Arctic Cat SnowMobile all 2-stroke Service Manual 2007

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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. 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. Do not use gasolines containing methanol.

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

RECOMMENDED OIL 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.
0726-383

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.

Break-In Procedure
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.

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
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.

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.

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

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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). High altitude information decal(s) are located beneath the hood of the snowmobile.

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.

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

7. Start the engine and allow to idle. With the engine idling, spray Arctic Cat Engine Storage Preserver (p/n 0436-888) 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 all models except the 370 cc/570 cc, secure the air silencer boots onto the intake bores. NOTE: On the 370 cc/570 cc models, install the baffle/resonator and the cover/tool tray assembly.

The M-Series snowmobiles are initially set up at the factory for operation between 6000-9000 feet. Consult the appropriate specifications for this information.

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).

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). 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. 3. Place the rear of the snowmobile up on a shielded safety stand.
NOTE: On all models except the 370 cc/570 cc, the air silencer boot can be pried forward to access the intake bores. Pry the boot forward; then proceed to step 7. NOTE: On the 370 cc/570 cc 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.

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

B. Pour 29.5 ml (1 fl oz) of SAE #30 petroleumbased 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 carbureted models, drain the gas from each carburetor float chamber. 11. Fill the gas tank to its rated capacity; then add Arctic Cat Fuel Stabilizer (p/n 0436-907) to the gas tank following directions on the container for the stabilizer/gasoline ratio. Tighten the gas tank cap securely. 12. On models with a chain case, drain the 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, chaincase cover, and seal; then pour Arctic Cat Transmission Lube (p/n 4639-364) into the filler hole 236 ml (8 fl oz) for standard transmission or 354 ml (12 fl oz) for reverse transmission. 13. On models with a gear case,
change the gear case lubricant (see Section 8). 14. Clean and inspect the drive clutch and driven pulley.

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.

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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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