 1 Turn the engine off then open the access panel 2 Make sure the drive belt is sitting at the top of the driven pulley sheaves
34. 0 2 Over 240 3 W NOTE These cam position set tings are suggestions only Personal riding style will greatly influence cam position settings Spend time to determine setting preferences Rear spring pre load adjustment is accom plished by rotating the adjusting cams Position 3 provides the stiffest ride and position 1 is for the light driver or slow speed trail riding Position 2 is for the average operator under normal conditions Always rotate the cam from the lighter position to the heavier position CAUTION Never force the adjustment cams from the low position to the high position Cam damage may occur Qu gt gt aN Q J Position 3 a E Position 1 EN FJ O aw o eo 741 450 To rotate an adjusting cam use the spark plug wrench from the tool kit Rotate the wrench until the cam is in the desired position To stiffen the ride rotate the cam so as to raise the spring end Make the appropriate adjustment on the other cam Adjusting Skid Frame Rear Arm Shock Spring M XF Models Proper adjustment of rear arm shock absorber spring pre load is necessary to get the most desirable ride The rear arm shock spring is adjustable for the terrain conditions and driving style and weight of the operator The spring adjuster nut has been set at the fac tory so the correct amount of threads are exposed between the adjuster nut and the threade
35. AUTION Never exceed the standard charging rate A WARNING An overheated battery could explode causing severe injury or death Always monitor charging times and charge rates carefully Stop charging if the battery becomes very warm to the touch Allow it to cool before resuming charging Battery Charging Chart Constant Current Charger Battery Charge Time Voltage Charge Required at 1 5 DC 2 0 Amps 12 5 mini 10096 None mum 12 2 12 4 75976 99976 3 6 hours 12 0 12 2 5096 7496 5 11 hours 11 0 11 9 25926 49926 13 hours minimum 11 5 or less 0 24 20 hours minimum B NOTE If the battery voltage is 11 5 DC Volts or less some chargers may cut off and fail to charge If this occurs connect a fully charged booster battery in parallel positive to positive and negative to negative for a short period of time with the charger connected After 10 15 min utes disconnect the booster battery leaving the charger connected and the charger should continue to charge If the charger cuts off replace the battery 7 After charging the battery for the specified time remove the battery charger and allow the battery to sit for 1 2 hours 8 Connect the multimeter and test the battery voltage The meter should read no less than 12 5 DC Volts If the voltage is as specified the bat tery is ready for service W NOTE If voltage in step 8 is below specifications
36. Arctic Cat Snow mobile dealer for service If not under warranty this service is at the discretion and expense of the snowmobile owner 800 cc Models Additional codes are displayed on the readout screen Refer to the following chart for diagnostic codes Code Trouble 2 Failure in injector s 4 Open or short circuit in barometric pressure sensor 5 Open or short circuit in intake air tem perature sensor 6 Open or short circuit in water tempera ture sensor 7 Openor short circuit in throttle position sensor 12 Failure in ignition coil s 16 Incorrect adjustment failure in APV cable 17 Failure in exhaust temperature sensor 18 Failure in servomotor 21 Open or short circuit in or loose knock sensor Low octane gasoline OCTN 1100 cc Models These diagnostic codes are displayed on the readout screen incorporated within the speedometer tachometer Refer to the following chart for diagnostic codes Code Trouble 1 Failure in the fuel system Failure in injector PTO Failure in injector MAG Failure in barometric pressure sensor Open or short circuit in intake mani fold air temperature sensor 6 Openor short circuit in water temper ature sensor 7 Open or short circuit in throttle posi tion sensor 8 Open or short circuit in manifold air pressure sensor on BR Gd Po Code Trouble 9 Failure in
37. Arctic Cat Snowmobile meets or exceeds the standards of the Snowmobile Safety and Certification Committee and displays the SSCC decal Arctic Cat Inc endorses and encourages the safe use of all snowmobiles Always wear a helmet and eye protection Drive with caution observe all state and local regulations and respect the rights of others ISMA members like Arctic Cat do their part to improve trails sponsor events and generally support the sport of snowmobiling As a mem ber of the National Snowmobile Foundation Arctic Cat Inc promotes snowmobil ing through education charity and research programs 2012 Arctic Cat Inc Printed in U S A Declaration of Conformity EMC Directive 2004 108 EC Application of council directives Issued by European Commission Type of Equipment Snowmobile EC Machinery Directive 2006 42 EC Brand Name Arctic Cat Model Numbers S2013F8HLXUSG S2013XFHLXUSB S2013F1NEPUSG S2013M1NE3USB S2013F8HLXUSB S2013XFHSPUSG S2013F1NEPUSO 2013M1NE4USG S2013F8HEPUSG S2013XFHSPUSO S2013F1NELUSW S20183M1NE4USO S2013F8HEPOSG S2013XFHSPOSG S2013F1NELUSB S2013M1NLEUSW S2013F8HEPUSO S2013XFHLEUSW S2013M1N3EUSB S20183M1NLEUSB S2013F8HRRUSS S2013XFHLEUSB S2013XFNLXUSG S20183M1NHCUSVV S2013F8HRROSS S2013XFHSPUSB S2013XFNLXUSB S2013XFNTSUSG S2013F8HRRUSG S2013XFHHCUSW S2013XFNSPUSG S2013XFNTSUSB S2013F8HRROSG S2013XFHHCUSB S2013XFNSPUSO S2013XFNTPUSG S2013F8HRRUSW S2013XFHXPUSO S2013XFNELUSW S2013XFNTPUSO S2013F8HRROSW S2013
38. By pushing the left button once the RPM and MPH will be displayed one on the readout screen and one with the needle By pushing the button once again the functions will be reversed ammmon By pushing the left button with speed being displayed for more than two sec onds the display will change between standard mph or metric kph Release the button when desired display appears With RPM displayed on the readout screen by pushing and holding the left button max imum RPM will be displayed on the readout screen The maximum RPM readout will reset when the right button is pushed while maximum RPM is displayed Odometer Trip Meter 1 Trip Meter 2 Hour Mieter Clock B NOTE The clock is available on electric start models only By pushing the right button the readout screen will display odometer trip meter 1 trip meter 2 hour meter and clock To reset the trip meter with the trip meter displayed push and hold the right button until the display is cleared The hour meter readout will not reset Clock Electric Start With the clock selected on the readout screen by pushing and holding the right button for two seconds the option of selecting the 12 hour or 24 hour clock is available Push the left button for 12 hour display push the right button for 24 hour display At this point the hours and min utes will begin to flash Push the left but ton to change the hour display push the right button to chan
39. HIGH beam posi tion DO NOT USE LOW BEAM 6 Observe the headlight beam aim Proper aim is when the most intense beam is centered on the vertical mark 5 cm 2 in below the horizontal mark on the aiming surface 52 Aiming Surface 8m 25f f Horizontal Mark Intense Beam REM 5 5cm 2 in 0745 813 7 Adjust the headlight using the adjusting screw on the backside of the headlight using a 4 mm swivel socket and long extension until cor rect aim is obtained Shut the engine off then disengage the brake lever lock Adjusting Screw 0746 807 Ski Wear Bars The ski wear bar is a replaceable bar attached 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 con trol If the snowmobile is operated pri marily in deep snow ski wear bar wear will be minimal however if the snow mobile is operated on terrain where the snow cover is minimal the ski wear bar will wear faster To maintain positive steering characteristics Arctic Cat rec ommends that the ski wear bars be checked before each use and replaced if worn beyond 1 2 of the original diameter Ski wear bars are available from an authorized Arctic Cat Snowmobile dealer A WARNING the snowmobile excessively worn ski wear bars may result in a loss of steering control Removing Ski Wear Bars 1 Using
40. TE Since track tension and track alignment are interrelated always check both even if only one adjustment seems necessary A WARNING Always make sure the adjusting bolts are snug against the axle and the idler wheel cap screws and the axle nut on the RR models are tightened to specifications Failure to do so could cause the track to become extremely loose and under some operating conditions allow the idler wheels to climb over the track lugs forcing the track against the tunnel causing the track to lock If a track locks during operation severe per sonal injury could result Track Alignment Proper track alignment is obtained when the rear idler wheels are equal distance from the inner track drive lugs Excessive wear to the idler wheels drive lugs and track will occur if the track is improperly aligned Arctic Cat recommends that the track alignment be checked once a week or whenever the track tension is adjusted Checking Track Alignment A WARNING Make sure the ignition key is in the OFF position and the track is not rotating before checking or adjusting track alignment Personal injury could result if contact is made with a rotating track 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 shielded safety stand raise the rear of the snowmo bile off the floor m
41. XFHXPUSB S2013XFNELUSB S2013XFNLEUSW S2013F8H68USB S2013M8H3EOSB S2013XFNXPUSO S2013XFNLEUSB S2013F8HLEUSW S20183M8HSPOSG S20183XFNXPUSB S2013XFNTPUSB S2013F8HLEUSB S20183M8HSPOSO S2013M1N3EOSB S2013XFNHCUSW S2013M8H3EUSB S20183M8HSEOSG S2013XFNELOSW S2013XFNHCUSB S20183M8HSPUSG S20183M8HSEOSO S20183XFNELOSB S2013XFNXTUSO S2013M8HSPUSO 2013M8HLEOSW S2013XFNXPOSO S2013XFNXTUSB S2013M8HSEUSG S20183M8HLEOSB S2013XFNXPOSB 2013M1NE30SB S2013M8HSEUSO 2013M8HHCOSW S2013F1NTSUSG S20183M1NE4OSG S2013M8HLEUSW S2013XFHLXOSG S2013F1NTSUSB 2013M1NLEOSW S2013M8HLEUSB S2013XFHLEOSW S2013F1NTPUSG S20183M1NLEOSB S20183M8HELUSVV S2013XFHLEOSB S2013F1NTPUSO 2013M1NHCOSW S20183M8HELUSB S2013XFHSPOSB S2013F1NTRUSS S2013XFNLEOSW S2013M8HPSUSW S2013XFHHCOSW S2013F1NTROSS S2013XFNLEOSB S2013M8HPSUSB S2013XFHHCOSB S2013F1NTRUSG S2013XFNTPOSB S2013M8HPEUSW S2013XFHXPOSO S2013F1NTRUSW S2013XFNHCOSW S20183M8HPEUSB S2013XFHXPOSB S2013F1NLEUSW S2013XFNHCOSB S2013M8HHCUSW S2013F1NLXUSG S2013F1NLEUSB S2013XFNXTOSO S2013XFHLXUSG S2013F1NLXUSB S2013F1NLEOSB S2013XFNXTOSB Standards to which conformity is declared EMC EN 55012 EN 61000 6 2 MACHINERY EN 12100 2010 Arctic Cat Inc 601 Brooks Ave S Thief River Falls MN 56701 USA I the undersigned hereby declare that the equipment specified above conforms to the directive s and standard s as specified Brad Darling Vice President General Manager Snowmobile Division Manufacturer if not issuing agent
42. a heavy 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 sea son will assure many miles and hours of trouble free snowmobiling Arctic Cat recommends the following procedure 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 intake silencer for obstructions 3 Inspect all control wires and cables for signs of wear or fraying Replace if necessary Use cable ties or tape to route wires and cables away from hot or rotating parts 4 Inspect the drive belt for cracks and tears Check belt specifications Replace 1f damaged or worn Install the drive belt E NOTE If the old belt is worn but in reasonable condition retain it with the snowmobile as a spare in case of emergency 5 Inspect all fuel hoses and oil hoses for deterioration or cracks replace if necessary Make sure all connections are tight then on the 800 cc models fill the oil injection reservoir with the recommended 2 cycle oil see Gaso line Oil Recommended Injection Oil sub section in the General Infor mation section W NOTE After prolonged storage of the 800 cc models Arctic Cat r
43. achometer 1s a digital readout screen FZ001A A High Beam B Oil Pressure Low Oil 10 Coolant Temperature Increment Button Select Button Decrement Button Service Charging System 1100 cc Mod els RPM MPH kph By pushing the increment button once the RPM and MPH will be displayed one on the readout screen and one with the needle By pushing the button once again the functions will be reversed momummon By pushing the increment button with speed being displayed for more than two seconds the display will change between standard mph or metric kph With RPM displayed on the readout screen by pushing and holding the incre ment button maximum RPM will be dis played on the readout screen The maximum RPM readout will reset when the decrement button is pushed while maximum RPM is displayed Odometer Trip IMeter 1 Trip Meter 2 Hour Meter By pushing the decrement button the readout screen will display odometer trip meter 1 trip meter 2 and hour meter To reset the trip meter with the trip meter displayed push and hold the decre ment button until the display is cleared The hour meter readout will not reset Clock Altimeter By pushing the select button the readout screen will display clock altimeter and maximum altimeter To set the clock select clock on the display by pushing and holding the select button for two seconds the option of selecting the 12 hour or 24 hour cl
44. after filling the gas tank the bed of the trailer must be maintained level to prevent gasoline from draining out through the gas tank vent hose A WARNING Always fill the gas tank in a well ven tilated area Never add gasoline to the snowmobile gas tank near any open flames or with the engine running DO NOT SMOKE while filling the gas tank Do not sit on the snowmobile without first installing the gas tank cap Break In Gas Oil Mixing Instructions 800 cc Models Before mixing gasoline and oil make sure the oil is at room temperature 20 C 68 F Use a U L approved 22 7 1 6 U S gal gasoline container for mixing the gasoline and oil To properly mix the fuel at a 100 1 ratio use the following procedure CAUTION Never mix oil and gasoline in the snowmobile gas tank 1 Pour gasoline into the gasoline con tainer until approximately half full 2 Pour 236 ml 8 fl oz of the recom mended 2 cycle oil into the gasoline container 3 Install cap on gasoline container and shake the mixture vigorously 4 Fill the gasoline container with gaso line then cap the gasoline container and shake the mixture vigorously 5 Using a fine mesh screened funnel pour the fuel mixture from the gaso line container into the snowmobile gas tank A WARNING Always fill the gas tank in a well ven tilated area Never add gasoline to the snowmobile gas tank near any open flames or with the
