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Snowmobile Arctic Cat (2002 year). Manual - part 2

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RECOMMENDED OIL

(4-Stroke Model)

The recommended oil to use is a multi-grade oil cali-

brated to the ambient temperature at which the engine is

run. See the viscosity chart for details.

GEN-0048

After the engine break-in period, the engine oil should be

changed every 3500 miles (on the 4-Stroke Touring and

Trail) and before prolonged storage.

Break-In Procedure

(2-Stroke Models)

The Arctic Cat 2-stroke engine (when new or rebuilt)

requires a short break-in period before the engine is sub-

jected to heavy load conditions. Arctic Cat requires that

the first tankful of fuel be premixed at a 100:1 ratio in all

oil-injection models.

During the break-in period, a maximum of 1/2 throttle is

recommended; however, brief full-throttle accelerations

and variations in driving speeds contribute to good engine

break-in.

Break-In Procedure

(4-Stroke Model)

The Arctic Cat 4-stroke engine (when new or rebuilt)

requires a short break-in period before the engine is sub-

jected to heavy load conditions.

This engine does not require any pre-mixed fuel during

the break-in period.

To ensure trouble-free operation, careful adherence to the

following break-in guidelines will be beneficial.

* With occasional full-throttle operation.

To ensure proper engine break-in, Arctic Cat recommends

that the engine oil and filter be changed after 600 miles or

after one month, whichever comes first. This service is at

the discretion and expense of the snowmobile owner.

Genuine Parts

! CAUTION

Any oil used in place of the recommended oil
may cause serious damage.

Multi-Grade

! CAUTION

DO NOT exceed the one (1) tankful limitation of a
100:1 gas/oil break-in mixture. Continuous use of
a gas/oil mixture, unless consistently operating
in extremely cold conditions (-26°C/-15°F or
colder), could cause spark plug fouling and
excessive carbon buildup. A 100:1 gas/oil
mixture must be used in conjunction with the oil-
injection system to ensure adequate engine
lubrication in extremely cold conditions.

! CAUTION

DO NOT use premixed fuel in the snowmobile gas
tank. Engine damage 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 *

When replacement of parts is necessary, use only genuine

Arctic Cat parts. They are precision-made to ensure high

quality and correct fit.

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High Altitude Operation

Operating a snowmobile at varying altitudes requires

changes in performance components. These changes

affect drive train components (on all models) and carbure-

tion components (on carbureted models).

A high altitude information decal is located beneath the

hood of the snowmobile. On carbureted models, the infor-

mation is incorporated into the Main Jet Chart decal.

A number of Arctic Cat snowmobiles are initially set up

at the factory for operation between 5000-9000 feet. Con-

sult the appropriate specifications for this information.

Drive Chain

Lubrication

(120 cc)

The drive chain should be lubricated every 20 operating

hours with a dry, graphite-based chain lubricant. By using

a dry, graphite-based chain lubricant, dirt buildup on the

drive chain will be minimized. Before each lubrication,

inspect the drive chain for dirt accumulation.

To lubricate the drive chain, shut the engine off and wait

for all moving parts to stop, remove the drive chain guard

and lubricate the drive chain. After lubricating the drive

chain, install the drive chain guard.

If the drive chain is excessively dirty, it should be

removed and cleaned prior to being lubricated (see Drive

Chain and Sprockets in Section 8).

NOTE: If a dry, graphite-based chain lubricant is

not available, lubricate the drive chain with several
drops of petroleum-based oil. If the snowmobile is
operated in the summer with the optional wheel
kit, the drive chain should be lubricated more fre-
quently.

Preparation

For Storage

Prior to storing the snowmobile, it must be properly ser-

viced to prevent corrosion and component deterioration.

An authorized Arctic Cat Snowmobile dealer should per-

form this service; however, the owner/operator can per-

form this service if desired. To prepare the snowmobile

for storage, Arctic Cat recommends the following proce-

dure:

1. Clean the seat cushion with a damp cloth and

Arctic Cat Vinyl Protectant (p/n 0638-313).

2. Clean the snowmobile thoroughly by hosing dirt,

oil, grass, and other foreign matter from the skid

frame, tunnel, hood, and belly pan. Allow the

snowmobile to dry thoroughly. DO NOT get water

into any part of the engine.

NOTE: Steps 3-7 are only for models with an oil-

injection system.

3. Place the rear of the snowmobile up on a shielded

safety stand.

NOTE: On some models, the air-intake silencer

is a one-piece unit, and the silencer boot(s) can be
removed to access the intake bore(s). Remove the
boots; then proceed to step 7.

NOTE: On some models, the air-intake silencer

includes a cover/tool tray assembly and a baffle/
r es o na to r, a nd the s i l e nc e r bo ot ca n no t b e
removed to access the intake bores. Proceed to
step 4.

4. Open the air-intake silencer cover; then remove

the three screws securing the cover/tool tray

assembly to the silencer.

5. Close the cover; then tip the cover/tool tray

assembly forward and out of its slots and remove

the assembly.

