2009 arctic cat m8 153 hcr snowmobiles service repair manual

SECTION 1 -
GENERAL INFORMATION!
SPECIFICATIONS
TABLE OF
CONTENTS
General Specifications ............................................ 1-2
Snowmobile Identification ....................................... 1-2
Recommended Gasoline and Oil ............................ 1-2
Break-In Procedure ................................................. 1-3
Genuine Parts ......................................................... 1-3
High Altitude Operation ........................................... 1-3
Drive Chain Lubrication (120 cc) ............................. 1-6
Low Oil Pressure Warning Light (1100 cc) .............. 1-6
Preparation For Storage .......................................... 1-6
Preparation After Storage ....................................... 1-7
After Break-In Checkup (100 Miles -2-Stroke/
600 Miles -4-Stroke) ............................................ 1-8
After Break-In Checkup Checklist ........................... 1-9
Engine Specifications (2-Stroke) ...........
................
1-10
Engine Specifications (4-Stroke) ........................... 1-11
Cylinder Head Volume Specifications (2-Stroke) .. 1-12
Engine Piston Travel Versus
Crank Angle Chart (2-Stroke) ............................ 1-12
Crankshaft RunoutiRepair Specifications
(2-Stroke) ....................................................
....... 1-12
Fraction/Decimal Conversions .............................. 1-13
M
M/I N. Conversions .............................. ................ 1-13
Torque Conversions (ft-Ib/N-m) ............................. 1-14
Tightening Torque (General Bolts) ........................ 1-14
Assembly Schematics/Torque Specifications
(Table of Contents) ............................................. 1-14
Engine Torque Patterns (1100 cc) ......................... 1-28
Arctic Power Valve (APV) System
Specifications (2-Stroke) .................................... 1-30
Oil Consumption Specifications (2-Stroke) ............ 1-31
EFI Specifications ................................................. 1-31
Throttle Valve Angle Specifications ....................... 1-31
Fuel Pump Specifications (570 cc) ........................ 1-31
Carburetor Specifications ..................... ................. 1-31
Electrical Specifications ........................................ 1-32
Ignition Timing Specifications (2-Stroke) ........ ....... 1-38
Steering/Body Torque Specifications .................... 1-40
Drive System Specifications .................. ................ 1-41
Drive Clutch/Driven Pulley-Related
Specifications ..................................................... 1-41
Arctic Cat Drive Belt Dimensions .......................... 1-41
Drive System Components ................... ................ 1-41
Gear Case Performance Calibrations ................... 1-42
Drive System Torque Specifications ...............
....... 1-43
Rear Suspension Torque Specifications ............... 1-43
Track Warranty
Guidelines .................................... 1-45
Track Specifications ............................................... 1-46
Front Suspension Specifications ..........
................. 1-46
Rear Suspension Specifications ........................... 1-46
Shock Absorber Specifications .............
................. 1-47
Idler Wheel Dimensions ........................................ 1-47
1-1

General Specifications
-NOTE: General specifications for each 2009 Arctic
Cat Snowmobile can be accessed from the Arctic Cat
Cat Tracker Dealer Communication System online.
Snovvmobile
Identification
The Arctic Cat Snowmobile has two important identi
fication 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.
VIN
0726-383
-NOTE: The VIN also appears on a decal beneath
the seat (CrossfireIM-Series) or attached to the
right-side tunnel (remaining models). The decal
also displays pertinent production information.
These numbers are required to complete warranty
claims properly. No warranty will
be allowed by Arc
tic Cat Inc.
if the engine serial number or VIN is
removed or mutilated in any way.
Recommended
Gasoline and Oil
A CAUTION
Do not use white gas or gasolines containing metha-
nol. Only Arctic Cat approved gasoline additives
should be used.
A CAUTION
Any oil used in place of the recommended oil may
cause serious damage.
1-2
RECOMMENDED
GASOLINE
(Carbureted Models)
The recommended gasoline to use in these snowmo
biles
is 87 octane regular unleaded.
-NOTE: 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 carbu
retor main jet must be one size larger than the
main jet required for regular unleaded gasoline.
For example, if a 220 main jet is recommended for
regular unleaded gasoline, a 230 main jet must be
installed if using an oxygenated gasoline.
When using ethanol blended gasoline, adding a gaso
line antifreeze is not necessary since ethanol will pre
vent the accumulation
of moisture in the fuel system.
RECOMMENDED
GASOLINE
(EFI Models)
The recommended gasoline to use in these snowmo
biles is
87 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.
-NOTE: For optimum performance, do not exceed
the recommended 87 octane gasoline. Using a
higher octane gasoline will not increase overall
performance.
-NOTE: The Z1 Turbo models will detect lower
octane gasoline and reduced engine performance will
result. 91 octane (minimum) gasoline should be used
in these models.
RECOMMENDED OIL (2-Stroke)
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 carbu
reted model break-in) and meets all
of the lubrication
requirements
of the Arctic Cat snowmobile engine.
RECOMMENDED
OIL (120 ee)
The recommended oil to use is a multi-grade oil cali
brated to the ambient temperature at which the engine
is run. See the viscosity chart for details.
2009 Arctic Cat Snowmobiles Factory Service Manual -all Models -www.ReadManuals.com

SAE#
ENGINE
OIL
Multi-Grade
~c -35 -29 -23 -18 "12 -7 1 " 10 15 21 21 32
TEMP ~F -30 -.20 -10 0 10 20 30 40 SO 60 10 80 90
GEN-0048
RECOMMENDED OIL (1100 ee)
The recommended oil to use is Synthetic Turbo OW-40
Oil in all temperatures and conditions.
Multi-Grade Engine Oil
ENGINE
OIL
TEMP~OC ____ -3_0_-_20_-_10 __ 0 __ 1_0 __ 20 __ 30 __ 4_0~
-22 -4 14 32 50 68 86 104
OILCHARTJ
After the engine break-in period, the engine oil should
be changed every 2500-3000 miles and before pro
longed storage.
Break-In Procedure
2-STROKE
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 112 throttle
is recommended; however, brief full-throttle
accelera
tions and variations in driving speeds contribute to
good engine break-in.
& 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.
120 ee
The Arctic Cat engine requires a short break-in period
(approximately
10 operating hours) before being
sub
jected to heavy load conditions or full-throttle opera
tion. Strict adherence to the break-in procedure will
contribute to optimum performance and longevity
of
the engine.
During break-in, a maximum
of 112 throttle is
recom
mended; however, brief full-throttle accelerations and
variations in driving speeds contribute to good engine
break-in. After the 10 hour break-in period, the snow
mobile may be taken to an authorized Arctic Cat
Snowmobile dealer for a checkup and oil change at the
discretion and expense
of the snowmobile owner. 1100 ee
The Arctic Cat engine (when new or rebuilt) requires a
short break-in period before the engine
is subjected to
heavy load conditions.
This engine does not require any pre-mixed fuel
dur
ing the break-in period.
& CAUTION
DO NOT use premixed fuel in the snowmobile gas
tank. Engine damage will occur.
To ensure trouble-free operation, careful adherence to
the following break-in guidelines will be beneficial.
0-200 miles 1/2 Throttle (45 MPH-max)
200-400 miles 1/2-3/4 Throttle
400-600 miles 1/2-3/4 Throttle *
* With occasional full-throttle operation.
To ensure proper engine break-in, Arctic Cat recom
mends 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
gen
uine Arctic Cat parts. They are precision-made to
ensure high quality and correct fit.
High
Altitude Operation
Operating a snowmobile at varying altitudes requires
changes in performance components. These changes
affect drive train components and carburetion compo
nents (570 cc).
-NOTE: The 120 cc and 1100 cc turbo do not
require calibration changes for varying altitudes.
2009 Arctic Cat Snowmobiles Factory Service Manual -all Models -www.ReadManuals.com

High altitude information decal(s) are located beneath
the hood
of the snowmobile.
A CAUTION
On carbureted models, carefully follow the Main Jet
Chart recommendations for proper main jet selection
for altitude, temperature, and gasoline being used.
The M-Series snowmobiles are initially set up at the
factory for operation between 6000-9000 feet. Consult
the appropriate specifications for this information.
Following are basic high altitude theories for clutch
ing, engine, suspension, and track.
CLUTCHING
As altitude changes, engine horsepower changes with
it. As you go up in altitude, the engine loses horse
power. Because
of this, the constant velocity transmis
sion (CVT) system needs to be changed to compensate
for the horsepower loss.
At altitudes above
5000 ft, clutch engagement RPM is
normally higher than the standard setting due to the
horsepower loss at altitude
as opposed to what would
be seen for horsepower at sea level. The engine will
lose peak horsepower but will also lose horsepower at
engagement speed. For this reason, higher engagement
speeds are usually needed at altitude in order to attain
acceptable acceleration. This higher engagement speed
can be attained several ways. Some
of the methods
will affect other characteristics
of CVT operation, so
you must be careful what you change. Drive clutch
springs are the most common way to increase engage
ment speed; however, by simply changing the cam
arms to a lighter weight from the heavier sea level cam
arm, you will gain some engagement speed.
Other more complicated methods exist such
as
engagement notches and changing the position of the
cam arm center
of gravity in relation to the roller. This
is called
"tucking the weight" and can be used, but,
like the engagement notch, it can hurt belt life.
The driven clutch will also
playa part in CVT tuning
for high altitude operation. A steeper helix (torque
bracket) angle in the driven clutch will mean a quicker
up-shift. A shallower angle will mean a slower up
shift.
If the up-shift is too quick, due to a very steep
helix, RPM will be pulled down under the peak operat
ing RPM
of the engine (where the horsepower is) and
performance will suffer. The engine may even bog.
If
you have a helix that is too shallow, the engine may
over-rev or have poor acceleration. Usually, angles
shallower than the sea level calibrations work best.
The driven spring will also affect driven clutch tuning.
Tighten the spring, and RPM will increase. Loosen the
spring, and RPM will decrease. The spring should be
used to fine-tune and complement the helix selection.
Carburetor calibration changes for high altitude opera
tion will have an effect on the CVT system and how it
operates. Understanding the basics
of CVT operation
is important in order to make the correct high altitude
CVT calibration changes.
1-4
ENGINE
A normally aspirated engine will generate more horse
power at sea level than it does at higher altitudes.
Many reasons for this are possible, but the biggest rea
son is that the higher you go, less oxygen is available
for the engine to use during its combustion process.
Less oxygen means it needs less fuel to obtain the cor
rect air/fuel ratio to operate properly. This is why the
fuel ratio has to be recalibrated. High altitude engines
operate as though they have a lower compression ratio.
This, along with less oxygen and less fuel, means that
the engine generates less horsepower.
The carbureted models will also have lower pressure
applied to the float chamber because
of pressure
changes in the atmosphere between high altitude and
sea level. All
of these characteristics will become more
evident the higher the altitude.
It will be necessary to make changes to the fuel sys
tems (carbureted models) and drive systems that sup
port engine operation
as altitude changes.
TURBOCHARGING
Turbocharging is one method of compensating for loss
of air density that works extremely well when applied
to four-cycle internal combustion engines.
Exhaust gasses are directed through the turbocharger
turbine wheel which
is attached to the compressor
through a common shaft. As the exhaust gasses spin
the turbine, the compressor is spun at very high RPM.
Inlet air is drawn into the compressor, compressed, and
routed to the intake manifold
of the engine. Intake
pressure, therefore,
is maintained at the optimum level
as altitude or temperature increases.
The turbocharger output must be regulated to maintain
the optimum manifold pressure throughout the
designed operating range. This is accomplished by
regulating the volume
of exhaust gasses passing
through the turbine by controlling a diverter valve
(waste-gate) at the turbocharger turbine inlet. At lower
altitudes/temperatures, excessive exhaust gasses are
diverted past the turbine and into the exhaust down
stream
of the turbocharger thus limiting the compres
sor output to maintain correct manifold pressure.
As altitude increases, the manifold pressure is held
constant by diverting less exhaust past the turbine, thus
increasing compressor speed. This will continue until
the waste-gate is completely closed at which time
manifold pressure will start to decrease much the same
as a normally aspirated engine.
The waste-gate is controlled by a spring/diaphragm
mechanism that is connected to the intake manifold by
an air line. A mechanical linkage connects the dia
phragm to the waste-gate control arm.
2009 Arctic Cat Snowmobiles Factory Service Manual -all Models -www.ReadManuals.com

