Arctic Cat Tigershark Barracuda 1995 Factory Service Repair Manual

Service Training Manual 1995 Barracuda Daytona Monte Carlo Montego Montego Deluxe TigerShark 900

~, _______ F_o_r_e_vv __ o __ r_d ______ -,~ This manual contains service, maintenance, and troubleshooting information for all 1995 Tigershark Personal Watercraft. The manual is designed to aid service personnel in service-oriented applications and may be used as a textbook for service training. This manual is divided into sections. Each section of the manual covers a specific watercraft component or system and, in addition to the standard service procedures, includes assembling, disassembling, and inspecting instructions. A troubleshooting section is also included in this manual. The service technician should become familiar with the operation and construction of each component or system of the Tigershark by carefully studying this manual. This manual will assist the service technician in becoming more aware of, and efficient with, service procedures. Such efficiency not only helps build consumer confidence, but also saves time and labor. The procedures in this manual cover the complete disassembly of the 1995 Tigershark Watercraft components. When servicing the watercraft, however, the technician should use discretion about how much disassembly is needed to correct any given condition. All Arctco publications and watercraft decals display the words Warning, Caution, and Note to emphasize important information. The symbol LD. WARNING identifies personal safety-related information. Be sure to follow the directive because it deals with the possibility of severe injury or even death. The symbol LD. CAUTION identifies unsafe practices that may result in watercraft-related damage. Follow the directive because it deals with the possibility of damaging a part or parts of the watercraft. The symbol _ NOTE: identifies supplementary information worthy of particular attention. At the time of publication, all information, photographs, and illustrations were technically correct. Because Arctco, Inc. constantly refines and improves its products, no retroactive obligation is incurred. All materials and specifications are subject to change without notice. Keep this manual accessible in the shop area for reference. Service Department Arctco, Inc.

SECTION 1 - GENERAL INFORMATION ) C TABLE OF _____ C_O __ N_T_E_N __ T_S ____ _ Specifications (Barracuda) Specifications (Daytona) . Specifications (Monte Carlo) Specifications (Montego) .. Specifications (Montego Deluxe) Specifications (Tigershark 900) Break-In Procedure ... Recommended Gasoline Recommended Oil .. . Genuine Parts. . . . . . Preparation For Storage Preparation After Storage . Submerged Watercraft . . .4 .5 .6 .7 .8 .9 10 10 10 10 10 12 12 3

Specifications * (Barracuda) Engine Engine Model PJ640 -AC Displacemenl 639 cc (39.0 cu in.) Horsepower 72 Operaling RPM (W.O.T.) 6700 ± 200 RPM RPM Limiler Digilall71 00 ± 200 RPM Bore X Stroke 75.7 X 71 mm (2.98 X 2.78 in.) Compression Ratio 7.6: 1 Piston-Ring End Gap Range 0.20-0.80 mm (0.008-0.03 1 in.) Piston Skirt/Cylinder Clearance 0.105-0.200 mm Range (0.004-0.008 in.) Piston Pin D iameter Range 19.980-20.000 mm (0.7866-0.7874 in.) Piston-Pin Bore Diameter Range 20.010-20.030 mm (0.7875-0.7886 in.) Connectin~-Rod Small End 26.003-26.011 mm Diameter ange (1.0237-1.0241 in.) Crankshatt End Play R ange 0.05-0.10 mm (0.002-0.004 in.) Crankshatt Runout (max.) 0.05 mm ( Total Indicator Reading) (0.002 in.) Cylinder Trueness (max.) 0.10 mm (0.004 in.) Lighting Coil Output 12V/ l05W Ignition Type COl, Digital Spar!< Plug NGK BR9ES Ignition Timing 20' BlDC @ 3200 RPM 2.4 mm 0.095 in. Spark Plug Gap Range 0.7 - 0.8 mm (0.028-0.031 in.) Cooling System Forced Water Intake Overheat Protection DigitaVRPM Limiter Intake System Crankcase Reed Valves Exhaust System Tuned Pipe Starting System E lectric Start Carburetor Number 1 Type BN 46-42 Mikuni Style Buttertly wlfuel pump Choke Manual L ow Speed Jet 125 High Speed Jet 175 4 Carburetor (cont.) Needle Valve Setting (Hi gh Speed) Needle Valve Setting ( Low Speed) Idle Speed (in water) Drive System Jet Pump T ype Impeller Type Impeller Pitch Impeller Rotation Nozzle P ivot (maximum) Coupling Operating Water Level ( mi n imum) Hull Length Width Height Miscellany D ry Weight ( Approximate) Recommended Gasoline Engine Oil Break- In Fuel Mixture I njection Oil Tank Capacity Gas Tank Capacity (Actual) Gas Tank Capacity (Rated) Jet Pump Lubricant Carrying Capacity (Maximum) Riders (Maximum) Battery Starting System Fuse B ilge Pump Fuse Power Trim Fuse 1 Turn (11 /2 Turns") 1 Turn (1 1 /2 Turns") 1500 RPM Axial F low Single Stage Stainless Steel Blade 16.5' Counterclockwise 28' Direct D rive wlDampener 60 cm (2 tt l 235 cm (92.5 in.) 105 cm (41.5 in.) 96 cm (37.75 in.) 162 kg (360 Ib) 87 Octane Regular Unleaded TIgershar!< 50:1 Injection Oil 50:1 plus oil injection 4.7 L (5.0 U .S. qt) 26.5 L (7 U.S. gaL) 23.8 L (6.3 U.S. gaL) T~ershark Drive Unit Oil ( II oz.) 64 kg (185 Ib) 1 12V/19AMP/hour 15Amp 3Amp 6Amp • Subject to change without notice . .. Over 2134 mAlt (7000 ft Alt)

