1994 Arctic Cat Tigershark PWC Watercraft Factory Service Manual Barracuda Daytona Monte Carlo 640 Montego 650 Montego Deluxe 65

1995 Carbure tor Recalibration Specifications Monte Cark> Carbur etor cahbration changos must be m ade In conjunction wi th sWitching the eXlstlng flame ar restor for the Montego flame arres t or using the following compon ents. Quanllty Part Number Item 0673·044 Flame arrestor base 0673·045 Flame arrestor cover 0673'()46 SerM" ~ 0624'()53 Cap screw 0624·036 lock washer 0624·046 Cap screw 0624·036 lock washe r The parts listed above must be instalied with the flame arrestor Intake opening positioned toward the rear of the boat . • NOTE : High-s peed and low-speed screw calibrations may dllfer slightly from area to area as water temperature will effect then .ettlng •. These calibrations will not work on the Monte Carlo models unIe •• the above mentioned flame arrestor Is Installed. 19915 Mon'tego and M ontego Del uxe Item SpeCification Low Speed Screw 1 118 Tums Spnng tIS Needle 1.5 Low Speed Jet 120 I hgh Speed Jet 115 High Speed Screw 1 Tum , 995 Mont.. Carlo w it h W ater to M uffler lIem Specification Low Speed Screw 1 Tum Spring 95 Needle 1.5 -- Low Speed Jet tIS High Speed Jet 14' 5 High Speed Screw 3/4 Tum - - , 996 Daytona Needle Low Speed Jet High Speed Jel Speed Screws 95 2.0 67 .5 100 7/8 Tum , 995 Monte Carlo vvlthout Water to M uffler Item SpeCification Low Speed Screws 1 1/4 Turns Spnng 95 Needle 2.0 Low Speed Jel lt7.5 High Speed Jet 140.0 High Speed Screw 314 Tum

SERVICE WATS LINE INSTRUCTIONS \+, I~.(" I"" ,10-_ 1'1 ~"'" '. , ... _. MESSAGE t1 INOTE • ".IUII'*" ....... ,.-m ...., ... 10 ""SSAGf Il) • .., ... _ MUm'*' _ .,v.1d .,. ....... 'IrI1 be I' ,""'. IN -.Iff, """ 11)'<1" I ".1ICOI'Id 1tv.1d f\IJI'I'tI)ef II '**""<I. ItItI ~ Vilt! be I'I .... r ... _1 ~'tI,1I! "'r ", 'IlJj,"f~'A ..... ,.,or;~~ .,lUII.j"Jyw '''''''l_ MESSAGE 11 h, .... ........ ......... ,..-- OiaII .... _, , .. ,.'_~~I) """~"t"r"""" ti'l.u","""" ly.J"., .. ",.oWl ,I", .... ..t...u,,·"", o.aJ2. 11_ ............ _~""'1IlI ,"'('''''''''- DI.13 It' ................... .-r_. ' ..... , I, .,M \,W,&.w •• ..,.r" ... Die! 4 .,... ••• , ~k~ DUI5. tt, .... ......... .JI_..,.. .,.," , .. '/1"""" ",n/l·rolI,,. ,. .-..., v>Nlt_"_!",, IF I tS DlALID ' ........ IAI, '';'' I We.tern Central Re Eaatern Re ~ Ward Brink SeMot ~ttve s.n.:. Repr ... nl/dllltl A, .. , AI .. 3 ...,..4 ~ Harry Kramer s.rv1Cll A~11'ItI s.Mce AI9fIMl1IiIlWl ....... 5 A.-. Rick Kelilf CUIiICItMI' se-. £MIefo'I R

Bulletin No . 95-01W Model: 1995 Monlogoll 1995 Mont.got' DeluXG I lieS Mont. C&r1o'" SERVICE BULLETIN Subject : Date : Bilge Pump Fu se Holder February 8, 1995 CONDITION: Severa l wa tercraft were manufac tured without a fu se in the ci rcuit LO protect the bilge pump. The following Ibt shows the models affected and the serial nllmber range thallhcsc models fall within. 