Arctic Cat 2007 Operator's Manual

20072007SnowmobileOperator’sManualp/n 2257-617

6 GENERAL INFORMATIONT660/Bearcat Wide Track Models741-632ABearcat 570 Model740-586APanther 570/660 Models741-634A

96 PREPARATION FOR STORAGE8. Start the engine and allow to idle.With the engine idling, spray Arc-tic Cat Engine Storage Preserver(p/n 0636-177) into

PREPARATION FOR STORAGE 9717. Apply light oil to the upper steer-ing post bushing, ski spindles andbolts, front and rear pivot bush-ings of the skid f

98 PREPARATION AFTER STORAGEPREPARATION AFTER STORAGETaking the snowmobile out of storageand correctly preparing it for anotherseason will assure many

PREPARATION AFTER STORAGE 9910. Lubricate the rear suspension,spindles, speedometer driveadapter, and driven shaft supportbearing with a low-temperatu

100U.S. EPA EMISSION CONTROL STATEMENT/ WARRANTY COVERAGE(U.S. Only)STATEMENT/WARRANTYArctic Cat warrants to the original retail purchaser, and each s

101CHANGE OF ADDRESS, OWNERSHIP, OR WARRANTY TRANSFERArctic Cat Inc. keeps on file the current name and address of theowner of this snowmobile. This w

Fold Back OncePlaceStampHereCHANGE OF ADDRESS/OWNERSHIPARCTIC CAT INC.PRODUCT SERVICE ANDWARRANTY DEPT.P.O. BOX 810THIEF RIVER FALLS, MN 56701

WARRANTY PROCEDURE/OWNER RESPONSIBILITYAt the time of sale, an Owner Registration form (included with eachnew snowmobile) is to be completed by the se

104MAINTENANCE RECORDDATE MILEAGESERVICE PERFORMED/NOTES

105MAINTENANCE RECORDDATE MILEAGESERVICE PERFORMED/NOTES

GENERAL INFORMATION 7TIPPED SNOWMOBILETipping a snowmobile on its side issometimes desirable for maintenancepurposes; however, on a 660 cc model,Arcti

106MAINTENANCE RECORDDATE MILEAGESERVICE PERFORMED/NOTES

Printed in U.S.A. Trademarks of Arctic Cat Inc. Thief River Falls, MN 56701 p/n 2257-617®TMARCTIC CAT®

8 GENERAL INFORMATIONGASOLINE-OILRecommended Gasoline (Carbureted Models)The recommended gasoline to use inthese snowmobiles is 87 minimumoctane regul

GENERAL INFORMATION 9OILCHARTDAfter the engine break-in period, theengine oil should be changed every2500-3000 miles on standard 660 ccmodels.Recommen

10 GENERAL INFORMATION4. Fill the gasoline container withgasoline; then cap the gasolinecontainer and shake the mixturevigorously.5. Using a fine-mesh

GENERAL INFORMATION 11To ensure proper engine break-in onthe 1100 cc Z1 and 660 cc models,Arctic Cat recommends that theengine oil and filter be chang

12 GENERAL INFORMATIONCOOLANT TEMPERATURE WARNING LIGHT (Carbureted Models/Bearcat W/T Non-Turbo/Panther 660)If the coolant temperature is at themaxim

GENERAL INFORMATION 13ZJ001AA. Chassis Control UnitB. Oil Pressure/Low OilC. High BeamD. Check EngineE. Coolant Temperature Top ButtonBy pushing the t

14 GENERAL INFORMATIONLow Oil Warning Light (Crossfire/F-Series/M-Series Models)The Low Oil Warning Light isdesigned to alert the snowmobileoperator w

GENERAL INFORMATION 15ZJ004A NOTE: When air can no longerbe heard, purging from oil pumpbleed, tighten the bleed bolt to1.05 kg-m (7.5 ft-lb).4. Star

LIMITED WARRANTY Arctic Cat Inc. (hereinafter referred to as Arctic Cat) extends a limited warranty on each new Arctic CatSnowmobile it manufactures a

16 GENERAL INFORMATIONDIAGNOSTIC CODES/CHECK ENGINE (JAGUAR Z1)These diagnostic codes are flashed bythe check engine light. Refer to thefollowing char

GENERAL INFORMATION 17HANDLEBAR TILTThe handlebar can be adjusted to theposition providing the operator withthe most comfort. To adjust the han-dlebar

18 GENERAL INFORMATION735-501B2. Adjust the handlebar up or downto operator’s desired tilt, tightenthe cap screws evenly to 3.5 kg-m(25 ft-lb), and ch