Specifications * (Daytona) Engine Engine Model PJ640 -AC Displacemenl 639 cc (39.0 cu in.) Horsepcwer 78 Operating RPM (W.O.T.) 7000 ± 200 RPM RPM Umiter DigitaV7100 ± 200 RPM Bore X Stroke 75.7 X 71 mm (2.98 X 2.78 in.) Compression Ratio 7.6: 1 Piston-Ring End Gap Range 0.20-0.80 mm (0.008-0.031 in.) Piston SkirVCylinder Clearance Range 0.105-0.200 mm (0.004-0.008 in. Piston Pin Diameter Range 19.980-20.000 mm (0.7866-0.7874 in.) Piston-Pin Bore Diameter Range 20.010-20.030 mm (0.7875-0.7886 in.) Connectin~-Rod Small End 26.003-26.0 11 mm Diameter ange (1.0237-1.0241 in.) Crankshaft E nd Play Range 0.05-0.10 mm (0.002-0.004 in.) Crankshaft Runout (max.) (Total Indicator Reading) 0.05 mm (0.002 in.) Cylinder Trueness (max.) 0.10 mm (0.004 in.) Lighting Coil Output 12V/l05W Ignition Type CDI, Digital Spark Plug NGK BR9ES Ignition Timing 20' BTDC @ 3200 RPM 2.4mm 0.095 in. Spark Plug Gap Range 0.7 - 0.8 mm (0.028-0.031 in.) Cooling System Forced Water I ntake Overheat Protection DigitaVRPM Limiter Intake System Crankcase Reed Valves Exhaust System Tuned P ipe Starting System Electric Start Carburetor Number 2 Type BN 38 Mikuni Style Buttertly w/luel pump Choke Manual Low Speed Jet 75 High Speed Jet 100 Carburetor (cont) Needle Valve Setting (High Speed) Needle Valve Setting (L ow Speed) Idle Speed (in water) Drive System Jet Pump Type Impeller Type Impeller Pitch Impeller Rotation Nozzle Pivot (maximum) Coupling Operating Water Level (minimum) Hull Length Width Height Miscellany Dry Weight (Approximate) Recommended Gasoline Engine Oil Break-In Fuel Mixture Injection Oil Tank Capacity Gas Tank Capacity ( Actual ) Gas Tank Capacity ( Rated) Jet Pump L ubricant Carrying Capacity (Maximum) Riders (Maximum) Battery Starting System Bilge Pump Fuse Power Tri m F use 1 T urn (1 1 /2 Turns") 1 Turn (1 112 Turns") 1500 RPM Axial F low Single Stage Stainl ess Steel Blade 16.5' Counterclockwise 28' Direct Drive w/ Dampener 60 cm (2 ft) 282 cm (111 in.) 110 cm (43.5 in.) 93 cm (36.5 in.) 182 kg (405I b) 87 Octane Regular U nleaded Tigershark 50:1 Injection Oil 50:1 plus oil injection 4.7 L (5.0 U.S. qt) 43.5 L (11.5 U.S. gaL) 38.9 L (10.3 U.S. gaL) Ti~ershark Drive Unit Oi (6110z.) 168 kg (370 Ib) 2 (1 operator & 1 passenger) 12V119AMPlhour Circuit Breaker 3Amp 6Amp • Subject to change without notice_ •• Over 2134 mAlt (7000 fI Alt) 5

