Snowmobile Arctic Cat (2004 year). Manual - part 3

 

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Snowmobile Arctic Cat (2004 year). Manual - part 3

 

 

1-9

1

MM/IN. Conversion

Chart

mm

in.

mm

in.

mm

in.

mm

in.

mm

in.

.01

.00039

.41

.01614

.81

.03189

21

.82677

61

2.40157

.02

.00079

.42

.01654

.82

.03228

22

.86614

62

2.44094

.03

.00118

.43

.01693

.83

.03268

23

.90551

63

2.48031

.04

.00157

.44

.01732

.84

.03307

24

.94488

64

2.51968

.05

.00197

.45

.01772

.85

.03346

25

.98425

65

2.55905

.06

.00236

.46

.01811

.86

.03386

26

1.02362

66

2.59842

.07

.00276

.47

.01850

.87

.03425

27

1.06299

67

2.63779

.08

.00315

.48

.01890

.88

.03465

28

1.10236

68

2.67716

.09

.00354

.49

.01929

.89

.03504

29

1.14173

69

2.71653

.10

.00394

.50

.01969

.90

.03543

30

1.18110

70

2.75590

.11

.00433

.51

.02008

.91

.03583

31

1.22047

71

2.79527

.12

.00472

.52

.02047

.92

.03622

32

1.25984

72

2.83464

.13

.00512

.53

.02087

.93

.03661

33

1.29921

73

2.87401

.14

.00551

.54

.02126

.94

.03701

34

1.33858

74

2.91338

.15

.00591

.55

.02165

.95

.03740

35

1.37795

75

2.95275

.16

.00630

.56

.02205

.96

.03780

36

1.41732

76

2.99212

.17

.00669

.57

.02244

.97

.03819

37

1.45669

77

3.03149

.18

.00709

.58

.02283

.98

.03858

38

1.49606

78

3.07086

.19

.00748

.59

.02323

.99

.03898

39

1.53543

79

3.11023

.20

.00787

.60

.02362

1.0

.03937

40

1.57480

80

3.14960

.21

.00827

.61

.02402

1

.03937

41

1.61417

81

3.18897

.22

.00866

.62

.02441

2

.07874

42

1.65354

82

3.22834

.23

.00906

.63

.02480

3

.11811

43

1.69291

83

3.26771

.24

.00945

.64

.02520

4

.15748

44

1.73228

84

3.30708

.25

.00984

.65

.02559

5

.19685

45

1.77165

85

3.34645

.26

.01024

.66

.02598

6

.23622

46

1.81102

86

3.38582

.27

.01063

.67

.02638

7

.27559

47

1.85039

87

3.42519

.28

.01102

.68

.02677

8

.31496

48

1.88976

88

3.46456

.29

.01142

.69

.02717

9

.35433

49

1.92913

89

3.50393

.30

.01181

.70

.02756

10

.39370

50

1.96850

90

3.54330

.31

.01220

.71

.02795

11

.43307

51

2.00787

91

3.58267

.32

.01260

.72

.02835

12

.47244

52

2.04724

92

3.62204

.33

.01299

.73

.02874

13

.51181

53

2.08661

93

3.66141

.34

.01339

.74

.02913

14

.55118

54

2.12598

94

3.70078

.35

.01378

.75

.02953

15

.59055

55

2.16535

95

3.74015

.36

.01417

.76

.02992

16

.62992

56

2.20472

96

3.77952

.37

.01457

.77

.03032

17

.66929

57

2.24409

97

3.81889

.38

.01496

.78

.03071

18

.70866

58

2.28346

98

3.85826

.39

.01535

.79

.03110

19

.74803

59

2.32283

99

3.89763

.40

.01575

.80

.03150

20

.78740

60

2.36220

100

3.93700

1-10

Servicing Symbols

Listed in the table below are symbols indicating special
instructions and other important information necessary
for proper servicing. Please note the definition for each
symbol. These symbols are used throughout this two-vol-
ume set.

