1998 Arctic Cat Tigershark PWC Service & Repair Manual

1 I , • I

C TABLE OF J _____ C_O __ N_T_E_N_T_S ____ _ Section 1. General Information iI 2. Engine a 3. Fuel System EI 4. Jet Pump D 5. Electrical System EJ 6. Steering and Hull tfJ 7. Troubleshooting £I 8. Aids for Maintenance a ( TABLE OF ) _____ C_O ___ NT_E_N_T_S ____ _ Section 1. General Information II 2. Engine a 3. Fuel System EI 4. Jet Pump D 5. Electrical System EI 6. Steering and Hull tfJ 7. Troubleshooting iI 8. Aids for Maintenance a

SECTION 1 - GENERAL INFORMATION ( TABLE OF J _____ C_O ___ NT_E_N_T_S ____ _ Specifications (TS 640 & TS 640 L) Specifications (TS 770) . . . . . . . Specifications (TS 770 L & TS 770 R) Specifications (TS 1000 L & TS 1000 R) Break-In Procedure ... Recommended Gasoline Recommended Oil ... Genuine Parts . . . . . . High Altitude Recommendations Preparation For Storage (640 cc) . Preparation For Storage (770 cc) . Preparation For Storage (1000 cc) Preparation After Storage . . . . . Servicing a Submerged Watercraft 1-2 1-3 1-3 1-4 1-5 1-5 1-6 1-6 1-6 1-6 1-7 1-9 . 1-10 . 1-11 1-1 SECTION 1 - GENERAL INFORMATION ( TABLE OF J , ____ C_O __ N_T_E_N __ T_S ____ _ Specifications (TS 640 & TS 640 L) Specifications (TS 770) . . . . . . . Specifications (TS 770 L & TS 770 R) Specifications (TS 1000 L & TS 1000 R) Break-In Procedure . .. Recommended Gasoline Recommended Oil ... Genuine Parts . . . . . . High Altitude Recommendations Preparation For Storage (640 cc) . Preparation For Storage (770 cc) . Preparation For Storage (1000 cc) Preparation After Storage . . . . . Servicing a Submerged Watercraft 1-2 1-3 1-3 1-4 1-5 1-5 1-6 1-6 1-6 1-6 1-7 1-9 . 1-10 . 1-11 1-1

Engine Specifications * (TS 640 & TS 640 L) Ignition Timi~ 8TDC @ 3200 RPM Sparl< Plug Gap Range 1-2 Idle RPM (in water) 1200-1500 Drive System Jet Pump Type Jumbo Jet wi1h Molded Intake Impeller T ype Stainless Steel Impeller Pitch 14° ·1S u Hub Diameter/Blade Length Large 17 5/8 in. Impeller Rolation Counterclockwise Coo~ing Threaded Operating Water Level (min) so em (2 tt) Hull Leng1h 282 em (111 in.) " 320 em (126 inY" Width 110 em (43.5 in. )" 121 em (47.5 in.) '" Height 93 em (36.5 in.)" 111 em (43.75 in.)'" Miscellany Dry Weight (approx) 184 kg (405lb)" 245 kg (540 Ib)'" Recommended Gasoline 87 Octane Regular Unleaded Engine Oil Tigersharl< 50: 1 Injec1ion Oil Break·ln Fuel Mixture 50:1 plus oil injectioo Inieclion Oil Reservoir Capaci1y 4. 71 (5.0 U.S. qt) Gas Tank Capaci1y (actual) 471 (12.5 U.S. ~F 60.61 (16 U.S. gW. '" Canryng Capaei1y (max) 168 kg (370 Ib)" 223 kg (490 Ib)''' Riders (max) 2 (operalor/passenger)" 3 (operatorl2 passengers)''' Battery 12V114Ampihoor 8i1ge Pump Fuse 3·Amp , SpecIfications subject to change Without notice. .. TS640 TS640 L Engine Specifications * (TS 640 & TS 640 L) Ignhion TimillJ BTOC @ 3200 RPM Sparl< Plug Gap Range 1-2 Drive System Width Heighl III em (43.75 in.)'" Miscellany Dry Weighl (apprax) 184 kg (405Ib)" 245 kg (540 Ib)'" Recommended Gasoline 87 Oct ane Regular Unleaded Engine Oil Tigersharl< 5O:llnjeclion Oil Break·ln Fuel Mixture 50:I plus oil injection Injeclion Oil Reservoir Gapacity 4.71 (5.0 U.S. Q1J Gas Tank Capacity (aclual) 471 (12.5 U.S. ~r 60. 61 (16 U.S. gel . ... Ca~ng Capacity (max) 168 kg (370 Ib)" 223 kg (490 Ib)''' R iders (max) 2 (operalor/passenger)" 3 (operalorl2 passengers)'" Battery 12V114Amp/hoor Bilge Pump Fuse 3-Amp .. Specifications subject to change WTthout notice . .. TS640 TS640 L

