Arctic Cat 2014 SNO PRO 500 User manual

SNO PRO 500

Limited Warranty
Arctic Cat Inc. (hereinafter referred to as Arctic Cat) extends a limited warranty as described below on each new Arctic Cat Snowmobile it assembles and on each
genuine Arctic Cat Snowmobile part and accessory assembled and sold by an authorized Arctic Cat Snowmobile dealer. The limited warranty on an Arctic Cat
Snowmobile is extended to the original retail purchaser for the time periods described below; however, the balance of the remaining warranty may be transferred to
another party unless the purchase is for commercial use (see below). Warranty coverage is only available in the country in which the original retail purchase occurs
to the original retail purchaser resident in that country or to a transferee resident in that country of the balance of the remaining warranty.
Arctic Cat warrants only the products it assembles and/or sells and does not warrant that other products will function properly when used with an Arctic Cat
Snowmobile or will not damage the Arctic Cat Snowmobile. Arctic Cat does not assume any liability for incidental or consequential damages.
Arctic Cat will repair or replace, at its option, free of charge (including any related labor charges), any parts that are found to be warrantable in material or workmanship.
This repair work MUST be done by an authorized Arctic Cat Snowmobile dealer. No transportation charges, rental charges, or inconvenience costs will be paid by Arctic
Cat. The warranty is validated upon examination of said parts by Arctic Cat or an authorized Arctic Cat Snowmobile dealer. Arctic Cat reserves the right to inspect such
parts at its factory for final determination if warranty should apply.
The warranty periods are as follows:
1. For snowmobiles used for recreational purposes:
—If purchased between May 1 and November 30, warranty expires ONE (1) YEAR from December 1 of the current year.
—If purchased between December 1 and April 30, ONE (1) YEAR from the date of sale.
2. For snowmobiles used for commercial purposes (including rental operations), ONE (1) YEAR from the date of invoice and/or 5000 MILES whichever comes first
(non-transferable).
3. THIRTY (30) DAYS from date of sale of snowmobile on Arctic Cat supplied batteries.
Exclusions to this warranty include normal wear, abuse (i.e. a track run on marginal snow conditions without proper lubrication or additional idler wheels), and the
following parts:
Fuel Filter Light Bulbs Windshield Drive Belt Torn or Punctured Upholstery
Wear Bars Brake Pads Spark Plugs Drive Clutch/Driven Clutch Wear Parts
Wear Strips Shock Absorber(s) - Standard* Shock Absorber(s) - Rebuildable**
* Limited to one (1) year or 1000 miles of “normal” riding conditions - replace for defective or leaking shock, corroded or pitted shaft, peeling chrome.
** Limited to one (1) year or 1000 miles of “normal” riding conditions - rebuild for leaking shock (warranted) - replace for defective shock, corroded or pitted shaft, peeling
chrome.
The following will VOID Arctic Cat’s warranty:
1. Failure to perform the proper break-in procedure and all related maintenance, storage procedures (if stored for extended periods), and/or service as
recommended in the Operator’s Manual.
2. Repairs and/or adjustments by anyone other than an authorized Arctic Cat Snowmobile dealer.
3. Use of an improper fuel mixture ratio.
4. Use of improper carburetor jets.
5. Use of improper gasoline, lubricating oils, or spark plugs.
6. An accident or subjecting the snowmobile to misuse, abuse, or negligent operation.
7. Any modification, addition, or removal of parts unless instructed to do so by Arctic Cat.
8. Use of the snowmobile in any way for racing purposes.
9. Removal of the engine for use in another vehicle.
10. Removal or mutilation of the Vehicle Identification Number or Engine Serial Number.
11. Use of parts not sold or approved by Arctic Cat.
12. Track and tunnel damage resulting from either ice stud or hooker plate installation.
13. Damage due to improper transportation.
Arctic Cat shall not be responsible for and this limited warranty excludes recovery of economic, punitive, consequential and incidental damages, lost profits, and loss
of use. Some states or provinces do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation may not apply to you. Arctic
Cat’s aggregate liability may not exceed the price of the product. The law of the State of Minnesota shall apply to all claims or disputes, exclusive of its conflicts of
law provisions.
IMPLIED WARRANTY EXCLUSION AND DISCLAIMER
To the fullest extent permitted by law, Arctic Cat excludes and disclaims all implied warranties of merchantability and fitness for a particular purpose.
