Snowmobile Arctic Cat 2-Stroke (2007 year). Instruction - part 2

 

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Snowmobile Arctic Cat 2-Stroke (2007 year). Instruction - part 2

 

 

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15. Remove the drive belt from the drive clutch/driven

pulley. Lay the belt on a flat surface or slide it into

a cardboard sleeve to prevent warping or distortion

during storage; then clean and inspect the drive

clutch and driven pulley.

16. Apply light oil to the upper steering post bushing,

ski spindles and bolts, front and rear pivot bushings

of the skid frame, and plungers of the shock

absorbers.

17. Lubricate all grease fittings (front and rear suspen-

sion, spindles, speedometer drive adapter, and the

driven shaft support bearing) with a low-tempera-

ture grease.

18. Tighten all nuts, bolts, and cap screws making sure

all calibrated nuts, bolts, and cap screws are tight-

ened to specifications. Make sure all rivets holding

the components together are tight. Replace all

loose rivets.

19. Clean and polish the hood, console, and chassis

with Arctic Cat Hood and Windshield Cleaner/

Polish (p/n 0636-174). DO NOT USE SOLVENTS

OR SPRAY CLEANERS. THE PRO- PELLENT

WILL DAMAGE THE FINISH.

20. On electric start models, disconnect the battery

cables making sure to disconnect the negative

cable first; then clean the battery posts and cables.

21. If possible, store the snowmobile indoors. Raise

the track off the floor by blocking up the back end

making sure the snowmobile is secure. Loosen the

track adjusting bolts to reduce track tension. Cover

the snowmobile with a machine cover or a heavy,

ventilated tarpaulin to protect it from dirt and dust.

22. If the snowmobile must be stored outdoors, posi-

tion the snowmobile out of direct sunlight; then

block the entire snowmobile off the ground making

sure the snowmobile is secure. Loosen the track

adjusting bolts to reduce track tension. Cover with

a machine cover or a heavy, ventilated tarpaulin to

protect it from dirt, dust, and rain.

Preparation After 

Storage

Taking the snowmobile out of storage and correctly

preparing it for another season will assure many miles

and hours of trouble-free snowmobiling. Arctic Cat

recommends the following procedure:

1. Clean the snowmobile thoroughly. Polish the exte-

rior of the snowmobile.

2. Clean the engine. Remove the cloth from the

exhaust system. Check exhaust system and air-

intake silencer/air filter for obstructions.

3. Inspect all control wires and cables for signs of

wear or fraying. Replace if necessary. Use cable

ties or tape to route wires and cables away from hot

or rotating parts.

4. Inspect the drive belt for cracks and tears. Check

belt specifications. Replace if damaged or worn.

Install the drive belt.

„NOTE: If the old belt is worn but in reasonable
condition, retain it with the snowmobile as a spare
in case of emergency.

5. On carbureted models, inspect the in-line fuel filter

and replace if necessary.

6. Inspect all fuel hoses and oil hoses for deterioration

or cracks; replace if necessary. Make sure all con-

nections are tight; then fill the oil-injection reser-

voir with the recommended injection oil.

„NOTE: After prolonged storage, Arctic Cat recom-
mends one tankful of 100:1 gas/oil mixture be used
in conjunction with the oil-injection system to
ensure proper lubrication.

7. Inspect the entire brake system, all controls, head-

light, taillight, brakelight, ski wear bars, and head-

light aim; adjust or replace as necessary.

8. Inspect each spark plug. Replace, gap, or clean as

necessary.

! CAUTION

Batteries require charging if left for extended non-
start periods. Arctic Cat recommends not servicing
the battery until the snowmobile is to be used or
trickle charging once a month. Follow the manufa-
turer’s instructions and cautions.

! CAUTION

On models with remote start, make sure to leave the
battery cables disconnected. Failure to disconnect
the battery cables when storing the snowmobile for
a prolonged period of time (six weeks or more) will
result in a discharged or damaged battery.

! CAUTION

Avoid storing in direct sunlight and using a plastic
cover as moisture may collect on the snowmobile
causing corrosion.

! CAUTION

On carbureted models if the gas in each carburetor
float chamber was not drained prior to storage, the
carburetor(s) must be cleaned before starting the
engine.

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9. Adjust the track to the proper tension and align-

ment. Lock the jam nuts.

10. Adjust the carburetor(s) and choke cable on carbu-

reted models and throttle cable on all models.

11. Tighten all nuts, bolts, and cap screws making sure

all calibrated nuts, bolts, and cap screws are tight-

ened to specifications.