GENERAL INFORMATION 194. After the handlebar is “locked” inposition, release the cam lever androtate it one turn clockwise; thenpress down on the cam

20 GENERAL INFORMATIONCOOLING SYSTEM (Liquid)Some snowmobiles are equipped witha closed liquid cooling system forengine cooling. The cooling systemsho

GENERAL INFORMATION 21When operating the snowmobile athigh altitudes, it may be necessary tochange certain component parts of thedrive clutch. See an

22 GENERAL INFORMATION NOTE: If the adjustment boltwill not turn using the fingers(because of dirty threads), use awrench to loosen the bolt; thenusi

GENERAL INFORMATION 23 NOTE: The frequency of ser-vicing rebuildable shock absorb-ers will vary according to thetypes of conditions and terrainthe sn

24 GENERAL INFORMATION NOTE: Stud installation can beperformed by the snowmobileowner if qualified to do so. If theowner does not feel qualified,take

GENERAL INFORMATION 25Always use minimal speed when oper-ating in reverse and come to a com-plete stop before shifting from eitherforward to reverse o

Table of ContentsLimited Warranty...Inside Front CoverForeword...1Declaration of

26 GENERAL INFORMATION0741-438 NOTE: The system will notshift until the button is released.3. To shift into forward, stop thesnowmobile and allow the

GENERAL INFORMATION 270735-854To install the rear seat, use the follow-ing procedure:1. Place the seat into position on thetunnel making sure the two

28 GENERAL INFORMATION2. Lift up on the back of the seat;then move the front of the seat upor down into one of the sevenavailable positions.3. Press d

GENERAL INFORMATION 29The system consists of an exhaustvalve assembly mounted to theexhaust side of each cylinder and con-nected by adjustable cables

30 GENERAL INFORMATIONIf a system fault is suspected, use anohmmeter to check continuity of theexhaust pipe temperature sensorlocated in the expansion

OPERATING INSTRUCTIONS 31OPERATING INSTRUCTIONSSTARTING AND STOPPING ENGINEIt is imperative that the brake systembe checked for wear and proper opera-

32 OPERATING INSTRUCTIONS740-159A0740-588 NOTE: On models with a sightglass if the sight glass appearsdark, there is a sufficientamount of fluid in t

OPERATING INSTRUCTIONS 33 NOTE: On carbureted modelswhen the engine is being startedwith aid of the choke, DO NOTCOMPRESS THE THROTTLECONTROL LEVER.

34 OPERATING INSTRUCTIONS10. Flooding — On carbureted mod-els if the engine does not startwhen the choke is being used butseems ready to start, move t

OPERATING INSTRUCTIONS 35HIGH RPM OPERATION(660 cc Models)On a 660 cc model when the enginespeed returns to idle after a sustainedperiod of high RPM o

REFERENCE INFORMATIONWrite the appropriate information for your Arctic Cat Snowmobile in the spacesbelow. Always use these numbers when referring to y

36 OPERATING INSTRUCTIONS3. Never ride the brake. Even main-taining minimal pressure on thebrake lever will cause the brakepads to drag on the disc an

OPERATING INSTRUCTIONS 37 NOTE: On 660 cc models,ensure that the ignition switchkey is in the OFF position whenthe engine is not running. Leav-ing th

38 OPERATING INSTRUCTIONS NOTE: On fan-cooled modelsif the throttle control lever oper-ates properly and the enginedoes not start, either a malfunc-t

OPERATING INSTRUCTIONS 39 NOTE: The monitor switch isnow bypassed. With exceptionof the monitor switch and theemergency stop switch, all otherignitio

40 LUBRICATIONLUBRICATIONSTANDARD CHAIN CASE (Every 40 Operating Hours)The recommended amount of trans-mission lube in the chain case is 236ml (8 fl o

LUBRICATION 41ACT DRIVE GEAR CASE (Each Season Prior to Storage) NOTE: Flushing the gear caseand replacing the lubricant canbe done by the snowmobile

42 LUBRICATION5. Tip the snowmobile back to theupright position; then place adrain pan on the floor next to thedrain hose and tip the snowmobiletoward

LUBRICATION 4315. Tip the snowmobile onto its rightside and place a piece of card-board underneath.16. Remove the drain plug from thegear case; then i

44 LUBRICATION0739-724F-Series/Jaguar Z1741-335AOn the Crossfire/F-Series/M-Series/Jaguar Z1 models, pump grease intothe upper steering shaft grease f