1995 Montego, Serial No. 0922 through 5076 1995 Montego Deluxe, Serial No. 0363 through 1421 1995 Monte Carlo, Serial No. 4054 through 5075 SOLUTION: When selling up one of the above models within the I)crial number nangc, disconnect the brown bilge pump wire from the main harness orange/green wire, Attoch lhe red fu~e holder wire to the hrown wire from the bilge pump and the opposite end to lhe orange/green wire. Apply dielectric grcusc to ouch connection. PARTS: Order one fuse holder (pin 0630·082) for each model you have In the "bove ... erial number runge. WA RRA TV: A group warranty clajm contai ning up to 10 serial numbers will be accepted. Write 95-0 1 W in the f ai lu re code section of the warranty claim form . A labor allowance of 0.1 hours will be paid for cilch waterc raft within the serial number range thaI is upd ated. ARCTCO SALES. INC PO BOX 810 600 SOUTH BROOKS "veNUE THIEF RIVEA FALLS, MN 5670' TELEPHONE (218) 681-11558 . ,111 Trlll,mllk. Dr AtC1ce , Inc " Thill Rlvlr FIlii , MN 567111

March 10. 1995 Dear Service Manager. hlcloscd )'ou wIll rind a Gusset Kit, wluch must be v"elded on the four place Wntercrnft ltailer hItch (as shown 111 the kit inSlnlClion sheet) to reinforce the hitch aren. It IS \iel) Important that the gussets arc welded on the hitch as sito,",," to prc\'Cnl poSSible hitch damage in the event of jock Mtifing while to\.\-iog the trailer Aficr completing the gusset installation, please complete a warranty c1aull for each tmiler repaired. Claim 0.5 hours for the repair, and U~ failure code PI) in the failure code s<xtion of the claim Bost Regards. TilE ARCTCO SERVICE DEPARTMENT AAClCO SALES INC PO BOX .10, lot SOUTH sROOttS AVE~E THIEf Rt\lfR FAllS. ~N 5111)\ TELEPHONE (211)ea1..(1!1Y fAA 1211)1111·)162 . .. Tra4erMrh 01 AttkO. lilt., fNlllIl¥. F,,- MH U'OI

ServIce News VOL. 2. NO. 1 English Edition April 21 . 1995 In This Issue: PAGE 14 o.fN(IOd Rood Valva Symptom. • S".,k-Plug Fouling • MI.ce,t.neou. Part Hum"'" PAGE 15 Procedure Afte, Compl.t. EngIne Rap"cament 1993 Hanger a..rlng Repillcement Proper WS' nlnty Proc«lures t 994 Models Sut Adjustment 1995 AIr Core Tachometer. DI.eharpa FINIng Plug Optfonal Shur·(J/' Valva (pin 0744·013) Optional Fire Extlngulshe, PAGE 16 Uprlghlfng Capsfzad Watereran (11/95 ",_,.) Aretca Gel Coat 1995 Mont. Carlo' lII Slotagll c.nJ.ht, 900 Jet Pump 011 1995 Dayton" or 900 Gaugea Loose Trim Inu'" Seat Base Seals HBleh S. al Kit (pin 0637· 106) Sec uring 1995 Daytona &- 900 Mod.ls to A Tra iler 1994 "'_, RIdIng C.poem •• 1995 Daytona Carburetor Speclflcallons (S.a Level) Engine Fallur" Troubleshooting PAGE 17 1995 Daytona Carburetor Fuel Screws Exhaust Component Ollerhutlng Overha.t Sensor DAMAGED REED VALVE SYMPTOMS We 1I.1\'C hod ~veral calls wondenng what types of !!.ymptom .. a dUl11ltged reed valve might cause. A damaged rced va lve may cause ha rd stalling. rough Idhng. mnning on one cylinder. or forcing of the fuclJair mixture hotcl. lip through Ihc carburetor ven luri Cit her while the watercraft is idling or when anemptlng to sian 14 SPARK·PLUG FOULING Spark· plug fouling IS more likely 10 occur when operating the watcrcmfl In an area where there are no wake zones. When continuous spark·plug (ou\lng IS encountered, perform the follOWing tests: Check thai the oil·IRJcclian pump alignment mark .. arc properly ahgncd. 