1996 Arctic Cat Tigershark PWC Watercraft Factory Service Manual Montego 640 Montego Deluxe 640 Monte Carlo 640 770 900 Daytona

This service manuals covers the 1996 Tigershark watercraft series. This manual is fully searchable, just hold down the control key and the F key to search on any word. If you bought this manual from any other seller, they are reselling my work. Please leave them negative feedback & email me at sales@midwestmanuals.com . Our goal is to be one of the BEST sellers on eBay and the internet by providing you with the BEST customer service and the BEST manuals on the market. Thank you for choosing us.

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Bulletins & Newsletters sales@midwestmanuals.com www.midwestmanuals.com sales@midwestmanuals.com www.midwestmanuals.com

sales@midwestmanuals.com www.midwestmanuals.com sales@midwestmanuals.com www.midwestmanuals.com 1995 Carburetor Recalibration Specifications Monte Carlo Carburetor Calibration changes must be made in conjunction with switching the existing flame arrestor for the Montego flame arrestor using the following components. Quantity Part Number Item 1 0673-044 Flame arrestor base 1 0673-045 Flame arrestor cover 1 0673-046 Screen 4 0624-053 Cap screw 4 0624-036 Lock washer 2 0624-046 Cap screw 2 0624-036 Lock washer The pa rt s listed above must be installed with the fl ame arrestor intake opening positioned toward the rear of the boat. • NOTE: High-speed and low-speed screw calibrations may differ slightly from area to area as water temperature will effect these settings. These calibrations will not work on the Monte Carlo models unless the above mentioned flame arrestor is Installed. 1995 Montego and Montego Deluxe Item Specification Low Speed Screw 1 1/8 Turns Spring 115 Needle 1.5 Low Speed Jet 120 ~gh Speed Jet 115 High Speed Screw 1 Turn 1 996 Monte Carlo with Water to Muffler Item Specification Low Speed Screw 1 Turn Spring 95 Needle 1.5 Low Speed Jet 115 High Speed Jet 142.5 High Speed Screw 3/4 Turn 1995 Daytona Item Specification Low Speed Screw 2.0 Turns Spring 95 Needle 2.0 Low Speed Jet 67.5 High Speed Jet 100 High Speed Screws 7/8 Turn 1995 Monte Carlo without Water to Muffler Item Specification Low Speed Screws 1 1/4 Turns Spring 95 Needle 2.0 Low Speed Jet 11 7.5 High Speed Jet 140.0 High Speed Screw 3/4 Tum

sales@midwestmanuals.com www.midwestmanuals.com sales@midwestmanuals.com www.midwestmanuals.com SERVICE WATS LINE INSTRUCTIONS ""/com .. ro 'M A"'k'D &nk .. fhp<Jtlm(nt Plnrr<" tnt", '"QUr tkul .. rn"m~~ MESSAGE '2 (NOTE; H the number I. valid, sysI&m '...,11."'0 MESSAGE '3) It the dealer number is invalid, the message will be: I II a 5&COnd Invalid number Is received, the message will be- f'I~"H ,'""IIKI A,nro, /" .... by ("oiling 218-68/·8558 "I,,,,, rh,..i- ,h .. mwwu un" If)' <lImn or 2/8·68/.4999 n",,,k )'OU. MESSAGE 13 ,[you htu'" (l .«hnka' 'I"",ion, Di al 1 ('WI"" """>ius II) "''''''g'' #41_ 1/),,,,, hm' .. (l 'I"u /iO/, Clmcullj"ll '''''1'''''1''.\' clwlUJ' or ''''''''''1\- d,,;m. sOIb",j.ud, Dial 2. If )""" htu'" a 'I"cSlioll conca",,,/( "!I/slml/o!/J, Dial 3. 1/)"0" hlU'e a q"~stio,, cmwu"'''1{ S"rlke 'l'ru)n/"iI '" Ihe SluorkMMler /''''11''''''_ 01a14. Ii.'-""' """t" ("II ,,,"a rnmll" {1m?' s/,Qrw;:t <"'I' IH"' $ ""I~r. 0 111 15. IF 5 IS DIALED ••. For <lueStil/OS c""u"'/tI~ (>I"'s ,,,,It(. " ",,<ltd /H"'. or pariS "",rn.I'/"'U <Iii.! j·8(){).U9-9.J 19 "m/ IIsk/or nwm<ltl j to I/r 4()() To piau a I""m onk .. plffl'it d'(J11·8QO·279·1281 Western Re Ion ::...::.;0'----, Central Re Eastern Re Ion =-=-::'--------, Bob Klade Service Represenlallve Area 1 [QI~ Joe Koch Ward Brink Service Representallve Area 2 Service Represenlahve Area 3 Don Berg Service Represenlali ve Aree 4 Customer SeMce, Western A lOll Custom9( Service, Cenlral R ~ Harry Kramer Service Represenlalive AreaS Service RepresM/allve AraaS Rick Kezar Customer Servlce, Eastem A

