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ARCTIC CAT F 800 LXR OPERATOR'S MANUAL

 2012
Operator’s Manual
Crossover/Mountain/
Performance Models
F 800 LXR/Sno Pro
F 1100 LXR/Sno Pro/LTD
F 1100 Turbo LXR/Sno Pro/LTD
M 800/Sno Pro/HCR
M 1100/Sno Pro/LTD
M 1100 Turbo/Sno Pro/LTD/HCR
XF 800 LXR/Sno Pro/High Country
XF 1100 LXR/Sno Pro/LTD
XF 1100 Turbo LXR/Sno Pro/LTD

S H AR E OUR PA SSION.
TM

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 Limited Warranty
Arctic Cat Inc. (hereinafter referred to as Arctic Cat) extends a limited warranty on each new Arctic Cat
Snowmobile it assembles and on each part and accessory assembled or sold by Arctic Cat. The warranty
is extended to the original retail purchaser only on parts and accessories sold through an authorized
Arctic Cat Snowmobile dealer. Warranty on snowmobiles is extended to the original retail purchaser;
however, the balance of the unused warranty may be transferred to another party. Warranty coverage is
only available in the country in which the original retail purchase occurs to the original retail purchaser
resident in that country or to a transferee resident in that country of the balance of the unused warranty.
Arctic Cat warrants only the products it assembles and/or sells and does not warrant that other products
will function properly when used with an Arctic Cat Snowmobile or will not damage the Arctic Cat
Snowmobile. Arctic Cat does not assume any liability for incidental or consequential damages.
Arctic Cat will repair or replace, at its option, free of charge (including any related labor charges), any parts
that are found to be warrantable in material or workmanship. This repair work MUST be done by an
authorized Arctic Cat Snowmobile dealer. No transportation charges, rental charges, or inconvenience costs
will be paid by Arctic Cat. The warranty is validated upon examination of said parts by Arctic Cat or an
authorized Arctic Cat Snowmobile dealer. Arctic Cat reserves the right to inspect such parts at its factory for
final determination if warranty should apply.
The warranty periods are as follows:
1. For snowmobiles used for recreational purposes:
—If purchased between May 1 and November 30, warranty expires ONE (1) YEAR from December 1
of the current year.
—If purchased between December 1 and April 30, ONE (1) YEAR from the date of sale.
2. For snowmobiles used for commercial purposes (including rental operations), ONE (1) YEAR from
the date of invoice and/or 5000 MILES whichever comes first (non-transferable).
3. THIRTY (30) DAYS from date of sale of snowmobile on Arctic Cat supplied batteries.
4. THIRTY (30) DAYS from date of sale for all dealer installed genuine Arctic Cat service parts and
accessories.
5. UNTIL EXPIRATION OF THE NEW PRODUCT WARRANTY (paragraphs 1 and 2 above) for all
eligible replacement parts on new product.
Exclusions to this warranty include normal wear, abuse (i.e. a track run on marginal snow conditions
without proper lubrication or additional idler wheels), and the following parts:
Fuel Filter Light Bulbs Windshield Drive Belt Torn or Punctured
Upholstery
Wear Bars Brake Pads Spark Plugs Drive Clutch/Driven Pulley Wear Parts
Wear Strips Shock Absorber(s) - Standard* Shock Absorber(s) - Rebuildable**
* Limited to one (1) year or 1000 miles of “normal” riding conditions - replace for defective or leaking shock,
corroded or pitted shaft, peeling chrome.
** Limited to one (1) year or 1000 mile of “normal” riding conditions - rebuild for leaking shock (warranted)
- replace for defective shock, corroded or pitted shaft, peeling chrome.
The following will VOID Arctic Cat’s warranty:
1. Failure to perform the proper break-in procedure and all related maintenance, storage procedures (if
stored for extended periods), and/or service as recommended in the Operator’s Manual.
2. Repairs and/or adjustments by anyone other than an authorized Arctic Cat Snowmobile dealer.
3. Use of an improper fuel mixture ratio.
4. Use of improper carburetor main jets.
5. Use of improper gasoline, lubricating oils, or spark plugs.
6. An accident or subjecting the snowmobile to misuse, abuse, or negligent operation.
7. Any modification, addition, or removal of parts unless instructed to do so by Arctic Cat.
8. Use of the snowmobile in any way for racing purposes.
9. Removal of the engine for use in another vehicle.
10. Removal or mutilation of the Vehicle Identification Number or Engine Serial Number.
11. Use of parts not sold or approved by Arctic Cat.
12. Track and tunnel damage resulting from either ice stud or hooker plate installation.
13. Damage due to improper transportation.
In consideration of the foregoing, any implied warranty is limited in duration to the various warranty
periods set forth. This warranty gives you specific legal rights, and you may also have other rights which
vary from state/province to state/province and country to country. Some jurisdictions do not allow
limitations on how long an implied warranty lasts, so the above limitations may not apply to you.

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 Table of Contents
Limited Warranty........................ Inside Front Cover Emergency Stopping......................................... 26
Foreword ............................................................... 1 Throttle/Ignition Monitor Switch......................... 26
Declaration of Conformity ..................................... 2 Varying Altitude Operation ................................ 27
Snowmobile Safety Rules ..................................... 3 Lubrication ..................................................... 29-30
General Information ......................................... 4-23 Chain Case ....................................................... 29
Snowmobile Identification ................................... 4 Rear Suspension............................................... 30
Control Locations ................................................ 4 Maintenance .................................................. 31-53
Gasoline-Oil ........................................................ 5 Periodic Maintenance Checklist ........................ 31
Engine Break-In .................................................. 6 Air Cleaner/Filter (1100 cc Turbo Models)......... 32
Drive Belt Break-In .............................................. 6 Fuel System ...................................................... 32
Cold Drive-Away Function (1100 cc Models) ...... 7 Checking Engine Oil Level (1100 cc Models).... 33
Speedometer/Tachometer................................... 7 Changing Engine Oil/Filter (1100 cc Models).... 33
Diagnostic Codes .............................................. 12 Coolant Level .................................................... 35
Handlebar Height/Tilt (M 800 Sno Pro/LTD/ Spark Plugs....................................................... 35
HCR/XF 800 High Country Models) ................ 13 Checking/Adjusting Valve Clearance (1100 cc
Handlebar Tilt.................................................... 13 Models)............................................................ 37
Speedometer/Tachometer Angle....................... 14 Checking/Adjusting APV Cables
Exhaust System ................................................ 14 (800 cc Models)............................................... 37
Air-Intake Silencer............................................. 14 Battery (Electric Start)....................................... 38
Cooling System ................................................. 14 Fuses ................................................................ 40
Battery (Electric Start)....................................... 14 Brake System .................................................... 41
Jump-Starting (1100 cc Models) ....................... 15 Burnishing Brake Pads...................................... 44
Drive Clutch and Driven Pulley ......................... 16 Drive Belt........................................................... 44
Drive Clutch/Driven Pulley Alignment................ 16 Track Tension .................................................... 46
Fuel Pump......................................................... 16 Track Alignment................................................. 47
Shock Absorbers............................................... 17 Suspension ....................................................... 48
Standard Track (XF/F Models) .......................... 17 Lights................................................................. 51
Paddle Track (XF High Country/M Models) ....... 17 Ski Wear Bars ................................................... 52
Track Studs (XF/F Models)................................ 17 Adjusting Ski Stance (M/XF Models)................. 53
Reverse Operation ............................................ 18 Rail Wear Strips ................................................ 53
Access Panel/Hood (Removing/Installing) ........ 20 Performance Tips........................................... 54-55
Removable Seat................................................ 21 Preparation for Storage.................................. 56-57
Towing ............................................................... 21 Preparation after Storage.................................... 58
Arctic Power Valve (APV) System U.S. EPA Emission Control Statement/Warranty
(800 cc Models)............................................... 22 Coverage (U.S. Only) ...................................... 59
Exhaust Controlled Timing (ECT) System Change of Address, Ownership, or Warranty
(800 cc Models)............................................... 22 Transfer............................................................ 61
Operating Instructions.................................... 24-28 Warranty Procedure/Owner
Starting and Stopping Engine ........................... 24 Responsibility ......................... Inside Back Cover
Braking .............................................................. 25

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 Reference Information
Write the appropriate information for your Arctic Cat Snowmobile in the spaces
below.
Always use these numbers when referring to your snowmobile.
Model: _________________________________________________
Date of Purchase: ________________________________________
Vehicle Identification Number: _______________________________
Engine Serial Number: _____________________________________
Your Arctic Cat Dealer: ___________________________________
Address: _______________________________________________
Phone: _________________________________________________

! WARNING
A snowmobile is a very high performance vehicle. Because it does accelerate
rapidly and is capable of very high speeds, it should not be operated by a nov-
ice or an inexperienced operator. Never accelerate rapidly or drive at high speed
beyond the limits of visibility or without being totally familiar with the terrain
and what lies in front of you. Obey speed limits and never operate at speeds
that do not allow adequate maneuvering and stopping distances. Read and
study the entire Operator’s Manual and Safety Handbook.
Failure to follow this warning could result in personal injury to yourself or others.

Personal Injury
• To avoid injury to yourself and others, NEVER operate the snowmobile without
first reading and understanding this manual and the Snowmobile Safety Hand-
book; then follow the instructions and heed the warnings given.
• USE COMMON SENSE.
• DON’T DRINK and DRIVE.
• STAY IN CONTROL at ALL TIMES.
• TELL YOUR FRIENDS. If you see a friend operating a snowmobile recklessly, at
excessive speeds, while intoxicated, or in other unsafe ways, don’t wait until it is
too late to warn of the consequences of snowmobile misuse. Such conduct
endangers everyone. TAKE AN ACTIVE ROLE IN THE SAFETY OF YOUR-
SELF AND OTHERS.

Parts and Accessories

When in need of replacement parts, oil, or accessories for your Arctic Cat Snowmo-
bile, be sure to only use GENUINE ARCTIC CAT PARTS, OIL, AND ACCESSO-
RIES. Only genuine Arctic Cat parts, oil, and accessories are engineered to meet the
standards and requirements of your Arctic Cat Snowmobile. For a complete list of
accessories, refer to the current Arctic Cat Accessory Catalog. To aid in service and
maintenance procedures on these snowmobiles, an Illustrated Parts Manual and a
Service Manual are available through your local Arctic Cat Snowmobile dealer.

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 Foreword
Congratulations! You have chosen a quality Arctic Cat Snowmobile designed and
assembled to give dependable service. Be sure, as the owner/operator of an Arctic
Cat Snowmobile, to become thoroughly familiar with its basic operation, mainte-
nance, and off-season storage procedures. Read this manual and the accompanying
Snowmobile Safety Handbook before operating the snowmobile to learn safe and
proper use of your new Arctic Cat Snowmobile. Always operate the snowmobile
within your level of skill and current terrain conditions.
The Operator’s Manual, Snowmobile Safety Handbook, and Snowmobile Decals
display the words Warning, Caution, and Note to emphasize important information.
The symbol ! WARNING identifies personal safety-related information. Be
sure to follow the directive because it deals with the possibility of serious personal
injury or even death. A CAUTION identifies unsafe practices which may result
in snowmobile-related damage. Follow the directive because it deals with the possi-
bility of damaging part or parts of the snowmobile. The symbol  NOTE: identi-
fies supplementary information worthy of particular attention.
This manual covers operator-related maintenance, operating instructions, and off-
season storage instructions. If major repair or service is ever required, contact an
authorized Arctic Cat Snowmobile dealer for professional service.
At the time of publication, all information and illustrations were technically cor-
rect. Some illustrations used in this manual are used for clarity purposes only and
are not designed to depict actual conditions. Because Arctic Cat Inc. constantly
refines and improves its products, no retroactive obligation is incurred.
This Operator’s Manual should be considered a permanent part of the snowmobile
and must remain with the snowmobile at the time of resale. If the snowmobile
changes ownership more than once, contact Arctic Cat Inc., Service Department,
P.O. Box 810, Thief River Falls, MN 56701, for proper registration information.
This manual was prepared by the Product Service and Warranty Department of
Arctic Cat Inc.
Every Arctic Cat Snowmobile meets or exceeds the standards of the Snowmobile
Safety and Certification Committee and displays the SSCC decal. Arctic Cat Inc.
endorses and encourages the safe use of all snowmobiles. Always wear a helmet
and eye protection. Drive with caution, observe all state and local regulations, and
respect the rights of others. ISMA members like Arctic Cat do their part to improve
trails, sponsor events, and generally support the sport of snowmobiling. As a mem-
ber of the National Snowmobile Foundation, Arctic Cat Inc. promotes snowmobil-
ing through education, charity, and research programs.
© 2011 Arctic Cat Inc.
Printed in U.S.A.

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 Declaration of Conformity
Application of council directives: EMC Directive 2004/108/EC
Issued by European Commission. EC Machinery Directive 2006/42/EC

Type of Equipment: Snowmobile

Brand Name: Arctic Cat
Model Numbers:

S2012F1NANUSB S2012F8HEPUSG S2012M1NNAUSB S2012XFHSPUSO

S2012F1NELUSW S2012F8HEPUSO S2012M1NSPUSG S2012XFNANUSB
S2012F1NEPUSG S2012F8HLEUSW S2012M1NSPUSO S2012XFNELUSW
S2012F1NEPUSO S2012F8HLXUSB S2012M8H3EUSB S2012XFNLEUSW
S2012F1NLEUSW S2012F8HLXUSG S2012M8HHCUSW S2012XFNLXUSB
S2012F1NLXUSB S2012M1N3EUSB S2012M8HSEUSG S2012XFNLXUSG
S2012F1NLXUSG S2012M1NANUSB S2012M8HSEUSO S2012XFNNAUSB
S2012F1NNAUSB S2012M1NE3USB S2012M8HSPUSG S2012XFNTPUSB
S2012F1NTPUSG S2012M1NE4USG S2012M8HSPUSO S2012XFNTPUSG
S2012F1NTPUSO S2012M1NE4USO S2012XFHLXUSB S2012XFNTPUSO
S2012F1NTSUSB S2012M1NELUSW S2012XFHLXUSG S2012XFNTSUSB
S2012F1NTSUSG S2012M1NHCUSW S2012XFHSPUSB S2012XFNTSUSG
S2012F8HANUSB S2012M1NLEUSW S2012XFHSPUSG

Standards to which conformity is declared:

EMC: EN 55012, EN 61000-6-2
MACHINERY: EN 12100:2010
Manufacturer (if not issuing agent): Arctic Cat Inc.
601 Brooks Ave. S.
Thief River Falls, MN
56701 USA

I, the undersigned, hereby declare that the equipment specified above conforms to the
directive(s) and standard(s) as specified.

Brad Darling
Vice President/General Manager - Snowmobile Division

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 Snowmobile Safety Rules

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 General Information
Snowmobile These numbers are required by the dealer
Identification to complete warranty claims properly. No
The Arctic Cat Snowmobile has two warranty will be allowed by Arctic Cat
important identification numbers. The Inc. if the engine serial number or VIN is
Vehicle Identification Number (VIN) is removed or mutilated in any way.
stamped into the tunnel near the right- Always provide the snowmobile name,
side footrest and on a decal beneath the VIN, and ESN when contacting an autho-
seat. The decal also displays pertinent rized Arctic Cat Snowmobile dealer for
production information. The Engine parts, service, accessories, or warranty. If
Serial Number (ESN) is stamped into the the complete engine must be replaced,
crankcase of the engine. ask the dealer to notify Arctic Cat for
correct registration information.
Control Locations
Shown are the typical control locations
for Arctic Cat snowmobiles. Location of
a specific control will vary according to
model.

0726-383

XF 800/XF 1100/M 800/M 1100 Models

0745-832

F 800/F 1100 Models

0745-842

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 Gasoline-Oil Recommended Injection
Recommended Gasoline Oil (800 cc Models)
(1100 cc Models) The recommended oil to use in the oil-
injection system is either Arctic Cat APV
The recommended gasoline to use in these Synthetic 2-Cycle Oil (p/n 4639-349 - qt)
snowmobiles is 87 octane regular unleaded. or (p/n 5639-469 - gal.) or Formula SS
In many areas, oxygenates (either ethanol Semi-Synthetic Oil (p/n 5639-470 - qt) or
or MTBE) are added to the gasoline. Oxy- (p/n 5639-471 - gal.). These oils are spe-
genated gasolines containing up to 10% cially formulated to be used either as an
ethanol are acceptable gasolines. injection oil or as a pre-mix oil (for
 NOTE: The turbo models will break-in) and meets all of the lubrication
detect lower octane gasoline and requirements of the Arctic Cat snowmo-
reduced engine performance will bile engine.
result. It is recommended that 91
octane (minimum) gasoline be used CAUTION
in these models.
Any oil used in place of the recom-
When using ethanol blended gasoline, it is mended oil could cause serious
not necessary to add a gasoline antifreeze engine damage.
since ethanol will prevent the accumula- Recommended Engine Oil
tion of moisture in the fuel system.
(1100 cc Models)
CAUTION The recommended oil to use is Synthetic
Do not use white gas or gasolines 0W-40 Oil (p/n 5639-172 - qt) or (p/n
containing methanol. Only Arctic Cat 5639-173 - gal.).
approved gasoline additives should After the engine break-in period, the
be used. engine oil should be changed every 2500-
Recommended Gasoline 3000 miles on the non-turbo models or
(800 cc Models) 1500-2000 miles on the turbo models and
before prolonged storage.
The only recommended gasoline to use in
these snowmobiles is 91 octane (minimum). Filling Gas Tank
 NOTE: For optimum performance, Since gasoline expands as its temperature
use only 91 octane (minimum) gaso- increases, the gas tank must be filled to
line. its rated capacity only. Expansion room
must be maintained in the tank particu-
CAUTION larly if the tank is filled with cold gaso-
line and then moved to a warm area.
If a situation arises wherein 91 octane
gasoline is not available, 87 octane Also, if the snowmobile is to remain on a
gasoline can be substituted; how- trailer after filling the gas tank, the bed of
ever, do not prolong the usage of 87 the trailer must be maintained level to
octane gasoline as it will cause poor prevent gasoline from draining out
engine performance. through the gas tank vent hose.
In many areas, oxygenates (either ethanol ! WARNING
or MTBE) are added to the gasoline.
Oxygenated gasolines containing up to Always fill the gas tank in a well-ven-
10% ethanol are acceptable gasoline. Do tilated area. Never add gasoline to the
not use gasolines containing methanol. snowmobile gas tank near any open
flames or with the engine running.
DO NOT SMOKE while filling the gas
CAUTION tank. Do not sit on the snowmobile
Do not use white gas or gasolines without first installing the gas tank
containing methanol. Only Arctic Cat cap.
approved gasoline additives should
be used.