2. The idle RPM screw should be '1.e1 between 1500 nnd 1800 RPM (with the watercraft In the water). 3. Check that the low· and high-speed fucl screws are adjusted properly for your area MISCELLANEOUS PART NUMBERS • R,vllut InstallatIon Tool (pill ()6.14·232) Used for In~Ullhn~ sponsons on 1993 mooel walercr:lofl • Ri"nut (pIn 0623 ·557) Used In secure sponsons on 1995 model walercmll • Sm,,· Type CIt/nip (pi" JOOJ·2181 Used 10 secure the nll -lnJect' On Imc to the nlpplc on the Intake mBl11fold • Hatch Slums (pit! 0673-401) Used nn 1i)94-9S model h:uch CQ\-er Imc.h • HlIIgt SllIms (pi" (673402) Used on 1994·95 model hatch cover hmge • 1905 Ti1:trshark Wart'rrraji S~rvJct! Tminllll{ Manllal (2255·2~7) • Tif' -Dml-II Strap Kit (067R· 266) Sc=(ure.'1 cllhc=r a 1995 Daytona or 900 to a Leland Irtliler • Trmlu Wltf ch Kit (0696 ·175) Se~urc.!l all models Il) Lclamlltllliel • N~I\ 1995 WarralllV Failurt Codt Willi Cht/rl (2255 · 201 I

PROCEDURE AFTER COMPLETE ENGINE REPLACEMENT When rcplilcmg a ,omp lclc cogllle, he .. ure:: 10 U'4' the nn!!IOJI engine map: nclo hou.., l0& In ortler 10 ~ccp the ~na l number of the cngme correct wit h the cu~tomcr'''1 rcg l~l rallon ca rd tr lh e unpil1 .!1 engine mag neto hou~ lng cannot he. uo..ed, ca ll MO ni ca CIt c:(1. 81 1 to re- reg,\ten he n c'W en gine.' ..,erlal number wit h the hull 'icna l n umbe r 1993 HANGER BEARING REPLACEMENT When rep l ac ing u hange r beJJ1ng on a I99J Tigcf"'hll r~. al wiJY .. pee n IhedrJ\'C',ha ft at the pC lI nt the han ger beanng ", III he \ <x:a led .t nd J Ppl)' LOCTI TE to th e areJ be fore In ... tai llng the h. Ul ger bearmg 11m will preven t the dn ve .. hah frum "' pIlUlln ~ tn 'ilde the hanger beanng ' ..... llI ch ",ould make the: beanng Ikt h ~C.l bu.;h mg) • NO TE : The t hi ck p orti on of th e ha ng er beari ng Is th e front si de. PROPER WARRANTY PROCEDURES Plt-a\c reme mber to U~e th e new fa ilure code~ from ei ther the I W~ Wu ll Chart (pin 215:'i-2011 or lrom pa~c 2-26 01 the 1 ',)119 .lOd Procedure Manual when rl lll ll~ (lut a ll warrant)' c llum'" or the clai m md} Ix rCJcch:d The potrtt h. tI c~tll \ed the progre!l!i. I\'e damage IIl U\! hc h\ lc: d on the fm t li ne of the WBrra nty cla im In the C:\lenlt hat th e part that cau\ed the damage wU!>Il' t rc pl oced ffor cltilln ple, d loo-.e fu!> tenc: r), ... u ll h ~t the part numbe r of the part thtlt cauM:d the progrc\!II\oe: d'llnage IInrl lll chc:tl e .1qu unllt y of 0 AL \VA YS aU.&i.: h it rrd wammt y part \ tag and l'lC nd the pam with the c1u un unl es!'. ,", truct ed to do O! he rwl ltt by cltlle r ,I bull ellll/nelh,lelt er or a ~rvICC: rtpro!