SYMBOL

DESCRIPTION

Torque control required

242 - apply blue Loctite #242 (p/n 1639-815)
243 - apply blue Loctite #243 (p/n 1639-413)
270 - apply green Loctite #270 (p/n 1639-817)
271 - apply red Loctite #271 (p/n 1639-820)
609 - apply green Loctite #609 (p/n 1639-821)

Lubricate with Arctic Cat 50:1 Injection Oil (p/n 0636-286)
Lubricate with Arctic Cat Extreme 50:1 Injection Oil (p/n 0639-112)

Lubricate with Arctic Cat Low-Temp Grease (p/n 0636-593)

3B - Three Bond Sealant (p/n 0636-070)
HT - High-Temp Sealant (p/n 0636-069)
AS - Anti-Seize Thread Compound (p/n 0678-146)

2-2

c

@

 1

4

0

0

 RPM  

     

     

   *E

ng

in

e W

a

rm

d

@ 18

00

 RP

M

e

@ 20

00

 RP

M

f

@ 25

00

 RP

M

g

@ 32

00

 RP

M

h

@ 35

00

 RP

M

IT

EM

370 cc

44

0 

c

c 

50

0 c

c w

/o

 APV

500

 cc

 w/

 AP

V

550 cc

5

70 cc

600 cc

 ST

D

600 c

c “La

ydo

wn” 

Ca

rb

60

0 cc

 “La

ydo

wn” 

EFI

70

0 c

c Ca

rb

70

0 cc EFI

80

0 cc 

900

 c

c Carb

9

00 cc EFI

E

ng

ine

 Mo

de

l 

Nu

m

ber

A

A

37

A6

AS

44

A7

A

W

50L

3

A

V

50L3

A

C

B5

5L

5

AA5

6A

3

A

D

60L

8

A

H

60L

1

A

J60

L1

A

E70

L2

A

D

70L2

AB

78L

4

A

A86

L3

AB8

6L

3

D

is

pl

ac

em

en

t    

          

          

        

          

  

—

 c

c

— cu

 in.

36

7 

22

.41

43

1 

26

.3

49

9 

30

.4

49

9 

30

.4

55

0 

33

.56

56

5 

34

.5

59

9 

36

.54

599 

36

.54

59

9 

36

.54

69

8 

42

.59

69

8 

42

.59

78

5 

47

.9

862 

52

.6

86

2 

52

.6

No

. o

f Cyli

nd

er

s

2

2

2

2

2

2

2

2

2

2

2

2

2

2

B

ore

— mm

— in.

60

2.

362

65

2.

55

9

71

2.

795

71

2.

795

73

.4 

2.

890

73

.8 

2.9

10

78

3.

071

73

.8

2.

906

73

.8

2.9

06

79

.7

3.

145

79

.7

3.

145

81

3.

188

85

3.

346

85

3.3

46

St

ro

ke

— m

m

— in.

65

 

2.

559

65

 

2.

55

9

63

2.

480

63

2.

480

65

 

2.

559

66

 

2.5

98

62

.7 

2.

469

70

2.

755

70

2.7

55

70

2.

755

70

2.

755

76

 

2.

992

76

 

2.

992

76

 

2.9

92

C

om

pre

ssi

on Ra

tio

6.3:

1

6.

5:1

6.34

:1

6.

30:

1

6.6:

1

6.4

:1

6.26

:1

6.46

:1

6.4

6:1

6.49

:1

6.

49:

1

6.

29:

1

6.41

:1

6.4

1:1

Co

oli

ng

 S

yst

em

Fa

n Coo

le

d

Fa

n Co

ole

d

Liq

ui

d Co

ol

ed

Li

qu

id

 Coo

le

d

Liq

ui

d Co

ol

ed

Fa

n 

Co

ol

ed

Liq

ui

d Co

ol

ed

Li

qu

id

 C

oo

led

Li

qu

id

 Co

ole

d

Liq

ui

d C

oo

le

d

Li

qui

d C

ool

ed

Li

qui

d C

ool

ed

Li

qui

d 

C

ool

ed

Li

qu

id C

ool

ed

Ga

soline

 Octa

ne

 