12. Lubricate all grease fittings (rear suspension, spin-

dles, speedometer drive adapter, and the driven

shaft support bearing) with a low-temperature

grease.

13. On liquid cooled models, check the coolant level

and all coolant hoses and connections for deteriora-

tion or cracks. Add properly mixed coolant as nec-

essary.

14. On fan cooled models, clean the engine cooling

fins and all vents.

15. On electric start models, charge the battery; then

connect the battery cables making sure to connect

the positive cable first. Test the electric start system.

After Break-In Checkup 

(100 Miles)

The 100 mile checkup offered by some dealerships

reduces problems and warranty costs. A program of

this kind should be offered by all dealerships. Many

dealerships have added the price of the checkup into

the selling price of the snowmobile, and others offer it

as a bonus to the customers who purchase snowmobiles

from their dealership.

There are three areas that require adjustment after the

break-in period in order to obtain peak performance.

These areas are the following.

A. Carburetor jetting

B. Drive belt deflection/Break-In

C. Track tension and alignment

CARBURETOR JETTING (Carbureted Mod-

els)— Altitude, temperature, and the use of oxygenated

gasoline affect the carburetion needed for optimum

engine performance. The carburetor main jets must be

changed in conjunction with changes in operating alti-

tude, oxygenated gasoline usage, and temperature.

DRIVE BELT DEFLECTION — Drive belt deflec-

tion is very important to the snowmobile. Even if it is

checked and is correct when the snowmobile is set up,

it does change (more so during the break-in period).

This is because the rubber engine mounts and the rub-

ber snubber on the torque link will all take a “set” dur-

ing the first 100 miles, which allows the distance

between the drive clutch and driven pulley to shorten.

When this happens, the snowmobile will appear to

have a too long drive belt. To add to this, the drive belt

itself wears and stretches somewhat. This all leads to a

low-end performance problem and, if not corrected,

causes premature drive belt wear.

After the break-in period, drive belt deflection should

be checked according to the instructions given in this

manual.

DRIVE BELT BREAK-IN — It is critical for maxi-

mum drive belt life to allow the belt to break in before

subjecting it to hard use such as wide-open-throttle

operation or hill climbing.

The first 20 miles on the drive belt should be at 1/2

throttle or lower. This will allow the belt to gain its

optimum flexibility and will extend belt life. Do not

exceed 50 MPH during the first 20 miles.

If this procedure isn’t followed, it is possible to destroy

a new drive belt in less than 50 miles. This should be

explained to customers at the time of drive belt sales.

To increase the life of a drive belt, it is very important

that the belt be warmed up before subjecting it to any

type of use. In cold temperature (0° or below), the

engine should be allowed to idle for a period of 8 to 10

minutes. This will allow heat from the engine compart-

ment to soften the drive belt. Not only will this proce-

dure increase belt life but will also help prevent engine

damage from cold seizure.

Each operator should be instructed to drive the snow-

mobile for several minutes at a low throttle setting to

warm the belt up before using wide-open-throttle. This

practice should be followed on all models for maxi-

mum belt life.

In addition to instructing each operator about these

drive belt break-in procedures, Arctic Cat also recom-

mends that the operators be informed that a drive belt

(like brake pads, wear strips, etc.) is considered a nor-

mal wear item and is listed as an exclusion on the Arc-

tic Cat Limited Warranty.

TRACK TENSION AND ALIGNMENT — There is

a certain amount of stretch on all tracks during the first

500 miles. The track must be adjusted after the first 50

to 100 miles to the specifications given in the Setup

and Pre-delivery Manual and periodically thereafter. If

these adjustments aren’t performed, the track may

“derail” which leads to track and slide rail damage.

! WARNING

On carbureted models, be sure to tighten the swivel
adapter jam nuts securely. If a jam nut isn’t tight-
ened, the adjuster can rotate out of the carburetor
cap causing the piston valve not to return to the full-
closed position.

1-6

Along with these three major areas, there are also other

areas that should be checked and adjusted during the

“After Break-In Checkup.” A checklist to assist you

with this service follows. Not only will the customer be

happier, but it also gets the customer back into your

dealership, which in many cases will mean additional

sales in accessories, belts, oil, etc.

After Break-In Checkup 

Checklist

Below is a recommended list of items to check after the

break-in period. By performing this inspection, war-

ranty cost can be reduced and customer satisfaction can

be increased.

The recommended mileage for this inspection is

between 100 and 300 miles. Please encourage the cus-

tomers to have this important checkup done.