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 Break-In Gas/Oil Mixing During the break-in period, a maximum
Instructions (800 cc of 1/2 throttle is recommended; however,
Models) brief full-throttle accelerations and varia-
tions in driving speeds contribute to good
Before mixing gasoline and oil, make engine break-in. After one (1) tankful
sure the oil is at room temperature (20° break-in period, the snowmobile may be
C/68° F). Use a U.L. approved 22.7 l (6 taken to an authorized Arctic Cat Snow-
U.S. gal.) gasoline container for mixing mobile dealer for a checkup. This
the gasoline and oil. To properly mix the checkup is at the discretion and the
fuel at a 100:1 ratio, use the following expense of the snowmobile owner.
procedure:
CAUTION
CAUTION
DO NOT exceed the one (1) tankful
Never mix oil and gasoline in the limitation of a 100:1 gas/oil break-in
snowmobile gas tank. mixture. Continuous use of a gas/oil
mixture could cause spark plug foul-
1. Pour gasoline into the gasoline con- ing and excessive carbon buildup.
tainer until approximately half full.
1100 cc Models
2. Pour 236 ml (8 fl oz) of the recom-
mended 2-cycle oil into the gasoline This engine does not require any pre-
container. mixed fuel during the break-in period.
3. Install cap on gasoline container and
shake the mixture vigorously. CAUTION
DO NOT use premixed fuel in the
4. Fill the gasoline container with gaso- snowmobile gas tank. Engine dam-
line; then cap the gasoline container age will occur.
and shake the mixture vigorously.
To ensure trouble-free operation, careful
5. Using a fine-mesh screened funnel, adherence to the following break-in
pour the fuel mixture from the gaso- guidelines will be beneficial.
line container into the snowmobile
gas tank. 0-200 miles 1/2 Throttle (45 MPH-max)
200-400 miles 1/2-3/4 Throttle
! WARNING
400-600 miles 1/2-3/4 Throttle *
Always fill the gas tank in a well-ven-
tilated area. Never add gasoline to the * With occasional full-throttle operation.
snowmobile gas tank near any open To ensure proper engine break-in, Arctic
flames or with the engine running. Cat recommends that the engine oil and
DO NOT SMOKE while mixing fuel or filter be changed after 500 miles. This
filling the gas tank. service is at the discretion and expense of
the snowmobile owner.
Engine Break-In
The Arctic Cat engine (when new or Drive Belt Break-In
rebuilt) requires a short break-in period Drive belts require a break-in period of
before the engine is subjected to heavy approximately 25 miles. Drive the snow-
load conditions. mobile for 25 miles at 3/4 throttle or less.
By revving the engine up and down (but
800 cc Models not exceeding 60 mph), the exposed cord
Arctic Cat requires that the first tankful on the side of a new belt will be worn
of fuel be premixed at a 100:1 ratio in all down. This will allow the drive belt to
oil-injection models. gain its optimum flexibility and will
extend drive belt life.

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  NOTE: Before starting the snowmo- Speedometer/
bile in extremely cold temperatures, Tachometer
the drive belt should be removed and These snowmobiles are equipped with
warmed up to room temperature.
Once the drive belt is at room temper- different speedometer/tachometer styles.
ature, install the drive belt (see Drive Determine which style your model is
Belt sub-section in the Maintenance equipped with and use the appropriate
section). following information.
Indicator Icons (Standard
CAUTION Gauge)
Never run the engine with the drive Certain models are equipped with a stan-
belt removed. Excessive revving of dard gauge combination speedometer/
the engine could result in serious
engine damage and drive clutch fail- tachometer. Indicator icons are incorpo-
ure. rated within the speedometer/tachome-
ter. Also incorporated into the
Cold Drive-Away speedometer/tachometer is a digital read-
Function (1100 cc out screen.
Models)
On these models, there is a “cold drive-
away” function incorporated within the
engine.
 NOTE: When cold-starting the
engine, the coolant temperature
warning icon will illuminate and the
TEMP display on the readout screen
will begin to flash. With the engine in
this temperature range, the RPM
FZ003C
“limit” of the engine will be below
drive system engagement speed. As A. Oil Pressure/Low Oil
the engine warms, the coolant tem- B. Coolant Temperature
perature warning icon will begin to
flash, the TEMP display will continue C. Low Fuel
to flash, and the RPM “limit” of the
engine will increase allowing the D. Fuel Level
snowmobile to move without full- E. Service
throttle operation. When the engine
reaches proper operating tempera- F. High Beam
ture, the coolant temperature warn- G. Charging System (1100 cc Models)
ing icon and the TEMP display will
go out. RPM/MPH (kph)
By pushing the left button once, the RPM
CAUTION and MPH will be displayed (one on the
It is extremely important that the readout screen and one with the needle).
engine is properly warmed up before By pushing the button once again, the
subjecting the engine to high speed functions will be reversed.
operation or heavy loads. The engine
should be allowed to idle at least 3-4 By pushing the left button (with speed
minutes before it is operated at more being displayed) for more than two sec-
than 1/2 throttle. In extremely cold onds, the display will change between
conditions, the warm-up time will be standard mph or metric kph. Release the
longer. Cold seizure and piston scuff- button when desired display appears.
ing caused by insufficient warm-up
will not be covered by warranty. Also,
do not idle the engine for excessively
long periods of time.

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 With RPM displayed on the readout Coolant Temperature
screen by pushing and holding the left Warning Icon
button, maximum RPM will be displayed
on the readout screen. The maximum  NOTE: On the 1100 cc models
RPM readout will reset when the right when cold-starting the engine, the
button is pushed (while maximum RPM coolant temperature warning icon will
is displayed). illuminate, the readout screen will
display TEMP, and engine RPM limit
Odometer/Trip-Meter (1)/ will be below drive system engage-
Trip-Meter (2)/Hour- ment speed.
Meter/Clock When the engine reaches proper operat-
 NOTE: The clock is available on ing temperature, the coolant temperature
electric start models only. warning icon and TEMP display will
cease to flash.
By pushing the right button, the readout
screen will display odometer, trip-meter If the coolant temperature rises too far
(1), trip-meter (2), hour-meter, and clock. above proper operating temperature, the
To reset the trip meter with the trip meter coolant temperature warning icon will
displayed, push and hold the right button flash a warning (alert) and the engine will
until the display is cleared. The hour- “surge” to alert the operator. If the cool-
meter readout will not reset. ant temperature rises to a critical point
above proper operating temperature, the
Clock (Electric Start) coolant temperature warning icon will
With the clock selected on the readout cease flashing and will remain constantly
screen by pushing and holding the right illuminated.
button for two seconds, the option of  NOTE: If the coolant temperature
selecting the 12-hour or 24-hour clock is icon is constantly on, the engine will
available. Push the left button for 12-hour shut off if vehicle speed is reduced
display; push the right button for 24-hour to 1.5 kph (0.9 MPH) or slower.
display. At this point, the hours and min-
utes will begin to flash. Push the left but- CAUTION
ton to change the hour display; push the
right button to change the minute display At this point, take precautionary mea-
(either tap the buttons for individual num- sures such as changing to loose
snow terrain, shutting the engine off
ber display or push and hold the buttons (allowing the engine to cool down),
for rapid number display). and checking coolant level. If unable
 NOTE: During clock setting if nei- to either determine or remedy the
ther button (left, right) is pushed problem, take the snowmobile to an
authorized Arctic Cat Snowmobile
within a 5-second time period, the dealer for service. If not under war-
clock-setting mode will be exited ranty, this service is at the discretion
with changes saved. and expense of the snowmobile
Service Icon owner.
On electric start models, the icon should Charging System Warning
illuminate each time the key is turned to Icon (1100 cc Models)
RUN or START, and it should go out when
the engine starts. If the icon stays illumi- The Charging System Warning Icon is
nated (on electric start models) or it illumi- designed to warn the operator if the bat-
nates while the engine is running, the tery charging system is not functioning.
system is receiving input that is outside of The icon should illuminate each time the
its established parameters. If the icon illu- key is turned to RUN or START, and it
minates indicating an error, take the snow- should go out when the engine starts. If
mobile to an authorized Arctic Cat the icon stays illuminated or it illuminates
Snowmobile dealer for service. If not under while the engine is running, the battery is
warranty, this service is at the discretion not being charged, and the snowmobile is
and expense of the snowmobile owner. running on battery reserve power only.

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 If the Charging System Warning Icon
illuminates, you should, as soon as possi-
ble, take the snowmobile to an authorized
Arctic Cat Snowmobile dealer for ser-
vice. If not under warranty, this service is
at the discretion and expense of the
snowmobile owner. The engine WILL
NOT RUN without battery power.
Low Oil Warning Icon (800
cc Models) 0746-166
The Low Oil Warning Icon is designed to 2. Open the air bleed bolt located on
alert the snowmobile operator when the the oil pump (beneath the coolant
oil in the oil injection reservoir gets below tank) to purge air from the oil hose.
a prescribed level; however, it is highly
recommended that a visual verification of
the oil level in the reservoir be done prior
to operating the snowmobile. Once the
Low Oil Warning Icon illuminates during
operation of the snowmobile, the operator
must periodically monitor the level of oil
in the reservoir and must fill the reservoir
the next time gasoline is added to the gas
tank. The “alert level” of the Low Oil
Warning Icon is approximately equal to 1 PC016A
tankful of gasoline under normal operat-
ing conditions.  NOTE: When air can no longer be
heard purging from oil pump bleed,
Oil Pressure Warning Icon tighten the bleed bolt to 7.5 ft-lb.
(1100 cc Models)
The Oil Pressure Warning Icon indicates CAUTION
engine oil pressure, not the oil level; Do not attempt to start the engine
however, if the oil level is low, it may with the bleed bolt open.
affect oil pressure.
3. Start the engine. The warning icon
The icon should illuminate each time the should go out within five seconds.
ignition switch is turned to RUN or
START, and it should go out when the 4. If the warning icon does not go out,
engine starts. If the icon illuminates shut the engine off immediately and
while the engine is running, oil pressure repeat step 2; then repeat step 3.
has been lost and the engine will auto- If the warning icon does not go out or if
matically shut off. the engine does not start, take the snow-
If oil pressure is lost, use the following mobile to an authorized Arctic Cat Snow-
procedure to check the oil level: mobile dealer. If not under warranty, this
service is at the discretion and expense of
1. With the engine off, note the oil the snowmobile owner.
level in the sight glass. If the level is
below the sight glass, add only Indicator Icons (Deluxe
enough recommended oil until it is Gauge)
visilbe in the sight glass. DO NOT Certain models are equipped with a
overfill the reservoir with oil. deluxe gauge combination speedometer/
tachometer. Indicator icons are incorpo-
rated within the speedometer/tachome-
ter. Also incorporated into the
speedometer/tachometer is a digital read-
out screen.

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 Clock/Altimeter
By pushing the select button, the readout
screen will display clock, altimeter, and
maximum altimeter.
To set the clock, select clock on the dis-
play by pushing and holding the select
button for two seconds; the option of
selecting the 12-hour or 24-hour clock
mode is available. Push the increment
FZ001A button to toggle between the 12-hour dis-
A. High Beam play and the 24-hour display. When
desired mode is displayed, push the
B. Oil Pressure/Low Oil select button.
C. Coolant Temperature At this point, the hours display will begin
D. Increment Button to flash. Push the increment button to
increase the hours; push the decrement
E. Select Button button to decrease the hours. Pushing and
F. Decrement Button holding a button will accelerate the num-
ber display. When desired hour number is
G. Service displayed, push the select button.
H. Charging System (1100 cc Models) At this point, the minutes display will
RPM/MPH (kph) begin to flash. Push the increment button
to increase the minutes; push the decre-
By pushing the increment button once, ment button to decrease the minutes.
the RPM and MPH will be displayed Pushing and holding a button will accel-
(one on the readout screen and one with erate the number display. When desired
the needle). By pushing the button once minute number is displayed, push the
again, the functions will be reversed. select button.
By pushing the increment button (with  NOTE: During clock setting if no
speed being displayed) for more than two button (increment, decrement,
seconds, the display will change between select) is pushed within a 5-second
standard mph or metric kph. time period, the clock-setting mode
With RPM displayed on the readout will be exited with changes saved.
screen by pushing and holding the incre-  NOTE: The altimeter readout is
ment button, maximum RPM will be dis- based off barometric pressure and
played on the readout screen. The may require calibration as weather
maximum RPM readout will reset when conditions change.
the decrement button is pushed (while
maximum RPM is displayed). To set/calibrate the altimeter to an estab-
lished altitude with altimeter selected on
Odometer/Trip-Meter (1)/ the display screen by pushing and hold-
Trip-Meter (2)/Hour-Meter ing the select button for a minimum of
By pushing the decrement button, the two seconds, the acronym CAL will be
readout screen will display odometer, displayed on the readout screen for one
trip-meter (1), trip-meter (2), and hour- second; then the altitude value will flash.
meter. To reset the trip meter with the trip Push the increment button to increase the
meter displayed, push and hold the decre- displayed altitude; push the decrement
ment button until the display is cleared. button to decrease the displayed altitude.
The hour-meter readout will not reset. Pushing and holding a button will accel-
erate the number display.

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  NOTE: If MPH has been selected in
the speed readout, the altitude value CAUTION
will be displayed in feet. If kph has been
selected in the speed readout, the alti- At this point, take precautionary mea-
tude value will be displayed in meters. sures such as changing to loose
snow terrain, shutting the engine off
To reset the maximum altimeter readout (allowing the engine to cool down),
with the maximum altimeter displayed, and checking coolant level. If unable
push and hold the select button for a min- to either determine or remedy the
imum of two seconds. problem, take the snowmobile to an
authorized Arctic Cat Snowmobile
Service Icon dealer for service. If not under war-
On electric start models, the icon should ranty, this service is at the discretion
and expense of the snowmobile
briefly illuminate each time the key is owner.
turned to RUN or START, and engine is
started; then it should go out when the Charging System Warning
engine starts. If the icon stays illuminated Icon (1100 cc LXR
(on electric start models) or it illuminates Models)
while the engine is running, the system is
receiving input that is outside of its estab- The Charging System Warning Icon is
lished parameters. If the icon illuminates designed to warn the operator if the battery
indicating an error, take the snowmobile charging system is not functioning. The
to an authorized Arctic Cat Snowmobile icon should illuminate each time the key is
dealer for service. If not under warranty, turned to RUN or START, and it should go
this service is at the discretion and out when the engine starts. If the icon stays
expense of the snowmobile owner. illuminated or it illuminates while the
engine is running, the battery is not being
Coolant Temperature charged, and the snowmobile is running on
Warning Icon battery reserve power only.
 NOTE: On the 1100 cc models If the Charging System Warning Icon
when cold-starting the engine, the illuminates, you should, as soon as possi-
coolant temperature warning icon ble, take the snowmobile to an authorized
will illuminate, the readout screen Arctic Cat Snowmobile dealer for ser-
will display TEMP, and engine RPM vice. If not under warranty, this service is
limit will be below drive system
engagement speed. at the discretion and expense of the
snowmobile owner. The engine WILL
When the engine reaches proper operat- NOT RUN without battery power.
ing temperature, the coolant temperature Low Oil Warning Icon (800
warning icon and TEMP display will
cease to flash. cc Models)
If the coolant temperature rises too far The Low Oil Warning Icon is designed to
above proper operating temperature, the alert the snowmobile operator when the
coolant temperature warning icon will oil in the oil injection reservoir gets below
flash a warning (alert) and on the 1100 cc a prescribed level; however, it is highly
models, the engine will “surge” to alert recommended that a visual verification of
the operator. If the coolant temperature the oil level in the reservoir be done prior
rises to a critical point above proper oper- to operating the snowmobile. Once the
ating temperature, the coolant temperature Low Oil Warning Icon illuminates during
warning icon will cease flashing and will operation of the snowmobile, the operator
remain constantly illuminated. must periodically monitor the level of oil
in the reservoir and must fill the reservoir
 NOTE: On the 1100 cc models if the next time gasoline is added to the gas
the coolant temperature icon is con- tank. The “alert level” of the Low Oil
stantly on, the engine will shut off if Warning Icon is approximately equal to 1
vehicle speed is reduced to 1.5 kph tankful of gasoline under normal operat-
(0.9 MPH) or slower. ing conditions.

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 Oil Pressure Warning Icon
(1100 cc LXR Models) CAUTION
The Oil Pressure Warning Icon indicates Do not attempt to start the engine
engine oil pressure, not the oil level; with the bleed bolt open.
however, if the oil level is low, it may
affect oil pressure. 3. Start the engine. The warning icon
should go out within five seconds.
The icon should illuminate each time the
ignition switch is turned to RUN or 4. If the warning icon does not go out,
START, and it should go out when the shut the engine off immediately and
engine starts. If the icon illuminates repeat step 2; then repeat step 3.
while the engine is running, oil pressure If the warning icon does not go out or if
has been lost and the engine will auto- the engine does not start, take the snow-
matically shut off. mobile to an authorized Arctic Cat Snow-
If oil pressure is lost, use the following mobile dealer. If not under warranty, this
procedure to check the oil level: service is at the discretion and expense of
the snowmobile owner.
1. With the engine off, note the oil
level in the sight glass. If the level is Diagnostic Codes
below the sight glass, add only Diagnostic codes are activated by the
enough recommended oil until it is ECU and may be displayed on the read-
visilbe in the sight glass. DO NOT out screen for a number of reasons.
overfill the reservoir with oil.
If a code is displayed while the engine is
running, the ECU is receiving input that
is outside of its established parameters. If
a code has been activated, take the snow-
mobile to an authorized Arctic Cat Snow-
mobile dealer for service. If not under
warranty, this service is at the discretion
and expense of the snowmobile owner.
800 cc Models
Additional codes are displayed on the
readout screen. Refer to the following
0746-166
2. Open the air bleed bolt located on chart for diagnostic codes.
the oil pump (beneath the coolant
tank) to purge air from the oil hose. Code Trouble
2 Failure in injector(s).
4 Open or short circuit in barometric
pressure sensor.
5 Open or short circuit in intake air tem-
perature sensor.
6 Open or short circuit in water tempera-
ture sensor.
7 Open or short circuit in throttle position
sensor.
12 Failure in ignition coil(s).
PC016A 16 Incorrect adjustment/failure in APV
 NOTE: When air can no longer be cable.
heard purging from oil pump bleed, 17 Failure in exhaust temperature sensor.
tighten the bleed bolt to 7.5 ft-lb. 18 Failure in servomotor.
21 Open or short circuit in/or loose knock
sensor.
OCTN Low octane gasoline.

