Snowmobile Arctic Cat 2-Stroke (2007 year). Manual - part 66

4-38

INSTALLING

1. In turn on each front union bolt, install a gasket,

check valve, and gasket; then install on the oil-

injection pump.

2. Place the gasket and oil-injection pump near the

engine; then install the lower union bolt through a

gasket, check valve, and gasket.

3. Position the oil-injection pump on the engine mak-

ing sure the oil-injection pump gear is correctly

aligned with the oil-injection pump drive gear.

4. Secure the pump with two screws, lock washers (if

applicable), and washers (if applicable). Tighten

screws to 1.1 kg-m (8 ft-lb).

5. Connect the two oil-delivery hoses to the adapter

plates. Secure with clamps.

6. Connect the oil-injection cable/control rod to the

pump and secure.

7. Connect the oil-supply hose to the oil-injection

pump inlet fitting. Secure with the clamp.

8. Bleed the oil-injection system (see Bleeding Oil-

Injection System in this sub-section).

9. Check the oil-injection system synchronization

(see Synchronizing Oil-Injection Pump in this sub-

section). Tighten the jam nuts securely.

„NOTE: On EFI models to install the exhaust sys-
tem and the air silencer, see Section 2.

10. Install the carburetors/throttle bodies.

11. On carbureted models, turn the shut-off valve to

the OPEN position.

Synchronizing 

Oil-Injection Pump

„NOTE: On certain models, the oil pump cable
adjuster is located at the juncture of the throttle
cable.

728-713A

742-331A

738-338C

! CAUTION

Use a 100:1 fuel mixture for the following procedure. 

370/570 cc

500 cc

600 cc

4

4-39

742-326A

INSPECTING/ADJUSTING/
SYNCHRONIZING

1. With the engine off on models with a cable oper-

ated oil pump, disconnect the throttle cable from

the throttle lever.

2. Pull the throttle cable to the FULL-OPEN posi-

tion; then using a suitable clamping device, secure

the cable in this position.

„NOTE: On models with a control rod operated
oil pump, rotate the control arm until it contacts
the stop screw.

3. Check to be sure the mark on the control arm is

aligned with alignment mark on the oil pump boss.

4. If the marks are not aligned, adjust synchroniza-

tion by loosening the jam nut(s) on the adjuster.

Rotate the jam nuts/adjuster nut until proper align-

ment is attained. Tighten jam nut(s).

5. Return the control arm/throttle cable to the

CLOSED position.

„NOTE: On models with a cable operated oil
pump, connect the throttle cable to the throttle
lever.

„NOTE: When the cable/linkage adjusting nut is
adjusted correctly, the throttle lever will move
approximately 3.2 mm (1/8 in.) before the oil-injec-
tion pump control arm begins to move. This will
ensure the throttle/ignition monitor switch will
function properly and will prevent spark plug foul-
ing at low RPM operation.

6. Inspect all oil hoses that they are full of oil. If they

are not full of oil or air bubbles are detected,

bleeding is necessary.

Bleeding Oil-Injection 

System 

(370/500/570 cc)

1. Fill the oil reservoir with recommended injection

oil.

2. On remaining models, place an absorbent towel

below the oil bleed plug; then remove the bleed

plug 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 plug.

„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.

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 con-

trol 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.

! CAUTION

Care must be taken when securing the cable not to
kink or damage the cable.

800/1000 cc

! CAUTION

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

! CAUTION

On the F5 model, do not remove the oil bleed plug for
this procedure.

! WARNING

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

4-40

Bleeding Oil-Injection 

System 

(600/800/1000 cc)

„NOTE: The oil reservoir must be full for this
procedure and the oil bleed plug should not be
removed.

1. With the ignition switch and the emergency stop

switch in the OFF position and the brake lever

lock engaged, secure the throttle lever to the

handlebar in the fully open position.

