Arctic Cat F6 Firecat EFI Sno Pro 2004 Factory Service & Work Shop Manual

2004 Snowmobile Service Manual Volume 1 & 2 A A RC CC T T I ®

TABLE OF CONTENTS CLICK ON THE RED TEXT TO GO! FORWARD 1. General Information (Vol. I) 2. Engine (Vol. I) 3. Engine-Related Items (Vol. I) 4. Fuel Systems (Vol. I) 5. Engine Electrical Systems (Vol. I) 6. Chassis Electrical Systems (Vol. II) 7. Steering and Body (Vol. II) 8. Drive Train and Brake Systems (Vol. II) 9. Track/Rear Suspension (Vol. II)

1-1 1 SECTION 1 — GENERAL INFORMATION TABLE OF CONTENTS Snowmobile Identification ....................................... 1-2 Recommended Gasoline and Oil ........................... 1-2 Break-In Procedure ................................................ 1-3 Genuine Parts ........................................................ 1-3 High Altitude Operation .......................................... 1-3 Preparation For Storage ......................................... 1-3 Preparation After Storage ....................................... 1-4 After Break-In Checkup (100 Miles) ....................... 1-5 After Break-In Checkup Checklist .......................... 1-6 Torque Conversions ............................................... 1-7 Tightening Torque (General Bolts) ........................ 1-7 Fraction/Decimal Conversion Chart ....................... 1-8 Drill Bit Sizes (Number) Chart ................................ 1-8 MM/In. Conversion Chart ....................................... 1-9 Servicing Symbols ................................................ 1-10

1-2 Snowmobile Identification The Arctic Cat Snowmobile has two important identification numbers. The Vehicle Identification Number (VIN) is stamped into the tunnel near the right-side footrest. The Engine Serial Number (ESN) is stamped into the crank- case of the engine. 0726-383 These numbers are required to complete warranty claims properly. No warranty will be allowed by Arctic Cat Inc. if the engine serial number or VIN is removed or muti- lated in any way. Recommended Gasoline and Oil RECOMMENDED GASOLINE (Carbureted Models) The recommended gasoline to use in these snowmobiles is 87 minimum octane regular unleaded. 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; however, whenever using oxygenated gasolines, the carburetor main jet must be one size larger than the main jet required for regular unleaded gasoline. For example, if a 400 main jet is recommended for regular unleaded gasoline, a 410 main jet must be installed if using an oxygenated gasoline. When using ethanol blended gasoline, it is not necessary to add a gasoline antifreeze since ethanol will prevent the accumulation of moisture in the fuel system. RECOMMENDED GASOLINE (EFI Models) The recommended gasoline to use in these snowmobiles is 87 minimum octane regular unleaded. 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. Do not use gasolines containing methanol. NOTE: When using the recommended gasoline, the Fuel Designation Connector at the ECU must be connected. NOTE: When using oxygenated gasolines, the Fuel Designation Connector at the ECU must be disconnected. 734-482A NOTE: In order for the ECU to change modes, the engine must be OFF when connecting or discon- necting the Fuel Designation Connector. RECOMMENDED OIL The recommended oil to use in the oil-injection system is Arctic Cat 50:1 Injection Oil (for standard models) or Arctic Cat Synthetic APV 2-Cycle Oil (for APV models). The oil is specially formulated to be used either as an injection oil or as a pre-mix oil (for carbureted model break-in) and meets all of the lubrication requirements of the Arctic Cat snowmobile engine. ! CAUTION Do not use white gas or gasolines containing methanol. Only Arctic Cat approved gasoline additives should be used. ! CAUTION Do not use white gas or gasoline containing methanol. Only Arctic Cat approved gasoline additives should be used. ! CAUTION If oxygenated gasoline is to be used, it is extremely important that the Fuel Designation Connector at the ECU is disconnected. If not, severe engine damage may occur.

