Index Snowmobiles / ATV Snowmobile Arctic Cat - service manual 2004 year

Snowmobile Arctic Cat (2004 year). Manual - part 1

1-1

SECTION 1 — GENERAL INFORMATION

TABLE OF

CONTENTS

1-2

Snowmobile

Identification

The Arctic Cat Snowmobile has two important identifica-
tion numbers. The Vehicle Identification Number (VIN)
is stamped into the tunnel near the right-side footrest. The
Engine Serial Number (ESN) is stamped into the crank-
case of the engine.

0726-383

These numbers are required to complete warranty claims
properly. No warranty will be allowed by Arctic Cat Inc.
if the engine serial number or VIN is removed or muti-
lated in any way.

Recommended

Gasoline and Oil

RECOMMENDED GASOLINE
(Carbureted Models)

The recommended gasoline to use in these snowmo-
biles is 87 minimum octane regular unleaded. In many
areas, oxygenates (either ethanol or MTBE) are added
to the gasoline. Oxygenated gasolines containing up to
10% ethanol or up to 15% MTBE are acceptable gaso-
lines; however, whenever using oxygenated gasolines,
the carburetor main jet must be one size larger than the
main jet required for regular unleaded gasoline. For
example, if a 400 main jet is recommended for regular
unleaded gasoline, a 410 main jet must be installed if
using an oxygenated gasoline.

When using ethanol blended gasoline, it is not necessary
to add a gasoline antifreeze since ethanol will prevent the
accumulation of moisture in the fuel system.

RECOMMENDED GASOLINE
(EFI Models)

The recommended gasoline to use in these snowmobiles
is 87 minimum octane regular unleaded. In many areas,
oxygenates (either ethanol or MTBE) are added to the
gasoline. Oxygenated gasolines containing up to 10%
ethanol or up to 15% MTBE are acceptable gasolines. Do
not use gasolines containing methanol.

NOTE: When using the recommended gasoline,

the Fuel Designation Connector at the ECU must
be connected.

NOTE: When using oxygenated gasolines, the

Fuel Designation Connector at the ECU must be
disconnected.

734-482A

NOTE: In order for the ECU to change modes, the

engine must be OFF when connecting or discon-
necting the Fuel Designation Connector.

RECOMMENDED OIL

The recommended oil to use in the oil-injection system is
Arctic Cat 50:1 Injection Oil (for standard models) or
Arctic Cat Synthetic APV 2-Cycle Oil (for APV models).
The oil is specially formulated to be used either as an
injection oil or as a pre-mix oil (for carbureted model
break-in) and meets all of the lubrication requirements of
the Arctic Cat snowmobile engine.

! CAUTION

Do not use white gas or gasolines containing
methanol. Only Arctic Cat approved gasoline
additives should be used.

! CAUTION

Do not use white gas or gasoline containing
methanol. Only Arctic Cat approved gasoline
additives should be used.

! CAUTION

If oxygenated gasoline is to be used, it is
extremely important that the Fuel Designation
Connector at the ECU is disconnected. If not,
severe engine damage may occur.

1-3

Break-In Procedure

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.

Genuine Parts

When replacement of parts is necessary, use only genuine
Arctic Cat parts. They are precision-made to ensure high
quality and correct fit.

High Altitude Operation

Operating a snowmobile at varying altitudes requires
changes in performance components. These changes
affect drive train components (on all models) and carbure-
tion components (on carbureted models).

High altitude information decal(s) are located beneath the
hood of the snowmobile.

King Cat and Mountain Cat snowmobiles are initially set
up at the factory for operation between 6000-9000 feet.
Consult the appropriate specifications for this informa-
tion.

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.

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

safety stand.

NOTE: On “Laydown” engine models, the air

silencer boot can be pried forward to access the
intake bores. Pry the boot forward; then proceed
to step 7.

NOTE: On some standard 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 standard models, the air-intake

silencer includes a cover/tool tray assembly and a
baffle/resonator, and the silencer boot cannot be
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

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

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

1-4

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 “Laydown” engine models, secure the

air silencer boots onto the intake bores.

NOTE: On some standard models, install the air-

intake silencer boot(s); on some standard models,
install the baffle/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 carbureted models, drain the gas from each

carburetor float chamber.

11. 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.

12. 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.

13. Clean and inspect the drive clutch and driven

pulley.

14. 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.

15. 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.

16. Lubricate all grease fittings (front and rear

suspension, spindles, speedometer drive adapter,
and the driven shaft support bearing) with a low-
temperature grease.

17. 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.

18. 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.

19. On electric start models, disconnect the battery

cables making sure to disconnect the negative
cable first; then clean the battery posts and cables.

20. 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.

21. 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.

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:

! 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.

! 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.

Content .. 1 2 3 ..