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 1100 cc Models
These diagnostic codes are displayed on
the readout screen incorporated within
the speedometer/tachometer. Refer to the
following chart for diagnostic codes.
Code Trouble
1 Failure in the fuel system.
2 Failure in injector (PTO).
3 Failure in injector (MAG). 0745-843

4 Failure in barometric pressure sensor. 2. With the tabs compressed, adjust the
5 Open or short circuit in intake mani- handlebar up or down to the desired
fold air temperature sensor. position; then release the tabs to lock
6 Open or short circuit in water temper- the handlebar in place.
ature sensor. To adjust handlebar tilt, use the following
7 Open or short circuit in throttle posi- procedure:
tion sensor.
8 Open or short circuit in manifold air
1. Loosen the four cap screws and tilt
pressure sensor. the handlebar to the desired position.
9 Failure in crankshaft position sensor.
11 Failure in speed sensor.
12 Failure in coil (MAG).
13 Failure in coil (PTO).
14 Failure in ISC valve.
15 Failure in oxygen sensor.
19 Failure in camshaft position sensor.
21 Open or short circuit in/or loose knock
sensor.
0745-845
22* Failure in injector (PTO secondary).
2. Tighten the four cap screws to 15 ft-
23* Failure in injector (MAG secondary). lb.
25 Failure in shifting system/gear posi-
tion switch.
! WARNING
26 Malfunction in air pressure sensor.
Tighten the cap screws according to
29 Malfunction in shift control switch. specifications to prevent unexpected
OCTN* Low octane gasoline. “movement” of the handlebar during
operation over rough terrain. DO NOT
* Turbo models position handlebar so steering (maxi-
Handlebar Height/Tilt mum right/left turning capabilities) or
(M 800 Sno Pro/LTD/ throttle and brake controls are
HCR/XF 800 High affected.
Country Models) Handlebar Tilt
To adjust handlebar height, use the fol- The handlebar can be adjusted to the
lowing procedure: operator’s preference. To adjust the han-
1. From each side of the steering post, dlebar, use the following procedure:
compress the locking tabs to unlock 1. Remove the handlebar cover; then
the handlebar. loosen the eight cap screws securing
the handlebar caps to the riser and the
riser to the steering post.

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 Air-Intake Silencer
Used in conjunction with the fuel intake
system is a specially designed air-intake
silencer. The purpose of the silencer is to
quiet the intake of fresh air. Since the fuel
intake system is calibrated with the air-
intake silencer in place, the engine must
never be run with the silencer removed.
Performance will not be improved if the
air-intake silencer is removed. In con-
0745-848
trast, severe engine damage will occur.
2. Adjust the handlebar to operator’s
desired position, tighten the cap CAUTION
screws evenly to 15 ft-lb, and check
steering for maximum right/left These snowmobiles are not designed
turning capabilities. to be operated in dusty conditions.
Operating the snowmobile in dusty
 NOTE: Do not rotate the handlebar conditions will result in severe
to a position that allows air to enter engine damage.
the brake system.
Cooling System
! WARNING These snowmobiles are equipped with a
closed liquid cooling system for engine
Tighten cap screws according to cooling. The cooling system should be
specifications to prevent unexpected inspected daily for leakage and damage.
“movement” of the handlebar during Also, the coolant level should be checked
operation over rough terrain. DO NOT
position the handlebar so steering
daily. If leakage or damage is detected,
(maximum right/left turning capabili- take the snowmobile to an authorized
ties) or throttle and brake controls Arctic Cat Snowmobile dealer for ser-
are affected. vice. If not under warranty, this service is
at the discretion and expense of the
Speedometer/ snowmobile owner.
Tachometer Angle When filling the cooling system reser-
The speedometer/tachometer can be voir, use an ethylene glycol-based cool-
adjusted to the operator’s desired posi-ant/water mixture which will satisfy the
tion. To adjust, use the following proce-
coldest anticipated weather conditions of
dure. your area in accordance with the coolant
1. Loosen the lock nuts and cap screws manufacturer’s recommendations.
on each side of the speedometer/  NOTE: On the HCR models if oper-
tachometer bracket. ating on ice or hard-packed snow,
2. Adjust the speedometer/tachometer the ice scratchers must be engaged
to the desired angle; then tighten the to reduce engine overheating.
lock nuts securely. For checking/filling cooling system, refer
Exhaust System to Coolant Level sub-section in the Main-
tenance section.
The exhaust system is designed to reduce
noise and to improve the total perfor- Battery (Electric Start)
mance of the engine. If any exhaust sys- It is extremely important that the battery
tem component is removed from the be maintained at full charge at all times
engine and the engine is run, severe and that the battery connections be clean
engine damage will result. and tight. If charging the battery becomes
necessary, refer to Battery sub-section in
the Maintenance section.

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 CAUTION ! WARNING
On the 1100 cc models, always turn If any of these conditions exist, DO
the ignition switch key to the OFF NOT attempt to jump-start, boost, or
position when the snowmobile is not charge the battery. An explosion
being used. Leaving the ignition could occur causing serious injury.
switch in the ON position will result in
discharging the battery and possible 3. Inspect the vehicle to be used for
damage to the battery. jump-starting to determine if voltage
and ground polarity are compatible.
Jump-Starting (1100 cc The vehicle must have a 12-volt DC,
Models) negative ground electrical system.

 NOTE: Arctic Cat does not recom- CAUTION

mend jump-starting a snowmobile Always make sure the electrical sys-
with a dead battery but rather to tems are of the same voltage and
remove the battery, service it, and ground polarity prior to connecting
correctly charge it; however, in an jumper cables. If not, severe electri-
emergency, it may be necessary to cal damage may occur.
jump-start a snowmobile. If so, use
the following procedure to carefully 4. Move the vehicle to be used for the
and safely complete this procedure. jump-start close enough to ensure
the jumper cables easily reach; then
! WARNING set and lock the brakes, shut off all
Improper handling or connecting of a
electrical accessories, and turn the
battery may result in severe injury ignition switch OFF.
including acid burns, electrical burns,  NOTE: Make sure all switches on
or blindness as a result of an explo- the snowmobile to be jump-started
sion. Always remove rings and are turned OFF.
watches.
5. Disconnect all external accessories
 NOTE: To access the battery, the such as cell phones, GPS units, and
seat must be removed (see Remov- radios on both vehicles.
able Seat sub-section in this sec-
tion). CAUTION
1. On the snowmobile to be jump-started, Failure to disconnect electronic
slide any terminal boots away. accessories during jump-starting
may cause system damage due to
! WARNING power spikes.
Any time service is performed on a 6. Attach one clamp of the positive
battery, the following must be (red) cable to the positive (+) termi-
observed: keep sparks, open flame, nal (1) of the dead battery (C) being
cigarettes, or any other flame away. careful not to touch any metal with
Always wear safety glasses. Protect
skin and clothing when handling a the other clamp; then attach the
battery. When servicing a battery in other clamp of the positive (red)
an enclosed space, keep the area cable to the positive (+) terminal (2)
well-ventilated. of the good battery (B).
2. Inspect the battery for any signs of
electrolyte leaks, loose terminals, or
bulging sides. Leaking or bulging
battery cases may indicate a frozen
or shorted battery.

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 However, the drive clutch and driven pul-
ley should be disassembled, cleaned, and
inspected by an authorized Arctic Cat
Snowmobile dealer after every 800 miles
of operation or at the end of the snowmo-
biling season whichever occurs first. This
service is at the discretion and expense of
the snowmobile owner.
When operating the snowmobile at high
0744-527
altitudes, it may be necessary to change
certain component parts of the drive
 NOTE: Some jumper cables may be clutch and/or the driven pulley. See an
the same color but the clamps or ends authorized Arctic Cat Snowmobile dealer
will be color-coded red and black. for further information.
7. Attach one clamp of the negative
jumper cable (black) to the negative (- CAUTION
) terminal (3) of the good battery (B); DO NOT attempt to service the drive
then attach the other clamp of the neg- clutch and driven pulley. The drive
ative jumper cable (black) (4) to an clutch and driven pulley must be ser-
unpainted metal surface (A) on the viced by an authorized Arctic Cat
engine or frame well away from dead Snowmobile dealer only.
battery and fuel system components.
Drive Clutch/Driven
! WARNING Pulley Alignment
The alignment between the drive clutch
Never make the final connection to a and driven pulley is set at the factory.
battery as a spark could ignite hydro-
gen gases causing an explosion of Normally, no adjustment is necessary as
the battery resulting in acid burns or long as neither the drive clutch nor the
blindness. driven pulley is removed or disassem-
bled. However, if premature drive belt
8. Stand well away from the dead bat- wear is experienced or if the drive belt
tery and start the vehicle with the turns over, the drive clutch/driven pulley
good battery. Allow the vehicle to alignment must be checked. Take the
run for several minutes applying snowmobile to an authorized Arctic Cat
some charge to the dead battery. Snowmobile dealer for this service. If not
under warranty, this service is at the dis-
9. Start the snowmobile with the dead cretion and expense of the snowmobile
battery and allow it to run for several owner.
minutes before disconnecting the
jumper cables. Fuel Pump
10. Remove the jumper cables in opposite The fuel pump is designed to provide
order of hook-up (4, 3, 2, 1). Be careful adequate amount of gas to the injectors
not to short cables against bare metal. at all throttle settings. If a fuel delivery
problem is suspected, take the snowmo-
 NOTE: Have the battery and elec- bile to an authorized Arctic Cat Snowmo-
trical system checked prior to oper- bile dealer. If not under warranty, this
ating the snowmobile again. service is at the discretion and expense of
Drive Clutch and Driven the snowmobile owner.
Pulley
The drive clutch and driven pulley do not
require lubrication; therefore, no special
maintenance is required by the snowmo-
bile owner except for periodical cleaning
(see the Periodic Maintenance Checklist
in the Maintenance section).

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 Shock Absorbers Paddle Track (XF High
Rebuildable Gas Country/M Models)
These models are equipped with a Power
Each shock absorber should be visibly Claw style track which is specially
checked weekly for fluid leakage, cracks
designed for use in powder snow riding
or breaks in the body/reservoir, or a bent
conditions. When the Power Claw track is
shaft. If any one of these conditions is
operated in hard-packed snow conditions,
detected, replacement or service is neces-
it will run slightly slower than a standard
sary. Take the snowmobile to an autho-track and it will accelerate wear strip
rized Arctic Cat Snowmobile dealer forwear. To decrease the amount of wear
this service. If not under warranty, this
strip wear, slower speeds must be main-
service is at the discretion and expense of
tained when operating on hard-packed
the snowmobile owner. trails. Accelerated wear strip wear caused
 NOTE: When the snowmobile is by operating a Power Claw track on hard-
operated in extremely cold weather (- packed snow conditions is NOT covered
23° C/-10° F or colder), a small under Arctic Cat Inc. warranty policy.
amount of leakage may be present.
Unless the leakage is excessive,  NOTE: If operating on ice or hard-
replacement is not necessary. packed snow conditions, it is recom-
mended that Ice Scratchers (p/n 5639-
 NOTE: The frequency of servicing 897) be installed to reduce wear strip
rebuildable shock absorbers will wear and engine overheating.
vary according to the types of condi-
tions and terrain the snowmobile has Track Studs (XF/F
been subjected to. If riding quality Models)
deteriorates (or seems to be deterio-  NOTE: Stud or hooker plate installa-
rating), take the snowmobile to an tion will void track and tunnel warranty.
authorized Arctic Cat Snowmobile
dealer for shock absorber evaluation  NOTE: Stud installation can be per-
and/or servicing. This service is at formed by the snowmobile owner if
the discretion and expense of the qualified to do so. If the owner does
snowmobile owner. not feel qualified, take the snowmo-
bile to an authorized Arctic Cat Snow-
Servicing rebuildable shock absorbers is mobile dealer for this service. This
considered normal maintenance and is service is at the discretion and
the responsibility of the owner. Take the expense of the snowmobile owner.
snowmobile to an authorized Arctic Cat
Snowmobile dealer for this service. This ! WARNING
service is at the discretion and expense of
the snowmobile owner. Kits are available When installing studs on a single-ply
to either stiffen or soften gas shock valv- track, it is important to use Arctic
Cat-approved studs (proper head
ing. If changes in shock valving are diameter). If approved studs (proper
desired, see an authorized Arctic Cat head diameter) are not used, studs
Snowmobile dealer. This service is at the could tear free of the track causing
discretion and expense of the snowmo- possible injury or even death. Con-
bile owner. sult an authorized Arctic Cat Snow-
mobile dealer for information.
Standard Track (XF/F
Models) CAUTION
Accelerated wear strip and track clip To prevent tunnel damage from the
wear caused by operating on ice or hard- studs, Tunnel Protector Kit (p/n 5639-
packed snow conditions is NOT covered 752) for the XF models or (p/n 5639-668)
under Arctic Cat Inc. warranty policy. for the F models must be installed.
For proper installation, use the following
procedure:

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 1. Using the appropriate stud template
(see chart), mark the desired stud ! WARNING
pattern to be used. DO NOT stand behind the snowmo-
bile or near the rotating track. NEVER
Stud Template Chart run the track at high speed when the
Track Length p/n track is suspended.
128 in. 4639-443 Reverse Operation
141 in. 4639-991 The engine reverse function offers the
2. Using the proper-sized stud hole operator the convenience of being able to
drill bit, drill out the stud holes. back up the snowmobile rather than hav-
ing to turn the snowmobile around by
3. Push the stud through the hole from hand. This feature, under most situations,
inside the track; then place the should not be used to free a stuck snow-
domed support plate and lock nut on mobile as it will tend to dig the skis
the exposed stud. deeper into the snow. Always use mini-
4. Using a wrench to secure the stud, mal speed when operating in reverse and
tighten the lock nut on the exposed stud. come to a complete stop before shifting
from either forward to reverse or reverse
It is also recommended that whenever to forward.
studs are installed on a track, carbide
wear bars should be installed on the skis. Shifting Into Reverse (800
Carbide wear bars complement the track cc Models)
studs to balance steering control under
these conditions. The length of the car-
bide on the wear bars should be propor-
tionate to the number of track studs (i.e.
small number of track studs — short
length of carbide...many track studs —
long length of carbide). The proper pro-
portion between the number of studs and
carbide length on the wear bar will main-
tain steering balance.
741-438A
! WARNING
 NOTE: Correct drive belt tension
Always balance the snowmobile with (deflection) is important for the
the proper proportion between the reverse function to operate properly.
number of studs and carbide length If the belt is too tight, difficulty in
on the wear bars. Do not “over drive” engaging reverse will be experi-
conditions; use common sense in all enced (the reverse function will
operating conditions. make up to three attempts to engage
into reverse, and if the function is
CAUTION not completed after the third
Do not use studs that are more than attempt, the engine will shut down).
9.525 mm (0.375 in.) longer than the
track lug height. 1. Always warm up the engine for 2-3
minutes prior to shifting into
! WARNING reverse. The reverse function is can-
celled when engine temperature is
Do not operate a snowmobile with below or above normal operating
loose studs as they may be thrown
from the track. Always use a shielded range.
safety stand whenever performing 2. Shift only with the engine at idle
any maintenance or adjustments. RPM and the snowmobile com-
pletely stopped. The reverse func-
tion will not engage if engine speed
is above 3000 RPM.

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 3. If attempting to shift into reverse at
too high engine RPM (above 3000 ! WARNING
RPM), the reverse function will be
cancelled and the coolant tempera- Do not use high speed when backing
ture warning icon will flash. This up. Control could be lost and injury
indicates the reverse switch button could occur.
was pressed at too high RPM. The CAUTION
operator must reduce engine RPM
below 3000 and press the button a Do not use high speed when backing
second time. up. Damage to the drive belt and
driven pulley components may occur.
4. Upon pressing the reverse switch
button, the reverse function will  NOTE: While operating in reverse,
make up to three attempts to engage a “rev-limiter” will activate at 6500
into reverse. If the function is not RPM.
completed after the third attempt, 4. To shift into forward, stop the snow-
the engine will shut down. mobile and allow the engine to idle
(under 3000 RPM); then press the
CAUTION reverse button and release. The for-
Never shift into reverse while the ward selection will be complete.
snowmobile is moving forward as it is
hard on the driven pulley torque 5. After shifting from reverse to for-
bracket and the cam rollers. ward (or from forward to reverse),
apply the throttle slowly and evenly
Operating in Reverse (800 to allow the driven pulley to engage
cc Models) properly.

CAUTION 6. The reverse function is cancelled

whenever the engine is shut off.
Never pull the recoil starter rope when
the engine is running or when operat-
ing in reverse. Damage to the engine CAUTION
and/or recoil start system will occur. After reversing in deep powder snow
conditions, make sure the snowflap
1. When reverse is engaged, a reverse does not become “caught up” in the
icon will illuminate in the speedom- track. Track and/or snowflap damage
eter/tachometer and a reverse alarm may occur.
will sound.
2. If the throttle lever is compressed
CAUTION
before complete reverse engage- If the snowmobile is equipped with
ment, the engine may shut down. ice scratchers, the scratchers must
Always wait for the reverse icon to be disengaged or component dam-
illuminate and the reverse alarm to age will occur.
sound before backing up. Shifting Into Reverse
3. The system will not shift until the but- (1100 cc Models)
ton is released. Also, the reverse func-
tion will cancel if operated in reverse
longer than 45 seconds. Whenever the
reverse function has been cancelled,
the engine must be run in the forward
mode for a minimum of 60 seconds at
2000 RPM before the reverse function
can be used again.