    Jet carburetor(s) according to average temper-

ature, type of gasoline being used, and altitude

    Adjust drive belt deflection

    Adjust track tension and alignment

    Check throttle cable tension

    Check oil-injection pump adjustment

    Check engine idle

    Check coolant level

    Check chain case/gear case lubricant level

    Check lights (high/low beam, brakelight)

    Check safety switch operation

    Check driveshaft area for any rubbing compo-

nents

    Check steering hardware for tightness

    Check skid frame and A-arm mounting hard-

ware for tightness

    Check brake lever travel and adjustment

    Grease all lubrication points

Check Engine Light 

(Crossfire/F-Series/

M-Series Models)

The Check Engine Light is controlled by the ECU and

may illuminate for a number of reasons. The light

should illuminate each time the key is turned to RUN

or START, and it should go out when the engine starts.

If the light stays illuminated or it illuminates while the

engine is running, the ECU is receiving input that is

outside of its established parameters.

Diagnostic Codes/

Check Engine 

(Crossfire/F-Series/

M-Series Models)

These diagnostic codes are flashed by the check engine

light incorporated within the speedometer/tachometer.

Refer to the following chart for diagnostic code

sequences.

„NOTE: On single-digit codes (2, 4, etc.), the num-
ber indicated will flash in an uninterrupted
sequence. On double-digit codes (1-2, 1-6, etc.), the
first number indicated will flash in an uninterrupted
sequence, there will be a short pause, and the sec-
ond number indicated will flash in an uninterrupted
sequence.

If the coolant temperature is at or above 80° C (176°

F), the coolant temperature light will flash a warning

(alert). If the coolant temperature is at or above 93° C

(200° F), the coolant temperature light will cease flash-

ing and will remain constantly illuminated.

Number of Flashes

Trouble

1-2

(Check Engine Light)

Failure in ignition coil.

1-6

(Check Engine Light)

Incorrect adjustment/failure in 
APV cable.

1-7

(Check Engine Light)

Failure in exhaust temperature 
sensor.

1-8

(Check Engine Light)

Failure in servomotor.

2

(Check Engine Light)

Failure in injector(s).

2-1

(Check Engine Light)

Failure in knock sensor.

2-3

(Check Engine Light)

Failure in knock control system.

4

(Check Engine Light)

Open or short circuit in baromet-
ric pressure sensor.

5

(Check Engine Light)

Open or short circuit in intake air 
temperature sensor.

6

(Check Engine Light) 

Open or short circuit in water 
temperature sensor.

7

(Check Engine Light) 

Open or short circuit in throttle 
position sensor.

Steady Flash

(Coolant Temperature Light)

Coolant Temperature Above 80° 
C (176° F).

Constant On

(Coolant Temperature Light) 

Coolant Temperature Above 93° 
C (200° F).

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Chassis Control Unit

(Crossfire/F-Series/

M-Series Models)

The Chassis Control Icon may illuminate for a number

of reasons. The light should illuminate each time the

key is turned to RUN or START, and it should go out

when the engine starts. If the light stays illumintated or

it illuminates while the engine is running, the CCU is

receiving input that is outside of its established param-

eters.

Diagnostic Codes/

Chassis Control Unit             

(Crossfire/F-Series/

M-Series Models)

These diagnostic codes are flashed by the wrench icon

light incorporated within the speedometer/tachometer.

Refer to the following chart for diagnostic code

sequences.

„NOTE: On these double-digit codes (3-1, 3-2, etc.),
the first number indicated will flash in an uninter-
rupted sequence, there will be a short pause, and
the second number indicated will flash in an unin-
terrupted sequence.

Number of Flashes

Trouble

3-1

(CCU Icon)

Stator failure

(input open or shorted).

3-2

(CCU Icon)

High power DC output deactivated 

(headlight/handwarmer).

3-3

(CCU Icon)

High power DC output shorted

(headlight/handwarmer).

3-4

(CCU Icon)

Low power DC output deactivated 

(gauge/taillight/APV valves).

3-5 

(CCU Icon)

Low power DC output shorted

(gauge/taillight/APV valves).

3-6 

(CCU Icon)

System under voltage

(below 11 volts).

3-7 

(CCU Icon)

System over voltage.

(above 15.5 volts).

3-8 

(CCU Icon)

Gear shift actuator failure

(over current or over temperature).

4-2

(CCU Icon)

Tachometer input failure (engine run-

ning - no tachometer

signal present).

4-3

(CCU Icon)

Gear position switch failure (did not 

change - no (or invalid)

position input).

4-4

(CCU Icon)

CCU over temperature

(above 105° C - 221° F).

 

 

 

 

 

 

 

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