1974 ARCTIC CAT PANTHER 440 VIP Factory Service & Work Shop Manual

Chapter One II General Information Chapter Two II Periodic Maintenance and Tune-up Chapter Three II Troubleshooting Chapter Four Engine Chapter Five II Fuel System Chapter Six II Electrical System Chapter Seven II Power Train Chapter Eight II Front Suspension and Track - Chapter Nine II Rear Suspension and Track - Supplement _ 1978 and Later Service Information .... Index III

CONTENTS QUICK REFERENCE DATA CHAPTER ONE GENERAL INFORMATION Manual organization Machine identification and parts replacement Operation Service hints CHAPTER TWO Tools Expendable supplies Working safely Snowmobiling code of ethics Snowmobile safety PERIODIC MAINTENANCE AND TUNE-UP Service intervals Fuel filter Chaincase oil level Drive belt Brake Drive clutch and driven pulley Track tension CHAPTER THREE TROUBLESHOOTING Operating requirements Principles of 2-cycle engines Engine starting Engine performance Engine failure analysis Electrical system CHAPTER FOUR ENGINE Upper end overhaul CHAPTER FIVE FUEL SYSTEM Walbro carburetor Mikuni carburetor Intake silencers Track alignment Suspension adjustment Tune-up Cylinder head bolts Ignition system Carburetion Off~season storage Power train Drive belt wear analysis Ski s and steering Track assembly Track wear analysis Lower end overhaul Fuel tank Inline fuel filter Fuel pump VII 12 31 42 57

CHAPTER SIX ELECTRICAL SYSTEM Capacitor discharge igoition (CDI) Magneto ignition Lighting system Testing CHAPTER SEVEN POWER TRAIN Drive belt Drive clutch Driven pulley CHAPTER EIGHT FRONT SUSPENSION AND STEERING Ski wear bars Skis Tie rods Ski alignment CHAPTER NINE REAR SUSPENSION AND TRACK Suspension removal and installation SUPPLEMENT 1978- 1979 SERVICE INFORMATION 1978-1979 models INDEX Suspension adjustment- EI Tigre models Drive belt specifications Ignition specifications Basic air screw setting- Mikuni carburetors Headlight and bulb replacement Headlight aiming Brake/taillight bulb replacement Drive chain and sprockets Driven shaft Track drive shaft and track Spindle Steering post Throttle handle Brake handle 75 85 91 . ... . 100 Hi -Fax slide replacement . . .. 104 Engine specifications and tightening torques Liquid.cooled engine (EI Tigre 6000) Upper-end rebuild Lower-end rebuild Engine pressure testing Reed valve (EI Tigre) .... 123

QUICI\ REFERENCE DATA Choke adjuster stop screw BASIC AIR SCREW SETTING- WALBRO CARBURETORS Model/Engine Low speed mi x ture needle High speed mixture needle Throttle cable s lack Setting 1 turn out 1 Va turns out 116 in. BASIC AIR SCREW SETTING- MIKUNI CARBURETORS Model/Engine EITigre 1974-1975 All models 1976-1977 4000 5000 1978-1979 Jag All models TUrns Out lynx All models 1 '/2 Pantera All models thru 1977 1 1978 Fan 1 1/2 1978 Free-air 1 1979 all PI. Panther/Cheetah 4000 3/. 5000 thru 1977 50001978-1979 1 IV .. DRIVE BELT SPECIFICATIONS Model Year Outside Circumference Width Lynx All yea rs 43 % in. 11 k in. Pantera Through 1975 43%i n. 11 k in . 1976 on 46% in . l 'k in. Jag Through 1977 44~i n . 1 %: in. 1978-1979 45 % in . Cheetah All years 43% i n. 1 %: in . EITigre Through 1977 46% in . 1% in. 1978-1979 43% in . 1% in. Panther All years 43% in . 1% in . Vll Idle stop screw