45. aking sure the track is free to rotate A WARNING The tips of the skis must be posi tioned against a wall or similar object A WARNING DO NOT stand behind the snowmo bile or near the rotating track NEVER run the track at high speed when the track is suspended 3 Start the engine and accelerate slightly Use only enough throttle to turn the track several revolutions SHUT ENGINE OFF E NOTE Allow the track to coast to a stop DO NOT apply the brake because it could produce an inaccu rate alignment condition 4 When the track stops rotating check the relationship of the rear idler wheels and the inner track drive lugs If the rear idler wheels are centered between the inner track drive lugs no adjustment is necessary Idler Wheel Assem Pa Cf f Ay AA f LA I jT Inner Track Lugs 4 E Inner Track Lugs 0745 809 5 If the idler wheels are not centered between the inner track drive lugs an adjustment is necessary Adjusting Track Alignment On the side of the track which has the inner track drive lugs closer to the rear idler wheel loosen the idler wheel axle cap screw then rotate the adjusting bolt clockwise 1 to 1 1 2 turns 47 E NOTE On the RR models this pro cedure should be done from the right side only Track Adjuster Rg Adjusting Bolt Axle Cap Screw 0745 811 2 Check track alignment and continue adjustment until pro
46. ancelled when engine temperature is below or above normal operating range 2 Shift only with the engine at idle RPM and the snowmobile com pletely stopped The reverse func tion will not engage if engine is above 3000 RPM 3 If attempting to shift into reverse at too high engine RPM above 3000 RPM the reverse function will be cancelled and the coolant temperature warning icon will flash This indicates the reverse switch button was pressed at too high RPM The operator must reduce engine RPM below 3000 and press the button a second time 4 Upon pressing the reverse switch button the reverse function will make up to three attempts to engage into reverse If the function is not completed after the third attempt the engine will shut down CAUTION Never shift into reverse while the snowmobile is moving forward as it is hard on the driven pulley torque bracket and the cam rollers Operating in Reverse 800 cc Models CAUTION Never pull the recoil starter rope when the engine is running or when operat ing in reverse Damage to the engine and or recoil start system will occur 1 When reverse is engaged a reverse icon will illuminate in the speedom eter tachometer and a reverse alarm will sound 2 If the throttle lever is compressed before complete reverse engage ment the engine may shut down Always wait for the reverse icon to illuminate and the reverse alarm to sound be
47. ant manufacturer s recommendations B NOTE On the HCR and M LTD models if operating on ice or hard packed snow the ice scratchers must be engaged to reduce engine overheating E NOTE If operating on ice or hard packed snow conditions it is recom mended that Ice Scratchers p n 5639 897 be installed to reduce wear strip wear and engine overheat ing For checking filling cooling system refer to Coolant Level sub section in the Main tenance section Battery Electric Start It is extremely important that the battery be maintained at full charge at all times and that the battery connections be clean and tight If charging the battery becomes necessary refer to Battery sub section in the Maintenance section CAUTION On the 1100 cc models always turn the ignition switch key to the OFF position when the snowmobile is not being used Leaving the ignition switch in the ON position will result in discharging the battery and possible damage to the battery Jump Starting 1100 cc Models E NOTE Arctic Cat does not recom mend jump starting a snowmobile with a dead battery but rather to remove the battery service it and correctly charge it however in an emergency it may be necessary to jump start a snowmobile If so use the following procedure to carefully and safely complete this procedure A WARNING Improper handling or connecting of a battery may result in severe injury including a
48. ant is at least halfway up in the sight glass then install the shift actuator w extension and connect the actuator wiring harness E NOTE Make sure the reverse sen Sor wire is routed up so the wires do not become pinched between the actuator and the case XM014A When installing the shift actuator rotate the actuator back and forth to properly align it with the extension gear Failure to do so could cause component damage 6 Install and secure the exhaust reso nator E NOTE On the 1100 cc models the resonator gasket s between the exhaust pipe s and resonator must be replaced 7 On the 1100 cc models start the engine and verify proper reverse and forward operation by shifting in and out of reverse three times CAUTION The correct lubricant to use in the chain case is Arctic Cat Synthetic Chain Lube Any substitute may cause serious damage to the drive system Rear Suspension This procedure should be done every 40 operating hours W NOTE Arctic Cat recommends that Arctic Cat All Temp Grease p n 4639 365 be used for this proce dure W NOTE Illustrated are the general locations of grease fittings Actual locations will vary from model to model 1 Shut engine off and wait for all mov ing parts to stop 2 With the gas tank nearly empty less than 1 4 full and using Handlebar Stand p n 5639 152 or Steering Post Stand p n 5639 946 or a suit able
49. at Snowmobile dealer for this service This service is at the discretion and expense of the snowmobile owner 2 On the 800 cc models if the lube level is low remove the fill plug from the chain case then add the appropriate amount of Arctic Cat Synthetic Trans mission Lube p n 5639 039 in the fill hole Install the plug 3 On the 1100 cc models if the lube level is low remove the three screws securing the shift actuator to the chain case disconnect the actuator wiring harness and remove the actu ator w extension then add apropri ate amount of Arctic Cat Synthetic Chain Lube p n 5639 039 through the shift actuator opening When the lube is halfway up the sight glass install the shift actuator w extension and connect the actuator wiring har ness Tighten screws to 36 in lb 28 Wire Harness Shift Actuator Screw Qty 3 0746 804 CAUTION When installing the shift actuator rotate the actuator back and forth to properly align it with the extension gear Failure to do so could cause component damage 4 On the 1100 cc models start the engine and verify proper reverse and forward operation by shifting in and out of reverse three times W NOTE If excessive build up of moisture or discolored oil is detected in the chain case it may be necessary to replace the lube E NOTE Replacing the lubricant can be done by the snowmobile owner if qualified to do so If the owner does no
50. attery chargers and battery products B NOTE Battery maintenance may be done by the snowmobile owner if qualified to do so If the owner does not feel qualified take the snowmo bile to an authorized Arctic Cat Snowmobile dealer for this service This service is at the discretion and expense of the snowmobile owner To remove and charge the battery use the following procedure A WARNING Any time service is performed on a bat tery the following must be observed Keep sparks open flame cigarettes or any other flame away Always wear safety glasses Protect skin and cloth ing when handling batteries When ser vicing battery in enclosed space keep the area well ventilated A WARNING Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the state of California to cause cancer and reproductive harm Wash hands after handling 1 Remove the torx head screw from the rear underside of the seat then remove the seat CAUTION On the LXR models make sure to dis connect the seat heater harness con nector prior to removing the seat 2 Remove the negative battery cable and ground wire then remove the positive cable E NOTE For installing purposes prior to removing the battery note the routing and securing locations of the cables and harness wires 38 3 Remove the two screws and lock nuts securing the battery bracket solenoi
51. be replaced Periodic checks at least once a month under normal usage of two drive belt specifications are essential 43 1 Measure the outside circumference of the drive belt The belt should be within the recommended range in circumference see appropriate spec ifications sheet 2 Measure the outside width of the drive belt The belt should be within the recommended range in width 3 Check the belt for cracking fraying etc If any of the specifications or conditions are unsatisfactory replace the drive belt B NOTE Drive belts should be pur chased from an authorized Arctic Cat Snowmobile dealer as Arctic Cat drive belts are made to exact specifi cations and of quality material Belts made by other manufacturers may not be of the same specifications or quality and therefore usage could result in poor performance and pre mature belt failure E NOTE Before starting the snowmo bile in extremely cold temperatures the drive belt should be removed and warmed up to room temperature Once the drive belt is at room temper ature install the drive belt Also new drive belts have a break in period of approximately 25 miles After installing a new drive belt drive the snowmobile for 25 miles at 3 4 throttle or less By revving the engine up and down but not exceeding 60 mph the exposed cord on the side of a new belt will be worn down This allows the drive belt to gain its optimum flexibility and will exte
52. be ser viced by an authorized Arctic Cat Snowmobile dealer only Drive Clutch Driven Pulley Alignment The alignment between the drive clutch and driven pulley is set at the factory Normally no adjustment is necessary as long as neither the drive clutch nor the driven pulley is removed or disassem bled However if premature drive belt wear is experienced or if the drive belt turns over the drive clutch driven pulley alignment must be checked Take the snowmobile to an authorized Arctic Cat Snowmobile dealer for this service If not under warranty this service is at the dis cretion and expense of the snowmobile owner Fuel Pump The fuel pump is designed to provide adequate amount of gas to the injectors at all throttle settings If a fuel delivery problem is suspected take the snowmo bile to an authorized Arctic Cat Snowmo bile dealer If not under warranty this service is at the discretion and expense of the snowmobile owner Shock Absorbers Rebuildable Gas Each shock absorber should be visibly checked weekly for fluid leakage cracks or breaks in the body reservoir or a bent shaft If any one of these conditions is detected replacement or service is neces sary Take the snowmobile to an autho rized Arctic Cat Snowmobile dealer for this service If not under warranty this service is at the discretion and expense of the snowmobile owner B NOTE When the snowmobile is operated in extremely cold
53. be warrantable in material or workmanship This repair work MUST be done by an authorized Arctic Cat Snowmobile dealer No transportation charges rental charges or inconvenience costs will be paid by Arctic Cat The warranty is validated upon examination of said parts by Arctic Cat or an authorized Arctic Cat Snowmobile dealer Arctic Cat reserves the right to inspect such parts at its factory for final determination if warranty should apply The warranty periods are as follows 1 For snowmobiles used for recreational purposes lf purchased between May 1 and November 30 warranty expires ONE 1 YEAR from December 1 of the current year lf purchased between December 1 and April 30 ONE 1 YEAR from the date of sale 2 For snowmobiles used for commercial purposes including rental operations ONE 1 YEAR from the date of invoice and or 5000 MILES whichever comes first non transferable 3 THIRTY 30 DAYS from date of sale of snowmobile on Arctic Cat supplied batteries Exclusions to this warranty include normal wear abuse i e a track run on marginal snow conditions without proper lubrication or additional idler wheels and the following parts Fuel Filter Light Bulbs Windshield Drive Belt Torn or Punctured Upholstery Wear Bars Brake Pads Spark Plugs Drive Clutch Driven Pulley Wear Parts Wear Strips Shock Absorber s Standard Shock Absorber s Rebuildable Limited to one 1 year or 1000 miles of normal riding conditions
54. bulb retainer counter clockwise until it unlocks from the housing then remove the bulb Headlight Bulb Retainer TX Grommet Headlight Bulb 0746 096 3 Install the bulb and retainer then rotate the retainer clockwise until it properly locks in place 51 4 Install the rubber grommet then connect the headlight harness con nector to the bulb 5 Check headlight aim see Adjusting Headlight Aim in this sub section A WARNING Do not operate the snowmobile unless headlight beam is adjusted properly An incorrectly adjusted beam will not provide the operator the optimum amount of light Adjusting Headlight Aim The headlight can be adjusted for vertical aim of the HIGH LOW beam The geo metric center of HIGH beam zone is to be used for vertical aiming 1 Position the snowmobile on a level floor so the headlight is approxi mately 8 m 25 ft from an aiming surface wall or similar surface B NOTE There should be an aver age operating load on the snowmo bile when adjusting headlight aim 2 Measure the distance from the floor to midpoint of the headlight 3 Using the measurement obtained in step 2 make a horizontal mark on the aiming surface 4 Make a vertical mark which inter sects the horizontal mark on the aim ing surface directly in front of the headlight 5 Engage the brake lever lock and start the engine Move the headlight dim mer switch to the
55. ches operating temperature see Cold Drive Away Function sub section in the General Information section CAUTION On the 800 cc models it is extremely important that the engine is properly warmed up before subjecting the engine to high speed operation or heavy loads The engine should be allowed to idle at least 3 4 minutes before it is operated at more than 1 2 throttle In extremely cold condi tions the warm up time will be lon ger Cold seizure and piston scuffing caused by insufficient warm up will not be covered by warranty Also do not idle the engine for excessively long periods of time 9 Flooding If the engine does not start but seems ready to start engage the brake lever lock then compress the throttle control lever fully and try to start the engine When the engine starts release the throttle control lever immediately After the warm up release the brake lever lock W NOTE On the 800 cc models if the engine fails to start during the attempt with the throttle control lever com pressed remove the spark plugs and clean and dry them thoroughly or install a new set of properly gapped recommended spark plugs 10 To shut off the engine turn the igni tion key to the OFF position or push the emergency stop switch to the DOWN position CAUTION On the 1100 cc models always turn the ignition switch key to the OFF position when the snowmobile is not being used Leaving the ignition swi