741-438A

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 1. Always warm up the engine for 2-3 2. After shifting from reverse to for-
minutes prior to shifting into ward (or from forward to reverse),
reverse. apply the throttle slowly and evenly
to allow the driven pulley to engage
2. With the engine at idle (under 2500 properly.
RPM) and the snowmobile at a com-
plete stop, press the reverse switch
button; then release the button. The CAUTION
reverse selection will be complete. After reversing in deep powder snow
conditions, make sure the snowflap
 NOTE: The snowmobile must be at does not become “caught up” in the
a complete stop and the engine run- track. Track and/or snowflap damage
ning under 2500 RPM before the sys- may occur.
tem will allow shifting.
CAUTION
 NOTE: The system will not shift
until the button is released. If the snowmobile is equipped with
ice scratchers, the scratchers must
3. When reverse is engaged, a reverse be disengaged or component dam-
icon will illuminate in the speedom- age will occur.
eter/tachometer and a reverse alarm
will sound. Access Panel/Hood
(Removing/Installing)
CAUTION To remove the access panel and hood, use
Never shift into reverse while the
the following procedure:
snowmobile is moving forward as it is
hard on the driven pulley torque 800 cc
bracket and the cam rollers.
4. To shift into forward, stop the snow-
mobile and allow the engine to idle
(under 2500 RPM); then press the
reverse button and release. The for-
ward selection will be complete.
Operating in Reverse
(1100 cc Models) 746-089A

1100 cc Non-Turbo
! WARNING
Use caution and minimal speed when
operating the snowmobile in reverse.
Be sure the button is in the desired
position.
CAUTION
Never engage the electric starter
when the engine is running or when 746-090A
operating in reverse. Damage to the
engine and/or the electric start sys- 1100 cc Turbo
tem will occur.
1. When shifting into reverse, always
wait for the reverse icon to illumi-
nate and the reverse alarm to sound
before backing up.
 NOTE: The reverse function is can-
celled whenever the engine is shut
off.
746-091A

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 1. Remove the hairpin clip from the pin 3. Install the access panel onto the
located at the front of the access lower console; then close the access
panel. Move the panel up and off the panel and scure with the hairpin clip.
pin; then swing the panel all the way
out and unhinge the panel from the Removable Seat
lower console. These snowmobiles are equipped with a
removable seat. To remove the seat, use
2. Remove the two torx-head screws the following procedure:
securing the hood (located on the
underside of the hood above the rear Remove the torx-head screw from the
tube of the upper A-arm); then underside of the seat; then lift on the back
remove the two torx-head screws of the seat and move it up and rearward
from the top-side of the hood secur- to remove it from the tunnel.
ing the hood to the upper console.
CAUTION
 NOTE: On the turbo models,
remove the two torx-head screws On the 1100 cc LXR models prior to
from under the nosepiece of the removing the seat, lift the rear of the
hood. seat and disconnect the seat heater
harness connector.
3. Locate the hood harness connector
(located in front of the speedometer)
and unplug the connector; then
move the hood slightly forward and
remove the hood.
 NOTE: On the turbo models, first
unhook the rubber straps securing
the air filter housing to the intake
plenum of the hood; then move the
hood slightly forward and remove
the hood.
746-088A
To install the access panel and hood, use To install the seat, use the following pro-
the following procedure: cedure:
1. Position the hood onto the snowmo- Slide the front of the seat into the locking
bile and connect the hood harness position of the seat support bracket; then
connector. lower the rear of the seat into position on
 NOTE: On the turbo models prior the tunnel. Secure with the torx-head
to securing the hood, make sure the screw.
rubber straps of the air filter housing  NOTE: On the 1100 cc LXR models
are accessible. prior to lowering and securing the
2. Secure the hood with the six torx- seat, connect the seat heater har-
head screws and tighten securely. ness connector.

 NOTE: Before installing the hood, Towing

make sure the mounting screw clips If the snowmobile is to be towed by
are in position. another snowmobile, do not tow using
the loops in the skis. The tow rope should
 NOTE: On the 1100 cc non-turbo be attached to the spindles.
models, make sure the foam seal is
in place on the air intake.
 NOTE: On the turbo models, make
sure the air filter housing is properly
connected and secured with the rub-
ber straps to the intake plenum of
the hood and turbocharger.

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 Arctic Power Valve At high RPM, the exhaust valves are
(APV) System (800 cc raised. This creates a “high port” exhaust
Models) design calibrated to provide maximum
performance at high RPM.
CAUTION
The recommended engine oil to use
is either Arctic Cat APV Synthetic 2-
Cycle Oil or Formula SS Semi-Syn-
thetic Oil (see Gasoline-Oil - Recom-
mended Injection Oil sub-section in
this section). Any substitute may
cause an APV malfunction.
This RPM controlled servomotor (servo)
actuated system adjusts the size of the
exhaust ports to provide peak perfor- 739-152H
mance throughout the RPM range.  NOTE: The RPM ranges will vary
The system consists of an exhaust valve from model to model.
assembly mounted to the exhaust side of  NOTE: If the servomotor cycles
each cylinder and connected by adjust- three times and then shuts down, the
able cables to an electronic servo exhaust valve cables are not
mounted beneath the hood. adjusted correctly. The exhaust
 NOTE: The mounting location of the valves may also be sticking.
servo will vary from model to model.  NOTE: APV cleaning may be done
by the snowmobile owner if qualified
to do so. If the owner does not feel
qualified, take the snowmobile to an
authorized Arctic Cat Snowmobile
dealer for this service. This service
is at the discretion and expense of
the snowmobile owner.
Exhaust Controlled
Timing (ECT) System
739-152F (800 cc Models)
At low RPM, the exhaust valves are held This system automatically adjusts the
in the DOWN position by return springs. ignition timing to provide maximum per-
This gives the engine a “low port” formance through a variety of operating
exhaust design calibrated to provide conditions. The ECU receives input on
maximum low RPM power and improve engine RPM (demand) and exhaust pipe
fuel economy at trail speeds. temperature (engine condition) and
adjusts the ignition timing accordingly.
This system is not adjustable and is main-
tenance free.
If a system fault is suspected, use an ohm-
meter to check continuity of the exhaust
pipe temperature sensor located in the
expansion chamber. A reading of either 0
ohm or infinity indicates a failed sensor.

739-152G

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  NOTE: A disabled ECT system
WILL NOT cause engine damage;
however, a failed ECT system will
have slower throttle response and
may produce slightly less top-end
performance.

0737-314

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 Operating Instructions
Starting and Stopping 3. If the brake fluid is below the high
Engine brake fluid mark, add Arctic Cat
It is imperative that the brake system be approved DOT 4 brake fluid until
checked for wear and proper operation the fluid is at the recommended
and that all safety checks found in the level. Install and secure the reservoir
accompanying Snowmobile Safety cover. Do not allow moisture to con-
Handbook be performed before attempt- taminate the brake system.
ing to start the engine. After the engine
has been started, check the headlights CAUTION
(high and low beam), taillight, and brake- Brake fluid is highly corrosive. Do not
light to be sure they are working properly spill brake fluid on any surface of the
and adjusted correctly. Make sure all snowmobile.
lights are clean to provide maximum illu-
mination. The headlight and taillight ! WARNING
must be clean and must be illuminated Do not overfill the brake fluid reser-
whenever the engine is running. voir. Overfilling the reservoir may
1. Test the operation of the brake system cause the brake system to hydrauli-
cally lock. Use only Arctic Cat
by compressing the brake lever. The approved brake fluid.
brake lever must feel firm when com-
pressed; then while holding the brake ! WARNING
lever in the compressed position, mea-
sure the distance between the brake Do not start the engine if the brake sys-
lever and the handlebar. The distance tem is not functioning properly. Service
must be greater than 2.54 cm (1 in.). the brake system or have it properly
repaired prior to operating the snow-
mobile. Serious personal injury or even
death may occur if the brake system is
not operating properly.
4. Test the throttle control lever by
completely compressing and releas-
ing it several times. The lever
MUST return to the idle position
quickly and completely.

CAUTION
0745-816
Always check the coolant level before
2. With the brake fluid reservoir in a starting the engine.
level position and the cover
removed, check the fluid level. The 5. Move the emergency stop switch to
brake fluid level must be at the high the UP or RUN position.
brake fluid mark in the reservoir. 6. Insert key into ignition switch; then
rotate key to the RUN position.
 NOTE: On the 800 cc models when
a cold engine is being started, DO
NOT COMPRESS THE THROTTLE
CONTROL LEVER. If the throttle con-
trol lever is compressed, the engine
will not start because the fuel/air
mixture will be too lean.

0745-817

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 7. On models with manual start, pull 9. Flooding — If the engine does not
the recoil handle slowly until resis- start but seems ready to start, engage
tance is felt; then give a short quick the brake lever lock; then compress
pull. Repeat until the engine starts. the throttle control lever fully and try
 NOTE: In extremely cold weather, to start the engine. When the engine
pull the recoil handle slowly two to starts, release the throttle control
three times to begin the starting pro- lever immediately. After the warm-
cedure. up, release the brake lever lock.
 NOTE: On the 800 cc models if the
CAUTION engine fails to start during the
To avoid damaging the recoil starter, attempt with the throttle control lever
DO NOT pull the recoil rope to its limit compressed, remove the spark plugs
or release the recoil handle from an and clean and dry them thoroughly or
extended position. Allow the rope to install a new set of properly gapped,
rewind slowly. recommended spark plugs.

 NOTE: On electric start models, 10. To shut off the engine, turn the igni-
rotate the key to the START position; tion key to the OFF position or push
then when the engine starts, release the emergency stop switch to the
the key. DOWN position.

CAUTION CAUTION
Do not continuously run the starter On the 1100 cc models, always turn
for more than 5 seconds at a time. the ignition switch key to the OFF
position when the snowmobile is not
 NOTE: When the engine starts, being used. Leaving the ignition
allow it to warm up properly. Idle the switch in the ON position will result in
engine several minutes until the discharging the battery and possible
engine has reached normal operat- damage to the battery.
ing temperature. Do not idle the Braking
engine for excessively long periods
of time. The following items are items that the
operator must be familiar with when
8. On the 1100 cc models, there is a operating this snowmobile and its
“cold drive-away” function incorpo- hydraulic brake system. Important addi-
rated within the engine. This func- tional information on the proper mainte-
tion is active until the engine reaches nance of the brake system is found in the
operating temperature (see Cold Maintenance section.
Drive-Away Function sub-section in
the General Information section). 1. Use the brakes wisely. Each time the
brakes are applied in all hydraulic
CAUTION brake systems (including automotive
applications), heat is transferred to
On the 800 cc models, it is extremely the brake fluid. The amount of heat
important that the engine is properly transferred during high speed stops
warmed up before subjecting the and/or repetitive use may be high
engine to high speed operation or enough to boil the brake fluid and
heavy loads. The engine should be
allowed to idle at least 3-4 minutes cause the brakes to either fade or may
before it is operated at more than 1/2 cause an unexpected loss of brakes.
throttle. In extremely cold conditions,
the warm-up time will be longer. Cold
seizure and piston scuffing caused
by insufficient warm-up will not be
covered by warranty. Also, do not idle
the engine for excessively long peri-
ods of time.

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 If this occurs, the brake fluid
requires a cool-down period before ! WARNING
the brakes will again function prop-
erly. This cool-down period will The brake lever lock is not a parking
vary depending upon the ambient air brake and should not be applied for
temperature and the temperature of periods exceeding 5 minutes. The
the brake fluid. If loss of brakes has brake lever lock maintains the brake
lever in the compressed position and
occurred because of high fluid tem- maintains pressure against the brake
peratures, do not operate the snow- disc; however, after a period of time,
mobile until the cool-down period the pressure applied to the brake disc
has expired and brake lever firmness may relax below the amount required
has returned. to hold the snowmobile stationary.

! WARNING 5. Pumping the brake lever is permissi-

ble; however, if pumping the brake
Excessive, repetitive use of the lever more than twice is necessary to
hydraulic brake for high speed stops
will cause overheating of the brake obtain the necessary stopping power,
fluid and premature brake pad wear immediately take the snowmobile to
which will result in an unexpected an authorized Arctic Cat Snowmobile
loss of brakes. dealer for service. If not under war-
ranty, this service is at the discretion
2. Be sure to maintain the brake fluid at and expense of the snowmobile owner.
the proper level and take care not to
get any moisture in the system as 6. When new brake pads are installed,
moisture in the brake fluid lowers the a “burnishing” process is required
boiling point. If the brake fluid is ever (see Brake System in the Mainte-
boiled (by high speed stops or repeti- nance section of this manual).
tive use) or if moisture is allowed to Emergency Stopping
enter the system, it must be changed.
There are several methods of stopping or
Never substitute or mix different types
slowing the snowmobile under a variety
or grades of brake fluid. of situations. Identified in the following
chart are the ways a snowmobile may be
! WARNING brought to a stop and the effectiveness
Use only Arctic Cat approved DOT 4 under normal conditions.
brake fluid. Never substitute or mix
different types or grades of brake Item Function Condition
fluid. Brake loss can result. Check Emergency interrupts igni- ALL
brake fluid level and pad wear before Stop Switch tion circuit
each use. Brake loss can result in Throttle/Ignition interrupts igni- ALL
severe injury or even death. Monitor Switch tion circuit
3. Never ride the brake. Even main- Ignition Switch interrupts igni- ALL
taining minimal pressure on the tion circuit
brake lever will cause the brake pads Brake slows the drive ALL
to drag on the disc and may overheat system
the brake fluid. Throttle/Ignition
4. The brake lever lock is not a parking Monitor Switch
brake and should not be applied for The throttle control is equipped with a
periods exceeding 5 minutes. monitor switch for safety purposes which
NEVER OPERATE THE SNOW- will stop the engine when a loss of return
MOBILE WITH THE BRAKE spring force occurs. If ice forms in the
LEVER LOCK ENGAGED. throttle system or if there is some other
malfunction of the throttle system result-
ing in a loss of return spring force, the
monitor switch will stop the engine when
the throttle control lever is released.

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  NOTE: If the throttle control lever
! WARNING operates properly and the engine
does not start, a malfunctioning
If any malfunction of the throttle sys- monitor switch may be the problem.
tem occurs (such as freezing in fluffy Take the snowmobile to an autho-
snow) and the monitor switch does rized Arctic Cat Snowmobile dealer
not shut off the engine, press down for service. If not under warranty,
on the emergency stop switch IMME- this service is at the discretion and
DIATELY to stop the engine. DO NOT expense of the snowmobile owner.
start the engine until the malfunction However, if a dire emergency exists
in the throttle system has been wherein the engine must be started,
located and corrected. disconnect the throttle monitor
If the snowmobile engine stops abruptly switch located in the right-side han-
when the throttle control lever is released dlebar control.
and the activation of the monitor switch  NOTE: If disconnection of the
is suspected, use the following proce- throttle monitor switch is needed to
dure: start the engine, take the snowmo-
1. Rotate the ignition key to the OFF bile to an authorized Arctic Cat
position. Snowmobile dealer for service as
soon as possible. If not under war-
2. Remove ice and snow from the ranty, this service is at the discretion
throttle system and wait 5-10 min- and expense of the snowmobile
utes for the engine heat to thaw ice owner.
from the throttle system.
3. Test the throttle control lever by
! WARNING
compressing and releasing it several Under no circumstances should dis-
times. The lever MUST return to the connection of the throttle control wir-
idle position quickly and completely. ing harness be used as a substitute
for the monitor switch during normal
 NOTE: If the throttle control lever operation of the snowmobile. Per-
operates properly and the engine sonal injury and damage could occur
does not start, compress the throttle if the throttle system malfunctions or
lever slightly (approximately 1/8 if the operator is unable to stop the
throttle) and try starting the engine. engine in an emergency. If the snow-
If the engine now starts and stops mobile must be operated with a dis-
when the throttle lever is released, connected throttle control wiring
take the snowmobile to an autho- harness, EXTREME CAUTION MUST
rized Arctic Cat Snowmobile dealer BE TAKEN. NEVER EXCEED 10 MPH
for service. If not under warranty, WITH THE THROTTLE CONTROL
this service is at the discretion and WIRING HARNESS DISCONNECTED.
expense of the snowmobile owner.
 NOTE: The monitor switch is now
bypassed. All other ignition/electri-
! WARNING cal features (ignition switch, emer-
If the throttle control lever does not gency stop switch, headlight,
work properly, DO NOT ATTEMPT TO taillight, and brakelight) will operate
START THE ENGINE. properly.
4. If the throttle control lever operates Varying Altitude
properly, rotate the ignition key to Operation
the RUN position and go through Operating a snowmobile at varying alti-
normal starting procedures. tudes requires changes in performance
components. These changes affect drive
train components (on certain models).
For altitude information, see the appro-
priate specifications sheet.

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  NOTE: Just as important as cali- M models and the XF 800 High Country
brating the snowmobile for higher alti- model are initially set up at the factory
tudes is recalibrating the snowmobile for operation between 6000-9000 feet.
when going to lower altitudes.
 NOTE: Drive train changes can be
XF models (except the XF 800 High made by the snowmobile owner if
Country model) are initially set up at the qualified to do so. If the owner does
factory for operation between 0-3000 feet. not feel qualified, take the snowmo-
bile to an authorized Arctic Cat
F models are initially set up at the factory Snowmobile dealer for this service.
for operation between 0-5000 feet. This service is at the discretion and
expense of the snowmobile owner.

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 Lubrication
Chain Case
 NOTE: The snowmobile must be CAUTION
on a level surface for this procedure. When installing the shift actuator,
1. Check the lubricant level in the rotate the actuator back and forth to
chain case by using the sight glass. properly align it with the extension
gear. Failure to do so could cause
component damage.
4. On the 1100 cc models, start the
engine and verify proper reverse and
forward operation.

0746-115

 NOTE: The correct level is when

the lubricant is at least halfway up in
the sight glass.
 NOTE: Adding lubricant can be PC019A
done by the snowmobile owner if
qualified to do so. If the owner does  NOTE: If excessive build-up of
not feel qualified, take the snowmo- moisture or discolored oil is
bile to an authorized Arctic Cat detected in the chain case, it may be
Snowmobile dealer for this service. necessary to replace the chain lube.
This service is at the discretion and  NOTE: Replacing the lubricant can
expense of the snowmobile owner. be done by the snowmobile owner if
2. On the 800 cc models if the lube qualified to do so. If the owner does
not feel qualified, take the snowmo-
level is low, remove the fill plug bile to an authorized Arctic Cat
from the chain case; then add the Snowmobile dealer for this service.
appropriate amount of Arctic Cat This service is at the discretion and
Synthetic Chain Lube (p/n 5639- expense of the snowmobile owner.
038) in the fill hole. Install the plug.
3. On the 1100 cc models if the lube To replace the lubricant, use the follow-
level is low, remove the three screws ing procedure:
securing the shift actuator to the  NOTE: The exhaust resonator
chain case, disconnect the actuator must be removed for this procedure.
wiring harness, and remove the actu-
ator w/extension; then add the 1. Place a drain pan on the floor beneath
appropriate amount of Arctic Cat the snowmobile to allow the lubri-
Synthetic Chain Lube (p/n 5639- cant to drain from the chain case into
038) through the shift actuator open- the drain pan.
ing. When the lube is halfway up the 2. Remove the cap screws securing the
sight glass, install the shift actuator chain case cover (with oil reservoir)
w/extension and connect the actua- to the chain case. Remove the cover
tor wiring harness. and allow the oil to drain into the
drain pan.
 NOTE: It is critical that the snow-
mobile is on a level surface to
ensure the lubricant drains properly
and completely.

