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Snowmobile Arctic Cat (2008 year). Manual - part 3

1-7

CARBURETOR JETTING (Carbureted Models) —

Altitude, temperature, and the use of oxygenated gaso-

line affect the carburetion needed for optimum engine

performance. The carburetor main jets must be changed

in conjunction with changes in operating altitude, oxy-

genated gasoline usage, and temperature.

DRIVE BELT DEFLECTION — Drive belt deflec-

tion 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 rub-

ber snubber on the torque link will all take a “set” dur-

ing 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 maxi-

mum 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 proce-

dure increase belt life but will also help prevent engine

damage from cold seizure.

Each operator should be instructed to drive the snow-

mobile 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 maxi-

mum belt life.

In addition to instructing each operator about these

drive belt break-in procedures, Arctic Cat also recom-

mends 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 there-

after. If these adjustments aren’t performed, the track

may “derail” which leads to track and slide rail dam-

age.

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 satisfac-

tion can be increased.

The recommended mileage for this inspection is

between 100 and 300 miles. Please encourage the cus-

tomers to have this important checkup done.

Jet carburetor(s) according to average tempera-

ture, type of gasoline being used, and altitude

Check drive belt deflection

Adjust track tension and alignment

Check throttle cable tension

Check oil-injection pump adjustment

Check engine idle

Check coolant level

Check chain case/gear case lubricant level

Check lights (high/low beam, brakelight)

Check safety switch operation

Check driveshaft area for any rubbing compo-

nents

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

1-8

Arctic Cat Engine

Specifications

* F-Series/Crossfire
** M-Series

ITEM

370 cc

500 cc

570 cc

600 cc

800 cc

1000 cc

Engine Model Number

AB37A1

AX50L7

AA56A7

AJ60L5

AB80L1

AB10L2

Displacement —

— cu in.

367
22.41

499
30.4

565
34.5

599
36.54

794
48.45

999
60.96

No. of Cylinders

Bore

— mm
— in.

60
2.362

71
2.795

73.8
2.910

73.8
2.906

85
3.346

90.3
3.556

Stroke

— mm

— in.

65
2.559

63
2.480

66
2.598

70
2.755

78
3.071

Compression Ratio

6.30:1

6.38:1

6.41:1

6.46:1

6.39:1

6.41:1

Cooling System

Fan Cooled

Liquid Cooled

Fan Cooled

Liquid Cooled Liquid Cooled

Liquid Cooled

Gasoline Octane (min)

Fuel Mixture

Oil Injection

Ignition Timing
Engine Warm
@2000 RPM

degrees
— mm
— in.

18
2.012
0.079

12
0.867
0.034

20
2.522
0.099

15
1.509
0.059

12*
1.062
0.042

15**
1.655
0.065

Spark Plug (NGK)

BR9EYA

Spark Plug Gap

— mm
— in.

0.7-0.8
0.028-0.031

Lighting Coil Output

12V/185W

12V/280W

12V/210W

12V/280W

Ignition Type

CDI/NOI

CD/NOI

CDI/NOI

Piston Skirt/Cylinder
Clearance Range

— mm
— in.

0.066-0.086
0.0026-0.0034

0.075-0.105
0.0029-0.0041

0.085-0.115
0.0035-0.0045

0.075-0.105
0.0029-0.0041

Piston Ring End Gap
Range

— mm
— in.

0.15-0.35
0.006-0.014

0.20-0.40
0.008-0.016

0.30-0.50
0.012-0.0196

Cylinder Trueness
Limit (max)

— mm
— in.

0.1
0.004

Piston Pin Diameter
Range

— mm
— in.

17.995-18.000
0.7085-0.7087

21.995-22.000
0.8659-0.8661

17.995-18.000
0.7085-0.7087

21.995-22.000
0.8659-0.8661

23.995-24.000
0.9447-0.9449

Piston Pin Bore
Diameter Range

— mm
— in.

18.002-18.010
0.7087-0.7090

22.002-22.010
0.8662-0.8665

18.002-18.010
0.7087-0.7090

22.002-22.010
0.8662-0.8665

24.002-24.010
0.9450-0.9453

Connecting Rod
Small End Bore
Diameter Range

— mm
— in.

23.003-23.011
0.9056-0.9059

27.003-27.011
1.0631-1.0634

23.003-23.011
0.9056-0.9059

27.003-27.011
1.0631-1.0634

29.003-29.011
1.1410-1.1420

Connecting Rod
Radial Play Range

— mm
— in.

0.003-0.020
0.0001-0.0008

Crankshaft Runout
(t.i.r.)

— mm
— in.

0.05
0.002

Crankshaft End Play
Range

— mm
— in.

