Snowmobile Arctic Cat (2008 year). Manual - part 1

FOREWORD

This Arctic Cat Service Manual contains service and maintenance information for the Model Year 2008 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 con-

dition.

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 impor-

tant 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 informa-

tion 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.

September 2007

®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN

TABLE OF

CONTENTS

Click on the red text to go.

Foreword

Section

1. General Information/Specifications

2. Engine

3. Engine-Related Items

4. Fuel Systems

5. Electrical Systems

6. Drive Train and Brake Systems

7. Track/Rear Suspension

8. Steering and Body

1-1

1

SECTION 1 — 

GENERAL INFORMATION/

SPECIFICATIONS

TABLE OF

CONTENTS

Snowmobile Identification ....................................... 1-2
Recommended Gasoline and Oil ............................ 1-2
Break-In Procedure ................................................. 1-2
Genuine Parts ......................................................... 1-3
High Altitude Operation ........................................... 1-3
Preparation For Storage.......................................... 1-4
Preparation After Storage ....................................... 1-6
After Break-In Checkup (100 Miles) ........................ 1-6
After Break-In Checkup Checklist ........................... 1-7
Arctic Cat Engine Specifications ............................. 1-8
Cylinder Head Volume Specifications ..................... 1-9
Engine Piston Travel Versus 

Crank Angle Chart ............................................... 1-9

Crankshaft Runout/Repair Specifications ............. 1-10
Fraction/Decimal Conversion Chart ...................... 1-11
Drill Bit Sizes (Number) Chart............................... 1-11
MM/IN. Conversion Chart...................................... 1-11
Torque Conversions (ft-lb/N-m) ............................. 1-12
Tightening Torque (General Bolts) ........................ 1-12
Assembly Schematics/Torque Specifications

(Table of Contents)............................................. 1-12

Arctic Power Valve (APV) System 

Specifications..................................................... 1-25

Oil Consumption Specifications ............................ 1-26
EFI Specifications ................................................. 1-26
Carburetor Specifications...................................... 1-26

Fuel Pump Specifications...................................... 1-26
Mikuni Tuning Components ................................... 1-27
Major Tuning Components .................................... 1-28
Electrical Specifications ........................................ 1-29
Ignition Timing Specifications................................ 1-35
Steering/Body Torque Specifications .................... 1-37
Drive System Specifications.................................. 1-38
Drive Clutch/Driven Pulley-Related

Specifications..................................................... 1-41

Arctic Cat Drive Belt Dimension Chart .................. 1-41
Drive System Components ................................... 1-42
Arctic Cat Cam Arms............................................. 1-43
Arctic Cat Cam Arm Profiles ................................. 1-44
Chain Case Performance Calibrations .................. 1-47
Gear Case Performance Calibrations ................... 1-49
Chains and Sprockets ........................................... 1-50
Drive System Torque Specifications...................... 1-51
Rear Suspension Torque Specifications ............... 1-51
Drive Sprocket Location Specifications ................. 1-52
Track Warranty Guidelines .................................... 1-53
Track Specifications............................................... 1-54
Idler Wheel Dimensions ........................................ 1-54
Front Suspension Specifications ........................... 1-54
Rear Suspension Specifications ........................... 1-55
Non-Rebuildable Shock Specifications ................. 1-55
Rebuildable Shock Specifications ......................... 1-56

1-2

Snowmobile 

Identification

The Arctic Cat Snowmobile has two important identi-

fication 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

„NOTE: The VIN also appears on a decal beneath
the seat (Crossfire/M-Series) or attached to the
right-side tunnel (remaining models). The decal
also displays pertinent production information.

These numbers are required to complete warranty

claims properly. No warranty will be allowed by Arc-

tic 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 snowmo-

biles is 87 octane regular unleaded. 

„NOTE: 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 carbu-
retor main jet must be one size larger than the
main jet required for regular unleaded gasoline.
For example, if a 220 main jet is recommended for
regular unleaded gasoline, a 230 main jet must be
installed if using an oxygenated gasoline.

When using ethanol blended gasoline, it is not neces-

sary to add a gasoline antifreeze since ethanol will pre-

vent the accumulation of moisture in the fuel system.

RECOMMENDED GASOLINE
(EFI Models)

The recommended gasoline to use in these snowmo-

biles is 87 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: For optimum performance, do not exceed
the recommended 87 octane gasoline. Using a
higher octane gasoline will not increase overall
performance.

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 carbu-

reted 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. 

! CAUTION

Do not use white gas or gasolines containing metha-
nol. Only Arctic Cat approved gasoline additives
should be used.

! CAUTION

Do not use white gas or gasoline containing metha-
nol. 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 condi-
tions.