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  NOTE: Inspect the chain case CAUTION
cover seal for nicks or damage.
The correct lubricant to use in the
3. When the lubricant has completely chain case is Arctic Cat Synthetic
drained from the case and the chain Chain Lube. Any substitute may
case is cleaned of old oil, properly cause serious damage to the drive
seat the seal in the cover; then install system.
the chain case cover. Tighten the cap Rear Suspension
screws to 100 in.-lb.
This procedure should be done every 40
4. On the 800 cc models, pour recom- operating hours.
mended chain case lube into the fill
hole until the lubricant is at least  NOTE: Arctic Cat recommends
halfway up in the sight glass; then that Arctic Cat All-Temp Grease (p/n
install the plug. 4639-365) be used for this proce-
dure.
5. On the 1100 cc models, remove the
three screws securing the shift actua-  NOTE: Illustrated are the general
tor to the chain case, disconnect the locations of grease fittings. Actual
actuator wiring harness, and remove locations will vary from model to
model.
the actuator w/extension. Pour rec-
ommended chain case lube through 1. Shut engine off and wait for all mov-
the shift actuator opening until the ing parts to stop.
lubricant is at least halfway up in the
sight glass; then install the shift 2. With the gas tank nearly empty (less
actuator w/extension and connect than 1/4 full) and using Handlebar
the actuator wiring harness. Stand (p/n 5639-152) or a suitable
substitute, lay the snowmobile on its
CAUTION left side.
When installing the shift actuator, 3. Remove ice and snow buildup from
rotate the actuator back and forth to the skid frame to expose the grease
properly align it with the extension fittings.
gear. Failure to do so could cause
component damage.
6. Install and secure the exhaust reso-
nator.
 NOTE: On the 1100 cc models, the
resonator gasket(s) between the
exhaust pipe(s) and resonator must
be replaced.
7. On the 1100 cc models, start the
engine and verify proper reverse and 0746-093
forward operation. 4. Lubricate the grease fittings with all-
temperature grease.

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 Maintenance
Periodic Maintenance Checklist
Item Interval Page Remarks
Brake System Daily 41 Check for binding, leakage, and proper operation;
lever firmness, travel, caliper, disc, and pads
Cooling System - Liquid Daily 14,35 Check for leakage, damage, obstructions, coolant
level
Oil-Injection System Daily — Check for leakage, damage, and injection/engine
oil level
Engine Oil (1100 cc Non-Turbo 2500 Mi/ 33 Change oil and filter
Models) Seasonal
Engine Oil (1100 cc Turbo Mod- 2000 Mi/ 33 Change oil and filter
els) Seasonal
Battery Daily 14,38 Check for proper charge and tight connections
Stop Switch Daily — Check for proper operation
Hoses Daily — Check for damage, leakage, and wear
Headlight & Taillight/Brakelight Daily 51-52 Check for proper operation and cleanliness
Steering System Daily — Check for proper operation, tightness of bolts,
and binding
Throttle Control System Daily 26 Check for binding, sticking, proper operation,
throttle cable tension, and wear
Drive Belt Daily 44 Check for wear, cracks, and fraying
Monthly Check length and width dimensions
Ski Wear Bars Daily 52 Check for wear and damage
Electrical Wiring Weekly — Check for wear, damage, and tight connections
Exhaust System Weekly 14 Check for damage, leakage, and obstructions
Nuts, Bolts, Fasteners Weekly — Check tightness
Recoil Starter Weekly — Check rope for wear, fraying, and proper operation
Shock Absorbers Weekly 17,49 Check for fluid leakage and damage and air pres-
sure (Fox Air Shocks)
Spark Plugs 3500 Mi 35 Check center electrode insulator color, carbon,
and gap
Valve Clearance (1100 cc Mod- 5000 Mi/ 37 Check/adjust
els) Seasonal
Suspension Weekly 48 Check for damage, loose components, and
proper adjustment
Track Tension/Alignment Weekly 46,47 Check/adjust as necessary
Wear Strips Weekly 53 Check for wear and damage
Wires & Cables Weekly — Check for wear, damage, and fraying
Fuel System - Tank, Pump, In- Weekly — Check for damage, wear, obstructions, and leak-
Line Filter, & Vent Hose age
Fuel Filter (1100 cc Models) 5000 Mi/ — Replace
2 years
Air Silencer (800 cc Models) Seasonal — Inspect/clean
Air Cleaner/Filter (1100 cc Turbo Weekly/ 32 Check/replace
Models) Seasonal
APV System Monthly 22 Check/adjust as necessary
Chain Case Daily 29 Check lube level and for leakage
Chain Case - Lubricant Seasonal 29 Replace
Heat Exchangers Monthly — Check for wear, leakage, and damage
Drive Clutch/Driven Pulley Monthly 16 Check for damage, binding, and wear/remove
drive belt, clean drive clutch/driven pulley with
compressed air, and clean sheaves with suitable
parts-cleaning solvent
Rear Suspension Monthly 30 Grease

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 The longevity and safety of the snowmo-
bile can be increased by making periodic CAUTION
checks of the items in the preceding A torn air filter can cause damage to
checklist. the turbocharger/engine. Contami-
nants may get inside the turbo-
If, at any time, abnormal noises, vibra- charger/engine if the filter is torn.
tions, or improper working conditions of Carefully examine the filter for holes
any component of this snowmobile are or tears. Replace the filter with a new
detected, DO NOT OPERATE THE one if it is torn.
SNOWMOBILE. Take the snowmobile 3. Clean any debris from inside the air
to an authorized Arctic Cat Snowmobile intake plenum.
dealer for inspection and adjustment or
repair. If not under warranty, this service 4. Place the new filter (if necessary)
is at the discretion and expense of the into the housing.
snowmobile owner. 5. Install the hood (see Access Panel/Hood
The snowmobile should be taken to an (Removing/Installing) in the General
authorized Arctic Cat Snowmobile dealer Information section of this manual).
at the end of each snowmobiling season
for general inspection and for off-season CAUTION
storage servicing. This inspection and Do not run the engine without the air
servicing is at the expense of the snow- filter installed. Severe damage to the
mobile owner. turbocharger/engine will occur.
Air Cleaner/Filter (1100 Fuel System
cc Turbo Models)
The air filter inside the air cleaner housing ! WARNING
must be kept clean to provide good engine Whenever any maintenance or inspec-
power and gas mileage. If the snowmobile tion is made on the fuel system in
is used under normal conditions, inspect which there may be fuel leakage, there
the filter weekly and replace the filter at should be no welding, smoking, open
the intervals specified. If operated in flames, etc., in the area.
adverse conditions, inspect and service the In-Line Fuel Filter (1100 cc
filter more frequently. Use the following Models)
procedure to remove the filter and to
inspect and/or replace it. Arctic Cat recommends that the in-line fuel
filter be replaced every 5000 miles. The fil-
CAUTION ter must be clean to allow the fuel hose to
transmit the amount of gasoline required.
Failure to inspect the air filter fre-
quently if the snowmobile is used in If the in-line fuel filter is obstructed, gas-
adverse conditions can damage the oline flow will be restricted; therefore,
turbocharger/engine. the filter must be replaced. To remove
and install the in-line fuel filter, use the
 NOTE: For this procedure, the following procedure:
hood must be removed (see Access
Panel/Hood (Removing/Installing) in
the General Information section of ! WARNING
this manual). Since the fuel supply hose may be
under pressure, always wear safety
1. Remove the air filter from the housing. glasses; then remove the hose slowly
2. Inspect the air filter for dirt or damage. to release the pressure. Place an
absorbent towel around the connec-
tion to absorb the fuel.
CAUTION
Do not use compressed air in an  NOTE: Before removing the fuel fil-
attempt to clean the filter. Damage to ter, take note that the filter is direc-
the filter may occur. If the filter is tional and the arrow should be
dirty, it must be replaced. directed towards the engine.

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  NOTE: On the non-turbo models, Checking Engine Oil
the fuel filter is located below the Level (1100 cc Models)
steering support. To access the filter, 1. Park the snowmobile on a level sur-
the hood must be removed (see
Access Panel/Hood (Removing/ face; then start the engine and allow
Installing) in the General Information it to warm up for 5-10 minutes, or if
section of this manual). the snowmobile was operated, allow
the engine to idle for approximately
 NOTE: On the turbo models, the 30 seconds.
fuel filter is located between the gas
tank and the rear belt guard and is  NOTE: The snowmobile must be
secured to the tunnel with a filter on a level surface for this procedure.
bracket. To access the filter, the left- 2. Shut the engine off; then remove the
side access panel must be opened right-side access panel and verify oil
and the lower console must be is visible at least halfway up in the
unlatched and opened.
sight glass.
1. Remove the hose clamps and dis-
card; then slowly remove the fuel
hoses from the fuel filter. Dispose of
the excess fuel from the filter prop-
erly.
2. Inspect the fuel hoses thoroughly for
any signs of cracking, cuts, or wear
points.
3. Place the new hose clamps on the
fuel hoses; then with the fuel pump 0746-166
inlet and outlet noted, connect the 3. If oil is not visible halfway up in the
fuel hoses to the fuel filter. Secure sight glass, add recommended
with the hose clamps. engine oil until oil is visible half-
 NOTE: After completing the way up the sight glass.
changing of the fuel filter and the
engine is started for the first time,  NOTE: Care must be taken not to
inspect the filter area for any signs over-fill the reservoir with oil.
of leaks. Changing Engine Oil/
Gasoline Additives Filter (1100 cc Models)
Fuel de-icer can be used for all models. ! WARNING
Also, periodic use of an injector cleaner Care must be taken if a hot drain plug
for 800 cc models is recommended espe- is removed by hand. Burning could
cially in the last tank of gasoline before occur.
storage. Arctic Cat Fuel Stabilizer (p/n
0436-907) should also be added to the  NOTE: Recycle or properly dis-
last tank of gasoline before storage. pose of the used engine oil.
Fuel Pickup Valves  NOTE: The access panels and
hood must be removed for this pro-
If ever there is a restricted fuel flow and a cedure (see Access Panel/Hood -
pickup valve is suspected, take the snow- Removing/Installing in the General
mobile to an authorized Arctic Cat Snow- Information section).
mobile dealer for this service. If not
under warranty, this service is at the dis- 1. Park the snowmobile on a level sur-
cretion and expense of the snowmobile face; then start the engine and allow
owner. it to warm up for 5-10 minutes, or if
the snowmobile was operated, allow
the engine to idle for approximately
30 seconds. Shut the engine off.

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 2. Remove the torx-head screws and  NOTE: On the turbo models, the oil
the access plate from beneath the filter is accessible between the front
snowmobile. opening of the chassis and the lower
intercooler hose.
3. Place a drain pan beneath the engine oil
pan drain plug; then remove the plug 8. Apply a light coat of fresh engine oil
and allow the oil to drain completely. to the seal of the new oil filter.
9. Install the new oil filter by turning
the oil filter by hand until the seal
has contacted the oil filter mounting
surface; then tighten the oil filter to
15 ft-lb. Remove the drain pan.
10. Pour 2.9 l (3 U.S. qt) of the recom-
mended engine oil into the oil reservoir.
11. Open the air bleed bolt located on
the oil pump (beneath the coolant
PC010A tank) to purge air from the oil hose.
4. Install the engine oil drain plug with
a new gasket; then tighten the plug
to 16 ft-lb.
5. Remove the four torx-head screws
securing the right-side footrest to the
tunnel and the support; then with a
drain pan in position, remove the
drain plug from the oil reservoir.

PC016A

 NOTE: When air can no longer be

heard purging from oil pump bleed,
tighten the bleed bolt to 7.5 ft-lb.

CAUTION
Do not attempt to start the engine
with the bleed bolt open.
746-121A
12. Without starting the engine, place
 NOTE: To aid in draining the oil the handlebar emergency stop
from the reservoir, position a funnel
between the reservoir and the open- switch to the RUN position and the
ing of the tunnel running board. ignition switch to the ON position.
The Oil Pressure Warning Icon
6. After the oil has drained completely, should illuminate.
install the drain plug with a new O-
ring and tighten to 16 ft-lb.  NOTE: If the warning icon does not
illuminate, take the snowmobile to an
 NOTE: Always install a new Oil Pan authorized Arctic Cat Snowmobile
Drain Plug Gasket (p/n 3402-011) and dealer for service. If not under war-
a new Reservoir Drain Plug O-Ring (p/ ranty, this service is at the discretion
n 1602-213) when changing the oil. and expense of the snowmobile owner.
7. Using Oil Filter Wrench (p/n 0644- 13. If the warning icon illuminates
551), loosen (but do not remove) the (from step 12), start the engine. The
oil filter and allow the oil to drain warning icon should go out within
from the filter into the drain pan; five seconds. If it does, proceed to
then remove the filter. step 14.

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  NOTE: If the warning icon does not 1. Remove the filler cap from the cool-
go out, shut the engine off immedi- ant reservoir.
ately and repeat step 11; then place
the ignition switch to the ON posi- 2. Verify the coolant level is at the bot-
tion and repeat step 13. If the warn- tom of the tab in the filler neck.
ing icon does not go out, take the
snowmobile to an authorized Arctic
Cat Snowmobile dealer for service. If
not under warranty, this service is at
the discretion and expense of the
snowmobile owner.
14. Shut the engine off; then add oil to
the oil reservoir until oil is visible
halfway up in the sight glass.
15. Install the access plate and torx-head 0746-117
screws beneath the snowmobile; 3. If the coolant is below the tab, add
then install the hood and access pan- coolant to the reservoir until at the tab.
els (see Access Panel/Hood -
Removing/Installing in the General
Information section). CAUTION
If the coolant is below the tab and if
Coolant Level coolant has been added, immediately
 NOTE: Use a good quality, ethylene inspect for leakage and/or damage. If
glycol-based, automotive-type coolant. leakage or damage is detected, take
the snowmobile to an authorized Arc-
 NOTE: Always check the coolant tic Cat Snowmobile dealer for ser-
level with the engine cold. vice. If not under warranty, this
service is at the discretion and
800 cc Models expense of the snowmobile owner.
Open the left-side access panel and locate  NOTE: On the HCR model if operat-
the coolant filler neck behind the steering ing on ice or hard-packed snow, the
support. The coolant should be visible at ice scratchers must be engaged to
least 3/4-way to the top of the filler neck. reduce engine overheating.
If coolant must be added, the hood must
be removed (see Access Panel/Hood - Spark Plugs
Removing Installing sub-section in the 1100 cc Models
General Information section).
 NOTE: Always use the recom-
CAUTION mended spark plugs in the engine.
See the appropriate specifications
After operating the snowmobile for sheet for correct spark plug gap.
the initial 5-10 minutes, stop the
engine, allow the engine to cool Varying terrain conditions and operating
down, and check the coolant level. usage may require spark plugs of a differ-
Add coolant as necessary. ent heat range. For example, sustained
 NOTE: On the HCR model if operat- cross-country riding will usually require
ing on ice or hard-packed snow, the colder heat-range spark plugs while trail
ice scratchers must be engaged to riding or other continual slow speed
reduce engine overheating. operation will usually require hotter heat-
range spark plugs.
1100 cc Models
 NOTE: The access panels and CAUTION
hood must be removed for this pro- If adjusting spark plug gap is neces-
cedure (see Access Panel/Hood - sary, do not use the center electrode
Removing/Installing sub-section in as a leverage point. Damage to the
the General Information section). plug may occur.

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 Removing/Installing Spark
Plugs CAUTION
 NOTE: Spark plug maintenance If adjusting spark plug gap is neces-
may be done by the snowmobile sary, do not use the center electrode
owner if qualified to do so. If the as a leverage point. Damage to the
owner does not feel qualified, take plug may occur.
the snowmobile to an authorized
Arctic Cat Snowmobile dealer for Removing/Installing Spark
this service. This service is at the Plugs
discretion and expense of the snow-
mobile owner.  NOTE: For this procedure, the
hood must be removed (see Access
 NOTE: For this procedure, the Panel/Hood (Removing/Installing) in
hood must be removed (see Access the General Information section of
Panel/Hood (Removing/Installing) in this manual).
the General Information section of
this manual). 1. Remove the springs securing the
expansion chamber to the exhaust
1. On the turbo models, remove the manifold and resonator.
spark plug end caps; on the non-
turbo models, remove the two cap 2. Move the expansion chamber out of
screws securing the ignition coils to the way to access the spark plugs.
the cylinder head cover. 3. Remove the spark plug caps from
2. Using a 3/8-in. drive ratchet, the plugs.
adapter, and a 5/8-in. spark plug 4. Using a spark plug wrench, remove
socket, remove the two spark plugs. the plugs.
 NOTE: Prior to installing the spark 5. Install the plugs and finger-tighten.
plugs, check the gap between the
electrode and ground strap. The 6. Tighten the spark plugs to 19 ft-lb;
clearance should be 9 mm (0.035 in.). then install the spark plug caps.
3. Install the spark plugs. Tighten to 7. Place the expansion chamber into
96 in.-lb. position and secure to the exhaust
manifold and resonator with the
4. On the non-turbo models, install the springs.
ignition coils onto the cylinder head
cover and tighten the two 6 mm cap 8. Install the hood (see Access Panel/
screws to 96 in.-lb. On the turbo mod- Hood (Removing/Installing) in the
els, install the spark plug end caps. General Information section of this
manual).
5. Install the hood (see Access Panel/Hood
(Removing/Installing) in the General Checking Spark Plugs
Information section of this manual). 800 cc Models
800 cc Models To see if the spark plugs being used are of
 NOTE: Always use the recom- the proper heat range (after the snowmo-
mended spark plugs in the engine. bile has been operated under normal driv-
See the appropriate specifications ing conditions), remove the spark plugs
sheet for correct spark plug gap. and examine the condition of the center
electrode insulator of each spark plug.
Varying terrain conditions and operating
usage may require spark plugs of a differ-
ent heat range. For example, sustained
cross-country riding will usually require
colder heat-range spark plugs while trail
riding or other continual slow speed
operation will usually require hotter heat-
range spark plugs.

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  NOTE: Take the snowmobile to an
authorized Arctic Cat Snowmobile
dealer for inspection and service.
This service is at the discretion and
expense of the snowmobile owner.

CAUTION
It is critical that the checking/adjust-
ing valve clearance be done at the
recommended intervals or severe
AO352A engine damage may occur.
A. TAN or LIGHT BROWN insula-
tor indicates correct spark plugs Checking/Adjusting
(heat range). APV Cables (800 cc
B. LIGHT GRAY or WHITE insula- Models)
tor indicates over-heating of the Proper cable adjustment is critical to the
engine. This condition is caused byoperation of the APV system. Although
a too lean condition or incorrect inspecting cable adjustment is recom-
spark plugs (heat range too hot). mended every 1000-2000 miles, the cable
should not need adjustment often. To
C. BLACK insulator indicates fuel check the cable adjustment, use the fol-
in the combustion chamber is not lowing procedure:
burning completely. This condi-
tion is caused by a too rich con-
dition, too much oil, or incorrect
spark plugs (heat range too cold).
 NOTE: If the center electrode insu-
lators are light gray, white, or black
and if the oil-injection pump synchro-
nization, and ignition timing are cor-
rect, different heat-range spark plugs
may be necessary. Authorized Arctic
Cat Snowmobile dealers have 0745-819
detailed spark plug information. Con-
sult a dealer before changing spark 1. Using a small needle-nose pliers,
plugs, as incorrect heat-range spark remove the servomotor cable holder.
plugs could cause poor engine per-
formance or engine damage.