Engine Specifications * (TS 770) i. Piston SkirtlCyiinder Clearance Range i Small End Diameter Electrical System Batte 12V114 Am our Fuse 3-Am 12V/l05W CDI , Di 'tal NGKBR9EYA Recommended Oil Break·ln Fuel Mixture 1 ~1~n'~OC~liOO~~~'I~R~~~NO~i~rC~~L-__ -t~~~~~~ ________ ~ Gas Tank C ac" max Forced Waler Intake Oi ilaV\jmiter 3200 m Intake Stem Crankcase Reed Valves Exhaust Stem Cast AluminunvTuned Pi Start;n S lem Electric w/Circuit Breaker • Specifications subject to change without notice . Specifications * (TS 770 L & TS 770 R) Engine Engine Model PJno Displacement 768 cc (46.86 cu in.) Horsepower 90 Peak RPM (full-open) 6800.100 RPM Limiter Digitatl7100 ± 100 RPM Bore X Stroke 83X71mm (3. 27 X 2. 80 in.) Compression Ratio 7.1 : 1 Piston-Ring End Gap Range 0. 70-0. 90 mm (0.028-0.035 in.) Piston Skirt/Cylinder Clearance 0. 095-0.135 mm Range (0.004-0.005 in.) Piston Pin Diameter Range 19. 995-20.000 mm (0.7872-0.7874 in.) Piston-Pin Bore D iameter Range 20. 002-20.010 mm (0.7875-0.7878 in.) Connecting-Aod Small Eoo Diameter 26. 003-26.011 mm Range (1.0237-1.0241 in.) Connecting-Rod Radial ~ay Range 0. 003-0. 018 mm (0.0001-0.0007 in.) Crankshah End Play Range 0.05-0.10 mm (0.002-0.004 in.) Crankshaft Runout (max) 0. 05 mm (0. 002 in.) (total indicator reading) C~inder Trueness (max) 0.10 mm (0.004 in.) Reed Stopper Height 10.2 mm (0. 40 in.) 1-3 Specifications * (TS 770) Electrical System • Specifications subject to change without notice. Specifications * (TS 770 L & TS 770 R) Engine Engine Model PJ770 Displacement 768 cc (46.86 cu in.) Horsepower 90 Peak RPM (full-open) 6800± 100 RPMUmiter DigilaII7100 ± 100 RPM Bore X Stroke 83X71 mm (3.27 X2. 80 in.) Compression Ratio 7.1: 1 P~ton·Ring End Gap Range 0. 70-0.90 mm (0.028-{) . 035In.) Pist on SkirVCylinder Clearance 0. 095-0.135 mm Range (0.004·0.005 in.) Piston Pin Diameter Range 19.995·20. 000 mm (0. 7872-{).7874 in.) PistOfl-Pin Bore Diameter Range 20. 002·20.010 mm (0.7875-{). 7878 in.) Coonecting-Rod Small End Di ameter 26.003·26. 011 mm Range (1.0237· 1 .0241 in.) Coonecling-Rod Radial Play Range 0. 003-{).018 mm (0. OOO1-{).0007 in.) Crank'haff End Play Range 0. 05·0. 10 mm (0.002-{) . 004 in.) Crankshaft Runout (max) 0. 05 mm (0.002 in.) (total indicator reading) Cylinder Trueness (max) 0.10 mm (0.004 In.) Reed Stopper Height 10.2 mm (0.40 in .) 1-3

Carburetor Number 2 Type (Miku~) BN 3lII37 w/Iv.:c Pump Style Buttertly Choke Manual low-Speed Jet 57S' 50'" High-Speed Jet 125" 120'" High-Speed (Fixed) Jet 85 low-Speed MiXlure Screw 314" 7/8'" (turn Oul) Needle ar<! Seat 1.2 Pop-Off Pressure 29p~ Sprino 51 g ttle RPM (in water) 1300-1600 Accelerator Pump 0.4 cc (output per carburetor) Recharge Jet O.Smm Drive System Jet Pump Type Jumbo Jet wlMolded Inlel Impeller Type Stainless Sleel Impeller Pitcll 13S·19S·· 15°·19°'" Hub Diameter/8lade Length Nu.Jell5 112 in." Medium 17 3/8 in . ••• Impeller Rotation Counterclockwise Coupling Threaded 0 pe rating Water Level (min) 60 em (2 h) Hull lerJglh 320 em (126 in.)" 282 em (111 in.)'" Witlh 121 em (47.5 in.)" 110 em (43.5 in.)'" Height 111 em (43.75 in.)" 104 em (41 in.)'" Electrical System Battery 12VI14 AmJiHoor" 12V/ 19 Am(iHoor'" Bilge Pump Fuse 3-Amp Ughting Coil OUtput 12V/l05W IgrOtion Type CDI.Digilal Sparl< Plug NGK BR9EYA Ignition TIming 20' BTOC @ 3200 RPM 3.196 mm (0.126 in.) Sparl< Plug Gap Range 0.7 - 0.8 mm (0.028-0.031 in.) 1-4 Miscellany Dry Weight (approx) 254 kg (560 Ib)" 188 kg (415 Ib)'" Recommended Gasoline 91 Octane Regular Un"aded (min) Recommended 0;1 ~rshark 50:1 Injection Oil Break-In Fuel Mixture 50:1 (plus oil injectioo) Injection Oil Reservoir Capaeily 4.7 1 (5 U.S. qt) Gas Tank Capacity (actual) 60.61(16 U.S. gaL)" 471 (12.5 U .S. gal.)'" Carrying Capacity (max) 223 kg (490 Ib)" 1 68 kg (370 Ib)'" Riders (max) 3 (operatorl2 passengers)" 2 (operator/passenger)'" Cooling System Forced Water Intake Overheat Protection DigilaVUmiter (3200 rpm) Intake System Crankcase Reec Valves Exhaust System Cast A1uminumfTuned Pipe" Tuned Pipe'" Starting System Electric w/ Circuit Breaker .. Specifications subject to change Without notice . .. TS770L TS 770 R Specifications * (TS 1000 L & TS 1000 R) Engine Engine Model PJ11lOO-AC Displacement 999 cc (60.95 cu in.) Horsepower 115 Peak RPM (full-open) 6700.200 RPM Umi1er Di!lnaV7100 .100 RPM Bore x Stroke 61 x 64.7 mm (3_168 x 2.547 in.) Compression Ratio 6.8: 1 Piston-Ring Er<! Gap Range 0. 20-0.40 mm (0.008-0.016 in.) Piston Skirt/Cytinder Clearance 0.090-0.130 mm (0.0035-0.0050 in.) Range P iston Pin Diameter Range 21 .995-22.000 mm (0.8659-0.8661 in.) Piston-Pin Sofa Diameter Range 22.002-22.008 mm (0.8662-0.6684 in.) Connecting-Rod Small Er<! Diameter Aange 27.003-27.011 mm (1 . 0631-1.0634 in.) Connecting-Rod Radial Play 0.003-0.020 (0.0001-0.0008 in.) Crankshah Er<! Play Range 0.05-0.10 mm (0_002-0.004 in.) Crankshaft Runout (max) 0.05 mm (0.002 in.) (total incicalor reading) C~inder Trueness (max) 0.10 mm (0.004 in.) Reec Stopper Height 10.2 mm (0.401 in.) Carburetor Number 2 Type (Mlkunl) BN 38/37 wiN:!:; Pump Style Butterfly Choke Manual Low-Speed Jel 57. 5-- 60--' High-Speed Jel 125-- 120--' High-Speed (Fixed) Jel 85 Low-Speed Mixture Screw 314-- 7/8--' (Iurn out) Neede and Seal 12 Pop-Off Pressure 29p~ Spring 51 g Idle RPM (In waler) 1300-1600 Accelerator Pump 0.4 cc (output per carburelor) Recharge Jel O.5mm Drive System Jel Pump Type Jumbo Jet wlMolded Inlel Impeller Tvpe Siainiess Sleel Impeller Pilch 13.5~·19.5"" 15°·19 .. ••• Hub Dlameler/Blade Length Nu-Jell5 112 In. -- Medium 17 318 in.' " Impeller Rotation Counterclockwise Coopllng Threaded Operating Waler Level (min) 60cm (2 ft) Hull 1-4 Miscellany Dry Weighl (approx) 254 kg (560 Ib)-- 188 kg (415Ib)--' Recommended Gasoline 91 Oclane Regular Unleaded (min) Recommended Oil Tlgeffihark 50:1 Injection Oil Break-In Fuel Mixture 50:1 (plus oil injection) Injection Oil Reservoir Gapacity 4. 71(5 U.S. qt) Gas Tank Capacity (adual) 60. 61(16 U.S. gaI .) -- 471(12.5 U.S. gaI .)'-- Carrying Capacity (max) 223 kg (490 Ib)-- 168 kg (370 I b) -- ' Riders (max) 3 (operalorl2 passe_f19O'S)-- 2 (operalor /passenger)--' COOing Syslem Forced Water Intake Overheat Protection DigilaJlljmiler (3200 rpm) Inlake Syslem Crankcase Reed Vatves Exhaust SYSlem Cast AluminumfTuned Pipe" Tuned Pipe-- ' Starting System Electric w/Circuil Breaker .. Specifications subject to change Without notice. •• TS770L TS 770 R Specifications It (TS 1000 L & TS 1000 R) Engine Engine Model PJ1000-AC Displacemenl 999 cc (60.95 cu in.) Horsepower 115 Peak RPM (Iull-open) 6700.200 RPM Umi1er Digi1aV71oo. 100 RPM Bore x Slrol<e 81 x 64.7 mm (3_ 188 x 2. 547 in.) Compression Aatio 6.8 : 1 Piston-Ring End Gap Range 0. 20-0. 40 mm (0.008-0.016 in.) Piston Skirt/Cytinder Clearance O.~. 130 mm (0.0035-0.0050 In.) Range P iston Pin Diameter Range 21.995·22.000 mm (0.8659-0.8661 In.) Piston-Pin Bore Diameter Range 22. 002-22.008 mm (O.8662-o.8664 in.) Connecting-Rod Smail End Diameler Range 27. 003-27.011 mm (1.063",,0634 in.) Connecting·Rod Radial Pl ay 0. 003-0. 020 (0. 0001 -0. 0008 in.) Crankshaft End Play Range 0. 05-0. 10 mm (0.002-0.004 in.) Crankshaft Runout (max) 0.05 mm (0.002 in.) (total in<icalor reading) C~lnder Trueness (max) 0.10 mm (0.004 in.) Reed S10pper Heighl 10.2 mm (0.401 in.)