Air is heated by friction and compression through the
turbocharger and air density is lost by heating the air;
therefore, an after-cooler is installed between the tur
bocharger compressor and the intake manifold. This is
an air-to-air after-cooler that uses outside air directed
through a radiator-type cooler to cool the compressed
air prior to entering the intake manifold.
SUSPENSION
The different riding styles of the individual operator,
the varying snow conditions, and the type
of terrain are
all factors that affect the suspension at high altitude.
Trail riding versus powder snow riding versus combi
nation riding will all require different suspension set
tings.
The normal setting for front ski suspension is as little
spring pre-load tension as possible for powder snow
riding allowing the skis to float across the snow with
the least amount
of resistance. Trail riding will require
more spring tension to carry the varying load more
effectively. Many different settings and spring tensions
to consider exist when adjusting for riding style and
snow conditions.
The rear suspension has a number
of spring settings
that produce different riding characteristics.
The front arm spring and shock will also affect the ride
and handling when either on a trail
or in powder snow.
A strong spring setting on this shock will cause the
snowmobile to tend to
"dig" more when riding in the
powder snow rather than climbing up on top
of the
snow. But, it will work more effectively when riding
on a trail. A softer spring setting will allow the front
of
the rear suspension to collapse much quicker and
change the angle
of the track to the snow. A more
gradual angle will tend to raise the snowmobile up on
the snow rather than digging into it.
Many possible variables and adjustments to the rear
suspension exist depending on snow conditions, riding
style, and type
of terrain. These adjustments can be
made to individualize the snowmobile to the riding
style
of the operator.
M-Series/Crossfire
As snow cover and riding conditions change, several
different adjustments can be made to change the ride
and handling characteristics for operator preference.
Located on the front suspension arm are limiter straps.
They limit the amount
of
"fallout" the front arm can
have. These straps may be adjusted in
or out due to
conditions and riding style. The more the straps are
brought up, the more steering power the operator has
due to the amount
of ski pressure.
Another adjustment that can be made on the rear sus
pension is the front arm shock spring tension. As trail
conditions change, the spring pre-load may be used to
decrease the chance
of the front end
"bottoming out."
With a stiffer spring pre-load, the ride
of the snowmo
bile will improve on the trail but will affect the perfor
mance in the deep powder snow. In deep powder snow,
the stiffer spring pre-load will cause the front-end to "dig" and possibly take longer for it to plane off. Sev
eral different-rate springs are available for different
riding styles and terrain conditions.
On the standard models, the front shock springs are
also individually adjustable for the terrain conditions
and driving style
of the operator. The spring adjuster
has been set at the factory
so the correct amount of
threads are exposed between the spring adjuster and
the shock housing as an initial setting. Additional ski
pressure can be obtained by tightening the spring ten
sion; ski pressure can be decreased by relaxing spring
tension. Springs with different spring rates are avail
able for operator choice and snow conditions. A limit
exists as to how far you can pre-load the springs before
"coil bind" takes effect where the wire on the spring
actually runs into itself and causes binding. Equal
adjustments should be maintained on both sides
of the
snowmobile.
On the Sno Pro models with air shocks,
they are individually adjustable for the terrain condi
tions and driving style
of the operator. The ski shocks
are preset at 4.6 kg/cm2 (65 psi) as an initial setting on
the Crossfire Sno
Pro models or at 4.2 kg/cm2 (60 psi)
on the M-Series Sno Pro models. The rear arm shock is
preset at 9.8 kg/cm2 (140 psi) on the Crossfire and M
Series Sno Pro models. The shocks can be "fine
tuned" to match the operator's weight, riding style, and
terrain conditions.
-NOTE: Care should be taken to have equal pres
sure
in the ski shocks before operating the snowmobile.
Finally, track tension should be looked at to make sure
that it is within recommended specifications to affect
the efficiency
of the snowmobile.
On models with the
torque sensing link, the track is actually tightening as
the suspension moves through its range
of motion
causing the track to sag in the middle and rub on the
top part
of the rear suspension arm.
TRACK
Carefully matching the riding requirements to the type
of track will ensure the maximum use of all available
engine power. Lug height and track durometer are the
two main concerns when selecting a track for various
riding styles.
Tracks exist with lug heights from
0.750 in. up to 2.25
in. to accommodate various snow conditions. Gener
ally, the deeper the snow, the taller the lug.
It must be
noted that the installation
of any deep-lug track may
reduce top end speed and promote premature wear
strip wear in marginal snow conditions.
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Durometer is a measurement of how hard a rubber is.
The lugs on most tracks range between 60 and 80
durometer. On the durometer scale, the higher the
number, the harder the lugs. For riding in deep powder
snow, a softer 60 durometer track works best. The
softer rubber allows the track to "give" a little and
pack the snow creating lift rather than digging its way
straight down. When hill-climbing, the harder lug
of
an
80 durometer track works the best due to penetrat
ing the hard snow creating more bite.
Some tracks come with a dual durometer rating, such
as a track with a
80/60 durometer rating. The lugs on
this track are 80% 80 durometer rubber, and the top
20% is made of the softer 60 durometer rubber. This
track is designed to be a good all-around track for rid
ing mostly in deep powder snow but can climb the
occasional hard snow hill.
Drive Chain Lubrication
(120 ee)
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 lubri
cation, 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 lubri
cating 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
(120 cc) in Section 6).
-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.
Lovv Oil Pressure
Warning Light
(1100 ee)
The Low Oil Pressure Warning Light indicates engine
oil pressure, not the oil level; however,
if the oil level
is
low, it may affect oil pressure. The light should illu
minate each time the ignition switch 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, oil pressure has been lost and the
engine will automatically shut off.
-NOTE: The following oil check procedures are valid
only if the oil pressure warning light has activated.
If oil pressure is lost, use the following procedure:
1-6
1. With the engine off, remove the engine oil level
stick and wipe it clean. Without screwing it in, set
the stick back in the oil tank. Remove it and
observe the oil level on the stick.
-NOTE: To ensure an accurate reading, the snow
mobile should be on level ground.
2. If the oil level is at or below the ADD mark on the
oil level stick, add only enough recommended oil
to raise the level to the NORMAL range. DO NOT
overfill the reservoir with oil.
3. After adding oil if the engine starts, oil pressure
should be normal.
Preparation For
Storage
Prior to storing the snowmobile, it must be properly
serviced to prevent corrosion and component deterio
ration.
To prepare the snowmobile for storage, Arctic
Cat recommends the following procedure:
1. Clean the seat cushion with a damp cloth and Arc
tic Cat 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.
3.
On the 4-stroke models, change the engine oil;
then on the 120 cc and turbo models, clean the air
filter (see Section 3).
4.
On the 2-stroke models, place the rear of the
snowmobile up on a shielded safety stand.
5.
On the 500/600/800/1000 cc engine models, start
the engine and allow to idle. With the engine
idling, pry the intake boot forward; then 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. Tum engine off.
Install the intake boot.
6.
On the 570 cc engine models, carefully pry the
intake boots partially over the carburetor inlets;
then start the engine and allow to idle. With the
engine idling, 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. Tum engine off. Install the intake boots.
& CAUTION
Do not run the engine without the belt guard in place
and secured.
7. Plug the exhaust system outlet with a clean cloth.
8. On the 2-stroke models with the ignition switch in
the OFF position:
2009 Arctic Cat Snowmobiles Factory Service Manual -all Models -www.ReadManuals.com

A. Disconnect the high tension leads from the
spark plugs; then remove the plugs, connect
them to the leads, and ground them on the cyl
inder heads.
& CAUTION
Never crank the engine over without grounding the
spark plugs. Damage to ignition system 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 connect the high ten
sion leads.
9.
On carbureted models, drain the gas from each
carburetor float chamber.
10. Fill the gas tank to its rated capacity; then add Arc
tic Cat Fuel Stabilizer to the gas tank following
directions on the container for the stabilizer/gaso
line ratio. Tighten the gas tank cap securely.
11. Flush the gear case and change the lubricant (see
Section 6).
12. 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.
-NOTE: For removing drive belt, see Removing!
Installing Drive Belt in Section 6 of this manual.
13. Clean and inspect the drive clutch and driven pul
ley.
14. Apply light oil to the shafts of the shock absorbers;
then lubricate all grease fittings (front and rear
suspension, spindles, and upper steering shafts on
the
CrossfirelM -Series or steering arms on the
Bearcat/F-Series/ZliT-Series) with a low-tempera
ture grease.
15. Tighten all nuts, bolts, and cap screws making sure
all calibrated nuts, bolts, and cap screws are tight
ened to specifications. Make sure all rivets holding
the components together are tight. Replace all
loose rivets.
16. Clean and polish the hood, console, and chassis
with Arctic Cat Hood and Windshield Cleaner/
Polish. DO NOT USE SOLVENTS OR SPRAY
CLEANERS. THE PROPELLENT WILL DAM
AGE THE FINISH.
17.
On electric start models, disconnect the battery
cables making sure to disconnect the negative
cable first; then clean the battery posts and cables.
& CAUTION
Batteries require charging if left for extended non-start
periods.
Arctic
Cat recommends trickle charging once
a month. Follow the manufacturer'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 pro-
longed period of time (six weeks or more) will result in
a
discharged or damaged battery.
18. 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.
19. If the snowmobile must be stored outdoors, posi
tion the snowmobile out
of direct sunlight; then
block the entire snowmobile
off the ground mak
ing sure the snowmobile is secure. Loosen the
track adjusting bolts to reduce track tension. Cover
with a machine cover
or a heavy, ventilated tar
paulin 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 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
carburetors must be cleaned before starting the
engine.
1. Clean the snowmobile thoroughly. Polish the exte
rior
of the snowmobile.
2. Clean the engine. Remove the cloth from the
exhaust system. Check exhaust system and air
silencer for obstructions.
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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. Remove and inspect the drive belt for cracks and
tears. Check belt specifications. Replace
if dam
aged or worn. Install the drive belt.
-NOTE: For installing drive belt, see Removing!
Installing Drive Belt in Section 6 of this manual.
-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 fil
ter and replace
if necessary.
6. Inspect all fuel hoses and oil hoses for deteriora
tion or cracks; replace
if necessary. Make sure all
connections are tight; then on the 2-stroke models,
fill the oil-injection reservoir with the recom
mended injection oil. -NOTE: On the 2-stroke models 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 lubrica
tion.
7. On the 2-stroke models, inspect each spark plug.
Replace, gap, or clean
as necessary.
8. Adjust the carburetor(s) and choke cable on carbu
reted 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 caus
ing the piston valve not to return to the full-closed
position.
9. Tighten all nuts, bolts, and cap screws making sure
all calibrated nuts, bolts, and cap screws are tight
ened to specifications.
10. On the 120 cc, inspect the drive chain and drive
chain tightener. Replace
if necessary; then lubri
cate the binding screw drum with
WD-40 and the
drive chain with a dry, graphite-based chain lubri
cant.
11. If not done during preparation for storage, lubricate
all grease fittings (front and rear suspension, spin
dles, and upper steering shafts on the Crossfire/M
Series or steering arms on the BearcatlF -Series/Z
11
T-Series) with a low-temperature grease.
12.
On liquid cooled models, check the coolant level
and all coolant hoses and connections for deterio
ration or cracks. Add properly mixed coolant as
necessary.
1-8
13.
On fan cooled models, clean the engine cooling
fins and all shrouding.
14.
On electric start models, charge the battery; then
connect the battery cables making sure to connect
the positive cable first. Test the electric start sys
tem.
15. Inspect the entire brake system, all controls, head
light, taillight, brakelight, ski wear bars, and head
light aim; adjust or replace
as necessary.
16. Adjust the track to the proper tension and align
ment. Lock the jam nuts.
After
Break-In Checkup
(100 Miles -2-Strokel
600 Miles -4-Stroke)
Certain areas require adjustment after the break-in
period in order to obtain peak performance. These
areas are the following.
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 alti
tude, oxygenated gasoline usage, and temperature.
DRIVE BELT DEFLECTION -Drive belt deflec
tion
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 rub
ber snubber on the torque link will all take a
"set" dur
ing the first 100 miles allowing 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 leading to a low-end
performance problem and,
if not corrected, causes pre
mature drive belt wear.
After the break-in period, drive belt deflection should
be checked according to the instructions given in Sec
tion 6
of this manual.
DRIVE BELT BREAK-IN -For maximum drive
belt life, 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 112
throttle or lower allowing 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, a new drive belt can
be destroyed in less than 50 miles.
2009 Arctic Cat Snowmobiles Factory Service Manual -all Models -www.ReadManuals.com

