ARCTIC CAT ALL 2002 SNOWMOBILE SERVICE SHOP MANUAL -IMPROVED-

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Snowmobile Identification
The Arctic Cat Snowmobile has two important identification numbers. The Vehicle Identification Number (VIN) is stamped into the tunnel near the right-side footrest. The Engine Serial Number (ESN) is stamped into the crankcase of the engine.

RECOMMENDED GASOLINE (EFI Models)
The recommended gasoline to use in these snowmobiles is 87 minimum octane regular unleaded, and the Fuel Designation Connector at the ECU must be connected. In many areas, oxygenates (either ethanol or MTBE) are added to the gasoline. Oxygenated gasolines containing up to 10% ethanol or up to 15% MTBE are acceptable gasolines; however, if oxygenated gasoline is used, the Fuel Designation Connector at the ECU must be disconnected. Do not use gasolines containing methanol.

0726-383 734-482A

These numbers are required to complete warranty claims properly. No warranty will be allowed by Arctic Cat Inc. if the engine serial number or VIN is removed or mutilated in any way.

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

Recommended Gasoline and Oil
RECOMMENDED GASOLINE (Carbureted Models) The recommended gasoline to use in these snowmobiles is 87 minimum octane regular unleaded. In many areas, oxygenates (either ethanol or MTBE) are added to the gasoline. Oxygenated gasolines containing up to 10% ethanol or up to 15% MTBE are acceptable gasolines; however, whenever using oxygenated gasolines, the carburetor main jet must be one size larger than the main jet required for regular unleaded gasoline. For example, if a 400 main jet is recommended for regular unleaded gasoline, a 410 main jet must be installed if using an oxygenated gasoline.
When using ethanol blended gasoline, it is not necessary to add a gasoline antifreeze since ethanol will prevent the accumulation of moisture in the fuel system.

! CAUTION
If oxygenated gasoline is to be used, it is extremely important that the Fuel Designation Connector at the ECU is disconnected. If the connector is not disconnected when using oxygenated gasoline, severe engine damage may occur. NOTE: In order for the ECU to change modes, the engine must be OFF when connecting or disconnecting the Fuel Designation Connector.

RECOMMENDED OIL (Oil-Injection System)
The recommended oil to use in the oil-injection system is Arctic Cat 50:1 Injection Oil (for standard models) or Arctic Cat Synthetic APV 2-Cycle Oil (for APV models). The oil is specially formulated to be used either as an injection oil or as a pre-mix oil (for carbureted model break-in) and meets all of the lubrication requirements of the Arctic Cat snowmobile engine.

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

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

! CAUTION
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 oilinjection system to ensure adequate engine lubrication in extremely cold conditions.

! CAUTION
Any oil used in place of the recommended oil may cause serious damage.
Multi-Grade

Break-In Procedure
(4-Stroke Model)
The Arctic Cat 4-stroke engine (when new or rebuilt) requires a short break-in period before the engine is subjected to heavy load conditions.
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After the engine break-in period, the engine oil should be changed every 3500 miles (on the 4-Stroke Touring and Trail) and before prolonged storage.

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 damage will occur.

Break-In Procedure
(2-Stroke Models)
The Arctic Cat 2-stroke engine (when new or rebuilt) requires a short break-in period before the engine is subjected to heavy load conditions. Arctic Cat requires that the first tankful of fuel be premixed at a 100:1 ratio in all oil-injection models. During the break-in period, a maximum of 1/2 throttle is recommended; however, brief full-throttle accelerations and variations in driving speeds contribute to good engine break-in.

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 * With occasional full-throttle operation. 1/2 Throttle (45 MPH-max) 1/2-3/4 Throttle 1/2-3/4 Throttle *

To ensure proper engine break-in, Arctic Cat recommends that the engine oil and filter be changed after 600 miles or after one month, whichever comes first. This service is at the discretion and expense of the snowmobile owner.

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

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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.

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:

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

1. Clean the seat cushion with a damp cloth and Arctic Cat Vinyl Protectant (p/n 0638-313). 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 oilinjection 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.

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, inspect the drive chain for dirt accumulation. To lubricate the drive chain, shut the engine off and wait for all moving parts to stop, remove the drive chain guard and lubricate the drive chain. After lubricating the drive chain, install the drive chain guard. If the drive chain is excessively dirty, it should be removed and cleaned prior to being lubricated (see Drive Chain and Sprockets 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.

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/ reso nato r, and the silencer bo ot can no t b e removed to access the intake bores. Proceed to step 4.

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.

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