CAUTION
If a spark plug is light gray, white, or
black and another is tan or light
brown, take the snowmobile to an
authorized Arctic Cat Snowmobile
dealer for inspection and service. If
not under warranty, this service is at
the discretion and expense of the 0745-823
snowmobile owner.
2. Using an adjustable wrench, rotate
Checking/Adjusting the servomotor actuator counter-
Valve Clearance (1100 clockwise to loosen the cable; then
cc Models) pull the cable housings down and
out of the servomotor.
After 5000 miles or prior to seasonal
storage, valve clearance should be
checked and adjusted as necessary.

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  NOTE: The measurements must be
CAUTION within the specifications from the
chart. If the measurements are
Do not use the nut securing the pul- within specifications, no adjustment
ley to the servomotor to rotate the is necessary (proceed to step 8). If
actuator. they are not within specifications,
proceed to step 6.
 NOTE: For installing purposes,
note the side that the servomotor 6. Loosen the jam nut on the cable to
cables are installed on. be adjusted; then using the adjusting
3. Slide each cable drum out of the slot nuts, lengthen or shorten the housing
of the servomotor actuator. as needed.
4. While holding the cable housing 7. Once the proper length has been
firmly, pull the cable as far out as it attained, hold the adjusting nut in place
will go; then release. Repeat three to and tighten the jam nut securely.
four times. The cable/exhaust valve 8. Place the cable housings into posi-
should move freely without binding. tion in the servomotor. Secure the
 NOTE: If the cable/exhaust valve cable housings with the cable holder.
does not move freely, the exhaust valve
assembly will need to be removed for CAUTION
further inspection. Take the snowmo- Assure the cables are rotated and
bile to an authorized Arctic Cat Snow- secured properly to avoid contacting
mobile dealer for this service. exhaust components.
 NOTE: When measuring the cables, Battery (Electric Start)
they are to be routed as close to their These sealed batteries after being in ser-
installed position as possible. vice require regular cleaning and
5. While holding the cable housing, recharging in order to deliver peak per-
lightly pull on one cable end to formance and maximum service life. The
remove any slack; then measure the following procedures are recommended
amount of exposed cable from the for cleaning and maintaining sealed bat-
cable housing to the end of the cable teries. Always read and follow instruc-
(cable drum). tions provided with battery chargers and
battery products.
APV CABLE LENGTH
 NOTE: Battery maintenance may
800 cc 1.377 in. ± 0.039 in. be done by the snowmobile owner if
qualified to do so. If the owner does
not feel qualified, take the snowmo-
bile to an authorized Arctic Cat
Snowmobile dealer for this service.
This service is at the discretion and
expense of the snowmobile owner.
To remove and charge the battery, use the
following procedure:

! WARNING
0735-516
Any time service is performed on a
 NOTE: The two cable measure- battery, the following must be
ments must be equal in length or observed: Keep sparks, open flame,
less than 0.5 mm (0.020 in.) differ- cigarettes, or any other flame away.
ence in length from each other. Always wear safety glasses. Protect
skin and clothing when handling bat-
 NOTE: Repeat steps 4 and 5 for each teries. When servicing battery in
cable; then compare the measure- enclosed space, keep the area well-
ments to the APV Cable Length chart. ventilated.

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 4. Thoroughly wash the battery with
! WARNING soap and water; then using a wire
Battery posts, terminals, and related brush, clean the battery posts and
accessories contain lead and lead cable ends removing all corrosive
compounds, chemicals known to the buildup. Replace damaged cables or
state of California to cause cancer cable ends.
and reproductive harm. Wash hands
after handling.  NOTE: If battery posts or cable
1. Remove the torx-head screw from ends have a build-up of white/green
the rear underside of the seat; then powder residue, apply water and
remove the seat. baking soda to neutralize acid; then
flush off with warm soapy water.
CAUTION
CAUTION
On the LXR models, make sure to dis-
connect the seat heater harness con- Do not remove seal strip on a sealed
nector prior to removing the seat. battery.

2. Remove the negative battery cable ! WARNING

and ground wire; then remove the Battery acid is harmful if it contacts
positive cable. eyes, skin, or clothing. Care must be
 NOTE: For installing purposes taken whenever handling a battery.
prior to removing the battery, note 5. Using a multimeter, test the battery
the routing and securing locations of voltage. The meter must read no less
the cables and harness wires.
than 12.5 DC Volts for a fully
3. Remove the two torx-head cap screws charged battery.
and lock nuts securing the battery  NOTE: At this point if the meter
bracket/solenoid to the seat-base; then reads as specified, the battery may
move the bracket up and out of the be returned to service (see step 9).
way and remove the battery.
6. If the meter reads less than specified
voltage, charge the battery using the
following guidelines.
A. When using an automatic battery
charger, always follow the char-
ger manufacturer’s instructions.
B. When using a constant-current
battery charger, use the follow-
ing Battery Charging Chart.
746-170A
CAUTION
! WARNING Never exceed the standard charging
Avoid spillage and contact with skin, rate.
eyes, and clothing.
! WARNING
CAUTION An overheated battery could explode
Do not charge the battery while it is in causing severe injury or death.
the snowmobile with the battery ter- Always monitor charging times and
minals connected. charge rates carefully. Stop charging
if the battery becomes very warm to
the touch. Allow it to cool before
resuming charging.

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 Battery Charging Chart
(Constant-Current Charger) CAUTION
Battery Charge Time Connecting cables in reverse (posi-
Voltage Charge Required (at 1.5-
State tive to negative and negative to posi-
(DC) 2.0 Amps) tive) can cause serious damage to
12.5 (mini- 100% None the electrical system.
mum)
 NOTE: Assure the harness wires
12.2-12.4 75%-99% 3-6 hours and cables are routed properly as
12.0-12.2 50%-74% 5-11 hours noted during removing battery pro-
cedure.
11.0-11.9 25%-49% 13 hours (minimum)
11.5 or less 0-24% 20 hours (minimum)
 NOTE: If the battery voltage is 11.5
DC Volts or less, some chargers may
“cut off” and fail to charge. If this
occurs, connect a fully charged
booster battery in parallel (positive
to positive and negative to negative)
for a short period of time with the
charger connected. After 10-15 min-
utes, disconnect the booster battery PC021A
leaving the charger connected and
the charger should continue to 11. Install the battery bracket/solenoid
charge. If the charger “cuts off,” and tighten the torx-head cap screws
replace the battery. and lock nuts to 105 in.-lb; then
install the seat and secure with the
7. After charging the battery for the torx-head screw. Tighten securely.
specified time, remove the battery
charger and allow the battery to sit  NOTE: On the 1100 cc LXR models
for 1-2 hours. prior to lowering and securing the
seat, connect the seat heater har-
8. Connect the multimeter and test the ness connector.
battery voltage. The meter should
read no less than 12.5 DC Volts. If Fuses
the voltage is as specified, the bat- Fuses protect the snowmobile electrical
tery is ready for service. system from overloading. If electrical
 NOTE: If voltage in step 8 is below parts in the snowmobile are not working,
specifications, charge the battery an the system may have been overloaded and
additional 1-5 hours; then retest. The caused a blown fuse. Before repairing or
battery is ready for service. replacing any electrical part, check the
appropriate fuses. If a fuse blows (opens a
9. Place the battery into position in the circuit), all the parts of the snowmobile
snowmobile; then coat the battery that use that circuit will not work.
posts and cable ends with a light
coat of multi-purpose grease. Once which fuse to check has been deter-
mined, perform the following steps:
CAUTION 1. Locate the fuse block and remove
Before installing the battery, make sure the fuse block cover.
the ignition switch is in the OFF position.
 NOTE: To locate the fuse block on
10. Connect the battery cables (positive the 1100 cc models, open the left-side
cable first). access panel; the fuse block is on the
belt guard. On the 800 cc models,
open the right-side access panel; the
fuse block is on the upper spar.

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 Brake System
1100 cc Models Arctic Cat recommends that the brake
system (brake lever, fluid reservoir, hose,
caliper, pads, and brake disc) be checked
daily for fluid leakage, wear, or damage
and for proper operation. Also, the brake
fluid level must be checked every time
before starting the engine.

! WARNING
PC004A DO NOT operate the snowmobile
when the brake lever lock is engaged
800 cc Models or when any component in the brake
system is damaged, worn, or
adjusted improperly. If the snowmo-
bile is operated and the brake system
is not functioning properly, severe
personal injury could result.
Checking/Adding Brake
Fluid
PC020A
1. With the brake fluid reservoir in a
level position and the cover
 NOTE: There are spare fuses removed, check the fluid level. The
beneath the fuse block cover. brake fluid level must be at the high
2. Remove the suspected fuse. barke fluid mark in the reservoir.
 NOTE: Fuse function desciptions
are next to the fuse contacts in the
fuse block.
3. Look through the clear side of the
fuse to see if the element inside is
burned or separated. If it is, the fuse
is blown and should be replaced
with a fuse of the correct amperage
rating.

! WARNING 0745-817
2. If the brake fluid is below the high
Always replace a fuse with one hav- brake fluid mark, add Arctic Cat
ing the same specified amperage rat- approved DOT 4 brake fluid until
ing. Using a fuse with a higher rating
can cause severe wire damage and
the fluid is at the recommended
could start a fire. level. Install and secure the reservoir
cover. Do not allow moisture to con-
4. Install the fuse block cover and close taminate the brake system.
the access panel.
Even after replacing a fuse, it may con- CAUTION
tinue to blow if the cause of the overload Brake fluid is highly corrosive. Do not
is not determined. If the fuse continues to spill brake fluid on any surface of the
blow, take the snowmobile to an autho- snowmobile.
rized Arctic Cat Snowmobile dealer for
service. If not under warranty, this ser-
vice is at the discretion and expense of
the snowmobile owner.

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 ! WARNING
! WARNING
Do not overfill the brake fluid reser-
voir. Overfilling the reservoir may Do not operate the snowmobile if the
cause the brake system to hydrauli- compressed distance between the
cally lock. Use only Arctic Cat brake lever and the handlebar is less
approved DOT 4 brake fluid. Never than 2.54 cm (1 in.). Brake loss may
substitute or mix different types or occur. Brake loss can result in severe
grades of brake fluid. Brake loss can personal injury.
result. Brake loss can result in severe
injury or even death. Bleeding Brake System
Changing Brake Fluid If the brake lever feels spongy when
applied, the brake system may need to be
The brake fluid must be changed on a reg- bled. To bleed the brake, use the follow-
ular basis and whenever the brake fluid ing procedure:
has been overheated or contaminated. The
brake fluid should be changed every 1000  NOTE: The brake system may be
miles or at the end of the snowmobiling bled by the snowmobile owner if
season, whichever occurs first. Take the qualified to do so. If the owner does
snowmobile to an authorized Arctic Cat not feel qualified, take the snowmo-
Snowmobile dealer for this service. This bile to an authorized Arctic Cat
service is at the discretion and expense of Snowmobile dealer for this service.
the snowmobile owner. This service is at the discretion and
expense of the snowmobile owner.
Checking Brake Lever
Travel 1. Remove the reservoir cover and (if
necessary) fill the reservoir to the
Before each use, check the brake lever high brake fluid mark with Arctic
travel using the following procedure: Cat approved DOT 4 brake fluid.
1. Compress the brake lever fully.
CAUTION
 NOTE: Do not pump the brake Brake fluid is highly corrosive. Do not
lever as it will produce an inaccurate spill brake fluid on any surface of the
reading. snowmobile.
2. Measure the distance between the
brake lever and the handlebar. The ! WARNING
distance must be greater than 2.54 Use only Arctic Cat approved DOT 4
cm (1 in.). brake fluid. Any substitute may result
in a loss of brakes.
2. Slide a piece of flexible tubing over
the ball of the bleeder valve and
direct the other end into a container.

0745-816
3. If the resultant distance is less than
specified, take the snowmobile to an
authorized Arctic Cat Snowmobile
dealer for service. If not under war- PC005A
ranty, this service is at the discretion
and expense of the snowmobile owner.

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 3. Slowly compress the brake lever  NOTE: The above procedure will
until maximum pressure is attained; allow room for the fluid from the cali-
then hold the lever in the com- per when the pistons are pushed
pressed position to maintain pres- into the caliper for installing new
sure. Open the bleeder valve to brake pads. Replacing the cover will
release the fluid and air. When the prevent fluid spillage.
fluid stops, close the bleeder valve; 2. Open the left-side access panel and
then release the brake lever. remove the rear belt guard. Remove
4. Repeat step 3 until the brake fluid the driven pulley.
flows free of air bubbles. 3. Remove the two torx-head screws
 NOTE: It may be necessary to refill securing the brake shield to the belt
the reservoir during the bleeding guard mount; then remove the cap
process. Never allow the brake fluid screws securing the brake shield to
to go below the low brake fluid mark the brake caliper.
in the reservoir.
4. Carefully move the shield out of the
5. When the brake fluid is free of all air way; then remove the hairpin clip
and the brake lever feels firm when securing the brake pads to the cali-
compressed, fill the reservoir to the per assembly.
high brake fluid mark; then install and 5. Using a pair of pliers, pull the outer
secure the cover. Remove the tube brake pad out of the caliper assembly.
from the bleeder valve.
Checking/Changing Brake
Pads
The condition of the brake pads must be
checked daily and changed if worn or
damaged. To check and change the brake
pads, use the following procedure:
 NOTE: The brake pads may be
changed by the snowmobile owner if
qualified to do so. If the owner does PC013
not feel qualified, take the snowmo-
bile to an authorized Arctic Cat  NOTE: Changing one pad at a time
Snowmobile dealer for this service. will prevent one piston from pushing
This service is at the discretion and out the other piston from the caliper.
expense of the snowmobile owner. 6. Measure the thickness of the brake pad.
 NOTE: When installing new brake The brake pad thickness must be greater
pads, always install them as a set. than 5.0 mm (0.20 in.). If the brake pad
Never install just one pad or use thickness is less than specified, replace-
brake pads which have been used in ment of both pads is necessary.
another snowmobile.
1. Remove the brake fluid reservoir
cover; then remove most of the
brake fluid from the reservoir. Install
the cover.

CAUTION
Brake fluid is highly corrosive. Do not
spill brake fluid on any surface of the
snowmobile.
PC011A
7. Using a flat-blade tool, slowly and care-
fully push the piston into the caliper.

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 8. Position the outer brake pad into the 3. Repeat procedure 10-15 times allow-
caliper; then install the hair-pin clip ing some cooling between stops.
into the caliper assembly.
 NOTE: Do not repeat too soon or
9. Repeat steps 5-8 for the inner pad; then too aggressively as to get the brake
secure the pad with the hairpin clip. disc “red hot.”
10. Remove the reservoir cover and
remove the remaining fluid; then fill ! WARNING
the reservoir with fresh fluid and Do not attempt sudden stops or put
install the cover. yourself into a situation where a sud-
den stop will be required until the
11. Pump the brake lever to ensure cor- brake pads are properly burnished.
rect positioning of the brake pads
and proper brake lever travel (see  NOTE: This procedure stabilizes
Checking Brake Lever Travel sub- the pad material and extends the life
section); then release. of the pads.
 NOTE: If brake lever travel is not Drive Belt
within specification, bleed the brake The drive belt transfers power from the
system (see Bleeding Brake System drive clutch to the driven pulley. If the
sub-section). belt is worn, cracked, or stretched, maxi-
12. Remove the reservoir cover and fill mum power will not be transmitted and
the reservoir (if necessary) to the the belt could also fail and therefore must
proper level with fresh brake fluid; be replaced. Periodic checks (at least
then install the cover. once a month under normal usage) of two
drive belt specifications are essential.
13. Secure the brake shield, the driven
pulley (tightened to 20 ft-lb), and the 1. Measure the outside circumference
rear belt guard; then close and of the drive belt. The belt should be
secure the left-side access panel. within the recommended range in
circumference (see appropriate spec-
 NOTE: When new brake pads are ifications sheet).
installed, a “burnishing” process is
required (see Burnishing Brake Pads 2. Measure the outside width of the
sub-section). drive belt. The belt should be within
the recommended range in width.
Burnishing Brake Pads
3. Check the belt for cracking, fraying, etc.
After changing brake pads, the new brake
pads must be burnished to achieve full If any of the specifications or conditions
braking effectiveness. Braking distance are unsatisfactory, replace the drive belt.
will be extended until brake pads are
properly burnished.  NOTE: Drive belts should be pur-
chased from an authorized Arctic
To properly burnish the brakes, use fol- Cat Snowmobile dealer, as Arctic Cat
lowing procedure: drive belts are made to exact specifi-
cations and of quality material. Belts
1. Choose an area sufficiently large to made by other manufacturers may
safely accelerate to 30-40 mph and not be of the same specifications or
to brake to a stop. quality and, therefore, usage could
 NOTE: This procdure can also be result in poor performance and pre-
accomplished using a shielded jack mature belt failure.
stand.  NOTE: Before starting the snow-
2. Accelerate to 30-40 mph; then com- mobile in extremely cold tempera-
press brake lever to decelerate to a stop. tures, the drive belt should be
removed and warmed up to room
 NOTE: Lightly apply the brake lever temperature. Once the drive belt is at
to come to an easy stop; do not over- room temperature, install the drive
apply brakes or “lock up” the track. belt.