56. cid burns electrical burns or blindness as a result of an explo Always remove rings and watches E NOTE To access the battery the seat must be removed see Remov able Seat sub section in this sec tion 1 On the snowmobile to be jump started slide any terminal boots away A WARNING Any time service is performed on a battery the following must be observed keep sparks open flame cigarettes or any other flame away Always wear safety glasses Protect skin and clothing when handling a battery When servicing a battery in an enclosed space keep the area well ventilated 2 Inspect the battery for any signs of electrolyte leaks loose terminals or bulging sides Leaking or bulging battery cases may indicate a frozen or shorted battery A WARNING If any of these conditions exist DO NOT attempt to jump start boost or charge the battery An explosion could occur causing serious injury 3 Inspect the vehicle to be used for jump starting to determine if voltage and ground polarity are compatible The vehicle must have a 12 volt DC negative ground electrical system 15 CAUTION Always make sure the electrical sys tems are of the same voltage and ground polarity prior to connecting jumper cables If not severe electri cal damage may occur 4 Move the vehicle to be used for the jump start close enough to ensure the jumper cables easily reach then set and lock the b
57. d To bleed the brake use the follow ing procedure E NOTE The brake system may be bled by the snowmobile owner if qualified to do so If the owner does not feel qualified take the snowmo bile to an authorized Arctic Cat Snowmobile dealer for this service This service is at the discretion and expense of the snowmobile owner 1 Remove the reservoir cover and if necessary fill the reservoir to the high brake fluid mark with Arctic Cat approved DOT 4 brake fluid CAUTION Brake fluid is highly corrosive Do not spill brake fluid on any surface of the snowmobile 41 A WARNING Use only Arctic Cat approved DOT 4 brake fluid Any substitute may result in a loss of brakes 2 Slide a piece of flexible tubing over the ball of the bleeder valve and direct the other end into a container 3 Slowly compress the brake lever until maximum pressure is attained then hold the lever in the com pressed position to maintain pres sure Open the bleeder valve to release the fluid and air When the fluid stops close the bleeder valve then release the brake lever 4 Repeat step 3 until the brake fluid flows free of air bubbles E NOTE It may be necessary to refill the reservoir during the bleeding process Never allow the brake fluid to go below the low brake fluid mark in the reservoir 5 When the brake fluid is free of all air and the brake lever feels firm when compressed fill the reservoir t
58. d carry ing capability of the snowmobile and should be adjusted for the weight and rid ing preference of the operator E NOTE On Sno Pro models with a rear arm float shock this adjustment is achieved by increaseing or decreasing the air pressure in the rear arm air shock absorber Adjusting Front Ski Shock Springs The front ski shock springs are individu ally adjustable for the terrain conditions and driving style of the operator The spring adjuster nut has been set at the factory so the correct amount of threads are exposed between the adjuster nut and the threaded shock body as an initial setting Additional ski pressure can be obtained by tightening the spring tension ski pressure can be decreased by relaxing spring tension E NOTE Equal adjustments should be maintained on both sides of the snowmobile Front ski shock spring pre load adjust ment is accomplished by loosening the adjuster nut locking collar B from the adjuster nut A and using the Spring Adjuster Tool from the tool kit rotating the adjuster nut in whichever direction is desired Tighten the locking collar against the adjuster nut S a Shock Body 0745 159 Adjusting Fox Air Shocks Sno Pro Models E NOTE It is recommended to moni tor the air pressure in the air shocks once every month B NOTE Adjusting air shocks may be done by the snowmobile owner if qualified to do so If the owner does not feel qualified tak
59. d packed snow conditions it will run slightly slower than a standard track and it will accelerate wear strip wear To decrease the amount of wear strip wear slower speeds must be maintained when operating on hard packed trails Acceler ated wear strip wear caused by operating a Power Claw track on hard packed snow conditions is NOT covered under Arctic Cat Inc warranty policy E NOTE If operating on ice or hard packed snow conditions it is recom mended that Ice Scratchers p n 5639 897 be installed to reduce wear strip wear and engine overheating 17 Track Studs XF F Models E NOTE Stud or hooker plate installa tion will void track and tunnel warranty E NOTE Arctic Cat does not recom mend studding a track with a 1 5 inch lug or greater E NOTE Stud installation can be per formed by the snowmobile owner if qualified to do so If the owner does not feel qualified take the snowmo bile to an authorized Arctic Cat Snow mobile dealer for this service This service is at the discretion and expense of the snowmobile owner A WARNING When installing studs on a single ply track it is important to use Arctic Cat approved studs proper head diame ter If approved studs proper head diameter are not used studs could tear free of the track causing possible injury or even death Consult an authorized Arctic Cat Snowmobile dealer for information CAUTION To prevent tunnel damage from the studs
60. d shock body as an initial setting Rear spring pre load adjustment is accomplished by loosening the adjuster nut locking collar B from the adjuster nut A and using the Spring Adjuster Tool from the tool kit rotating the adjuster nut in whichever direction is desired Tighten the locking collar against the adjuster nut Threaded Shock Body 0745 159 Lights For the correct headlight bulb and or tail light brakelight LED see the appropriate specifications sheet Removing and Installing Taillight Brakelight These models are equipped with an LED taillight brakelight If the LED fails it must be replaced To remove and install the LED use the following procedure Taillight _ Tks 746 097B 1 Disconnect the taillight harness con nector 2 Remove the two torx head screws securing the taillight to the bracket 3 Connect the taillight harness connec tor then secure the taillight to the bracket with the two torx head screws Removing Installing Headlight Bulb E NOTE The bulb portion of headlight is fragile HANDLE WITH CARE When replacing the headlight bulb the bulb assembly must first be removed from the housing Do not touch the glass portion of the bulb If the glass is touched it must be cleaned with a dry cloth before installing 1 Disconnect the headlight harness connector from the bulb then remove the rubber grommet from the headlight housing 2 Rotate the
61. d to the seat base then move the bracket up and out of the way and remove the battery Lock Nuts KL Battery Bracket Pe 746 170A A WARNING Avoid spillage and contact with skin eyes and clothing CAUTION Do not charge the battery while it is in the snowmobile with the battery ter minals connected 4 Thoroughly wash the battery with soap and water then using a wire brush clean the battery posts and cable ends removing all corrosive buildup Replace damaged cables or cable ends E NOTE If battery posts or cable ends have a build up of white green powder residue apply water and baking soda to neutralize acid then flush off with warm soapy water CAUTION Do not remove seal strip on a sealed battery A WARNING Battery acid is harmful if it contacts eyes skin or clothing Care must be taken whenever handling a battery 5 Using a multimeter test the battery voltage The meter must read no less than 12 5 DC Volts for a fully charged battery E NOTE At this point if the meter reads as specified the battery may be returned to service see step 9 6 If the meter reads less than specified voltage charge the battery using the following guidelines A When using an automatic battery charger always follow the char ger manufacturer s instructions B When using a constant current battery charger use the follow ing Battery Charging Chart C
62. des of brake fluid Brake loss can result Brake loss can result in severe injury or even death Changing Brake Fluid The brake fluid must be changed on a reg ular basis and whenever the brake fluid has been overheated or contaminated The brake fluid should be changed every 1000 miles or at the end of the snowmobiling season whichever occurs first Take the snowmobile to an authorized Arctic Cat Snowmobile dealer for this service This service is at the discretion and expense of the snowmobile owner Checking Brake Lever Travel Before each use check the brake lever travel using the following procedure 1 Compress the brake lever fully ENOTE Do not pump the brake lever as it will produce an inaccurate reading 2 Measure the distance between the brake lever and the handlebar The distance must be greater than 2 54 cm 1 in 0745 816 3 If the resultant distance is less than specified take the snowmobile to an authorized Arctic Cat Snowmobile dealer for service If not under war ranty this service is at the discretion and expense of the snowmobile owner A WARNING Do not operate the snowmobile if the compressed distance between the brake lever and the handlebar is less than 2 54 cm 1 in Brake loss may occur Brake loss can result in severe personal injury Bleeding Brake System If the brake lever feels spongy when applied the brake system may need to be ble
63. driven pulley is serviced B NOTE For checking offset it is necessary to use Clutch Alignment Bar p n 0644 588 to obtain a drive clutch driven pulley offset of 1 450 in This special tool can be pur chased from an authorized Arctic Cat snowmobile dealer To check offset use the following proce dure 1 Open the left side access panel then remove the belt guard 2 Install the clutch alignment bar between the drive clutch sheaves 3 Allow the bar to rest on the drive clutch shaft and against the outside edge of the driven pulley stationary sheave E NOTE The alignment bar must extend beyond the front edge of the drive clutch 56 4 With the bar against the outside edge of the driven pulley stationary sheave at points A and B the bar should just clear the inside edge of the stationary sheave of the drive clutch and rest on the stationary shaft at point C with a maximum 0 060 in clearance at point C At this point measurement between points A and C should be 1 450 in with a maximum 0 030 in clear ance If the bar either will not clear the inside edge or is more than the specified amount the offset must be corrected C 16 mm 0 030 in Max 0746 808 E NOTE If the offset is out of speci fication take the snowmobile to an authorized Arctic Cat Snowmobile dealer for drive system evaluation and or servicing This service is at
64. e If leakage or damage is detected take the snowmobile to an authorized Arc tic Cat Snowmobile dealer for ser vice If not under warranty this service is at the discretion and expense of the snowmobile owner E NOTE On the HCR and M LTD mod els if operating on ice or hard packed snow the ice scratchers must be engaged to reduce engine overheating Spark Plugs 1100 cc Models MNOTE Always use the recom mended spark plugs in the engine See the appropriate specifications sheet for correct spark plug gap Varying terrain conditions and operating usage may require spark plugs of a differ ent heat range For example sustained cross country riding will usually require colder heat range spark plugs while trail riding or other continual slow speed operation will usually require hotter heat range spark plugs CAUTION If adjusting spark plug gap is neces sary do not use the center electrode as a leverage point Damage to the plug may occur Removing Installing Spark Plugs B NOTE Spark plug maintenance may be done by the snowmobile owner if qualified to do so If the owner does not feel qualified take the snowmobile to an authorized Arctic Cat Snowmobile dealer for this service This service is at the discretion and expense of the snow mobile owner E NOTE For this procedure the hood must be removed see Access Panel Hood Removing Installing in the Gen eral Information sect
65. e Sensor Air Bypass Valve Oxygen Sensor Turbo Waste Gate Control Valve Throttle Position Sensor Crankcase Ventilation System ISC Valve Ignition System Miscellaneous Items Used in Aforementioned Systems Ignition Coil Connectors Knock Sensor System Switches Crankshaft Position Sensor Grommets Exhaust Temperature Sensor Clamps Capacitive Discharge Ignition CDI Module Hoses Magneto Pick Up Ties Spark Plugs Gaskets Wiring OWNER S RESPONSIBILITIES The owner of any snowmobile warranted under this Arctic Cat Emission Control Statement is responsible for the proper maintenance and use of the snowmobile in accordance with Arctic Cat s recommendations in the Operator s Manual 60 Change of Address Ownership or Warranty Transfer Arctic Cat Inc keeps on file the current name and address of the owner of this snowmobile This will allow Arctic Cat to reach the current owner with any important safety information which may be necessary to protect customers from personal injury or property damage Please make sure a copy of this form is completed and returned to Arctic Cat Inc if you move or if the snowmobile is sold to another party This form may also be used to transfer the unused portion of the original warranty to a second party In order to transfer warranty fill out this form completely then return a copy of this form to Arctic Cat Inc Arctic Cat will then process the application and issue warranty for the ba
66. e the snowmo bile to an authorized Arctic Cat Snowmobile dealer for this service This service is at the discretion and expense of the snowmobile owner The air shocks are individually adjustable for the terrain conditions and driving style of the operator The shocks are pre set at the factory see chart as an initial setting however it is possible to fine tune the shocks to match the operator s weight riding style and terrain condi tions B NOTE Adding air pressure will increase the air spring force reduc ing air pressure will decrease air spring force Checking and adjusting air pressure must be done at riding temperature outside Also it is advisable to check air pressure when the outside temperature varies more than 25 Initial Setting Chart Front Shock Rear Arm Model Ski Shock M XF Sno 6 3 kg cm 10 2 10 6 kg cm Pro Models 90 psi 145 150 psi F Sno Pro 5 3 kg cm N A Models 75 psi RR Models 250 psi nitro 250 psi nitrogen gen 25 225 psi air W NOTE Care should be taken to have equal pressure in the front ski shocks before operating the snow mobile XF Cross Tour Rear Shock Setting Chart opor bd Rear Shock Pressure psi 190 Shop 70 F Trail 20 F 145 psi 130 psi can Rear Shock Pressure psi 100 Shop 70 F Trail 20 F 155 psi 140 psi 140 Shop 70 F Trail 20 F 165 psi 150 psi 180 Shop 70 F Tra