(m

in

)

87

87

87

87

87

87

87

87

87

87

87

87

87

87

Fue

l Mi

xt

ur

e

O

il I

nje

ct

io

n

O

il Inje

ctio

n

O

il I

nje

ction

O

il Inj

ection

O

il I

nje

ct

io

n

O

il In

jectio

n

O

il 

In

je

ct

io

n

O

il Inje

ction

O

il In

jecti

on

O

il I

nje

ction

O

il Inj

ectio

n

O

il Inj

ectio

n

O

il Inje

ction

O

il In

jectio

n

Ig

ni

tion

 T

im

in

g

deg

ree

s

— mm

— in.

18

e

*

2.

01

2 

0.

079

18

e

*

2.

01

2 

0.

07

9

25

d

*

3.

692

0.

145

30

e

*

5.

258

0.

207

33

e

*

6.

55

6 

0.

258

 18

e

*

2.

04

9 

0.0

81

24

h

*

3.

39

0 

0.

133

24

f

*

3.

808

0.

150

20

h

*

2.6

63

0.1

05

25

g

*

4.

123

0.

162

15

c

*

1.

509

0.

059

26

f

*

4.

796

0.

189

17

e

*

2.

08

2 

0.

082

23

f

*

3.

77

5 

0.1

49

Sp

ark Pl

ug (

N

GK)

B

R

9EY

A

B

R

9EY

A

B

R9

EY

A

B

R

9E

YA

B

R

9EY

A

B

R

9E

YA

B

R

9EY

A

B

R

9EY

A

B

R

9E

YA

B

R9

EY

A

B

R

9EY

A

B

R

9E

YA

B

R9

EY

A

B

R

9E

YA

Sp

ark Plu

g G

ap

—

 m

m

— in.

0.

7-

0.

8 

0.

02

8-

0.

031

0.

7-

0.8

 

0.

02

8-

0.0

31

0.

7-

0.

8

0.

02

8-

0.

031

0.

7-

0.8

0.

028

-0

.0

31

0.

7-

0.

8 

0.

02

8-

0.

03

1

0.

7-

0.

8 

0.

02

8-

0.

031

0.

7-

0.

8 

0.

02

8-

0.

03

1

0.

7-

0.

8 

0.

02

8-

0.0

31

0.

7-

0.

8 

0.

02

8-

0.

031

0.

7-

0.

8

0.

02

8-

0.

031

0.

7-

0.8

0.

028

-0.0

31

0.

7 -

0.

8

0.

028

-0.0

31

0.

7-

0.

8 

0.

02

8-

0.0

31

0.7

-0.8

 

0.

02

8-

0.

031

Li

gh

tin

g C

oil

 O

utp

ut

12

V

/18

5W

12

V/1

85

W

12

V/

15

6W

12

V/1

56

W

12

V

/18

0W

12

V/2

10W

12

V

/19

0W

12

V/

156

W

12

V/19

0W

12V/

15

6W

12

V/1

90

W

12

V/1

90

W

12V/

156

W

12

V

/1

90W

Ig

nition

 T

ype

CDI/NO

I

CDI/NOI

CDI/NOI

CDI/NOI

CDI/

N

O

I

C

D

I/NOI

CDI/

N

O

I

CD/NOI

C

D

/N

O

I

CDI/NOI

CDI/NOI

CDI/NOI

CDI/NOI

CD

I/NOI

Pist

on

 Skir

t/C

ylin

de

r 

C

lea

ra

nc

e Ra

ng

e

— mm

— in.

0.

06

0-

0.

150

0.

00

24

-0

.00

59

0.

08

0-

0.1

50

0.

00

31-

0.

00

59

0.

07

5-

0.

105

0.

00

29

-0

.00

41

0.

075

-0

.1

05

0.

002

9-

0.

004

1

0.

09

5-

0.

15

0

0.

00

37

-0

.0

059

0.

09

5-

0.

150

0.

00

37

-0

.0

05

9

0.

08

3-

0.

15

0

0.

00

33

-0

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059

0.