To increase the life of a drive belt, the belt must 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 allowing
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 sei
zure.
& WARNING
When following this procedure, the operator must not
leave the snowmobile unattended during the warm-up
period.
Each operator should be instructed to drive the snow
mobile 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 maxi
mum belt life.
DRIVE
CLUTCHIDRIVEN PULLEY
ALIGNMENT -The parallelism and the offset
between the drive clutch and driven pulley are set at
the factory. Normally, no adjustment
is necessary;
however,
if premature drive belt wear or poor perfor
mance
is experienced, the drive clutch/driven pulley
alignment must be checked.
TRACK TENSION AND ALIGNMENT - A cer
tain amount
of stretch occurs 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 there
after.
If these adjustments aren't performed, the track
may
"derail" which leads to track and slide rail dam
age.
Along with these three major areas, other areas should
be checked and adjusted during the "After Break-In
Checkup." A checklist to assist you with this service
follows.
After
Break-In Checkup
Checklist
Below is a recommended list of items to check after
the break-in period. The recommended mileage for
this inspection is between 100 and 300 miles.
o Jet carburetors according to average tempera
ture, type of gasoline being used, and altitude
(570 cc)
o Check drive belt deflection -drive clutch/driven
pulley alignment and parallelism (800/1000/
1100cc)
o Adjust track tension and alignment
o Check throttle cable tension
o Check oil-injection pump adjustment (2-stroke)
o Check engine idle
o Check coolant level
o Check gear case lubricant level
o Check engine oil (4-stroke)
o Check lights (high/low beam, brakelight)
o Check safety switch operation
o Check engine compartment for any rubbing
components
o Check steering hardware for tightness
o Check skid frame and A-arm mounting hard
ware for tightness
o Check brake
lever travel and adjustment
o Grease all lubrication points
2009 Arctic Cat Snowmobiles Factory Service Manual -all Models -www.ReadManuals.com 1-9

Engine Specifications
(2-Stroke)
ITEM 500 cc 570 cc
Engine Model Number AX50L7 AA56A8
Displacement 499 cc 565 cc
No. of Cylinders 2 2
Bore x Stroke
71 x 63 73.8 x 66
Compression Ratio 6.
38:1 6.41 :1
Cooling System Liquid Fan
Fuel Mixture Oil Injection Oil Injection
Ignition Timing (Engine Warm) 12° @ 2000 RPM 20° @ 2000 RPM
0.034 in. 0.099 in.
Spark Plug (NGK) BR9EYA BR9EYA
Spark Plug Gap 0.028-0.031 in. 0.028-0.031 in.
Piston Skirt/Cylinder Clearance 0.0030-0.0041 in. 0.0033-0.0045 in.
Piston Ring End Gap 0.008-0.016 in. 0.012-0.0196 in.
Cylinder Trueness Limit 0.004 in. 0.004 in.
Piston Pin Diameter 0.8659-0.8661 in. 0.7085-0.7087 in.
Piston Pin Bore Diameter 0.8661-0.8665 in. 0.7087-0.7091 in.
Connecting Rod Small End Bore 1.0631-1.0634 in. 0.9056-0.9059 in.
Connecting Rod Radial Play 0.0001-0.0008 in. 0.0001-0.0008 in.
Crankshaft Runout (t.i.r.) 0.002 in. 0.002 in.
Crankshaft End Play 0.002-0.004 in. 0.002-0.004 in.
Reed Stopper Height 0.315 in. 0.236 in.
* F-Series
** Crossfire/M-Series
1-10
600 cc 800 cc 1000 cc
AJ60L6 AB80L3 AB10L3
599 cc 794 cc 999 cc
2 2 2
73.8 x 70 85 x 70 90.3 x 78
6.46:1 6.39:1
6.41 :1
Liquid Liquid Liquid Oil Injection Oil Injection Oil Injection
15° @ 2000 RPM 25° @ 3250 RPM 20° @ 3750 ro @ 1800
0.059 in. 0.162 in. RPM* RPM**
0.113 in. 0.057 in.
BR9EYA BR9EYA BR9EYA
0.028-0.031 in. 0.028-0.031 in. 0.028-0.031 in.
0.0030-0.0041 in. 0.0030-0.0041 in. 0.0030-0.0041 in.
0.012-0.0196 in. 0.012-0.0196 in. 0.012-0.0196 in.
0.004 in. 0.004 in. 0.004 in.
0.8659-0.8661 in. 0.8659-0.8661 in. 0.9447-0.9449 in.
0.8661-0.8665 in. 0.8661-0.8665 in. 0.9450-0.9453 in.
1.0631-1.0634 in. 1.0631-1.0634 in. 1.1418-1.1422 in.
0.0001-0.0008 in. 0.0001-0.0008 in. 0.0001-0.0008 in.
0.002 in. 0.002 in. 0.002 in.
0.002-0.004 in. 0.002-0.004 in. 0.002-0.004 in.
0.433 in. 0.433 in. 0.512 in.
2009 Arctic Cat Snowmobiles Factory Service Manual -all Models -www.ReadManuals.com

Engine Specifications
(120 ee)
ITEM 120 cc
Engine Model Number AA12A2
Displacement 119 cc
No. of Cylinders 1
Bore x Stroke 60 x 42
Cooling System Air
Spark Plug (NGK) BPR6ES
Spark Plug Gap 0.028-0.031 in.
Piston SkirtiCylinder Clearance 0.0008-0.0047 in.
Piston Pin Diameter 0.5898-0.5904 in.
Piston Pin Bore Diameter 0.5908-0.5917 in.
Piston Pin/Connecting Rod Small End Clearance 0.0002-0.0020 in.
Piston Ring End Gap (1 stl2nd) 0.0079-0.0280 in.
Piston Ring/Groove Clearance (1 stl2nd) 0.0012-0.0039 in.
Piston Ring Thickness 0.058-0.059 in.
Piston Diameter (10 mm from skirt edge) 2.3575-2.3618 in.
Cylinder/Head Distortion (max) 0.0012 in.
Connecting Rod Small End Bore Inside Diameter 0.5908-0.5917 in.
Connecting Rod Big End Inside Diameter 1.0242-1.0246 in.
Connecting Rod Big End Side Clearance 0.0079-0.0472 in.
Cam Lobe Height (min) 1.189 in.
Crank Pin Diameter 1.0232-1.0236 in.
Crank Pin/Connecting Rod Clearance 0.0006-0.0028 in.
Crankshaft Rod Journal (Out-of-Round/Taper) 0.004 in.
Crankshaft Runout (t.i.r.) 0.004 in.
Valve Guide Inside Diameter 0.2165-0.2170 in.
Valve Guide/Stem Clearance (max) (Int) 0.0032 in.
(Exh) 0.0039 in.
Valve Guide Bore Diameter 0.4409-0.4416 in.
Valve Face Width 0.032-0.039 in.
Valve Face Runout (max) 0.0012 in.
Valve Clearance -Cold (59°_77° F) (IntlExh) 0.030-0.070 in.
Valve Seat Contact Width (IntlExh) 0.032-0.039 in.
Valve Stem Diameter (IntlExh) 0.2150-0.2156 in.
Valve Stem Runout (max) 0.002 in.
Valve Spring Free Length (max) 1.22 in.
Engine Specifications
(1100 ee)
ITEM 1100 cc
Engine Model Number AA11L1
Displacement 1056 cc
No. of Cylinders 2
Bore x Stroke 98 x 70
Cooling System Liquid
Spark Plug (NGK) -Non-Turbo CR8EIB-9
Spark Plug (NGK) -Turbo MR8AI-9
Spark Plug Gap -Non-Turbo 0.031-0.035 in.
Spark Plug Gap -Turbo 0.035 in.
Piston SkirtiCylinder Clearance (Non-Turbo) 0.0011-0.0016 in.
Piston SkirtiCylinder Clearance (Turbo) 0.0006-0.0010 in.
Piston Pin Diameter (Non-Turbo) 0.8658-0.8661 in.
Piston Pin Diameter (Turbo) 0.9447-0.9449 in.
Piston Pin Bore Diameter (Non-Turbo) 0.8662-0.8664 in.
Piston Pin Bore Diameter (Turbo) 0.9449-0.9451 in.
Piston Pin/Connecting Rod Small End Clearance 0.0004-0.0010 in.
(Non-Turbo)
Piston Pin/Connecting Rod Small End Clearance 0.0004-0.0009 in.
(Turbo)
Piston Ring End Gap (1st) 0.0059-0.0138 in.
(2nd) 0.0118-0.0177 in.
(Oil) 0.0078-0.0275 in.
Piston Ring/Groove Clearance (1st -Top) 0.0059-0.0074 in.
(1st -Bottom) 0.0008-0.0035 in.
(2nd) 0.0008-0.0024 in.
(Oil) 0.0024-0.0059 in.
Piston Diameter (10 mm from skirt edge) 3.8568-3.8574 in.
(Non-Turbo)
Piston Diameter (10 mm from skirt edge) (Turbo) 3.8574-3.8580 in.
Cylinder/Head Distortion (max) 0.002 in.
Connecting Rod Small End Bore Inside Diameter 0.866-0.867 in.
(Non-Turbo)
Connecting Rod Small End Bore Inside Diameter 0.945-0.946 in.
(Turbo)
Cam Lobe Height (Non-Turbo) (Int) 1.487-1.489 in.
Cam Lobe Height (Turbo) (Int) 1.436-1.437 in.
Cam Lobe Height (Non-Turbo) (Exh) 1.432-1.433 in.
Cam Lobe Height (Turbo) (Exh) 1.417-1.418 in.
Camshaft Journal Outside Diameter 0.8650-0.8658 in.
Camshaft Journal Bore Diameter 0.8666-0.8670 in.
Camshaft Journal Clearance 0.0007-0.0020 in.
Crank Pin Diameter 1.7707-1.7720
in.
Crankshaft Runout
0.002 in.
Crankshaft Main Bearing Clearance 0.0006-0.0016 in.
Crankshaft Thrust Runout (max) 0.0043 in.
Crankshaft Main/Rod Journals (Bearing Surfaces) 0.0012 in.
Valve Guide Inside Diameter 0.2165-0.2170 in.
Valve Guide/Stem Clearance (max) (Int) 0.0015 in.
(Exh) 0.0022 in.
Valve Face Width 0.0197 in.
Valve Clearance -Cold (59°_77° F) (Int) 0.0039-0.0078 in.
(Exh -Non-Turbo) 0.0078-0.0118 in.
(Exh -Turbo) 0.0118-0.0157 in.
Valve Seat Contact Width (IntlExh) 0.0354-0.0433 in.
Valve Stem Diameter (Int) 0.2155-0.2161 in.
(Exh) 0.2147-0.2153
in.
2009 Arctic Cat Snowmobiles Factory Service Manual -all Models -www.ReadManuals.com 1-11