2. Using a needle-nose pliers, apply pressure to the

oil pump control rod connector until it snaps free

of the throttle body pulley. Take care to maintain

the control rod in the fully open position.

3. Use a length of wire to secure the control rod in

the fully open position away from the throttle

linkage.

4. Remove the restraint from the throttle lever at the

handlebar and allow it to go to the fully closed

(idle) position.

5. Start the engine and allow it to idle for five min-

utes to ensure the pump is properly bled.

6. Shut the engine off and allow it to cool; then

remove the wire from the control rod and using a

suitable pliers, install the control rod connector

onto the throttle body pulley.

Testing

Oil-Injection Pump

„NOTE: These tests must be made with the
snowmobile and the oil at a “room” temperature of
20°-30° C (68°-86° F).

1. Disconnect the oil pump cable/control rod from

the control arm on the pump.

2. Clamp off the oil-supply hose between the oil res-

ervoir and oil pump; then remove the supply hose

from the pump.

3. 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 Synthetic

APV 2-Cycle Oil.

„NOTE: On all engines, use Arctic Cat Synthetic
APV 2-Cycle Oil (p/n 2639-512). Use of any other oil
will cause inaccurate oil consumption readings.

„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.

4. Fill the usage tool with recommended oil to the 0 line.

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

attach the tool to the oil-supply hose and remove

the bulb.

6. 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.

„NOTE: On Crossfire/M-Series to access the oil
pump, tip the snowmobile on its left side; then
using a torx-bit, remove the screws securing the
center belly pan (skid plate) to the front end.

7. Remove the oil bleed plug from the oil pump; then

allow the oil to drain from the pump until test oil is

visible. Install the bleed plug; then refill the usage

tool to the 0 line.

„NOTE: On the 600/800/1000 cc, the control rod
must be secured in the FULL-CLOSED (Idle) posi-
tion. It is advisable to secure the rod to a conve-
nient engine component away from any moving
parts. Securing the rod prevents misalignment of
the control arm due to engine/chassis movement.

! CAUTION

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

! CAUTION

Assure that the throttle linkage has returned to the
fully closed (idle) position and has not remained in a
partial open position.

! CAUTION

When installing the control rod connector, care must
be taken to ensure the socket and ball are properly
aligned and even pressure is applied or damage to
the connector could occur.

! WARNING

Always wear safety glasses when performing this
test.

4

4-41

8. With the control arm secured in the FULL-

CLOSED (Idle) position, start the engine and run

the engine at recommended RPM for 3 minutes.

Compare the amount of oil used against the speci-

fications on the chart.

9. With the control arm secured in the FULL-OPEN

position (line-to-line), run the engine at recom-

mended RPM for 2 minutes. Compare the amount

of oil used against the specifications on the chart.

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

specifications, see Testing Oil-Injection Check

Valves in this sub-section.

11. 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.

12. Bleed the oil-injection system (see appropriate

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

„NOTE: After testing the oil pump, it is critical
that the oil pump is correctly synchronized with
the carburetor(s)/throttle bodies (see Synchroniz-
ing Oil-Injection Pump on page 38 in this section).

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-injec-

tion pump.

Fuel Pump

(Carbureted Models)

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 speci-

fied pressures must be indicated.

! WARNING

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

Oil Consumption

MODEL

RPM

FULL-CLOSED 

(Idle)

3 Minutes

FULL-OPEN

2 Minutes

370 cc

2000

0.9-1.9 cc

4.9-6.6 cc

500 cc 

1833

1.0-2.5 cc

7.4-10.3 cc

570 cc

2000

1.4-2.2 cc

6.9-9.4 cc

600 cc 

1833

1.3-3.2 cc

10.9-15.2 cc

800 cc 

1833

2.1-4.5 cc

12.7-17.6 cc

1000 cc

1833

2.2-4.9 cc

15.8-22.0 cc

KEY

1. Gasket

2. Check Valve

3. Gasket

4. Union