1-3 1 Break-In Procedure The Arctic Cat 2-stroke engine (when new or rebuilt) requires a short break-in period before the engine is subjected to heavy load conditions. Arctic Cat requires that the first tankful of fuel be premixed at a 100:1 ratio in all oil-injection models. During the break-in period, a maximum of 1/2 throttle is recommended; however, brief full-throttle accelerations and variations in driving speeds contribute to good engine break-in. Genuine Parts When replacement of parts is necessary, use only genuine Arctic Cat parts. They are precision-made to ensure high quality and correct fit. High Altitude Operation Operating a snowmobile at varying altitudes requires changes in performance components. These changes affect drive train components (on all models) and carburetion components (on carbureted models). High altitude information decal(s) are located beneath the hood of the snowmobile. King Cat and Mountain Cat snowmobiles are initially set up at the factory for operation between 6000-9000 feet. Consult the appropriate specifications for this information. Preparation For Storage Prior to storing the snowmobile, it must be properly ser- viced to prevent corrosion and component deterioration. An authorized Arctic Cat Snowmobile dealer should per- form this service; however, the owner/operator can per- form this service if desired. To prepare the snowmobile for storage, Arctic Cat recommends the following procedure: 1. Clean the seat cushion with a damp cloth and Arctic Cat Vinyl Protectant (p/n 0638-313). 2. Clean the snowmobile thoroughly by hosing dirt, oil, grass, and other foreign matter from the skid frame, tunnel, hood, and belly pan. Allow the snowmobile to dry thoroughly. DO NOT get water into any part of the engine. 3. Place the rear of the snowmobile up on a shielded safety stand. NOTE: On “Laydown” engine models, the air silencer boot can be pried forward to access the intake bores. Pry the boot forward; then proceed to step 7. NOTE: On some standard models, the air-intake silencer is a one-piece unit, and the silencer boot(s) can be removed to access the intake bore(s). Remove the boots; then proceed to step 7. NOTE: On some standard models, the air-intake silencer includes a cover/tool tray assembly and a baffle/resonator, and the silencer boot cannot be removed to access the intake bores. Proceed to step 4. 4. Open the air-intake silencer cover; then remove the three screws securing the cover/tool tray assembly to the silencer. 5. Close the cover; then tip the cover/tool tray assembly forward and out of its slots and remove the assembly. 6. Using a large flat-blade screwdriver, remove the baffle/resonator tabs from the air-intake silencer slots and remove the baffle/resonator to access the intake bores. ! CAUTION DO NOT exceed the one (1) tankful limitation of a 100:1 gas/oil break-in mixture. Continuous use of a gas/oil mixture, unless consistently operating in extremely cold conditions (-26°C/-15°F or colder), could cause spark plug fouling and excessive carbon buildup. A 100:1 gas/oil mixture must be used in conjunction with the oil- injection system to ensure adequate engine lubrication in extremely cold conditions. ! CAUTION On carbureted models, carefully follow the Main Jet Chart recommendations for proper main jet selection for altitude, temperature, and gasoline being used.

1-4 NOTE: The baffle/resonator can be removed more easily by removing the back tabs first. 7. Start the engine and allow to idle. With the engine idling, spray Arctic Cat Engine Storage Preserver (p/n 0636-177) into the intake(s) until the engine exhaust starts to smoke heavily or until the engine starts to drop in RPM. Turn engine off. NOTE: On “Laydown” engine models, secure the air silencer boots onto the intake bores. NOTE: On some standard models, install the air- intake silencer boot(s); on some standard models, install the baffle/resonator and the cover/tool tray assembly. 8. Plug the exhaust system outlet with a clean cloth. 9. With the ignition switch in the OFF position: A. Disconnect the high tension lead(s) from the spark plug(s); then remove the plug(s), connect it/them to the lead(s), and ground it/them on the cylinder head(s). B. Pour 29.5 ml (1 fl oz) of SAE #30 petroleum- based oil into each spark plug hole and pull the recoil starter handle slowly about 10 times. C. Install the spark plug(s) and connect the high tension lead(s). 10. On carbureted models, drain the gas from each carburetor float chamber. 11. Fill the gas tank to its rated capacity; then add Arctic Cat Fuel Stabilizer (p/n 0638-165) to the gas tank following directions on the container for the stabilizer/gasoline ratio. Tighten the gas tank cap securely. 12. Drain the chain-case lubricant by removing the chain-case drain plug located on the backside of the chain-case assembly. Remove the chain-case cover and inspect chain, sprockets, chain tensioner, and rollers for wear and the chain for proper tension. Install the drain plug, chain-case cover, and seal; then pour Arctic Cat Transmission Lube (p/n 0636-817) into the filler hole according to appropriate specifications. 13. Clean and inspect the drive clutch and driven pulley. 14. Remove the drive belt from the drive clutch/driven pulley. Lay the belt on a flat surface or slide it into a cardboard sleeve to prevent warping or distortion during storage; then clean and inspect the drive clutch and driven pulley. 15. Apply light oil to the upper steering post bushing, ski spindles and bolts, front and rear pivot bushings of the skid frame, and plungers of the shock absorbers. 16. Lubricate all grease fittings (front and rear suspension, spindles, speedometer drive adapter, and the driven shaft support bearing) with a low- temperature grease. 17. Tighten all nuts, bolts, and cap screws making sure all calibrated nuts, bolts, and cap screws are tightened to specifications. Make sure all rivets holding the components together are tight. Replace all loose rivets. 18. Clean and polish the hood, console, and chassis with Arctic Cat Hood and Windshield Cleaner/ Polish (p/n 0636-174). DO NOT USE SOL- VENTS OR SPRAY CLEANERS. THE PRO- PELLENT WILL DAMAGE THE FINISH. 19. On electric start models, disconnect the battery cables making sure to disconnect the negative cable first; then clean the battery posts and cables. 20. If possible, store the snowmobile indoors. Raise the track off the floor by blocking up the back end making sure the snowmobile is secure. Loosen the track adjusting bolts to reduce track tension. Cover the snowmobile with a machine cover or a heavy tarpaulin to protect it from dirt and dust. 21. If the snowmobile must be stored outdoors, position the snowmobile out of direct sunlight; then block the entire snowmobile off the ground making sure the snowmobile is secure. Loosen the track adjusting bolts to reduce track tension. Cover with a machine cover or a heavy tarpaulin to protect it from dirt, dust, and rain. Preparation After Storage Taking the snowmobile out of storage and correctly pre- paring it for another season will assure many miles and hours of trouble-free snowmobiling. Arctic Cat recommends the following procedure: ! CAUTION Never crank the engine over without grounding the spark plug(s). Damage to coils and/or CDI unit may result. ! CAUTION Avoid storing in direct sunlight and using a plastic cover as moisture may collect on the snowmobile causing corrosion. ! CAUTION On carbureted models if the gas in each carburetor float chamber was not drained prior to storage, the carburetor(s) must be cleaned before starting the engine.