Specifications * (Monte Carlo) Engine Engine Model PJ640 ·AC Displacement 639 cc (39.0 cu in.) Horsepower 72 Operating RPM (W.O.T.) 6700 ± 200 RPM RPM Limiter DigitaV7tOO ± 200 RPM Bore X Stroke 75.7 X 7t mm (2.98 X 2.78 in.) Compression Ratio 7.6: t Piston·Ring End Gap Range 0.20·0.80 mm (0.008·0.031 in.) Piston SkirVCylinder Clearance Range 0.105·0.200 mm (0.004·0.008 in. Piston Pin Diameter Range 19.980·20.000 mm (0.7866·0.7874 in.) Piston· Pin Bore Diameter Range 20.010·20.030 mm (0.7875·0.7886 in.) connectin~.Rod Small E nd 26.003·26.011 mm Diameter ange (1.0237·1.0241 in.) Crankshaft End Play Range 0.05·0.10 mm (0.002·0.004 in.) Crankshaft Runout (max.) (Total Indicator Reading) 0.05 mm (0.002 in.) Cylinder Trueness (max.) 0.10 mm (0.004 in.) Lighting Coil Output 12V/l05W Ignition Type CDI , Digital Spark Plug NGK BR9ES Ignition Timing 20' BTDC @ 3200 RPM 2.4 mm 0. 095 in. Spark Plug Gap Range 0.7 . 0.8 mm (0.028·0.031 in.) Cooling System Forced Water Intake Overheat Protection DigitaVR PM limiter Intake System Crankcase Reed Valves Exhaust System Tuned Pipe Starting System Electric Start Carburetor Number 1 Type BN 46·42 Mikuni Style Buttertly wlfuel pump Choke Manual Low Speed Jet 120 High Speed Jet 205 6 Carburetor (cont.) Needle Val ve Setting (H igh Speed) Needle Valve Setting (L ow Speed) Idle Speed (in water) , Drive System Jet Pump Type I mpeller T ype I mpeller Pitch Impeller Rotation Nozzle Pivot (maximum) Coupling Operating Water Level (minimum) Hull L ength Width Height Miscellany Dry Weight (Ap proximate) R ecommended Gasol ine E ngi ne Oil Break·ln F uel Mixture Injection Oil Tank Capacity Gas Tank Capacity (Actual) Gas Tank Capacity (R ated) Jet P ump L ubricant Carrying Capacity (Maximum) Riders (Maximum) Battery Starting System Fuse Bi lge P ump F use 1 T urn (11/2 Turns") 1 Turn (1 112 Turns") 1500 RPM Axial F low Single Stage Cast Aluminum 16.5' Counterclockwise 28' Direct Drive wlDampener 80cm (2ft) 309 cm (121.5 in .) 121 cm (47.5 in.) 98 cm (38.5 in.) 216 kg (460 I b) 87 Octane R egular Unleaded Tigershark 50:1 Injection Oil 50:1 plus oil injection 4.7 L (5.0 U.S. qt) 43 .5 L (11.5 U.S. gal.) 38.9 L (10.3 U.S. gaL) Ti~ershark Drive U nit Oi (611 oz.) 223 kg (490 Ib) 3 (1 operator & 2 passengers) 12V/19AMPil1our 15 Amp'" 3Amp • Subject to change without notice. •• Over 2134 mAlt (7000 ft Alt) ••• Late production-Circuit Breaker