0.05-0.10
0.002-0.004

Reed Stopper Height — mm

— in.

N/A

8.0
0.315

6.0
0.236

11.0
0.433

13.0
0.512

1-9

Cylinder Head Volume

Specifications

NOTE: For cylinder head volume tests, see appropriate Measuring Critical Components sub-section in
Section 2.

Engine Piston Travel

Versus Crank Angle

Chart

NOTE: When using any of the charts blow, first know the engine stroke and timing in degrees; then select
the proper chart and read across from the degree figure to find timing in either mm or inches.

ENGINE TYPE

SQUISH - GAP

ENGINE TYPE

SQUISH - GAP

370 cc

2.27-2.95

in.

.089-.116

600 cc

1.5

in.

.059

500 cc

1.5

in.

.059

800 cc

1.5

in.

.059

570 cc

1.69

in.

.066

1000 cc

1.49

in.

.058

! CAUTION

These specifications are not intended to be used for engine modification. Reducing the head volume to a
smaller specification could cause piston detonation problems which is not a warranty situation.

500 cc

600/800 cc

370 cc

570 cc

1000 cc

63 mm stroke

70 mm stroke

65 mm stroke

66 mm stroke

78 mm stroke

Degree

BTDC

mm BTDC in. BTDC mm BTDC in. BTDC mm BTDC in. BTDC mm BTDC in. BTDC mm BTDC in. BTDC

0.867

0.034

0.969

0.038

0.901

0.035

0.917

0.036

1.062

0.042

1.351

0.053

1.509

0.059

1.403

0.055

1.429

0.056

1.655

0.065

1.937

0.076

2.164

0.085

2.012

0.079

2.049

0.081

2.374

0.093

2.384

0.094

2.663

0.105

2.476

0.097

2.522

0.099

2.869

0.113

1-10

Crankshaft Runout/

Repair Specifications

For those who have crankshaft work sent out to another shop, it is advisable to provide them with this information.

To use the specifications, first refer to the drawing; then find the letter which indicates the specification and refer to

the chart below the illustration. Be sure to note the proper engine column. Specifications are called out in both mil-

limeters and inches.

NOTE: We have given the proper location for checking crankshaft runout as the very edge of the straight
portion of the shaft where the oil seal makes contact. From the illustration, note that Arctic Cat has called
out three check points: at either end, out on the taper as shown, and also on the center bearing race. The
crankshaft is still supported on the outer bearings using V blocks. The maximum runout shouldn’t exceed
0.05 mm (0.002 in.).

728-144A

NOTE: Measure in from the shaft end the specified amount when checking runout at points D and F.
When checking runout in the center, place indicator on center of bearing as shown at point E. Maximum
runout at any of the 3 measuring points is ±0.05 mm (0.002 in.).

Engine

Bore X

Stroke

Runout D

and F Point

(± .002)

370 cc

mm
(in.)

60 X 65

100 ± 0.15
(3.937 ± 0.006)

55 ± 0.15
(2.165 ± 0.006)

100
(3.937)

22
(0.866)

D 35
(1.377)

F 22
(0.866)

(± .002)

500 cc

mm
(in.)

71 X 63

114.7 ± 0.15
(4.515 ± 0.006)

66.5 ± 0.15
(2.618 ± 0.006)

106 ± 0.4
(4.465 ± 0.015)

27
(1.062)

D 5
(0.196)

F 5
(0.197)

(± .002)

570 cc

mm
(in.)

73.8 X 66

119 ± 0.15
(4.70 ± 0.006)

62.3 ± 0.15
(2.45 ± 0.006)

109.7
(4.320)

24
(0.945)

D 30
(1.181)

F 15
(0.590)

(± .002)

600 cc

mm
(in.)

73.8 X 70

119.7 ± 0.15
(4.712 ± 0.006)

64 ± 0.15
(2.519 ± 0.006)

118 ± 0.4
(4.645 ± 0.015)

30
(1.181)

D 5
(0.196)

F 5
(0.196)

(± .002)

800 cc

mm
(in.)

85 X 70

120.7 ± 0.15
(4.751 ± 0.006)

64 ± 0.15
(2.519 ± 0.006)

118 ± 0.4
(4.645 ± 0.015)

30
(1.181)

D 5
(0.196)

F 5
(0.196)

(± .002)

1000 cc

mm
(in.)

90.3 X 78

129.6 ± 0.15
(5.10 ± 0.006)

71 ± 0.15
(2.79 ± 0.006)

128 + 0-0.4
(5.04 + 0-0.015)

32
(1.26)

D 5
(1.196)

F 5
(0.196)

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