sales@midwestmanuals.com www.midwestmanuals.com sales@midwestmanuals.com www.midwestmanuals.com Bulletin No. 95·01W Model: 1995 Montegoe 1995 MontegoeOeluxe 1995 Monle Carlo .... SERVICE BULLETIN Subject: Date: Bilge Pump Fuse Holder February 8, 1995 CON DITI ON : Several watercraft were manufactured without a fuse in the circuit to protect the bilge pump. The fO ll owing list shows the models affected and the serial number range that these models fa ll within. 1995 Montego, Serial No. 0922 through 5076 1995 Montego Deluxe, Serial No. 0363 through 1421 1995 Monte Carlo, Serial No. 4054 through 5075 SOLUTI ON: When setting up one of the above models within the ser iaJ number range, disconnect the brown bilge pump wire from the main harness orange/green wire. Auach the red fuse holder wire to the brown wire from the bilge pump and the opposite end to the orange/green wi re. App ly dielectric grease to each connec ti on. P ARTS: Order one fuse holder (pIn 0630~082) for each model you have in the above serial number range. WARRA NTY : A group warranty clajm containing up to 10 serial numbers wi ll be accepted. Wri te 95~OIW in the failure code section of the warranty claim form. A labor allowance of 0.1 hou rs will be paid for each watercraft within the serial number range th at is updated. ARCTCO SALES. INC po. BOX 810 600 SOUTH BROOKS AVENUE THIEF RIVER FALLS. MN 56701 TELEPHONE (218) 681-8558 01) T. Tra demar ks D I Ar ctco , I nc., TIIIII "Iver FIlls. MN 56101

sales@midwestmanuals.com www.midwestmanuals.com sales@midwestmanuals.com www.midwestmanuals.com March 10, 1995 Dear Service Manager, Enclosed you will find a Gusset Kit, which must be welded on the four place Watercraft trailer hitch (as shown in the kit instruction sheet) to reinforce the hitch area. It is very important that the gussets are welded on the hitch as shown to prevent possible hitch damage in the event of jack knifing while towing the trailer. After completing the gusset installation, please complete a warranty claim for each trailer repaired. Claim 0.5 hours for the repair, and use failure code P13 in the failure code section of the claim. Best Regards, THE ARCTCO SERVICE DEPARTMENT AReTca SALES INC. PO BOX 810, 600 SOUTH BROOKS AVENUE, THIEF RIVER FALLS, MN 56101 TELEPHONE (218) 681-8558 FAX (218) 681·3162 Equal Opport~nlty Employer ® ... Trldemarks of Arctco, Int" Thiel River Fills, MH Si701

sales@midwestmanuals.com www.midwestmanuals.com sales@midwestmanuals.com www.midwestmanuals.com VOL. 2, NO, 1 English Edition April 21, 1995 In This Issue: PAGE 14 • Damaged Reed Valve Symptoms • Spark~P'ug Fouling • Miscellaneous Part Numbers PAGE 15 • Procedure After Complete Engine Replacement • 1993 Hanger Searing Replacement • Proper Warranty Procedures • 1994 Models Seat Adjustment • 1995 Air Core Tachometers • Discharge Fitting Plug • Optional Shut-Off Valve (pin 0744-013) • Optional Fire Extinguisher PAGE 16 • Uprlght/ng Capsized Watercraft (1995 Models) • Arctco Gel Coat • 1995 Monte Car/arM Storage Canister • 900 Jet Pump Oil • 1995 Daytona tJ or 900 Gauges • Loose Trim Inserts • Seat Base Seals • Hatch Seal Kit (pin 0637~106) • SecurIng 1995 Daytona & 900 Models to A Trailer • 1994 Model Riding Capacities • 1995 Daytona Carburetor Specifications (Sea Level) • Engine Failure Troubleshooting PAGE 17 • 1995 Daytona Carburetor Fuel Screws • Exhaust Component Overheating • Overheat Sensor DAMAGED REED VALVE SYMPTOMS We have had several ca ll s wondering what types of sympto ms a da maged reed va l ve might cause. A damaged reed valve may cause hard start in g. rough idling. running on one cy li nder, or forcing of the fuel/air mixture back up through the carburetor venturi either whi le the watercraft is idling or when attempting to start . 14 SPARK-PLUG FOULING Spa rk-plug fouling is more li ke ly to occ ur when ope rating the watercra ft in an area where there are no wake zones. When co ntinuous spark-p lu g fou ling is enco untered, perform the fo ll ow in g test s; 1. Check th at the oil-injec ti on pump al ignme nt mar ks are prope rl y a li gned. 2. The idle RPM screw should be set between 1500 and 1800 RPM (w ith the watercraft in the water). 3. Check that the low- and high-speed fuel screws are adjusted properly for your area. MISCELLANEOUS PART NUMBERS • Rivllul Instal/ation Tool (pili 0644-232) Used for installing sponsons on 1995 model watercraft • Rivnllt (pin 0623-557) Used to secure sponsons on 1995 model watercraft • Screw-Type Clamp (pin 3003-218) Used to secure the oil-injection line to the nipple on the intake manifold • Hatch Shims (pin 0673-401) Used on 1994-95 model hatch cover latch • Hinge Shims (pin 0673-402) Used on 1994-95 model ha tch cover hinge • 1995 Tigershark Watercraft Service Training Mallual (2255-287) • Tie-Down Strap Kit (0678-266) Secures either a 1995 Daytona or 900 to a Leland trailer • Trailer Winch Kit (0696-275) Secures all models to Leland trailer • New 1995 Warrallty Failure Code Wall Chart (2255-201)