If you are not satisfied with warranty service or repairs, you should contact Arctic Cat at (U.S.) 1-218-681-9851 or (Canada) 1-204-982-1656.

FOREWORD
Congratulations! You have chosen a quality Arctic Cat Snowmobile designed and manufactured to give depend-
able service. Be sure, as the owner/operator of an Arctic Cat Snowmobile, to become thoroughly familiar with its
basic operation, maintenance, and off-season storage procedures. Read this manual and the accompanying Snow-
mobile Safety Handbook before operating the snowmobile to ensure safe and proper use of your new Arctic Cat
Snowmobile. Always operate the snowmobile within your level of skill and current terrain conditions.
The Operator’s Manual, Snowmobile Safety Handbook, and snowmobile decals display the words Warning, Cau-
tion, and Note to emphasize important 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. A 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 information worthy of particular attention.
This manual covers operator-related maintenance, operating instructions, and off-season storage instructions. If
major repair or service is ever required, contact an authorized Arctic Cat Snowmobile dealer for professional ser-
vice.
At the time of publication, all information and illustrations were technically correct. Some 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.
This Operator’s Manual should be considered a permanent part of the snowmobile and must remain with the snow-
mobile at the time of resale. If the snowmobile changes ownership more than once, contact Arctic Cat Inc., Service
Department, P.O. Box 810, Thief River Falls, MN 56701, for proper registration information.
Every Arctic Cat Snowmobile meets or exceeds the standards of the Snowmobile Safety and Certification Commit-
tee and displays the SSCC decal. Arctic Cat endorses and encourages the safe use of all snowmobiles. Always wear
a helmet and eye protection. Drive with caution, observe all state and local regulations, and respect the rights of
others. ISMA members like Arctic Cat do their part to improve trails, sponsor events, and generally support the
sport of snowmobiling. As a member of the National Snowmobile Foundation, Arctic Cat Inc. promotes snowmo-
biling through education, charity, and research programs.
© 2013 Arctic Cat Inc.
Printed in U.S.A. July 2013

If the snowmobile is purchased
through the Team Arctic Race
Department Racing Program, there
is no warranty.
Reference Information
The Arctic Cat Snowmobile has two important identi-
fication numbers. The Vehicle Identification Number
(VIN) is stamped on the top of the tunnel. The Engine
Serial Number (ESN) is stamped into the crankcase of
the engine.
0744-098
These numbers are required by the dealer to complete
warranty claims properly. No warranty will be allowed
by Arctic Cat Inc. if the engine serial number or VIN is
removed or mutilated in any way.
Always provide the snowmobile name, VIN, and ESN
when contacting an authorized Arctic Cat Snowmobile
dealer for parts, service, accessories, or warranty. If
the complete engine must be replaced, ask the dealer to
notify Arctic Cat for correct registration information.
Write the appropriate information for your Arctic Cat
Snowmobile in the spaces below. Always use these
numbers when referring to your snowmobile.
Model: ____________________________________
Date of Purchase: ____________________________
VIN (Vehicle Identification Number): ____________
ESN (Engine Serial Number):___________________
Your Arctic Cat Dealer: ______________________
Address: ___________________________________
Phone: ____________________________________
! WARNING
This snowmobile is a very high performance snowmo-
bile. Because it does accelerate rapidly and is capable
of very high speeds, it should not be operated by a
novice or an inexperienced operator. Never accelerate
rapidly or drive at high speed beyond the limits of visi-
bility or without being totally familiar with the terrain
and what lies in front of you. Obey speed limits and
never operate at speeds that do not allow adequate
maneuvering and stopping distances. Read and study
the entire Operator’s Manual and Safety Handbook.
Failure to follow this warning could result in personal
injury to yourself or others.
PARTS AND ACCESSORIES
When in need of replacement parts, oil, or accesso-
ries for your Arctic Cat Snowmobile, be sure to only
use GENUINE ARCTIC CAT PARTS, OIL, AND
ACCESSORIES. Only genuine Arctic Cat parts, oil,
and accessories are engineered to meet the standards
and requirements of your Arctic Cat Snowmobile.
For a complete list of accessories, refer to the current
Arctic Cat Accessory Catalog.
To aid in service and maintenance procedures on this
snowmobile, an Illustrated Parts Manual is available
through your local Arctic Cat Snowmobile dealer.