\Cntatt vc • NOTE: Remember that authorization numbers given out by your service ~ .... good for 30 days ONLY. Wtu rant y pa rt 'i mU'i t be ret urned to U\ wll hm 10 DAYS or warrn nt y will nol he gi\ en By returning lhem within 10 day!". )'00 Wi ll he: paid f .. !"te r and we Wi ll be ab le to ImalYle a poten ti A l part\ fat lu r!! by mode l and we\-c nt any future problclm If you re.CCIVC 11 11 ) watercraft With a damaged hull (conctu led cmte da mage) fr om Arelco. you mu!,, 1 fir~t cu ll your \c rvi cc re prcIOc nlall ve and then se nd In II phologrop h nnd on esti mate along wllh a leuer u\ kmg your ", rvlcc rc prcc..cn lnll\'e to ca ll you (pl ease Inc lude phone numher. dealer number. and the \e ri al numhc r of fh e wlIlercrart l 1994 MODELS SEAT ADJUSTMENT If expenc nc m~ a l oo'iC ~at wh en hoardmg a 1 994 w Ufcrc ntft . re pl ace !he ~a t bolt wilh n 0011 and wa~hc r Ihc ldmcnt ""''''t:<mb ly (pin 0773·28 1) avail able th ro ugh your nonnal pa rt , ch .... nnel 1995 AIR CORE TACHOMETERS Th e three ..... lre' for the 1 995 tuchomete r <.er"\! ttl( fo ll ow Illg pUrpo"C\ 1- Black = ground l-Vlolet = 12-volt power source 1- Yellow = Pulse (tachometer signal) .NOTE : A ir Cor e t ac hom eters do not completely return to zero when the watercraft Is not running; however, the tachometer will reset the next ti me the engi ne '8 run. F~ I 15 DISCHARGE FmlNG PLUG You may ha\'e nO ll ced on all 1 995 Da yton.n nd 2nd -ru n Moni C Carl o m ode ls (lie nal number ARJ 4{)54A4 95 and aOO .. 'e) <t di sc hnrge finlll g plu g ( with a 3/ 16 in . hole tn th c ce nt er) i nqall ed In the port '\Ide wuter oUll el d l~harge fill ln!!. Thi s plug cau~s most of the dl schti rge wa ler to CX lt th rough Ihe mufOer, whi ch help' reduce cx huufi t nOl ~, Th .... pl ug muM be un '\Crowed when bad -nushtngu 199~ D aylona or Mont e Carl o III the above senul numbe r ran i;c. Operating the wUlercraft Wllh Ol Il Ihe pli lf tn -.; tnll ed 1\ not reco mmend ed bec au .... c 11 W ill all tr camurelor calibration OPTIONAL SHUT· OFF VALVE (pin 0744-1>13) An opt io nal , hu l-o ff valve IS IlvUlhlbl c 10 customer, for bac k- nu shln g a 1 995 Daytona or II 1 995 2nd-run Montc C. rl o (Sc n. 1• ARJ 2:1461.A95 and .OOve). W,th"" , Ihe va lve, eU 'itom ers with a 1 995 Dayt ona or2 nd -run Moni c Ca rl o mu ~t be lnfonn ed to pinch off the water hne to th e mu rner be fore bac k- Ou 'ih mg Ih e cngme or engme damage mny re!"u lt OPTIONAL FIRE EXTINGUISHER The firecAtlngul, her (pln 0613-093) 1 '1 op tIonal for 1 995 model& but ICi ava il a bl e from th e Service Parts dcpanment

UPRIGHTING CAPSIZED WATERCRAFT (1995 MODELS) Bcci.lu\c of Ilite r.: hangC\,lhe operu tor', manuil lmdIC:II C!i the I mp~r dlret:llon 10 upnghl a cap\llcd waterenln The pr0r.cr way to upr ight a ll 1995 Tl gcr\har k Walcrcra I I'i h)' tummg CLOC KWI SE duc to tile new c,hau\! !I)" lcm on the DaY l ona and 2nd·run Monl cCarl o mode l, 'nle other models may be upng hlcd 10 clther dl,el,;llOn~ however. we would lik e you to educa te your cU l, lomc,", to alway ... up n gh l thelf wmcrcrafi in th e dlrcl,;lIon in(hcaled un t he decal at th e r'l!ar or the bo ,l! All 1 995 mode l decnl ... (01\ we ll U'i Ih<Ke on uny 1 993 or 94 rn c.xle l) nrc correct and \~lOuld be ro llowed AR CTCO GEL COAT Recau",: III ... hl PP lng rC\lncUon ... An.: l c;t) Gel Coal title, nlll contam \1clhy llJ hyl KC), lone Pc ro~ldc (Ml-.KI '). the a~cnl thaI at: t\ B\ iI hardener When u\lng Arch:O Gel CII,\!, yuu mu\' pre-mil; MLKP W ll h Ihe amount