LUBRICATION 45REAR SUSPENSION (Every 40 Operating Hours) NOTE: Arctic Cat recommendsthat Arctic Cat Low-TempGrease (p/n 0636-593) be usedfor this pro

1FOREWORDCongratulations! You have chosen a quality Arctic Cat Snowmobile designedand manufactured to give dependable service. Be sure, as the owner/o

46 MAINTENANCEMAINTENANCEPERIODIC MAINTENANCE CHECKLISTITEM INTERVAL PAGE REMARKSAir Filter(660 cc Turbo) 2000 miles/Seasonal__ ReplaceBrake System (H

MAINTENANCE 47The longevity and safety of the snow-mobile can be increased by makingperiodic checks of the items in the pre-ceding checklist.If, at an

48 MAINTENANCE3. Install the in-line fuel filter in thefuel hose so the arrow on the filterpoints toward the fuel pump.Make sure the fuel hoses fittig

MAINTENANCE 49 NOTE: It takes 800 ml (27 fl oz)to raise the oil level from thelower mark to the upper mark onthe bottom end of the stick.CHECKING ENG

50 MAINTENANCE2. Place a drain pan beneath thebelly pan plug hole; then removethe oil drain plug and washerfrom the underside of the crank-case.3. Rem

MAINTENANCE 517. Using Oil Filter Wrench (p/n0644-389), loosen (but do notremove) the oil filter and allowthe oil to drain from the filter;then remove

52 MAINTENANCEADJUSTING CARBURETOR(Single)The carburetor has been calibrated atthe factory for average riding condi-tions; however, altitude, temperat

MAINTENANCE 530727-1562. Loosen the jam nut securing thethrottle cable swivel adapter; thenrotate the swivel adapter clock-wise until the piston valve

54 MAINTENANCEAdjusting Engine Idle Speed1. With the snowmobile on ashielded safety stand, start theengine, release the parking brake,and thoroughly w

MAINTENANCE 55 NOTE: Carburetor adjust-ments and changing main jetsmay be done by the snowmobileowner if qualified to do so. If theowner does not fee

2DECLARATION OF CONFORMITYApplication of council directives: EMC Directive 89/336/EECEC Machinery Directive 98/37/ECIssued by European Commission.Type

56 MAINTENANCE NOTE: On some models, theair-intake silencer includes acover/tool tray assembly and abaffle/resonator, and thesilencer boot cannot ber

MAINTENANCE 579. In turn on each carburetor, place afinger against the piston valve.Rotate the idle speed screw clock-wise until it contacts the valve

58 MAINTENANCE5. With the snowmobile on ashielded safety stand, start theengine, release the brake leverlock, and thoroughly warm up. NOTE: Make engi

MAINTENANCE 59 NOTE: Carburetor main jet(s)may be changed by the snow-mobile owner if qualified to doso. If the owner does not feelqualified, take th

60 MAINTENANCEVarying terrain conditions and operat-ing usage may require spark plugs of adifferent heat range. For example, sus-tained cross-country

MAINTENANCE 613. Install the plugs and finger-tighten.4. Tighten the spark plugs to 2.5-2.8kg-m (18-20 ft-lb); then install thespark plug caps.Removin

62 MAINTENANCECHECKING/ADJUSTING VALVE CLEARANCE (660 cc/1100 cc Z1)After 3500 miles (660 cc)/5000 miles(1100 cc Z1) or prior to seasonal stor-age, va

MAINTENANCE 631. Remove the negative batterycable; then remove the positivecable and the battery vent tube.Remove the battery from thesnowmobile. Care

64 MAINTENANCESealed with Cap Strip1. Remove the battery from thesnowmobile. NOTE: This battery is perma-nently sealed. There is no needto remove the

MAINTENANCE 65736-448AOnce which fuse to check has beendetermined, perform the followingsteps:1. Open the hood and remove thefuse panel cover. The fus

SNOWMOBILE SAFETY RULES 3SNOWMOBILE SAFETY RULES

66 MAINTENANCE1. Open the right-side access panel;then remove the fuse panel cover.The fuse panel is located behindthe battery.ZJ005A NOTE: There are

MAINTENANCE 672. At the point where the disc islocked, check the distancebetween the brake lever and thelever stop. The distance must bewithin a range

68 MAINTENANCE NOTE: When adjusting thebrake, do not accidentally closethe gas tank shut-off valve. NOTE: When new brake padsare installed, a “burni

MAINTENANCE 69Changing Brake FluidThe brake fluid must be changed on aregular basis and whenever the brakefluid has been overheated or contami-nated.