Cylinder Head Volume
Specifications
(2-Stroke)
-NOTE: For cylinder head volume tests, see
appropriate Measuring Critical Components sub
section in Section 2.
ENGINE TYPE SQUISH -GAP
500 cc 0.059 in.
570 cc 0.066 in.
600 cc 0.059 in.
800 cc 0.059 in.
1000 cc 0.058 in.
A CAUTION
These specifications are not intended to be used for
engine modification. Reducing the
head
volume to a
smaller specification could cause piston detonation
problems which is not a warranty situation.
Engine Piston Travel
Versus Crank Angle
(2-Stroke)
-NOTE: When using the chart below, first know
the engine stroke and timing in degrees; then read
across from the degree figure to find timing.
500 cc 6001800 cc 570 cc 1000 cc
63mm 70mm 66mm 78mm
stroke stroke stroke stroke
Degrees
BTDC BTDC BTDC BTDC
BTDC
12 0.034 in. 0.038 in. 0.036 in. 0.042 in.
15 0.053 in. 0.059 in. 0.056 in. 0.065 in.
18 0.076 in. 0.085 in. 0.081 in. 0.093 in.
20 0.094 in. 0.105 in. 0.099 in. 0.113 in.
Crankshaft Runoutl
Repair Specifications
(2-Stroke)
For those who have crankshaft work sent out to
another shop, provide them with this information.
To use the specifications, first refer to the drawing;
then find the letter which indicates the specification
and refer to the chart below the illustration. Be sure to
note the proper engine
row.
1-12
-NOTE: We have given the proper location for
checking crankshaft runout as the very edge of the
straight portion of the shaft where the oil seal
makes contact. From the illustration, note that
three check points are called out: at either end, out
on the taper as shown, and also on the center
bearing race. The crankshaft is still supported on
the outer bearings using V blocks.
--A-I
iB-1
------
728-144A
570 cc in.
73.8 x 66
600 cc in.
73.8 x 70
800 cc in.
85 x 70
1000 cc in.
90.3 x 78
-NOTE: Measure in from the shaft end the speci
fied
amount when checking runout at points D and
F. When checking runout in the center,
place indi
cator on center of bearing as shown at point E.
Maximum runout at any of the three measuring
points is ± 0.002 in.
2009 Arctic Cat Snowmobiles Factory Service Manual -all Models -www.ReadManuals.com

8ths
1/8 =
.125
1/4 =
.250
3/8 =
.375
1/2 =
.500
5/8 =
.625
3/4 =
.750
7/8 =
.875
-
-
-
-
-
-
-
-
-
Fraction/Decimal
Conversions
16ths 32nds 64ths 64ths
1/16 =
.0625 1/32 = .03125 1/64 = .015625 33/64 = .515625
3/16 = .1875 3/32 = .09375 3/64 = .046875 35/64 = .546875
5/16 = .3125 5/32 = .15625 5/64 = .078125 37/64 = .578125
7/16 = .4375 7/32 = .21875
7/64= .109375 39/64 = .609375
9/16 = .5625 9/32 = .28125 9/64 = .140625
41 /64 = .640625
11/16 = .6875 11/32 = 11/64 = 43/64 = .671875
.34375 .171875
13/16 = .8125 13/32 = 13/64 = 45/64 = .703125
.40625 .203125
15/16 = .9375 15/32 = 15/64 = 47/64 = .734375
.46875 .234370
- 17/32 = 17/64 = 49/64 = .765625
.53125 .265625
- 19/32 = 19/64 = 51/64 = .796875
.59375 .296875
- 21/32 = 21/64 = 53/64 = .828125
.65625 .328125
- 23/32 = 23/64 = 55/64 = .859375
.71875 .359375
- 25/32 = 25/64 = 57/64 = .890625
.78125 .390625
- 27/32 = 27/64 = 59/64 = .921875
.84375 .421875
- 29/32 = 29/64 = 61/64 = .953125
.90625 .453125
- 31/32 = 31/64= 63/64 = .984375
.96875 .484375
MM/IN. Conversions
2009 Arctic Cat Snowmobiles Factory Service Manual -all Models -www.ReadManuals.com 1-13

Torque Conversions
(ft-lb/N-m)
Tightening Torque
(General Bolts)
Thread
Tightening
Type of Bolt Diameter A
(mm)
Torque
(Conventional or 4 Marked Bolt) 5 12-36 in.-Ib
~~ .qj
6 36-60 in.-Ib
® ','1"1, '
T·'I.I., -
8 7-11 ft-Ib
10 16-25 ft-Ib
(7 Marked Bolt) 5 24-48 in.-Ib
wmmtll« (j
6 6-8 ft-Ib
8 13-20 ft-Ib
10 29-43 ft-Ib
1-14
Assembly Schematicsl
Torque Specifications
(Table of Contents)
Servicing Symbols ................................................. 1-14
120 cc .................................................................... 1-15
570 cc .................................................................... 1-16
500 cc .................................................................... 1-18
OOO~ .................................................................... 1~0
800 cc .................................................................... 1-22
1000 cc .................................................................. 1-24
1100 cc .................................................................. 1-26
Servicing Symbols
Listed in the table below are symbols indicating spe
cial instructions and other important information nec
essary for proper servicing. Please note the definition
for each symbol.
-NOTE: Before engine assembly, ensure all
threaded areas are clean to assure an accurate
torque value is achieved.
& CAUTION
Torque values have a range of + or -20%.
SYMBOL DESCRIPTION
~_ID'
Torque control required
243 -apply blue Loctite #243
271 -apply red Loctite #271
Lubricate with Arctic Cat 50:1
Injection Oil -Non-APV Engines
Lubricate with Arctic Cat Synthetic APV
2-Cycle Oil -APV Engines
Lubricate with Arctic Cat
Low-Temp Grease
3B -Three Bond
Sealant
HT -High-Temp Sealant
AS -Anti-Seize Thread Compound
2009 Arctic Cat Snowmobiles Factory Service Manual -all Models -www.ReadManuals.com

120 cc
~
.t
e
~
96 in.-Ib
~ : . / 20 ft-Ib
.~ ' P @@~
"" \~
20 ft-Ib
~
I 96 in.-Ib
18 ft-Ib
~
15 ft-Ib
120-ENG09
2009 Arctic Cat Snowmobiles Factory Service Manual -all Models -www.ReadManuals.com1-15

570 cc
~
96 in.-Ib
@ ®
~ ©
(i) IJJ
~y c€ @
7
® ® Q) 0
8
11 4 210
570-ENG09
1-16
2009 Arctic Cat Snowmobiles Factory Service Manual -all Models -www.ReadManuals.com

~
28 ft-Ib
~
48 in.-Ib
~
15 ft-Ib
fJIJ-~~ -·
96 in.-Ib
48 in.-Ib .... ~ ... -
570ENG09
2009 Arctic Cat Sn owmobiles Factory S . ervlce Manual -all Mod I es-wwwR . eadManuals.com 1-17

500 cc
<D 0
-~<D

~ < 96in.·lb
~
108 in.·lb
500CC1A09
1-18
2009 Arctic Cat Snowmobiles Factory Service Manual -all Models -www.ReadManuals.com

~
96 in.-Ib
(C) 6 mm 96 in.-Ib
(D) Coolant Temperature Sensor 18 ft-Ib •
~ 20ft-lb ~
crossfire .. :, f;!i!J~ 15ft.O._:
/ 4fC <lll-" "~
(A)
(A)
. '-
(A)
~
22 ft-Ib
""-------~', " ~-
G @.
/~ .-
5
•
~
24 ft-Ib
~
F5/T500 / 50 ft-Ib
~ 0 /3~~
~ ~."~ 25ft-lb
~ -~ :,,;r::::
23ft-lb ";~/ ",
<lll-,
~
15 ft-Ib
2009 Arctic Cat Snowmobiles Factory Service Manual -all Models -www.ReadManuals.com
(B)
1-19

1-20
600 cc
1>--
48 in.·lb
®
@
0
@
(J)
\>--
96 in.·lb
ill ~ ----1
ill (Do(D
0
CD (!) @
ill
--
>--/
48 in.·lb
>--
96 in.·lb
2009 Arctic Cat Snow . Manual -all Models -www. mobiles Factory Service ReadManuals.com

~
96 in.·lb
~
20ft·lb
16ft·lb
F-Series
~ ~,.-
50 ft Ib 25f!;'.lb ~ . 15ft·lb
~
.~~ '~~.v~
~ "'<:J
23 ft·lb '-~ ..., '.
~
25 ft·lb
' ....
(A) 10 mm Step 1: 13 ft-Ib
Step 2: 31 It-Ib
(8) 6 mm 96In.·lb (8) (A) ( 8) (A)(C) (8)
(A) 1· i..'1"--o'k '©J lk-
;.1..1 Vl II
I ~/o ~ j _ I I
(A)~ -~I "-:''-@I ~I~ '
(A) 81J8 'l:Jttt:J ~
(A) (A) (A)
(C)Coolant Temperature Sensor 18 It.lb.
j~
@:j~ ~~
@ ,
~
48 in.·lb
2009 Arctic Cat Snowmobiles Factory Service Manual -all Models -www.ReadManuals.com 1-21

1-22
800 cc
:J ·
(A) 10 mm Step 1: 13 ft-Ib
Step 2: 31 ft·lb
(8) 8 mm 25 ft-Ib
(C) 6 mm 96 in.-Ib
(D) Coolant Temperature Sensor 18 ft·lb ..
:J ·
/ 96in.·lb
a
@ <D ill
@ 0 ill @
ill
*
9 513
I
I
®
0 ®
0 @
®
* Accessible from Top Side
:J :J •
19ft·lb
17 ft·lb
(Knock Sensor)
•
800 09 1
2009 Arctic Cat Snowmobiles Factory Service Manual -all Models -www.ReadManuals.com

:J
96 in.-Ib
30 ft-Ib
•
F-Series
:J. :J.
50 ft-Ib 25 ft-~Ib :J
--~ _ 17ft-lb
f'J Ai .,~~ "
23 ft-Ib -
•
19 ft·lb
•
96 in.-Ib
800 09 2
2009 Arctic Cat Snowmobiles Factory Service Manual -all Models -www.ReadManuals.com 1-23

