F 800 LXR/Sno ProF 1100 LXR/Sno Pro/LTDF 1100 Turbo LXR/Sno Pro/LTDM 800/Sno Pro/HCRM 1100/Sno Pro/LTDM 1100 Turbo/Sno Pro/LTD/HCRXF 800 LXR/Sno Pro/High CountryXF 1100 LXR/Sno Pro/LTDXF 1100 Turbo LXR/Sno Pro/LTD

Crossover/Mountain/Performance Models

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2012Operator’s Manual

Limited Warranty Arctic Cat Inc. (hereinafter referred to as Arctic Cat) extends a limited warranty on each new Arctic CatSnowmobile it assembles and on each part and accessory assembled or sold by Arctic Cat. The warrantyis extended to the original retail purchaser only on parts and accessories sold through an authorizedArctic 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 isonly available in the country in which the original retail purchase occurs to the original retail purchaserresident 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 productswill function properly when used with an Arctic Cat Snowmobile or will not damage the Arctic CatSnowmobile. 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 partsthat are found to be warrantable in material or workmanship. This repair work MUST be done by anauthorized Arctic Cat Snowmobile dealer. No transportation charges, rental charges, or inconvenience costswill be paid by Arctic Cat. The warranty is validated upon examination of said parts by Arctic Cat or anauthorized Arctic Cat Snowmobile dealer. Arctic Cat reserves the right to inspect such parts at its factory forfinal 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 1of 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 fromthe 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 conditionswithout 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 PartsWear 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 (ifstored 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 warrantyperiods set forth. This warranty gives you specific legal rights, and you may also have other rights whichvary from state/province to state/province and country to country. Some jurisdictions do not allowlimitations on how long an implied warranty lasts, so the above limitations may not apply to you.

Table of ContentsLimited Warranty........................ Inside Front CoverForeword............................................................... 1Declaration of Conformity ..................................... 2Snowmobile Safety Rules ..................................... 3General Information ......................................... 4-23Snowmobile Identification ................................... 4Control Locations ................................................ 4Gasoline-Oil ........................................................ 5Engine Break-In .................................................. 6Drive Belt Break-In .............................................. 6Cold Drive-Away Function (1100 cc Models) ...... 7Speedometer/Tachometer................................... 7Diagnostic Codes .............................................. 12Handlebar Height/Tilt (M 800 Sno Pro/LTD/HCR/XF 800 High Country Models) ................ 13

Handlebar Tilt.................................................... 13Speedometer/Tachometer Angle....................... 14Exhaust System ................................................ 14Air-Intake Silencer............................................. 14Cooling System................................................. 14Battery (Electric Start)....................................... 14Jump-Starting (1100 cc Models) ....................... 15Drive Clutch and Driven Pulley ......................... 16Drive Clutch/Driven Pulley Alignment................ 16Fuel Pump......................................................... 16Shock Absorbers............................................... 17Standard Track (XF/F Models) .......................... 17Paddle Track (XF High Country/M Models) ....... 17Track Studs (XF/F Models)................................ 17Reverse Operation ............................................ 18Access Panel/Hood (Removing/Installing) ........ 20Removable Seat................................................ 21Towing ............................................................... 21Arctic Power Valve (APV) System (800 cc Models)............................................... 22

Exhaust Controlled Timing (ECT) System (800 cc Models)............................................... 22

Operating Instructions.................................... 24-28Starting and Stopping Engine ........................... 24Braking .............................................................. 25

Emergency Stopping......................................... 26Throttle/Ignition Monitor Switch......................... 26Varying Altitude Operation ................................ 27

Lubrication ..................................................... 29-30Chain Case ....................................................... 29Rear Suspension............................................... 30

Maintenance .................................................. 31-53Periodic Maintenance Checklist ........................ 31Air Cleaner/Filter (1100 cc Turbo Models)......... 32Fuel System ...................................................... 32Checking Engine Oil Level (1100 cc Models).... 33Changing Engine Oil/Filter (1100 cc Models).... 33Coolant Level .................................................... 35Spark Plugs....................................................... 35Checking/Adjusting Valve Clearance (1100 cc Models)............................................................ 37

Checking/Adjusting APV Cables (800 cc Models)............................................... 37

Battery (Electric Start)....................................... 38Fuses ................................................................ 40Brake System.................................................... 41Burnishing Brake Pads...................................... 44Drive Belt........................................................... 44Track Tension .................................................... 46Track Alignment................................................. 47Suspension ....................................................... 48Lights................................................................. 51Ski Wear Bars ................................................... 52Adjusting Ski Stance (M/XF Models)................. 53Rail Wear Strips ................................................ 53

Performance Tips........................................... 54-55Preparation for Storage.................................. 56-57Preparation after Storage.................................... 58U.S. EPA Emission Control Statement/Warranty

Coverage (U.S. Only) ...................................... 59Change of Address, Ownership, or Warranty

Transfer............................................................ 61Warranty Procedure/Owner

Responsibility ......................... Inside Back Cover

Reference InformationWrite the appropriate information for your Arctic Cat Snowmobile in the spacesbelow.

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: _________________________________________________

! WARNINGA snowmobile is a very high performance vehicle. Because it does acceleraterapidly 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 speedbeyond the limits of visibility or without being totally familiar with the terrainand what lies in front of you. Obey speed limits and never operate at speedsthat do not allow adequate maneuvering and stopping distances. Read andstudy 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 istoo late to warn of the consequences of snowmobile misuse. Such conductendangers everyone. TAKE AN ACTIVE ROLE IN THE SAFETY OF YOUR-SELF AND OTHERS.

Parts and AccessoriesWhen 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 thestandards and requirements of your Arctic Cat Snowmobile. For a complete list ofaccessories, refer to the current Arctic Cat Accessory Catalog. To aid in service andmaintenance procedures on these snowmobiles, an Illustrated Parts Manual and aService Manual are available through your local Arctic Cat Snowmobile dealer.

ForewordCongratulations! You have chosen a quality Arctic Cat Snowmobile designed andassembled to give dependable service. Be sure, as the owner/operator of an ArcticCat Snowmobile, to become thoroughly familiar with its basic operation, mainte-nance, and off-season storage procedures. Read this manual and the accompanyingSnowmobile Safety Handbook before operating the snowmobile to learn safe andproper use of your new Arctic Cat Snowmobile. Always operate the snowmobilewithin your level of skill and current terrain conditions.

The Operator’s Manual, Snowmobile Safety Handbook, and Snowmobile Decalsdisplay the words Warning, Caution, and Note to emphasize important information.The symbol ! WARNING identifies personal safety-related information. Besure to follow the directive because it deals with the possibility of serious personalinjury or even death. A CAUTION identifies unsafe practices which may resultin 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 anauthorized 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 andare not designed to depict actual conditions. Because Arctic Cat Inc. constantlyrefines and improves its products, no retroactive obligation is incurred.

This Operator’s Manual should be considered a permanent part of the snowmobileand must remain with the snowmobile at the time of resale. If the snowmobilechanges 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 ofArctic Cat Inc.

Every Arctic Cat Snowmobile meets or exceeds the standards of the SnowmobileSafety and Certification Committee and displays the SSCC decal. Arctic Cat Inc.endorses and encourages the safe use of all snowmobiles. Always wear a helmetand eye protection. Drive with caution, observe all state and local regulations, andrespect the rights of others. ISMA members like Arctic Cat do their part to improvetrails, 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.

1

Declaration of Conformity

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

Brad DarlingVice President/General Manager - Snowmobile Division

Application of council directives:Issued by European Commission.

EMC Directive 2004/108/ECEC Machinery Directive 2006/42/EC

Type of Equipment: SnowmobileBrand Name: Arctic CatModel 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:MACHINERY:

EN 55012, EN 61000-6-2EN 12100:2010

Manufacturer (if not issuing agent): Arctic Cat Inc.601 Brooks Ave. S.Thief River Falls, MN56701 USA

2

Snowmobile Safety Rules

3

General InformationSnowmobile IdentificationThe Arctic Cat Snowmobile has twoimportant identification numbers. TheVehicle Identification Number (VIN) isstamped into the tunnel near the right-side footrest and on a decal beneath theseat. The decal also displays pertinentproduction information. The EngineSerial Number (ESN) is stamped into thecrankcase of the engine.

0726-383

These numbers are required by the dealerto complete warranty claims properly. Nowarranty will be allowed by Arctic CatInc. if the engine serial number or VIN isremoved or mutilated in any way.

Always provide the snowmobile name,VIN, and ESN when contacting an autho-rized Arctic Cat Snowmobile dealer forparts, service, accessories, or warranty. Ifthe complete engine must be replaced,ask the dealer to notify Arctic Cat forcorrect registration information.

Control LocationsShown are the typical control locationsfor Arctic Cat snowmobiles. Location ofa specific control will vary according tomodel.

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

0745-832

F 800/F 1100 Models

0745-842

4

Gasoline-OilRecommended Gasoline (1100 cc Models)

The recommended gasoline to use in thesesnowmobiles is 87 octane regular unleaded.In many areas, oxygenates (either ethanolor MTBE) are added to the gasoline. Oxy-genated gasolines containing up to 10%ethanol are acceptable gasolines.

NOTE: The turbo models willdetect lower octane gasoline andreduced engine performance willresult. It is recommended that 91octane (minimum) gasoline be usedin these models.

When using ethanol blended gasoline, it isnot necessary to add a gasoline antifreezesince ethanol will prevent the accumula-tion of moisture in the fuel system.

Recommended Gasoline (800 cc Models)

The only recommended gasoline to use inthese snowmobiles is 91 octane (minimum).

NOTE: For optimum performance,use only 91 octane (minimum) gaso-line.

In many areas, oxygenates (either ethanolor MTBE) are added to the gasoline.Oxygenated gasolines containing up to10% ethanol are acceptable gasoline. Donot use gasolines containing methanol.

Recommended Injection Oil (800 cc Models)

The recommended oil to use in the oil-injection system is either Arctic Cat APVSynthetic 2-Cycle Oil (p/n 4639-349 - qt)or (p/n 5639-469 - gal.) or Formula SSSemi-Synthetic Oil (p/n 5639-470 - qt) or(p/n 5639-471 - gal.). These oils are spe-cially formulated to be used either as aninjection oil or as a pre-mix oil (forbreak-in) and meets all of the lubricationrequirements of the Arctic Cat snowmo-bile engine.

Recommended Engine Oil (1100 cc Models)

The recommended oil to use is Synthetic0W-40 Oil (p/n 5639-172 - qt) or (p/n5639-173 - gal.).

After the engine break-in period, theengine oil should be changed every 2500-3000 miles on the non-turbo models or1500-2000 miles on the turbo models andbefore prolonged storage.

Filling Gas Tank

Since gasoline expands as its temperatureincreases, the gas tank must be filled toits rated capacity only. Expansion roommust be maintained in the tank particu-larly if the tank is filled with cold gaso-line and then moved to a warm area.

Also, if the snowmobile is to remain on atrailer after filling the gas tank, the bed ofthe trailer must be maintained level toprevent gasoline from draining outthrough the gas tank vent hose.

CAUTIONDo not use white gas or gasolinescontaining methanol. Only Arctic Catapproved gasoline additives shouldbe used.

CAUTIONIf a situation arises wherein 91 octanegasoline is not available, 87 octanegasoline can be substituted; how-ever, do not prolong the usage of 87octane gasoline as it will cause poorengine performance.

CAUTIONDo not use white gas or gasolinescontaining methanol. Only Arctic Catapproved gasoline additives shouldbe used.

CAUTIONAny oil used in place of the recom-mended oil could cause seriousengine damage.

! WARNINGAlways fill the gas tank in a well-ven-tilated area. Never add gasoline to thesnowmobile gas tank near any openflames or with the engine running.DO NOT SMOKE while filling the gastank. Do not sit on the snowmobilewithout first installing the gas tankcap.

5

Break-In Gas/Oil Mixing Instructions (800 cc Models)

Before mixing gasoline and oil, makesure the oil is at room temperature (20°C/68° F). Use a U.L. approved 22.7 l (6U.S. gal.) gasoline container for mixingthe gasoline and oil. To properly mix thefuel at a 100:1 ratio, use the followingprocedure:

1. Pour gasoline into the gasoline con-tainer until approximately half full.

2. Pour 236 ml (8 fl oz) of the recom-mended 2-cycle oil into the gasolinecontainer.

3. Install cap on gasoline container andshake the mixture vigorously.

4. Fill the gasoline container with gaso-line; then cap the gasoline containerand shake the mixture vigorously.

5. Using a fine-mesh screened funnel,pour the fuel mixture from the gaso-line container into the snowmobilegas tank.

Engine Break-InThe Arctic Cat engine (when new orrebuilt) requires a short break-in periodbefore the engine is subjected to heavyload conditions.

800 cc Models

Arctic Cat requires that the first tankfulof fuel be premixed at a 100:1 ratio in alloil-injection models.

During the break-in period, a maximumof 1/2 throttle is recommended; however,brief full-throttle accelerations and varia-tions in driving speeds contribute to goodengine break-in. After one (1) tankfulbreak-in period, the snowmobile may betaken to an authorized Arctic Cat Snow-mobile dealer for a checkup. Thischeckup is at the discretion and theexpense of the snowmobile owner.

1100 cc Models

This engine does not require any pre-mixed fuel during the break-in period.

To ensure trouble-free operation, carefuladherence to the following break-inguidelines will be beneficial.

* With occasional full-throttle operation.To ensure proper engine break-in, ArcticCat recommends that the engine oil andfilter be changed after 500 miles. Thisservice is at the discretion and expense ofthe snowmobile owner.

Drive Belt Break-InDrive belts require a break-in period ofapproximately 25 miles. Drive the snow-mobile for 25 miles at 3/4 throttle or less.By revving the engine up and down (butnot exceeding 60 mph), the exposed cordon the side of a new belt will be worndown. This will allow the drive belt togain its optimum flexibility and willextend drive belt life.

CAUTIONNever mix oil and gasoline in thesnowmobile gas tank.

! WARNINGAlways fill the gas tank in a well-ven-tilated area. Never add gasoline to thesnowmobile gas tank near any openflames or with the engine running.DO NOT SMOKE while mixing fuel orfilling the gas tank.

CAUTIONDO NOT exceed the one (1) tankfullimitation of a 100:1 gas/oil break-inmixture. Continuous use of a gas/oilmixture could cause spark plug foul-ing and excessive carbon buildup.

CAUTIONDO NOT use premixed fuel in thesnowmobile gas tank. Engine dam-age will occur.

0-200 miles 1/2 Throttle (45 MPH-max)

200-400 miles 1/2-3/4 Throttle

400-600 miles 1/2-3/4 Throttle *

6

NOTE: Before starting the snowmo-bile in extremely cold temperatures,the drive belt should be removed andwarmed up to room temperature.Once the drive belt is at room temper-ature, install the drive belt (see DriveBelt sub-section in the Maintenancesection).

Cold Drive-Away Function (1100 cc Models)On these models, there is a “cold drive-away” function incorporated within theengine.

NOTE: When cold-starting theengine, the coolant temperaturewarning icon will illuminate and theTEMP display on the readout screenwill begin to flash. With the engine inthis temperature range, the RPM“limit” of the engine will be belowdrive system engagement speed. Asthe engine warms, the coolant tem-perature warning icon will begin toflash, the TEMP display will continueto flash, and the RPM “limit” of theengine will increase allowing thesnowmobile to move without full-throttle operation. When the enginereaches proper operating tempera-ture, the coolant temperature warn-ing icon and the TEMP display willgo out.

Speedometer/TachometerThese snowmobiles are equipped withdifferent speedometer/tachometer styles.Determine which style your model isequipped with and use the appropriatefollowing information.

Indicator Icons (Standard Gauge)

Certain models are equipped with a stan-dard gauge combination speedometer/tachometer. Indicator icons are incorpo-rated within the speedometer/tachome-ter. Also incorporated into thespeedometer/tachometer is a digital read-out screen.

FZ003C

A. Oil Pressure/Low Oil

B. Coolant Temperature

C. Low Fuel

D. Fuel Level

E. Service

F. High Beam

G. Charging System (1100 cc Models)

RPM/MPH (kph)

By pushing the left button once, the RPMand MPH will be displayed (one on thereadout screen and one with the needle).By pushing the button once again, thefunctions will be reversed.

By pushing the left button (with speedbeing displayed) for more than two sec-onds, the display will change betweenstandard mph or metric kph. Release thebutton when desired display appears.

CAUTIONNever run the engine with the drivebelt removed. Excessive revving ofthe engine could result in seriousengine damage and drive clutch fail-ure.

CAUTIONIt is extremely important that theengine is properly warmed up beforesubjecting the engine to high speedoperation or heavy loads. The engineshould be allowed to idle at least 3-4minutes before it is operated at morethan 1/2 throttle. In extremely coldconditions, the warm-up time will belonger. Cold seizure and piston scuff-ing caused by insufficient warm-upwill not be covered by warranty. Also,do not idle the engine for excessivelylong periods of time.

7

With RPM displayed on the readoutscreen by pushing and holding the leftbutton, maximum RPM will be displayedon the readout screen. The maximumRPM readout will reset when the rightbutton is pushed (while maximum RPMis displayed).

Odometer/Trip-Meter (1)/Trip-Meter (2)/Hour-Meter/Clock

NOTE: The clock is available onelectric start models only.