LYNX IGNITION SPECIFICATIONS Contact breaker gap Flywheel bolt torque Timing Track tension Brake adjustment 0.012·0. 016 in. (0.3·0.4mm) 65·80 ft.·lb. (9·11 mkg) 18° or 0.073 in. (1.86mm) BlDC ADJUSTMENTS %-1 in. (19-25mm) slack between slide and inside surface of track lh·lA in. (12·18mm) between brake control lever and stop FUEL, LUBRICATION, AND CAPACITIES Fuel Engine oil Type Mixture ratio Except Wankel Wankel Chaincase Gil Octane rating 88 or higher. Use premium in all high performance machines. Arctic Cat Purple Powerlube II-Gel or Chemilube 20:1 30:1 Arctic Cat lube SPARK PLUG TYPE AND GAP Model/Engine Type' Gap Lynx 1970975 2000S NGK BR9HS 0.026·0.030 in. (0.66·0.76mm) Champion L77 J 1976·1979 2OO0S NGK BR9ESA 0.018·0.022 in. (0.46·0.56mm) Champion RN2 1976·1979 2000T NGK BR8ESA 0.018·0.022 in. (0.46·0.56mm) Champion RN3 EI Tigre 1970975 all NGK BR9EVA 0.016·0.020 in. (0.41·0.51mm) Champion RN2 1976·1977 4000 NGK BR8ESA 0.018·0.022 in. (0.46·0.56mm) Champion RN3 1976·1979 5000/6000 NGK BR9ESA 0.018·0.022 in. (0.46·0.56mm) Champion RN2 Panther ;Cheetah 1974·1975 all NGK B8ESA 0.020·0.032 in. (0.51·0.81mm) Champion N3 Bosch W215T 28 1976·1977 4000 NGK BR8ESA 0.018·0.022 in. (0.46·0.56mm) Champion RN3 1976·1979 5000 NGK BR9ESA 0.018·0.022 in. (0.46·0.56mm) Champion RNl Pantera All fan·cooled (e"ept 1978·1979) NGK BR8ESA 0.018·0.022 in. (0.46·0.56mm) Champion RN3 All free-air and 1978·1979 fan-cooled NGK BR9ESA 0.018·0.022 in. (0.46·0.56mm) Champion RN2 Jag 1975 NGK BR8ESA 0.030 in. (0.76mm) Champion RN3 1976·1979 NGK BR8ESA 0.018·0.022 in. (0.46·0.56mm) Champion RN3 1;I Heat ranges shown are for normal operation. 1f a colder plug is required because machine is operated at sustained high speeds, change one increment at a time (e.g., if BR8ESA is specified, change to BR9ESA). If a hotter plug is required because machine is operated at low speec!s, change one increment at a time (e .g., if BR8ESA is specified, change to BR7ESA). NGK spark plugs are recommended by the manufacturer; however, an equivalent plug from anothe r manufacturer can be substituted as long as its heat range corresponds to the NGK spark plug specified in this table.

ARCTICCAT 1974-1979 SERVICE. REPAIR. MAINTENANCE

CHAPTER ONE GENERAL INFORMATION Snowmobiling has in recent years become one of the most popular outdoor winter recreational past times. It provides an opportunity for an entire family to experience the splendor of winter and enjoy a season previously regarded by many as miserable. Snowmobiles also provide an invaluable service in the form of rescue and utility vehicles in areas that would otherwise be inaccessible. As with all sophisticated machines, snowmobiles require specific periodic maintenance and repair to ensure their reliability and usefulness. MANUAL ORGANIZATION This manual provides periodic maintenance, tune-up and general repair procedures for Arctic Cat snowmobiles (except those with Wankel engines) manufactured in 1974 and later. The supplement at the end of the book con- ta in s specific service information for 1978-1979 models. If a procedure is not mentioned in the Supplement, it remains the same as on earlier models. This chapter provides general information and hints to make all snowmobile work easier and more rewarding. Additional sections cover snowmobile operation, safety and survival techniques. Chapter Two provides all tune-up and periodic maintenance required to keep your snowmobile in top running condition. Chapter Three provides numerous methods and suggestions for finding and fixing troubles fast. The chapter also describes how a 2-cycle engine works, to help you analyze troubles logically. Troubleshooting procedures discuss symptoms and logical methods to pinpoint the trouble. Subsequent chapters describe specific systems such as engine, fuel system, and electrical system. Each provides disassembly, repair, and assembly procedures in easy-to-follow, step-by- step form. If a repair is impractical for home mechanics, it is so indicated. Usually, such re- pairs are quicker and more economically done by an Arctic Cat dealer or other competent snowmobile repair shop. Some of the procedures in this manual specify special tools. In all cases, the tool is illustrated in actual use or alone. The terms NOTE, CAUTION , and WARNING have specific meaning in this book. A NOTE provides additional information to make a step or procedure easier or clearer. Disregarding a NOTE could cause inconvenience, but would not cause damage or personal injury. A CAUTION emphasizes areas where equip- ment damage could result. Disregarding a CAU- TION could cause permanent mechanical damage; however, personal injury is unlikely. A WARNING emphasizes areas where personal injury or death could result from negligence. II

z Mechanical damage may also occur. WARNINGS are to be taken seriously. In some cases serious injury or death has been caused by mechanics disregarding similar warnings. MACHINE IDENTIFICATION AND PARTS REPLACEMENT Each snowmobile has a serial number applicable to the machine and a model and serial number for the engine. See Figure 1 for the location of the machine serial number on the right side of the tunnel. See Figure Z for the location of the VIN (vehicle identification number) . Figure 3 illustrates the location of engine numbers (intake side of block) for most engines. On some engines the number is stamped on the magneto cover (Figure 4). Unless specifically noted, all serial numbers called out in procedures in this manual are machine serial numbers and not engine numbers. II I I d ---- 5412935 CHAPTER ONE '--- J, ~Model Write down all serial and model numbers applicable to your machine and carry the numbers with you. When you order parts from a dealer, always order by year and engine and machine numbers. If possible, compare old parts to the new ones before purchasing them. If parts are not alike, have the parts manager explain the difference; the new part may be improved, but it could also be the wrong one. OPERATION Fuel Mixing WARNING Serious fire hazards always exist around gasoline. Do DOt allow any smoking in areas where fuel is mixed or when refueling your snowmobile. Always use fresh fuel. Gasoline loses its potency after sitting for a period of time. Old fuel can cause engine failure and leave you stranded in severe weather.

1974 ARCTIC CAT PANTHER 440 VIP Factory Service & Work Shop Manual

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