67. e track will stretch and take a set during break in Track deflection must be maintained within the recom mended range A WARNING Track tension must be properly main tained Personal injury could result if a track is allowed to become exces sively loose 45 Checking Track Tension A WARNING DO NOT attempt to check or adjust track tension with engine running Turn ignition key to the OFF position Personal injury could result from con tact with a rotating track Remove excess ice and snow buildup from the track track drive sprockets and the inside of the skid frame 2 Elevate the snowmobile on a shielded safety stand high enough to use a spring scale 3 At mid point of the track on the bottom side hook a spring scale around a track clip then pull down on the scale to the recommended pressure Measure the deflection distance between the bottom of the wear strip and the inside surface of the track clip Compare the measure ment with the chart After Break In Tension 2 in Setup Tension All Models 12 15 Ib 2 in 1 Loosen the idler wheel axle cap screws Track Adjuster Adjusting Bolt i Axle Cap Screw T I 12 15 Ib 5 4 6 8 kg Deflection 0746 788 B NOTE Measurement is from the bottom of the wear strip at the point of the shock pad on the slide rail B NOTE Onl
68. eat These snowmobiles are equipped with a removable seat To remove the seat use the following procedure 21 Remove the torx head screw from the underside of the seat then lift on the back of the seat and move it up and rearward to remove it CAUTION On the 1100 cc LXR models prior to removing the seat lift the rear of the seat and disconnect the seat heater harness connector 746 088A To install the seat use the following pro cedure Slide the front of the seat into the locking position of the seat support bracket then lower the rear of the seat into position on the tunnel Secure with the torx head screw E NOTE On the 1100 cc LXR models prior to lowering and securing the seat connect the seat heater har ness connector Towing If the snowmobile is to be towed by another snowmobile do not tow using the loops in the skis The tow rope should be attached to the spindles Arctic Power Valve APV System 800 cc Models CAUTION The recommended engine oil to use is either Arctic Cat APV Synthetic 2 Cycle Oil or Formula SS Semi Syn thetic Oil see Gasoline Oil Recom mended Injection Oil sub section in this section Any substitute may cause an APV malfunction This RPM controlled servomotor servo actuated system adjusts the size of the exhaust ports to provide peak perfor mance throughout the RPM range 22 The system consists of an exhaust va
69. ecom mends one tankful of 100 1 gas oil mix ture be used in conjunction with the oil injection system to ensure proper lubri cation 6 On the 800 cc models inspect the spark plugs Replace gap or clean as necessary 7 Tighten all nuts bolts and cap screws making sure all nuts bolts and cap screws are tightened securely 8 If not done during preparation for storage lubricate the rear suspen sion with all temperature grease 9 Check the coolant level and all cool ant hoses and connections for deteri oration or cracks Add properly mixed coolant as necessary 10 On electric start models charge the battery until fully charged see Bat tery sub section in the Maintenance section then connect the battery cables making sure to connect the positive cable first Test the electric start system 11 Inspect the entire brake system all controls headlight taillight brake light ski wear bars and headlight aim adjust or replace as necessary 12 Adjust the track to the proper tension and alignment see Track Tension and Track Alignment sub sections in the Maintenance section 59 U S EPA Emission Control Statement Warranty Coverage U S Only STATEMENT WARRANTY Arctic Cat warrants to the original retail purchaser and each subsequent purchaser that all U S EPA certified Arctic Cat snowmobiles are designed built and equipped to conform to all U S EPA Emission Control Regulations
70. engine running DO NOT SMOKE while mixing fuel or fill ing the gas tank Engine Break In The Arctic Cat engine when new or rebuilt requires a short break in period before the engine is subjected to heavy load conditions 800 cc Models 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 1 2 throttle is recommended however brief full throttle accelerations and varia tions in driving speeds contribute to good engine break in After one 1 tankful break in period the snowmobile may be taken to an authorized Arctic Cat Snow mobile dealer for a checkup This checkup is at the discretion and the expense of the snowmobile owner 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 could cause spark plug foul ing and excessive carbon buildup 1100 cc Models This engine does not require any pre mixed fuel during the break in period CAUTION DO NOT use premixed fuel in the snowmobile gas tank Engine dam age will occur To ensure trouble free operation careful adherence to the following break in guidelines will be beneficial 0 200 miles 200 400 miles 400 600 miles 1 2 Throttle 45 MPH max 1 2 3 4 Throttle 1 2 3 4 Throttle With occasional full throttle operation To
71. ensure proper engine break in Arctic Cat recommends that the engine oil and filter be changed after 500 miles This service is at the discretion and expense of the snowmobile owner Drive Belt Break In Drive belts require a break in period of approximately 25 miles Drive the snow mobile for 25 miles at 3 4 throttle or less By revving the engine up and down but not exceeding 60 mph the exposed cord on the side of a new belt will be worn down This will allow the drive belt to gain its optimum flexibility and will extend drive belt life E NOTE Before starting the snowmo bile in extremely cold temperatures the drive belt should be removed and warmed up to room temperature Once the drive belt is at room temperature install the drive belt see Drive Belt sub section in the Maintenance section CAUTION Never run the engine with the drive belt removed Excessive revving of the engine could result in serious engine damage and drive clutch failure Cold Drive Away Function 1100 cc Models On these models there is a cold drive away function incorporated within the engine ENOTE When cold starting the engine the coolant temperature warning icon will illuminate and the TEMP display on the readout screen will begin to flash With the engine in this temperature range the RPM limit of the engine will be below drive system engagement speed As the engine warms the coolant tem perature
72. er Falls MN 56701 p n 2259 386 Phone 218 681 9851 U S 204 982 1656 Canada
73. ey with compressed air and clean sheaves with suitable parts cleaning solvent Rear Suspension Monthly 29 Grease 30 The longevity and safety of the snowmo bile can be increased by making periodic checks of the items in the preceding checklist If at any time abnormal noises vibra tions or improper working conditions of any component of this snowmobile are detected DO NOT OPERATE THE SNOWMOBILE Take the snowmobile to an authorized Arctic Cat Snowmobile dealer for inspection and adjustment or repair If not under warranty this service is at the discretion and expense of the snowmobile owner The snowmobile should be taken to an authorized Arctic Cat Snowmobile dealer at the end of each snowmobiling season for general inspection and for off season storage servicing This inspection and servicing is at the expense of the snow mobile owner Air Cleaner Filter 1100 cc Turbo Models The air filter inside the air cleaner hous ing must be kept clean to provide good engine power and gas mileage If the snowmobile is used under normal condi tions inspect the filter weekly and replace the filter at the intervals speci fied If operated in adverse conditions inspect and service the filter more fre quently Use the following procedure to remove the filter and to inspect and or replace it CAUTION Failure to inspect the air filter fre quently if the snowmobile is used in adverse conditions
74. fore backing up 3 The system will not shift until the but ton is released Also the reverse func tion will cancel if operated in reverse longer than 45 seconds Whenever the reverse function has been cancelled the engine must be run in the forward mode for a minimum of 60 seconds at 2000 RPM before the reverse func tion can be used again A WARNING Do not use high speed when backing up Control could be lost and injury could occur CAUTION Do not use high speed when backing up Damage to the drive belt and driven pulley components may occur E NOTE While operating in reverse a rev limiter will activate at 6500 RPM 4 To shift into forward stop the snow mobile and allow the engine to idle under 3000 RPM then press the reverse button and release The for ward selection will be complete 5 After shifting from reverse to for ward or from forward to reverse apply the throttle slowly and evenly to allow the driven pulley to engage properly 19 6 The reverse function is cancelled whenever the engine is shut off CAUTION After reversing in deep powder snow conditions make sure the snowflap does not become caught up in the track Track and or snowflap damage may occur CAUTION If the snowmobile is equipped with ice scratchers the scratchers must be disengaged or component dam age will occur Shifting Into Reverse 1100 cc Models
75. g and holding a button will accelerate the number display E NOTE If MPH has been selected in the speed readout the altitude value will be displayed in feet If kph has been selected in the speed readout the alti tude value will be displayed in meters To reset the maximum altimeter readout with the maximum altimeter displayed push and hold the select button for a min imum of two seconds Service Icon On electric start models the icon should briefly illuminate each time the key is turned to RUN or START and engine is started then it should go out when the engine starts If the icon stays illuminated on electric start models or it illuminates while the engine is running the system is receiving input that is outside of its established parameters If the icon illuminates indicating an error take the snowmobile to an authorized Arctic Cat Snowmobile dealer for ser vice If not under warranty this service is at the discretion and expense of the snowmobile owner Coolant Temperature Warning Icon W NOTE On the 1100 cc models when cold starting the engine the coolant temperature warning icon will illuminate the readout screen will display TEMP and engine RPM limit will be below drive system engagement speed When the engine reaches proper operat ing temperature the coolant temperature warning icon and TEMP display will cease to flash If the coolant temperature rises too far above proper operating temperat
76. ge the minute display either tap the buttons for individual num ber display or push and hold the buttons for rapid number display 8 E NOTE During clock setting if nei ther button left right is pushed within a 5 second time period the clock setting mode will be exited with changes saved Service Icon On electric start models the icon should illuminate each time the key is turned to RUN or START and it should go out when the engine starts If the icon stays illumi nated on electric start models or it illumi nates while the engine is running the system is receiving input that is outside of its established parameters If the icon illu minates indicating an error take the snow mobile to an authorized Arctic Cat Snowmobile dealer for service If not under warranty this service is at the discretion and expense of the snowmobile owner Coolant Temperature Warning Icon W NOTE On the 1100 cc models when cold starting the engine the coolant temperature warning icon will illuminate the readout screen will display TEMP and engine RPM limit will be below drive system engage ment speed When the engine reaches proper operat ing temperature the coolant temperature warning icon and TEMP display will cease to flash If the coolant temperature rises too far above proper operating temperature the coolant temperature warning icon will flash a warning alert and the engine will surge to alert the operator If
77. he oil level 1 With the engine off note the oil level in the sight glass If the level is below the sight glass add only enough recommended oil until it is visible in the sight glass DO NOT overfill the reservoir with oil 3 Lo J ON OY MAX LE i on I VEL gt D SNO 244A 2 Open the air bleed bolt located on the oil pump beneath the coolant tank to purge air from the oil hose PC016A E NOTE When air can no longer be heard purging from oil pump bleed tighten the bleed bolt to 7 5 ft Ib CAUTION Do not attempt to start the engine with the bleed bolt open 3 Start the engine The warning icon should go out within five seconds If the warning icon goes out check oil level 4 If the warning icon does not go out shut the engine off immediately and repeat step 2 then repeat step 3 If the warning icon does not go out or if the engine does not start take the snow mobile to an authorized Arctic Cat Snow mobile dealer If not under warranty this service is at the discretion and expense of the snowmobile owner Diagnostic Codes Diagnostic codes are activated by the ECU and may be displayed on the read out screen for a number of reasons If a code is displayed while the engine is running the ECU is receiving input that is outside of its established parameters If a code has been activated take the snow mobile to an authorized
78. he sight glass Tip the snowmobile to the right at a 45 angle then check to see if oil is present in the sight glass 1 With the engine off note the oil level in the sight glass If the level is below the sight glass add only enough recommended oil until it is visible in the sight glass DO NOT overfill the reservoir with oil Cs V M MAX um D Qo br SN E NE SNO 244A 2 Open the air bleed bolt located on the oil pump beneath the coolant tank to purge air from the oil hose PCO16A E NOTE When air can no longer be heard purging from oil pump bleed tighten the bleed bolt to 7 5 ft Ib CAUTION Do not attempt to start the engine with the bleed bolt open 3 Start the engine The warning icon should go out within five seconds If the warning icon goes out check oil level 4 If the warning icon does not go out shut the engine off immediately and repeat step 2 then repeat step 3 If the warning icon does not go out or if the engine does not start take the snow mobile to an authorized Arctic Cat Snow mobile dealer If not under warranty this service is at the discretion and expense of the snowmobile owner Indicator Icons Deluxe Gauge Certain models are equipped with a deluxe gauge combination speedometer tachome ter Indicator icons are incorporated within the speedometer tachometer Also incorpo rated into the speedometer t
79. hind the driven shaft ENOTE After completing the changing of the fuel filter and the engine is started for the first time inspect the filter area for any signs of leaks Towards rear of snowmobile Filter Lip 0746 802 32 Gasoline Additives Fuel de icer can be used for all models Also periodic use of an injector cleaner for 800 cc models is recommended espe cially in the last tank of gasoline before storage Arctic Cat Fuel Stabilizer p n 0436 907 should also be added to the last tank of gasoline before storage Fuel Pickup Valves If ever there is a restricted fuel flow and a pickup valve is suspected take the snow mobile to an authorized Arctic Cat Snow mobile dealer for this service If not under warranty this service is at the discretion and expense of the snowmobile owner Checking Engine Oil Level 1100 cc Models E NOTE The engine must be at operating temperature before check ing the oil level or an incorrect oil level will result CAUTION If the engine and oil are not at oper ating temperature the oil will not be visible in the sight glass Tip the snowmobile to the right at a 45 angle then check to see if oil is present in the sight glass 1 Park the snowmobile on a level surface then start the engine and allow to warm up for 5 10 minutes or if the snowmo bile was operated allow the engine to idle for approximately 30 seconds E