By pushing the right button, the readoutscreen will display odometer, trip-meter(1), trip-meter (2), hour-meter, and clock.To reset the trip meter with the trip meterdisplayed, push and hold the right buttonuntil the display is cleared. The hour-meter readout will not reset.

Clock (Electric Start)

With the clock selected on the readoutscreen by pushing and holding the rightbutton for two seconds, the option ofselecting the 12-hour or 24-hour clock isavailable. Push the left button for 12-hourdisplay; push the right button for 24-hourdisplay. At this point, the hours and min-utes will begin to flash. Push the left but-ton to change the hour display; push theright button to change the minute display(either tap the buttons for individual num-ber display or push and hold the buttonsfor rapid number display).

NOTE: During clock setting if nei-ther button (left, right) is pushedwithin a 5-second time period, theclock-setting mode will be exitedwith changes saved.

Service Icon

On electric start models, the icon shouldilluminate each time the key is turned toRUN or START, and it should go out whenthe engine starts. If the icon stays illumi-nated (on electric start models) or it illumi-nates while the engine is running, thesystem is receiving input that is outside ofits established parameters. If the icon illu-minates indicating an error, take the snow-mobile to an authorized Arctic CatSnowmobile dealer for service. If not underwarranty, this service is at the discretionand expense of the snowmobile owner.

Coolant Temperature Warning Icon

NOTE: On the 1100 cc modelswhen cold-starting the engine, thecoolant temperature warning icon willilluminate, the readout screen willdisplay TEMP, and engine RPM limitwill be below drive system engage-ment speed.

When the engine reaches proper operat-ing temperature, the coolant temperaturewarning icon and TEMP display willcease to flash.

If the coolant temperature rises too farabove proper operating temperature, thecoolant temperature warning icon willflash a warning (alert) and the engine will“surge” to alert the operator. If the cool-ant temperature rises to a critical pointabove proper operating temperature, thecoolant temperature warning icon willcease flashing and will remain constantlyilluminated.

NOTE: If the coolant temperatureicon is constantly on, the engine willshut off if vehicle speed is reducedto 1.5 kph (0.9 MPH) or slower.

Charging System Warning Icon (1100 cc Models)

The Charging System Warning Icon isdesigned to warn the operator if the bat-tery charging system is not functioning.The icon should illuminate each time thekey is turned to RUN or START, and itshould go out when the engine starts. Ifthe icon stays illuminated or it illuminateswhile the engine is running, the battery isnot being charged, and the snowmobile isrunning on battery reserve power only.

CAUTIONAt this point, take precautionary mea-sures such as changing to loosesnow terrain, shutting the engine off(allowing the engine to cool down),and checking coolant level. If unableto either determine or remedy theproblem, take the snowmobile to anauthorized Arctic Cat Snowmobiledealer for service. If not under war-ranty, this service is at the discretionand expense of the snowmobileowner.

8

If the Charging System Warning Iconilluminates, you should, as soon as possi-ble, take the snowmobile to an authorizedArctic Cat Snowmobile dealer for ser-vice. If not under warranty, this service isat the discretion and expense of thesnowmobile owner. The engine WILLNOT RUN without battery power.

Low Oil Warning Icon (800 cc Models)

The Low Oil Warning Icon is designed toalert the snowmobile operator when theoil in the oil injection reservoir gets belowa prescribed level; however, it is highlyrecommended that a visual verification ofthe oil level in the reservoir be done priorto operating the snowmobile. Once theLow Oil Warning Icon illuminates duringoperation of the snowmobile, the operatormust periodically monitor the level of oilin the reservoir and must fill the reservoirthe next time gasoline is added to the gastank. The “alert level” of the Low OilWarning Icon is approximately equal to 1tankful of gasoline under normal operat-ing conditions.

Oil Pressure Warning Icon (1100 cc Models)

The Oil Pressure Warning Icon indicatesengine oil pressure, not the oil level;however, if the oil level is low, it mayaffect oil pressure.

The icon should illuminate each time theignition switch is turned to RUN orSTART, and it should go out when theengine starts. If the icon illuminateswhile the engine is running, oil pressurehas been lost and the engine will auto-matically shut off.

If oil pressure is lost, use the followingprocedure to check the oil level:

1. With the engine off, note the oillevel in the sight glass. If the level isbelow the sight glass, add onlyenough recommended oil until it isvisilbe in the sight glass. DO NOToverfill the reservoir with oil.

0746-166

2. Open the air bleed bolt located onthe oil pump (beneath the coolanttank) to purge air from the oil hose.

PC016A

NOTE: When air can no longer beheard purging from oil pump bleed,tighten the bleed bolt to 7.5 ft-lb.

3. Start the engine. The warning iconshould go out within five seconds.

4. If the warning icon does not go out,shut the engine off immediately andrepeat step 2; then repeat step 3.

If the warning icon does not go out or ifthe engine does not start, take the snow-mobile to an authorized Arctic Cat Snow-mobile dealer. If not under warranty, thisservice is at the discretion and expense ofthe snowmobile owner.

Indicator Icons (Deluxe Gauge)

Certain models are equipped with adeluxe gauge combination speedometer/tachometer. Indicator icons are incorpo-rated within the speedometer/tachome-ter. Also incorporated into thespeedometer/tachometer is a digital read-out screen.

CAUTIONDo not attempt to start the enginewith the bleed bolt open.

9

FZ001A

A. High Beam

B. Oil Pressure/Low Oil

C. Coolant Temperature

D. Increment Button

E. Select Button

F. Decrement Button

G. Service

H. Charging System (1100 cc Models)

RPM/MPH (kph)

By pushing the increment button once,the RPM and MPH will be displayed(one on the readout screen and one withthe needle). By pushing the button onceagain, the functions will be reversed.

By pushing the increment button (withspeed being displayed) for more than twoseconds, the display will change betweenstandard mph or metric kph.

With RPM displayed on the readoutscreen by pushing and holding the incre-ment button, maximum RPM will be dis-played on the readout screen. Themaximum RPM readout will reset whenthe decrement button is pushed (whilemaximum RPM is displayed).

Odometer/Trip-Meter (1)/Trip-Meter (2)/Hour-Meter

By pushing the decrement button, thereadout screen will display odometer,trip-meter (1), trip-meter (2), and hour-meter. To reset the trip meter with the tripmeter displayed, push and hold the decre-ment button until the display is cleared.The hour-meter readout will not reset.

Clock/Altimeter

By pushing the select button, the readoutscreen will display clock, altimeter, andmaximum altimeter.

To set the clock, select clock on the dis-play by pushing and holding the selectbutton for two seconds; the option ofselecting the 12-hour or 24-hour clockmode is available. Push the incrementbutton to toggle between the 12-hour dis-play and the 24-hour display. Whendesired mode is displayed, push theselect button.

At this point, the hours display will beginto flash. Push the increment button toincrease the hours; push the decrementbutton to decrease the hours. Pushing andholding a button will accelerate the num-ber display. When desired hour number isdisplayed, push the select button.

At this point, the minutes display willbegin to flash. Push the increment buttonto increase the minutes; push the decre-ment button to decrease the minutes.Pushing and holding a button will accel-erate the number display. When desiredminute number is displayed, push theselect button.

NOTE: During clock setting if nobutton (increment, decrement,select) is pushed within a 5-secondtime period, the clock-setting modewill be exited with changes saved.

NOTE: The altimeter readout isbased off barometric pressure andmay require calibration as weatherconditions change.

To set/calibrate the altimeter to an estab-lished altitude with altimeter selected onthe display screen by pushing and hold-ing the select button for a minimum oftwo seconds, the acronym CAL will bedisplayed on the readout screen for onesecond; then the altitude value will flash.Push the increment button to increase thedisplayed altitude; push the decrementbutton to decrease the displayed altitude.Pushing and holding a button will accel-erate the number display.

10

NOTE: If MPH has been selected inthe speed readout, the altitude valuewill be displayed in feet. If kph has beenselected in the speed readout, the alti-tude value will be displayed in meters.

To reset the maximum altimeter readoutwith the maximum altimeter displayed,push and hold the select button for a min-imum of two seconds.

Service Icon

On electric start models, the icon shouldbriefly illuminate each time the key isturned to RUN or START, and engine isstarted; then it should go out when theengine starts. If the icon stays illuminated(on electric start models) or it illuminateswhile the engine is running, the system isreceiving input that is outside of its estab-lished parameters. If the icon illuminatesindicating an error, take the snowmobileto an authorized Arctic Cat Snowmobiledealer for service. If not under warranty,this service is at the discretion andexpense of the snowmobile owner.

Coolant Temperature Warning Icon

NOTE: On the 1100 cc modelswhen cold-starting the engine, thecoolant temperature warning iconwill illuminate, the readout screenwill display TEMP, and engine RPMlimit will be below drive systemengagement speed.

When the engine reaches proper operat-ing temperature, the coolant temperaturewarning icon and TEMP display willcease to flash.

If the coolant temperature rises too farabove proper operating temperature, thecoolant temperature warning icon willflash a warning (alert) and on the 1100 ccmodels, the engine will “surge” to alertthe operator. If the coolant temperaturerises to a critical point above proper oper-ating temperature, the coolant temperaturewarning icon will cease flashing and willremain constantly illuminated.

NOTE: On the 1100 cc models ifthe coolant temperature icon is con-stantly on, the engine will shut off ifvehicle speed is reduced to 1.5 kph(0.9 MPH) or slower.

Charging System Warning Icon (1100 cc LXR Models)

The Charging System Warning Icon isdesigned to warn the operator if the batterycharging system is not functioning. Theicon should illuminate each time the key isturned to RUN or START, and it should goout when the engine starts. If the icon staysilluminated or it illuminates while theengine is running, the battery is not beingcharged, and the snowmobile is running onbattery reserve power only.

If the Charging System Warning Iconilluminates, you should, as soon as possi-ble, take the snowmobile to an authorizedArctic Cat Snowmobile dealer for ser-vice. If not under warranty, this service isat the discretion and expense of thesnowmobile owner. The engine WILLNOT RUN without battery power.

Low Oil Warning Icon (800 cc Models)

The Low Oil Warning Icon is designed toalert the snowmobile operator when theoil in the oil injection reservoir gets belowa prescribed level; however, it is highlyrecommended that a visual verification ofthe oil level in the reservoir be done priorto operating the snowmobile. Once theLow Oil Warning Icon illuminates duringoperation of the snowmobile, the operatormust periodically monitor the level of oilin the reservoir and must fill the reservoirthe next time gasoline is added to the gastank. The “alert level” of the Low OilWarning Icon is approximately equal to 1tankful of gasoline under normal operat-ing conditions.

CAUTIONAt this point, take precautionary mea-sures such as changing to loosesnow terrain, shutting the engine off(allowing the engine to cool down),and checking coolant level. If unableto either determine or remedy theproblem, take the snowmobile to anauthorized Arctic Cat Snowmobiledealer for service. If not under war-ranty, this service is at the discretionand expense of the snowmobileowner.

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Oil Pressure Warning Icon (1100 cc LXR Models)

The Oil Pressure Warning Icon indicatesengine oil pressure, not the oil level;however, if the oil level is low, it mayaffect oil pressure.

The icon should illuminate each time theignition switch is turned to RUN orSTART, and it should go out when theengine starts. If the icon illuminateswhile the engine is running, oil pressurehas been lost and the engine will auto-matically shut off.

If oil pressure is lost, use the followingprocedure to check the oil level:

1. With the engine off, note the oillevel in the sight glass. If the level isbelow the sight glass, add onlyenough recommended oil until it isvisilbe in the sight glass. DO NOToverfill the reservoir with oil.

0746-166

2. Open the air bleed bolt located onthe oil pump (beneath the coolanttank) to purge air from the oil hose.

PC016A

NOTE: When air can no longer beheard purging from oil pump bleed,tighten the bleed bolt to 7.5 ft-lb.

3. Start the engine. The warning iconshould go out within five seconds.

4. If the warning icon does not go out,shut the engine off immediately andrepeat step 2; then repeat step 3.

If the warning icon does not go out or ifthe engine does not start, take the snow-mobile to an authorized Arctic Cat Snow-mobile dealer. If not under warranty, thisservice is at the discretion and expense ofthe snowmobile owner.

Diagnostic Codes Diagnostic codes are activated by theECU and may be displayed on the read-out screen for a number of reasons.

If a code is displayed while the engine isrunning, the ECU is receiving input thatis outside of its established parameters. Ifa code has been activated, take the snow-mobile to an authorized Arctic Cat Snow-mobile dealer for service. If not underwarranty, this service is at the discretionand expense of the snowmobile owner.

800 cc Models

Additional codes are displayed on thereadout screen. Refer to the followingchart for diagnostic codes.

CAUTIONDo not attempt to start the enginewith the bleed bolt open.

Code Trouble2 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).

16 Incorrect adjustment/failure in APV cable.

17 Failure in exhaust temperature sensor.

18 Failure in servomotor.

21 Open or short circuit in/or loose knock sensor.

OCTN Low octane gasoline.

12

1100 cc Models

These diagnostic codes are displayed onthe readout screen incorporated withinthe speedometer/tachometer. Refer to thefollowing chart for diagnostic codes.

* Turbo models

Handlebar Height/Tilt (M 800 Sno Pro/LTD/HCR/XF 800 High Country Models)To adjust handlebar height, use the fol-lowing procedure:

1. From each side of the steering post,compress the locking tabs to unlockthe handlebar.

0745-843

2. With the tabs compressed, adjust thehandlebar up or down to the desiredposition; then release the tabs to lockthe handlebar in place.

To adjust handlebar tilt, use the followingprocedure:

1. Loosen the four cap screws and tiltthe handlebar to the desired position.

0745-845

2. Tighten the four cap screws to 15 ft-lb.

Handlebar TiltThe handlebar can be adjusted to theoperator’s preference. To adjust the han-dlebar, use the following procedure:

1. Remove the handlebar cover; thenloosen the eight cap screws securingthe handlebar caps to the riser and theriser to the steering post.

Code Trouble1 Failure in the fuel system.

2 Failure in injector (PTO).

3 Failure in injector (MAG).

4 Failure in barometric pressure sensor.

5 Open or short circuit in intake mani-fold air temperature sensor.

6 Open or short circuit in water temper-ature sensor.

7 Open or short circuit in throttle posi-tion sensor.

8 Open or short circuit in manifold air pressure sensor.

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.

22* Failure in injector (PTO secondary).

23* Failure in injector (MAG secondary).

25 Failure in shifting system/gear posi-tion switch.

26 Malfunction in air pressure sensor.

29 Malfunction in shift control switch.

OCTN* Low octane gasoline.

! WARNINGTighten the cap screws according tospecifications to prevent unexpected“movement” of the handlebar duringoperation over rough terrain. DO NOTposition handlebar so steering (maxi-mum right/left turning capabilities) orthrottle and brake controls areaffected.

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0745-848

2. Adjust the handlebar to operator’sdesired position, tighten the capscrews evenly to 15 ft-lb, and checksteering for maximum right/leftturning capabilities.

NOTE: Do not rotate the handlebarto a position that allows air to enterthe brake system.

Speedometer/Tachometer AngleThe speedometer/tachometer can beadjusted to the operator’s desired posi-tion. To adjust, use the following proce-dure.

1. Loosen the lock nuts and cap screwson each side of the speedometer/tachometer bracket.

2. Adjust the speedometer/tachometerto the desired angle; then tighten thelock nuts securely.

Exhaust SystemThe exhaust system is designed to reducenoise and to improve the total perfor-mance of the engine. If any exhaust sys-tem component is removed from theengine and the engine is run, severeengine damage will result.

Air-Intake SilencerUsed in conjunction with the fuel intakesystem is a specially designed air-intakesilencer. The purpose of the silencer is toquiet the intake of fresh air. Since the fuelintake system is calibrated with the air-intake silencer in place, the engine mustnever be run with the silencer removed.Performance will not be improved if theair-intake silencer is removed. In con-trast, severe engine damage will occur.

Cooling SystemThese snowmobiles are equipped with aclosed liquid cooling system for enginecooling. The cooling system should beinspected daily for leakage and damage.Also, the coolant level should be checkeddaily. If leakage or damage is detected,take the snowmobile to an authorizedArctic Cat Snowmobile dealer for ser-vice. If not under warranty, this service isat the discretion and expense of thesnowmobile owner.

When filling the cooling system reser-voir, use an ethylene glycol-based cool-ant/water mixture which will satisfy thecoldest anticipated weather conditions ofyour area in accordance with the coolantmanufacturer’s recommendations.

NOTE: On the HCR models if oper-ating on ice or hard-packed snow,the ice scratchers must be engagedto reduce engine overheating.

For checking/filling cooling system, referto Coolant Level sub-section in the Main-tenance section.

Battery (Electric Start)It is extremely important that the batterybe maintained at full charge at all timesand that the battery connections be cleanand tight. If charging the battery becomesnecessary, refer to Battery sub-section inthe Maintenance section.

! WARNINGTighten cap screws according tospecifications to prevent unexpected“movement” of the handlebar duringoperation over rough terrain. DO NOTposition the handlebar so steering(maximum right/left turning capabili-ties) or throttle and brake controlsare affected.

CAUTIONThese snowmobiles are not designedto be operated in dusty conditions.Operating the snowmobile in dustyconditions will result in severeengine damage.

14

Jump-Starting (1100 cc Models)

NOTE: Arctic Cat does not recom-mend jump-starting a snowmobilewith a dead battery but rather toremove the battery, service it, andcorrectly charge it; however, in anemergency, it may be necessary tojump-start a snowmobile. If so, usethe following procedure to carefullyand safely complete this procedure.

