2007 Arctic Cat Jaguar Z1 Snowmobile OEM Service & Repair Manual

FOREWORD This Arctic Cat Service Manual contains service and maintenance information for the Model Year 2007 Arctic Cat 2-Stroke Snowmobiles. This manual is designed to aid service personnel in service-oriented applications. This manual is divided into sections. The sections cover specific snowmobile components or systems and, in addition to the standard service procedures, includes assembling, disassembling, and inspecting instructions. When using this manual as a guide, the technician should use discretion as to how much disassembly is needed to correct any given condition. The service technician should become familiar with the operation and construction of the components or systems by carefully studying the complete manual. This will assist the service technician in becoming more aware of and efficient with servicing procedures. Such efficiency not only helps build consumer confidence but also saves time and labor. All Arctic Cat publications and snowmobile decals display the words Warning, Caution, and Note to emphasize important information. The symbol ! WARNING identifies personal safety-related information. Be sure to follow the directive because it deals with the possibility of severe personal injury or even death. The symbol ! CAUTION identifies unsafe practices which may result in snowmobile-related damage. Follow the directive because it deals with the possibility of damaging part or parts of the snowmobile. The symbol NOTE: identifies supplementary information worthy of particular attention. At the time of publication, all information, photographs, and illustrations were technically correct. Some photographs and illustrations used in this manual are used for clarity purposes only and are not designed to depict actual conditions. Because Arctic Cat 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. Product Service and Warranty Department Arctic Cat Inc. © 2007 Arctic Cat Inc. January 2007

Snowmobile Service Manual Snowmobile Service Manual 2-Stroke 2-Stroke TABLE OF CONTENTS Foreword Click on the red text to go. Section 1. General Information 2. Engine 3. Engine-Related Items 4. Fuel Systems 5. Engine Electrical Systems 6. Chassis Electrical Systems 7. Steering and Body 8. Drive Train and Brake Systems 9. Track/Rear Suspension

1-1 1 SECTION 1 — GENERAL INFORMATION TABLE OF CONTENTS Snowmobile Identification ....................................... 1-2 Recommended Gasoline and Oil ........................... 1-2 Break-In Procedure ................................................ 1-2 Genuine Parts ........................................................ 1-2 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 Check Engine Light (Crossfire/F-Series/M-Series Models) ................. 1-6 Diagnostic Codes/Check Engine (Crossfire/F-Series/M-Series Models) ................. 1-6 Chassis Control Unit (Crossfire/F-Series/M-Series Models) ................. 1-7 Diagnostic Codes/Chassis Control Unit (Crossfire/F-Series/M-Series Models) ................. 1-7 Torque Conversions ............................................... 1-8 Tightening Torque (General Bolts) ......................... 1-8 Fraction/Decimal Conversion Chart ....................... 1-9 Drill Bit Sizes (Number) Chart ................................ 1-9 MM/In. Conversion Chart ..................................... 1-10 Servicing Symbols ............................................... 1-11 Back to TOC

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 crankcase 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 mutilated 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. 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. 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 accelera- tions 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. ! 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 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 car- bon 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. Back to TOC Back to Section TOC Next

1-3 1 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. The M-Series 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 serviced to prevent corrosion and component deterioration. An authorized Arctic Cat Snowmobile dealer should perform this service; however, the owner/operator can perform 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 Arc- tic 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 all models except the 370 cc/570 cc, the air silencer boot can be pried forward to access the intake bores. Pry the boot forward; then proceed to step 7. NOTE: On the 370 cc/570 cc 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. 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 0436-888) 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 all models except the 370 cc/570 cc, secure the air silencer boots onto the intake bores. NOTE: On the 370 cc/570 cc 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 Arc- tic Cat Fuel Stabilizer (p/n 0436-907) to the gas tank following directions on the container for the stabilizer/gasoline ratio. Tighten the gas tank cap securely. 12. On models with a chain case, drain the 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 Trans- mission Lube (p/n 4639-364) into the filler hole - 236 ml (8 fl oz) for standard transmission or 354 ml (12 fl oz) for reverse transmission. 13. On models with a gear case, change the gear case lubricant (see Section 8). 14. Clean and inspect the drive clutch and driven pulley. ! CAUTION On carbureted models, carefully follow the Main Jet Chart recommendations for proper main jet selec- tion for altitude, temperature, and gasoline being used. ! CAUTION Never crank the engine over without grounding the spark plug(s). Damage to coils and/or CDI unit may result. Back to TOC Back to Section TOC Next Back