Specifications· (Montego) , I Engine Engine Model PJ640 -AC Displacemeflt 639 cc (39.0 ctJ in.) """po- 62 Operating RPM (W.O.T.) 6500 ± 200 RPM RPMUmitef OigitaV7100 ± 200 RPM Bore X Stroke 75.7 X 71 mm (2.98 X 2.78 in.) ComPfessioo Ratio 6.8: 1 Piston-Ring End Gap Range 0.20-0.80 mm (0.008-0.031 in.) Piston SkirtlCylinder Clearar.ce R",,, 0.105-0.200 mm (O.OO4{).OO8 in. Piston Pin Diameter Range 19.980-20.000 mm (0.7866-0. 7674 in.) Piston· Pin Bore Diameter Range 20.010-20 , 030 mm (0.7875-0.7886 in.) Connecti= Small End 2£.003-26.011 mm Diameter (1 .0237-1,0241 in.) Crankshaft End Ptay Range 0.05-0.10 mm (0.002-0.004 in.) Crankshaft Runout (max.) (T otal l ndicatOf Reading) 0.05 mm (0.002 in .) Cylinder Trueness (max .) 0.10 mm (0.004 in.) Lighting Coil Output 12V/1Q5W Ign~ion Type COl, Digital Spark Plug NGK BR9ES Ign~ion Timirnl 20' BlOC 0 3 00 RPM 2.4mm 0.095 in . Sparlo:. Plug Gap Range 0.7·0.8 mm (0.028-0.031 in.) Cool ing System Forced Water Int.:lko Ovelheat Prolection Dig~aVRPM Um~er Intake System Crankcase Reed Valves Exhaust System Tuned Pipe Starti S I,m Electric Start Carburetor Nurrber I TYP' BN 44 Mikuni Styto Butterfly wr1uel pump Choke Manual Low Speed Jet 125 High Speed Jet t07.5 Carburetor (cont ) Needle Vatve Sett ing (High S",,") Needle Valve Setting (low S",,") Idle Speed (in water) Drive System Jet Pump Type 1~ler Type Impeller Pilch Impeller Rotation Nozzle Pivol (maximum) Coupling Operating Water level (minimum) Hull 11/4 Tums (718 Tum··) 1 Tum 1500 RPM Axial Flow Single St age Aluminum 16.5° Counterclockwise 28' Direel Drive w/Dampener 60 em (2ft) Length 282 em (111'~i0'1.} _ __ ---j w""' 110 em (43.5 in.) Height 93 em (36.5 in.) Miscellany Dry Weight (Approximat e) 180 kg (400 Ib) Recommended Gasoline 87 Octane Regular Unleaded Engine Oil Tigershar1t 5O:1lnjeclion Oil Break·ln Fuel Mixture 50: 1 plus oil injection Injection Oil Tank Capacity 4.7 L (5.0 U.S. qt) Gas Tank Capacity (Actual) 43 .5 L (11.5 U. S. gal .) G(I$ Tank Capacity (Rated) 38.9 L (10.3 U.S. gal. ) Jet Pump Lubricant T~rshar1t Drive Un" Oi (6floz.) Carrying Capacity (Maximum) 168 kg (370 Ib) Riders (Maximum) 2 (1 operator & I passenger) Battery 12V/ 19AMP/hour Starting System Fuse 15 Amp Bilge Pump Fuse 3 Amp • Subject to change without notice. •• Over 2134 mAil (7000« All) 7