NOTE: To access the battery, theseat must be removed (see Remov-able Seat sub-section in this sec-tion).

1. On the snowmobile to be jump-started,slide any terminal boots away.

2. Inspect the battery for any signs ofelectrolyte leaks, loose terminals, orbulging sides. Leaking or bulgingbattery cases may indicate a frozenor shorted battery.

3. Inspect the vehicle to be used forjump-starting to determine if voltageand ground polarity are compatible.The vehicle must have a 12-volt DC,negative ground electrical system.

4. Move the vehicle to be used for thejump-start close enough to ensurethe jumper cables easily reach; thenset and lock the brakes, shut off allelectrical accessories, and turn theignition switch OFF.

NOTE: Make sure all switches onthe snowmobile to be jump-startedare turned OFF.

5. Disconnect all external accessoriessuch as cell phones, GPS units, andradios on both vehicles.

6. Attach one clamp of the positive(red) cable to the positive (+) termi-nal (1) of the dead battery (C) beingcareful not to touch any metal withthe other clamp; then attach theother clamp of the positive (red)cable to the positive (+) terminal (2)of the good battery (B).

CAUTIONOn the 1100 cc models, always turnthe ignition switch key to the OFFposition when the snowmobile is notbeing used. Leaving the ignitionswitch in the ON position will result indischarging the battery and possibledamage to the battery.

! WARNINGImproper handling or connecting of abattery may result in severe injuryincluding acid burns, electrical burns,or blindness as a result of an explo-sion. Always remove rings andwatches.

! WARNINGAny time service is performed on abattery, the following must beobserved: keep sparks, open flame,cigarettes, or any other flame away.Always wear safety glasses. Protectskin and clothing when handling abattery. When servicing a battery inan enclosed space, keep the areawell-ventilated.

! WARNINGIf any of these conditions exist, DONOT attempt to jump-start, boost, orcharge the battery. An explosioncould occur causing serious injury.

CAUTIONAlways make sure the electrical sys-tems are of the same voltage andground polarity prior to connectingjumper cables. If not, severe electri-cal damage may occur.

CAUTIONFailure to disconnect electronicaccessories during jump-startingmay cause system damage due topower spikes.

15

0744-527

NOTE: Some jumper cables may bethe same color but the clamps or endswill be color-coded red and black.

7. Attach one clamp of the negativejumper cable (black) to the negative (-) terminal (3) of the good battery (B);then attach the other clamp of the neg-ative jumper cable (black) (4) to anunpainted metal surface (A) on theengine or frame well away from deadbattery and fuel system components.

8. Stand well away from the dead bat-tery and start the vehicle with thegood battery. Allow the vehicle torun for several minutes applyingsome charge to the dead battery.

9. Start the snowmobile with the deadbattery and allow it to run for severalminutes before disconnecting thejumper cables.

10. Remove the jumper cables in oppositeorder of hook-up (4, 3, 2, 1). Be carefulnot to short cables against bare metal.

NOTE: Have the battery and elec-trical system checked prior to oper-ating the snowmobile again.

Drive Clutch and Driven PulleyThe drive clutch and driven pulley do notrequire lubrication; therefore, no specialmaintenance is required by the snowmo-bile owner except for periodical cleaning(see the Periodic Maintenance Checklistin the Maintenance section).

However, the drive clutch and driven pul-ley should be disassembled, cleaned, andinspected by an authorized Arctic CatSnowmobile dealer after every 800 milesof operation or at the end of the snowmo-biling season whichever occurs first. Thisservice is at the discretion and expense ofthe snowmobile owner.

When operating the snowmobile at highaltitudes, it may be necessary to changecertain component parts of the driveclutch and/or the driven pulley. See anauthorized Arctic Cat Snowmobile dealerfor further information.

Drive Clutch/Driven Pulley AlignmentThe alignment between the drive clutchand driven pulley is set at the factory.Normally, no adjustment is necessary aslong as neither the drive clutch nor thedriven pulley is removed or disassem-bled. However, if premature drive beltwear is experienced or if the drive beltturns over, the drive clutch/driven pulleyalignment must be checked. Take thesnowmobile to an authorized Arctic CatSnowmobile dealer for this service. If notunder warranty, this service is at the dis-cretion and expense of the snowmobileowner.

Fuel PumpThe fuel pump is designed to provideadequate amount of gas to the injectorsat all throttle settings. If a fuel deliveryproblem is suspected, take the snowmo-bile to an authorized Arctic Cat Snowmo-bile dealer. If not under warranty, thisservice is at the discretion and expense ofthe snowmobile owner.

! WARNINGNever make the final connection to abattery as a spark could ignite hydro-gen gases causing an explosion ofthe battery resulting in acid burns orblindness.

CAUTIONDO NOT attempt to service the driveclutch and driven pulley. The driveclutch and driven pulley must be ser-viced by an authorized Arctic CatSnowmobile dealer only.

16

Shock AbsorbersRebuildable Gas

Each shock absorber should be visiblychecked weekly for fluid leakage, cracksor breaks in the body/reservoir, or a bentshaft. If any one of these conditions isdetected, replacement or service is neces-sary. Take the snowmobile to an autho-rized Arctic Cat Snowmobile dealer forthis service. If not under warranty, thisservice is at the discretion and expense ofthe snowmobile owner.

NOTE: When the snowmobile isoperated in extremely cold weather (-23° C/-10° F or colder), a smallamount of leakage may be present.Unless the leakage is excessive,replacement is not necessary.

NOTE: The frequency of servicingrebuildable shock absorbers willvary according to the types of condi-tions and terrain the snowmobile hasbeen subjected to. If riding qualitydeteriorates (or seems to be deterio-rating), take the snowmobile to anauthorized Arctic Cat Snowmobiledealer for shock absorber evaluationand/or servicing. This service is atthe discretion and expense of thesnowmobile owner.

Servicing rebuildable shock absorbers isconsidered normal maintenance and isthe responsibility of the owner. Take thesnowmobile to an authorized Arctic CatSnowmobile dealer for this service. Thisservice is at the discretion and expense ofthe snowmobile owner. Kits are availableto either stiffen or soften gas shock valv-ing. If changes in shock valving aredesired, see an authorized Arctic CatSnowmobile dealer. This service is at thediscretion and expense of the snowmo-bile owner.

Standard Track (XF/F Models)Accelerated wear strip and track clipwear caused by operating on ice or hard-packed snow conditions is NOT coveredunder Arctic Cat Inc. warranty policy.

Paddle Track (XF High Country/M Models)These models are equipped with a PowerClaw style track which is speciallydesigned for use in powder snow ridingconditions. When the Power Claw track isoperated in hard-packed snow conditions,it will run slightly slower than a standardtrack and it will accelerate wear stripwear. To decrease the amount of wearstrip wear, slower speeds must be main-tained when operating on hard-packedtrails. Accelerated wear strip wear causedby operating a Power Claw track on hard-packed snow conditions is NOT coveredunder Arctic Cat Inc. warranty policy.

NOTE: If operating on ice or hard-packed snow conditions, it is recom-mended that Ice Scratchers (p/n 5639-897) be installed to reduce wear stripwear and engine overheating.

Track Studs (XF/F Models) NOTE: Stud or hooker plate installa-tion will void track and tunnel warranty.

NOTE: Stud installation can be per-formed by the snowmobile owner ifqualified to do so. If the owner doesnot feel qualified, take the snowmo-bile to an authorized Arctic Cat Snow-mobile dealer for this service. Thisservice is at the discretion andexpense of the snowmobile owner.

For proper installation, use the followingprocedure:

! WARNINGWhen installing studs on a single-plytrack, it is important to use ArcticCat-approved studs (proper headdiameter). If approved studs (properhead diameter) are not used, studscould tear free of the track causingpossible injury or even death. Con-sult an authorized Arctic Cat Snow-mobile dealer for information.

CAUTIONTo prevent tunnel damage from thestuds, Tunnel Protector Kit (p/n 5639-752) for the XF models or (p/n 5639-668)for the F models must be installed.

17

1. Using the appropriate stud template(see chart), mark the desired studpattern to be used.

2. Using the proper-sized stud holedrill bit, drill out the stud holes.

3. Push the stud through the hole frominside the track; then place thedomed support plate and lock nut onthe exposed stud.

4. Using a wrench to secure the stud,tighten the lock nut on the exposed stud.

It is also recommended that wheneverstuds are installed on a track, carbidewear bars should be installed on the skis.Carbide wear bars complement the trackstuds to balance steering control underthese 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 — shortlength of carbide...many track studs —long length of carbide). The proper pro-portion between the number of studs andcarbide length on the wear bar will main-tain steering balance.

Reverse OperationThe engine reverse function offers theoperator the convenience of being able toback up the snowmobile rather than hav-ing to turn the snowmobile around byhand. This feature, under most situations,should not be used to free a stuck snow-mobile as it will tend to dig the skisdeeper into the snow. Always use mini-mal speed when operating in reverse andcome to a complete stop before shiftingfrom either forward to reverse or reverseto forward.

Shifting Into Reverse (800 cc Models)

741-438A

NOTE: Correct drive belt tension(deflection) is important for thereverse function to operate properly.If the belt is too tight, difficulty inengaging reverse will be experi-enced (the reverse function willmake up to three attempts to engageinto reverse, and if the function isnot completed after the thirdattempt, the engine will shut down).

1. Always warm up the engine for 2-3minutes prior to shifting intoreverse. The reverse function is can-celled when engine temperature isbelow or above normal operatingrange.

2. Shift only with the engine at idleRPM and the snowmobile com-pletely stopped. The reverse func-tion will not engage if engine speedis above 3000 RPM.

Stud Template ChartTrack Length p/n

128 in. 4639-443141 in. 4639-991

! WARNINGAlways balance the snowmobile withthe proper proportion between thenumber of studs and carbide lengthon the wear bars. Do not “over drive”conditions; use common sense in alloperating conditions.

CAUTIONDo not use studs that are more than9.525 mm (0.375 in.) longer than thetrack lug height.

! WARNINGDo not operate a snowmobile withloose studs as they may be thrownfrom the track. Always use a shieldedsafety stand whenever performingany maintenance or adjustments.

! WARNINGDO NOT stand behind the snowmo-bile or near the rotating track. NEVERrun the track at high speed when thetrack is suspended.

18

3. If attempting to shift into reverse attoo high engine RPM (above 3000RPM), the reverse function will becancelled and the coolant tempera-ture warning icon will flash. Thisindicates the reverse switch buttonwas pressed at too high RPM. Theoperator must reduce engine RPMbelow 3000 and press the button asecond time.

4. Upon pressing the reverse switchbutton, the reverse function willmake up to three attempts to engageinto reverse. If the function is notcompleted after the third attempt,the engine will shut down.

Operating in Reverse (800 cc Models)

1. When reverse is engaged, a reverseicon will illuminate in the speedom-eter/tachometer and a reverse alarmwill sound.

2. If the throttle lever is compressedbefore complete reverse engage-ment, the engine may shut down.Always wait for the reverse icon toilluminate and the reverse alarm tosound before backing up.

3. The system will not shift until the but-ton is released. Also, the reverse func-tion will cancel if operated in reverselonger than 45 seconds. Whenever thereverse function has been cancelled,the engine must be run in the forwardmode for a minimum of 60 seconds at2000 RPM before the reverse functioncan be used again.

NOTE: While operating in reverse,a “rev-limiter” will activate at 6500RPM.

4. To shift into forward, stop the snow-mobile and allow the engine to idle(under 3000 RPM); then press thereverse button and release. The for-ward selection will be complete.

5. After shifting from reverse to for-ward (or from forward to reverse),apply the throttle slowly and evenlyto allow the driven pulley to engageproperly.

6. The reverse function is cancelledwhenever the engine is shut off.

Shifting Into Reverse (1100 cc Models)

741-438A

CAUTIONNever shift into reverse while thesnowmobile is moving forward as it ishard on the driven pulley torquebracket and the cam rollers.

CAUTIONNever pull the recoil starter rope whenthe engine is running or when operat-ing in reverse. Damage to the engineand/or recoil start system will occur.

! WARNINGDo not use high speed when backingup. Control could be lost and injurycould occur.

CAUTIONDo not use high speed when backingup. Damage to the drive belt anddriven pulley components may occur.

CAUTIONAfter reversing in deep powder snowconditions, make sure the snowflapdoes not become “caught up” in thetrack. Track and/or snowflap damagemay occur.

CAUTIONIf the snowmobile is equipped withice scratchers, the scratchers mustbe disengaged or component dam-age will occur.

19

1. Always warm up the engine for 2-3minutes prior to shifting intoreverse.

2. With the engine at idle (under 2500RPM) and the snowmobile at a com-plete stop, press the reverse switchbutton; then release the button. Thereverse selection will be complete.

NOTE: The snowmobile must be ata complete stop and the engine run-ning under 2500 RPM before the sys-tem will allow shifting.

NOTE: The system will not shiftuntil the button is released.

3. When reverse is engaged, a reverseicon will illuminate in the speedom-eter/tachometer and a reverse alarmwill sound.

4. To shift into forward, stop the snow-mobile and allow the engine to idle(under 2500 RPM); then press thereverse button and release. The for-ward selection will be complete.

Operating in Reverse (1100 cc Models)

1. When shifting into reverse, alwayswait for the reverse icon to illumi-nate and the reverse alarm to soundbefore backing up.

NOTE: The reverse function is can-celled whenever the engine is shutoff.

2. After shifting from reverse to for-ward (or from forward to reverse),apply the throttle slowly and evenlyto allow the driven pulley to engageproperly.

Access Panel/Hood (Removing/Installing)To remove the access panel and hood, usethe following procedure:

746-089A

746-090A

746-091A

CAUTIONNever shift into reverse while thesnowmobile is moving forward as it ishard on the driven pulley torquebracket and the cam rollers.

! WARNINGUse caution and minimal speed whenoperating the snowmobile in reverse.Be sure the button is in the desiredposition.

CAUTIONNever engage the electric starterwhen the engine is running or whenoperating in reverse. Damage to theengine and/or the electric start sys-tem will occur.

CAUTIONAfter reversing in deep powder snowconditions, make sure the snowflapdoes not become “caught up” in thetrack. Track and/or snowflap damagemay occur.

CAUTIONIf the snowmobile is equipped withice scratchers, the scratchers mustbe disengaged or component dam-age will occur.

800 cc

1100 cc Non-Turbo

1100 cc Turbo

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1. Remove the hairpin clip from the pinlocated at the front of the accesspanel. Move the panel up and off thepin; then swing the panel all the wayout and unhinge the panel from thelower console.

2. Remove the two torx-head screwssecuring the hood (located on theunderside of the hood above the reartube of the upper A-arm); thenremove the two torx-head screwsfrom the top-side of the hood secur-ing the hood to the upper console.

NOTE: On the turbo models,remove the two torx-head screwsfrom under the nosepiece of thehood.

3. Locate the hood harness connector(located in front of the speedometer)and unplug the connector; thenmove the hood slightly forward andremove the hood.

NOTE: On the turbo models, firstunhook the rubber straps securingthe air filter housing to the intakeplenum of the hood; then move thehood slightly forward and removethe hood.

To install the access panel and hood, usethe following procedure:

1. Position the hood onto the snowmo-bile and connect the hood harnessconnector.

NOTE: On the turbo models priorto securing the hood, make sure therubber straps of the air filter housingare accessible.

2. Secure the hood with the six torx-head screws and tighten securely.

NOTE: Before installing the hood,make sure the mounting screw clipsare in position.

NOTE: On the 1100 cc non-turbomodels, make sure the foam seal isin place on the air intake.

NOTE: On the turbo models, makesure the air filter housing is properlyconnected and secured with the rub-ber straps to the intake plenum ofthe hood and turbocharger.

3. Install the access panel onto thelower console; then close the accesspanel and scure with the hairpin clip.

Removable SeatThese snowmobiles are equipped with aremovable seat. To remove the seat, usethe following procedure:

Remove the torx-head screw from theunderside of the seat; then lift on the backof the seat and move it up and rearwardto remove it from the tunnel.

746-088A

To install the seat, use the following pro-cedure:

Slide the front of the seat into the lockingposition of the seat support bracket; thenlower the rear of the seat into position onthe tunnel. Secure with the torx-headscrew.

NOTE: On the 1100 cc LXR modelsprior to lowering and securing theseat, connect the seat heater har-ness connector.

TowingIf the snowmobile is to be towed byanother snowmobile, do not tow usingthe loops in the skis. The tow rope shouldbe attached to the spindles.

CAUTIONOn the 1100 cc LXR models prior toremoving the seat, lift the rear of theseat and disconnect the seat heaterharness connector.

21

Arctic Power Valve (APV) System (800 cc Models)

This RPM controlled servomotor (servo)actuated system adjusts the size of theexhaust ports to provide peak perfor-mance throughout the RPM range.

The system consists of an exhaust valveassembly mounted to the exhaust side ofeach cylinder and connected by adjust-able cables to an electronic servomounted beneath the hood.

NOTE: The mounting location of theservo will vary from model to model.

739-152F

At low RPM, the exhaust valves are heldin the DOWN position by return springs.This gives the engine a “low port”exhaust design calibrated to providemaximum low RPM power and improvefuel economy at trail speeds.

739-152G

At high RPM, the exhaust valves areraised. This creates a “high port” exhaustdesign calibrated to provide maximumperformance at high RPM.