1-4 15. 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. 16. 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. 17. Lubricate all grease fittings (front and rear suspension, spindles, speedometer drive adapter, and the driven shaft support bearing) with a low-temperature grease. 18. Tighten all nuts, bolts, and cap screws making sure all calibrated nuts, bolts, and cap screws are tight- ened to specifications. Make sure all rivets holding the components together are tight. Replace all loose rivets. 19. Clean and polish the hood, console, and chassis with Arctic Cat Hood and Windshield Cleaner/ Polish (p/n 0636-174). DO NOT USE SOLVENTS OR SPRAY CLEANERS. THE PRO- PELLENT WILL DAMAGE THE FINISH. 20. On electric start models, disconnect the battery cables making sure to disconnect the negative cable first; then clean the battery posts and cables. 21. 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, ventilated tarpaulin to protect it from dirt and dust. 22. 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, ventilated tarpaulin to protect it from dirt, dust, and rain. Preparation After Storage Taking the snowmobile out of storage and correctly preparing it for another season will assure many miles and hours of trouble-free snowmobiling. Arctic Cat recommends the following procedure: 1. Clean the snowmobile thoroughly. Polish the exte- rior 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 reser- voir 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. ! CAUTION Batteries require charging if left for extended non- start periods. Arctic Cat recommends not servicing the battery until the snowmobile is to be used or trickle charging once a month. Follow the manufa- turer’s instructions and cautions. ! CAUTION On models with remote start, make sure to leave the battery cables disconnected. Failure to disconnect the battery cables when storing the snowmobile for a prolonged period of time (six weeks or more) will result in a discharged or damaged battery. ! 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. Back to TOC Back to Section TOC Next Back

1-5 1 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 tight- ened 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 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 Mod- els)— 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 somewhat. This all leads to a low-end performance problem and, if not corrected, causes premature drive belt wear. After the break-in period, drive belt deflection should be checked according to the instructions given in this manual. 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 gain its optimum flexibility and will extend belt life. Do not exceed 50 MPH during the first 20 miles. 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 compart- ment to soften the drive belt. Not only will this procedure increase belt life but will also help prevent engine damage from cold seizure. 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. In addition to instructing each operator about these drive belt break-in procedures, Arctic Cat also recommends that the operators be informed that a drive belt (like brake pads, wear strips, etc.) is considered a nor- mal wear item and is listed as an exclusion on the Arc- tic Cat Limited Warranty. 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. ! WARNING On carbureted models, be sure to tighten the swivel adapter jam nuts securely. If a jam nut isn’t tight- ened, the adjuster can rotate out of the carburetor cap causing the piston valve not to return to the full- closed position. Back to TOC Back to Section TOC Next Back