Carburetor Number 3 Type (Mikuni) eN 411'38 w/Arx; Pump Style Butterfly Choke Manual Low-Speed Jets 70 High-Speed Jets MAG - CENTER - PTO tOS - t35 - t20 High-Speed (Fixed) Jets MAG - CENTER - PTO tOO - 95 95 l ow-Speed Mixture Scr ews MAG -CENTER - PTO (turn out) 7/S" - 314" - 314" 314'" - 5IS'" - 5IS'" Inlet Valve t.2 Sp<ing 51 g Pop-Off Pressure 29 psi Idk! RPM (in water) 1300-1600 Accelerator Pump O.266cc (output per carburetor) Drive System 104cm(41 in.)''' Electrical System Battery 12V/14 Amj>Hour ~Ige Pump Fuse 3-Amp Power Trim IS-Amp Circuit Breaker Lighting Coil Output 12V1105W Ignition Type CDI , Digital Sparl< Plug NGK BR9EYA Ignition nming 19' BTDG @ 3200 RPM 2.202 mm (0. 086 in.) Sparl< P lug Gap Range 0.7 - O.S mm (0.02S-o.031 in.) Miscellany Dry Weight (approx) 293 kg (645lb)" 234 kg (515Ib)'" Recommended Gasoline 87 Octane Regular Unleaded Recommended Oil Togershar1< 50:1 Injection Oil Break-In Fuel Mixture 50:1 ~us oil injection Injection Oil Reservoir Capacity 4.71 (5 U.S. qt) Gas Tank Capacity (actu~) 60. 61 (16 U.S. gal .) " 471 (t2.5 U.s. gat)'" Carrying Capacity ( max) 222 kQ (490 Ib)"' 168 kg (370 Ib) '" Riders (max) 3 (operatorl2 passengers)" 2 (operator/passenger)'" Cooling System Forced Water Intake Overheat Protection D igital.timiter (3200 rpm) Intake System Crankcase Reed Valves Exhaust System Cast AluminumITuned P ipe Starting System Electric Specifications subject to change Without notice. .. TS 1000 L TS 1000 R ( Break-In procedure) " New and overha ul ed Tigershark watercraft engines require a short break-in period (1 tankful of fuel)_ During the break-in period, pre-mix the first tankful of fuel at a 50: 1 ratio in conjunction with the oil-injection system_ When using the watercraft, a maximum of 112 throttle is recommended_ However, brief full-throttle accelerations and variations in driving speed contribute to good engine break-in_ FOllowing the break-in period, the carburetor may need to be re-calibrated and/or adjusted depending on the operating altitude. Eecommended GaSOlin~ ~ The recommended gasoline to use is 87 minimum octane regular unleaded for the 640 cc and 1000 cc models and 91 minimum octane premium grade for the 770 cc models. 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. Whenever an oxygenated gasoline is being used, Arctic Cat recommends that the fixed jet mu st be increased by one jet size. 1-5 Carburetor Number 3 Type (Mikuni) BN 4008 wJ Acc Pump Style Butterfly ChokB Manual Low·Speed Jets 70 High·Speed Jets MAG . CENTER· PTO 105 . 135 ·120 High·Speed (Fixed) Jels MAG • CENTER· PTO 100 . 95 95 Low·Speed Mooure Screws MAG . CENTER· PTO (rum 001) 718" • 314" ·314" 314'" • 5/8'" . 5/8'" Inlel Valve 1.2 Sp<ing 51 g ~Pressure 29 psi Idle RPM (in waler) 1300-1600 Accelerator Pump (ou1pu1 per cartJure1or) O.266cc Drive System Jumbo Jo1 wlMolded Inlo1 Widlh Heighl 104 cm (41 in.)''' Electrical System Battery 12Vi14 Amp'Hour Bilge Pump Fuse 3-Amp Power Trim 15-Amp Circuit Breaker Ughling Coil Ou1pul 12Vil05W Ignition Type COl , Digital Spar!< Plug NGK BR9EYA Ignition nmlng 19' BTOC 0 3200 RPM 2.202 mm (0.086 in.) Spar!< Plug Gap Range 0. 7· O .B mm (0.02B·0.031 in.) Miscellany Dry Weighl (approx) 293 kg (645 Ib)" 234 kg (515Ib)'" Recommended Gasoline 87 Octane Regular Unleaded Recommended Oil ngersharl< 50:1 Injection Oil Break-In Fuel Mixture 50:1 plus 011 injection Injeclioo Oil Reservoir Capacity 4.71 (5 U.S. qI) Gas Tank Capacity (actual) 60. 61 (16 U.S. gal .) " 471 (12.5 U.S. gal . )'" Carrying Capacity ( max) 222 kg (490 Ib) " 168 kg (370 Ib)''' Riders (max) 3 (OjlBralorl2 passengers)" 2 (OjlBralorJpassenger)'" Cooling Syslem Forced Waler Inlake Overheat Protection I DigitalJUmiler (3200 rpm) Intake Syslem Crankcase Reed Valves Exhaust System Cast A1uminumfTuned Pipe Slarnng Syslem Electric Specifications subject to change Without notice. " TS 1000 L TS 1000 R ( Break-In procedure) " New and overhauled Tigershark watercraft engines require a short break-in period (1 tankful of fuel). During the break-in period, pre- mix the fIrst tankful of fuel at a 50: I ratio in conjunction with the oil-injection system. When using the watercraft, a maximum of 112 throttle is recommended. However, brief full-throttle accelerations and variations in driving speed contribute to good engine break-in. Following the break-in period, the carburetor may need to be re-calibrated and/or adjusted depending on the operating altitude. Eecommended GaSOlin~ ~ The recommended gasoline to use is 87 minimum octane regular unleaded for the 640 cc and 1000 cc models and 91 minimum octane premium grade for the 770 cc models. 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. Whenever an oxygenated gasoline is being used, Arctic Cat recommends that the fixed jet must be increased by one jet size. 1-5