sales@midwestmanuals.com www.midwestmanuals.com sales@midwestmanuals.com www.midwestmanuals.com PROCEDURE AFTER COMPLETE ENGINE REPLACEMENT When replacing a comp lete engine. be sure to use the o ri gi nal eng in e magneto hous in g in order to keep the se ri al number of the engine co rrect with the customer's regist ration ca rd. If the o ri ginal engine magneto housing ca nn ot be used, ca ll Mo ni ca @ ex t. 811 to fe-register the new engi ne se rial num ber with the hull serial number. 1993 HANGER BEARING REPLACEMENT When replacing a hanger bearing on a 1993 Tigershark, always peen thed ri veshart at the point the hanger bearing will be located and apply LOCTITE to th e area before in stalling th e hanger bearing. This will preve nt the driveshaft fro m spinning ins id e th e hanger bearing (w hi ch wou ld make the beari ng act like a bushin g), .NOTE: The thick portion of the hanger bearing is the front side. PROPER WARRANTY PROCEDURES Pl ease remembe r to lise the new failure codes from either the 1 995 Wall Chart (pIn 2255·20 1) or from page 2·26 of the Policy and Procedure Manual whe n filling out all warranty claims or the claim may be rejected. The part that caused the progressive damage must be li sted on the first line of the warra nty claim. In the event that the part that c aused the dama ge wasn 't replaced (fo r example. a loose fastener), still li st the part number of Ih e part that caused the progressive dama ge and in dicate a quantity of O. AI.. WA YS attach a red warranty parts tag and send th e parts with lhe claim unless instructed to do otherwise by either a bulletinlnewsletter or a servi ce representative. • NOTE: Remember that authorization numbers given out by your service representative are good for 30 days ONLY. Warranty parts must be returned to us within 10 DA YS or warranty will not be given . By returning them within 10 day s, you will be paid faster and we will be able to analyze a potential parts failure by model and prevent any future problems. If you rece ive any wate rcra ft with a damaged hull ( concealed crate damage) from Arctco, you must first ca ll yo ur serv ice representative and then send in a ph otogra ph and an estimate along with a leiter asking your servi ce re presenta ti ve to ca ll you (please in cl ud e ph one number, deal er number, and the serial number of th e watcrcraft). 1994 MODELS SEAT ADJUSTMENT If experiencing a loose scat when boarding a 1994 watercraft, replace th e seat bolt with a bo lt and washer weldment assembly (pin 0773·281) available through your normal parts cha nn e l. 1995 AIR CORE TACHOMETERS Thc three wires for the 1995 tachometer serve th e following purposes: l -Black = ground 1-Violet = 12·volt power source 1- Yeltow = Pulse (tachometer signal) .NOTE: Air Core tachometers do not completely return to zero when the watercraft is not running; however, the tachometer will reset the next time the engine is run . Fig. 1 15 DISCHARGE FITTING PLUG You may have noticed on a ll 1995 lJaytona and 2nd·run Monte Ca rl o models (serial number ARJ4054A495 and above) a discharge fitting plug (with a 3116 in. hole in the ce nter) installed in the port- side water outlet di scharge fitting. This plug causes most of th e di scharge water to ex it through the mufn er, which helps reduce exhaust noise. This plug must be un screwed when back· Ou shing a 1995 Daytona or Monte Car lo in the above serial number ran ge. Operating the watercraft without the plug in stalled is not recommended beca u se it will alter carburetor calibration. OPTIONAL SHUT-OFF VALVE (pin 0744-013) An opti onal shu t·off valve is avail able to customers for back- Ou shing a 1995 Daytona or a 1995 2nd·run Monle Carlo (Serial # ARJ2546L495 and above). Without th e valve, customers with a 1995 Daytona or 2nd-run Monte Ca rlo must be informed to pinch off the water line to the muffler before back· nu shing the engine or engine damage may resu lt . OPTIONAL FIRE EXTINGUISHER TIle fire extinguisher(p/n 0673·093) is optional for 1995 modcl s but is availab lc from the Senice Part s department.

