Snowmobile Arctic Cat 2-Stroke (2007 year). Manual - part 1

TABLE OF

CONTENTS

Foreword

Click on the red text to go.

Section

1. General Information 

2. Engine 

3. Engine-Related Items 

4. Fuel Systems 

5. Engine Electrical Systems 

6. Chassis Electrical Systems 

7. Steering and Body 

8. Drive Train and Brake Systems 

9. Track/Rear Suspension 

1-1

1

SECTION 1 — GENERAL INFORMATION

TABLE OF

CONTENTS

Snowmobile Identification ....................................... 1-2
Recommended Gasoline and Oil  ........................... 1-2
Break-In Procedure  ................................................ 1-2
Genuine Parts  ........................................................ 1-2
High Altitude Operation  .......................................... 1-3
Preparation For Storage ......................................... 1-3
Preparation After Storage  ...................................... 1-4
After Break-In Checkup (100 Miles)  ....................... 1-5
After Break-In Checkup Checklist  .......................... 1-6
Check Engine Light

(Crossfire/F-Series/M-Series Models) ................. 1-6

Diagnostic Codes/Check Engine

(Crossfire/F-Series/M-Series Models) ................. 1-6

Chassis Control Unit 

(Crossfire/F-Series/M-Series Models) ................. 1-7

Diagnostic Codes/Chassis Control Unit

(Crossfire/F-Series/M-Series Models) ................. 1-7

Torque Conversions  ............................................... 1-8
Tightening Torque (General Bolts)  ......................... 1-8
Fraction/Decimal Conversion Chart  ....................... 1-9
Drill Bit Sizes (Number) Chart ................................ 1-9
MM/In. Conversion Chart  ..................................... 1-10
Servicing Symbols  ............................................... 1-11

1-2

Snowmobile 

Identification

The Arctic Cat Snowmobile has two important identifi-

cation 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 crankcase 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 mutilated 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 neces-

sary to add a gasoline antifreeze since ethanol will pre-

vent the accumulation of moisture in the fuel system.

RECOMMENDED GASOLINE
(EFI 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. Do not use gasolines containing methanol.

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 carbu-

reted model break-in) and meets all of the lubrication

requirements of the Arctic Cat snowmobile engine.

Break-In Procedure

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

requires a short break-in period before the engine is

subjected 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 accelera-

tions and variations in driving speeds contribute to

good engine break-in. 

Genuine Parts

When replacement of parts is necessary, use only genu-

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

high quality and correct fit.

! CAUTION

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

! CAUTION

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

! 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 car-
bon 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 condi-
tions.

1-3

1

High Altitude Operation

Operating a snowmobile at varying altitudes requires

changes in performance components. These changes

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

buretion components (on carbureted models).

High altitude information decal(s) are located beneath

the hood of the snowmobile.

The M-Series snowmobiles are initially set up at the

factory for operation between 6000-9000 feet. Consult

the appropriate specifications for this information.

Preparation For Storage

Prior to storing the snowmobile, it must be properly

serviced to prevent corrosion and component deteriora-

tion. An authorized Arctic Cat Snowmobile dealer

should perform this service; however, the owner/opera-

tor can perform this service if desired. To prepare the

snowmobile for storage, Arctic Cat recommends the

following procedure:

1. Clean the seat cushion with a damp cloth and Arc-

tic 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 all models except the 370 cc/570 cc,
the air silencer boot can be pried forward to access
the intake bores. Pry the boot forward; then pro-
ceed to step 7.

„NOTE: On the 370 cc/570 cc 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 assem-

bly 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.

„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 0436-888) 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 all models except the 370 cc/570 cc,
secure the air silencer boots onto the intake bores.

„NOTE: On the 370 cc/570 cc 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 car-

buretor float chamber.

11. Fill the gas tank to its rated capacity; then add Arc-

tic Cat Fuel Stabilizer (p/n 0436-907) to the gas

tank following directions on the container for the

stabilizer/gasoline ratio. Tighten the gas tank cap

securely.

12. On models with a chain case, drain the 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 Trans-

mission Lube (p/n 4639-364) into the filler hole -

236 ml (8 fl oz) for standard transmission or 354

ml (12 fl oz) for reverse transmission.

13. On models with a gear case, change the gear case

lubricant (see Section 8).

14. Clean and inspect the drive clutch and driven pul-

ley.

! CAUTION

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

! CAUTION

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