1
TABLE OF CONTENTS
Specifications/Charts/Patterns/Diagrams ............. 2-13
Engine Specifications ............................................. 2
General Specifications............................................ 2
Engine Torque Specifications ................................. 2
Engine Torque Patterns .......................................... 2
Torque Conversions (ft-lb/N-m)............................... 3
Electrical Specifications.......................................... 3
Oil Consumption Specifications.............................. 3
EFI Specifications................................................... 3
Throttle Valve Angle Specifications......................... 3
Component Voltage/Resistance Chart - Coolant
Temperature ........................................................ 4
Component Voltage/Resistance Chart - Air
Temperature ........................................................ 4
Cylinder Head Volume Specifications..................... 5
Crankshaft Runout/Repair Specifications............... 5
Drive System Specifications ................................... 5
Driven Clutch Optional Components ...................... 5
Drive Clutch Spring Chart....................................... 5
Drive Clutch Cam Arms.......................................... 6
Chain Case Performance Calibrations.................... 7
Chains and Sprockets............................................. 8
Rear Spring Selection Chart................................... 8
Installed Spring Rate Chart .................................... 8
Front Suspension Sway Bar (Optional)................... 9
Ski Shock Springs................................................... 9
Rebuildable Shock Tools Required......................... 9
Valve Stacks/Specifications .................................. 10
Rebuildable Shock Accessory Part Numbers....... 11
Wiring Diagram (Hood)......................................... 12
Wiring Diagram (Ignition/Main) ............................ 13
Setup Instructions ............................................... 15-22
Removing Snowmobile From Crate/
Handlebar Assembly ......................................... 15
Installing Windshield............................................. 15
Installing Spindle/A-Arm ....................................... 15
Installing Front Shock Absorbers.......................... 15
Installing Skis........................................................ 15
Installing Sway Bar (Optional)............................... 16
Oil-Injection Pump Synchronization...................... 16
Checking/Adjusting Throttle Lever Free-Play
(Tension)............................................................ 16
Brake System........................................................ 17
Drive Belt .............................................................. 17
Handlebar Alignment............................................ 17
Handlebar Height Adjustment............................... 18
Steering Speed Ratio Adjustment......................... 18
Recommended Gasoline...................................... 18
Preoperation Checks ............................................ 19
Checking Headlight Aim........................................ 19
Track Tension/Track Alignment.............................. 19
Ski Alignment........................................................ 20
Test Ride............................................................... 22
General Information ............................................ 22-27
Control Locations.................................................. 22
Engine Break-In .................................................... 22
Speedometer/Tachometer..................................... 22
Diagnostic Codes.................................................. 23
Handlebar Tilt........................................................ 23
Rear Bumper......................................................... 23
Exhaust System.................................................... 23
Air-Intake Silencer................................................. 23
Liquid Cooling System.......................................... 24
Drive Belt .............................................................. 24
Drive Clutch and Driven Clutch............................. 24
Drive Clutch/Driven Clutch Alignment................... 24
Drive Chain Tension.............................................. 24
EFI System ........................................................... 25
Shock Absorbers................................................... 27
Track Studs ........................................................... 27
Towing................................................................... 27
Operating Instructions.........................................27-29
Starting and Stopping Engine............................... 27
Braking.................................................................. 28
Emergency Stopping............................................. 29
Lubrication...........................................................29-30
Chain Case ........................................................... 29
Front Suspension.................................................. 29
Rear Suspension .................................................. 30
Maintenance........................................................31-71
Periodic Maintenance Checklist............................ 31
Pre-Race/Practice Checklist ................................. 32
Engine................................................................... 32
Individual EFI Components................................... 53
Individual Fuel System Components .................... 57
Spark Plugs........................................................... 61
Track Drive ............................................................ 61
Brake System........................................................ 62
Brake Fluid............................................................ 62
Checking Brake Lever Travel.................................62
Bleeding Brake System......................................... 62
Checking/Changing Brake Pads ........................... 63
Drive Belt .............................................................. 63
Driven Clutch ........................................................ 64
Ski Shock Absorber Springs ................................. 66
Servicing Zero Pro Shock Absorbers
(Ski Shock) ........................................................ 67
Adjusting Rear Transfer Adjuster Cams................ 69
Lights .................................................................... 70
Ski Wear Bar......................................................... 70
Rail Wear Strip...................................................... 71
Performance Tips..................................................... 72
Preparation For Storage......................................72-73
Preparation After Storage......................................... 73
Genuine Arctic Cat Products.................................... 73
Special Tools.......................................................74-83
Declaration of Conformity......................................... 84

2
Engine Specifications
General Specifications
Engine Torque
Specifications
*With Blue Loctite #243
**With Red Loctite #271
Engine Torque Patterns
0738-204
0742-746
ITEM 500 cc
Engine Model Number AX50L7
Displacement 499 cc
No. of Cylinders 2
Bore x Stroke 71 x 63
Compression Ratio 6.38:1
Cooling System Liquid
Fuel Mixture Oil Injection
Ignition Timing (Engine Warm) 12° @ 2000 RPM
0.034 in.
