Snowmobile Arctic Cat (2004 year). Manual - part 56

4-59

2. Move the throttle lever to the full-open position.

3. Rotate the jam nuts/control rod in the proper

direction until the marks align.

4. Lock the jam nuts to secure the adjustment.

NOTE: On “Laydown” engine models if the

snowmobile has been tipped on its side for an
extended period of time, inspect the oil-line hose
for any signs of air bubbles. If air bubbles are visi-
ble, see the appropriate Bleeding Oil-Injection Sys-
tem in this sub-section.

Bleeding Oil-Injection

System

(Standard Models)

1. Fill the oil reservoir with recommended injection

oil.

2. Place an absorbent towel below the oil bleed

screw; then remove the bleed screw from the
pump. Allow the oil to flow through the oil-supply
hose until the hose is filled with oil and free of air
bubbles; then install the bleed screw.

NOTE: To aid in bleeding the oil system, blow

into the vent hose to force the oil toward the pump.
The oil reservoir cap must be on for this proce-
dure.

727-185C

738-338A

3. Using a shielded safety stand, raise the rear of the

snowmobile. Engage the brake lever lock; then
start the engine and allow it to idle.

4. Using a stiff wire with a hooked end, pull the

control arm upward to the full-open position.

5. Idle the engine until oil flowing to the top of the

oil-delivery hoses is free of air bubbles.

6. When oil flows free of all air bubbles, shut the

engine off and check for leakage.

7. Release the brake lever lock.

Bleeding Oil-Injection

System

(“Laydown” Engine Models)

NOTE: The oil reservoir must be full for this pro-

cedure.

1. Tip the snowmobile onto its left side; then using a

torx-bit, remove the screws securing the center
belly pan (skid plate) to the front end.

2. Loosen, but don’t remove, the oil bleed screw;

then finger-tighten the bleed screw.

3. Tip the snowmobile back to the upright position;

then raise the rear of the snowmobile onto a safety
stand so the track is at least 61 cm (24 in.) off the
ground.

! CAUTION

Whenever bleeding the oil-injection system, use
a 100:1 gas/oil mixture in the gas tank to ensure
adequate engine lubrication. Failure to use the
100:1 mixture during oil-injection system
bleeding will result in severe engine damage.

! WARNING

Keep hands and clothing away from all moving or
rotating parts.

4-60

4. Place a drain pan beneath the engine compartment;

then loosen the bleed screw until oil begins to
drain out.

5. Allow the oil to drain out until there are no visible

signs of air bubbles in the oil-line hose; then
tighten the bleed screw.

6. Lower the rear of the snowmobile, tip the

snowmobile onto its left side, ensure the bleed
screw is secure, and install the center belly pan
(skid plate).

NOTE: If the snowmobile has been tipped on its

side for an extended period of time, inspect the oil-
line hose for any signs of air bubbles. If air bub-
bles are visible, repeat the bleeding procedure.

NOTE: Prior to operating the snowmobile, make

sure the oil reservoir is full of recommended oil.

Testing

Oil-Injection Pump

1. Clamp off the oil-supply hose between the oil

reservoir and oil pump; then remove the supply
hose from the pump.

2. Attach a suitable length of oil-supply hose to the

oil pump; then using Oil Injection Usage Tool (p/n
0644-007), fill the hose with Arctic Cat 50:1
Injection Oil.

NOTE: On APV equipped engines, use Arctic Cat

Synthetic APV 2-Cycle Oil (p/n 2639-512).

AE108

NOTE: When filling the oil-supply hose with oil,

do not insert the usage tool until it is tight in the
hose. There must be enough room around the tip
of the tool and the hose to allow air in the hose to
escape.

3. Fill the usage tool with recommended oil to the 0

line.

4. Wipe the tip of the tool to remove excess oil; then

attach the tool to the oil-supply hose and remove
the bulb.

5. Secure the tool to the oil reservoir by twisting the

rubber strap one half turn and placing the rubber
strap around the tool and the oil reservoir filler
neck.

6. Start the engine and run the engine at 3000 RPM

for 3 minutes with the control arm in the FULL-
CLOSED position. Compare the amount of oil
used against the specifications on the chart.

7. Using a stiff wire, pull the oil-injection control

arm to the FULL-OPEN position. Run the engine
at 3000 RPM for 2 minutes. Compare the amount
of oil used against the specifications on the chart.

8. If the oil-injection pump output does not meet the

specifications, see Testing Oil-Injection Check
Valves in this sub-section.

9. Disconnect the oil usage tool, remove the plug

from the reservoir, attach the oil-supply hose to
the oil reservoir, and remove the vacuum pump.

10. Bleed the oil-injection system (see appropriate

Bleeding Oil-Injection System in this sub-section).

! WARNING

Always wear safety glasses when performing this
test.

! WARNING

Keep hands and clothing away from all moving or
rotating parts.