739-152H

NOTE: The RPM ranges will varyfrom model to model.

NOTE: If the servomotor cyclesthree times and then shuts down, theexhaust valve cables are notadjusted correctly. The exhaustvalves may also be sticking.

NOTE: APV cleaning may be doneby the snowmobile owner if qualifiedto do so. If the owner does not feelqualified, take the snowmobile to anauthorized Arctic Cat Snowmobiledealer for this service. This serviceis at the discretion and expense ofthe snowmobile owner.

Exhaust Controlled Timing (ECT) System (800 cc Models)This system automatically adjusts theignition timing to provide maximum per-formance through a variety of operatingconditions. The ECU receives input onengine RPM (demand) and exhaust pipetemperature (engine condition) andadjusts 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 exhaustpipe temperature sensor located in theexpansion chamber. A reading of either 0ohm or infinity indicates a failed sensor.

CAUTIONThe recommended engine oil to useis either Arctic Cat APV Synthetic 2-Cycle Oil or Formula SS Semi-Syn-thetic Oil (see Gasoline-Oil - Recom-mended Injection Oil sub-section inthis section). Any substitute maycause an APV malfunction.

22

0737-314

NOTE: A disabled ECT systemWILL NOT cause engine damage;however, a failed ECT system willhave slower throttle response andmay produce slightly less top-endperformance.

23

Operating InstructionsStarting and Stopping EngineIt is imperative that the brake system bechecked for wear and proper operationand that all safety checks found in theaccompanying Snowmobile SafetyHandbook be performed before attempt-ing to start the engine. After the enginehas been started, check the headlights(high and low beam), taillight, and brake-light to be sure they are working properlyand adjusted correctly. Make sure alllights are clean to provide maximum illu-mination. The headlight and taillightmust be clean and must be illuminatedwhenever the engine is running.

1. Test the operation of the brake systemby compressing the brake lever. Thebrake lever must feel firm when com-pressed; then while holding the brakelever in the compressed position, mea-sure the distance between the brakelever and the handlebar. The distancemust be greater than 2.54 cm (1 in.).

0745-816

2. With the brake fluid reservoir in alevel position and the coverremoved, check the fluid level. Thebrake fluid level must be at the highbrake fluid mark in the reservoir.

0745-817

3. If the brake fluid is below the highbrake fluid mark, add Arctic Catapproved DOT 4 brake fluid untilthe fluid is at the recommendedlevel. Install and secure the reservoircover. Do not allow moisture to con-taminate the brake system.

4. Test the throttle control lever bycompletely compressing and releas-ing it several times. The leverMUST return to the idle positionquickly and completely.

5. Move the emergency stop switch tothe UP or RUN position.

6. Insert key into ignition switch; thenrotate key to the RUN position.

NOTE: On the 800 cc models whena cold engine is being started, DONOT COMPRESS THE THROTTLECONTROL LEVER. If the throttle con-trol lever is compressed, the enginewill not start because the fuel/airmixture will be too lean.

CAUTIONBrake fluid is highly corrosive. Do notspill brake fluid on any surface of thesnowmobile.

! WARNINGDo not overfill the brake fluid reser-voir. Overfilling the reservoir maycause the brake system to hydrauli-cally lock. Use only Arctic Catapproved brake fluid.

! WARNINGDo not start the engine if the brake sys-tem is not functioning properly. Servicethe brake system or have it properlyrepaired prior to operating the snow-mobile. Serious personal injury or evendeath may occur if the brake system isnot operating properly.

CAUTIONAlways check the coolant level beforestarting the engine.

24

7. On models with manual start, pullthe recoil handle slowly until resis-tance is felt; then give a short quickpull. Repeat until the engine starts.

NOTE: In extremely cold weather,pull the recoil handle slowly two tothree times to begin the starting pro-cedure.

NOTE: On electric start models,rotate the key to the START position;then when the engine starts, releasethe key.

NOTE: When the engine starts,allow it to warm up properly. Idle theengine several minutes until theengine has reached normal operat-ing temperature. Do not idle theengine for excessively long periodsof time.

8. On the 1100 cc models, there is a“cold drive-away” function incorpo-rated within the engine. This func-tion is active until the engine reachesoperating temperature (see ColdDrive-Away Function sub-section inthe General Information section).

9. Flooding — If the engine does notstart but seems ready to start, engagethe brake lever lock; then compressthe throttle control lever fully and tryto start the engine. When the enginestarts, release the throttle controllever immediately. After the warm-up, release the brake lever lock.

NOTE: On the 800 cc models if theengine fails to start during theattempt with the throttle control levercompressed, remove the spark plugsand clean and dry them thoroughly orinstall a new set of properly gapped,recommended spark plugs.

10. To shut off the engine, turn the igni-tion key to the OFF position or pushthe emergency stop switch to theDOWN position.

BrakingThe following items are items that theoperator must be familiar with whenoperating this snowmobile and itshydraulic brake system. Important addi-tional information on the proper mainte-nance of the brake system is found in theMaintenance section.

1. Use the brakes wisely. Each time thebrakes are applied in all hydraulicbrake systems (including automotiveapplications), heat is transferred tothe brake fluid. The amount of heattransferred during high speed stopsand/or repetitive use may be highenough to boil the brake fluid andcause the brakes to either fade or maycause an unexpected loss of brakes.

CAUTIONTo avoid damaging the recoil starter,DO NOT pull the recoil rope to its limitor release the recoil handle from anextended position. Allow the rope torewind slowly.

CAUTIONDo not continuously run the starterfor more than 5 seconds at a time.

CAUTIONOn the 800 cc models, it is extremelyimportant that the engine is properlywarmed up before subjecting theengine to high speed operation orheavy loads. The engine should beallowed to idle at least 3-4 minutesbefore it is operated at more than 1/2throttle. In extremely cold conditions,the warm-up time will be longer. Coldseizure and piston scuffing causedby insufficient warm-up will not becovered by warranty. Also, do not idlethe engine for excessively long peri-ods of time.

CAUTIONOn the 1100 cc models, always turnthe ignition switch key to the OFFposition when the snowmobile is notbeing used. Leaving the ignitionswitch in the ON position will result indischarging the battery and possibledamage to the battery.

25

If this occurs, the brake fluidrequires a cool-down period beforethe brakes will again function prop-erly. This cool-down period willvary depending upon the ambient airtemperature and the temperature ofthe brake fluid. If loss of brakes hasoccurred because of high fluid tem-peratures, do not operate the snow-mobile until the cool-down periodhas expired and brake lever firmnesshas returned.

2. Be sure to maintain the brake fluid atthe proper level and take care not toget any moisture in the system asmoisture in the brake fluid lowers theboiling point. If the brake fluid is everboiled (by high speed stops or repeti-tive use) or if moisture is allowed toenter the system, it must be changed.Never substitute or mix different typesor grades of brake fluid.

3. Never ride the brake. Even main-taining minimal pressure on thebrake lever will cause the brake padsto drag on the disc and may overheatthe brake fluid.

4. The brake lever lock is not a parkingbrake and should not be applied forperiods exceeding 5 minutes.NEVER OPERATE THE SNOW-MOBILE WITH THE BRAKELEVER LOCK ENGAGED.

5. Pumping the brake lever is permissi-ble; however, if pumping the brakelever more than twice is necessary toobtain the necessary stopping power,immediately take the snowmobile toan authorized Arctic Cat Snowmobiledealer for service. If not under war-ranty, this service is at the discretionand expense of the snowmobile owner.

6. When new brake pads are installed,a “burnishing” process is required(see Brake System in the Mainte-nance section of this manual).

Emergency StoppingThere are several methods of stopping orslowing the snowmobile under a varietyof situations. Identified in the followingchart are the ways a snowmobile may bebrought to a stop and the effectivenessunder normal conditions.

Throttle/Ignition Monitor SwitchThe throttle control is equipped with amonitor switch for safety purposes whichwill stop the engine when a loss of returnspring force occurs. If ice forms in thethrottle system or if there is some othermalfunction of the throttle system result-ing in a loss of return spring force, themonitor switch will stop the engine whenthe throttle control lever is released.

! WARNINGExcessive, repetitive use of thehydraulic brake for high speed stopswill cause overheating of the brakefluid and premature brake pad wearwhich will result in an unexpectedloss of brakes.

! WARNINGUse only Arctic Cat approved DOT 4brake fluid. Never substitute or mixdifferent types or grades of brakefluid. Brake loss can result. Checkbrake fluid level and pad wear beforeeach use. Brake loss can result insevere injury or even death.

! WARNINGThe brake lever lock is not a parkingbrake and should not be applied forperiods exceeding 5 minutes. Thebrake lever lock maintains the brakelever in the compressed position andmaintains pressure against the brakedisc; however, after a period of time,the pressure applied to the brake discmay relax below the amount requiredto hold the snowmobile stationary.

Item Function ConditionEmergency Stop Switch

interrupts igni-tion circuit

ALL

Throttle/Ignition Monitor Switch

interrupts igni-tion circuit

ALL

Ignition Switch interrupts igni-tion circuit

ALL

Brake slows the drive system

ALL

26

If the snowmobile engine stops abruptlywhen the throttle control lever is releasedand the activation of the monitor switchis suspected, use the following proce-dure:

1. Rotate the ignition key to the OFFposition.

2. Remove ice and snow from thethrottle system and wait 5-10 min-utes for the engine heat to thaw icefrom the throttle system.

3. Test the throttle control lever bycompressing and releasing it severaltimes. The lever MUST return to theidle position quickly and completely.

NOTE: If the throttle control leveroperates properly and the enginedoes not start, compress the throttlelever slightly (approximately 1/8throttle) and try starting the engine.If the engine now starts and stopswhen the throttle lever is released,take the snowmobile to an autho-rized Arctic Cat Snowmobile dealerfor service. If not under warranty,this service is at the discretion andexpense of the snowmobile owner.

4. If the throttle control lever operatesproperly, rotate the ignition key tothe RUN position and go throughnormal starting procedures.

NOTE: If the throttle control leveroperates properly and the enginedoes not start, a malfunctioningmonitor switch may be the problem.Take the snowmobile to an autho-rized Arctic Cat Snowmobile dealerfor service. If not under warranty,this service is at the discretion andexpense of the snowmobile owner.However, if a dire emergency existswherein the engine must be started,disconnect the throttle monitorswitch located in the right-side han-dlebar control.

NOTE: If disconnection of thethrottle monitor switch is needed tostart the engine, take the snowmo-bile to an authorized Arctic CatSnowmobile dealer for service assoon as possible. If not under war-ranty, this service is at the discretionand expense of the snowmobileowner.

NOTE: The monitor switch is nowbypassed. All other ignition/electri-cal features (ignition switch, emer-gency stop switch, headlight,taillight, and brakelight) will operateproperly.

Varying Altitude OperationOperating a snowmobile at varying alti-tudes requires changes in performancecomponents. These changes affect drivetrain components (on certain models).

For altitude information, see the appro-priate specifications sheet.

! WARNINGIf any malfunction of the throttle sys-tem occurs (such as freezing in fluffysnow) and the monitor switch doesnot shut off the engine, press downon the emergency stop switch IMME-DIATELY to stop the engine. DO NOTstart the engine until the malfunctionin the throttle system has beenlocated and corrected.

! WARNINGIf the throttle control lever does notwork properly, DO NOT ATTEMPT TOSTART THE ENGINE.

! WARNINGUnder no circumstances should dis-connection of the throttle control wir-ing harness be used as a substitutefor the monitor switch during normaloperation of the snowmobile. Per-sonal injury and damage could occurif the throttle system malfunctions orif the operator is unable to stop theengine in an emergency. If the snow-mobile must be operated with a dis-connected throttle control wiringharness, EXTREME CAUTION MUSTBE TAKEN. NEVER EXCEED 10 MPHWITH THE THROTTLE CONTROLWIRING HARNESS DISCONNECTED.

27

NOTE: Just as important as cali-brating the snowmobile for higher alti-tudes is recalibrating the snowmobilewhen going to lower altitudes.

XF models (except the XF 800 HighCountry model) are initially set up at thefactory for operation between 0-3000 feet.

F models are initially set up at the factoryfor operation between 0-5000 feet.

M models and the XF 800 High Countrymodel are initially set up at the factoryfor operation between 6000-9000 feet.

NOTE: Drive train changes can bemade by the snowmobile owner ifqualified to do so. If the owner doesnot feel qualified, take the snowmo-bile to an authorized Arctic CatSnowmobile dealer for this service.This service is at the discretion andexpense of the snowmobile owner.

28

LubricationChain CaseNOTE: The snowmobile must beon a level surface for this procedure.

1. Check the lubricant level in thechain case by using the sight glass.

0746-115

NOTE: The correct level is whenthe lubricant is at least halfway up inthe sight glass.

NOTE: Adding lubricant can bedone by the snowmobile owner ifqualified to do so. If the owner doesnot feel qualified, take the snowmo-bile to an authorized Arctic CatSnowmobile dealer for this service.This service is at the discretion andexpense of the snowmobile owner.

2. On the 800 cc models if the lubelevel is low, remove the fill plugfrom the chain case; then add theappropriate amount of Arctic CatSynthetic Chain Lube (p/n 5639-038) in the fill hole. Install the plug.

3. On the 1100 cc models if the lubelevel is low, remove the three screwssecuring the shift actuator to thechain case, disconnect the actuatorwiring harness, and remove the actu-ator w/extension; then add theappropriate amount of Arctic CatSynthetic Chain Lube (p/n 5639-038) through the shift actuator open-ing. When the lube is halfway up thesight glass, install the shift actuatorw/extension and connect the actua-tor wiring harness.

4. On the 1100 cc models, start theengine and verify proper reverse andforward operation.

PC019A

NOTE: If excessive build-up ofmoisture or discolored oil isdetected in the chain case, it may benecessary to replace the chain lube.

NOTE: Replacing the lubricant canbe done by the snowmobile owner ifqualified to do so. If the owner doesnot feel qualified, take the snowmo-bile to an authorized Arctic CatSnowmobile dealer for this service.This service is at the discretion andexpense of the snowmobile owner.

To replace the lubricant, use the follow-ing procedure:

NOTE: The exhaust resonatormust be removed for this procedure.

1. Place a drain pan on the floor beneaththe snowmobile to allow the lubri-cant to drain from the chain case intothe drain pan.

2. Remove the cap screws securing thechain case cover (with oil reservoir)to the chain case. Remove the coverand allow the oil to drain into thedrain pan.

NOTE: It is critical that the snow-mobile is on a level surface toensure the lubricant drains properlyand completely.

CAUTIONWhen installing the shift actuator,rotate the actuator back and forth toproperly align it with the extensiongear. Failure to do so could causecomponent damage.

29

NOTE: Inspect the chain casecover seal for nicks or damage.

3. When the lubricant has completelydrained from the case and the chaincase is cleaned of old oil, properlyseat the seal in the cover; then installthe chain case cover. Tighten the capscrews to 100 in.-lb.

4. On the 800 cc models, pour recom-mended chain case lube into the fillhole until the lubricant is at leasthalfway up in the sight glass; theninstall the plug.

5. On the 1100 cc models, remove thethree screws securing the shift actua-tor to the chain case, disconnect theactuator wiring harness, and removethe actuator w/extension. Pour rec-ommended chain case lube throughthe shift actuator opening until thelubricant is at least halfway up in thesight glass; then install the shiftactuator w/extension and connectthe actuator wiring harness.

6. Install and secure the exhaust reso-nator.

NOTE: On the 1100 cc models, theresonator gasket(s) between theexhaust pipe(s) and resonator mustbe replaced.

7. On the 1100 cc models, start theengine and verify proper reverse andforward operation.

Rear SuspensionThis procedure should be done every 40operating hours.

NOTE: Arctic Cat recommendsthat Arctic Cat All-Temp Grease (p/n4639-365) be used for this proce-dure.

NOTE: Illustrated are the generallocations of grease fittings. Actuallocations will vary from model tomodel.

1. Shut engine off and wait for all mov-ing parts to stop.

2. With the gas tank nearly empty (lessthan 1/4 full) and using HandlebarStand (p/n 5639-152) or a suitablesubstitute, lay the snowmobile on itsleft side.

3. Remove ice and snow buildup fromthe skid frame to expose the greasefittings.

0746-093

4. Lubricate the grease fittings with all-temperature grease.

CAUTIONWhen installing the shift actuator,rotate the actuator back and forth toproperly align it with the extensiongear. Failure to do so could causecomponent damage.

CAUTIONThe correct lubricant to use in thechain case is Arctic Cat SyntheticChain Lube. Any substitute maycause serious damage to the drivesystem.