If oxygenated gasoline is used and the fixed jet is not increased by one size, engine damage will result. .&. CAUTION Only Arctic Cat approved gasoline additives should be used. , ( Recommended Oil) The recommended oil to use in the oil-injection system is Tigershark 50: 1 Injection Oil. This oil is also the correct oil to use during the break-in period. This oil is specially formulated to be used either as an injection oi l or as a pre-mix oil and meets all of the lubrication requirements of the Tigershark watercraft engine. Any oil used in place of the recommended oil could cause serious engine damage. C ... __ G_e_n_U_in_e_p_a_rt_s __ .-) When replacement of parts is necessary, use only genuine Arctic Cat Tigershark parts. They are precision-made to ensure high quality and correct fit. High Altitude Recommendations Due to variations in air temperature, water temperature, barometric pressure, humidity, and elevation, carburetion changes must be made to achieve optimum performance. • NOTE: At the time of publication, the high altitude carburetion recommendations were not available. Arctic Cat Inc. will issue a Service Advisory when the recommendations become available. 1-6 Preparation For Storage (640 ee) Before storing the watercraft for any extended period (30 days or more), the hull, engine, electrical system, and jet pump must be properly serviced to prevent rust, corrosion, and possible damage caused by freezing temperatures. To properly prepare the watercraft for storage, use the following procedure. 1. Replace the oil filter. 2. Remove the drain plug at the rear of the watercraft. 3. Wash the entire watercraft with mild soap and water. Do not use abrasive cleaners or harsh detergents when cleaning. 4. Wash and degrease the inside of the watercraft using a mild degreaser. Sponge out any remaining moisture. Do not get water into the carburetor or on electrical connections. 5. Using compressed air, clear all cables of any moisture. 6. Lubricate the cable ball joints, handlebar shaft, and bushings with Arctic Cat Silicone Spray (pin 0636-594). 7. Fill the gas tank; then add Tigershark Fuel Stabilizer (pin 0678-032) to the tank following the directions on the container for the stabilizerlgasoline ratio. 8. Flush the cooling system allowing the engine to idle for a minimum of 2-3 minutes (5 minutes if used in salt water). 9. With the water turned off and the fuel valve in the OFF position, start the engine and run at low RPM for 30 seconds while spraying Tigershark Engine Fogger/Preserver (pin 0678-023) into the carburetor intakes until the exhaust starts to smoke heavily or the engine stalls; then stop the engine. .&. CAUTION If oxygenated gasoline is used and the fixed jet is not increased by one size, engine damage will result. .&. CAUTION Only Arctic Cat approved gasoline additives should be used .. C Recommended Oil) The recommended oil to use in the oil-injection system is Tigershark 50: I Injection Oil. This oil is also the correct oil to use during the break-in period. This oil is specially formulated to be used either a. an injection oil or as a pre-mix oil and meets all of the lubrication requirements of Lbe Tigershark watercraft engine. .&. CAUTION Any oil used in place of the recommended oil could cause serious engine damage. C ... __ G_e_"_U_in_e_p_a_rt_s __ ..... ) When replacement of parts is necessary. u e only genuine Arctic Cat Tigershark parts. They are precision-made to ensure high quality and correct fit. High Altitude Recommendations Due to variations in air temperature, water temperature, barometric pressure , humidity, and elevation, carburetion cbanges must be made to ac hi eve optimum performance. • NOTE: At the time of publication, the high altitude carburetion recommendations were not available. Arctic Cat Inc. will issue a Service Advisory when the recommendations become available. 1-6 Preparation For Storage (640 ee) ~--------------------------------~ . Before storing the watercraft for any extended period (30 days or more), the hull, engine, electrical system, and jet pump must be properly serviced to prevent rust, corrosion, and possible damage caused by freezing temperatures. To properly prepare the watercraft for storage, use the following procedure. I. Replace the oil filter. 