Specifications * (Montego Deluxe) Engine Engine Model PJ640 -AC Displacemenl 639 cc (39.0 cu in.) Horsepcwer 62 Operating RPM (W.O.T.) 6500 ± 200 RPM RPM Umiter DigitaV7100 ± 200 RPM Bore X Stroke 75.7 X 71 mm (2.98 X 2.78 in.) Compression Ratio 6.8: 1 Piston-Ring End Gap Range 0.20-0.80 mm (0.008-0.031 in.) Piston Skirt/Cylinder Clearance Range 0.105-0.200 mm (0.004-0.008 in. Piston Pin Diameter Range 19. 980-20.000 mm (0.7866-0.7874 in.) Piston-Pin Bore Diameter Range 20.010-20.030 mm (0.7875-0.7886 in.) connectin~-Rod Small End 26.003-26.011 mm Diameter ange (1.0237-1.024 1 in.) Crankshaft End Play Range 0.05-0.10 mm (0.002-0.004 in.) Crankshaft Runout (max.) (Total Indicator Reading) 0.05 mm (0.002 in.) Cylinder Trueness (max.) 0.10 mm (0.004 in.) Lighting Coil Output 12V/ l05W Ignition Type COl , Digital Spark Plug NGKBR9ES Ignition Timing 20' BlDC @ 3200 RPM 2.4mm 0.095 in. Spark Plug Gap Range 0.7 - 0.8 mm (0.028-0.031 in.) Cooling System Forced Water Intake Overheat Protection Digital/ RPM Limiter Intake System Crankcase Reed Valves Exhaust System Tuned Pipe Starting System E lectric Start Carburetor Number 1 Type BN 44 Mikuni Style Butterily w/fuel pump Choke Manual Low Speed Jel 125 High Speed Jet 107.5 8 Carburetor (cont .) Needle Valve Setting (High Speed) Needle Valve Setting (Low Speed) Idle Speed (in water) Drive System Jet Pump Type Impeller Type Impeller Pitch Impeller Rotation Nozzle Pivot (maximum) Coupling Operating Water Level (minimum) Hull Length Width Height Miscellany Dry Weight (Approximate) Recommended Gasoline Engine Oil Break-In Fuel Mix1ure Injection Oil Tank Capacity Gas Tank Capacity ( Actual) Gas Tank Capacity (Rated) Jet Pump Lubricant Carrying Capacity (Maximum) Riders (Maximum) Battery Starting System Fuse Bilge Pump Fuse 1 114 Turns (7/8 Turn") 1 Turn 1500 RPM Axial Flow Single Stage Stainless Steel Blade 16.5' Counterclockwise 28' Direct Drive wl Dampener 60 cm (2 ft) 309 cm (121.5 in.) 110 cm (43.5 in.) 93 cm (36.5 in.) 209 kg (460 Ib) 87 Octane Regular Unleaded Tigershark 50: 1 Injection Oil 50:1 plus oil injection 4.7 L (5.0 U.S. qt) 43.5 L (11.5 U.S. gal.) 38.9 L (10.3 U.S. gal.) Ti~ershark Drive Unit A' (6floz.) 168 kg (370 Ib) 2 (1 operator & 1 passenger) 12V119AMPlhour 15 Amp 3Amp * Subject to change without notice. ** Over 2134 mAlt (7000 ft Alt)

