2007 Arctic Cat Snowmobiles service repair workshop manuals

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15. Remove the drive belt from the drive clutch/driven pulley. Lay the belt on a flat surface or slide it into a cardboard sleeve to prevent warping or distortion during storage; then clean and inspect the drive clutch and driven pulley. 16. Apply light oil to the upper steering post bushing, ski spindles and bolts, front and rear pivot bushings of the skid frame, and plungers of the shock absorbers. 17. Lubricate all grease fittings (front and rear suspension, spindles, speedometer drive adapter, and the driven shaft support bearing) with a low-temperature grease. 18. Tighten all nuts, bolts, and cap screws making sure all calibrated nuts, bolts, and cap screws are tightened to specifications. Make sure all rivets holding the components together are tight. Replace all loose rivets. 19. Clean and polish the hood, console, and chassis with Arctic Cat Hood and Windshield Cleaner/ Polish (p/n 0636-174). DO NOT USE SOLVENTS OR SPRAY CLEANERS. THE PRO- PELLENT WILL DAMAGE THE FINISH. 20. On electric start models,
disconnect the battery cables making sure to disconnect the negative cable first; then clean the battery posts and cables.

! CAUTION
Avoid storing in direct sunlight and using a plastic cover as moisture may collect on the snowmobile causing corrosion.

Preparation After Storage
Taking the snowmobile out of storage and correctly preparing it for another season will assure many miles and hours of trouble-free snowmobiling. Arctic Cat recommends the following procedure:

! CAUTION
On carbureted models if the gas in each carburetor float chamber was not drained prior to storage, the carburetor(s) must be cleaned before starting the engine.

1. Clean the snowmobile thoroughly. Polish the exterior of the snowmobile. 2. Clean the engine. Remove the cloth from the exhaust system. Check exhaust system and airintake silencer/air filter 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 if damaged or worn. Install the drive belt.
NOTE: If the old belt is worn but in reasonable condition, retain it with the snowmobile as a spare in case of emergency.

! CAUTION
Batteries require charging if left for extended nonstart periods. Arctic Cat recommends not servicing the battery until the snowmobile is to be used or trickle charging once a month. Follow the manufaturer's instructions and cautions.

! CAUTION
On models with remote start, make sure to leave the battery cables disconnected. Failure to disconnect the battery cables when storing the snowmobile for a prolonged period of time (six weeks or more) will result in a discharged or damaged battery.

5. On carbureted models, inspect the in-line fuel filter and replace if necessary. 6. Inspect all fuel hoses and oil hoses for deterioration or cracks; replace if necessary. Make sure all connections are tight; then fill the oil-injection reservoir with the recommended injection oil.
NOTE: After prolonged storage, Arctic Cat recommends one tankful of 100:1 gas/oil mixture be used in conjunction with the oil-injection system to ensure proper lubrication.

21. If possible, store the snowmobile indoors. Raise the track off the floor by blocking up the back end making sure the snowmobile is secure. Loosen the track adjusting bolts to reduce track tension. Cover the snowmobile with a machine cover or a heavy, ventilated tarpaulin to protect it from dirt and dust. 22. If the snowmobile must be stored outdoors, position the snowmobile out of direct sunlight; then block the entire snowmobile off the ground making sure the snowmobile is secure. Loosen the track adjusting bolts to reduce track tension. Cover with a machine cover or a heavy, ventilated tarpaulin to protect it from dirt, dust, and rain.

7. Inspect the entire brake system, all controls, headlight, taillight, brakelight, ski wear bars, and headlight aim; adjust or replace as necessary. 8. Inspect each spark plug. Replace, gap, or clean as necessary.

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9. Adjust the track to the proper tension and alignment. Lock the jam nuts. 10. Adjust the carburetor(s) and choke cable on carbureted models and throttle cable on all models.

! WARNING
On carbureted models, be sure to tighten the swivel adapter jam nuts securely. If a jam nut isn't tightened, the adjuster can rotate out of the carburetor cap causing the piston valve not to return to the fullclosed position.

DRIVE BELT DEFLECTION -- Drive belt deflection is very important to the snowmobile. Even if it is checked and is correct when the snowmobile is set up, it does change (more so during the break-in period). This is because the rubber engine mounts and the rubber snubber on the torque link will all take a "set" during the first 100 miles, which allows the distance between the drive clutch and driven pulley to shorten. When this happens, the snowmobile will appear to have a too long drive belt. To add to this, the drive belt itself wears and stretches somewhat. This all leads to a low-end performance problem and, if not corrected, causes premature drive belt wear. After the break-in period, drive belt deflection should be checked according to the instructions given in this manual. DRIVE BELT BREAK-IN -- It is critical for maximum drive belt life to allow the belt to break in before subjecting it to hard use such as wide-open-throttle operation or hill climbing. The first 20 miles on the drive belt should be at 1
/2 throttle or lower. This will allow the belt to gain its optimum flexibility and will extend belt life. Do not exceed 50 MPH during the first 20 miles. If this procedure isn't followed, it is possible to destroy a new drive belt in less than 50 miles. This should be explained to customers at the time of drive belt sales. To increase the life of a drive belt, it is very important that the belt be warmed up before subjecting it to any type of use. In cold temperature (0° or below), the engine should be allowed to idle for a period of 8 to 10 minutes. This will allow heat from the engine compartment to soften the drive belt. Not only will this procedure increase belt life but will also help prevent engine damage from cold seizure. Each operator should be instructed to drive the snowmobile for several minutes at a low throttle setting to warm the belt up before using wide-open-throttle. This practice should be followed on all models for maximum belt life. In addition to instructing each operator about these dr
ive belt break-in procedures, Arctic Cat also recommends that the operators be informed that a drive belt (like brake pads, wear strips, etc.) is considered a normal wear item and is listed as an exclusion on the Arctic Cat Limited Warranty. TRACK TENSION AND ALIGNMENT -- There is a certain amount of stretch on all tracks during the first 500 miles. The track must be adjusted after the first 50 to 100 miles to the specifications given in the Setup and Pre-delivery Manual and periodically thereafter. If these adjustments aren't performed, the track may "derail" which leads to track and slide rail damage.