80. hut off the engine press down on the emergency stop switch IMME DIATELY to stop the engine DO NOT start the engine until the malfunction in the throttle system has been located and corrected If the snowmobile engine stops abruptly when the throttle control lever is released and the activation of the monitor switch is suspected use the following procedure 1 Rotate the ignition key to the OFF position 2 Remove ice and snow from the throttle system and wait 5 10 min utes for the engine heat to thaw ice from the throttle system 3 Test the throttle control lever by compressing and releasing it several times The lever MUST return to the idle position quickly and completely E NOTE If the throttle control lever operates properly and the engine does not start compress the throttle lever slightly approximately 1 8 throttle and try starting the engine If the engine now starts and stops when the throttle lever is released take the snowmobile to an autho rized Arctic Cat Snowmobile dealer for service If not under warranty this service is at the discretion and expense of the snowmobile owner A WARNING If the throttle control lever does not work properly DO NOT ATTEMPT TO START THE ENGINE 4 If the throttle control lever operates properly rotate the ignition key to the RUN position and go through normal starting procedures E NOTE If the throttle control lever operates properly and the engi
81. il 20 F 170 psi 155 psi 220 Shop 70 F Trail 20 F 180 psi 160 psi To increase or decrease air pressure use the following procedure W NOTE When adjusting air pres sure all weight must be removed from the suspension and the shock absorbers must be fully extended Remove the air valve cap from the shock 2 Thread the valve of Shock Absorber Air Pump onto the shock air valve approximately six rotations E NOTE As the pump is being attached to the shock the hose will fill with air This will result in a lower E pressure 0 14 3 52 kg cm 2 5 psi 3 To decrease air pressure in the shock press the black bleed valve button half way down and hold until desired pressure is attained W NOTE Pressing the button fully down and releasing it will allow only a small amount of air to escape micro adjust 4 To increase air pressure in the shock pump until desired pressure is attained 5 Remove the pump valve from the shock air valve 49 E NOTE As the pump valve is being removed from the shock the sound of air loss is from the pump hose not from the shock 6 Install the air valve cap onto the shock Adjusting Skid Frame Front Arm The skid frame front arm shock spring tension and the limiter straps are adjust able However Arctic Cat recommends that the shock spring be maintained at the factory preset of 1 8 1 4 in preload Tightening the skid frame front arm shock sp
82. ion of this manual 1 On the turbo models remove the spark plug end caps on the non turbo models remove the two cap screws securing the ignition coils to the cylinder head cover 2 Using a 3 8 in drive ratchet adapter and a 5 8 in spark plug socket remove the two spark plugs W NOTE Prior to installing the spark plugs check the gap between the electrode and ground strap The mo should be 0 9 mm 0 035 in 3 Install the spark plugs Tighten to 96 in lb 4 On the non turbo models install the ignition coils onto the cylinder head cover and tighten the two cap screws to 96 in lb On the turbo models install the spark plug end caps 5 Install the hood see Access Panel Hood Removing Installing in the General Information section of this manual 800 cc Models E NOTE Always use the recom mended spark plugs in the engine See the appropriate specifications sheet for correct spark plug gap Varying terrain conditions and operating usage may require spark plugs of a differ ent heat range For example sustained cross country riding will usually require colder heat range spark plugs while trail riding or other continual slow speed operation will usually require hotter heat range spark plugs CAUTION If adjusting spark plug gap is neces sary do not use the center electrode as a leverage point Damage to the plug may occur Removing Installing Spark Plugs W NOTE For this
83. lance of the time remaining of the original warranty L Address Change L Ownership Change L Warranty Transfer CHANGE OF ADDRESS OWNERSHIP WARRANTY TRANSFER TO Name Address City State Province Zip Code Postal Code Phone Year and Model Snowmobile Vehicle Identification Number VIN Fold Back Once Place Stamp Here CHANGE OF ADDRESS OWNERSHIP ARCTIC CAT INC PRODUCT SERVICE AND WARRANTY DEPT P O BOX 810 THIEF RIVER FALLS MN 56701 Warranty Procedure Owner Responsibility At the time of sale an Owner Registration form is to be completed by the selling dealer and consumer The receipt of the registration form by Arctic Cat is a condi tion precedent to warranty coverage It is the selling dealer s responsibility to retain and or submit the appropriate copies of the form to the appropriate place s to initi ate warranty coverage The dealer will furnish to the consumer a signed copy of the form which must be presented to the dealer when requesting warranty service The registration form is the consumer s proof of ownership and warranty eligibility The form is used by the dealer to validate the warranty claim Retain your copy of the form and keep it in a safe place When warranty repair is suspected the snowmobile should be taken to the selling dealer who has the primary responsibility to perform warranty repairs Subject to the limitations set forth
84. lve assembly mounted to the exhaust side of each cylinder and connected by adjust able cables to an electronic servo mounted beneath the hood W NOTE The mounting location of the servo will vary from model to model Actuating Cable RE Return Spring Exhaust Valve 739 152F At low RPM the exhaust valves are held in the DOWN position by return springs This gives the engine a low port exhaust design calibrated to provide maximum low RPM power and improve fuel economy at trail speeds Down Position gt Exhaust Flow 739 152G At high RPM the exhaust valves are raised This creates a high port exhaust design calibrated to provide maximum performance at high RPM Up Position gt Exhaust Flow 739 152H W NOTE The RPM ranges will vary from model to model W NOTE If the servomotor cycles three times and then shuts down the exhaust valve cables are not adjusted correctly The exhaust valves may also be sticking E NOTE APV cleaning may be done by the snowmobile owner if qualified to do so If the owner does not feel qualified take the snowmobile to an authorized Arctic Cat Snowmobile dealer for this service This service is at the discretion and expense of the snowmobile owner Exhaust Controlled Timing ECT System 800 cc Models This system automatically adjusts the ignition timing to provide maximum per formance through a va
85. ment is recommended every 1000 2000 miles the cable should not need adjustment often To check the cable adjustment use the following procedure 0745 819 1 Using a small needle nose pliers remove the servomotor cable holder Adjusting Nut Jam Nut Adjusting Nut 0745 823 2 Using an adjustable wrench rotate the servomotor actuator counter clockwise to loosen the cable then pull the cable housings down and out of the servomotor 5 While holding the cable housing lightly pull on one cable end to remove any slack then measure the amount of exposed cable from the cable housing to the end of the cable cable drum APV CABLE LENGTH 800 cc 1 377 in 0 039 in I SSSSSSSSSSSSSSSSSS aa SSSSSSSSSSSSSSSSSSSSSY 7 CAUTION Do not use the nut securing the pul ley to the servomotor to rotate the actuator B NOTE For installing purposes note the side that the servomotor cables are installed on 3 Slide each cable drum out of the slot of the servomotor actuator 4 While holding the cable housing firmly pull the cable as far out as it will go then release Repeat three to four times The cable exhaust valve should move freely without binding B NOTE If the cable exhaust valve does not move freely the exhaust valve assembly will need to be removed for further inspection Take the snowmo bile to an autho
86. move and install the in line fuel filter use the following procedure A WARNING Since the fuel supply hose may be under pressure always wear safety glasses then remove the hose slowly to release the pressure Place an absorbent towel around the connec tion to absorb the fuel E NOTE Before removing the fuel fil ter take note that the filter is direc tional and the arrow should be directed towards the engine 31 E NOTE On the non turbo models the fuel filter is located below the steering support To access the filter the hood must be removed see Access Panel Hood Removing Installing in the General Information section of this manual E NOTE On the turbo models the fuel filter is located between the gas tank and the rear belt guard and is secured to the tunnel with a filter bracket To access the filter the left side access panel must be opened and the lower console must be unlatched and opened Remove the hose clamps and dis card then slowly remove the fuel hoses from the fuel filter Dispose of the excess fuel from the filter prop erly 2 Inspect the fuel hoses thoroughly for any signs of cracking cuts or wear points 3 Place the new hose clamps on the fuel hoses then with the fuel pump inlet and outlet noted connect the fuel hoses to the fuel filter Secure with the hose clamps CAUTION Make sure the fuel filter is properly seated into the holder located on the tunnel be
87. move the shield out of the way then remove the hairpin clip securing the brake pads to the cali per assembly 5 Using a pair of pliers pull the outer brake pad out of the caliper assembly E NOTE Changing one pad at a time will prevent one piston from pushing out the other piston from the caliper 6 Measure the thickness of the brake pad The brake pad thickness must be greater than 5 0 mm 0 20 in If the brake pad thickness is less than specified replacement of both pads is necessary PCO11A 7 Using a flat blade tool slowly and care fully push the piston into the caliper 8 Position the outer brake pad into the caliper then install the hair pin clip into the caliper assembly 9 Repeat steps 5 8 for the inner pad then secure the pad with the hairpin clip 10 Remove the reservoir cover and remove the remaining fluid then fill the reservoir with fresh fluid and install the cover 11 Pump the brake lever to ensure cor rect positioning of the brake pads and proper brake lever travel see Checking Brake Lever Travel sub section then release B NOTE If brake lever travel is not within specification bleed the brake system see Bleeding Brake System sub section 12 Remove the reservoir cover and fill the reservoir if necessary to the proper level with fresh brake fluid then install the cover 13 Secure the brake shield the driven pulley tightened to 20 ft lb and the rear belt g
88. mped into the tunnel near the right side footrest and on a decal beneath the seat The decal also displays pertinent production information The Engine Serial Number ESN is stamped into the crankcase of the engine VIN p en y 4 n d aU rice ind er de 0726 383 These numbers are required by the dealer 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 Always provide the snowmobile name VIN and ESN when contacting an autho rized Arctic Cat Snowmobile dealer for parts service accessories or warranty If the complete engine must be replaced ask the dealer to notify Arctic Cat for correct registration information Control Locations Shown are the typical control locations for Arctic Cat snowmobiles Location of a specific control will vary according to model XF M Models Accessory Outlet Brake Lever Lock Brake M MR Headlight Dimmer Switch Emergency Stop Switch Reverse Switch Thumb Warmer Throttle Lever Handlebar Warmer Switches lenition Switch Tether Switch HCR 0745 832 F 800 F 1100 Models Accessory Outlet E seda Brake Lever Lock ae i Brake Lever Headlight Dimmer Switch Thumb Warmer Handlebar Warmer Switches Throttle Lever Seat Warmer Switch lenition Switch 1100 LXR 7 0745 842 RR Models Accessory Outlet Brake Lever Lock
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90. nd drive belt life CAUTION Never run the engine with the drive belt removed Excessive revving of the engine could result in serious engine damage and drive clutch failure 44 Checking Adjusting Drive Belt Deflection Drive Clutch Drive Belt Driven Pulley 0746 092 The drive belt must have the proper fit in the drive clutch and driven pulley To check for proper drive belt fit use the following procedure 1 Place a straightedge on the top of the drive belt The straightedge should reach from the drive clutch to the top of the driven pulley E NOTE Make sure the drive belt is all the way out in the driven pulley before checking drive belt deflection 2 Using a stiff ruler centered between the drive clutch and driven pulley push down on the drive belt just enough to remove all slack and note the amount of deflection The deflec tion should be within the range of 28 5 31 8 mm 1 1 8 1 1 4 in 3 To correct drive belt deflection remove the sheave adjuster from the pulley remove or add shim washers to the adjuster and install the adjuster W NOTE Adding shim washers will decrease belt deflection and remov ing shim washers will increase belt deflection Available shim washers from Arctic Cat are p n 0648 714 0 090 in one included in the tool kit p n 0648 715 0 030 in and p n 0648 716 0 060 in E NOTE Removing adding shim washers may be done by the snow
91. ne does not start a malfunctioning monitor switch may be the problem Take the snowmobile to an autho rized Arctic Cat Snowmobile dealer for service If not under warranty this service is at the discretion and expense of the snowmobile owner However if a dire emergency exists wherein the engine must be started disconnect the throttle monitor switch located in the right side han dlebar control E NOTE If disconnection of the throt tle monitor switch is needed to start the engine take the snowmobile to an authorized Arctic Cat Snowmobile dealer for service as soon as possi ble If not under warranty this service is at the discretion and expense of the snowmobile owner A WARNING Under no circumstances should dis connection of the throttle control wir ing harness be used as a substitute for the monitor switch during normal operation of the snowmobile Per sonal injury and damage could occur if the throttle system malfunctions or if the operator is unable to stop the engine in an emergency If the snow mobile must be operated with a dis connected throttle control wiring harness EXTREME CAUTION MUST BE TAKEN NEVER EXCEED 10 MPH WITH THE THROTTLE CONTROL WIRING HARNESS DISCONNECTED E NOTE The monitor switch is now bypassed All other ignition electri cal features ignition switch emer gency stop switch headlight taillight and brakelight will operate properly Varying Altitude Operation Operating a sn