07

5-

0.1

05

0.

00

29-

0.

00

41

0.

07

5-

0.

105

0.

00

29

-0

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04

1

0.

07

5-

0.

105

0.

00

29

-0

.00

41

0.

075

-0.1

05

0.

002

9-

0.

004

1

0.

083

-0.1

50

0.

003

3-

0.

005

9

0.

07

5-

0.1

05

0.

00

29

-0

.00

41

0.

07

5-

0.

105

0.

00

29

-0

.0

04

1

Pi

st

on Ri

ng

 E

nd

G

ap Ra

ng

e

— mm

— in.

0.

15

-0

.8

0

0.

00

6-

0.

031

0.

15

-0

.83

0.

00

6-

0.0

33

0.

20

-0

.4

0

0.

00

8-

0.

016

0.

20-

0.

40

0.

008

-0

.0

16

0.

20

-0

.8

3

0.

00

8-

0.

03

3

0.2

0-

0.

83

0.

00

8-

0.

033

0.

20

-0

.8

3

0.

00

8-

0.

03

3

0.

30-

0.

50

0.

01

2-

0.0

19

6

0.3

0-

0.

50

0.

01

2-

0.

019

6

0.

30

-0

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0

0.

01

2-

0.

019

6

0.

30-

0.

50

0.

012

-0.0

196

0.

30-

0.

50

0.

012

-0.0

20

0.

30-

0.

50

0.

01

2-

0.0

20

0.3

0-

0.

50

0.

01

2-

0.

020

C

yl

inde

r T

rue

ne

ss

Li

mi

t (m

ax)

— mm

— in.

0.

1 

0.

004

0.

1 

0.

00

4

0.

1

0.

004

0.

1

0.

004

0.

1 

0.

004

0.1

 

0.0

04

0.

1 

0.

004

0.

1 

0.

004

0.1

 

0.0

04

0.

1

0.

004

0.

1

0.

004

0.

1 

0.

004

0.

1 

0.

004

0.1

 

0.0

04

Pist

on Pin

D

iam

et

er

 Ran

ge

— mm

— in.

17.9

95

-1

8.0

00

0.

70

85

-0

.70

87

15

.9

95-

16

.0

00

0.

62

97-

0.

62

99

21.9

95

-2

2.0

00

0.

86

59

-0

.86

61

21

.9

95

-2

2.

00

0

0.

865

9-

0.

866

1

19.9

95

-2

0.

000

0.

78

72

-0

.7

874

17

.9

95

-1

8.

00

0

0.

70

85

-0

.7

08

7

19.9

95

-2

0.

000

0.

78

72

-0

.7

874

21

.9

95-

22

.0

00

0.

86

59-

0.

86

61

21

.9

95

-2

2.

00

0

0.

86

59

-0

.8

66

1

21.9

95

-2

2.0

00

0.

86

59

-0

.86

61

21

.9

95

-2

2.

00

0

0.

865

9-

0.

866

1

23

.9

95

-2

4.

00

0

0.

944

7-

0.

944

9

23.9

95

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4.0

00

0.

94

47

-0

.94

49

23

.9

95

-2

4.

00

0

0.

94

47

-0

.9

44

9

Pi

st

on Pi

n 

B

or

e 

D

iam

et

er

 Ran

ge

— mm

— in.

17.9

98

-1

8.0

06

0.

70

86

-0

.70

89

15

.9

96-

16

.0

04

0.

62

98-

0.

63

01

22.0

02

-2

2.0

10

0.

86

62

-0

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65

22

.0

02

-2

2.

01

0

0.

866

2-

0.

866

5

20.0

02

-2

0.

010

0.

78

75

-0

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878

17

.9

98

-1

8.

00

6

0.

70

86

-0

.7

08

9

20.0

02

-2

0.

010

0.

78

75

-0

.7

878

22

.0

02-

22

.0

10

0.

86

62-

0.

86

65

22

.0

02

-2

2.

01

0

0.

86

62

-0

.8

66

5

22.0

02

-2

2.0

10

0.

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