1-5 1 1. Clean the snowmobile thoroughly. Polish the exterior of the snowmobile. 2. Clean the engine. Remove the cloth from the exhaust system. Check exhaust system and air- intake silencer/air filter for obstructions. 3. Inspect all control wires and cables for signs of wear or fraying. Replace if necessary. Use cable ties or tape to route wires and cables away from hot or rotating parts. 4. Inspect the drive belt for cracks and tears. Check belt specifications. Replace if damaged or worn. Install the drive belt. NOTE: If the old belt is worn but in reasonable condition, retain it with the snowmobile as a spare in case of emergency. 5. On carbureted models, inspect the in-line fuel filter and replace if necessary. 6. Inspect all fuel hoses and oil hoses for deterioration or cracks; replace if necessary. Make sure all connections are tight; then fill the oil- injection reservoir with the recommended injection oil. NOTE: After prolonged storage, Arctic Cat recommends one tankful of 100:1 gas/oil mixture be used in conjunction with the oil-injection system to ensure proper lubrication. 7. Inspect the entire brake system, all controls, headlight, taillight, brakelight, ski wear bars, and headlight aim; adjust or replace as necessary. 8. Inspect each spark plug. Replace, gap, or clean as necessary. 9. Adjust the track to the proper tension and alignment. Lock the jam nuts. 10. Adjust the carburetor(s) and choke cable on carbureted models and throttle cable on all models. 11. Tighten all nuts, bolts, and cap screws making sure all calibrated nuts, bolts, and cap screws are tightened to specifications. 12. Lubricate all grease fittings (rear suspension, spindles, speedometer drive adapter, and the driven shaft support bearing) with a low- temperature grease. 13. On liquid cooled models, check the coolant level and all coolant hoses and connections for deterioration or cracks. Add properly mixed coolant as necessary. 14. On fan cooled models, clean the engine cooling fins and all vents. 15. On EFI models, place the rear of the snowmobile on a shielded safety stand; then start the engine. Allow the engine to idle; then using a long stiff wire with a hooked end, raise the oil-injection pump control arm to the wide-open position until the engine starts to smoke heavily. Release the control arm and turn off the engine. 16. On electric start models, charge the battery; then connect the battery cables making sure to connect the positive cable first. Test the electric start system. After Break-In Checkup (100 Miles) The 100 mile checkup offered by some dealerships reduces problems and warranty costs. A program of this kind should be offered by all dealerships. Many dealerships have added the price of the checkup into the selling price of the snowmobile, and others offer it as a bonus to the customers who purchase snowmobiles from their dealership. There are three areas that require adjustment after the break-in period in order to obtain peak performance. These areas are the following. A. Carburetor jetting B. Drive belt deflection/Break-In C. Track tension and alignment CARBURETOR JETTING (Carbureted Models)— Altitude, temperature, and the use of oxygenated gasoline affect the carburetion needed for optimum engine performance. The carburetor main jets must be changed in conjunction with changes in operating altitude, oxygenated gasoline usage, and temperature. DRIVE BELT DEFLECTION — Drive belt deflection is very important to the snowmobile. Even if it is checked and is correct when the snowmobile is set up, it does change (more so during the break-in period). This is because the rubber engine mounts and the rubber snubber on the torque link will all take a “set” during the first 100 miles, which allows the distance between the drive clutch and driven pulley to shorten. When this happens, the snowmobile will appear to have a too long drive belt. To add to this, the drive belt itself wears and stretches some- what. This all leads to a low-end performance problem and, if not corrected, causes premature drive belt wear. ! WARNING On VM-style carburetors, be sure to tighten the swivel adapter jam nuts securely. If a jam nut isn’t tightened, the adjuster can rotate out of the carburetor cap causing the piston valve not to return to the full-closed position.