92. nt of the handlebar during operation over rough terrain DO NOT position handlebar so steering maxi mum right left turning capabilities or throttle and brake controls are affected Handlebar Tilt The handlebar can be adjusted to the operator s preference To adjust the han dlebar use the following procedure 1 Remove the handlebar cover then loosen the eight cap screws securing the handlebar caps to the riser and the riser to the steering post 0745 848 2 Adjust the handlebar to operator s desired position tighten the cap screws evenly to 15 ft lb and check steering for maximum right left turning capabilities 14 E NOTE Do not rotate the handlebar to a position that allows air to enter the brake system A WARNING Tighten cap screws according to specifications to prevent unexpected movement of the handlebar during operation over rough terrain DO NOT position the handlebar so steering maximum right left turning capabili ties or throttle and brake controls are affected Speedometer Tachometer Angle The speedometer tachometer can be adjusted to the operator s desired posi tion To adjust use the following proce dure 1 Loosen the lock nuts and cap screws on each side of the speedometer tachometer bracket 2 Adjust the speedometer tachometer to the desired angle then tighten the lock nuts securely Exhaust System The exhaust sy
93. o 7 5 ft Ib CAUTION Do not attempt to start the engine with the bleed bolt open 12 Without starting the engine place the handlebar emergency stop switch to the RUN position and the ignition switch to the ON position The Oil Pressure Warning Icon should illuminate E NOTE If the warning icon does not illuminate take the snowmobile to an authorized Arctic Cat Snowmobile dealer for service If not under war ranty this service is at the discretion and expense of the snowmobile owner 13 If the warning icon illuminates from step 12 start the engine The warning icon should go out within five sec onds If it does proceed to step 14 B NOTE If the warning icon does not go out shut the engine off immedi ately and repeat step 11 then place the ignition switch to the ON posi tion and repeat step 13 If the warn ing icon does not go out take the snowmobile to an authorized Arctic Cat Snowmobile dealer for service If not under warranty this service is at the discretion and expense of the snowmobile owner 14 Shut the engine off then add oil to the oil reservoir until oil is visible halfway up in the sight glass E NOTE If the oil and engine are not at operating temperature the oil level may read too low Always make sure the engine is at operating tem perature before checking the oil 34 15 Install the access plate and torx head screws beneath the snowmobile then install the hood
94. o the high brake fluid mark then install and secure the cover Remove the tube from the bleeder valve Checking Changing Brake Pads The condition of the brake pads must be checked daily and changed if worn or damaged To check and change the brake pads use the following procedure 42 E NOTE The brake pads may be changed by the snowmobile owner if qualified to do so If the owner does not feel qualified take the snowmo bile to an authorized Arctic Cat Snowmobile dealer for this service This service is at the discretion and expense of the snowmobile owner E NOTE When installing new brake pads always install them as a set Never install just one pad or use brake pads which have been used in another snowmobile 1 Remove the brake fluid reservoir cover then remove most of the brake fluid from the reservoir Install the cover CAUTION Brake fluid is highly corrosive Do not spill brake fluid on any surface of the snowmobile W NOTE The above procedure will allow room for the fluid from the cali per when the pistons are pushed into the caliper for installing new brake pads Replacing the cover will prevent fluid spillage 2 Open the left side access panel and remove the rear belt guard Remove the driven pulley 3 Remove the two torx head screws securing the brake shield to the belt guard mount then remove the cap screws securing the brake shield to the brake caliper 4 Carefully
95. ock mode is avail able Push the increment button to toggle between the 12 hour display and the 24 hour display When desired mode is dis played push the select button At this point the hours display will begin to flash Push the increment button to increase the hours push the decrement button to decrease the hours Pushing and holding a button will accelerate the num ber display When desired hour number is displayed push the select button At this point the minutes display will begin to flash Push the increment button to increase the minutes push the decrement button to decrease the minutes Pushing and holding a button will accelerate the number display When desired minute number is displayed push the select button B NOTE During clock setting if no button increment decrement select is pushed within a 5 second time period the clock setting mode will be exited with changes saved B NOTE The altimeter readout is based off barometric pressure and may require calibration as weather conditions change To set calibrate the altimeter to an estab lished altitude with altimeter selected on the display screen by pushing and holding the select button for a minimum of two seconds the acronym CAL will be displayed on the readout screen for one second then the alti tude value will flash Push the increment button to increase the displayed altitude push the decrement button to decrease the displayed altitude Pushin
96. ome states or provinces do not allow the exclusion or limitation of incidental or consequential damages so the above limitation may not apply to you Arctic Cat s aggregate liability may not exceed the price of the product The law of the State of Minnesota shall apply to all claims or disputes exclusive of its conflicts of law provisions IMPLIED WARRANTY EXCLUSION AND DISCLAIMER To the fullest extent permitted by law Arctic Cat excludes and disclaims all implied warranties of merchantability and fitness for a particular purpose If you are not satisfied with warranty service or repairs you should contact Arctic Cat at U S 1 218 681 9851 or Canada 1 204 982 1656 Table of Contents Limited Warranty Foreword Declaration of Conformity Snowmobile Safety Rules General Information Snowmobile Identification Control Locations Gasoline Oil Engine Break In Drive Belt Break In ias Cold Drive Away Function 1100 cc Models Speedometer Tachometer Diagnostic Codes Handlebar Height Tilt M 800 Sno Pro LTD HCR XF 800 High Country Models Handlebar Tilt 14 Speedometer Tachometer Angle Exhaust System Air Intake Silencer Cooling System Battery Electric Start Jump Starting 1100 cc Models Drive Clutch and Driven Pulley Drive Clutch Driven Pulley Alignment Fuel Pum Shock Absorbers Standard Track XF F Models
97. ote to emphasize important information The symbol WARNING identifies personal safety related information Be sure to follow the directive because it deals with the possibility of serious personal injury or even death A CAUTION identifies unsafe practices which may result in snowmobile related damage Follow the directive because it deals with the possi bility of damaging part or parts of the snowmobile The symbol BB NOTE identi fies supplementary information worthy of particular attention This manual covers operator related maintenance operating instructions and off season storage instructions If major repair or service is ever required contact an authorized Arctic Cat Snowmobile dealer for professional service At the time of publication all information and illustrations were technically cor rect Some illustrations used in this manual are used for clarity purposes only and are not designed to depict actual conditions Because Arctic Cat Inc constantly refines and improves its products no retroactive obligation is incurred This Operator s Manual should be considered a permanent part of the snowmobile and must remain with the snowmobile at the time of resale If the snowmobile changes ownership more than once contact Arctic Cat Inc Service Department P O Box 810 Thief River Falls MN 56701 for proper registration information This manual was prepared by the Product Service and Warranty Department of Arctic Cat Inc Every
98. owmobile at varying alti tudes requires changes in performance components These changes affect drive train components on certain models For altitude information see the appro priate specifications sheet E NOTE Just as important as cali brating the snowmobile for higher altitudes is recalibrating the snow mobile when going to lower alti tudes XF models except the XF 800 High Country model are initially set up at the factory for operation between 0 3000 feet F models are initially set up at the factory for operation between 0 5000 feet M models and the XF 800 High Country model are initially set up at the factory for operation between 6000 9000 feet E NOTE Drive train changes can be made by the snowmobile owner if qualified to do so If the owner does not feel qualified take the snowmo bile to an authorized Arctic Cat Snowmobile dealer for this service This service is at the discretion and expense of the snowmobile owner 27 Lubrication Chain Case B NOTE The snowmobile must be on a level surface for this procedure 1 Check the lubricant level in the chain case by using the sight glass Full Level 0746 115 B NOTE The correct level is when the lubricant is at least halfway up in the sight glass B NOTE Adding lubricant can be done by the snowmobile owner if qualified to do so If the owner does not feel qualified take the snowmo bile to an authorized Arctic C
99. p screw through the ski accounting for the rub ber damper inserts and washers E NOTE Install the cap screw so the slotted nut will be located to the inside of the ski 6 Apply red Loctite 7271 to the threads of the cap screw then tighten the nut to 45 ft Ib 7 Place the cotter pin into the ski cap screw and spread the pin 8 Repeat procedure for the other ski Rail Wear Strips Arctic Cat recommends that the wear strips be checked weekly and replaced as necessary Measure the wear strips at 25 4 cm 10 in intervals Wear strips must be 10 7 mm 0 42 in thick or thicker 53 Minimum Thickness 10 7 mm 0 42 in MR La Ra Ens axe Wea D loz X A eee ed Ae 0745 807 If wear strip measurements are less than specified replacement of both wear strips is necessary to prevent premature track clip wear and possible track damage Take the snowmobile to an authorized Arctic Cat Snowmobile dealer for this service This service is at the discretion and expense of the snowmobile owner 54 Each time a new set of wear strips are installed they should be tempered Tem per the wear strips by driving the snow mobile for approximately a mile on a hard pack trail then immediately drive into deep snow and allow the wear strips to cool Repeat the procedure warming up the wear strips then cooling them down two or three times E NOTE The rail
100. per alignment is obtained E NOTE Make sure correct track tension is maintained after adjust ing track alignment see Track Ten sion sub section in this section 3 After proper track alignment is obtained tighten the idler wheel axle cap screw to 34 ft lb then tighten the adjusting bolts securely against the axle A WARNING Always make sure the adjusting bolts are snug against the axle and the idler wheel cap screws and the right side axle nut on the RR are tightened to specifications Failure to do so could cause the track to become extremely loose and under some operating conditions allow the idler wheels to climb over the track lugs forcing the track against the tunnel causing the track to lock If a track locks during operation severe per sonal injury could result 4 Field test the track under actual con ditions 5 After the field test check the align ment of the track If additional adjust ment is necessary repeat Adjusting Track Alignment procedure Suspension The suspension should be adjusted for the operational needs and riding prefer ence of the operator 48 The front shock springs determine the amount of ski pressure and the reaction of the front suspension to rough terrain The amount of ski pressure can also be changed by adjusting the length of the skid frame front arm limiter straps On standard models the rear arm shock absorber spring influences the loa
101. pnbas pods ajsanb Ip onupuoa oyiatumieATP Un Jod spiisojoui step ezzeinors ej ebeu pa auagsos 3 amp 5 pony e7 3LLIISOLOW 31 43d VZZ3HfDIS Id 3440N 401014 DO ojn 49 np AQU 2u2jbaJ 2ssip prie BISA eGjocosdus AE Xruq PIA JOUBAISIO OSUIN e J amp upiojddo je9 opony YILOOISONS AV UNS 404 331938SL3H3HODIIS uApody ef wany ussiopueu ueeuied nj ejsnprepijox 3ees uoexepnou uecppe efojuees EHEN eon AEA AJ uofo oxt4osoo UW ecjsnuuey ef eejsoJox 3859 HOY LONNVYSVAUNL NUITIDITI LLOOW Ij Jeueu 3e opory IJ YOO 931 1e np Jeu 191594 essep pale 194 Suruiexrojoysous pia jouDrpirsaoi 9SNINYONYALONSONS GIA u11938S 13H32 VS gunos op SAd wo sucgongsur Sa nod 1nayeJado op Jjanuew ne 1919494 SNOA ZaJ IngA egi deo SOA Uo 9s zesinpuoo ja oiessao9u uogeuuo e zeuayqo d oaae pods 89 Jonbre1d ap juosgeuusd snoa mb sjuaulejba seo sanofnoy zeyoodsogt aba uo ssjno ep carejunogs uogesijnn eBejnoouo jo essopus 3 9 0OY a J9HNOLOW N3 3113023S 3d S1N30 31934 opes 961 690 NUCL 5 134500 DOS Solilqedeo no unpim ayeredo pue uiure 194014 8419993 pods ou jo juouiKofuo ponunuoo ano ainsua oj Sajn assy oljoj Kev soliqouimcus Je jo ssn ejes suy sebeAnoous pue sosiopus JEJ OHO SIINA ALIIVS 31I30WMONS suononjjsur General Information Snowmobile Identification The Arctic Cat Snowmobile has two important identification numbers The Vehicle Identification Number VIN is sta
102. position mea sure the distance between the brake lever and the handlebar The distance must be greater than 2 54 cm 1 in 3 If brake fluid is below the high brake fluid mark add Arctic Cat approved DOT 4 brake fluid until fluid is at the recommended level Install and secure the reservoir cover Do not allow mois ture to contaminate the brake system CAUTION Brake fluid is highly corrosive Do not spill brake fluid on any surface of the snowmobile A WARNING Do not overfill the brake fluid reser voir Overfilling the reservoir may cause the brake system to hydrauli cally lock Use only Arctic Cat approved brake fluid A WARNING Do not start the engine if the brake sys tem is not functioning properly Service the brake system or have it properly repaired prior to operating the snow mobile Serious personal injury or even death may occur if the brake system is not operating properly 4 Test the throttle control lever by completely compressing and releas ing it several times The lever MUST return to the idle position quickly and completely CAUTION 0745 816 2 With the brake fluid reservoir in a level position and the cover removed check the fluid level The brake fluid level must be at the high brake fluid mark in the reservoir High Brake Fluid Mark Low Brake Fluid Mark mp P 0745 817 24 Always check the coolant level befo