of Ge l CO;lI 10 he u"Cd ill a ra llO of 1-211 by quanlt l)' For exampl e. U 'lC 2: ml MEKP 10 every ICX) ml of Gel Coal Any r~ma l nmJ:! mixed ... olullOn mu~1 be dl\cardcd hecau<;c t nc Ml-KP wil l call~ the ge l coat to haruen MFKP rna)' he purc ha.se OI l nearly all aUlo ,,"11 1' "lore 1995 MONTE CARLO STORAGE CANISTER Thc ... ,orngc cnnl\lcr u<;cd In I he 1 995 Mont e Carl o may he u ... cd 111 11 1 994 Mo ni c Carlo; however, In order 10 mount the (:ilm"',cr, you W ill h a\c to drill n ew holel, 900 JET PUMP OIL ' 111e 1 99~ (X)() Jet pu mp wi ll come fro m Arc lca fill ed \Ylth R I 1111 (2 3/4 n Ol,) Tl gc"hur~ Jel Pump 011 (pIn IK,7K- 1 201 1995 DAYTONA OR 900 GAUGES If non e: of Ihe: ~au~c\ on a 1995 Daytona or 90() mode l \YorL.. 'heck. th at the I amp fU \e (located In lhe \Ylre IwllC ... \ near the carburetor a~'tC mbly) IS not bl o \\on LOOSE TRIM INSERTS To \c!cure n tn m m\ertl hat ha\ l ()O'.C net.l. m"tall 4 pU 'i h pm' (pin 0621· 585) 10 the ce nt er of the tn m m'-t rt SEAT BA SE SEALS If a \Ca l h<1~ sen l become ... loo~ and IS not da maged. clean th e 'Ca t ~~ with alcohol and SL"Cure the \eat ba~ .. ca l W ith ", upe r glue" New 'icals may be o rdered throu!! h yOUI' no rmal panl, chann el u"' ln g part n um be r (pin 0771-47R) . HATCH SEAL KIT (PIN 0637-106) Tn I\! placeu hatch -.ea l thDI ha ... poor ad he"' lon orprevent 'i the hatch fr am ope mn g orci O!! mg eas il y. order the Halch Sea l Kit (pin 0637· 106) One }. II pe r wa tercra ft 1 ~ reqUired and the kit will lit a ll Ti ger~har~ mode l ... U\C fmlu recodc MOl and e lUlm n I llbor all awance of 0.5 h OUf\ for each wa tercraO repa ired 16 SECURING 1995 DAYTONA & 900 MODELS TO A TRAILER Duc to c: hall gc: .. In the 1 9951>3)' ton<l and 900 model txl~ C)CI, . It 1\ ncl.:e .... ary to U\C e ll her the ue·do\\on ... trap }.U (pin 0678·266) or lhe trai ler \Yl nc h kit {pin 06%·275) w properly 'lCCure e uhcr of thc"ie mode ls to a trailer 1994 MODEL RIDI NG CAPACITIES So me dca le ~ ha .. ·c call ed "' ~Ing If th ey cancon\'c n 1994 Barrac uda ar Monlego Del uxe ndlng capaC III C\ Into 1 99." Barracud a or Mont ego De luxe ri dlnp capat lll es Thi 'i mod ifi cat ion etln not he pe rformed 1995 DAYTONA CARBURETOR SPECIFICATIONS (SEA LEVEL) At sea le1l c l. adj ust the scre~ s as follow .. low speed ::: 1 tUrn High speed = 7/8 mIg , 3/4 pto Other model s peC ifi ca ti ons ca n be found In the Se t-Cp and Prede li very Man ual s Untt! other hIg h ah lt ude \peclfic ati on ... are u\' :tI lahlc. re fer to lhe Se t -Up and Predel Ivery manuals ENGINE FAILURE TROUBLESHOOTING Before dlsasse rn bltn g an englnc thai ha s 'ie lzed or bu rn t a hole III a pi ston for no ab\'lou'i n~asoll. pleu !\c '" "pc!.:t th e fo li ow lO g area!!. before c:tllln g your ,en-Ice I c, hlll cHm Inspect the fu el hne routing for ~lOk\ 2 In s pect the carburetor( ~) for I lIIproper leltln}; or dlny onfices. In spect the 01 1 pum p and otllme!r. lor alrbubbleo; 4 Chec}. the nlco hol content of th e fu el UMn!; the Alcahol Test KII ( pin 0644·(}44 ) Exceo;s lvc alc ohol canl ent IS o\'er IO'l 5 If exce"" lve alcohol 10; n ot thc cau~. pn !s\ure lest thl! cng tne u~mg the Pre!r.~ure Testi ng Kit (pin 0644- 1 99) and SD. 1PY \Ya ter 10 tn Spec l fo r air leaks around th e crank case hal ves. cranh ha ft end seal s. ar damaged gaskets. Plea 'iC perform nil of these t es ts before di sasse mbltng Ibe engine or calling your servi ce lechnlclM