70 MAINTENANCEBleeding Brake SystemIf the brake lever feels spongy whenapplied, the brake system may need tobe bled. To bleed the brake, use thefollow

MAINTENANCE 71Checking/Changing Brake PadsThe condition of the brake pads mustbe checked daily and changed if wornor damaged. To check and change theb

72 MAINTENANCE5. Using a flat-blade tool, slowlyand carefully push the piston intothe caliper.6. Position the new brake pads intothe caliper.7. Repeat

MAINTENANCE 73Also, drive belts have a break-inperiod of approximately 20 miles.After installing a new drive belt, drivethe snowmobile for 20 miles at

74 MAINTENANCE4. After the belt is installed properly,close and secure the belt guardand the hood.5. Release the brake lever lock.Removing Drive Belt

MAINTENANCE 75741-721B7. On Style A with the O-ring andshim washers removed, carefullythread the sheave adjuster backinto the driven pulley; thentight

4 GENERAL INFORMATIONGENERAL INFORMATIONSNOWMOBILE IDENTIFICATIONThe Arctic Cat Snowmobile has twoimportant identification numbers. TheVehicle Identif

76 MAINTENANCE5. Release the brake lever lock.TRACK TENSIONTrack tension is directly related to theoverall performance of the snowmo-bile. If the trac

MAINTENANCE 77729-429A NOTE: On the M-Series, mea-surement is from the bottom ofthe wear strip at the point of theshock pad on the slide rail.Adjusti

78 MAINTENANCETRACK ALIGNMENTProper track alignment is obtainedwhen the rear idler wheels are equaldistance from the inner track drivelugs. Excessive

MAINTENANCE 790727-7290739-6375. If the idler wheels are not cen-tered between the inner trackdrive lugs, an adjustment is nec-essary.Adjusting Track

80 MAINTENANCEAdjusting Front Shock Springs (STD) NOTE: On some models, thefront shock springs are notadjustable.The front shock springs are individu

MAINTENANCE 81To increase or decrease air pressure,use the following procedure. NOTE: When adjusting airpressure, all weight must beremoved from the

82 MAINTENANCE0730-5370739-714Adjusting Rear Spring Pre-LoadProper adjustment of rear spring pre-load is necessary to get the most com-fortable ride.

MAINTENANCE 83Articulating Skid Fame(Bearcat Wide Track Models)The rear articulating portion of theskid frame has two adjusters whichcontrol the amoun

84 MAINTENANCE2. Push in on the bulb and rotate itcounterclockwise to remove itfrom the socket.3. Install the new bulb in the socketby pushing it in a

MAINTENANCE 852. Rotate the headlight bulb basecounterclockwise and remove thebulb from the headlight housing.Installing Headlight Bulb (3-Bulb Style)

GENERAL INFORMATION 5Z Models734-268AF-Series/Jaguar Z1 Models741-375BCrossfire/M-Series Models741-633A

86 MAINTENANCERemoving Headlight Bulb (Crossfire/M-Series Models) NOTE: The bulb portion ofheadlight is fragile. HANDLEWITH CARE. When replacing theh

MAINTENANCE 87Removing Headlight Bulb (F-Series/Jaguar Z1) NOTE: The bulb portion ofheadlight is fragile. HANDLEWITH CARE. When replacing theheadlig

88 MAINTENANCEInstalling Headlight Bulb (F-Series/Jaguar Z1)1. Plug the wiring harness into theheadlight bulb.2. Insert the bulb into the headlighthou

MAINTENANCE 894. Make a vertical mark which inter-sects the horizontal mark on theaiming surface directly in front ofthe headlight.5. Engage the brake

90 MAINTENANCE3. Remove the lock nuts and wash-ers (if applicable) securing thewear bar to the ski.737-454A731-037D0739-5960739-0164. Remove the wear

MAINTENANCE 912. Remove the cotter pin; thenremove the slotted nut and capscrew securing the ski assemblyto the spindle. Remove the ski.Account for th

92 MAINTENANCE1. Be sure ignition key is in the OFFposition.2. Lift the hood and remove thescrews securing the fan cover;then remove the fan cover.3.

MAINTENANCE 93Adjusting Belt Tension1. Remove the bolts securing thebelt guard to the engine; thenremove the belt guard from theengine compartment.2.

94 PERFORMANCE TIPSPERFORMANCE TIPSOperating a high performance snow-mobile requires a special attention thatis not required by a low performancesnowm

PREPARATION FOR STORAGE 95PREPARATION FOR STORAGEPrior to storing the snowmobile, itmust be properly serviced to preventcorrosion and component deteri