1000 cc
/~ '"
~
18 ft·lb
:J -
(8)
(8) 6
mm 96
in.·lb
(A)
~ ..
~ ____ J -~ ~ /~ 48in.·lb
96 in.·lb 0:> c(; <::e /
( ,.'~' . t?
. ' .
. '-'" 'J..'
~~~~U .. ~ ~
/
~
il~ 50ft.lb
~
48 in.·lb
1-24
® ill <D
@
0
ill ill
0
0 0
ill @ ® ill
*
14
I
* Accessible from Top Side
~
19 ft·lb
~~
2009 Arctic Cat Snowmobiles Factory Service Manual -all Models -www.ReadManuals.com
@
@
7
1000 09 2

~ F-Series
501t-lb
.(
~
501t.lb~ QP
~
25 It-Ib
/
.'
(!PeP
iCa
~
50 It-Ib
•
~
108 in.-Ib
2009 Arctic Cat S nowmobiles Facto
96 in.-Ib --69' Yo' ,~
~/
" 0J
, ~
ry Service Ma nual -all Models -www.ReadManuals.com 1-25

1100 cc
Engine Case Torque Value
15 ft-Ib
Qty 4 -96 in.-Ib
• 6 mm Cap Screw S 1 120 in -Ib
at 18- tep .
.. 8
mm Cap Screw y Step 2 19
ft-Ib
Oty 6 -Step 1 13 ft-Ib
... 10 mm Cap Screw Step 2 33 ft-Ib
1100ccJAG09
1-26
2009 Arctic Cat Snow -Manual -all Models -mobiles Factory Service www.ReadManuals.com

84 in.-Ib
60 in.-Ib
60 in.-Ib
30 ft-Ib
2009 Arctic Cat Snowmobiles Facto . ry Service Manual -all Models -www.ReadManuals.com
,
'~
84 in.-Ib
1100ccZ1RV09
1-27

Engine Torque Patterns
(1100 ee)
Engine Case Oil Separator Plates
741-582A 741-737A
Oil Pan Plate Oil Pan
741-738A 741-584A
Cylinder Head
741-617A
1-28
2009 Arctic Cat Snowmobiles Factory Service Manual -all Models -www.ReadManuals.com

Camshaft Cover Engine Cover
741-624A 741-580A
Magneto Cover Exhaust Manifold
741-583A
744-0038
2009 Arctic Cat Snowmobiles Factory Service Manual -all Models -www.ReadManuals.com 1-29

Arctic Povver Valve
(APV) System
Specifications
(2-Stroke)
-NOTE: The servo will activate once at APV cycle
RPM. If the servo cycles three times, cable length
adjustment or valve inspection is required.
APV Position/RPM
ENGINE VALVE POSITION CYCLE RPM
600 cc Full-Open 73-7400 (Low/High All)
800 cc Mid-Open 60-6500 (Low/High All)
Full-Open 78-8100 (Low/High All)
1000 cc Mid-Open 6300 (Low/High All)
Full-Open 6500 (Low/High All)
-NOTE: The 800 cc and 1000 cc have a three-stage
exhaust valve system. The stages are closed, mid
open, and full-open. Each model has a designated
RPM at
which the system is synchronized and
checked by
the
ECU for proper operation occuring
once each time the engine is started. The 800 cc
system is checked at 4800 RPM and the 1000 cc
system is checked at 6100 RPM (CrossfirelF
Series)
or at
6270 RPM (M-Series).
F-Series
Servomotor
741-635A
Crossfire/M-Series
(600 ee)
Support Tube -" ...
Steering Post
739-715A
1-30
ENGINE
600 cc
800 cc
1000 cc
Crossfire/M-Series
(800/1000 ee)
Servomotor
/
742-209A
APV CABLE LENGTH
CENTER
±
0.039 in.
1.417 in.
1.377 in.
1.319 in.
•
0735-516
2009 Arctic Cat Snowmobiles Factory Service Manual -all Models -www.ReadManuals.com

Oil Consumption
Specifications
(2-Stroke)
FULL-CLOSED
FULL-OPEN
ENGINE RPM (Idle)
2 Minutes
3 Minutes
500 cc 1833 1.0-2.5 cc 7.4-10.3 cc
570 cc 2000 1.4-2.2 cc 6.9-9.4 cc
600 cc 1833 1.3-3.2 cc 10.9-15.2 cc
800 cc 1833 1.32-3.48 cc 8.74-10.8 cc
1000 cc 1833 1.96-3.57 cc 8.96-10.72 cc
EFI Specifications
Fuel Pressure (2-Stroke) 42.8-47.3 psi
Fuel Pressure (1100 cc Non-Turbo) 43.5 psi
Fuel Pressure (1100 cc Turbo) 36.0 psi -Idle
55.0 psi -Full Boost
Throttle Valve Angle
Specifications
TPSTOOL ANALYZER TOOL
(DC VOLTS) (DC VOLTS)
500
cc Idle 0.710-0.818 0.710-0.818
Full-Open 3.472-4.048 3.470-4.046
600 cc Idle 0.646-0.754 0.646-0.754
Full-Open 3.472-4.485 3.470-4.046
DIAGNOSTIC TOOL
800 cc Idle 0.646-0.754 3.99° -6.66°
Full-Open 3.472-4.485 74.97"-89.37"
1000 cc Idle 0.591-0.699 4.75°-7.55°
Full-Open 3.477-4.054 77.39°-91.66°
1100 cc Idle 1.100-1.140 8.5°
Non-Turbo
Full-Open 4.300-4.500 90°
1100 cc Turbo Idle 0.690-1.110 10°
Full-Open 4.000-4.200 90°
-NOTE:
Breaking the seal on the idle screw jam
nut or the screws
on the
TPS will void warranty.
Fuel Pump
Specifications
(570 ee)
RPM PSI KG/CM
2
1000-2000
3000-4000
3.0-3.5 0.21-0.25
4.5-5.5 0.32-0.39
Carburetor
Specifications
PILOT AIR FLOAT HEIGHT MAIN PILOT THROTTLE
SCREW SETTING
(TURNS OUT) (mm) AIR JET OUTLET VALVE
1 1/2 22-24
-NOTE: The above specifications are production
settings. For high altitude jetting and settings,
refer to the jet chart beneath the snowmobile
hood. For optional tuning components, see the
Quick Reference Guide.
2009 Arctic Cat Snowmobiles Factory Service Manual -all Models -www.ReadManuals.com 1-31

Electrical
Specifications
(570 ee)
-NOTE: The ignition system is a Normally Open Ignition (NOI).
Description
Resistance Test
Test Value
Ignition Coil Primary (External) 0.26-0.35 ohm orange
Secondary 6800-10,200 ohms high tension wire
Charge Coil (1) 12-18 ohms black/red
Charge Coil (2) 12-18 ohms brown/white
Ignition Timing Sensor 148-222 ohms green/white
Lighting Coil 0.12-0.18 ohm yellow
Spark-Plug Cap 4000-6000 ohms cap end
Description Test Value
Voltage Regulator/Rectifier 11-14 AC volts yellow
Low Oil-Light Sending Unit Less than 1 ohm (float end down) terminal
Ignition Switch Less than 1 ohm (key in OFF posi-terminal
tion)
Description Peak Voltage Test
Primary Coil (External) 254-266V orange
Charge Coil (1) 13.7-15.4V black/red
Charge Coil (2) 14.5-15.7V brown/white
Ignition Timing Sensor 4.8-6.4V green/white
Lighting Coil 6.5-7.0V yellow
+ Test Connections -
black/white
high tension wire
green/red
green/red
brown
yellow
cap end
+ Test Connections -
brown
terminal
terminal
+ Test Connections -
black/white
green/red
green/red
brown
yellow
Peak Voltage Tests were made with the Fluke Model 73 Multimeter (pin 0644-191) set to the DC Volt scale and the
Peak Voltage Reading Adapter (pin 0644-307) with the main harness connectors plugged in (except on the primary
coil/CCU tests), spark plugs removed and grounded, and by pulling the recoil starter rope briskly.
-NOTE: Lighting coil output is unregulated voltage.
A WARNING
Most voltages generated by the ignition system are sufficient to interrupt pacemakers! All technicians, especially
those using pacemakers, must avoid contact with all electrical connections when pulling the recoil starter rope or
after the engine has been started.
1-32
2009 Arctic Cat Snowmobiles Factory Service Manual -all Models -www.ReadManuals.com

Electrical
Specifications
(500 ee)
-NOTE: The ignition system is a Normally Open Ignition (NOI).
Description
Resistance Test
Test Value
Ignition Coil
Primary 0.24-0.36 ohm orange/black
Secondary 6800-10,200 ohms high tension wire
Charge Coil (1) 7.2-10.8 ohms black/red
Charge Coil (2) 7.2-10.8 ohms brown/white
Lighting Coil 0.08-0.12 ohm yellow
Ignition Timing Sensor 80.8-121 ohms green/white
Injection Coil 15.2-22.8 ohms blue/white
Fuel Pump Coil 1.52-2.28 ohms orange
Spark-Plug Cap 4000-6000 ohms cap end
Description Test Value
Chassis Control Unit* 10-15 DC Volts red/blue (low power)
+ Test Connections -
orange/red
high tension wire
green/red
green/red
yellow
brown/green
blue/white
orange
cap end
+ Test Connections -black (low power)
(Crossfire/F-Series) red/black (high power) black (high power)
Voltage Regulator/Rectifier 10-15 DC Volts red/blue black
(T500) 11-14 AC Volts yellow black
Low Oil-Light Sending Unit Less than 1 ohm (float end down) terminal terminal
Ignition Switch Less than 1 ohm (key in OFF position) terminal terminal
Description Peak Voltage Test + Test Connections -
Primary Coil* 104V orange/black orange/red
Charge Coil (1) 13.2-14.1V black/red green/red
Charge Coil (2) 13.6-14.2V brown/white green/red
Lighting Coil 8.3V yellow yellow
Ignition Timing Sensor 4.8V green/white brown/green
Injection Coil 13.2V blue/white blue/white
Fuel Pump Coil 12.8V orange orange
Lighting Coil 14.8-22.2V (@ 2000 RPM) yellow brown
* Harness plugged III
-NOTE: To test the coolant temperature sensor, see Section 5.
Peak Voltage Tests were made at room temperature with the MaxiClips (pin 0744-041), Fluke Model 73 Multime
ter
(pin 0644-191) set to the DC Volt scale, and the
Peak Voltage Reading Adapter (pin 0644-307). Also, the main
harness connectors must be unplugged (except on the primary coil/CCU tests), the spark plugs removed and
grounded, and by pulling the recoil starter rope briskly.
-NOTE: Lighting coil output is unregulated voltage.
A WARNING
Most voltages generated by the ignition system are sufficient to interrupt pacemakers! All technicians, especially
those using pacemakers, must avoid contact with all electrical connections when pulling the recoil starter rope or
after the engine has been started.
2009 Arctic Cat Snowmobiles Factory Service Manual -all Models -www.ReadManuals.com 1-33

Electrical
Specifications
(600 ee)
-NOTE: The ignition system is a Normally Open Ignition (NOI).
Description
Resistance Test
Test Value
Ignition Coil
Primary 0.24-0.36 ohm orange/black
Secondary 6800-10,200 ohms high tension wire
Charge Coil (1) 7.2-10.8 ohms black/red
Charge Coil (2) 7.2-10.8 ohms brown/white
Lighting Coil 0.08-0.12 ohm yellow
Ignition Timing Sensor 80.8-121 ohms green/white
Injection Coil 15.2-22.8 ohms blue/white
Fuel Pump Coil 1.52-2.28 ohms orange
Spark-Plug Cap 4000-6000 ohms cap end
Description Test Value
Chassis Control Unit* 10-15 DC Volts red/blue (low power)
+ Test Connections -
orange/red
high tension wire
green/red
green/red
yellow
brown/green
blue/white
orange
cap end
+ Test Connections -black (low power)
red/black (high power) black (high power)
Low Oil-Light Sending Unit Less than 1 ohm (float end down) terminal terminal
Servomotor 12 DC Volts red/black (counterclockwise) black/red (counterclockwise)
black/red (clockwise) red/black (clockwise)
Ignition Switch Less than 1 ohm (key in OFF position) terminal terminal
Description Peak Voltage Test + Test Connections -
Primary Coil* 104V orange/black orange/red
Charge Coil (1) 13.2-14.1V black/red green/red
Charge Coil (2) 13.6-14.2V brown/white green/red
Lighting Coil 8.3V yellow yellow
Ignition Timing Sensor 4.8V green/white brown/green
Injection Coil 13.2V blue/white blue/white
Fuel Pump Coil 12.8V orange orange
Lighting Coil 14.8-22.2V (@ 2000 RPM) yellow brown
* Harness plugged III
-NOTE: To test the coolant temperature sensor, see Section 5.
Peak Voltage Tests were made at room temperature with the MaxiClips (pin 0744-041), Fluke Model 73 Multime
ter
(pin 0644-191) set to the DC Volt scale, and the
Peak Voltage Reading Adapter (pin 0644-307). Also, the main
harness connectors must be unplugged (except on the primary coil/CCU tests), the spark plugs removed and
grounded, and by pulling the recoil starter rope briskly.
-NOTE: Lighting coil output is unregulated voltage.
A WARNING