30

MaintenancePeriodic Maintenance Checklist

Item Interval Page RemarksBrake System Daily 41 Check for binding, leakage, and proper operation;

lever firmness, travel, caliper, disc, and padsCooling System - Liquid Daily 14,35 Check for leakage, damage, obstructions, coolant

levelOil-Injection System Daily — Check for leakage, damage, and injection/engine

oil levelEngine Oil (1100 cc Non-Turbo Models)

2500 Mi/Seasonal

33 Change oil and filter

Engine Oil (1100 cc Turbo Mod-els)

2000 Mi/Seasonal

33 Change oil and filter

Battery Daily 14,38 Check for proper charge and tight connectionsStop Switch Daily — Check for proper operationHoses Daily — Check for damage, leakage, and wearHeadlight & Taillight/Brakelight Daily 51-52 Check for proper operation and cleanlinessSteering System Daily — Check for proper operation, tightness of bolts,

and bindingThrottle Control System Daily 26 Check for binding, sticking, proper operation,

throttle cable tension, and wearDrive Belt Daily

Monthly44 Check for wear, cracks, and fraying

Check length and width dimensionsSki Wear Bars Daily 52 Check for wear and damageElectrical Wiring Weekly — Check for wear, damage, and tight connectionsExhaust System Weekly 14 Check for damage, leakage, and obstructionsNuts, Bolts, Fasteners Weekly — Check tightness Recoil Starter Weekly — Check rope for wear, fraying, and proper operationShock 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 gapValve Clearance (1100 cc Mod-els)

5000 Mi/Seasonal

37 Check/adjust

Suspension Weekly 48 Check for damage, loose components, and proper adjustment

Track Tension/Alignment Weekly 46,47 Check/adjust as necessaryWear Strips Weekly 53 Check for wear and damageWires & Cables Weekly — Check for wear, damage, and frayingFuel System - Tank, Pump, In-Line Filter, & Vent Hose

Weekly — Check for damage, wear, obstructions, and leak-age

Fuel Filter (1100 cc Models) 5000 Mi/2 years

— Replace

Air Silencer (800 cc Models) Seasonal — Inspect/cleanAir Cleaner/Filter (1100 cc Turbo Models)

Weekly/Seasonal

32 Check/replace

APV System Monthly 22 Check/adjust as necessaryChain Case Daily 29 Check lube level and for leakageChain Case - Lubricant Seasonal 29 ReplaceHeat Exchangers Monthly — Check for wear, leakage, and damageDrive 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

31

The longevity and safety of the snowmo-bile can be increased by making periodicchecks of the items in the precedingchecklist.

If, at any time, abnormal noises, vibra-tions, or improper working conditions ofany component of this snowmobile aredetected, DO NOT OPERATE THESNOWMOBILE. Take the snowmobileto an authorized Arctic Cat Snowmobiledealer for inspection and adjustment orrepair. If not under warranty, this serviceis at the discretion and expense of thesnowmobile owner.

The snowmobile should be taken to anauthorized Arctic Cat Snowmobile dealerat the end of each snowmobiling seasonfor general inspection and for off-seasonstorage servicing. This inspection andservicing is at the expense of the snow-mobile owner.

Air Cleaner/Filter (1100 cc Turbo Models)The air filter inside the air cleaner housingmust be kept clean to provide good enginepower and gas mileage. If the snowmobileis used under normal conditions, inspectthe filter weekly and replace the filter atthe intervals specified. If operated inadverse conditions, inspect and service thefilter more frequently. Use the followingprocedure to remove the filter and toinspect and/or replace it.

NOTE: For this procedure, thehood must be removed (see AccessPanel/Hood (Removing/Installing) inthe General Information section ofthis manual).

1. Remove the air filter from the housing.

2. Inspect the air filter for dirt or damage.

3. Clean any debris from inside the airintake plenum.

4. Place the new filter (if necessary)into the housing.

5. Install the hood (see Access Panel/Hood(Removing/Installing) in the GeneralInformation section of this manual).

Fuel System

In-Line Fuel Filter (1100 cc Models)

Arctic Cat recommends that the in-line fuelfilter be replaced every 5000 miles. The fil-ter must be clean to allow the fuel hose totransmit the amount of gasoline required.

If the in-line fuel filter is obstructed, gas-oline flow will be restricted; therefore,the filter must be replaced. To removeand install the in-line fuel filter, use thefollowing procedure:

NOTE: Before removing the fuel fil-ter, take note that the filter is direc-tional and the arrow should bedirected towards the engine.

CAUTIONFailure to inspect the air filter fre-quently if the snowmobile is used inadverse conditions can damage theturbocharger/engine.

CAUTIONDo not use compressed air in anattempt to clean the filter. Damage tothe filter may occur. If the filter isdirty, it must be replaced.

CAUTIONA torn air filter can cause damage tothe turbocharger/engine. Contami-nants may get inside the turbo-charger/engine if the filter is torn.Carefully examine the filter for holesor tears. Replace the filter with a newone if it is torn.

CAUTIONDo not run the engine without the airfilter installed. Severe damage to theturbocharger/engine will occur.

! WARNINGWhenever any maintenance or inspec-tion is made on the fuel system inwhich there may be fuel leakage, thereshould be no welding, smoking, openflames, etc., in the area.

! WARNINGSince the fuel supply hose may beunder pressure, always wear safetyglasses; then remove the hose slowlyto release the pressure. Place anabsorbent towel around the connec-tion to absorb the fuel.

32

NOTE: On the non-turbo models,the fuel filter is located below thesteering support. To access the filter,the hood must be removed (seeAccess Panel/Hood (Removing/Installing) in the General Informationsection of this manual).

NOTE: On the turbo models, thefuel filter is located between the gastank and the rear belt guard and issecured to the tunnel with a filterbracket. To access the filter, the left-side access panel must be openedand the lower console must beunlatched and opened.

1. Remove the hose clamps and dis-card; then slowly remove the fuelhoses from the fuel filter. Dispose ofthe excess fuel from the filter prop-erly.

2. Inspect the fuel hoses thoroughly forany signs of cracking, cuts, or wearpoints.

3. Place the new hose clamps on thefuel hoses; then with the fuel pumpinlet and outlet noted, connect thefuel hoses to the fuel filter. Securewith the hose clamps.

NOTE: After completing thechanging of the fuel filter and theengine is started for the first time,inspect the filter area for any signsof leaks.

Gasoline Additives

Fuel de-icer can be used for all models.Also, periodic use of an injector cleanerfor 800 cc models is recommended espe-cially in the last tank of gasoline beforestorage. Arctic Cat Fuel Stabilizer (p/n0436-907) should also be added to thelast tank of gasoline before storage.

Fuel Pickup Valves

If ever there is a restricted fuel flow and apickup valve is suspected, take the snow-mobile to an authorized Arctic Cat Snow-mobile dealer for this service. If notunder warranty, this service is at the dis-cretion and expense of the snowmobileowner.

Checking Engine Oil Level (1100 cc Models)

1. Park the snowmobile on a level sur-face; then start the engine and allowit to warm up for 5-10 minutes, or ifthe snowmobile was operated, allowthe engine to idle for approximately30 seconds.

NOTE: The snowmobile must beon a level surface for this procedure.

2. Shut the engine off; then remove theright-side access panel and verify oilis visible at least halfway up in thesight glass.

0746-166

3. If oil is not visible halfway up in thesight glass, add recommendedengine oil until oil is visible half-way up the sight glass.

NOTE: Care must be taken not toover-fill the reservoir with oil.

Changing Engine Oil/Filter (1100 cc Models)

NOTE: Recycle or properly dis-pose of the used engine oil.

NOTE: The access panels andhood must be removed for this pro-cedure (see Access Panel/Hood -Removing/Installing in the GeneralInformation section).

1. Park the snowmobile on a level sur-face; then start the engine and allowit to warm up for 5-10 minutes, or ifthe snowmobile was operated, allowthe engine to idle for approximately30 seconds. Shut the engine off.

! WARNINGCare must be taken if a hot drain plugis removed by hand. Burning couldoccur.

33

2. Remove the torx-head screws andthe access plate from beneath thesnowmobile.

3. Place a drain pan beneath the engine oilpan drain plug; then remove the plugand allow the oil to drain completely.

PC010A

4. Install the engine oil drain plug witha new gasket; then tighten the plugto 16 ft-lb.

5. Remove the four torx-head screwssecuring the right-side footrest to thetunnel and the support; then with adrain pan in position, remove thedrain plug from the oil reservoir.

746-121A

NOTE: To aid in draining the oilfrom the reservoir, position a funnelbetween the reservoir and the open-ing of the tunnel running board.

6. After the oil has drained completely,install the drain plug with a new O-ring and tighten to 16 ft-lb.

NOTE: Always install a new Oil PanDrain Plug Gasket (p/n 3402-011) anda new Reservoir Drain Plug O-Ring (p/n 1602-213) when changing the oil.

7. Using Oil Filter Wrench (p/n 0644-551), loosen (but do not remove) theoil filter and allow the oil to drainfrom the filter into the drain pan;then remove the filter.

NOTE: On the turbo models, the oilfilter is accessible between the frontopening of the chassis and the lowerintercooler hose.

8. Apply a light coat of fresh engine oilto the seal of the new oil filter.

9. Install the new oil filter by turningthe oil filter by hand until the sealhas contacted the oil filter mountingsurface; then tighten the oil filter to15 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 onthe oil pump (beneath the coolanttank) to purge air from the oil hose.

PC016A

NOTE: When air can no longer beheard purging from oil pump bleed,tighten the bleed bolt to 7.5 ft-lb.

12. Without starting the engine, placethe handlebar emergency stopswitch to the RUN position and theignition switch to the ON position.The Oil Pressure Warning Iconshould illuminate.

NOTE: If the warning icon does notilluminate, take the snowmobile to anauthorized Arctic Cat Snowmobiledealer for service. If not under war-ranty, this service is at the discretionand expense of the snowmobile owner.

13. If the warning icon illuminates(from step 12), start the engine. Thewarning icon should go out withinfive seconds. If it does, proceed tostep 14.

CAUTIONDo not attempt to start the enginewith the bleed bolt open.

34

NOTE: If the warning icon does notgo out, shut the engine off immedi-ately and repeat step 11; then placethe ignition switch to the ON posi-tion and repeat step 13. If the warn-ing icon does not go out, take thesnowmobile to an authorized ArcticCat Snowmobile dealer for service. Ifnot under warranty, this service is atthe discretion and expense of thesnowmobile owner.

14. Shut the engine off; then add oil tothe oil reservoir until oil is visiblehalfway up in the sight glass.

15. Install the access plate and torx-headscrews beneath the snowmobile;then install the hood and access pan-els (see Access Panel/Hood -Removing/Installing in the GeneralInformation section).

Coolant Level NOTE: Use a good quality, ethyleneglycol-based, automotive-type coolant.

NOTE: Always check the coolantlevel with the engine cold.

800 cc Models

Open the left-side access panel and locatethe coolant filler neck behind the steeringsupport. The coolant should be visible atleast 3/4-way to the top of the filler neck.If coolant must be added, the hood mustbe removed (see Access Panel/Hood -Removing Installing sub-section in theGeneral Information section).

NOTE: On the HCR model if operat-ing on ice or hard-packed snow, theice scratchers must be engaged toreduce engine overheating.

1100 cc Models

NOTE: The access panels andhood must be removed for this pro-cedure (see Access Panel/Hood -Removing/Installing sub-section inthe General Information section).

1. Remove the filler cap from the cool-ant reservoir.

2. Verify the coolant level is at the bot-tom of the tab in the filler neck.

0746-117

3. If the coolant is below the tab, addcoolant to the reservoir until at the tab.

NOTE: On the HCR model if operat-ing on ice or hard-packed snow, theice scratchers must be engaged toreduce engine overheating.

Spark Plugs1100 cc Models

NOTE: Always use the recom-mended spark plugs in the engine.See the appropriate specificationssheet for correct spark plug gap.

Varying terrain conditions and operatingusage may require spark plugs of a differ-ent heat range. For example, sustainedcross-country riding will usually requirecolder heat-range spark plugs while trailriding or other continual slow speedoperation will usually require hotter heat-range spark plugs.

CAUTIONAfter operating the snowmobile forthe initial 5-10 minutes, stop theengine, allow the engine to cooldown, and check the coolant level.Add coolant as necessary.

CAUTIONIf the coolant is below the tab and ifcoolant has been added, immediatelyinspect for leakage and/or damage. Ifleakage or damage is detected, takethe snowmobile to an authorized Arc-tic Cat Snowmobile dealer for ser-vice. If not under warranty, thisservice is at the discretion andexpense of the snowmobile owner.

CAUTIONIf adjusting spark plug gap is neces-sary, do not use the center electrodeas a leverage point. Damage to theplug may occur.

35

Removing/Installing Spark Plugs

NOTE: Spark plug maintenancemay be done by the snowmobileowner if qualified to do so. If theowner does not feel qualified, takethe snowmobile to an authorizedArctic Cat Snowmobile dealer forthis service. This service is at thediscretion and expense of the snow-mobile owner.

NOTE: For this procedure, thehood must be removed (see AccessPanel/Hood (Removing/Installing) inthe General Information section ofthis manual).

1. On the turbo models, remove thespark plug end caps; on the non-turbo models, remove the two capscrews securing the ignition coils tothe cylinder head cover.

2. Using a 3/8-in. drive ratchet,adapter, and a 5/8-in. spark plugsocket, remove the two spark plugs.

NOTE: Prior to installing the sparkplugs, check the gap between theelectrode and ground strap. Theclearance should be 9 mm (0.035 in.).

3. Install the spark plugs. Tighten to96 in.-lb.

4. On the non-turbo models, install theignition coils onto the cylinder headcover and tighten the two 6 mm capscrews to 96 in.-lb. On the turbo mod-els, install the spark plug end caps.

5. Install the hood (see Access Panel/Hood(Removing/Installing) in the GeneralInformation section of this manual).

800 cc Models

NOTE: Always use the recom-mended spark plugs in the engine.See the appropriate specificationssheet for correct spark plug gap.

Varying terrain conditions and operatingusage may require spark plugs of a differ-ent heat range. For example, sustainedcross-country riding will usually requirecolder heat-range spark plugs while trailriding or other continual slow speedoperation will usually require hotter heat-range spark plugs.

Removing/Installing Spark Plugs

NOTE: For this procedure, thehood must be removed (see AccessPanel/Hood (Removing/Installing) inthe General Information section ofthis manual).

1. Remove the springs securing theexpansion chamber to the exhaustmanifold and resonator.

2. Move the expansion chamber out ofthe way to access the spark plugs.

3. Remove the spark plug caps fromthe plugs.

4. Using a spark plug wrench, removethe plugs.

5. Install the plugs and finger-tighten.

6. Tighten the spark plugs to 19 ft-lb;then install the spark plug caps.

7. Place the expansion chamber intoposition and secure to the exhaustmanifold and resonator with thesprings.

8. Install the hood (see Access Panel/Hood (Removing/Installing) in theGeneral Information section of thismanual).

Checking Spark Plugs

800 cc Models

To see if the spark plugs being used are ofthe proper heat range (after the snowmo-bile has been operated under normal driv-ing conditions), remove the spark plugsand examine the condition of the centerelectrode insulator of each spark plug.

CAUTIONIf adjusting spark plug gap is neces-sary, do not use the center electrodeas a leverage point. Damage to theplug may occur.

36

AO352A

A. TAN or LIGHT BROWN insula-tor indicates correct spark plugs(heat range).

B. LIGHT GRAY or WHITE insula-tor indicates over-heating of theengine. This condition is caused bya too lean condition or incorrectspark plugs (heat range too hot).

C. BLACK insulator indicates fuelin the combustion chamber is notburning completely. This condi-tion is caused by a too rich con-dition, too much oil, or incorrectspark plugs (heat range too cold).

NOTE: If the center electrode insu-lators are light gray, white, or blackand if the oil-injection pump synchro-nization, and ignition timing are cor-rect, different heat-range spark plugsmay be necessary. Authorized ArcticCat Snowmobile dealers havedetailed spark plug information. Con-sult a dealer before changing sparkplugs, as incorrect heat-range sparkplugs could cause poor engine per-formance or engine damage.

Checking/Adjusting Valve Clearance (1100 cc Models)After 5000 miles or prior to seasonalstorage, valve clearance should bechecked and adjusted as necessary.

NOTE: Take the snowmobile to anauthorized Arctic Cat Snowmobiledealer for inspection and service.This service is at the discretion andexpense of the snowmobile owner.

Checking/Adjusting APV Cables (800 cc Models)Proper cable adjustment is critical to theoperation of the APV system. Althoughinspecting cable adjustment is recom-mended every 1000-2000 miles, the cableshould not need adjustment often. Tocheck the cable adjustment, use the fol-lowing procedure:

0745-819

1. Using a small needle-nose pliers,remove the servomotor cable holder.

0745-823

2. Using an adjustable wrench, rotatethe servomotor actuator counter-clockwise to loosen the cable; thenpull the cable housings down andout of the servomotor.

CAUTIONIf a spark plug is light gray, white, orblack and another is tan or lightbrown, take the snowmobile to anauthorized Arctic Cat Snowmobiledealer for inspection and service. Ifnot under warranty, this service is atthe discretion and expense of thesnowmobile owner.

CAUTIONIt is critical that the checking/adjust-ing valve clearance be done at therecommended intervals or severeengine damage may occur.

37

NOTE: For installing purposes,note the side that the servomotorcables are installed on.

3. Slide each cable drum out of the slotof the servomotor actuator.

4. While holding the cable housingfirmly, pull the cable as far out as itwill go; then release. Repeat three tofour times. The cable/exhaust valveshould move freely without binding.

NOTE: If the cable/exhaust valvedoes not move freely, the exhaust valveassembly will need to be removed forfurther inspection. Take the snowmo-bile to an authorized Arctic Cat Snow-mobile dealer for this service.

NOTE: When measuring the cables,they are to be routed as close to theirinstalled position as possible.

5. While holding the cable housing,lightly pull on one cable end toremove any slack; then measure theamount of exposed cable from thecable housing to the end of the cable(cable drum).

0735-516

NOTE: The two cable measure-ments must be equal in length orless than 0.5 mm (0.020 in.) differ-ence in length from each other.

NOTE: Repeat steps 4 and 5 for eachcable; then compare the measure-ments to the APV Cable Length chart.