103. pport then with a drain pan in position remove the drain plug from the oil reservoir ol Drain Plug L Torx Head Screws d 746 121A W NOTE To aid in draining the oil from the reservoir position a funnel between the reservoir and the open ing of the tunnel running board 6 After the oil has drained completely install the drain plug with a new O ring and tighten to 16 ft lb W NOTE Always install a new Oil Pan Drain Plug Gasket p n 3402 011 and a new Reservoir Drain Plug O Ring p n 1602 213 when changing the oil 7 Using Oil Filter Wrench p n 0644 551 loosen but do not remove the oil filter and allow the oil to drain from the filter into the drain pan then remove the filter E NOTE On the turbo models the oil filtrer is accessible between the front opening of the chassis and the lower intercooler hose 8 Apply a light coat of fresh engine oil to the seal of the new oil filter 9 Install the new oil filter by turning the oil filter by hand until the seal has contacted the oil filter mounting surface then tighten the oil filter to 15 ft Ib Remove the drain pan 10 Pour 2 9 1 3 U S qt of the recom mended engine oil into the oil reser voir 11 Open the air bleed bolt located on the oil pump beneath the coolant tank to purge air from the oil hose 33 PC016A E NOTE When air can no longer be heard purging from oil pump bleed tighten the bleed bolt t
104. procedure the hood must be removed see Access Panel Hood Removing Installing in the General Information section of this manual 35 1 Remove the springs securing the expansion chamber to the exhaust manifold and resonator 2 Move the expansion chamber out of the way to access the spark plugs 3 Remove the spark plug caps from the plugs 4 Using a spark plug wrench remove the plugs 5 Install the plugs and finger tighten 6 Tighten the spark plugs to 19 ft lb then install the spark plug caps 7 Place the expansion chamber into position and secure to the exhaust manifold and resonator with the springs 8 Install the hood see Access Panel Hood Removing Installing in the General Information section of this manual Checking Spark Plugs 800 cc Models To see if the spark plugs being used are of the proper heat range after the snow mobile has been operated under normal driving conditions remove the spark plugs and examine the condition of the center electrode insulator of each spark plug Center Electrode Insulator AO352A A TAN or LIGHT BROWN insula tor indicates correct spark plugs heat range B LIGHT GRAY or WHITE insula tor indicates over heating of the engine This condition is caused by a too lean condition or incorrect spark plugs heat range too hot 36 C BLACK insulator indicates fuel in the combustion chamber is not burning completely This condi
105. r in other unsafe ways don t wait until it is too late to warn of the consequences of snowmobile misuse Such conduct endangers everyone TAKE AN ACTIVE ROLE IN THE SAFETY OF YOUR SELF AND OTHERS Parts and Accessories When in need of replacement parts oil or accessories for your Arctic Cat Snowmo bile be sure to only use GENUINE ARCTIC CAT PARTS OIL AND ACCESSO RIES Only genuine Arctic Cat parts oil and accessories are engineered to meet the standards and requirements of your Arctic Cat Snowmobile For a complete list of accessories refer to the current Arctic Cat Accessory Catalog To aid in service and maintenance procedures on these snowmobiles an Illustrated Parts Manual and a Service Manual are available through your local Arctic Cat Snowmobile dealer Foreword Congratulations You have chosen a quality Arctic Cat Snowmobile designed and assembled to give dependable service Be sure as the owner operator of an Arctic Cat Snowmobile to become thoroughly familiar with its basic operation mainte nance and off season storage procedures Read this manual and the accompanying Snowmobile Safety Handbook before operating the snowmobile to learn safe and proper use of your new Arctic Cat Snowmobile Always operate the snowmobile within your level of skill and current terrain conditions The Operator s Manual Snowmobile Safety Handbook and Snowmobile Decals display the words Warning Caution and N
106. r steering post bushing and shafts of the shock absorbers 13 Lubricate the rear suspension with all temperature grease 14 Tighten all nuts bolts and cap screws making sure all nuts bolts and cap screws are tightened securely Make sure all rivets hold ing the components together are tight Replace all loose rivets 57 15 Clean and polish the hood console and chassis with Cat Cleaner p n 4639 371 DO NOT USE SOL VENTS THE PROPELLANT WILL DAMAGE THE FINISH B NOTE On electric start models disconnect the battery cables making sure to disconnect the negative cable first then clean the battery posts and cables Charge the battery CAUTION Sealed batteries require charging if left for extended non start periods Arctic Cat recommends trickle charg ing once a month Follow the manu facturer s instructions and cautions 58 16 If possible store the snowmobile indoors Raise the track off the floor by blocking up the back end making sure the snowmobile is secure Loosen the track adjusting bolts to reduce track tension Cover the snowmobile with a machine cover or a heavy tarpaulin to protect it from dirt and dust 17 If the snowmobile must be stored out doors 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
107. rakes shut off all electrical accessories and turn the ignition switch OFF B NOTE Make sure all switches on the snowmobile to be jump started are turned OFF 5 Disconnect all external accessories such as cell phones GPS units and radios on both vehicles CAUTION Failure to disconnect electronic accessories during jump starting may cause system damage due to power spikes 6 Attach one clamp of the positive red cable to the positive termi nal 1 of the dead battery C being careful not to touch any metal with the other clamp then attach the other clamp of the positive red cable to the positive terminal 2 of the good battery B A Unpainted Surface on Engine B Good Battery ol o C Dead Battery B D D A c 0744 527 E NOTE Some jumper cables may be the same color but the clamps or ends will be color coded red and black 16 7 Attach one clamp of the negative jumper cable black to the negative terminal 3 of the good battery B then attach the other clamp of the nega tive black jumper cable 4 to an unpainted metal surface A on the engine or frame well away from dead battery and fuel system components A WARNING Never make the final connection to a bat tery as a spark could ignite hydrogen gases causing an explosion of the bat tery resulting in acid burns or blindness
108. re starting the engine 5 Move the emergency stop switch to the UP or RUN position 6 Insert key into ignition switch then rotate key to the RUN position E NOTE On the 800 cc models when a cold engine is being started DO NOT COMPRESS THE THROTTLE CONTROL LEVER If the throttle con trol lever is compressed the engine will not start because the fuel air mixture will be too lean 7 On models with manual start pull the recoil handle slowly until resis tance is felt then give a short quick pull Repeat until the engine starts W NOTE In extremely cold weather pull the recoil handle slowly two to three times to begin the starting procedure CAUTION To avoid damaging the recoil starter DO NOT pull the recoil rope to its limit or release the recoil handle from an extended position Allow the rope to rewind slowly E NOTE On electric start models rotate the key to the START position then when the engine starts release the key CAUTION Do not continuously run the starter for more than 5 seconds at a time B NOTE When the engine starts allow it to warm up properly Idle the engine several minutes until the engine has reached normal operating temperature Do not idle the engine for excessively long periods of time 8 On the 1100 cc models there is a cold drive away function incorpo rated within the engine This func tion is active until the engine rea
109. riety of operating conditions The ECU receives input on engine RPM demand and exhaust pipe temperature engine condition and adjusts the ignition timing accordingly This system is not adjustable and is main tenance free If a system fault is suspected use an ohm meter to check continuity of the exhaust pipe temperature sensor located in the expansion chamber A reading of either 0 ohm or infinity indicates a failed sensor Exhaust Pipe m7 T iE Sensor 0737 314 E NOTE A disabled ECT system WILL NOT cause engine damage however a failed ECT system will have slower throttle response and may produce slightly less top end performance 23 Operating Instructions Starting and Stopping Engine It is imperative that the brake system be checked for wear and proper operation and that all safety checks found in the accompanying Snowmobile Safety Handbook be performed before attempt ing to start the engine After the engine has been started check the headlights high and low beam taillight and brake light to be sure they are working properly and adjusted correctly Make sure all lights are clean to provide maximum illu mination The headlight and taillight must be clean and must be illuminated whenever the engine is running 1 Test the operation of the brake system by compressing the brake lever The brake lever must feel firm when com pressed then while holding the brake lever in the compressed
110. ring may cause improper balance and may ruin the handling features of the snowmobile The length adjustment of the front arm limiter straps determines the weight dis tribution between the front of the skid frame and the skis Tightening the limiter strap shortening the strap will pull up on the front of the skid frame and will increase ski pressure Loosening the lim iter strap lengthening the strap lowers the front of the skid frame and decreases ski pressure When customizing the amount of ski pressure be sure to adjust both straps equally and do not over adjust the limiter straps to adversely affect steering and operator control of the snowmobile Some experimentation may be required until the proper adjustment for the opera tor s individual style is obtained MNOTE If the limiter straps are adjusted it is highly recommended that at least a minimum of 1 8 in preload on the shock spring be maintained A WARNING Do not adjust the front arm limiter straps to a point at which steering and operator control of the snowmo bile are adversely affected 50 Adjusting Rear Spring Pre Load F Models Proper adjustment of rear spring pre load is necessary to get the most desirable ride The chart is designed to help in set ting up rear spring pre load however riding style is the single greatest factor in determining rear spring requirements Rider Weight Ib Cam Position Up to 180 1 180 24
111. rized Arctic Cat Snow mobile dealer for this service E NOTE When measuring the cables they are to be routed as close to their installed position as possible 0735 516 W NOTE The two cable measure ments must be equal in length or less than 0 5 mm 0 020 in differ ence in length from each other E NOTE Repeat steps 4 and 5 for each cable then compare the measure ments to the APV Cable Length chart E NOTE The measurements must be within the specifications from the chart If the measurements are within specifications no adjustment is necessary proceed to step 8 If they are not within specifications proceed to step 6 6 Loosen the jam nut on the cable to be adjusted then using the adjusting nuts lengthen or shorten the housing as needed 7 Once the proper length has been attained hold the adjusting nut in place and tighten the jam nut securely 8 Place the cable housings into posi tion in the servomotor Secure the cable housings with the cable holder CAUTION Assure the cables are rotated and secured properly to avoid contacting exhaust components 37 Battery Electric Start These sealed batteries after being in ser vice require regular cleaning and recharging in order to deliver peak per formance and maximum service life The following procedures are recommended for cleaning and maintaining sealed bat teries Always read and follow instruc tions provided with b
112. snowmobile owner The engine WILL NOT RUN without battery power Low Oil Warning Icon 800 cc Models The Low Oil Warning Icon is designed to alert the snowmobile operator when the oil in the oil injection reservoir gets below a prescribed level however it is highly recommended that a visual verification of the oil level in the reservoir be done prior to operating the snowmobile Once the Low Oil Warning Icon illuminates during operation of the snowmobile the operator must periodically monitor the level of oil in the reservoir and must fill the reservoir the next time gasoline is added to the gas tank The alert level of the Low Oil Warning Icon is approximately equal to 1 tankful of gasoline under normal operat ing conditions Oil Pressure Warning Icon 1100 cc Models The Oil Pressure Warning Icon indicates engine oil pressure not the oil level however if the oil level is low it may affect oil pressure The icon should illuminate each time the ignition switch is turned to RUN or START and it should go out when the engine starts If the icon illuminates while the engine is running oil pressure has been lost and the engine will auto matically shut off If oil pressure is lost use the following procedure to check the oil level CAUTION The snowmobile will be manufac tured with the correct amount of oil in the reservoir If the engine and oil are not at operating temperature the oil will not be visible in t
113. stem is designed to reduce noise and to improve the total perfor mance of the engine If any exhaust sys tem component is removed from the engine and the engine is run severe engine damage will result Air Intake Silencer Used in conjunction with the fuel intake system is a specially designed air intake silencer The purpose of the silencer is to quiet the intake of fresh air Since the fuel intake system is calibrated with the air intake silencer in place the engine must never be run with the silencer removed Performance will not be improved if the air intake silencer is removed In con trast severe engine damage will occur CAUTION These snowmobiles are not designed to be operated in dusty conditions Operating the snowmobile in dusty conditions will result in severe engine damage Cooling System These snowmobiles are equipped with a closed liquid cooling system for engine cooling The cooling system should be inspected daily for leakage and damage Also the coolant level should be checked daily If leakage or damage is detected take the snowmobile to an authorized Arctic Cat Snowmobile dealer for ser vice If not under warranty this service is at the discretion and expense of the snowmobile owner When filling the cooling system reser voir use an ethylene glycol based cool ant water mixture which will satisfy the coldest anticipated weather conditions of your area in accordance with the cool