2. Remove the drain plug at the rear of the watercraft. 3. Wash the entire watercraft with mild soap and water. .&. CAUTION Do not use abrasive cleaners or harsh detergents when cleaning . 4. Wash and degrease the inside of Lbe watercraft using a mild degreaser. Sponge out any remaining moisture. .&. CAUTION Do not get water into the carburetor or on electrical connections. 5. Using compressed air, clear all cables of any moisture. 6. Lubricate the cable ball joints, handlebar shaft, and bushings with Arctic Cat Silicone Spray (pin 0636-594). 7. Fill the gas tank; then add Tigershark Fuel Stabilizer (pin 0678-032) to the tank following Lbe directions on the container for the stabilizerlgasoline ratio. 8. Flush Lbe cooling system allowing the engine to idle for a minimum of 2-3 minutes (5 minutes if used in salt water). 9. With the water turned off and the fuel valve in the OFF position, star1 the engine and run at low RPM for 30 seconds while spraying Tigershark Engine Fogger/Preserver (pin 0678-023) into tbe carburetor intakes until the exhaust Star1S to smoke heavily or the engine stalls; then stop the engine.

10. Remove the spark plugs and pour 29.5 ml (I fl oz) of SAE #30 petroleum-based oi l into each spark plug hole. Apply a sma ll amount of dielectric grease to the threads of each spark plug; then install the spark plugs. Connect a seco nd set of spark plugs to the spark plug leads and ground those spark plugs on the cylinder head; then crank the engine over several times to di stri bute the oil in the cy linders. Never crank the engine over without spark plugs connected to the spark plug leads and grounded on the engine. Damage to the coils and/or COl unit may result. II. Disconnect the seco nd set of spark plugs; then connect the spark plug leads to the existing spark plugs. 12. Disconnect the negative (black) le ad from the battery; then disconnect the positive (red) lead and remove the battery. Fill the battery to the full line with distilled water. Trickle-charge the battery at 1.9 amps for 15-20 hours. Store the battery in a cool, dry location. Charge the battery once a month to prolong its life. & WARNING Always wear safety glasses when connecting or disconnecting a battery charger. Do not smoke or allow open flames near a battery. If battery acid contacts the skin, rinse thoroughly with water; then cover the affected area with moistened sodium bicarbonate. If battery acid contacts the eyes, flush first with water; then flush with a 1 % solution of freshly prepared sodium bicarbonate. Immediately call a physician. 13. Coat the carburetor shafts and the idle stop (RPM) screw with a high quality salt-water-proof grease. 14. Spray the engine exterior with Tigershark Solution 2 (pIn 0678-271). 15. Remove the thermostat cap; then pour 236 ml (8 fl oz) of biodegradable (recreational vehicle type) antifreeze into the thermostat housing. Seal the thermostat housing with silicone; then install the gasket and the thermostat cap . • NOTE: The 1998 models are not equipped with a thermostat. 16. Replace the fuel fi l ter. Drain the seat base of any residual water. Place a board between the seat and hull to allow adequate ventilation to the engine compartment. 17. Clean the vinyl with Arctic Cat Vinyl Protectant (pIn 0638-313) . 1 8. Plug the exhaust outlet with steel wool. 19. Wax the watercraft usi ng Tigershark Polish & Wax (pIn 0678-025). 20. Cover with a watercraft cover or tarpaulin . Store the watercraft in a we ll -ventilated, indoor location. Preparation For Storage (770 ee) .. Before storing th e watercraft for any extended period (30 days or more), the hull, engine, electrical system, and jet pump must be properly serviced to prevent rust, corrosion, and possible damage caused by freezing temperatures. To properly prepare the watercraft for stora ge, use the following procedure. I. Replace the oil filter. 2. Remove the drain plug at the rear of the watercraft. 3. Wash the entire watercraft with mild soap and water. Do not use abrasive cleaners or harsh detergents when cleaning. 4. Wash and degrease th e inside of the watercraft using a mild degreaser. Sponge out any remaining moisture. Do not get water into the carburetor or on electrical connections. 5. Using compressed air, clear a ll cables of any moisture. 6. Lubricate th e cable ball joints, handlebar shaft, and bushings with Arctic Cat Silicone Spray (pIn 0636-594). 