( Specifications' (Tigershark 900) '\ ) Engine Engine Model pJ900 ·AC Displacement 896 cc (54.67 cu in.) Horsepower 100 Operabng RPM (W.O.T.) 6900 ± 200 RPM RPM Limiter Digi t aV7100 ± 200 RPM Bore X Stroke 76.5 X 65 mm (3.011 X 2.559 in.) Compression Ratio 6.7: 1 Piston-Ring End Gap Range O.2!Hl.83 mm (0.008-0.033 In.) Pisloo SkirtlCylir1der Clearance O.095-0.150mm R,,,,, (0,0037-0.0059 in.) Piston Pin Diameter Range 19.995-20.000 mm (0.7872-0.7874 in.) Piston· Pin Bore Diameter Range 2Q.002-20.010 mm (0.7875-0.7878 in.) Connecti~.Rod Small End 26.003-26.011 mm Diameter ange (1.0237-1.0241 in.) Crankshaft End Play Range 0.05-0.10 mm (O.lX)2{).OO4 in.) CrankShaft Aunoul (max.) (T otallodicator Reading) 0.05 mm (0 , 002 in.) Cylinder Trueness (max .) 0.10 mm (0.004 in.) Ughting Coil Output 12V/l05W Ign~ion Type COl, Digital Spark Plug NGK SR9ES Ign~ion nm~ 19' BlOC@ 00 RPM 2.202 mm 0.086 in. Spar1\ Plug Gap Ral'l96 0.7·0.8 mm (O.028{l,031 in.) Cooling System Forced Water Intake Overheat Protection DigijaVRPM Umijer Intake System Cran k case Reed Valves Exhaust Syslem Tuned Pipe Starti S 10m Electric Start Carburetor Number , Typo BN 44 Mikuni S1y1o Butterfly w/!uel pump Chok. Manual Low Speed Jet 60 High Speed Jet 100 Carburetor (cont ) Need le Valve Sening (High Speed) Needle Valve Setting (low Speed) Idle Speed (in water) Drive System Jet PUfl\') Type I mpeller Type Impeller P~ch Impeller Rotation Nozzle Pivot (maximum) Coupling Operating Water level (minimum) Hull length w"" Heighl Miscellany Dry Weight (Approximate) Recommended Gasoline Engine Oil Break-In Fuel MOCture InjectIOn Oil Tank Capacity Gas Tank Capacity (Adual) GII$ Tllnk Capacity (Rll t ed) Jet Pump L ubricant Carrying Capacity (Maximum) Riders (Maximum) B"., Starting System Bilge Pump F use Power Trim Fuse 1 1/8 T ums (1 1/2 Tums") 1 112 T urns 1500 RPM Axial Flow Single Stage Stainless Steel Blade 16,5· Counterclockwise ,,' Direct Drive wlDampener 60 em (2 It) 309 em (121.5 in.) 121 em (47.5 in.) l03cm (40.5 in.) 254 kg (565lb) 87 Octane Regular Unleaded T tgershark 50:1 Injection Oil 50:1 plus oil injection 4.7l (5.0 U.S. qt) 43.5 L (11.5 U.S. gaL) 38 .9 L (10.3 U.S. 9a L) T ~ershark Drive Un~ Oi (6f10Z .) 223 kg (490 Ib) 3 (1 operat or & 2 passengers) 12VI19AMPihour Circuit Breaker 'Amp 6 Amp • Subject to change without notice . •• Over 2134 mAlt (7000 ft Alt) 9

( Break-In Procedure ) C~ __ G_e_n_U_i_n_e_p_a_rt_s _____ ) New and rebuilt Ti gershark Watercraft engines require a shan break-in period (one tankful offucl). Premi", the fin;1 tank of fuel at :l 50; I ratio in conjunction with the oil-injection system. During the break-in pe ri od. a maximum of 112 throtlle is recommended. However, brief full -throttle accelerations and variations in driving speed cont ri bute to good engine break-in. Foll owi ng the break-in period, the curhuretor(s) may need to be re-calibralcd andlor adjusted depending upon the operating altitude. ( Recommended ) Gasoline ~-~ The recommended ga!tOline to use in the Tigen;hark is 87 minimum octane regular unleaded. In many areas. oxygcn:Hcs (either ethanol or MTBE) are added to the gasoline. Oxygenated gasolines containing up 10 10% et hanol or up to 1 5% MTBE are acceptable gasol in es. Use only genuine liger;hark gasoline additive~. Unapproved gasoline additives and white gas MUST NOT BE USED. ( Recommended Oil ) Using an 011 other than the recommended oil could cause serious engine damage. The recommended oil to use in the oil-injection system is ligel'!iohark 50:1 Injection Oi l.Thi., oil is also the correct premix oil to U"C during the break-in period. This oil is specially formulated for use either as an injec ti on oil or as a premix oil and meets all of the lubrication requirements of the ligershark Wmereraft engine. 10 When replacement of pans is neee~sary, use on ly Genuine Aretco ligen;hark Pall!>. Oil. and Accessories. They are precision-made to ensure high quality and correct fit. Refer to the appropriate Illustrated PailS Manual for the correct pall number, quantit y, and description. / Preparation For Storage Before storing the Tigcr!>hark watercraft for any extended period (30 days or more). the hull, engi ne. elect ri cal !>ystem, and jet pump must be properly serviced to prevent rust, corrosion, and possible da mage caused by freeling temperatures. To properly prepare the watereraft for storage, u;e the following procedure: I. Replace Ihe oil filter. 2. Remove the drdin plug at the rear of the waten:raft. 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(s) electrical connections. or on 5. Using compressed air, clear all cables of any moisture. 6. Lubricate the cable ball joims, handlebar shaft. and bushings with Arclco Silicone Spray (pIn 0636-594).

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Arctic Cat Tigershark Barracuda 1995 Factory Service Repair Manual

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