114. substitute lay the snowmobile on its left side Grease Fittings 0746 093 3 Lubricate the grease fittings with all temperature grease 29 Maintenance Periodic Maintenance Checklist Item Interval Page Remarks Brake System Daily 40 Check for binding leakage and proper operation lever firmness travel caliper disc and pads Cooling System Liquid Daily 15 34 Check for leakage damage obstructions coolant level Oil Injection System Daily Check for leakage damage and injection engine oil level Engine Oil 1100 cc Non Turbo 2500 Mi 32 Change oil and filter Models Seasonal Engine Oil 1100 cc Turbo Mod 2000 Mi 33 Change oil and filter els Seasonal Battery Daily 15 38 Check for proper charge and tight connections Stop Switch Daily Check for proper operation Hoses Daily Check for damage leakage and wear Headlight amp Taillight Brakelight Daily 51 52 Check for proper operation and cleanliness Steering System Daily Check for proper operation tightness of bolts and binding Throttle Control System Daily 26 Check for binding sticking proper operation throttle cable tension and wear Drive Belt Daily 43 Check for wear cracks and fraying Monthly Check length and width dimensions Ski Wear Bars Daily 52 Check for wear and damage Electrical Wiring Weekly
115. t feel qualified take the snowmo bile to an authorized Arctic Cat Snowmobile dealer for this service This service is at the discretion and expense of the snowmobile owner To replace the lubricant use the follow ing procedure E NOTE The side panels hood and exhaust resonator must be removed for this procedure 1 Place a drain pan on the floor beneath the snowmobile to allow the lubri cant to drain from the chain case into the drain pan 2 Loosen the eleven torx head screws securing the chain case cover with oil reservoir to the chain case Remove the cover and allow the oil to drain into the drain pan E NOTE It is critical the snowmobile is on a level surface to ensure the lubri cant drains properly and completely W NOTE Inspect the chain case cover seal for nicks or damage 3 When the lubricant has completely drained from the case and the chain case is cleaned of old oil properly seat the seal in the cover then install the chain case cover Tighten the cap screws to 105 in Ib 4 On the 800 cc models pour recom mended chain case lube into the fill hole until the lubricant is at least halfway up in the sight glass then install the plug 5 On the 1100 cc models remove the three screws securing the shift actua tor to the chain case disconnect the actuator wiring harness and remove the actuator w extension Pour rec ommended chain lube through the shift actuator opening until the lubri c
116. tch in the ON position will result in discharging the battery and possible damage to the battery Braking The following items are items that the operator must be familiar with when operating this snowmobile and its hydraulic brake system Important addi tional information on the proper mainte nance of the brake system is found in the Maintenance section 1 Use the brakes wisely Each time the brakes are applied in all hydraulic brake systems including automotive applica tions heat is transferred to the brake fluid The amount of heat transferred during high speed stops and or repeti tive use may be high enough to boil the brake fluid and cause the brakes to either fade or may cause an unexpected loss of brakes If this occurs the brake fluid requires a cool down period before the brakes will again function properly This cool down period will vary depending upon the ambient air temperature and the temperature of the brake fluid If loss of brakes has occurred because of high fluid tempera tures do not operate the snowmobile until the cool down period has expired and brake lever firmness has returned A WARNING Excessive repetitive use of the hydrau lic brake for high speed stops will cause overheating of the brake fluid and pre mature brake pad wear which will result in an unexpected loss of brakes 25 2 Be sure to maintain the brake fluid at the proper level and take care not to
117. the cool ant temperature rises to a critical point above proper operating temperature the coolant temperature warning icon will cease flashing and will remain constantly illuminated W NOTE If the coolant temperature icon is constantly on the engine will shut off if vehicle speed is reduced to 1 5 kph 0 9 MPH or slower CAUTION At this point take precautionary mea sures such as changing to loose snow terrain shutting the engine off allowing the engine to cool down and checking coolant level If unable to either determine or remedy the problem take the snowmobile to an authorized Arctic Cat Snowmobile dealer for service If not under war ranty this service is at the discretion and expense of the snowmobile owner Charging System Warning Icon 1100 cc Models The Charging System Warning Icon is designed to warn the operator if the bat tery charging system is not functioning The icon should illuminate each time the key is turned to RUN or START and it should go out when the engine starts If the icon stays illuminated or it illuminates while the engine is running the battery is not being charged and the snowmobile is running on battery reserve power only If the Charging System Warning Icon illuminates you should as soon as possi ble take the snowmobile to an authorized Arctic Cat Snowmobile dealer for ser vice If not under warranty this service is at the discretion and expense of the
118. uard then close and secure the left side access panel E NOTE When new brake pads are installed a burnishing process is required see Burnishing Brake Pads sub section Burnishing Brake Pads After changing brake pads the new brake pads must be burnished to achieve full braking effectiveness Braking distance will be extended until brake pads are properly burnished To properly burnish the brakes use fol lowing procedure 1 Choose an area sufficiently large to safely accelerate to 30 40 mph and to brake to a stop E NOTE This procedure can also be accomplished using a shielded jack stand 2 Accelerate to 30 40 mph then com press brake lever to decelerate to a stop W NOTE Lightly apply the brake lever to come to an easy stop do not over apply brakes or lock up the track 3 Repeat procedure 10 15 times allowing some cooling between stops E NOTE Do not repeat too soon or too aggressively as to get the brake disc red hot A WARNING Do not attempt sudden stops or put yourself into a situation where a sud den stop will be required until the brake pads are properly burnished E NOTE This procedure stabilizes the pad material and extends the life of the pads Drive Belt The drive belt transfers power from the drive clutch to the driven pulley If the belt is worn cracked or stretched maxi mum power will not be transmitted and the belt could also fail and therefore must
119. ure the coolant temperature warning icon will flash a warning alert and on the 1100 cc models the engine will surge to alert the operator If the coolant temperature rises to a critical point above proper oper ating temperature the coolant temperature warning icon will cease flashing and will remain constantly illuminated W NOTE On the 1100 cc models if the coolant temperature icon is con stantly on the engine will shut off if vehicle speed is reduced to 1 5 kph 0 9 MPH or slower CAUTION At this point take precautionary mea sures such as changing to loose snow terrain shutting the engine off allow ing the engine to cool down and checking coolant level If unable to either determine or remedy the prob lem take the snowmobile to an autho rized Arctic Cat Snowmobile dealer for service If not under warranty this ser vice is at the discretion and expense of the snowmobile owner 11 Charging System Warning Icon Electric Start Models The Charging System Warning Icon is designed to warn the operator if the battery charging system is not functioning The icon should illuminate each time the key is turned to RUN or START and it should go out when the engine starts If the icon stays illuminated or it illuminates while the engine is running the battery is not being charged and the snowmobile is running on battery reserve power only If the Charging System Warning Icon illuminates
120. w the belt to be removed 7 Remove the drive belt from the driven pulley first then from the drive clutch E NOTE Before installing the drive belt use a suitable cleaning solvent to thoroughly clean the sheaves Installing Drive Belt m NOTE If a new drive belt is being installed see Drive Belt Break In sub section in the General Infor mation section Place the drive belt so the part num ber can be read and the arrows are facing the front of the snowmobile between the sheaves of the drive clutch first then between the sheaves of the driven pulley 2 Install the cap screw lock washer washer and sheave adjuster back into the driven pulley Tighten the cap screw to 20 ft lb 3 Install and secure the rear belt guard then close the left side access panel A WARNING Never operate the snowmobile with out the belt guard access panel secured in place 4 Release the brake lever lock Track Tension Track tension is directly related to the overall performance of the snowmobile If the track is too loose it may slap against the tunnel causing wear or it may ratchet on the track drive sprockets If extremely loose the idler wheels may climb over the track lugs forcing the track against the tunnel causing the track to lock Arctic Cat recommends that the track tension be checked daily during the first 300 miles of operation and once a week thereafter and adjusted according to need Th
121. warning icon will begin to flash the TEMP display will continue to flash and the RPM limit of the engine will increase allowing the snowmobile to move without full throttle operation When the engine reaches proper oper ating temperature the coolant temper ature warning icon and the TEMP display will go out CAUTION It is extremely important that the engine is properly warmed up before subjecting the engine to high speed operation or heavy loads The engine should be allowed to idle at least 3 4 minutes before it is operated at more than 1 2 throttle In extremely cold conditions the warm up time will be longer Cold seizure and piston scuff ing caused by insufficient warm up will not be covered by warranty Also do not idle the engine for excessively long periods of time Speedometer Tachometer These snowmobiles are equipped with different speedometer tachometer styles Determine which style your model is equipped with and use the appropriate following information Indicator Icons Standard Gauge Certain models are equipped with a stan dard gauge combination speedometer tachometer Indicator icons are incorpo rated within the speedometer tachometer Also incorporated into the speedometer tachometer is a digital readout screen FZ003C A Oil Pressure Low Oil B Coolant Temperature Low Fuel Fuel Level Service High Beam Charging System 1100 cc Mod els RPM MPH kph
122. weather 23 C 10 F or colder a small amount of leakage may be present Unless the leakage is excessive replacement is not necessary E NOTE The frequency of servicing rebuildable shock absorbers will vary according to the types of condi tions and terrain the snowmobile has been subjected to If riding quality deteriorates or seems to be deterio rating take the snowmobile to an authorized Arctic Cat Snowmobile dealer for shock absorber evaluation and or servicing This service is at the discretion and expense of the snowmobile owner Servicing rebuildable shock absorbers is considered normal maintenance and is the responsibility of the owner Take the snowmobile to an authorized Arctic Cat Snowmobile dealer for this service This service is at the discretion and expense of the snowmobile owner Kits are available to either stiffen or soften gas shock valv ing If changes in shock valving are desired see an authorized Arctic Cat Snowmobile dealer This service is at the discretion and expense of the snowmo bile owner Standard Track XF F Models Accelerated wear strip and track clip wear caused by operating on ice or hard packed snow conditions is NOT covered under Arctic Cat Inc warranty policy Paddle Track XF High Country M Models These models are equipped with a Power Claw style track which is specially designed for use in powder snow riding conditions When the Power Claw track is operated in har
123. y tighten track until the track does not ratchet Too tight of a track will cause the rear suspension to not work properly Adjusting Track Tension E NOTE To ensure proper track ten sion adjustment perform all adjust ments on both sides of the snowmobile 46 0745 811 E NOTE On RR models using Axle Nut Spanner Wrench p n 0644 558 from the tool kit loosen the right side rear axle nut Track Adjuster N N Pd Adjusting Bolt Rear Idler Wheels 0744 067 W NOTE On RR models always loosen the right side rear axle nut when adjusting track tension align ment The left side rear axle nut is secured with green Loctite 609 and should not be loosened or removed 2 If the deflection distance between the bottom of the wear strip and the inside surface of the track clip exceeds specifications tighten the adjusting bolts to take up excessive slack in the track 3 If the distance between the bottom of the wear strip and the inside surface of the track clip is less than specified loosen the adjusting bolts to increase the slack in the track CAUTION Always maintain track tension within recommended specification 4 Check track alignment see Track Alignment sub section in this sec tion 5 After proper track tension is obtained tighten the idler wheel axle cap screws to 34 ft lb then tighten the adjusting bolts securely against the axle MNO
124. you should as soon as possi ble take the snowmobile to an authorized Arctic Cat Snowmobile dealer for ser vice If not under warranty this service is at the discretion and expense of the snowmobile owner The engine WILL NOT RUN without battery power Low Oil Warning Icon 800 cc Models The Low Oil Warning Icon is designed to alert the snowmobile operator when the oil in the oil injection reservoir gets below a prescribed level however it is highly recommended that a visual verification of the oil level in the reservoir be done prior to operating the snowmobile Once the Low Oil Warning Icon illuminates during operation of the snowmobile the operator must periodically monitor the level of oil in the reservoir and must fill the reservoir the next time gasoline is added to the gas tank The alert level of the Low Oil Warning Icon is approximately equal to 1 tankful of gasoline under normal operat ing conditions Oil Pressure Warning Icon 1100 cc Models The Oil Pressure Warning Icon indicates engine oil pressure not the oil level however if the oil level is low it may affect oil pressure The icon should illuminate each time the ignition switch is turned to RUN or START and it should go out when the engine starts If the icon illuminates while the engine is running oil pressure has been lost and the engine will auto matically shut off 12 If oil pressure is lost use the following procedure to check t

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