NOTE: The measurements must bewithin the specifications from thechart. If the measurements arewithin specifications, no adjustmentis necessary (proceed to step 8). Ifthey are not within specifications,proceed to step 6.

6. Loosen the jam nut on the cable tobe adjusted; then using the adjustingnuts, lengthen or shorten the housingas needed.

7. Once the proper length has beenattained, hold the adjusting nut in placeand tighten the jam nut securely.

8. Place the cable housings into posi-tion in the servomotor. Secure thecable housings with the cable holder.

Battery (Electric Start)These sealed batteries after being in ser-vice require regular cleaning andrecharging in order to deliver peak per-formance and maximum service life. Thefollowing procedures are recommendedfor cleaning and maintaining sealed bat-teries. Always read and follow instruc-tions provided with battery chargers andbattery products.

NOTE: Battery maintenance maybe done by the snowmobile owner ifqualified to do so. If the owner doesnot feel qualified, take the snowmo-bile to an authorized Arctic CatSnowmobile dealer for this service.This service is at the discretion andexpense of the snowmobile owner.

To remove and charge the battery, use thefollowing procedure:

CAUTIONDo not use the nut securing the pul-ley to the servomotor to rotate theactuator.

APV CABLE LENGTH 800 cc 1.377 in. ± 0.039 in.

CAUTIONAssure the cables are rotated andsecured properly to avoid contactingexhaust components.

! WARNINGAny time service is performed on abattery, the following must beobserved: Keep sparks, open flame,cigarettes, or any other flame away.Always wear safety glasses. Protectskin and clothing when handling bat-teries. When servicing battery inenclosed space, keep the area well-ventilated.

38

1. Remove the torx-head screw fromthe rear underside of the seat; thenremove the seat.

2. Remove the negative battery cableand ground wire; then remove thepositive cable.

NOTE: For installing purposesprior to removing the battery, notethe routing and securing locations ofthe cables and harness wires.

3. Remove the two torx-head cap screwsand lock nuts securing the batterybracket/solenoid to the seat-base; thenmove the bracket up and out of theway and remove the battery.

746-170A

4. Thoroughly wash the battery withsoap and water; then using a wirebrush, clean the battery posts andcable ends removing all corrosivebuildup. Replace damaged cables orcable ends.

NOTE: If battery posts or cableends have a build-up of white/greenpowder residue, apply water andbaking soda to neutralize acid; thenflush off with warm soapy water.

5. Using a multimeter, test the batteryvoltage. The meter must read no lessthan 12.5 DC Volts for a fullycharged battery.

NOTE: At this point if the meterreads as specified, the battery maybe returned to service (see step 9).

6. If the meter reads less than specifiedvoltage, charge the battery using thefollowing guidelines.

A. When using an automatic batterycharger, always follow the char-ger manufacturer’s instructions.

B. When using a constant-currentbattery charger, use the follow-ing Battery Charging Chart.

! WARNINGBattery posts, terminals, and relatedaccessories contain lead and leadcompounds, chemicals known to thestate of California to cause cancerand reproductive harm. Wash handsafter handling.

CAUTIONOn the LXR models, make sure to dis-connect the seat heater harness con-nector prior to removing the seat.

! WARNINGAvoid spillage and contact with skin,eyes, and clothing.

CAUTIONDo not charge the battery while it is inthe snowmobile with the battery ter-minals connected.

CAUTIONDo not remove seal strip on a sealedbattery.

! WARNINGBattery acid is harmful if it contactseyes, skin, or clothing. Care must betaken whenever handling a battery.

CAUTIONNever exceed the standard chargingrate.

! WARNINGAn overheated battery could explodecausing severe injury or death.Always monitor charging times andcharge rates carefully. Stop chargingif the battery becomes very warm tothe touch. Allow it to cool beforeresuming charging.

39

NOTE: If the battery voltage is 11.5DC Volts or less, some chargers may“cut off” and fail to charge. If thisoccurs, connect a fully chargedbooster battery in parallel (positiveto positive and negative to negative)for a short period of time with thecharger connected. After 10-15 min-utes, disconnect the booster batteryleaving the charger connected andthe charger should continue tocharge. If the charger “cuts off,”replace the battery.

7. After charging the battery for thespecified time, remove the batterycharger and allow the battery to sitfor 1-2 hours.

8. Connect the multimeter and test thebattery voltage. The meter shouldread no less than 12.5 DC Volts. Ifthe voltage is as specified, the bat-tery is ready for service.

NOTE: If voltage in step 8 is belowspecifications, charge the battery anadditional 1-5 hours; then retest. Thebattery is ready for service.

9. Place the battery into position in thesnowmobile; then coat the batteryposts and cable ends with a lightcoat of multi-purpose grease.

10. Connect the battery cables (positivecable first).

NOTE: Assure the harness wiresand cables are routed properly asnoted during removing battery pro-cedure.

PC021A

11. Install the battery bracket/solenoidand tighten the torx-head cap screwsand lock nuts to 105 in.-lb; theninstall the seat and secure with thetorx-head screw. Tighten securely.

NOTE: On the 1100 cc LXR modelsprior to lowering and securing theseat, connect the seat heater har-ness connector.

Fuses

Fuses protect the snowmobile electricalsystem from overloading. If electricalparts in the snowmobile are not working,the system may have been overloaded andcaused a blown fuse. Before repairing orreplacing any electrical part, check theappropriate fuses. If a fuse blows (opens acircuit), all the parts of the snowmobilethat use that circuit will not work.

Once which fuse to check has been deter-mined, perform the following steps:

1. Locate the fuse block and removethe fuse block cover.

NOTE: To locate the fuse block onthe 1100 cc models, open the left-sideaccess panel; the fuse block is on thebelt guard. On the 800 cc models,open the right-side access panel; thefuse block is on the upper spar.

Battery Charging Chart(Constant-Current Charger)

Battery Voltage

(DC)

ChargeState

Charge Time Required (at 1.5-

2.0 Amps)

12.5 (mini-mum)

100% None

12.2-12.4 75%-99% 3-6 hours

12.0-12.2 50%-74% 5-11 hours

11.0-11.9 25%-49% 13 hours (minimum)

11.5 or less 0-24% 20 hours (minimum)

CAUTIONBefore installing the battery, make surethe ignition switch is in the OFF position.

CAUTIONConnecting cables in reverse (posi-tive to negative and negative to posi-tive) can cause serious damage tothe electrical system.

40

PC004A

PC020A

NOTE: There are spare fusesbeneath the fuse block cover.

2. Remove the suspected fuse.

NOTE: Fuse function desciptionsare next to the fuse contacts in thefuse block.

3. Look through the clear side of thefuse to see if the element inside isburned or separated. If it is, the fuseis blown and should be replacedwith a fuse of the correct amperagerating.

4. Install the fuse block cover and closethe access panel.

Even after replacing a fuse, it may con-tinue to blow if the cause of the overloadis not determined. If the fuse continues toblow, take the snowmobile to an autho-rized Arctic Cat Snowmobile dealer forservice. If not under warranty, this ser-vice is at the discretion and expense ofthe snowmobile owner.

Brake SystemArctic Cat recommends that the brakesystem (brake lever, fluid reservoir, hose,caliper, pads, and brake disc) be checkeddaily for fluid leakage, wear, or damageand for proper operation. Also, the brakefluid level must be checked every timebefore starting the engine.

Checking/Adding Brake Fluid

1. With the brake fluid reservoir in alevel position and the coverremoved, check the fluid level. Thebrake fluid level must be at the highbarke fluid mark in the reservoir.

0745-817

2. If the brake fluid is below the highbrake fluid mark, add Arctic Catapproved DOT 4 brake fluid untilthe fluid is at the recommendedlevel. Install and secure the reservoircover. Do not allow moisture to con-taminate the brake system.

! WARNINGAlways replace a fuse with one hav-ing the same specified amperage rat-ing. Using a fuse with a higher ratingcan cause severe wire damage andcould start a fire.

1100 cc Models

800 cc Models

! WARNINGDO NOT operate the snowmobilewhen the brake lever lock is engagedor when any component in the brakesystem is damaged, worn, oradjusted improperly. If the snowmo-bile is operated and the brake systemis not functioning properly, severepersonal injury could result.

CAUTIONBrake fluid is highly corrosive. Do notspill brake fluid on any surface of thesnowmobile.

41

Changing Brake Fluid

The brake fluid must be changed on a reg-ular basis and whenever the brake fluidhas been overheated or contaminated. Thebrake fluid should be changed every 1000miles or at the end of the snowmobilingseason, whichever occurs first. Take thesnowmobile to an authorized Arctic CatSnowmobile dealer for this service. Thisservice is at the discretion and expense ofthe snowmobile owner.

Checking Brake Lever Travel

Before each use, check the brake levertravel using the following procedure:

1. Compress the brake lever fully.

NOTE: Do not pump the brakelever as it will produce an inaccuratereading.

2. Measure the distance between thebrake lever and the handlebar. Thedistance must be greater than 2.54cm (1 in.).

0745-816

3. If the resultant distance is less thanspecified, take the snowmobile to anauthorized Arctic Cat Snowmobiledealer for service. If not under war-ranty, this service is at the discretionand expense of the snowmobile owner.

Bleeding Brake System

If the brake lever feels spongy whenapplied, the brake system may need to bebled. To bleed the brake, use the follow-ing procedure:

NOTE: The brake system may bebled by the snowmobile owner ifqualified to do so. If the owner doesnot feel qualified, take the snowmo-bile to an authorized Arctic CatSnowmobile dealer for this service.This service is at the discretion andexpense of the snowmobile owner.

1. Remove the reservoir cover and (ifnecessary) fill the reservoir to thehigh brake fluid mark with ArcticCat approved DOT 4 brake fluid.

2. Slide a piece of flexible tubing overthe ball of the bleeder valve anddirect the other end into a container.

PC005A

! WARNINGDo not overfill the brake fluid reser-voir. Overfilling the reservoir maycause the brake system to hydrauli-cally lock. Use only Arctic Catapproved DOT 4 brake fluid. Neversubstitute or mix different types orgrades of brake fluid. Brake loss canresult. Brake loss can result in severeinjury or even death.

! WARNINGDo not operate the snowmobile if thecompressed distance between thebrake lever and the handlebar is lessthan 2.54 cm (1 in.). Brake loss mayoccur. Brake loss can result in severepersonal injury.

CAUTIONBrake fluid is highly corrosive. Do notspill brake fluid on any surface of thesnowmobile.

! WARNINGUse only Arctic Cat approved DOT 4brake fluid. Any substitute may resultin a loss of brakes.

42

3. Slowly compress the brake leveruntil maximum pressure is attained;then hold the lever in the com-pressed position to maintain pres-sure. Open the bleeder valve torelease the fluid and air. When thefluid stops, close the bleeder valve;then release the brake lever.

4. Repeat step 3 until the brake fluidflows free of air bubbles.

NOTE: It may be necessary to refillthe reservoir during the bleedingprocess. Never allow the brake fluidto go below the low brake fluid markin the reservoir.

5. When the brake fluid is free of all airand the brake lever feels firm whencompressed, fill the reservoir to thehigh brake fluid mark; then install andsecure the cover. Remove the tubefrom the bleeder valve.

Checking/Changing Brake Pads

The condition of the brake pads must bechecked daily and changed if worn ordamaged. To check and change the brakepads, use the following procedure:

NOTE: The brake pads may bechanged by the snowmobile owner ifqualified to do so. If the owner doesnot feel qualified, take the snowmo-bile to an authorized Arctic CatSnowmobile dealer for this service.This service is at the discretion andexpense of the snowmobile owner.

NOTE: When installing new brakepads, always install them as a set.Never install just one pad or usebrake pads which have been used inanother snowmobile.

1. Remove the brake fluid reservoircover; then remove most of thebrake fluid from the reservoir. Installthe cover.

NOTE: The above procedure willallow room for the fluid from the cali-per when the pistons are pushedinto the caliper for installing newbrake pads. Replacing the cover willprevent fluid spillage.

2. Open the left-side access panel andremove the rear belt guard. Removethe driven pulley.

3. Remove the two torx-head screwssecuring the brake shield to the beltguard mount; then remove the capscrews securing the brake shield tothe brake caliper.

4. Carefully move the shield out of theway; then remove the hairpin clipsecuring the brake pads to the cali-per assembly.

5. Using a pair of pliers, pull the outerbrake pad out of the caliper assembly.

PC013

NOTE: Changing one pad at a timewill prevent one piston from pushingout the other piston from the caliper.

6. Measure the thickness of the brake pad.The brake pad thickness must be greaterthan 5.0 mm (0.20 in.). If the brake padthickness is less than specified, replace-ment of both pads is necessary.

PC011A

7. Using a flat-blade tool, slowly and care-fully push the piston into the caliper.

CAUTIONBrake fluid is highly corrosive. Do notspill brake fluid on any surface of thesnowmobile.

43

8. Position the outer brake pad into thecaliper; then install the hair-pin clipinto the caliper assembly.

9. Repeat steps 5-8 for the inner pad; thensecure the pad with the hairpin clip.

10. Remove the reservoir cover andremove the remaining fluid; then fillthe reservoir with fresh fluid andinstall the cover.

11. Pump the brake lever to ensure cor-rect positioning of the brake padsand proper brake lever travel (seeChecking Brake Lever Travel sub-section); then release.

NOTE: If brake lever travel is notwithin specification, bleed the brakesystem (see Bleeding Brake Systemsub-section).

12. Remove the reservoir cover and fillthe reservoir (if necessary) to theproper level with fresh brake fluid;then install the cover.

13. Secure the brake shield, the drivenpulley (tightened to 20 ft-lb), and therear belt guard; then close andsecure the left-side access panel.

NOTE: When new brake pads areinstalled, a “burnishing” process isrequired (see Burnishing Brake Padssub-section).

Burnishing Brake PadsAfter changing brake pads, the new brakepads must be burnished to achieve fullbraking effectiveness. Braking distancewill be extended until brake pads areproperly burnished.

To properly burnish the brakes, use fol-lowing procedure:

1. Choose an area sufficiently large tosafely accelerate to 30-40 mph andto brake to a stop.

NOTE: This procdure can also beaccomplished using a shielded jackstand.

2. Accelerate to 30-40 mph; then com-press brake lever to decelerate to a stop.

NOTE: Lightly apply the brake leverto come to an easy stop; do not over-apply brakes or “lock up” the track.

3. Repeat procedure 10-15 times allow-ing some cooling between stops.

NOTE: Do not repeat too soon ortoo aggressively as to get the brakedisc “red hot.”

NOTE: This procedure stabilizesthe pad material and extends the lifeof the pads.

Drive BeltThe drive belt transfers power from thedrive clutch to the driven pulley. If thebelt is worn, cracked, or stretched, maxi-mum power will not be transmitted andthe belt could also fail and therefore mustbe replaced. Periodic checks (at leastonce a month under normal usage) of twodrive belt specifications are essential.

1. Measure the outside circumferenceof the drive belt. The belt should bewithin the recommended range incircumference (see appropriate spec-ifications sheet).

2. Measure the outside width of thedrive belt. The belt should be withinthe recommended range in width.

3. Check the belt for cracking, fraying, etc.

If any of the specifications or conditionsare unsatisfactory, replace the drive belt.

NOTE: Drive belts should be pur-chased from an authorized ArcticCat Snowmobile dealer, as Arctic Catdrive belts are made to exact specifi-cations and of quality material. Beltsmade by other manufacturers maynot be of the same specifications orquality and, therefore, usage couldresult in poor performance and pre-mature belt failure.

NOTE: Before starting the snow-mobile in extremely cold tempera-tures, the drive belt should beremoved and warmed up to roomtemperature. Once the drive belt is atroom temperature, install the drivebelt.

! WARNINGDo not attempt sudden stops or putyourself into a situation where a sud-den stop will be required until thebrake pads are properly burnished.

44

Also, new drive belts have a break-inperiod of approximately 25 miles. Afterinstalling a new drive belt, drive thesnowmobile for 25 miles at 3/4 throttle orless. By revving the engine up and down(but not exceeding 60 mph), the exposedcord on the side of a new belt will beworn down. This allows the drive belt togain its optimum flexibility and willextend drive belt life.

Checking/Adjusting Drive Belt Deflection

0746-092

The drive belt must have the proper fit inthe drive clutch and driven pulley. Tocheck for proper drive belt fit, use thefollowing procedure.

1. Place a straightedge on the top of thedrive belt. The straightedge shouldreach from the drive clutch to the topof the driven pulley.

NOTE: Make sure the drive belt isall the way out in the driven pulleybefore checking drive belt deflection.

2. Using a stiff ruler centered betweenthe drive clutch and driven pulley,push down on the drive belt justenough to remove all slack and notethe amount of deflection. The deflec-tion should be within the range of28.5-31.8 mm (1 1/8-1 1/4 in.).

3. To correct drive belt deflection,remove the sheave adjuster from thepulley, remove or add shim washersto the adjuster, and install theadjuster.

NOTE: Adding shim washers willdecrease belt deflection and remov-ing shim washers will increase beltdeflection. Available shim washersfrom Arctic Cat are p/n 0648-714(0.090 in.) - one included in the toolkit, p/n 0648-715 (0.030 in.), and p/n0648-716 (0.060 in.).

NOTE: Removing/adding shimwashers may be done by the snow-mobile owner if qualified to do so. Ifthe owner does not feel qualified,take the snowmobile to an autho-rized Arctic Cat Snowmobile dealerfor this service. This service is at thediscretion and expense of the snow-mobile owner.