1-6 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 happier, 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 satisfaction 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. R Jet carburetor(s) according to average temperature, type of gasoline being used, and altitude R Adjust drive belt deflection R Adjust track tension and alignment R Check throttle cable tension R Check oil-injection pump adjustment R Check engine idle R Check coolant level R Check chain case/gear case lubricant level R Check lights (high/low beam, brakelight) R Check safety switch operation R Check driveshaft area for any rubbing components R Check steering hardware for tightness R Check skid frame and A-arm mounting hardware for tightness R Check brake lever travel and adjustment R Grease all lubrication points Check Engine Light (Crossfire/F-Series/ M-Series Models) The Check Engine Light is controlled by the ECU and may illuminate for a number of reasons. The light should illuminate each time the key is turned to RUN or START, and it should go out when the engine starts. If the light stays illuminated or it illuminates while the engine is running, the ECU is receiving input that is outside of its established parameters. Diagnostic Codes/ Check Engine (Crossfire/F-Series/ M-Series Models) These diagnostic codes are flashed by the check engine light incorporated within the speedometer/tachometer. Refer to the following chart for diagnostic code sequences. NOTE: On single-digit codes (2, 4, etc.), the number indicated will flash in an uninterrupted sequence. On double-digit codes (1-2, 1-6, etc.), the first number indicated will flash in an uninterrupted sequence, there will be a short pause, and the second number indicated will flash in an uninterrupted sequence. If the coolant temperature is at or above 80° C (176° F), the coolant temperature light will flash a warning (alert). If the coolant temperature is at or above 93° C (200° F), the coolant temperature light will cease flash- ing and will remain constantly illuminated. Number of Flashes Trouble 1-2 (Check Engine Light) Failure in ignition coil. 1-6 (Check Engine Light) Incorrect adjustment/failure in APV cable. 1-7 (Check Engine Light) Failure in exhaust temperature sensor. 1-8 (Check Engine Light) Failure in servomotor. 2 (Check Engine Light) Failure in injector(s). 2-1 (Check Engine Light) Failure in knock sensor. 2-3 (Check Engine Light) Failure in knock control system. 4 (Check Engine Light) Open or short circuit in baromet- ric pressure sensor. 5 (Check Engine Light) Open or short circuit in intake air temperature sensor. 6 (Check Engine Light) Open or short circuit in water temperature sensor. 7 (Check Engine Light) Open or short circuit in throttle position sensor. Steady Flash (Coolant Temperature Light) Coolant Temperature Above 80° C (176° F). Constant On (Coolant Temperature Light) Coolant Temperature Above 93° C (200° F). Back to TOC Back to Section TOC Next Back

1-7 1 Chassis Control Unit (Crossfire/F-Series/ M-Series Models) The Chassis Control Icon may illuminate for a number of reasons. The light should illuminate each time the key is turned to RUN or START, and it should go out when the engine starts. If the light stays illumintated or it illuminates while the engine is running, the CCU is receiving input that is outside of its established parameters. Diagnostic Codes/ Chassis Control Unit (Crossfire/F-Series/ M-Series Models) These diagnostic codes are flashed by the wrench icon light incorporated within the speedometer/tachometer. Refer to the following chart for diagnostic code sequences. NOTE: On these double-digit codes (3-1, 3-2, etc.), the first number indicated will flash in an uninterrupted sequence, there will be a short pause, and the second number indicated will flash in an uninterrupted sequence. Number of Flashes Trouble 3-1 (CCU Icon) Stator failure (input open or shorted). 3-2 (CCU Icon) High power DC output deactivated (headlight/handwarmer). 3-3 (CCU Icon) High power DC output shorted (headlight/handwarmer). 3-4 (CCU Icon) Low power DC output deactivated (gauge/taillight/APV valves). 3-5 (CCU Icon) Low power DC output shorted (gauge/taillight/APV valves). 3-6 (CCU Icon) System under voltage (below 11 volts). 3-7 (CCU Icon) System over voltage. (above 15.5 volts). 3-8 (CCU Icon) Gear shift actuator failure (over current or over temperature). 4-2 (CCU Icon) Tachometer input failure (engine running - no tachometer signal present). 4-3 (CCU Icon) Gear position switch failure (did not change - no (or invalid) position input). 4-4 (CCU Icon) CCU over temperature (above 105° C - 221° F). Back to TOC Back to Section TOC Next Back

1-8 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 Back to TOC Back to Section TOC Next Back

2007 Arctic Cat Jaguar Z1 Snowmobile OEM Service & Repair Manual

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