Oil Consumption @3000 RPM

MODEL

FULL-

CLOSED

3 Minutes

FULL-OPEN

2 Minutes

370 cc

0.975-1.86 cc

5.4-6.6 cc

440 cc

2.5-4.6 cc

6.2-9.2 cc

500 cc

0.9-2.0 cc

8.5-10.4 cc

550 cc

2.0-4.3 cc

10.2-15.5 cc

570 cc

1.1-2.0 cc

7.7-9.3 cc

600 cc STD

1.727-4.247 cc 9.224-11.558 cc

600 cc

“Laydown”/

700 cc

0.9-2.1 cc

11.7-14.3 cc

800/900 cc

1.3-2.0 cc

12.2-18.4 cc

4-61

Testing Oil-Injection

Check Valves

In the event there is an engine problem due to lack of
lubrication, the oil-injection pump check valves should
be tested using a vacuum pump to make sure the check
valves are operating properly.

When testing the check valves, remove them from the
pump assembly.

1. Remove the check valves from the oil-injection

pump.

731-551A

2. Attach the vacuum test pump hose to the check

valve.

3. Squeeze the vacuum pump handle and watch the

pump gauge. The check valve should release at
4.5-5 lb and again reset itself at 3.5-4 lb. If
“release” and “reset” are not within specifications,
replace the check valve.

4. Record the “release” and “reset” readings for the

valve; then perform the test on the other valve.
The “release” and “reset” readings must fall within
specifications and must be within 1.5 lb of each
other. If either or both are not met, replace the
check valves.

5. If the check valves are within specifications but

the oil-injection usage is not, replace the oil-
injection pump.

Fuel Pump

(Carbureted Models)

NOTE: When servicing a fuel pump, determine

which style pump is being serviced and follow the
appropriate procedure.

PRELIMINARY CHECKS

1. Make sure the gas tank shut-off valve is in the

OPEN position.

2. Make sure there is adequate gasoline in the gas

tank.

3. Make sure all hoses are clear and free of kinks and

obstructions.

4. Make sure the fuel filter is not plugged or

damaged.

5. Make sure fuel and impulse hoses are in good

condition.

6. Make sure there is evidence of good impulse at the

crankcase impulse fitting.

TESTING PRESSURE

1. Connect a pressure gauge between fuel pump and

carburetor using a piece of fuel hose and a T-
fitting.

2. Place snowmobile on a safety stand and start the

engine. At the following engine speeds, the
specified pressures must be indicated.

3. Remove gauge and hose and connect fuel hose to

carburetor.

TESTING VACUUM

NOTE: Make sure adequate fuel is in the carbure-

tor for this test.

1. Turn the gas tank shut-off valve to the CLOSED

position; then disconnect fuel supply hose from
the shut-off valve.

2. Connect a vacuum gauge directly to the fuel pump

inlet fitting.

3. With snowmobile on a safety stand, start the

engine and accelerate to 2000-3000 RPM for a
period of 30 seconds. Note maximum reading of
gauge. Reading must be within the range listed.

4. Stop engine. Connect fuel hose. Turn the shut-off

valve to the OPEN position.

KEY

1. Gasket
2. Check Valve
3. Gasket
4. Union

RPM

psi

kg/cm²

1000-2000

3.0-3.5

0.21-0.25

3000-4000

4.5-5.5

0.32-0.39

5000-6000

6.0-7.0

0.42-0.49

Acceptable Fuel Pump Vacuum (2-3000 RPM)

in.-hg

mm-hg

7-10

175-250

4-62

SERVICING

0727-830

1. Scribe a line across the fuel pump sections.

2. Remove the screws securing the fuel pump; then

from the top of the fuel pump, remove the top
case, gasket, diaphragm, and membrane.

NOTE: Be sure all fuel pump components are

clean and the fittings are tight.

3. In sequence on the bottom case of the fuel pump,

place the membrane, diaphragm, gasket, and top
case.

NOTE: Make sure the scribed line made during

disassembly is aligned and the tabs on the two
lower packings align with the tabs on the bottom
and valve section of the pump.

4. Secure the fuel pump with the screws. Tighten

securely.

SERVICING

1. Scribe a line across the fuel pump sections.

0728-279

2. Remove the screws securing the fuel pump; then

from the top of the fuel pump, remove the top,
packing, diaphragm, packing, valve section,
packing, diaphragm, and packing.

NOTE: Be sure all fuel pump components are

clean and the fittings are tight.

3. Push the grommets out of the valve section; then

remove the valve from each grommet.

4. Place a valve onto each grommet; then push each

valve with grommet into the valve section.

5. In sequence on the bottom of the fuel pump, place

a packing, diaphragm, packing, valve section,
packing, diaphragm, packing, and top.

NOTE: Make sure the scribed line made during

disassembly is aligned.

6. Secure the fuel pump with the screws. Tighten

securely.

SERVICING

730-349N

0738-347

1. Scribe a line across the fuel pump sections.

KEY

1. Case
2. Membrane
3. Diaphragm
4. Gasket
5. Case
6. Screw

KEY

1. Packing
2. Diaphragm
3. Packing
4. Valve Section w/Grommets

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