1-6 After the break-in period, drive belt deflection should be checked according to the instructions given in this manual. To correct for too much deflection, washer(s) from between the driven pulley sheaves can be removed to “tighten the drive belt” and allow the belt to return to the proper ratio for drive clutch engagement. DRIVE BELT BREAK-IN — It is critical for maximum drive belt life to allow the belt to break in before subjecting it to hard use such as wide-open-throttle operation or hill climbing. The first 20 miles on the drive belt should be at 1/2 throttle or lower. This will allow the belt to cure totally before it is subjected to hard use. If this procedure isn’t followed, it is possible to destroy a new drive belt in less than 50 miles. This should be explained to customers at the time of drive belt sales. To increase the life of a drive belt, it is very important that the belt be warmed up before subjecting it to any type of use. In cold temperature (0° or below), the engine should be allowed to idle for a period of 8 to 10 minutes. This will allow heat from the engine compartment to soften the drive belt. Not only will this procedure increase belt life but will also help prevent engine damage from cold sei- zure. Each operator should be instructed to drive the snowmobile for several minutes at a low throttle setting to warm the belt up before using wide-open-throttle. This practice should be followed on all models for maximum belt life. TRACK TENSION AND ALIGNMENT — There is a certain amount of stretch on all tracks during the first 500 miles. The track must be adjusted after the first 50 to 100 miles to the specifications given in the Setup and Pre- delivery Manual and periodically thereafter. If these adjustments aren’t performed, the track may “derail” which leads to track and slide rail damage. Along with these three major areas, there are also other areas that should be checked and adjusted during the “After Break-In Checkup.” A checklist to assist you with this service follows. Not only will the customer be hap- pier, but it also gets the customer back into your dealership, which in many cases will mean additional sales in accessories, belts, oil, etc. After Break-In Checkup Checklist Below is a recommended list of items to check after the break-in period. By performing this inspection, warranty cost can be reduced and customer satisfac- tion can be increased. The recommended mileage for this inspection is between 100 and 300 miles. Please encourage the customers to have this important checkup done. Jet carburetor(s) according to average temperature, type of gasoline being used, and altitude Adjust drive belt deflection Adjust track tension and alignment Adjust throttle cable tension Check oil-injection pump adjustment Check engine idle Check coolant level Check chain case lubricant level Check lights (high/low beam, brakelight) Check safety switch operation Check driveshaft area for any rubbing components Check steering hardware for tightness Check skid frame and A-arm mounting hardware for tightness Check brake lever travel and adjustment Grease all lubrication points