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 Also, new drive belts have a break-in  NOTE: Adding shim washers will
period of approximately 25 miles. After decrease belt deflection and remov-
installing a new drive belt, drive the ing shim washers will increase belt
snowmobile for 25 miles at 3/4 throttle or deflection. Available shim washers
less. By revving the engine up and down from Arctic Cat are p/n 0648-714
(but not exceeding 60 mph), the exposed (0.090 in.) - one included in the tool
cord on the side of a new belt will be kit, p/n 0648-715 (0.030 in.), and p/n
worn down. This allows the drive belt to 0648-716 (0.060 in.).
gain its optimum flexibility and will  NOTE: Removing/adding shim
extend drive belt life. washers may be done by the snow-
mobile owner if qualified to do so. If
CAUTION the owner does not feel qualified,
Never run the engine with the drive take the snowmobile to an autho-
belt removed. Excessive revving of the rized Arctic Cat Snowmobile dealer
engine could result in serious engine for this service. This service is at the
damage and drive clutch failure. discretion and expense of the snow-
mobile owner.
Checking/Adjusting Drive
Belt Deflection Removing Drive Belt
 NOTE: Changing a drive belt can
be done by the snowmobile owner if
qualified to do so. If the owner does
not feel qualified, take the snowmo-
bile to an authorized Arctic Cat
Snowmobile dealer for this service.
This service is at the discretion and
expense of the snowmobile owner.
1. Turn ignition key to the OFF posi-
tion and wait for all moving parts to
0746-092 stop.
The drive belt must have the proper fit in 2. Set the brake lever lock.
the drive clutch and driven pulley. To
check for proper drive belt fit, use the 3. Open the left-side access panel; then
following procedure. remove the rear belt guard.
1. Place a straightedge on the top of the  NOTE: On the 1100 cc models,
drive belt. The straightedge should move and secure the rear belt guard
reach from the drive clutch to the top up and out of the way.
of the driven pulley. 4. Remove the cap screw, lock washer,
 NOTE: Make sure the drive belt is washer, and sheave adjuster from the
all the way out in the driven pulley end of the driven pulley; then
before checking drive belt deflection. remove the sheave adjuster from the
cap screw.
2. Using a stiff ruler centered between
the drive clutch and driven pulley,
push down on the drive belt just
enough to remove all slack and note
the amount of deflection. The deflec-
tion should be within the range of
28.5-31.8 mm (1 1/8-1 1/4 in.).
3. To correct drive belt deflection,
remove the sheave adjuster from the
pulley, remove or add shim washers
to the adjuster, and install the 0743-395
adjuster.

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  NOTE: Assure that the shims and Track Tension
O-ring are not removed from the Track tension is directly related to the
adjuster. overall performance of the snowmobile. If
5. Install the 2-in. flat washer (from the the track is too loose, it may slap against
tool kit) onto the cap screw. the tunnel causing wear or it may “ratchet”
on the track drive sprockets. If extremely
6. Install the cap screw into the driven loose, the idler wheels may climb over the
pulley; then tighten the cap screw track lugs forcing the track against the tun-
until the movable sheave opens far nel causing the track to “lock.” Arctic Cat
enough to allow the belt to be recommends that the track tension be
removed. checked daily during the first 300 miles of
7. Remove the drive belt from the operation and once a week thereafter and
driven pulley first; then from the adjusted according to need. The track will
drive clutch. stretch and take a “set” during break-in.
Track deflection must be maintained
 NOTE: Before installing the drive within the recommended range.
belt, use a suitable cleaning solvent
to thoroughly clean the sheaves. ! WARNING
Installing Drive Belt Track tension must be properly main-
tained. Personal injury could result if
 NOTE: If a new drive belt is being a track is allowed to become exces-
installed, see Drive Belt Break-In sively loose.
sub-section in the General Infor-
mation section. Checking Track Tension

1. Place the drive belt (so the part num- ! WARNING

ber can be read) between the sheaves DO NOT attempt to check or adjust
of the drive clutch first; then track tension with engine running.
between the sheaves of the driven Turn ignition key to the OFF position.
pulley. Personal injury could result from
contact with a rotating track.
2. Remove the cap screw; then remove
the 2-in. flat washer from the cap 1. Remove excess ice and snow buildup
screw. from the track, track drive sprockets,
and the inside of the skid frame.
3. Install the cap screw, lock washer,
washer, and sheave adjuster back into 2. Elevate the snowmobile on a
the driven pulley. Tighten the cap screw shielded safety stand high enough to
to 20 ft-lb. use a spring scale.
4. Install and secure the rear belt guard; 3. At mid-point of the track (on the bot-
then close the left-side access panel. tom side), hook a spring scale around a
track clip; then pull down on the scale
! WARNING to the recommended pressure. Measure
the deflection (distance) between the
Never operate the snowmobile with- bottom of the wear strip and the inside
out the belt guard/access panel surface of the track clip. Compare the
secured in place. measurement with the chart.
5. Release the brake lever lock.
After
Model Setup Break-In
Tension Tension
F/XF Models @ 20 lb 44-51 mm 51-57 mm
(1.75-2 in.) (2-2.25 in.)
XF High Country 51 mm 51 mm
Model @ 20 lb (2 in.) (2 in.)
M Models @ 15 lb 51 mm 51 mm
(2 in.) (2 in.)

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 CAUTION
Always maintain track tension within
recommended specification.
4. Check track alignment (see Track
Alignment sub-section in this section).
5. After proper track tension is
obtained, tighten the idler wheel
0743-188 axle cap screws to 34 ft-lb; then
tighten the adjusting bolts securely
against the axle.
 NOTE: Since track tension and
track alignment are interrelated,
always check both even if only one
adjustment seems necessary.

! WARNING
Always make sure the adjusting bolts
0746-099 are snug against the axle and the
 NOTE: On the M models, measure- idler wheel cap screws are tightened
ment is from the bottom of the wear to specifications. Failure to do so
could cause the track to become
strip at the point of the shock pad on extremely loose and, under some
the slide rail. operating conditions, allow the idler
Adjusting Track Tension wheels to climb over the track lugs
forcing the track against the tunnel
 NOTE: To ensure proper track tension causing the track to “lock.” If a track
adjustment, perform all adjustments on “locks” during operation, severe per-
both sides of the snowmobile. sonal injury could result.
1. Loosen the idler wheel axle cap Track Alignment
screws. Proper track alignment is obtained when
the rear idler wheels are equal distance
from the inner track drive lugs. Excessive
wear to the idler wheels, drive lugs, and
track will occur if the track is improperly
aligned. Arctic Cat recommends that the
track alignment be checked once a week
or whenever the track tension is adjusted.
Checking Track Alignment
! WARNING
0745-811
2. If the deflection (distance between Make sure the ignition key is in the
OFF position and the track is not rotat-
the bottom of the wear strip and the ing before checking or adjusting track
inside surface of the track clip) alignment. Personal injury could result
exceeds specifications, tighten the if contact is made with a rotating track.
adjusting bolts to take up excessive
slack in the track. 1. Remove excess ice and snow
buildup from the track, track drive
3. If the distance between the bottom of sprockets, and the inside of the skid
the wear strip and the inside surface frame.
of the track clip is less than specified,
loosen the adjusting bolts to increase
the slack in the track.

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 2. Position the tips of the skis against a
wall; then using a shielded safety
stand, raise the rear of the snowmo-
bile off the floor making sure the
track is free to rotate.

! WARNING
The tips of the skis must be posi-
tioned against a wall or similar
object.
0745-811
! WARNING 2. Check track alignment and continue
DO NOT stand behind the snowmo- adjustment until proper alignment is
bile or near the rotating track. NEVER obtained.
run the track at high speed when the  NOTE: Make sure correct track
track is suspended. tension is maintained after adjust-
ing track alignment (see Track Ten-
3. Start the engine and accelerate sion sub-section in this section).
slightly. Use only enough throttle to
turn the track several revolutions. 3. After proper track alignment is
SHUT ENGINE OFF. obtained, tighten the idler wheel
axle cap screw to 34 ft-lb; then
 NOTE: Allow the track to coast to a tighten the adjusting bolts securely
stop. DO NOT apply the brake
because it could produce an inaccu- against the axle.
rate alignment condition.
! WARNING
4. When the track stops rotating, check Always make sure the adjusting bolts
the relationship of the rear idler are snug against the axle and the
wheels and the inner track drive lugs. idler wheel cap screws are tightened
If the rear idler wheels are centered to specifications. Failure to do so
between the inner track drive lugs, no could cause the track to become
adjustment is necessary. extremely loose and, under some
operating conditions, allow the idler
wheels to climb over the track lugs
forcing the track against the tunnel
causing the track to “lock.” If a track
“locks” during operation, severe per-
sonal injury could result.
4. Field test the track under actual con-
ditions.
5. After the field test, check the align-
ment of the track. If additional adjust-
0745-809
ment is necessary, repeat Adjusting
5. If the idler wheels are not centered Track Alignment procedure.
between the inner track drive lugs,
an adjustment is necessary. Suspension
The suspension should be adjusted for
Adjusting Track Alignment the operational needs and riding prefer-
1. On the side of the track which has ence of the operator.
the inner track drive lugs closer to The front shock springs determine the
the rear idler wheel, loosen the idler amount of ski pressure and the reaction
wheel axle cap screw; then rotate the of the front suspension to rough terrain.
adjusting bolt clockwise 1 to 1 1/2 The amount of ski pressure can also be
turns. changed by adjusting the length of the
skid frame front arm limiter straps.

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 On standard models, the rear arm shock  NOTE: Adjusting air shocks may
absorber spring influences the load carry-
be done by the snowmobile owner if
ing capability of the snowmobile and qualified to do so. If the owner does
should be adjusted for the weight and rid-
not feel qualified, take the snowmo-
ing preference of the operator. bile to an authorized Arctic Cat
Snowmobile dealer for this service.
 NOTE: On Sno Pro models, this This service is at the discretion and
adjustment is achieved by increase- expense of the snowmobile owner.
ing or decreasing the air pressure in
the rear arm air shock absorber. The air shocks are individually adjustable
for the terrain conditions and driving style
Adjusting Front (Ski) of the operator. The shocks are preset at
Shock Springs the factory (see chart) as an initial setting;
The front (ski) shock springs are individ- however, it is possible to “fine tune” the
ually adjustable for the terrain conditions shocks to match the operator’s weight,
and driving style of the operator. The riding style, and terrain conditions.
spring adjuster nut has been set at the fac- Checking and adjusting air pressure must
tory so the correct amount of threads are be done at riding temperature (outside).
exposed between the adjuster nut and the Also, it is advisable to check air pressure
threaded shock body as an initial setting. when the outside temperature varies
Additional ski pressure can be obtained more than 25°.
by tightening the spring tension; ski pres-
sure can be decreased by relaxing spring Initial Setting Chart
tension. Front Shock Rear Arm
Model (Ski) Shock
 NOTE: Equal adjustments should
be maintained on both sides of the M/XF Sno 6.3 kg/cm2 10.2-10.6 kg/cm2
snowmobile. Pro Models (90 psi) (145-150 psi)

Front (ski) shock spring pre-load adjust- F Sno Pro 5.3 kg/cm2 N/A
Models (75 psi)
ment is accomplished by loosening the
adjuster nut locking collar (B) from the  NOTE: Care should be taken to have
adjuster nut (A) and using the Spring equal pressure in the front (ski) shocks
Adjuster Tool from the tool kit, rotating before operating the snowmobile.
the adjuster nut in whichever direction is
desired. Tighten the locking collar To increase or decrease air pressure, use
against the adjuster nut. the following procedure.
 NOTE: When adjusting air pres-
sure, all weight must be removed
from the suspension, and the shock
absorbers must be fully extended.
 NOTE: Adding air pressure will
increase the air spring force; reduc-
ing air pressure will decrease air
spring force.
0745-159
! WARNING
Adjusting Fox Air Shocks Do not exceed 10.5 kg/cm2 (150 psi)
(Sno Pro Models) in the shock.
 NOTE: It is recommended to moni- 1. Remove the air valve cap from the
tor the air pressure in the air shocks shock.
once every month.
2. Thread the valve of Shock Absorber
Air Pump (p/n 2603-614) onto the
shock air valve approximately six
rotations.

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  NOTE: As the pump is being attached  NOTE: If the limiter straps are
to the shock, the hose will fill with air. adjusted, it is highly recommended that
This will result in a lower gauge pres- at least a minimum of 1/8 in. preload on
sure 0.14-3.52 kg/cm2 (2-5 psi). the shock spring be maintained.
3. To decrease air pressure in the ! WARNING
shock, press the black bleed valve
button half way down and hold until Do not adjust the front arm limiter
desired pressure is attained. straps to a point at which steering
and operator control of the snowmo-
 NOTE: Pressing the button fully bile are adversely affected.
down and releasing it will allow only
a small amount of air to escape Adjusting Rear Spring Pre-
(micro-adjust). Load (F Models)
4. To increase air pressure in the shock, Proper adjustment of rear spring pre-load
pump until desired pressure is is necessary to get the most desirable
attained. ride. The chart is designed to help in set-
ting up rear spring pre-load; however,
5. Remove the pump valve from the riding style is the single greatest factor in
shock air valve. determining rear spring requirements.
 NOTE: As the pump valve is being Rider Weight (lb) Cam Position
removed from the shock, the sound
of air loss is from the pump hose, Up to 180 1
not from the shock. 180-240 2
6. Install the air valve cap onto the shock. Over 240 3
Adjusting Skid Frame  NOTE: These cam position set-
Front Arm tings are suggestions only. Personal
riding style will greatly influence
The skid frame front arm shock spring cam position settings. Spend time to
tension and the limiter straps are adjust- determine setting preferences.
able. However, Arctic Cat recommends
that the shock spring be maintained at the Rear spring pre-load adjustment is accom-
factory preset of 1/8-1/4 in. preload. plished by rotating the adjusting cams.
Tightening the skid frame front arm shock Position 3 provides the stiffest ride, and
spring may cause improper balance and position 1 is for the light driver or slow-
may ruin the handling features of the speed trail riding. Position 2 is for the
snowmobile. average operator under normal conditions.
Always rotate the cam from the lighter
The length adjustment of the front arm position to the heavier position.
limiter straps determines the weight dis-
tribution between the front of the skid CAUTION
frame and the skis. Tightening the limiter
strap (shortening the strap) will pull up Never force the adjustment cams
on the front of the skid frame and will from the low position to the high
increase ski pressure. Loosening the lim- position. Cam damage may occur.
iter strap (lengthening the strap) lowers
the front of the skid frame and decreases
ski pressure.
When customizing the amount of ski
pressure, be sure to adjust both straps
equally and do not over-adjust the limiter
straps to adversely affect steering and
operator control of the snowmobile.
Some experimentation may be required
until the proper adjustment for the opera-
tor’s individual style is obtained. 741-450A

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 To rotate an adjusting cam, use the spark
plug wrench from the tool kit. Rotate the
wrench until the cam is in the desired
position. To stiffen the ride, rotate the cam
so as to raise the spring end. Make the
appropriate adjustment on the other cam.
Adjusting Skid Frame Rear
Arm Shock Spring (M/XF
Models)
Proper adjustment of rear arm shock 746-097A

absorber spring pre-load is necessary to 1. Disconnect the taillight harness con-

get the most desirable ride. nector.
The rear arm shock spring is adjustable 2. Remove the two torx-head screws
for the terrain conditions and driving securing the taillight to the bracket.
style and weight of the operator. The 3. Connect the taillight harness connec-
spring adjuster nut has been set at the fac- tor; then secure the taillight to the
tory so the correct amount of threads are bracket with the two torx-head screws.
exposed between the adjuster nut and the
threaded shock body as an initial setting. Removing/Installing
Headlight Bulb
Rear spring pre-load adjustment is
accomplished by loosening the adjuster  NOTE: The bulb portion of headlight
nut locking collar (B) from the adjuster is fragile. HANDLE WITH CARE. When
nut (A) and using the Spring Adjuster replacing the headlight bulb, the bulb
Tool from the tool kit, rotating the assembly must first be removed from
adjuster nut in whichever direction is the housing. Do not touch the glass
desired. Tighten the locking collar portion of the bulb. If the glass is
against the adjuster nut. touched, it must be cleaned with a dry
cloth before installing.
1. Disconnect the headlight harness
connector from the bulb; then
remove the rubber grommet from
the headlight housing.
2. Rotate the bulb retainer counter-
clockwise until it unlocks from the
housing; then remove the bulb.

0745-159

Lights
For the correct headlight bulb and/or tail-
light/brakelight LED, see the appropriate
specifications sheet.
Removing and Installing
Taillight/Brakelight
These models are equipped with an LED 0746-096
taillight/brakelight. If the LED fails, it 3. Install the bulb and retainer; then
must be replaced. To remove and install rotate the retainer clockwise until it
the LED, use the following procedure. properly locks in place.
4. Install the rubber grommet; then
connect the headlight harness con-
nector to the bulb.

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 5. Check headlight aim (see Adjusting 7. Adjust the headlight using the
Headlight Aim in this sub-section). adjusting screw on the backside of
the headlight housing until correct
! WARNING aim is obtained. Shut the engine off;
Do not operate the snowmobile
then disengage the brake lever lock.
unless headlight beam is adjusted
properly. An incorrectly adjusted
beam will not provide the operator
the optimum amount of light.
Adjusting Headlight Aim
The headlight can be adjusted for vertical
aim of the HIGH/LOW beam. The geo-
metric center of HIGH beam zone is to be
used for vertical aiming.
1. Position the snowmobile on a level PC014A

floor so the headlight is approxi- Ski Wear Bars

mately 8 m (25 ft) from an aiming The ski wear bar is a replaceable bar
surface (wall or similar surface). attached to the underside of the ski. The
 NOTE: There should be an “aver- purpose of the wear bar is to assist in
age” operating load on the snowmo- turning the snowmobile, to minimize ski
bile when adjusting headlight aim. wear, and to maintain good steering con-
trol. If the snowmobile is operated pri-
2. Measure the distance from the floor marily in deep snow, ski wear bar wear
to midpoint of the headlight. will be minimal; however, if the snow-
3. Using the measurement obtained in mobile is operated on terrain where the
step 2, make a horizontal mark on snow cover is minimal, the ski wear bar
the aiming surface. will wear faster. To maintain positive
steering characteristics, Arctic Cat rec-
4. Make a vertical mark which intersects ommends that the ski wear bars be
the horizontal mark on the aiming sur- checked before each use and replaced if
face directly in front of the headlight. worn beyond 1/2 of the original diameter.
5. Engage the brake lever lock and start Ski wear bars are available from an
the engine. Move the headlight dim- authorized Arctic Cat Snowmobile
mer switch to the HIGH beam posi- dealer.
tion. DO NOT USE LOW BEAM.
! WARNING
6. Observe the headlight beam aim.
Proper aim is when the most intense Operating the snowmobile with
beam is centered on the vertical mark excessively worn ski wear bars may
result in a loss of steering control.
5 cm (2 in.) below the horizontal
mark on the aiming surface. Removing Ski Wear Bars
 NOTE: Determine which type of
wear bar is being replaced and
remove and install accordingly.
1. Remove ice and snow buildup from
the ski.
2. Using a suitable safety stand or lift,
elevate the front of the snowmobile.
3. Remove the lock nuts securing the
0745-813 wear bar to the ski.