Spark Plug (NGK) BR9EYA
Spark Plug Gap 0.028-0.031 in.
Piston Skirt/Cylinder Clearance 0.0030-0.0041 in.
Piston Ring End Gap 0.008-0.016 in.
Cylinder Trueness Limit 0.004 in.
Piston Pin Diameter 0.8659-0.8661 in.
Piston Pin Bore Diameter 0.8661-0.8665 in.
Connecting Rod Small End Bore 1.0631-1.0634 in.
Connecting Rod Radial Play 0.0001-0.0008 in.
Crankshaft Runout (t.i.r.) 0.002 in.
Crankshaft End Play 0.002-0.004 in.
Reed Stopper Height 0.315 in.
Chassis Length (Overall) 299.0 cm (117.7 in.)
Height (Overall) 115.5 cm (45.5 in.)
Width (Overall) 121.9 cm (48 in.)
Spindle Center-to-Center
Distance (Stance) 108.0 cm (42.5 in.)
Dry Weight (approx) 204.1 kg (450 lb)
Gas Tank Capacity 38.2 l (10.1 U.S. gal.)
Oil Tank Capacity 2.6 l (2.75 U.S. qt)
Chain Case Lubricant Capacity 236 ml (8 fl oz)
Gasoline (Recommended) 87 Octane
Pre-Mix Oil (32:1 Ratio) Arctic Cat Formula 50 Injection Oil
Chain Case Lubricant Synthetic Chain Lube
Suspension Grease All-Temperature
Brake Fluid High-Temp DOT 4
Taillight/Brakelight Bulb p/n 0409-056
Headlight Bulb p/n 0409-073/0409-045
Cooling System Capacity 3.81 l (4.0 U.S. qt)
Starting System Manual Recoil
Oil Capacity 4.75 qt
ITEM VALUE
Cylinder Head 6 mm 96 in.-lb
8 mm 19 ft-lb
Cylinder Base 14-44 ft-lb (3 Steps)
Flywheel** 50 ft-lb
Exhaust Manifold 17 ft-lb
Intake Flange 96 in.-lb
Crankcase 6 mm 96 in.-lb
10 mm 13-37 ft-lb (2 Steps)
Spark Plug 19 ft-lb
MAG Housing 18 ft-lb
Oil-Injection Pump* 96 in.-lb
Water Pump Impeller* 108 in.-lb
Water Pump Cover 96 in.-lb
Thermostat Cap 96 in.-lb
Stator Plate* 96 in.-lb
Timing Sensor* 48 in.-lb
Stator* 96 in.-lb
Starter Pulley 19 ft-lb
Recoil Starter 96 in.-lb
Drive Clutch 50-55 ft-lb

3
0738-201
Torque Conversions
(ft-lb/N-m)
Electrical
Specifications
NOTE: The ignition system is a Normally Open
Ignition (NOI).