1-7 1 Torque Conversions Tightening Torque (General Bolts) ft-lb kg-m ft-lb kg-m ft-lb kg-m ft-lb kg-m ft-lb kg-m 1 0.1 21 2.9 41 5.7 61 8.4 81 11.2 2 0.3 22 3.0 42 5.8 62 8.6 82 11.3 3 0.4 23 3.2 43 5.8 63 8.7 83 11.5 4 0.6 24 3.3 44 6.1 64 8.9 84 11.6 5 0.7 25 3.5 45 6.2 65 9.0 85 11.8 6 0.8 26 3.6 46 6.4 66 9.1 86 11.9 7 1.0 27 3.7 47 6.5 67 9.3 87 12.0 8 1.1 28 3.9 48 6.6 68 9.4 88 12.2 9 1.2 29 4.0 49 6.8 69 9.5 89 12.3 10 1.4 30 4.2 50 6.9 70 9.7 90 12.5 11 1.5 31 4.3 51 7.1 71 9.8 91 12.6 12 1.7 32 4.4 52 7.2 72 10.0 92 12.8 13 1.8 33 4.6 53 7.3 73 10.1 93 12.9 14 1.9 34 4.7 54 7.5 74 10.2 94 13.0 15 2.1 35 4.8 55 7.6 75 10.4 95 13.1 16 2.2 36 5.0 56 7.7 76 10.5 96 13.3 17 2.4 37 5.1 57 7.9 77 10.7 97 13.4 18 2.5 38 5.3 58 8.0 78 10.8 98 13.6 19 2.6 39 5.4 59 8.2 79 10.9 99 13.7 20 2.8 40 5.5 60 8.3 80 11.1 100 13.8 Type of Bolt Thread Diameter A (mm) Tightening Torque kg-m ft-lb (Conventional or 4 Marked Bolt) 5 0.2-0.4 1.5-3.0 6 0.4-0.7 3.0-5.0 8 1.0-1.6 7.0-11.5 10 2.2-3.5 16.0-25.5 (7 Marked Bolt) 5 0.3-0.6 2.0-4.5 6 0.8-1.2 6.0-8.5 8 1.8-2.8 13.0-20.0 10 4.0-6.0 29.0-43.5

1-8 Fraction/Decimal Conversion Chart Drill Bit Sizes (Number) Chart 8ths 16ths 32nds 64ths 64ths (cont) 1/8 = .125 1/16 = .0625 1/32 = .03125 1/64 = .015625 33/64 = .515625 1/4 = .250 3/16 = .1875 3/32 = .09375 3/64 = .046875 35/64 = .546875 3/8 = .375 5/16 = .3125 5/32 = .15625 5/64 = .078125 37/64 = .578125 1/2 = .500 7/16 = .4375 7/32 = .21875 7/64 = .109375 39/64 = .609375 5/8 = .625 9/16 = .5625 9/32 = .28125 9/64 = .140625 41/64 = .640625 3/4 = .750 11/16 = .6875 11/32 = .34375 11/64 = .171875 43/64 = .671875 7/8 = .875 13/16 = .8125 13/32 = .40625 13/64 = .203125 45/64 = .703125 — 15/16 = .9375 15/32 = .46875 15/64 = .234370 47/64 = .734375 — — 17/32 = .53125 17/64 = .265625 49/64 = .765625 — — 19/32 = .59375 19/64 = .296875 51/64 = .796875 — — 21/32 = .65625 21/64 = .328125 53/64 = .828125 — — 23/32 = .71875 23/64 = .359375 55/64 = .859375 — — 25/32 = .78125 25/64 = .390625 57/64 = .890625 — — 27/32 = .84375 27/64 = .421875 59/64 = .921875 — — 29/32 = .90625 29/64 = .453125 61/64 = .953125 — — 31/32 = .96875 31/64 = .484375 63/64 = .984375 No. Size of Drill in Inches No. Size of Drill in Inches No. Size of Drill in Inches No. Size of Drill in Inches 1 .2280 21 .1590 41 .0960 61 .0390 2 .2210 22 .1570 42 .0935 62 .0380 3 .2130 23 .1540 43 .0890 63 .0370 4 .2090 24 .1520 44 .0860 64 .0360 5 .2055 25 .1495 45 .0820 65 .0350 6 .2040 26 .1470 46 .0810 66 .0330 7 .2010 27 .1440 47 .0785 67 .0320 8 .1990 28 .1405 48 .0760 68 .0310 9 .1960 29 .1360 49 .0730 69 .0292 10 .1935 30 .1285 50 .0700 70 .0280 11 .1910 31 .1200 51 .0670 71 .0260 12 .1890 32 .1160 52 .0635 72 .0250 13 .1850 33 .1130 53 .0595 73 .0240 14 .1820 34 .1110 54 .0550 74 .0225 15 .1800 35 .1100 55 .0520 75 .0210 16 .1770 36 .1065 56 .0465 76 .0200 17 .1730 37 .1040 57 .0430 77 .0180 18 .1695 38 .1015 58 .0420 78 .0160 19 .1660 39 .0995 59 .0410 79 .0145 20 .1610 40 .0980 60 .0400 80 .0135 kg-m x 7.235 = ft-lb ft-lb x 0.1383 = kg-m

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Arctic Cat F6 Firecat EFI Sno Pro 2004 Factory Service & Work Shop Manual

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