1-7 10. Remove the spark plugs and pour 29.5 ml (l fl oz) of SAE #30 petroleum-based oi l into each spark plug hole. Apply a smal l amount of dielectric grease to the threads of each spark plug; then install the spark plu gs. Connect a seco nd set of spark plugs to the spark plug leads and ground those spark plugs on the cylinder head; then crank th e engine over several times to di tribute the oil in th e cy linders. fuCAUTION Never crank the engine over without spark plugs connected to the spark plug leads and grounded on the engine . Damage to the coils and/or COl unit may result. 11. Disconnect the seco nd set of spark plugs; then connect the spark plug leads to the existing spark plugs. 1 2. Disconnect the negative (hlack) lead from the battery ; then di sconnect the positive (red) lead and remove the battery. Fill the battery to the fu ll line with distilled water. Trickle-charge the battery at 1.9 amps for 15-20 hours. Store the battery in a cool, dry location. Charge the battery once a month to prolong it s life. & WARNING Always wear safety glasses when connecting or disconnecting a battery charger . Do not smoke or allow open flames near a battery. If battery acid contacts the skIn, rinse thoroughly with water; then cover the affected area with moistened sodium bicarbonate. If battery acid contacts the eyes , flush first with water; then flush with a 1 % solution of freshly prepared sodium bicarbonate. Immediately call a physician. 13. Coat the carburetor shafts and the idle stop (RPM) screw with a high quality salt-water-proof grease. 14 . Spray the engine exterior with Tigershark Solution 2 (pIn 0678-27 1). l5. Remove the thermostat cap; then pour 236 mI (8 fl oz) of biodegradable (recreational ve hicle type) antifreeze into the thermostat housing. Seal the thermostat housing with silicone; then install the gasket and the thermostat cap . • NOTE: The 1998 models are not equipped with a thermostat. 16. Replace the fuel filter. Drain the seat base of any residual water. Place a board between th e seat and hull to allow adequate ventilation to the engine compartment. 17. Clean the vinyl with Arctic Cat Vinyl Protectant (pIn 0638-313). 1 8. Plug the exhaust outl et wi th steel wool. 1 9. Wax the watercraft us in g Tigershark Poli sh & Wax (pIn 0678-025). 20. Cover with a watercraft cover or tarpaulin . Store the watercraft in a well-ventilated, indoor loc atio n. Preparation For Storage (770 ee) ~--------------------------~ ~ Before storing th e watercraft for any extended period (30 days or more), the hull, engine, electrical system, and jet pump must be properly serviced to prevent ru st, corrosion, and poss ibl e damage caused by freezing temperatures. To properly prepare the watercraft for storage, use the following procedure. \. Replace the oi I filter. 2. Remove the drain plug at the rear of the watercraft. 3. Wash the entire watercraft with mild soap and water. ~CAUTION Do not use abrasive cleaners or harsh detergents when cleaning. 4. Was h and degrease the ins ide of the watercraft usi ng a mild degreaser. Sponge out any remaining moisture. ~CAUTION Do not get water into the carburetor or on electrical connections. 5. Using compressed air, clear all ca hl es of any moi sture. 6. Lubricate th e cable ball joints, handlebar shaft, and bushings with Arctic Cat Silicone Spray (pIn 0636-594). 1-7

7. Partially fill the gas tank; then add Tigershark Fuel Stabilizer (pin 0678-032) to the tank following the directions on the container for the stabilizerlgasoline ratio. Top off the tank with gasoline. 8. Flush the cooling system allowing the engine to idle for a minimum of 2-3 minutes (5 minutes if used in salt water). 9. With the water turned off and the fuel valve in the OFF position, start the engine and run at low RPM for 30 seconds while spraying Tigershark Eng ine FoggerlPreserver (pin 0678-023) into the carburetor intake(s) until the exhaust starts to smoke heavily or the engine stalls; then stop the engine. 881920 10. Remove the spark plugs and pour 29.5 ml (1 tl oz) of SAE #30 petroleum-based oil into each spark plug hole. Apply a small amount of dielectric grease to the threads of each spark plug; then install the spark plugs. Connect a second set of spark plugs to the spark plug leads and ground those spark plugs on the cylinder head; then crank the engine over several times to distribute the oil in the cylinders. Never crank the engine over without spark plugs connected to the spark plug leads and grounded on the engine. Damage to the coils and/or COl unit may result. 11. Disconnect the second set of spark plugs; then connect the spark plug leads to the existing spark plugs. 