Most voltages generated by the ignition system are sufficient to interrupt pacemakers! All technicians, especially
those using pacemakers, must avoid contact with all electrical connections when pulling the recoil starter rope or
after the engine has been started.
1-34
2009 Arctic Cat Snowmobiles Factory Service Manual -all Models -www.ReadManuals.com

Electrical
Specifications
(800 ee)
-NOTE: The ignition system is a Normally Open Ignition (NOI).
Description
Resistance Test
Test Value
Ignition Coil
Primary 0.24-0.36 ohm black/white
Secondary 5040-7560 ohms high tension wire
Charge Coil (1) 7.2-10.8 ohms black/red
Charge Coil (2) 7.2-10.8 ohms brown/white
Lighting Coil 0.08-0.12 ohm yellow
Ignition Timing Sensor (1) 148-222 ohms blue/white
Ignition Timing Sensor (2) 148-222 ohms green/white
Injection Coil 15.2-22.8 ohms blue/white
Fuel Pump Coil 1.52-2.28 ohms orange
Spark-Plug Cap 4000-6000 ohms cap end
Description Test Value
Voltage Regulator/Rectifier* 10-15 DC Volts red/violet
(F-Series)
Voltage Regulator/Rectifier* 10-15 DC Volts red/blue
(Crossfire/M-Series) 11-14 AC Volts yellow
Low Oil-Light Sending Unit Less than 1 ohm (float end down) terminal
Servomotor 12 DC Volts red/black (counter-
clockwise)
+ Test Connections -
white/blue
high tension wire
green/red
green/red
yellow
brown/green
brown/green
blue/white
orange
cap end
+ Test Connections -black
black
black
terminal
black/red (counter-
clockwise)
black/red (clockwise) red/black (clockwise)
Ignition Switch Less than 1 ohm (key in OFF position) terminal terminal
Description Peak Voltage Test + Test Connections -
MAG Primary Coil (Harness Sider 125-137V orange/red orange/black
PTa Primary Coil (Harness Sider 126-139V white/red white/black
Charge Coil (1) 13.6-14.8V black/red green/red
Charge Coil (2) 13.5-14.6V brown/white green/red
Lighting Coil 5.4-5.8V yellow yellow
Ignition Timing Sensor (1) 4.3V blue/white brown/green
Ignition Timing Sensor (2) 4.4V green/white brown/green
Injection Coil 6.8-7.3V blue/white blue/white
Fuel Pump Coil 12.3V orange orange
Lighting Coil 14.8-22.2V (@ 2000 RPM) yellow brown
* Malll harness plugged III
-NOTE: To test the coolant temperature sensor, see Section 5.
Peak Voltage Tests were made at room temperature with the MaxiClips (p/n 0744-041), Fluke Model 73 Multime
ter (p/n 0644-191) set to the DC Volt scale, and the Peak Voltage Reading Adapter (p/n 0644-307). Also, the main
harness connectors must be unplugged (except on the primary coil and voltage regulator/rectifier tests), the spark
plugs removed and grounded, and by pulling the recoil starter rope briskly.
-NOTE: Lighting coil output is unregulated voltage.
A WARNING
Most voltages generated by the ignition system are sufficient to interrupt pacemakers! All technicians, especially
those using pacemakers, must avoid contact with all electrical connections when pulling the recoil starter rope or
after the engine has been started.
2009 Arctic Cat Snowmobiles Factory Service Manual -all Models -www.ReadManuals.com 1-35

Electrical
Specifications
(1000 ee)
-NOTE: The ignition system is a Normally Open Ignition (NOI).
Description
Resistance Test
Test Value
Ignition Coil
Primary 0.24-0.36 ohm black/white
Secondary 5040-7560 ohms high tension wire
Charge Coil (1) 7.2-10.8 ohms black/red
Charge Coil (2) 7.2-10.8 ohms brown/white
Lighting Coil 0.08-0.12 ohm yellow
Ignition Timing Sensor (1) 148-222 ohms blue/white
Ignition Timing Sensor (2) 148-222 ohms green/white
Injection Coil 15.2-22.8 ohms blue/white
Fuel Pump Coil 1.52-2.28 ohms orange
Spark-Plug Cap 4000-6000 ohms cap end
Description Test Value
Voltage Regulator/Rectifier* 10-15 DC Volts red/violet
(F-Series)
Voltage Regulator/Rectifier* 10-15 DC Volts red/blue
(Crossfire/M-Series) 11-14 AC Volts yellow
Low Oil-Light Sending Unit Less than 1 ohm (float end down) terminal
Servomotor 12 DC Volts red/black (counter-
clockwise)
+ Test Connections -
white/blue
high tension wire
green/red
green/red
yellow
brown/green
brown/green
blue/white
orange
cap end
+ Test Connections -black
black
black
terminal
black/red (counter-
clockwise)
black/red (clockwise) red/black (clockwise)
Ignition Switch Less than 1 ohm (key in OFF position) terminal terminal
Description Peak Voltage Test + Test Connections -
MAG Primary Coil (Harness Sider 125-137V orange/red orange/black
PTa Primary Coil (Harness Sider 126-139V white/red white/black
Charge Coil (1) 13.6-14.8V black/red green/red
Charge Coil (2) 13.5-14.6V brown/white green/red
Lighting Coil 5.4-5.8V yellow yellow
Ignition Timing Sensor (1) 4.3V blue/white brown/green
Ignition Timing Sensor (2) 4.4V green/white brown/green
Injection Coil 6.8-7.3V blue/white blue/white
Fuel Pump Coil 12.3V orange orange
Lighting Coil 14.8-22.2V (@ 2000 RPM) yellow brown
* Malll harness plugged III
-NOTE: To test the coolant temperature sensor, see Section 5.
Peak Voltage Tests were made at room temperature with the MaxiClips (p/n 0744-041), Fluke Model 73 Multime
ter (p/n 0644-191) set to the DC Volt scale, and the Peak Voltage Reading Adapter (p/n 0644-307). Also, the main
harness connectors must be unplugged (except on the primary coil and voltage regulator/rectifier tests), the spark
plugs removed and grounded, and by pulling the recoil starter rope briskly.
-NOTE: Lighting coil output is unregulated voltage.
A WARNING
Most voltages generated by the ignition system are sufficient to interrupt pacemakers! All technicians, especially
those using pacemakers, must avoid contact with all electrical connections when pulling the recoil starter rope or
after the engine has been started.
1-36
2009 Arctic Cat Snowmobiles Factory Service Manual -all Models -www.ReadManuals.com

Electrical
Specifications
(1100 ee)
-NOTE: The ignition system is a Normally Open Ignition (NOI).
Description
Resistance Test
Test Value
Magneto Coil (three tests) 0.2-0.4 ohm yellow
Coil (1) 1.4 ohms red/green
Coil (2) 1.4 ohms red/green
Crankshaft Position Sensor 173-211 ohms green
Coolant Temperature Sensor 2.3k-2.6k ohms yellow/black
Injection Coil Starter Relay 3.6 ohms black/yellow
Spark-Plug Cap 4000-6000 ohms cap end
Description Test Value
-NOTE: To test the coolant temperature sensor, see Section 5.
+ Test Connections -
yellow
gray/green
brown/green
blue
ground
black
cap end
+ Test Connections -
These tests were made at room temperature with the MaxiClips (pin 0744-041), Fluke Model 73 Multimeter (pin
0644-191), and the Peak Voltage Reading Adapter (pin 0644-307). For ignition coil peak voltage test, the battery
must be fully charged. Also, the main harness connectors must be unplugged (except on the voltage regulator/recti
fier test).
& WARNING
Most voltages generated by the ignition system are sufficient to interrupt pacemakers! All technicians, especially
those using pacemakers, must avoid contact with all electrical connections when pulling the recoil starter rope or
after the engine has been started.
2009 Arctic Cat Snowmobiles Factory Service Manual -all Models -www.ReadManuals.com 1-37

500 cc
Ignition Timing
Specifications
(2-Stroke)
Ignition Timing -Engine Warm
BTDC -12°/2000 RPM -0.034 in.
Not
Adjustable
I~~:::~i, i!!~~
~_j-C_BT_DC_2_40 ___ ---,
•
Rotating Direction
570 cc
Ignition Timing -Engine Warm
BTDC -20°/2000 RPM -0.099 in.
Not
Adjustable
0742-218
Q,'"lrl/" II
~/I
~
0742-217
1-38
600 cc
Ignition Timing -Engine Warm
BTDC -15°/2000 RPM -0.059 in.
Not
Adjustable
ROTATING DIRECTION
800 cc
740-130A
-NOTE: For timing verification, use a dial indicator
and scribe a mark on the flywheel for 25° BTDC.
Ignition Timing -Engine Warm
BTDC -25°/3250 RPM -0.162 in.
Not
Adjustable
~
'Y~
BlDC 18°
BlDC 14" . BlDC 2T
BlDC IT ! -BlDC 24°
BlOC 16° /J' BlDC 21l"
:::;I~~ _I::~
~3J(-
•
Rotating Direction
0744-033
2009 Arctic Cat Snowmobiles Factory Service Manual -all Models -www.ReadManuals.com

1000 cc
(Crossfire/M-Series)
Ignition Timing -Engine Warm
BTDC -14°/1800 RPM -0.057 in.
Not
Adjustable
0744-034
1000 cc (F-Series)
Ignition Timing -Engine Warm
BTDC -20°/3750 RPM -0.113 in.
Not
Adjustable
BlDC 16"
ifI
: BTDCIII"
BTDC 15" i BTDC 20"
BTDC 14" i BTDC 22"
:::~~ i~::~
BlDC 8"~ _Ir= BlDC211"
I
•
Rotating Direction
2009 Arctic Cat Snowmobiles Factory Service Manual -all Models -www.ReadManuals.com
0744-035
1-39

Steering/Body Torque
Specifications
120 Sno Pro
Item
Tie Rod End (Spindle)*
Inner Tie Rod End/Steering*
Ski Shock/Shock Mount
A-Arm/Spindle
A-Arm/Chassis
Ski/Spindle
CrossfirelM-Series
Ski
Handlebar Adjuster Block/Post (Standard)
Handlebar Adjuster (Sno Pro)
Steering Post Mounting Block
Steering Post/Stop*
Steering Tie Rod/Shaft Arm*
Steering ArmlTie Rod
Steering PostlTie Rod*
Steering Link/Steering Arm
Spindle ArmlTie Rod
Suspension Arm/Spindle (Upper)
Suspension Arm/Spindle (Lower) (Crossfire)
Suspension Arm/Spindle (Lower) (M-Series)
Sway Bar Link/Front Arm (Crossfire)
Shock Absorber/Spindle
Front Suspension Arm/Chassis* (Upper)
Front Suspension Arm/Chassis* (Lower)
Steering Post/Chassis*
Steering Support/Chassis**
Center Steering Link/Steering Arm*
Gas Tank/Steering Support
* w/Green Loctite #609
** w/Blue Loctite #243
1-40
Torque
ft-Ib
15
20
20
30
30
20
35
120 in.-Ib
20
96 in.-Ib
30 30
30
30
20
30
30
40
30
96 in.-Ib
20
30
30
30
20
20
96 in.-Ib
BearcatIF-SerieslT-SerieslZ1
Item
Ski
Spindle Arm/Spindle**
Suspension Arm/Spindle
Front Suspension Arm (Upper)
Front Suspension Arm (Lower)
Steering Arm/Spindle*
Steering Arm/Suspension Mounting Bracket
Sway Bar Mounting Bracket/Suspension Mounting Bracket
Tie Rod Jam Nut**
Spindle Arm and Steering ArmlTie Rod*
Steering Post/Chassis*
Steering Post/Steering Tie Rod*
Steering Tie Rod/Steering Arm
Drag Link/Steering and Spindle Tie Rods*
Steering Post/Suspension Mounting Bracket*
Drag Link/Steering Arm (Bearcat/F-SerieslT-Series)**
Drag Link/Steering Arm
(Z1)**
Shock Absorber/Shock Mounting Frame
(Bearcat/F-SerieslT-Series)
Shock Absorber/Shock Mounting Frame (Z1)
Bearing Cap/Spindle**
Upper Bearing Bracket/Support Plate**
Shock Absorber/Spindle
Suspension Mounting Bracket/Chassis (Lower)
Suspension Mounting Bracket/Chassis (Upper)
Steering Support Plate/Steering Support
Shock Mount Frame/Suspension Mounting Bracket
Shock Mount Frame/Front Upper Frame
Spindle Retainer/Spindle**
Front Bumper (Bearcat)
Rear Bumper/Heat Exchanger**
(Bearcat/F-SerieslT-Series)
Rear Bumper/Heat Exchanger** (Upper)
(Z1)
Rear Bumper/Heat Exchanger** (Lower) (Z1)
Rear
RacklTunnel (Bearcat XT)
* w/Green Loctlte #609
** w/Blue Loctite #243
2009 Arctic Cat Snowmobiles Factory Service Manual -all Models -www.ReadManuals.com