1995 DAYTONA CARBURETOR FUEL SCREWS Tr a Duylul Ul h runnmg at low RPM (i. e.• lower than 6800-7200 RPM ) at wide-opcn -throttl c in the water, in spect the tape r on the fu el &C rews ( see Fi g. 2) fo r dama ge. Replace the fuel scrcw(s) If damage is prese nt. A se rv ice bull etin addre~smg thi S situation WI ll be out shortly, • NOTE: There should be no step on the taper. Flo 2 EXHAUST COMPONENT OVERHEATING If you have a probl em wit h .. Imps or ex haust hoc"e~ melting on a Ti gcr!l hark a nd you have ched .ed all po\!, lble ca uo,c!l (b l oc ked Int ake gral e. CIC. ). there , 0., onc of t wo area" 10 n\ wUYHhc/oJ. for. depending on lhe mooc l Ihall 'lo ... erh eatmg. Jr the model ha~ an alummum ex pansion chambe r equipped with n cas t pipe:. m~1 the bl eed hole for O b!r.lrucll ons (\ec Fig. 3) , If the model ha'l II Ii HlInl ess stee l ex pansion chamber, In specllh c.5 mm ex ha us t coo la nt orifi ce In the exhaust elbow . It mu ... t he clean 3nd un ob'o lru cted (see Fi g. 4) 17 Flo·' OVERHEAT SENSOR When y our cu.stomer takes deli ... c. ry of a wa t ercra ft. be !l ure to exp lain about th e ovc rhem se nsor nnd thc proper procedures to foll ow If the ove r hell t IIt n\() r is acti vat ed If the overhea t \C n so r I ~ activ at ed, Ih ey ... hould IInmedl ::ttei), SlOp the cngln e and clcan thc ml ake grate or. any deb n ~ (refer 10 the Ope rator' s Man ual) 2. If engme u ... cmco tln g is Mi ll ex pcn enced Jftcr S lartln g lheengmt!. liley shouJd shut the wate rcra ft o ff a nd .l:;cl lhc wat erc raO towed bac k to shore. If nobody I ~ ar ou nd to lOW them int o sh ore. lhey ~hould try to idle the wal ercrafl back to shore . without appl ying any additional thru st 3. If i dlmg th e watercruft does n'l pro vide en ough tlUll I 1.0 overcorne the ~Ul f and II lif c- lhreat l!ni ng situati on ex i!it'i , inslructlhe cuslomer lh al then and ONLY TIl EN shou ld they run the willerernrt up agulnst the o ... erheat !.ensor '!; RPM hmller (which IS approx im ately ),0 00 RPM). Wh en th e watercraft is opcmung lit 3,{)(X) RPM with th e overhea t s en so r activated, the coolin g hose1i wtll he se verel y damag ed Remember Ih at nmning Ih e engin e 10 ge l th e watercraft bac k to shore is II I w.t re'lort a nd should onl y be done In I1 fe- lhreatenlng M tu atl onJ. . • NOTE: Operating th e watercra ft accordi ng to the Opera tor '. Manua l will prevent the overheat sensor from becoming activated (I.e., operating the wate rc raft In at least two feet of water at all times).

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1994 Arctic Cat Tigershark PWC Watercraft Factory Service Manual Barracuda Daytona Monte Carlo 640 Montego 650 Montego Deluxe 65

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