12. Disconnect the negative (black) lead from the battery; then disconnect the positive (red) lead and remove the battery. Fill the battery to the full line with distilled water. Trickle-charge the battery at 1.9 amps for 15-20 hours. Store the battery in a cool, dry location. Charge the battery once a month to prolong its life. 1-8 6 WARNING Always wear safety glasses when connecting or disconnecting a battery charger. Do not smoke or allow open flames near a battery . If battery acid contacts the skin, rinse thoroughly with water; then cover the affected area with moistened sodium bicarbonate. If battery acid contacts the eyes, flush first with water; then flush with a 1 % solution of freshly prepared sodium bicarbonate. Immediately call a physician . 13. Coat the carburetor shafts and the idle stop (RPM) screw(s) with a high quality salt-water-proof grease. 14. Remove the cylinder plug and open the manifold drain valve allowing any water to drain out; then close the drain valve and tighten the cylinder plug. Fig . '·2 Exhaust Manifold---' Drain Valve Expansion Chamber Engine Cytinder Plug 0733-999 15. Remove the rear cylinder head inlet hose and using an auxiliary hose and funnel, pour biodegradable antifreeze in to protect the cylinder and pipe. Fig. 1-3 Auxiliary Hose with Funnel 0733-010 16. Spray the engine exterior with Tigershark Solution 2 (pin 0678-271). 17. Remove the water filter cover and pour 60 ml (2 tl oz) of biodegradable (recreational vehicle type) antifreeze into the filter housing; then install the cover. 7. Partially fill the gas tank; then add Tigershark Fuel Stabilizer (pIn 0678-032) to the tank following the directions on the container for the stabilizerlgasoline ratio. Top off the tank with gasoline. 8. Flush the cooling system allowing the engine to idle for a minimum of 2-3 minutes (5 minutes if used in salt water). 9. With the water turned off and the fuel valve in the OFF position, start the engine and run at low RPM for 30 econds while spraying Tigershark Engine FoggerlPreserver (pIn 0678-023) into the carburetor intake(s) until the exhaust starts to smoke heavily or the engine stalls; then stop the engine. Fig. 1·1 881920 10. Remove the spark plugs and pour 29.5 mI (I f1 oz) of SAE #30 petroleum-based oil into each spark plug hole. Apply a small amount of dielectric grease to the threads of each spark plug; then install the spark plugs. Connect a second set of spark plugs to the spark plug leads and ground those spark plugs on the cylinder head; then crank the engine over several times to distribute the oil in the cylinders . .&. CAUTION Never crank the engine over without spark plugs connected to the spark plug leads and grounded on the engine. Damage to the coils and/or COl unit may result. II. Disconnect the second set of spark plugs: then connect the spark plug leads to the existing spark plugs. 12. Disconnect the negative (black) lead from the battery; then di sconnect the positive (red) lead and remove the battery. Fill the battery to the full line with distilled water. Trickle-charge the battery at 1.9 amps for 15-20 hours. Store the battery in a cool, dry location. Charge the battery once a month to prolong its life. 1-8 6 WARNING Always wear safety glasses when connecting or disconnecting a battery charger. Do not smoke or allow open flames near a battery. If battery acid contacts the skin, rinse thoroughly with water; then cover the affected area with moistened sodium bicarbonate. If battery acid contacts the eyes, flush first with water; then flush with a 1 % solution of freshly prepared sodium bicarbonate. Immediately call a physician. 13. Coat the carburetor shafts and the idle stop (RPM) screw(s) with a high quality salt-water-proof grease. 14. Remove the cylinder plug and open the manifold drain valve allowing any water to drain out; then close the drain valve and tighten the cylinder plug. -"--~a Expansi on Chamber Exhaust Manifold --...I Dr ai n Valve Engine Cylinder Plug 0733-999 15. Remove the rear cylinder head inlet hose and using an auxiliary hose and funnel, pour biodegradable antifreeze in to protect the cylinder and pipe. Fig. 1-3 Aux iliary Ho se with Funnel 0733-010 16. Spray the engine exterior with Tigershark Solution 2 (pIn 0678-271). 17. Remove the water filter cover and pour 60 mI (2 f1 oz) of biodegradable (recreational vehicle type) antifreeze into the filter housing; then install the cover.

1998 Arctic Cat Tigershark PWC Service & Repair Manual

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