Torque
ft-Ib
26
30
32
32
32
40
20
120 in.-Ib
13
30
35 35
30
35
35
12
120 in.-Ib
32
32
13
96 in.-Ib
32
96 in.-Ib
20
96 in.-Ib
96 in.-Ib
20
13
32
25
25
20
20

Drive System
Specifications
Drive Clutch/Driven
Pulley-Related
Specifications
ALIGNMENT BAR
MODEL
OFFSET CENTER-
PIN TO-CENTER
OFFSET FLOAT
Crossfire/M-Series 0644-427 11.50" 1.655" None
Z1ITZ1 /Bearcat Z1 XT 0644-727 10.20" 1.655" None
Bearcat 570/F-Series/ 0644-496 11.50" 1.507" None
T-Series
& CAUTION
Do not allow the driven pulley to "float" on the output
shaft or damage to the driven pulley will occur.
Parallelism
800 eel 1 000 ee/11 00 ee
=
---'---~ ---
C J
;9 C
~
--r-
0.060 in. ~ 0.040 in.
0743-410
-NOTE: See Section 6 in this manual for alignment
and parallelism procedures.
Arctic Cat Drive Belt
Dimensions
BELT PIN LENGTH WIDTH
*0627-046 46 ± 3/16 inch 1 29/64 inch
*0627-047 4317/32 ± 3/16 inch 1 29/64 inch
**0627-060 46 ± 3/16 inch 1 29/64 inch
**0627-066 43 17/32 ± 3/16 inch 1 29/64 inch
**0627-067 45 13/32 ± 3/16 inch 1 13/32 inch
*Double-Cog High Performance Belt w/Hard Compound
**Double-Cog High Performance Belt w/High COF Compound
-NOTE: The difference between Drive Belt (pIn
0627-046) and Drive Belt (pIn 0627-060) is the hard
ness. The Drive Belt (pIn 0627-060) is more flexi
ble, and if used in place of Drive Belt (pIn 0627-
046), the engine will run at a lower RPM.
Drive System
Components
A list of Arctic Drive Clutch and Driven Pulley com
ponents that are available through the Arctic Cat Ser
vice Parts Department can be found in the Quick
Reference Guide. This information will be useful
when doing any fine-tuning on the drive system.
2009 Arctic Cat Snowmobiles Factory Service Manual -all Models -www.ReadManuals.com 1-41

Gear Case Performance Calibrations
Engine RPM
Drive
Gear Ratio 6200 6400 6600 6800 7000 7200 7400 7600 7800 8000 8200 8400 8600 8800 9000
Sprocket
Vehicle Speed (mph)
66 54 91 94 97 100 103 106 109 112 114 117 120 123 126 129 132
65 55 88 91 94 96 99 102 105 108 111 113 116 119 122 125 128
64 56 85
88 91 93 96 99 102 104 107 110 112 115 118 121 123
63 57 82 85 88 90 93 96 98 101 103 106 109 111 114 117 119
62 58 80 82 85 87 90 92 95 98 100 103 105 108 110 113 115
61 59 77 79 82 84 87 89 92 94 97 99 102 104 107 109 112
9 Tooth
60 60 74 77 79 82 84 86 89 91 94 96 98 101 103 106 108
(2.52" pitch)
59
61 72 74 77 79 81 84 86 88 91 93 95 98 100 102 104
58 62 70
72 74 76 79 81 83 85 88 90 92 94 97 99 101
57 63 67 70 72 74 76 78 80 83 85 87 89 91 93 96 98
56 64 65 67 69 71 74 76 78 80 82 84 86 88 90 92 95
55 65 63 65 67 69 71 73 75 77 79 81 83 85 87 89 91
54 66 61 63 65 67 69 71 73 75 77 79 81 83 84 86 88
66 54 101 104 108 111 114 117 121 124 127 130 134 137 140 143 147
65 55 98 101 104 107 110 113 117 120 123 126 129 132 136 139 142
64 56 95
98 101 104 107 110 113 116 119 122 125 128 131 134 137
63 57 91 94 97 100 103 106 109 112 115 118 121 124 127 130 133
62 58 88 91 94 97 100 103 106 108 111 114 117 120 123 125 128
61 59 85 88 91 94 97 99 102 105 108 110 113 116 119 121 124
10 Tooth
60 60 83 85 88 91 93 96 99 101 104 107 109 112 115 117 120
(2.52" pitch)
59
61 80 83 85 88 90 93 95 98 101 103 106 108 111 114 116
58 62
77 80 82 85 87 90 92 95 97 100 102 105 107 110 112
57 63 75 77 80 82 84 87 89 92 94 97 99 101 104 106 109
56 64 72
75 77 79 82 84 86 89 91 93 96 98 100 103 105
55 65 70
72 74 77 79 81 84 86 88 90 93 95 97 99 102
54 66 68
70 72 74 76 79 81 83 85 87 89 92 94 96 98
66 54 96 99 102 106 109 112 115 118 121 124 127 130 134 137 140
65 55 93 96 99 102 105 108 111 114 117 120 123 126 129 132 135
64 56 90
93 96 99 102 105 107 110 113 116 119 122 125 128 131
63 57 87 90 93 95 98 101 104 107 110 112 115 118 121 124 126
62 58 84 87 90 92 95 98 100 103 106 109 111 114 117 119 122
61 59 81 84 87 89 92 95 97 100 102 105 108 110 113 116 118
8 Tooth
60 60 79 81 84 86 89 91 94 97 99 102 104 107 109 112 114
(3.0" pitch)
59
61 76 79 81 84 86 88 91 93 96 98 101 103 106 108 111
58 62 74 76 78 81 83 86 88 90 93 95 97 100 102 105 107
57 63 71 74 76 78 80 83 85 87 90 92 94 97 99 101 103
56 64 69
71 73 76 78 80 82 84 87 89 91 93 96 98 100
55 65 67
69 71 73 75 77 80 82 84 86 88 90 92 95 97
54 66 64
67 69 71 73 75 77 79 81 83 85 87 89 91 94
Shaded rows indicate existing
tooled gear ratios
1-42
2009 Arctic Cat Snowmobiles Factory Service Manual -all Models -www.ReadManuals.com

Drive System Torque
Specifications
120 Sno Pro
Item Torque
ft-Ib
Centrifugal Clutch** 20
Secondary Sprocket** 20
Drive Sprocket Bearing/Chassis 20
BearcatIF-SerieslM-SerieslCrossfireIT-SeriesIZ1
Drive Clutch
Spider*
Spider Retainer Nut*
Drive Clutch Cover**
Cam Arm Pin Lock Nut
Cam Arm Set Screw*
Drive Clutch/Ring Gear*
Driven Pulley
Driven Shaft Jam Nut
Torque Bracket
Brakeline Fitting/Caliper
Brakeline/Master Cylinder
Torque Bracket Cover
Movable Sheave
Speedometer Sensor Bracket
Gear Case/Chassis
Brake Caliper Housing/Chassis
Outside Caliper Housing/Inside Caliper Housing
Gear Case Cover
Gear Case Drain Plug
Driveshaft/Output Shaft Cap Screw**
Driveshaft/Brake Disc Retaining Nut
Shift Actuator/Gear Case
*w/Green Loctite #620
**w/Blue Loctite #243
55 250
85
120 in.-Ib
11
19 in.-Ib
22
32
40
66 in.-Ib
10.5
21
72 in.-Ib
72 in.-Ib
17
20
20
17
12.5
12
70
120
41 in.-Ib
Rear Suspension
Torque Specifications
120 Sno Pro
Item
Torque
ft-Ib
End Cap/Rail 78 in.-Ib
Axle Housing/Rail 20
Rear Arm/Bracket* 20
Rear Wheel Axle* 20
Cross-Brace Axle/Rail* 20
Idler AxlelTunnel* 20
* w/Blue Loctite #243
Bearcat XT
Item
Wear Strip/Rail
End Cap/Rail
Mounting Block/Rail
Idler Wheel/Mounting Block
Slide Block/Rail
Pivot Arm/Idler Arm
Rear Arm/Rail
Rear Arm/Idler Arm
Front Arm/Rail
Idler Wheel/Shock Bracket -Rail
Idler Wheel/Pivot Assembly -Rail
Rear Arm Shock Pivot Axle/Rail
Front Arm Shock Bracket Axle/Rail
Rear Arm Limiter/Rail*
Front Rail Support/Rail*
Limiter Strap/Rail Support
Spring Slide Block/Rail
Outer Idler Wheel Mounting Block/Rail
Articulating Skid Frame/Rail
RaillTunnel
Crossfire/Crossfire R
Wear Strip/Rail
End Cap/Rail
Mounting Block/Rail
Idler Wheel/Mounting Block
Spring Slide/Slide Block -Rail (Standard)
Spring Slide/Slide Block -Rail (R)
Pivot Arm/Idler Arm (R)
Idler Wheel Axle/Rail
Rear Arm/Rail
Rear Arm Limiter/Rail*
Front Arm Mounting Bracket/Rail (R)
Rear Shock Pivot/Inner Idler Wheel -Rail
Front Arm Shock Axle/Rail
Front Rail Support/Rail* (Standard/Sno Pro)
Front Rail Support/Rail* (R)
Front Arm/Rail (Standard/Sno Pro)
Front Arm/Mounting Bracket
(R)
Limiter
Strap/Rail Support
Pivot Assembly/Rail
Track Adjuster Bracket/Rail
Rear Rail Support/Rail
Inner Idler Wheel/Rail
RaillTunnel
M-Series
Wear Strip/Rail
End Cap/Rail
Mounting Block/Rail
Inner Idler Wheel/Mounting Block
Idler Wheel Axle/Rail
Rear Arm/Rail
Idler Arm/Rear Arm
Rear Arm Limiter/Rail Support
Front Arm Shock Axle/Rail
Front Rail Support/Rail
Outer Idler Wheel/Mounting Block
Front Arm/Rail
Limiter Strap/Rail Support
Track Adjuster Bracket/Rail
RaillTunnel
* w/Blue Loctite #243
2009 Arctic Cat Snowmobiles Factory Service Manual -all Models -www.ReadManuals.com
Torque
ft-Ib
50 in.-Ib
80 in.-Ib
20
20
20
20
40
40
40
40
40
40
40
40
20
120 in.-Ib
20
20
20
40
50 in.-Ib
80 in.-Ib
20
20
40
34
20
40
40
40
20
40
40
20
30
40
40
120 in.-Ib
40
120 in.-Ib
20
40
40
50 in.-Ib
80 in.-Ib
20
20
40
40
34
20
40
20
20
40
120 in.-Ib
120 in.-Ib
40
1-43

F-SerieslZ1 Bearcat 5701T-Series
Item
Torque
ft-Ib
Item
Torque
ft-Ib
Wear Strip/Rail 50 in.-Ib Wear Strip/Rail 50 in.-Ib
End Cap/Rail 80 in.-Ib End Cap 80 in.-Ib
Mounting Block/Rail 20 Mounting Block/Rail 20
Idler Wheel/Mounting Block 20 Idler Wheel/Mounting Block 20
Rear Arm/Rail 40 Rear Arm/Rail 40
Rear Arm/Idler Arm 40 Rear Arm/Idler Arm 40
Spring Slide/Slide Block -Rail 20 Shock Pivot/Idler Wheel -Rail 20
Pivot Arm/Idler Arm 20 Spring Slide Block/Rail 20
Idler Wheel Axle/Rail 20 Pivot Arm/Idler Arm 20
Front Arm Shock Axle/Rail 40 Idler Wheel Axle/Rail 20
Front Arm/Rail 40 Front Arm Shock Axle/Rail 40
Rear Shock Pivot/Front Arm 20 Front Arm/Rail 40
Limiter Strap/Rail Support 120 in.-Ib Limiter Strap/Front Arm 120 in.-Ib
Rear Shock Pivot/Rail 40 Track Adjuster Bracket/Rail 120 in.-Ib
Rear Arm Limiter/Rail 50 Rear Arm Limiter/Rail* 50
Rail Support/Rail 20 Rail Support/Rail 20
RaillTunnel 40 Limiter Strap/Rail Support 120 in.-Ib
RaillTunnel 40
* w/Blue Loctlte #243
1-44
2009 Arctic Cat Snowmobiles Factory Service Manual -all Models -www.ReadManuals.com

Track Warranty Guidelines
Failure Mode Description Cause Warranty
Delamination (A) Condition in which the track fabric cleanly sepa-Result of poor adhesion between fabric and rubber material
rates or spreads apart from the rubber.
Tread/External
Lug Damage (B)
Condition in which the lugs are torn, cracked,
worn, or separated.
Most often a result of riding/spinning on rugged terrain ...
-rocks,
-jagged ice,
-metal objects,
-gravel roads.
High speed running with poor lubrication may produce gummy
external track lugs leading to separation.
Covered
Not Covered
Edge Tearing (C) A track failure that occurs along the side of the
track
in which tearing occurs either
parallel or
perpendicular to the track edge.
Rods out of center. If a rod is positioned off-center during track Covered
manufacturing, tearing along the side of the track may occur ± 1/2
in. from the edge.
Traction Product Cutting that occurs where a stud or pick is Often the result of contact having been made with a solid or jag-Not Covered
and Clip Damage attached to the track including tearing due to stud ged object (e.g. rocks, ice, metal, gravel, etc.).
Internal Lug
Damage
Broken Rods/
Missing Clip (D)
pull-through as well as track clips that are torn off.
Condition in which internal lugs are torn, worn, or Result of contact being made with a foreign object. Not Covered
cracked.
Track derailment can also cause this damage.
Condition
in which tracks are found to have bro-
Typically, results from track impacts and overheating. Not Covered
ken rods. Gummy tread sometimes accompanies
broken rods. Overheating of the rod can result from friction buildup due to poor
lubrication or riding at high continuous speeds for long periods of
Wear clip and rod section broken out and miss-time
in
minimal snow conditions.
ing.
Gummy tread and brown or dark brown rod color at the center
sometimes accompanies this failure.
Signs of wear strip material melted and sticking to the edges of
the wear clip. Also, wear clips that have started to turn blue in
color from overheating are all signs of operating the snowmobile
on minimal snow.
Large Deformities Condition