6. Using a large flat-blade screwdriver, remove the

baffle/resonator tabs from the air-intake silencer

slots and remove the baffle/resonator to access the

intake bores.

! CAUTION

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

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NOTE: The baffle/resonator can be removed

more easily by removing the back tabs first.

7. Start the engine and allow to idle. With the engine

idling, spray Arctic Cat Engine Storage Preserver

(p/n 0636-177) into the intake(s) until the engine

exhaust starts to smoke heavily or until the engine

starts to drop in RPM. Turn engine off.

NOTE: On some models, install the air-intake

silencer boot(s); on some models, install the baf-
fle/resonator and the cover/tool tray assembly.

8. Plug the exhaust system outlet with a clean cloth.

9. With the ignition switch in the OFF position:

A. Disconnect the high tension lead(s) from the

spark plug(s); then remove the plug(s), connect

it/them to the lead(s), and ground it/them on the

cylinder head(s).

B. Pour 29.5 ml (1 fl oz) of SAE #30 petroleum-

based oil into each spark plug hole and pull the

recoil starter handle slowly about 10 times.

C. Install the spark plug(s) and connect the high

tension lead(s).

10. On the 4-stroke model, change the engine oil; then

clean the air filter.

11. On carbureted models, drain the gas from each

carburetor float chamber.

12. Fill the gas tank to its rated capacity; then add

Arctic Cat Fuel Stabilizer (p/n 0638-165) to the

gas tank following directions on the container for

the stabilizer/gasoline ratio. Tighten the gas tank

cap securely.

13. If applicable, drain the chain-case lubricant by

removing the chain-case drain plug located on the

backside of the chain-case assembly. Remove the

chain-case cover and inspect chain, sprockets,

chain tensioner, and rollers for wear and the chain

for proper tension. Install the drain plug, chain-

case cover, and seal; then pour Arctic Cat

Transmission Lube (p/n 0636-817) into the filler

hole according to appropriate specifications.

14. Clean and inspect the drive clutch and driven

pulley.

15. If applicable, remove the drive belt from the drive

clutch/driven pulley. Lay the belt on a flat surface

or slide it into a cardboard sleeve to prevent

warping or distortion during storage; then clean

and inspect the drive clutch and driven pulley.

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

ski spindles and bolts, front and rear pivot

bushings of the skid frame, and plungers of the

shock absorbers.

17. Lubricate all grease fittings (front and rear

suspension, spindles, speedometer drive adapter,

and the driven shaft support bearing) with a low-

temperature grease.

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

all calibrated nuts, bolts, and cap screws are

tightened to specifications. Make sure all rivets

holding the components together are tight.

Replace all loose rivets.

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

with Arctic Cat Hood and Windshield Cleaner/

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

VENTS 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

tarpaulin to protect it from dirt and dust.

22. If the snowmobile must be stored outdoors,

position the snowmobile out of direct sunlight;

then block the entire snowmobile off the ground

making sure the snowmobile is secure. Loosen the

track adjusting bolts to reduce track tension. Cover

with a machine cover or a heavy tarpaulin to

protect it from dirt, dust, and rain.

! CAUTION

Do not do step 9 on the 4-stroke model; severe
engine damage could result.

! CAUTION

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

! CAUTION

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

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Preparation After

Storage

Taking the snowmobile out of storage and correctly pre-

paring it for another season will assure many miles and

hours of trouble-free snowmobiling. Arctic Cat recom-

mends the following procedure:

1. Clean the snowmobile thoroughly. Polish the

exterior of the snowmobile.

2. Clean the engine. Remove the cloth from the

exhaust system. Check exhaust system and 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. If applicable, 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 connections are tight; then on 2-stroke

models, fill the oil-injection reservoir with the

recommended 50:1 injection oil.

NOTE: On 2-stroke models after prolonged stor-

age, Arctic Cat recommends 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,

headlight, taillight, brakelight, ski wear bars, and

headlight aim; adjust or replace as necessary.

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

necessary.

9. Adjust the track to the proper tension and

alignment. Lock the jam nuts.

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

carbureted 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

tightened to specifications.

12. Lubricate all grease fittings (rear suspension,

spindles, speedometer drive adapter, and the

driven shaft support bearing) with a low-

temperature grease.

13. On the 120 cc model, inspect the drive chain and

drive chain tightener. Replace if necessary; then

lubricate the binding screw drum with WD-40 and

the drive chain with a dry, graphite-based chain

lubricant.

14. On liquid cooled models, check the coolant level

and all coolant hoses and connections for

deterioration or cracks. Add properly mixed

coolant as necessary.

15. On fan cooled models, clean the engine cooling

fins and all vents.

16. On EFI models, place the rear of the snowmobile

on a shielded safety stand; then start the engine.

Allow the engine to idle; then using a long stiff

wire with a hooked end, raise the oil-injection

pump control arm to the wide-open position until

the engine starts to smoke heavily. Release the

control arm and turn off the engine.

17. 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 dealer-

ships 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.

! 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.

! WARNING

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

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