Removing Drive Belt

NOTE: Changing a drive belt canbe done by the snowmobile owner ifqualified to do so. If the owner doesnot feel qualified, take the snowmo-bile to an authorized Arctic CatSnowmobile dealer for this service.This service is at the discretion andexpense of the snowmobile owner.

1. Turn ignition key to the OFF posi-tion and wait for all moving parts tostop.

2. Set the brake lever lock.

3. Open the left-side access panel; thenremove the rear belt guard.

NOTE: On the 1100 cc models,move and secure the rear belt guardup and out of the way.

4. Remove the cap screw, lock washer,washer, and sheave adjuster from theend of the driven pulley; thenremove the sheave adjuster from thecap screw.

0743-395

CAUTIONNever run the engine with the drivebelt removed. Excessive revving of theengine could result in serious enginedamage and drive clutch failure.

45

NOTE: Assure that the shims andO-ring are not removed from theadjuster.

5. Install the 2-in. flat washer (from thetool kit) onto the cap screw.

6. Install the cap screw into the drivenpulley; then tighten the cap screwuntil the movable sheave opens farenough to allow the belt to beremoved.

7. Remove the drive belt from thedriven pulley first; then from thedrive clutch.

NOTE: Before installing the drivebelt, use a suitable cleaning solventto thoroughly clean the sheaves.

Installing Drive Belt

NOTE: If a new drive belt is beinginstalled, see Drive Belt Break-Insub-section in the General Infor-mation section.

1. Place the drive belt (so the part num-ber can be read) between the sheavesof the drive clutch first; thenbetween the sheaves of the drivenpulley.

2. Remove the cap screw; then removethe 2-in. flat washer from the capscrew.

3. Install the cap screw, lock washer,washer, and sheave adjuster back intothe driven pulley. Tighten the cap screwto 20 ft-lb.

4. Install and secure the rear belt guard;then close the left-side access panel.

5. Release the brake lever lock.

Track TensionTrack tension is directly related to theoverall performance of the snowmobile. Ifthe track is too loose, it may slap againstthe tunnel causing wear or it may “ratchet”on the track drive sprockets. If extremelyloose, the idler wheels may climb over thetrack lugs forcing the track against the tun-nel causing the track to “lock.” Arctic Catrecommends that the track tension bechecked daily during the first 300 miles ofoperation and once a week thereafter andadjusted according to need. The track willstretch and take a “set” during break-in.Track deflection must be maintainedwithin the recommended range.

Checking Track Tension

1. Remove excess ice and snow buildupfrom the track, track drive sprockets,and the inside of the skid frame.

2. Elevate the snowmobile on ashielded safety stand high enough touse a spring scale.

3. At mid-point of the track (on the bot-tom side), hook a spring scale around atrack clip; then pull down on the scaleto the recommended pressure. Measurethe deflection (distance) between thebottom of the wear strip and the insidesurface of the track clip. Compare themeasurement with the chart.

! WARNINGNever operate the snowmobile with-out the belt guard/access panelsecured in place.

! WARNINGTrack tension must be properly main-tained. Personal injury could result ifa track is allowed to become exces-sively loose.

! WARNINGDO NOT attempt to check or adjusttrack tension with engine running.Turn ignition key to the OFF position.Personal injury could result fromcontact with a rotating track.

Model Setup Tension

After Break-In Tension

F/XF Models @ 20 lb 44-51 mm (1.75-2 in.)

51-57 mm(2-2.25 in.)

XF High Country Model @ 20 lb

51 mm (2 in.)

51 mm (2 in.)

M Models @ 15 lb 51 mm (2 in.)

51 mm (2 in.)

46

0743-188

0746-099

NOTE: On the M models, measure-ment is from the bottom of the wearstrip at the point of the shock pad onthe slide rail.

Adjusting Track Tension

NOTE: To ensure proper track tensionadjustment, perform all adjustments onboth sides of the snowmobile.

1. Loosen the idler wheel axle capscrews.

0745-811

2. If the deflection (distance betweenthe bottom of the wear strip and theinside surface of the track clip)exceeds specifications, tighten theadjusting bolts to take up excessiveslack in the track.

3. If the distance between the bottom ofthe wear strip and the inside surfaceof the track clip is less than specified,loosen the adjusting bolts to increasethe slack in the track.

4. Check track alignment (see TrackAlignment sub-section in this section).

5. After proper track tension isobtained, tighten the idler wheelaxle cap screws to 34 ft-lb; thentighten the adjusting bolts securelyagainst the axle.

NOTE: Since track tension andtrack alignment are interrelated,always check both even if only oneadjustment seems necessary.

Track AlignmentProper track alignment is obtained whenthe rear idler wheels are equal distancefrom the inner track drive lugs. Excessivewear to the idler wheels, drive lugs, andtrack will occur if the track is improperlyaligned. Arctic Cat recommends that thetrack alignment be checked once a weekor whenever the track tension is adjusted.

Checking Track Alignment

1. Remove excess ice and snowbuildup from the track, track drivesprockets, and the inside of the skidframe.

CAUTIONAlways maintain track tension withinrecommended specification.

! WARNINGAlways make sure the adjusting boltsare snug against the axle and theidler wheel cap screws are tightenedto specifications. Failure to do socould cause the track to becomeextremely loose and, under someoperating conditions, allow the idlerwheels to climb over the track lugsforcing the track against the tunnelcausing the track to “lock.” If a track“locks” during operation, severe per-sonal injury could result.

! WARNINGMake sure the ignition key is in theOFF position and the track is not rotat-ing before checking or adjusting trackalignment. Personal injury could resultif contact is made with a rotating track.

47

2. Position the tips of the skis against awall; then using a shielded safetystand, raise the rear of the snowmo-bile off the floor making sure thetrack is free to rotate.

3. Start the engine and accelerateslightly. Use only enough throttle toturn the track several revolutions.SHUT ENGINE OFF.

NOTE: Allow the track to coast to astop. DO NOT apply the brakebecause it could produce an inaccu-rate alignment condition.

4. When the track stops rotating, checkthe relationship of the rear idlerwheels and the inner track drive lugs.If the rear idler wheels are centeredbetween the inner track drive lugs, noadjustment is necessary.

0745-809

5. If the idler wheels are not centeredbetween the inner track drive lugs,an adjustment is necessary.

Adjusting Track Alignment

1. On the side of the track which hasthe inner track drive lugs closer tothe rear idler wheel, loosen the idlerwheel axle cap screw; then rotate theadjusting bolt clockwise 1 to 1 1/2turns.

0745-811

2. Check track alignment and continueadjustment until proper alignment isobtained.

NOTE: Make sure correct tracktension is maintained after adjust-ing track alignment (see Track Ten-sion sub-section in this section).

3. After proper track alignment isobtained, tighten the idler wheelaxle cap screw to 34 ft-lb; thentighten the adjusting bolts securelyagainst the axle.

4. Field test the track under actual con-ditions.

5. After the field test, check the align-ment of the track. If additional adjust-ment is necessary, repeat AdjustingTrack Alignment procedure.

SuspensionThe suspension should be adjusted forthe operational needs and riding prefer-ence of the operator.

The front shock springs determine theamount of ski pressure and the reactionof the front suspension to rough terrain.The amount of ski pressure can also bechanged by adjusting the length of theskid frame front arm limiter straps.

! WARNINGThe tips of the skis must be posi-tioned against a wall or similarobject.

! WARNINGDO NOT stand behind the snowmo-bile or near the rotating track. NEVERrun the track at high speed when thetrack is suspended.

! WARNINGAlways make sure the adjusting boltsare snug against the axle and theidler wheel cap screws are tightenedto specifications. Failure to do socould cause the track to becomeextremely loose and, under someoperating conditions, allow the idlerwheels to climb over the track lugsforcing the track against the tunnelcausing the track to “lock.” If a track“locks” during operation, severe per-sonal injury could result.

48

On standard models, the rear arm shockabsorber spring influences the load carry-ing capability of the snowmobile andshould be adjusted for the weight and rid-ing preference of the operator.

NOTE: On Sno Pro models, thisadjustment is achieved by increase-ing or decreasing the air pressure inthe rear arm air shock absorber.

Adjusting Front (Ski) Shock Springs

The front (ski) shock springs are individ-ually adjustable for the terrain conditionsand driving style of the operator. Thespring adjuster nut has been set at the fac-tory so the correct amount of threads areexposed between the adjuster nut and thethreaded shock body as an initial setting.Additional ski pressure can be obtainedby tightening the spring tension; ski pres-sure can be decreased by relaxing springtension.

NOTE: Equal adjustments shouldbe maintained on both sides of thesnowmobile.

Front (ski) shock spring pre-load adjust-ment is accomplished by loosening theadjuster nut locking collar (B) from theadjuster nut (A) and using the SpringAdjuster Tool from the tool kit, rotatingthe adjuster nut in whichever direction isdesired. Tighten the locking collaragainst the adjuster nut.

0745-159

Adjusting Fox Air Shocks (Sno Pro Models)

NOTE: It is recommended to moni-tor the air pressure in the air shocksonce every month.

NOTE: Adjusting air shocks maybe done by the snowmobile owner ifqualified to do so. If the owner doesnot feel qualified, take the snowmo-bile to an authorized Arctic CatSnowmobile dealer for this service.This service is at the discretion andexpense of the snowmobile owner.

The air shocks are individually adjustablefor the terrain conditions and driving styleof the operator. The shocks are preset atthe factory (see chart) as an initial setting;however, it is possible to “fine tune” theshocks to match the operator’s weight,riding style, and terrain conditions.

Checking and adjusting air pressure mustbe done at riding temperature (outside).Also, it is advisable to check air pressurewhen the outside temperature variesmore than 25°.

NOTE: Care should be taken to haveequal pressure in the front (ski) shocksbefore operating the snowmobile.

To increase or decrease air pressure, usethe following procedure.

NOTE: When adjusting air pres-sure, all weight must be removedfrom the suspension, and the shockabsorbers must be fully extended.

NOTE: Adding air pressure willincrease the air spring force; reduc-ing air pressure will decrease airspring force.

1. Remove the air valve cap from theshock.

2. Thread the valve of Shock AbsorberAir Pump (p/n 2603-614) onto theshock air valve approximately sixrotations.

Initial Setting Chart

Model Front Shock (Ski)

Rear Arm Shock

M/XF Sno Pro Models

6.3 kg/cm2

(90 psi)10.2-10.6 kg/cm2

(145-150 psi)

F Sno Pro Models

5.3 kg/cm2

(75 psi)N/A

! WARNINGDo not exceed 10.5 kg/cm2 (150 psi)in the shock.

49

NOTE: As the pump is being attachedto the shock, the hose will fill with air.This will result in a lower gauge pres-sure 0.14-3.52 kg/cm2 (2-5 psi).

3. To decrease air pressure in theshock, press the black bleed valvebutton half way down and hold untildesired pressure is attained.

NOTE: Pressing the button fullydown and releasing it will allow onlya small amount of air to escape(micro-adjust).

4. To increase air pressure in the shock,pump until desired pressure isattained.

5. Remove the pump valve from theshock air valve.

NOTE: As the pump valve is beingremoved from the shock, the soundof air loss is from the pump hose,not from the shock.

6. Install the air valve cap onto the shock.

Adjusting Skid Frame Front Arm

The skid frame front arm shock springtension and the limiter straps are adjust-able. However, Arctic Cat recommendsthat the shock spring be maintained at thefactory preset of 1/8-1/4 in. preload.Tightening the skid frame front arm shockspring may cause improper balance andmay ruin the handling features of thesnowmobile.

The length adjustment of the front armlimiter straps determines the weight dis-tribution between the front of the skidframe and the skis. Tightening the limiterstrap (shortening the strap) will pull upon the front of the skid frame and willincrease ski pressure. Loosening the lim-iter strap (lengthening the strap) lowersthe front of the skid frame and decreasesski pressure.

When customizing the amount of skipressure, be sure to adjust both strapsequally and do not over-adjust the limiterstraps to adversely affect steering andoperator control of the snowmobile.Some experimentation may be requireduntil the proper adjustment for the opera-tor’s individual style is obtained.

NOTE: If the limiter straps areadjusted, it is highly recommended thatat least a minimum of 1/8 in. preload onthe shock spring be maintained.

Adjusting Rear Spring Pre-Load (F Models)

Proper adjustment of rear spring pre-loadis necessary to get the most desirableride. The chart is designed to help in set-ting up rear spring pre-load; however,riding style is the single greatest factor indetermining rear spring requirements.

NOTE: These cam position set-tings are suggestions only. Personalriding style will greatly influencecam position settings. Spend time todetermine setting preferences.

Rear spring pre-load adjustment is accom-plished by rotating the adjusting cams.Position 3 provides the stiffest ride, andposition 1 is for the light driver or slow-speed trail riding. Position 2 is for theaverage operator under normal conditions.Always rotate the cam from the lighterposition to the heavier position.

741-450A

! WARNINGDo not adjust the front arm limiterstraps to a point at which steeringand operator control of the snowmo-bile are adversely affected.

Rider Weight (lb) Cam Position

Up to 180 1

180-240 2

Over 240 3

CAUTIONNever force the adjustment camsfrom the low position to the highposition. Cam damage may occur.

50

To rotate an adjusting cam, use the sparkplug wrench from the tool kit. Rotate thewrench until the cam is in the desiredposition. To stiffen the ride, rotate the camso as to raise the spring end. Make theappropriate adjustment on the other cam.

Adjusting Skid Frame Rear Arm Shock Spring (M/XF Models)

Proper adjustment of rear arm shockabsorber spring pre-load is necessary toget the most desirable ride.

The rear arm shock spring is adjustablefor the terrain conditions and drivingstyle and weight of the operator. Thespring adjuster nut has been set at the fac-tory so the correct amount of threads areexposed between the adjuster nut and thethreaded shock body as an initial setting.

Rear spring pre-load adjustment isaccomplished by loosening the adjusternut locking collar (B) from the adjusternut (A) and using the Spring AdjusterTool from the tool kit, rotating theadjuster nut in whichever direction isdesired. Tighten the locking collaragainst the adjuster nut.

0745-159

LightsFor the correct headlight bulb and/or tail-light/brakelight LED, see the appropriatespecifications sheet.

Removing and Installing Taillight/Brakelight

These models are equipped with an LEDtaillight/brakelight. If the LED fails, itmust be replaced. To remove and installthe LED, use the following procedure.

746-097A

1. Disconnect the taillight harness con-nector.

2. Remove the two torx-head screwssecuring the taillight to the bracket.

3. Connect the taillight harness connec-tor; then secure the taillight to thebracket with the two torx-head screws.

Removing/Installing Headlight Bulb

NOTE: The bulb portion of headlightis fragile. HANDLE WITH CARE. Whenreplacing the headlight bulb, the bulbassembly must first be removed fromthe housing. Do not touch the glassportion of the bulb. If the glass istouched, it must be cleaned with a drycloth before installing.

1. Disconnect the headlight harnessconnector from the bulb; thenremove the rubber grommet fromthe headlight housing.

2. Rotate the bulb retainer counter-clockwise until it unlocks from thehousing; then remove the bulb.

0746-096

3. Install the bulb and retainer; thenrotate the retainer clockwise until itproperly locks in place.

4. Install the rubber grommet; thenconnect the headlight harness con-nector to the bulb.

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5. Check headlight aim (see AdjustingHeadlight Aim in this sub-section).

Adjusting Headlight Aim

The headlight can be adjusted for verticalaim of the HIGH/LOW beam. The geo-metric center of HIGH beam zone is to beused for vertical aiming.

1. Position the snowmobile on a levelfloor so the headlight is approxi-mately 8 m (25 ft) from an aimingsurface (wall or similar surface).

NOTE: There should be an “aver-age” operating load on the snowmo-bile when adjusting headlight aim.

2. Measure the distance from the floorto midpoint of the headlight.

3. Using the measurement obtained instep 2, make a horizontal mark onthe aiming surface.

4. Make a vertical mark which intersectsthe horizontal mark on the aiming sur-face directly in front of the headlight.

5. Engage the brake lever lock and startthe engine. Move the headlight dim-mer switch to the HIGH beam posi-tion. DO NOT USE LOW BEAM.

6. Observe the headlight beam aim.Proper aim is when the most intensebeam is centered on the vertical mark5 cm (2 in.) below the horizontalmark on the aiming surface.

0745-813

7. Adjust the headlight using theadjusting screw on the backside ofthe headlight housing until correctaim is obtained. Shut the engine off;then disengage the brake lever lock.

PC014A

Ski Wear BarsThe ski wear bar is a replaceable barattached to the underside of the ski. Thepurpose of the wear bar is to assist inturning the snowmobile, to minimize skiwear, and to maintain good steering con-trol. If the snowmobile is operated pri-marily in deep snow, ski wear bar wearwill be minimal; however, if the snow-mobile is operated on terrain where thesnow cover is minimal, the ski wear barwill wear faster. To maintain positivesteering characteristics, Arctic Cat rec-ommends that the ski wear bars bechecked before each use and replaced ifworn beyond 1/2 of the original diameter.Ski wear bars are available from anauthorized Arctic Cat Snowmobiledealer.

Removing Ski Wear Bars

NOTE: Determine which type ofwear bar is being replaced andremove and install accordingly.