in which a track has
large deformities Manufacturing flaw.
of the Track or Air which may include air bubbles/pockets/voids
Covered
Bubbles within the track.
Lugs Torn Off
Outer Belt (B)
B
Condition normally found on deep lug tracks.
LugfTread Damage
A
Lug/
Tread Damag@
Typically, the result of operating a deep lug track on minimal snow Not Covered
at high rates of speed. This track is designed for deep snow
mountainous areas only.
c
734-522C
D
Broken Rod/Missing Clip
734-5228 734-522D
2009 Arctic Cat Snowmobiles Factory Service Manual -all Models -www.ReadManuals.com 1-45

Track Specifications
Below is a listing of drive tracks for Arctic Cat snow
mobiles with its specifications.
-NOTE: On the M-Series, measurement is from the
bottom of the wear strip at the point of the shock
pad on the
slide rail. All tracks are 15 in. wide
except for 120 Sno Pro (11 in.), Crossfire R (14 in.),
and Bearcat XT (20 in.). All models at 20 Ib except
M-Series (10 Ib).
Front Suspension
Specifications
SWAVBARS
SKI SHOCK SPRINGS
-NOTE: All springs have a 0.331" wire diameter
except 120 Sno Pro (0.235") and Z1m1 (0.343").
Model Free Rate LBI # of Coils Tab
Length Inch
F5fT500fT570 11.25" 90 6.2* 18.2** NO
M6/M8/M1000 (STO) 12.50" 120 12.75 YES
F 570 9.36" 90 8.5 NO
Bearcat 5701 10.10" 110 8.4 NO
Bearcat 570 XT
F8 (STO) 12.50" 95 14 YES
Crossfire (STO) 13.50" 120 12 NO
Z1fTZ1 10.50" 110 9.0 YES
120 Sno Pro 6.97" 85 9.0 NO
Crossfire R 13.00" 125 11.5 NO
Bearcat Z1 XT 10.10" 90 9.6 NO
* Active Coils
** Total Coils
1-46
Rear Suspension
Specifications
FRONT ARM SPRINGS
Model Free Length Rate LBllnch
Bearcat 570 9.5" 110
Bearcat XT 9.5" 140
F 570 9.5" 90
F5fT500fT570lZ1 fTZ1 7.75" 110
Crossfire/M-Series 7.75" 135
Crossfire R 8.0" 190
F8 8.25" 90/250
F-Series Sno ProlZ1 Turbo Sno Pro 8.25" 100/250
REAR ARM SPRINGS
0730-218
* Square wire
-NOTE: The wire diameter and length of the spring
have a large influence over the valving of the
shocks. A longer spring in areas (0) and (E) can be
selected if cut off to match the original spring.
Replacement springs must match the original
spring in areas (0) and (E).
2009 Arctic Cat Snowmobiles Factory Service Manual - all Models -www.ReadManuals.com

Shock Absorber
Specifications
Below is a list of shock absorbers used on the front and
rear suspensions
of Arctic Cat snowmobiles. Specifi
cations given for each shock absorber include col
lapsed and extended length, stroke, and piston depth
(if applicable).
If replacing a shock absorber, always
select a shock absorber with the same length, both col
lapsed and extended.
SKI SHOCK
Model
Collapsed Extended
Stroke
Piston
Length Length Depth
Bearcat 570/F5/F
5701 11.55" 17.50" 5.95" N/A
T500fT570
Crossfire 500 12.55" 18.75" 6.20" N/A
120 Sno Pro 7.78" 9.49" 1.71" N/A
Bearcat XT 10.67" 16.00" 5.33" N/A
Z1 fTZ1 fTZ1 Turbo 11.55" 17.50" 5.90" N/A
Crossfire 600/800/1 000 12.13" 18.72" 6.59" 1.40"
(STO)/Crossfire R
Crossfire Sno Pro 12.60" 18.80" 6.20" 6.97"
F8 (STO)/F8 LXR 11.47" 16.70" 5.21" 6.50"
F-Series Sno Prol 12.30" 16.75" 4.45" 7.00"
Z1 Turbo Sno Pro
M-Series (STO) 11.56" 17.55" 5.99" 1.25"
M-Series Sno Pro 12.00" 17.55" 5.55" 6.68"
FRONT ARM SHOCK
Model
Collapsed Extended
Stroke
Piston
Length Length Depth
Bearcat XT
8.42" 12.49" 4.07" N/A
F5/F 570lZ1 8.43" 12.53" 4.10" N/A
Bearcat 5701 8.09" 11.78" 3.69" N/A
Crossfire 500fT-Series
Crossfire R 8.17" 11.76" 3.59" 0.58"
F8 (STO)/F8 LXR 8.55" 12.49" 3.94" 4.85"
Crossfire 600/800/1 000 8.54" 12.51" 3.97" 0.62"
(STO)I
F-Series Sno Pro/Z1
Turbo Sno Pro
M-Series 8.11" 11.25" 3.14" 0.58"
REAR ARM SHOCK
Model
Collapsed Extended
Stroke
Piston
Length Length Depth
Bearcat
570fT-Series 10.91" 16.69" 5.78" N/A
Crossfire 500 9.89" 14.50" 4.61" N/A
F5 10.00" 15.00" 4.61" N/A
F 570 9.92" 15.00" 5.08" N/A
Bearcat XT 10.89" 16.67" 5.78" N/A
Z1 9.87" 14.51" 4.61" N/A
Crossfire (STO)I 9.88" 14.37" 4.48" 0.90"
Crossfire R
Crossfire Sno Pro/M- 11.10" 16.00" 4.90" 5.77"
Series
F8 (STO)/F8 LXR 9.89" 14.53" 4.64" 5.80"
F-Series Sno ProlZ1 10.13" 14.53" 4.40" 5.70"
Turbo Sno Pro
Idler Wheel Dimensions
Model Location 0.0. Bearing 1.0.
All Inside Rails 5.63 in. 0.787 in.
All Idler Arm 7.12 in. 1.181 in.
AII** Inside Rear Axle 7.12 in. 0.787 in.
F-Seriesl Outside Front 5.63 in. 0.787 in.
T-Series/Z1
F-Seriesl Outside Rear Axle 7.12 in. 0.787 in.
T-Series/Z1
M-Series* Inside Rear Axle 8.00 in. 0.787 in.
M-Series* Outside Rear Axle 8.00 in. 0.787 in.
Bearcat XT Rear Axle 6.38 in. 0.787 in.
* 8.00 in. idler wheel cannot be used with standard slide rails.
** Except M-Series
2009 Arctic Cat Snowmobiles Factory Service Manual -all Models -www.ReadManuals.com 1-47

SECTION 2 -ENGINE
TABLE OF
CONTENTS
Engine -120 Sno Pro .............................................. 2-2
Engine -Bearcat 570/F 5701T570 ......................... 2-22
Engine -Crossfire 500/600 -M-Series 600 ........... 2-47
Engine -Crossfire 800/1000 -
M-Series 800/1 000 ............................................. 2-76
Engine - F -Series 500/600 -T-Series 500 ........... 2 -109
Engine -F-Series 800/1000 ................................ 2-137
Engine -Bearcat Z1 XTITZ1/Z1 .......................... 2-167
Troubleshooting Engine (2-Stroke
Carbureted Models) ......................................... 2-203
Troubleshooting Engine (2-Stroke EFI Models) ... 2-205
Troubleshooting Engine (4-Stroke) ...................... 2-209
2009 Arctic Cat Snowmobiles Factory Service Manual -all Models -www.ReadManuals.com 2-1

Engine - 1 20 Sno Pro
This engine section has been organized into sub-sec
tions showing a progression for the complete servicing
of the Arctic
Cat 120 cc (120 Sno Pro) engine. For
consistency purposes, this section shows a complete
and thorough progression; however, for efficiency
it
may be preferable to remove and disassemble only
those components needing to be addressed and
to ser
vice only those components. Also, some components
may vary from model to model. The technician should
use discretion and sound judgment. For engine-related
servicing procedures, see Section 3
of this manual.
-NOTE: Some illustrations and photographs used
in this section are used for clarity purposes only
and are not designed to depict actual conditions.
-NOTE: Critical torque specifications are located
in Section 1 of this manual.
SPECIAL TOOLS
A number of special tools must be available to the
technician when servicing the engine.
Description pIn
V
Blocks 0644-022
Surface Plate 0644-016
Ball Hone 0644-290
-NOTE: Special tools are available from the Arctic
Cat Service Parts Department.
Table of Contents
Removing ............. ................................................... 2-2
Disassembling ......................................................... 2-3
Servicing Components ....
........................................ 2-8 Assembling ............................................................ 2-16
Installing ................................................................ 2-21
Removing Engine
-NOTE: The drive chain must be removed in order
to remove the engine (see Drive Chain and Sprock
ets sub-section in Section 6).
1. Disconnect the choke and throttle cables from the
carburetor; then on each cable, loosen the adjust
ment
jam nut closest to the carburetor and remove
the cables from the bracket. Route the cables out
of the way.
A046A
2. Remove the two cap screws securing the steering
post
to the steering post support. Account for two
bearing halves, two lock nuts, and a bearing
retainer.
A023A
3. Pull the steering post up and back and then out of
the lower steering post bearing.
4. Remove the two lock nuts securing the tie rods to
the steering post; then remove the tie rods from the
steering post. Place the steering post out of the
way on the right-hand side
of the engine compart
ment.
A024
5. Cut the cable tie; then disconnect all wires (a total
of four) at the front of the engine. Route them out
of the way.
2-2 2009 Arctic Cat Snowmobiles Factory Service Manual -all Models -www.ReadManuals.com

6. Turn the gas tank shut-off valve to the CLOSED
position.
& WARNING
Whenever any maintenance or inspection is made on
a fuel system when there may be fuel leakage, there
should be no welding, smoking, open flames, etc., in
the area.
7. Disconnect the fuel hose from the carburetor.
-NOTE: Be prepared to wipe up any fuel spillage.
8. Pull the recoil starter rope out approximately 60
em (24 in.); then tie a slip-knot in the starter rope
below the console and allow the rope to slowly
retract against the starter case.
9. Remove the knot at the handle and remove the
handle; then thread the rope through the bushing in
the console. 10. At this point, scribe a line at the front of the engine
and measure the distance between the crankshaft
and the driveshaft. Record the measurement for
installing purposes.
11. Lay the snowmobile on its side.
-NOTE: A piece of cardboard should be used to
protect the finish.
12. Using a flat-blade screwdriver, remove the four
belly pan plugs covering the engine mounting cap
screws; then remove the cap screws. Account for
eight washers and four lock nuts.
A049
-NOTE: The front center plug is to access the oil
drain plug.
13. Place the snowmobile in the upright position; then
on the left-hand side
of the engine, remove the
three cap screws securing the engine and brake
bracket to the front end.
14. Remove the engine from the engine compartment. Disassembling Engine
1. Remove the oil drain plug and drain the oil; then
install the oil plug and tighten securely.
GM300D
2. Remove the wing nut securing the air cleaner end
cap to the air cleaner housing.
2009 Arctic Cat Snowmobiles Factory Service Manual -all Models -www.ReadManuals.com

3. Remove the cap screw and flange nuts securing
the air cleaner housing to the carburetor and
engine.
GF314D
4. Remove the air breather hose from the air cleaner
housing; then remove the air cleaner housing from
the carburetor. Account for the gasket.
A001
GF316D
5. Mark the locations of the springs for assembly;
then disconnect the rod and spring from the carbu
retor.
GF208D
6. Slide the carburetor off the mounting studs.
Account for a gasket, insulator block, and a gas
ket.
7. Remove the recoil starter/fan housing assembly.
GM201E
8. Remove the screws securing the recoil starter pul
ley
to the flywheel; then remove the nut securing
the flywheel to the crankshaft.
2-4
2009 Arctic Cat Snowmobiles Factory Service Manual -all Models -www.ReadManuals.com

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