ARCTIC CAT 2001 SNOWMOBILE Service Repair Manual [IMPROVED]

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RECOMMENDED OIL (Oil-Injection System)

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Break-In Procedure
The Arctic Cat engine (when new or rebuilt) requires a short break-in period before the engine is subjected to heavy load conditions. Arctic Cat requires that the first tankful of fuel be premixed at a 100:1 ratio in all carbureted oil-injection models; however, Arctic Cat does not recommend any premixed fuel be used during break-in period for EFI models and the120 cc model.

The recommended oil to use in the oil-injection system is Arctic Cat 50:1 Injection Oil (for standard models) or Arctic Cat APV 50:1 Injection Oil (for APV models). The oil is specially formulated to be used either as an injection oil or as a pre-mix oil (for carbureted model break-in) and meets all of the lubrication requirements of the Arctic Cat snowmobile engine.
RECOMMENDED OIL (120 cc)

The recommended oil to use in the 120 cc is a multi-grade oil or single grade oil calibrated to the ambient temperature at which the engine is run. Select the proper viscosity chart for details.

! CAUTION
On EFI models and the 120 cc model, DO NOT use premixed fuel in the gas tank. Engine damage will occur.

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! CAUTION
Any oil used in place of the recommended oil may cause serious damage.
Fig. 1-3

During the break-in period, a maximum of 1/2 throttle is recommended; however, brief full-throttle accelerations and variations in driving speeds contribute to good engine break-in.

Multi-Grade

! CAUTION
20W-40, 20W-50

SAE #

ENGINE OIL

10W-30, 10W-40 5W-20, 5W-30

á

TEMP ·°F -30 -20 -10

°C -35 -29 -23 -18 -12 -7 1 4 10 15 21 27 32 0 10 20 30 40 50 60 70 80 90

On carbureted oil-injection models, DO NOT exceed the one (1) tankful limitation of a 100:1 gas/oil break-in mixture. Continuous use of a gas/oil mixture, unless consistently operating in extremely cold conditions (-26°C/-15°F or colder), could cause spark plug fouling and excessive carbon buildup. A 100:1 gas/oil mixture must be used in conjunction with the oil-injection system to ensure adequate engine lubrication in extremely cold conditions.

GEN-0048 Fig. 1-4

Genuine Parts
Single Grade

SAE #

ENGINE OIL TEMP ·°F -30 -20 -10

30

á
40

When replacement of parts is necessary, use only genuine Arctic Cat parts. They are precision-made to ensure high quality and correct fit.

10W

20 or 20W

°C -35 -29 -23 -18 -12 -7 1 4 10 15 21 27 32 0 10 20 30 40 50 60 70 80 90

High Altitude Operation
Operating a snowmobile at varying altitudes requires changes in performance components. These changes affect drive train components (on all models) and carburetion components (on carbureted models). A high altitude information decal is located beneath the hood of the snowmobile. On carbureted models, the information is incorporated into the Main Jet Chart decal.
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GEN-0049

After the engine break-in period, the engine oil should be changed every 100 operating hours (6 months) and before prolonged storage.

On carbureted models, carefully follow the Main Jet Chart recommendations for proper main jet selection for altitude, temperature, and gasoline being used.

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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.
NOTE: Steps 3-7 are only for models with an oil-injection system.

A number of Arctic Cat snowmobiles are initially set up at the factory for operation between 5000-9000 feet. Consult the appropriate specifications for this information.

3. Place the rear of the snowmobile up on a shielded safety stand.
NOTE: On some models, the air-intake silencer is a one-piece unit, and the silencer boot(s) can be removed to access the intake bore(s). Remove the boots; then proceed to step 7. NOTE: On some models, the air-intake silencer includes a cover/tool tray assembly and a baffle/resonator, and the silencer boot cannot be removed to access the intake bores. Proceed to step 4.

Drive Chain Lubrication
(120 cc)

The drive chain should be lubricated every 20 operating hours with a dry, graphite-based chain lubricant. By using a dry, graphite-based chain lubricant, dirt buildup on the drive chain will be minimized. Before each lubrication, ins pect the drive chain for dirt accumulation. To lubricate the drive chain, shut the engine off and wait for all moving parts to stop, remove the drive chain guard and lubricate the drive chain. After lubricating the drive chain, install the drive chain guard. If the drive chain is excessively dirty, it should be removed and cleaned prior to being lubricated (see Drive Chain and Sprockets in Section 8).
NOTE: If a dry, graphite-based chain lubricant is not available, lubricate the drive chain with several drops of petroleum-based oil. If the snowmobile is operated in the summer with the optional wheel kit, the drive chain should be lubricated more frequently.

4. Open the air-intake silencer cover; then remove the three screws securing the cover/tool tray assembly to the silencer. 5. Close the cover; then tip the cover/tool tray assembly forward and out of its slots and remove the assembly. 6. Using a large flat-blade screwdriver, remove the baffle/resonator tabs from the air-intake silencer slots and remove the baffle/resonator to access the intake bores.
NOTE: The baffle/resonator can be removed more easily by removing the back tabs first.

7. Start the engine and allow to idle. With the engine idling, spray Arctic Cat Engine Storage Preserver (p/n 0636-177) into the intake(s) until the engine exhaust starts to smoke heavily or until the engine starts to drop in RPM. Turn engine off.
NOTE: On some models, install the air-intake silencer boot(s); on some models, install the baffle/resonator and the cover/tool tray assembly.

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 perform this service; however, the owner/operator can perform this service if desired. To prepare the snowmobile for storage, Arctic Cat recommends the following procedure: 1. Clean the seat cushion with a damp cloth and Arctic Cat Vinyl Protectant (p/n 0638-313).

8. Plug the exhaust system outlet with a clean cloth. 9. With the ignition switch in the OFF position: A. Disconnect the high tension lead(s) from the spark plug(s); then remove the plug(s), connect it/them to the lead(s), and ground it/them on the cylinder head(s).

! CAUTION
Never crank the engine over without grounding the spark plug(s). Damage to coils and/or CDI unit may result.

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B. P our 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 plug(s) and connect the high tension lead(s). 10. On the 120 cc model, change the engine oil; then clean the air filter. 11. On carbureted models, drain the gas from each carburetor float chamber. 12. Fill the gas tank to its rated capacity; then add Arctic Cat Fuel Stabilizer (p/n 0638-165) to the gas tank following directions on the container for the stabilizer/gasoline ratio. Tighten the gas tank cap securely. 13. If applicable, drain the chain-case lubricant by removing the chain-case drain plug located on the backside of the chain-case assembly. Remove the chain-case cover and inspect chain, sprockets, chain tensioner, and rollers for wear and the chain for proper tension. Install the drain plug, chain-case cover, and seal; then pour Arctic Cat Transmission Lube (p/n 0636-817) into the filler hole according to appropriate specifications. 14. I
f applicable, 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. 15. 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. 16. Lubricate all grease fittings (front and rear suspension, spindles, and speedometer drive adapter) with a low-temperature grease. 17. 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. 18. On the model with steel skis, lightly sand the bottom of the skis; then using Metal Black Touch-Up Paint (p/n 0652-021), paint the entire bottom of the skis. 19. Clean and polish the hood, console, and chassis with Arctic Cat Hood and Windshield Cle
aner/ Polish (p/n 0636-174). DO NOT USE SOLVENTS OR SPRAY CLEANERS. THE PROPELLENT 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.

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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 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 tarpaulin to protect it from dirt, dust, and rain.

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! 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 air-intake 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. If applicable, 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.

5. On carbureted models, inspect the in-line fuel filter and replace if necessary.
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