sales@midwestmanuals.com www.midwestmanuals.com sales@midwestmanuals.com www.midwestmanuals.com UPRIGHTING CAPSIZED WATERCRAFT (1995 MODELS) Because of latc changes, the operator's manual indicates the improper direction to upright a capsized watercraft. The proper way \0 upright a ll 1995 Tige rs hark Watercraft is by tuming CLOCKW ISE due to the new exhaust system on the Daytona and 2 nd -run Monte Carlo mode ls. The other models may be upJighled in either direction; however. we would like you to educate your customers to always upright their watercra ft in the direction indicated on the decal at the rear of the boat. All 1995 model decals (as we ll as those on any 1993 or 94 model) are correct and shou ld be followed. ARCTCO GEL COAT Because of shipping re strictions, Arctco Gel Coat does not con lain Methyl Ethyl Key tone Peroxide (ME KP), the agent that acts as a hardener. When using Arctco Gel Coat, you must pre-mix MEKP with the amount of Gel Coat to be used at a ratio of 1-2% by quantity. For example, use 2 Illi MEKP to every 100 ml of Gel Coat. Any remaining mixed solu tion must be discarded because the MEKP will cause the gel coat to harden. MEKP may be purchase at nearly all auto parts store. 1995 MONTE CARLO STORAGE CANISTER The storage canister used in the 1995 Monte Carlo may be uscd in a 1994 Monte Carlo; however, in order to mount the canister, you will have to drill new holes. 900 JET PUMP OIL The 1995900 jet pump will come from Arctco filled with 81 ml (2 3/4 n oz.) Tigershark Jet Pump Oil (pin 0678- 120). 1995 DAYTONA OR 900 GAUGES If none of the gauges on a 1995 Daytona or 900 model work, chec k that the I amp fu se (located in the wi re harness near the carburetor assembly) is not blown. LOOSE TRIM INSERTS To secure a t ri m insert that has loosened, insta114 push pins (pIn 0623-585) in the center of the trim insert. SEAT BASE SEALS If a seat base seal becomes loose and is not damaged, clean the seat base with alcohol and secure the seat base se al with "s u per glue". New seals may be ordered through your normal parts channel using part number (pin 0773-478). HATCH SEAL KIT (PIN 0637-106) To replace a hatch seal that has poor adhesi on or prevents the hatch from opening or closing easily, order the Hatch Seal Kit (pIn 0637-106). One kit per watercraft is required and the kit will fit all Tigershark models. Use fai lu re code MOl and claim a labor allowance of 0.5 hours for each watercraft repaired. 16 SECURING 1995 DAYTONA & 900 MODELS TO A TRAILER Due to changes in the 1995 Daytona and 900 model bow eyes, it is necessary to use either the tie -down strap kit (pIn 0678-266) or Ihe trailer winch kit (pin 0696-275) to properly secure either of these models to a trailer. 1994 MODEL RIDING CAPACITIES Some dealers have called asking if they can convert 1994 Barracuda or Montego Deluxe riding capacities inlo 1995 Barracuda or Montego De lu xe riding capacities. This modification can not be performed. 1995 DAYTONA CARBURETOR SPECIFICATIONS (SEA LEVEL) At sea level, adjust the screws as follows: low speed = 1 turn High speed = 7/8 mag, 3/4 pta Other model specifications can be found in the Set-Up and Prede li very Manuals. Until other high a lt itude specifications are avail ab le, refer to th e Set-Up and Prede li very manuals. ENGINE FAILURE TROUBLESHOOTING Before disassembling an engine that ha s seized or burnt a hole in a piston for no obvious reason, please inspect the following areas before ca ll ing your se r vice technician: 1. Inspect the fuel line routing for kinks_ 2. Inspect the carburetor(s) for improper jetting or dirty orifices. 3. Inspect the oil pu mp and oil lines for air bubbles. 4. Check the alcohol content of the fue l using Ih e Al coho l Te st Kit (pIn 0644·044). Excessive alcohol co nt ent is over 10%. 5. If excessive alcohol is not the cause, pressure test the engine using th e Pressure Testmg Kit (pin 0644-199) and soapy water to in spect for air leaks around the cra nk case ha lves, crankshaft end seals, or damaged gaskets. Pl ease perform all of these tests before disassembling the engine or calling your service technician.

1996 Arctic Cat Tigershark PWC Watercraft Factory Service Manual Montego 640 Montego Deluxe 640 Monte Carlo 640 770 900 Daytona

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