1. Remove ice and snow buildup fromthe ski.

2. Using a suitable safety stand or lift,elevate the front of the snowmobile.

3. Remove the lock nuts securing thewear bar to the ski.

! WARNINGDo not operate the snowmobileunless headlight beam is adjustedproperly. An incorrectly adjustedbeam will not provide the operatorthe optimum amount of light.

! WARNINGOperating the snowmobile withexcessively worn ski wear bars mayresult in a loss of steering control.

52

0743-185

4. Remove the wear bar from the ski.

Installing Ski Wear Bars

1. Move the wear bar into position onthe bottom of the ski.

NOTE: If installing a double-offsetwear bar, the carbide edge should bedirected to the outside of the ski.

2. Align the wear bar studs with theholes in the ski; then install the locknuts. 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 skistance on these snowmobiles maybe applicable. Always comply withthe maximum width laws and/or reg-ulations when adjusting ski stance.

NOTE: Ski stance can be increased/decreased by 2.5 cm (1.0 in.).

1. Place the front of the snowmobile ona support stand.

2. Remove the cotter pin; then removethe slotted nut and cap screw secur-ing the ski assembly to the spindle.Remove the ski. Account for therubber damper, inserts, and washers.

3. To increase ski stance, place both skistance spacers to the outside of thespindle.

4. To decrease ski stance, place bothski stance spacers to the inside of thespindle.

5. Apply an all-temperature grease to thenon-threaded portion of the capscrew; then slide the cap screwthrough the ski accounting for the rub-ber damper, inserts, and washers.

NOTE: Install the cap screw so theslotted nut will be located to theinside of the ski.

6. Apply red Loctite #271 to thethreads of the cap screw; thentighten the nut to 45 ft-lb.

7. Place the cotter pin into the ski capscrew and spread the pin.

8. Repeat procedure for the other ski.

Rail Wear StripsArctic Cat recommends that the wear stripsbe checked weekly and replaced as neces-sary. Measure the wear strips at 25.4 cm(10 in.) intervals. Wear strips must be 10.7mm (0.42 in.) thick or thicker.

0745-807

If wear strip measurements are less thanspecified, replacement of both wear stripsis necessary to prevent premature trackclip wear and possible track damage.Take the snowmobile to an authorizedArctic Cat Snowmobile dealer for thisservice. This service is at the discretionand expense of the snowmobile owner.

Each time a new set of wear strips areinstalled, they should be tempered. Tem-per the wear strips by driving the snow-mobile for approximately a mile on ahard pack trail; then immediately driveinto deep snow and allow the wear stripsto cool. Repeat the procedure (warmingup the wear strips; then cooling themdown) two or three times.

NOTE: The rail wear strips will wearrapidly if the snowmobile is operatedon terrain on which the snow cover isminimal. Loose snow is required tocool and lubricate the wear strips andprevent accelerated wear.

53

Performance TipsOperating a high performance snowmo-bile requires a special attention that is notrequired by a low performance snowmo-bile. Often, a minor adjustment willresult in a large increase in performance.This section is intended to highlightminor conditions that adversely affectperformance and the adjustments neededto correct them. Be sure, however, tothoroughly read and understand thisentire manual especially the section onspark plugs, track tension and alignment,and suspension.

DRIVE BELT — This link between theengine and drive train is often the mostneglected component. The drive belt musthave the proper fit in the drive clutch anddriven pulley. Proper fit is when the topsurface of the drive belt is flush with thetop or up to 1/16 in. higher than the drivenpulley sheaves (with the sheaves fullyclosed). If drive belt deflection is abovespecification, the snowmobile will bog andlack power at engagement and will have aslower maximum speed. For good perfor-mance, proper belt deflection is critical. Tocorrect this condition, first determine if thedrive belt is within specifications (seeDrive Belt sub-section) and replace ifworn or too long. Always run the drivebelt in the same direction. Installing thedrive belt so the part number can be readwill ensure that the drive belt is alwaysrun the same direction.

DRIVE BELT DEFLECTION — Drivebelt length, condition, and deflection areall important for peak performance. Tocheck and adjust drive belt deflection,remove the belt guard; then use the fol-lowing procedure.

NOTE: It may be necessary toremove a shim washer from betweenthe driven pulley sheaves to allowthe driven pulley to close tighter.Adding shim washers will decreasebelt deflection and removing shimwashers will increase belt deflection.Available shim washers from ArcticCat are p/n 0648-714 (0.090 in.) - oneincluded in the tool kit, p/n 0648-715(0.030 in.), and p/n 0648-716 (0.060in.).

NOTE: Removing/adding shimwashers may be done by the snow-mobile owner if qualified to do so. Ifthe owner does not feel qualified,take the snowmobile to an autho-rized Arctic Cat Snowmobile dealerfor this service. This service is at thediscretion and expense of the snow-mobile owner.

1. Turn the engine off; then open theaccess panel.

2. Make sure the drive belt is sitting atthe top of the driven pulley sheaves.

3. Place a straightedge on top of thedrive belt. The straightedge shouldreach from the driven clutch to thetop of the driven pulley.

4. Using a stiff ruler centered betweenthe drive clutch and driven pulley,push down on the drive belt justenough to remove all slack. Note theamount of deflection on the ruler atthe bottom of the straightedge. Thedeflection should be at 1 1/4 in.

0746-092

NOTE: Push down on the belt withthe ruler only until the bottom of thebelt flexes upward; then read theamount of deflection.

5. To correct drive belt deflection,remove the sheave adjuster from thepulley, remove or add shim washersto the adjuster, and install theadjuster.

NOTE: Adding shim washers willdecrease belt deflection; removingshim washers will increase beltdeflection.

6. Install the belt guard; then close theaccess panel.

54

DRIVE CLUTCH AND DRIVENPULLEY — Keeping the drive clutchand driven pulley clean should be the pri-mary consideration of the operator. Thedrive clutch and driven pulley can becleaned of any drive belt accumulationusing compressed air. The sheaves can becleaned using a clean cloth and parts-cleaning solvent.

DRIVE CLUTCH/DRIVEN PULLEYOFFSET — If premature drive belt wearis experienced or if the drive belt turnsover, offset must be checked. Also, offsetmust be checked whenever either thedrive clutch or driven pulley is serviced.

NOTE: For checking offset, it isnecessary to use Clutch AlignmentBar (p/n 0644-428) to obtain a driveclutch/driven pulley offset of 1.485in. This special tool can be pur-chased from an authorized ArcticCat snowmobile dealer.

To check offset, use the following proce-dure.

1. Open the left-side access panel; thenremove the belt guard.

2. Install the clutch alignment barbetween the drive clutch sheaves.

3. Allow the bar to rest on the driveclutch shaft and against the outsideedge of the driven pulley stationarysheave.

NOTE: The alignment bar mustextend beyond the front edge of thedrive clutch.

4. With the bar against the outside edgeof the driven pulley stationarysheave at points A and B, the barshould just clear the inside edge ofthe stationary sheave of the driveclutch and rest on the stationaryshaft at point C with a maximum0.060 in. clearance at point C. Atthis point, measurement betweenpoints A and C should be 1.507 in.(with a maximum 0.060 in. clear-ance). If the bar either will not clearthe inside edge or is more than thespecified amount, the offset must becorrected.

0745-177

NOTE: If the offset is out of speci-fication, take the snowmobile to anauthorized Arctic Cat Snowmobiledealer for drive system evaluationand/or servicing. This service is atthe discretion and expense of thesnowmobile owner.

GASOLINE — On the 800 cc and turbomodels for optimum performance, use 91octane (minimum) gasoline.

55

Preparation for StoragePrior to storing the snowmobile, it must beproperly serviced to prevent corrosion andcomponent deterioration. An authorizedArctic Cat Snowmobile dealer should per-form this service; however, the owner/operator can perform this service ifdesired. This service is at the discretionand expense of the snowmobile owner. Toprepare the snowmobile for storage, ArcticCat recommends the following procedure:

1. Clean the seat cushion with a dampcloth and a Vinyl Protectant.

2. Clean the snowmobile thoroughlyby hosing dirt, oil, grass, and otherforeign matter from the skid frame,tunnel, hood, and belly pan. Allowthe snowmobile to dry thoroughly.DO NOT get water into any part ofthe engine.

NOTE: On the 1100 cc models,change the engine oil and replacethe air filter if necessary; then pro-ceed to step 6.

3. Place the rear of the snowmobile upon a shielded safety stand.

4. Carefully pry the intake boots partiallyover the throttle body inlets; then startthe engine and allow to idle.

5. Spray an Engine Storage Preserverinto the intakes until the engineexhaust starts to smoke heavily oruntil the engine starts to drop inRPM. Turn engine off. Install theintake boots.

6. Plug the exhaust system outlet witha clean cloth.

7. With the ignition switch in the OFFposition:

A. Disconnect the high tensionleads from the spark plugs; thenremove the plugs, connect themto the leads, and ground them onthe cylinder heads.

B. Pour 29.5 ml (1 fl oz) of SAE#30 petroleum-based oil intoeach spark plug hole and pull therecoil starter handle slowly about10 times.

C. Install the spark plugs and con-nect the high tension leads.

8. Fill the gas tank to its rated capacity;then add Arctic Cat Fuel Stabilizer(p/n 0436-907) to the gas tank fol-lowing directions on the containerfor the stabilizer/gasoline ratio.Tighten the gas tank cap securely.

9. With the snowmobile level, checkthe lubricant level in the chain case.If low, add chain lube through thefill plug hole.

10. Remove the drive belt from the driveclutch/driven pulley. Lay the belt ona flat surface or slide it into a card-board sleeve to prevent warping ordistortion during storage.

11. Clean and inspect the drive clutchand driven pulley.

12. Apply light oil to the upper steeringpost bushing and shafts of the shockabsorbers.

13. Lubricate the rear suspension withall-temperature grease.

14. Tighten all nuts, bolts, and capscrews making sure all nuts, bolts,and cap screws are tightenedsecurely. Make sure all rivets hold-ing the components together aretight. Replace all loose rivets.

CAUTIONDo not do steps 3-5 on the 1100 ccmodels; severe engine damage couldresult.

CAUTIONDo not run the engine without the beltguard in place and secured.

CAUTIONDo not do step 7 on the 1100 cc mod-els; severe engine damage couldresult.

CAUTIONNever crank the engine over withoutgrounding the spark plugs. Damageto coils and ECU may result.

56

15. Clean and polish the hood, console,and chassis with Cat Cleaner (p/n4639-371). DO NOT USE SOL-VENTS. THE PROPELLANTWILL DAMAGE THE FINISH.

NOTE: On electric start models,disconnect the battery cables makingsure to disconnect the negative cablefirst; then clean the battery posts andcables. Charge the battery.

16. If possible, store the snowmobileindoors. Raise the track off the floorby blocking up the back end makingsure the snowmobile is secure.Loosen the track adjusting bolts toreduce track tension. Cover thesnowmobile with a machine cover ora heavy tarpaulin to protect it fromdirt and dust.

17. If the snowmobile must be stored out-doors, position the snowmobile out ofdirect sunlight; then block the entiresnowmobile off the ground makingsure the snowmobile is secure. Loosenthe track adjusting bolts to reducetrack tension. Cover with a machinecover or a heavy tarpaulin to protect itfrom dirt, dust, and rain.

CAUTIONSealed batteries require charging ifleft for extended non-start periods.Arctic Cat recommends trickle charg-ing once a month. Follow the manu-facturer’s instructions and cautions.

CAUTIONAvoid storing in direct sunlight andusing a plastic cover as moisturemay collect on the snowmobile caus-ing corrosion.

57

Preparation after StorageTaking the snowmobile out of storageand correctly preparing it for another sea-son will assure many miles and hours oftrouble-free snowmobiling. Arctic Catrecommends the following procedure:

1. Clean the snowmobile thoroughly.Polish the exterior of the snowmobile.

2. Clean the engine. Remove the clothfrom the exhaust system. Checkexhaust system and air-intakesilencer for obstructions.

3. Inspect all control wires and cablesfor signs of wear or fraying. Replaceif necessary. Use cable ties or tape toroute wires and cables away fromhot or rotating parts.

4. Inspect the drive belt for cracks andtears. Check belt specifications.Replace if damaged or worn. Installthe drive belt.

NOTE: If the old belt is worn but inreasonable condition, retain it withthe snowmobile as a spare in case ofemergency.

5. Inspect all fuel hoses and oil hosesfor deterioration or cracks; replace ifnecessary. Make sure all connectionsare tight; then on the 800 cc models,fill the oil-injection reservoir with therecommended 2-cycle oil (see Gaso-line-Oil - Recommended InjectionOil sub-section in the General Infor-mation section).

NOTE: After prolonged storage ofthe 800 cc models, Arctic Cat recom-mends one tankful of 100:1 gas/oilmixture be used in conjunction withthe oil-injection system to ensureproper lubrication.

6. On the 800 cc models, inspect thespark plugs. Replace, gap, or cleanas necessary.

7. Tighten all nuts, bolts, and capscrews making sure all nuts, bolts,and cap screws are tightenedsecurely.

8. If not done during preparation forstorage, lubricate the rear suspen-sion with all-temperature grease.

9. Check the coolant level and all cool-ant hoses and connections for deteri-oration or cracks. Add properlymixed coolant as necessary.

10. On electric start models, charge thebattery until fully charged (see Bat-tery sub-section in the Maintenancesection); then connect the batterycables making sure to connect thepositive cable first. Test the electricstart system.

11. Inspect the entire brake system, allcontrols, headlight, taillight, brake-light, ski wear bars, and headlightaim; adjust or replace as necessary.

12. Adjust the track to the proper tensionand alignment (see Track Tensionand Track Alignment sub-sections inthe Maintenance section).

58

U.S. EPA Emission Control Statement/Warranty Coverage (U.S. Only)

STATEMENT/WARRANTYArctic 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 EmissionControl Regulations. Please read the following information completely.

Your authorized Arctic Cat snowmobile dealer will repair or replace any defective emission-relatedcomponent at no cost to you during the warranty period. You may have non-warranty service performedby any repair establishment that uses equivalent components. The regulations provide significant civilpenalties 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 inmaterials or workmanship that could cause the engine to fail to comply with applicable regulationsduring the warranty period.

If you have any questions about this information, or the emission warranty coverage statement, contactyour local authorized Arctic Cat snowmobile dealer.

WARRANTY PERIODThe emission warranty period for this snowmobile begins on the same date as the standard warrantycoverage and continues for 30 months or 2500 miles, whichever comes first.

COMPONENTS COVEREDThe emissions warranty covers major emissions control components and emission-related componentslisted as follows:

Engine Management and Sensors Fuel/Air SystemBarometric Pressure Sensor Fuel InjectorsCamshaft Position Sensor Fuel Pressure RegulatorEngine Control Unit (ECU) Fuel PumpEngine Coolant Temperature Sensor Carburetor(s)Intake Air Temperature Sensor Turbocharger AssemblyManifold Absolute Pressure Sensor Air Bypass ValveOxygen Sensor Turbo Waste Gate Control ValveThrottle Position Sensor Crankcase Ventilation System

ISC Valve

Ignition System Miscellaneous Items Used in Aforementioned Systems

Ignition Coil ConnectorsKnock Sensor System SwitchesCrankshaft Position Sensor GrommetsExhaust Temperature Sensor ClampsCapacitive Discharge Ignition (CDI) Module HosesMagneto Pick-Up Ties

GasketsWiring

OWNER'S RESPONSIBILITIESThe owner of any snowmobile warranted under this Arctic Cat Emission Control Statement isresponsible 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 itemsas air filter, oil and oil filter, or any other part, item, or device related to emissions control as specified inthe Operator's Manual. It is the owner's responsibility to ensure that the snowmobile is used in a mannerfor which it was designed.

59

NOTES

60

Change of Address, Ownership, or Warranty Transfer

Arctic Cat Inc. keeps on file the current name and address of theowner of this snowmobile. This will allow Arctic Cat to reach thecurrent owner with any important safety information which maybe necessary to protect customers from personal injury orproperty damage. Please make sure a copy of this form iscompleted and returned to Arctic Cat Inc. if you move or if thesnowmobile is sold to another party.

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

61

Fold Back Once

CHANGE OF ADDRESS/OWNERSHIP

ARCTIC CAT INC.PRODUCT SERVICE AND

WARRANTY DEPT.P.O. BOX 810

THIEF RIVER FALLS, MN 56701

PlaceStampHere

Warranty Procedure/Owner Responsibility

At the time of sale, an Owner Registration form is to be completed by the sellingdealer 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 retainand/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 bepresented to the dealer when requesting warranty service. The registration form isthe consumer’s proof of ownership and warranty eligibility. The form is usedby the dealer to validate the warranty claim. Retain your copy of the form andkeep it in a safe place.

When warranty repair is suspected, the snowmobile should be taken to the sellingdealer, who has the primary responsibility to perform warranty repairs. Subject tothe limitations set forth in the Limited Warranty, in the event the selling dealer hasceased to do business, you have moved, or you are in a location away from yourselling dealer, warranty may be performed by any authorized Arctic Cat Snowmo-bile dealer.

The authorized Arctic Cat Snowmobile dealer will examine the snowmobile or partto 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, freeof 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, theconsumer, will then be asked to sign a warranty form to ensure Arctic Cat that thewarranty 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 protectyourself and your snowmobile, follow all safety and service tips. Arctic Cat willNOT warrant repairs required as a result of not performing standard operatormaintenance, storage procedures, and service as outlined in the Operator’sManual.

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

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

®TM

ARCTIC CAT®