11. Tighten all nuts, bolts, and cap screws making sure all calibrated nuts, bolts, and cap screws are tightened to specifications. 12. Lubricate all grease fittings (rear suspension, spindles, speedometer drive adapter, and the driven shaft support bearing) with a low-temperature grease. 13. On liquid cooled models, check the coolant level and all coolant hoses and connections for deterioration or cracks. Add properly mixed coolant as necessary. 14. On fan cooled models, clean the engine cooling fins and all vents. 15. On electric start models, charge the battery; then connect the battery cables making sure to connect the positive cable first. Test the electric start system.

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After Break-In Checkup
(100 Miles)
The 100 mile checkup offered by some dealerships reduces problems and warranty costs. A program of this kind should be offered by all dealerships. Many dealerships have added the price of the checkup into the selling price of the snowmobile, and others offer it as a bonus to the customers who purchase snowmobiles from their dealership. There are three areas that require adjustment after the break-in period in order to obtain peak performance. These areas are the following. A. Carburetor jetting B. Drive belt deflection/Break-In C. Track tension and alignment CARBURETOR JETTING (Carbureted Models)-- Altitude, temperature, and the use of oxygenated gasoline affect the carburetion needed for optimum engine performance. The carburetor main jets must be changed in conjunction with changes in operating altitude, oxygenated gasoline usage, and temperature.

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Along with these three major areas, there are also other areas that should be checked and adjusted during the "After Break-In Checkup." A checklist to assist you with this service follows. Not only will the customer be happier, but it also gets the customer back into your dealership, which in many cases will mean additional sales in accessories, belts, oil, etc.

Diagnostic Codes/ Check Engine
(Crossfire/F-Series/ M-Series Models)

After Break-In Checkup Checklist
Below is a recommended list of items to check after the break-in period. By performing this inspection, warranty cost can be reduced and customer satisfaction can be increased. The recommended mileage for this inspection is between 100 and 300 miles. Please encourage the customers to have this important checkup done.
Jet carburetor(s) according to average temperature, type of gasoline being used, and altitude Adjust drive belt deflection Adjust track tension and alignment Check throttle cable tension Check oil-injection pump adjustment Check engine idle Check coolant level Check chain case/gear case lubricant level Check lights (high/low beam, brakelight) Check safety switch operation Check driveshaft area for any rubbing components Check steering hardware for tightness Check skid frame and A-arm mounting hardware for tightness Check brake lever travel and adjustment Grease all lubrication points

These diagnostic codes are flashed by the check engine light incorporated within the speedometer/tachometer. Refer to the following chart for diagnostic code sequences.
NOTE: On single-digit codes (2, 4, etc.), the number indicated will flash in an uninterrupted sequence. On double-digit codes (1-2, 1-6, etc.), the first number indicated will flash in an uninterrupted sequence, there will be a short pause, and the second number indicated will flash in an uninterrupted sequence.

If the coolant temperature is at or above 80° C (176° F), the coolant temperature light will flash a warning (alert). If the coolant temperature is at or above 93° C (200° F), the coolant temperature light will cease flashing and will remain constantly illuminated.
Number of Flashes
1-2 (Check Engine Light) 1-6 (Check Engine Light) 1-7 (Check Engine Light) 1-8 (Check Engine Light) 2 (Check Engine Light) 2-1 (Check Engine Light) 2-3 (Check Engine Light) 4 (Check Engine Light) 5 (Check Engine Light) 6 (Check Engine Light) 7 (Check Engine Light)

Trouble
Failure in ignition coil. Incorrect adjustment/failure in APV cable. Failure in exhaust temperature sensor. Failure in servomotor. Failure in injector(s). Failure in knock sensor. Failure in knock control system. Open or short circuit in barometric pressure sensor. Open or short circuit in intake air temperature sensor. Open or short circuit in water temperature sensor. Open or short circuit in throttle position sensor.

Check Engine Light
(Crossfire/F-Series/ M-Series Models)

Steady Flash Coolant Temperature Above 80° (Coolant Temperature Light) C (176° F). Constant On Coolant Temperature Above 93° (Coolant Temperature Light) C (200° F).

The Check Engine Light is controlled by the ECU and may illuminate for a number of reasons. The light should illuminate each time the key is turned to RUN or START, and it should go out when the engine starts. If the light stays illuminated or it illuminates while the engine is running, the ECU is receiving input that is outside of its established parameters.

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