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  NOTE: Install the cap screw so the
slotted nut will be located to the
inside of the ski.
6. Apply red Loctite #271 to the
threads of the cap screw; then
tighten the nut to 45 ft-lb.
7. Place the cotter pin into the ski cap
screw and spread the pin.
0743-185 8. Repeat procedure for the other ski.
4. Remove the wear bar from the ski. Rail Wear Strips
Installing Ski Wear Bars Arctic Cat recommends that the wear strips
be checked weekly and replaced as neces-
1. Move the wear bar into position on sary. Measure the wear strips at 25.4 cm
the bottom of the ski. (10 in.) intervals. Wear strips must be 10.7
 NOTE: If installing a double-offset mm (0.42 in.) thick or thicker.
wear bar, the carbide edge should be
directed to the outside of the ski.
2. Align the wear bar studs with the
holes in the ski; then install the lock
nuts. Tighten to 11-15 ft-lb.
Adjusting Ski Stance
(M/XF Models)
 NOTE: Local laws and/or regula-
tions as to maximum width of the ski
stance on these snowmobiles may 0745-807
be applicable. Always comply with If wear strip measurements are less than
the maximum width laws and/or reg- specified, replacement of both wear strips
ulations when adjusting ski stance. is necessary to prevent premature track
clip wear and possible track damage.
 NOTE: Ski stance can be increased/ Take the snowmobile to an authorized
decreased by 2.5 cm (1.0 in.).
Arctic Cat Snowmobile dealer for this
1. Place the front of the snowmobile on service. This service is at the discretion
a support stand. and expense of the snowmobile owner.
2. Remove the cotter pin; then remove Each time a new set of wear strips are
the slotted nut and cap screw secur- installed, they should be tempered. Tem-
ing the ski assembly to the spindle. per the wear strips by driving the snow-
Remove the ski. Account for the mobile for approximately a mile on a
rubber damper, inserts, and washers. hard pack trail; then immediately drive
into deep snow and allow the wear strips
3. To increase ski stance, place both ski to cool. Repeat the procedure (warming
stance spacers to the outside of the up the wear strips; then cooling them
spindle. down) two or three times.
4. To decrease ski stance, place both  NOTE: The rail wear strips will wear
ski stance spacers to the inside of the rapidly if the snowmobile is operated
spindle. on terrain on which the snow cover is
5. Apply an all-temperature grease to the minimal. Loose snow is required to
non-threaded portion of the cap cool and lubricate the wear strips and
screw; then slide the cap screw prevent accelerated wear.
through the ski accounting for the rub-
ber damper, inserts, and washers.

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 Performance Tips
Operating a high performance snowmo-  NOTE: Removing/adding shim
bile requires a special attention that is not washers may be done by the snow-
required by a low performance snowmo- mobile owner if qualified to do so. If
bile. Often, a minor adjustment will the owner does not feel qualified,
result in a large increase in performance. take the snowmobile to an autho-
This section is intended to highlight rized Arctic Cat Snowmobile dealer
minor conditions that adversely affect for this service. This service is at the
performance and the adjustments needed discretion and expense of the snow-
to correct them. Be sure, however, to mobile owner.
thoroughly read and understand this 1. Turn the engine off; then open the
entire manual especially the section on access panel.
spark plugs, track tension and alignment,
and suspension. 2. Make sure the drive belt is sitting at
the top of the driven pulley sheaves.
DRIVE BELT — This link between the
engine and drive train is often the most 3. Place a straightedge on top of the
neglected component. The drive belt must drive belt. The straightedge should
have the proper fit in the drive clutch and reach from the driven clutch to the
driven pulley. Proper fit is when the top top of the driven pulley.
surface of the drive belt is flush with the 4. Using a stiff ruler centered between
top or up to 1/16 in. higher than the driven the drive clutch and driven pulley,
pulley sheaves (with the sheaves fully push down on the drive belt just
closed). If drive belt deflection is above enough to remove all slack. Note the
specification, the snowmobile will bog and amount of deflection on the ruler at
lack power at engagement and will have a the bottom of the straightedge. The
slower maximum speed. For good perfor- deflection should be at 1 1/4 in.
mance, proper belt deflection is critical. To
correct this condition, first determine if the
drive belt is within specifications (see
Drive Belt sub-section) and replace if
worn or too long. Always run the drive
belt in the same direction. Installing the
drive belt so the part number can be read
will ensure that the drive belt is always
run the same direction.
DRIVE BELT DEFLECTION — Drive
belt length, condition, and deflection are 0746-092
all important for peak performance. To
check and adjust drive belt deflection,  NOTE: Push down on the belt with
remove the belt guard; then use the fol- the ruler only until the bottom of the
belt flexes upward; then read the
lowing procedure. amount of deflection.
 NOTE: It may be necessary to 5. To correct drive belt deflection,
remove a shim washer from between
the driven pulley sheaves to allow remove the sheave adjuster from the
the driven pulley to close tighter. pulley, remove or add shim washers
Adding shim washers will decrease to the adjuster, and install the
belt deflection and removing shim adjuster.
washers will increase belt deflection.  NOTE: Adding shim washers will
Available shim washers from Arctic decrease belt deflection; removing
Cat are p/n 0648-714 (0.090 in.) - one shim washers will increase belt
included in the tool kit, p/n 0648-715 deflection.
(0.030 in.), and p/n 0648-716 (0.060
in.). 6. Install the belt guard; then close the
access panel.

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 DRIVE CLUTCH AND DRIVEN 4. With the bar against the outside edge
PULLEY — Keeping the drive clutch of the driven pulley stationary
and driven pulley clean should be the pri- sheave at points A and B, the bar
mary consideration of the operator. The should just clear the inside edge of
drive clutch and driven pulley can be the stationary sheave of the drive
cleaned of any drive belt accumulation clutch and rest on the stationary
using compressed air. The sheaves can be shaft at point C with a maximum
cleaned using a clean cloth and parts- 0.060 in. clearance at point C. At
cleaning solvent. this point, measurement between
points A and C should be 1.507 in.
DRIVE CLUTCH/DRIVEN PULLEY (with a maximum 0.060 in. clear-
OFFSET — If premature drive belt wear ance). If the bar either will not clear
is experienced or if the drive belt turns the inside edge or is more than the
over, offset must be checked. Also, offset specified amount, the offset must be
must be checked whenever either the corrected.
drive clutch or driven pulley is serviced.
 NOTE: For checking offset, it is
necessary to use Clutch Alignment
Bar (p/n 0644-428) to obtain a drive
clutch/driven pulley offset of 1.485
in. This special tool can be pur-
chased from an authorized Arctic
Cat snowmobile dealer.
To check offset, use the following proce-
dure.
0745-177
1. Open the left-side access panel; then
remove the belt guard.  NOTE: If the offset is out of speci-
fication, take the snowmobile to an
2. Install the clutch alignment bar authorized Arctic Cat Snowmobile
between the drive clutch sheaves. dealer for drive system evaluation
and/or servicing. This service is at
3. Allow the bar to rest on the drive the discretion and expense of the
clutch shaft and against the outside snowmobile owner.
edge of the driven pulley stationary
sheave. GASOLINE — On the 800 cc and turbo
models for optimum performance, use 91
 NOTE: The alignment bar must octane (minimum) gasoline.
extend beyond the front edge of the
drive clutch.

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 Preparation for Storage
Prior to storing the snowmobile, it must be 7. With the ignition switch in the OFF
properly serviced to prevent corrosion and position:
component deterioration. An authorized
Arctic Cat Snowmobile dealer should per- A. Disconnect the high tension
form this service; however, the owner/ leads from the spark plugs; then
operator can perform this service if remove the plugs, connect them
desired. This service is at the discretion to the leads, and ground them on
and expense of the snowmobile owner. To the cylinder heads.
prepare the snowmobile for storage, Arctic
Cat recommends the following procedure: CAUTION
Never crank the engine over without
1. Clean the seat cushion with a damp grounding the spark plugs. Damage
cloth and a Vinyl Protectant. to coils and ECU may result.
2. Clean the snowmobile thoroughly
by hosing dirt, oil, grass, and other B. Pour 29.5 ml (1 fl oz) of SAE
foreign matter from the skid frame, #30 petroleum-based oil into
tunnel, hood, and belly pan. Allow each spark plug hole and pull the
the snowmobile to dry thoroughly. recoil starter handle slowly about
DO NOT get water into any part of 10 times.
the engine. C. Install the spark plugs and con-
 NOTE: On the 1100 cc models, nect the high tension leads.
change the engine oil and replace 8. Fill the gas tank to its rated capacity;
the air filter if necessary; then pro- then add Arctic Cat Fuel Stabilizer
ceed to step 6. (p/n 0436-907) to the gas tank fol-
lowing directions on the container
CAUTION for the stabilizer/gasoline ratio.
Do not do steps 3-5 on the 1100 cc Tighten the gas tank cap securely.
models; severe engine damage could 9. With the snowmobile level, check
result. the lubricant level in the chain case.
3. Place the rear of the snowmobile up If low, add chain lube through the
on a shielded safety stand. fill plug hole.
4. Carefully pry the intake boots partially 10. Remove the drive belt from the drive
over the throttle body inlets; then start clutch/driven pulley. Lay the belt on
the engine and allow to idle. a flat surface or slide it into a card-
board sleeve to prevent warping or
5. Spray an Engine Storage Preserver distortion during storage.
into the intakes until the engine
exhaust starts to smoke heavily or 11. Clean and inspect the drive clutch
until the engine starts to drop in and driven pulley.
RPM. Turn engine off. Install the 12. Apply light oil to the upper steering
intake boots. post bushing and shafts of the shock
absorbers.
CAUTION
13. Lubricate the rear suspension with
Do not run the engine without the belt all-temperature grease.
guard in place and secured.
14. Tighten all nuts, bolts, and cap
6. Plug the exhaust system outlet with screws making sure all nuts, bolts,
a clean cloth. and cap screws are tightened
securely. Make sure all rivets hold-
CAUTION ing the components together are
Do not do step 7 on the 1100 cc mod- tight. Replace all loose rivets.
els; severe engine damage could
result.

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 15. Clean and polish the hood, console, 16. If possible, store the snowmobile
and chassis with Cat Cleaner (p/n indoors. Raise the track off the floor
4639-371). DO NOT USE SOL- by blocking up the back end making
VENTS. THE PROPELLANT sure the snowmobile is secure.
WILL DAMAGE THE FINISH. Loosen the track adjusting bolts to
reduce track tension. Cover the
 NOTE: On electric start models, snowmobile with a machine cover or
disconnect the battery cables making a heavy tarpaulin to protect it from
sure to disconnect the negative cable
first; then clean the battery posts and dirt and dust.
cables. Charge the battery. 17. If the snowmobile must be stored out-
doors, position the snowmobile out of
CAUTION direct sunlight; then block the entire
Sealed batteries require charging if snowmobile off the ground making
left for extended non-start periods. sure the snowmobile is secure. Loosen
Arctic Cat recommends trickle charg- the track adjusting bolts to reduce
ing once a month. Follow the manu- track tension. Cover with a machine
facturer’s instructions and cautions. cover or a heavy tarpaulin 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 caus-
ing corrosion.

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 Preparation after Storage
Taking the snowmobile out of storage  NOTE: After prolonged storage of
and correctly preparing it for another sea- the 800 cc models, Arctic Cat recom-
son will assure many miles and hours of mends one tankful of 100:1 gas/oil
trouble-free snowmobiling. Arctic Cat mixture be used in conjunction with
recommends the following procedure: the oil-injection system to ensure
proper lubrication.
1. Clean the snowmobile thoroughly.
Polish the exterior of the snowmobile. 6. On the 800 cc models, inspect the
spark plugs. Replace, gap, or clean
2. Clean the engine. Remove the cloth as necessary.
from the exhaust system. Check
exhaust system and air-intake 7. Tighten all nuts, bolts, and cap
silencer for obstructions. screws making sure all nuts, bolts,
and cap screws are tightened
3. Inspect all control wires and cables securely.
for signs of wear or fraying. Replace
if necessary. Use cable ties or tape to 8. If not done during preparation for
route wires and cables away from storage, lubricate the rear suspen-
hot or rotating parts. sion with all-temperature grease.
4. Inspect the drive belt for cracks and 9. Check the coolant level and all cool-
tears. Check belt specifications. ant hoses and connections for deteri-
Replace if damaged or worn. Install oration or cracks. Add properly
the drive belt. mixed coolant as necessary.
 NOTE: If the old belt is worn but in 10. On electric start models, charge the
reasonable condition, retain it with battery until fully charged (see Bat-
the snowmobile as a spare in case of tery sub-section in the Maintenance
emergency. section); then connect the battery
cables making sure to connect the
5. Inspect all fuel hoses and oil hoses positive cable first. Test the electric
for deterioration or cracks; replace if start system.
necessary. Make sure all connections
are tight; then on the 800 cc models, 11. Inspect the entire brake system, all
fill the oil-injection reservoir with the controls, headlight, taillight, brake-
recommended 2-cycle oil (see Gaso- light, ski wear bars, and headlight
line-Oil - Recommended Injection aim; adjust or replace as necessary.
Oil sub-section in the General Infor- 12. Adjust the track to the proper tension
mation section). and alignment (see Track Tension
and Track Alignment sub-sections in
the Maintenance section).

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 U.S. EPA Emission Control Statement/Warranty
Coverage (U.S. Only)
STATEMENT/WARRANTY
Arctic Cat warrants to the original retail purchaser, and each subsequent purchaser, that all U.S. EPA-
certified Arctic Cat snowmobiles are designed, built, and equipped to conform to all U.S. EPA Emission
Control Regulations. Please read the following information completely.
Your authorized Arctic Cat snowmobile dealer will repair or replace any defective emission-related
component at no cost to you during the warranty period. You may have non-warranty service performed
by any repair establishment that uses equivalent components. The regulations provide significant civil
penalties for tampering that causes your snowmobile to no longer meet U.S. EPA emission standards.
Arctic Cat further warrants that the engine and its emission-related components are free from defects in
materials or workmanship that could cause the engine to fail to comply with applicable regulations
during the warranty period.
If you have any questions about this information, or the emission warranty coverage statement, contact
your local authorized Arctic Cat snowmobile dealer.
WARRANTY PERIOD
The emission warranty period for this snowmobile begins on the same date as the standard warranty
coverage and continues for 30 months or 2500 miles, whichever comes first.
COMPONENTS COVERED
The emissions warranty covers major emissions control components and emission-related components
listed as follows:
Engine Management and Sensors Fuel/Air System
Barometric Pressure Sensor Fuel Injectors
Camshaft Position Sensor Fuel Pressure Regulator
Engine Control Unit (ECU) Fuel Pump
Engine Coolant Temperature Sensor Carburetor(s)
Intake Air Temperature Sensor Turbocharger Assembly
Manifold Absolute Pressure Sensor Air Bypass Valve
Oxygen Sensor Turbo Waste Gate Control Valve
Throttle Position Sensor Crankcase Ventilation System
ISC Valve
Ignition System Miscellaneous Items Used in Aforementioned
Systems
Ignition Coil Connectors
Knock Sensor System Switches
Crankshaft Position Sensor Grommets
Exhaust Temperature Sensor Clamps
Capacitive Discharge Ignition (CDI) Module Hoses
Magneto Pick-Up Ties
Gaskets
Wiring

OWNER'S RESPONSIBILITIES
The owner of any snowmobile warranted under this Arctic Cat Emission Control Statement is
responsible for the proper maintenance and use of the snowmobile as stated in the Operator's Manual.
Proper maintenance generally includes replacement and service, at the owner's choosing, such items
as air filter, oil and oil filter, or any other part, item, or device related to emissions control as specified in
the Operator's Manual. It is the owner's responsibility to ensure that the snowmobile is used in a manner
for which it was designed.

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 NOTES

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 Change of Address, Ownership, or Warranty
Transfer
Arctic Cat Inc. keeps on file the current name and address of the
owner of this snowmobile. This will allow Arctic Cat to reach the
current owner with any important safety information which may
be necessary to protect customers from personal injury or
property damage. Please make sure a copy of this form is
completed and returned to Arctic Cat Inc. if you move or if the
snowmobile is sold to another party.

This form may also be used to transfer the unused portion of the
original warranty to a second party. In order to transfer warranty,
fill out this form completely; then return a copy of this form to
Arctic Cat Inc. Arctic Cat will then process the application and
issue warranty for the balance of the time remaining of the
original warranty.

 Address Change
 Ownership Change
 Warranty Transfer

CHANGE OF ADDRESS/OWNERSHIP/
WARRANTY TRANSFER TO:

Name ________________________________________
Address ______________________________________
City/State (Province)/Zip Code (Postal Code) __________
Phone # ( ) __________________________________
Year and Model Snowmobile ______________________
Vehicle Identification Number (VIN) _________________

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 Fold Back Once

Place
Stamp
Here
CHANGE OF ADDRESS/OWNERSHIP

ARCTIC CAT INC.

PRODUCT SERVICE AND
WARRANTY DEPT.
P.O. BOX 810
THIEF RIVER FALLS, MN 56701

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 Warranty Procedure/Owner Responsibility
At the time of sale, an Owner Registration form is to be completed by the selling
dealer and consumer. The receipt of the registration form by Arctic Cat is a condi-
tion precedent to warranty coverage. It is the selling dealer’s responsibility to retain
and/or submit the appropriate copies of the form to the appropriate place(s) to initi-
ate warranty coverage.
The dealer will furnish to the consumer a signed copy of the form which must be
presented to the dealer when requesting warranty service. The registration form is
the consumer’s proof of ownership and warranty eligibility. The form is used
by the dealer to validate the warranty claim. Retain your copy of the form and
keep it in a safe place.
When warranty repair is suspected, the snowmobile should be taken to the selling
dealer, who has the primary responsibility to perform warranty repairs. Subject to
the limitations set forth in the Limited Warranty, in the event the selling dealer has
ceased to do business, you have moved, or you are in a location away from your
selling dealer, warranty may be performed by any authorized Arctic Cat Snowmo-
bile dealer.
The authorized Arctic Cat Snowmobile dealer will examine the snowmobile or part
to determine if, in his opinion, a warrantable condition exists. If a warrantable con-
dition appears to exist, the dealer will repair or replace, at Arctic Cat’s option, free
of charge, including any related labor costs, all parts that are found to be warrant-
able and any other parts which the warrantable part caused to be damaged. You, the
consumer, will then be asked to sign a warranty form to ensure Arctic Cat that the
warranty work was actually performed.
It is the consumer’s responsibility to maintain and service the snowmobile in accor-
dance with Arctic Cat’s recommendations in the Operator’s Manual. To protect
yourself and your snowmobile, follow all safety and service tips. Arctic Cat will
NOT warrant repairs required as a result of not performing standard operator
maintenance, storage procedures, and service as outlined in the Operator’s
Manual.
Should you have any questions concerning the warranty, contact an authorized Arc-
tic Cat Snowmobile dealer.

Arctic Cat Inc., P.O. Box 810, Thief River Falls, MN 56701 (218) 681-8558

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 ARCTIC CAT
®

Printed in U.S.A. ®TM Trademarks of Arctic Cat Inc. Thief River Falls, MN 56701 p/n 2259-055
Phone: (218) 681-9851 - U.S./(204) 982-1656 - Canada

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