Oil Consumption
Specifications
EFI Specifications
Throttle Valve Angle
Specifications
ft-lb N-m ft-lb N-m ft-lb N-m ft-lb N-m
11.4 26 35.4 51 69.4 76 103.4
22.7 27 36.7 52 70.7 77 104.7
34.1 28 38.1 53 72.1 78 106.1
45.4 29 39.4 54 73.4 79 107.4
56.8 30 40.8 55 74.8 80 108.8
68.2 31 42.2 56 76.2 81 110.2
79.5 32 43.5 57 77.5 82 111.5
810.9 33 44.9 58 78.9 83 112.9
912.2 34 46.2 59 80.2 84 114.2
10 13.6 35 47.6 60 81.6 85 115.6
11 15 36 49 61 83 86 117
12 16.3 37 50.3 62 84.3 87 118.3
13 17.7 38 51.7 63 85.7 88 119.7
14 19 39 53 64 87 89 121
15 20.4 40 54.4 65 88.4 90 122.4
16 21.8 41 55.8 66 89.8 91 123.8
17 23.1 42 57.1 67 91.1 92 125.1
18 24.5 43 58.5 68 92.5 93 126.5
19 25.8 44 59.8 69 93.8 94 127.8
20 27.2 45 61.2 70 95.2 95 129.2
21 28.6 46 62.6 71 96.6 96 130.6
22 29.9 47 63.9 72 97.9 97 131.9
23 31.3 48 65.3 73 99.3 98 133.3
24 32.6 49 66.6 74 100.6 99 134.6
25 34 50 68 75 102 100 136
Description Resistance Test
Test Value + Test Connections -
Ignition Coil
Primary/
Secondary
0.24-0.36 ohm/
6800-10,200 ohms orange/black high tension
wire
orange/red/
high tension
wire
Charge Coil (1) 8.8-13.2 ohms black/red green/red
Charge Coil (2) 8.8-13.2 ohms brown/white green/red
Lighting Coil 0.08-0.12 ohm yellow yellow
Ignition Timing
Sensor 80.8-121 ohms green/white brown/green
Injector Coil 15.2-22.8 ohms blue/white blue/white
Fuel Pump Coil 1.52-2.28 ohms orange orange
Spark-Plug Cap 4000-6000 ohms cap end cap end
Description Test Value + Test Connections -
Voltage Regulator 11-14 AC Volts yellow brown
Regulator/Rectifier 11.2-16.8 DC Volts
(@ 2000 RPM) red/blue brown/yellow
Condenser 11.6-17.4 DC Volts
(@ 2000 RPM) red brown
Coolant
Temperature
Sensor
305 ohms + (coolant
temperature at or
above 176°F)
terminal #1 terminal #2
203 ohms +
(coolant temperature
at or above 200°F)
terminal #1 terminal #2
Tether Switch Less than 1 ohm
(tether cap removed) terminal terminal
ENGINE RPM FULL-CLOSED (Idle)
3 Minutes FULL-OPEN
2 Minutes
500 cc 1833 1.0-2.5 cc 7.4-10.3 cc
Fuel Pressure 42.8-47.3 psi
MODEL TPS TOOL
(DC VOLTS) ANALYZER TOOL (DC VOLTS)
500 cc Idle 0.710-0.818 0.710-0.818
Full-Open 3.472-4.048 3.470-4.046

4
Component Voltage/
Resistance Chart -
Coolant Temperature
Component Voltage/
Resistance Chart -
Air Temperature
Temperature Volts Ohms Temperature Volts Ohms
110 °C 230 °F 0.115 129 28 °C 82 °F 1.377 1800
108 °C 226 °F 0.129 137 26 °C 79 °F 1.459 1950
106 °C 223 °F 0.143 145 24 °C 75 °F 1.541 2100
104 °C 219 °F 0.157 153 22 °C 72 °F 1.623 2250
102 °C 216 °F 0.171 161 20 °C 68 °F 1.705 2400
100 °C 212 °F 0.185 169 18 °C 64 °F 1.806 2670
98 °C 208 °F 0.192 180 16 °C 61 °F 1.907 2940
96 °C 205 °F 0.199 191 14 °C 57 °F 2.008 3210
94 °C 201 °F 0.206 202 12 °C 54 °F 2.109 3480
92 °C 198 °F 0.213 213 10 °C 50 °F 2.210 3750
90 °C 194 °F 0.220 224 8 °C 46 °F 2.327 4170
88 °C 190 °F 0.235 240 6 °C 43 °F 2.444 4590
86 °C 187 °F 0.250 256 4 °C 39 °F 2.561 5010
84 °C 183 °F 0.265 273 2 °C 36 °F 2.678 5430
82 °C 180 °F 0.280 289 0 °C 32 °F 2.795 5850
80 °C 176 °F 0.295 305 -2 °C 28 °F 2.901 6510
78 °C 172 °F 0.317 327 -4 °C 25 °F 3.007 7170
76 °C 169 °F 0.339 349 -6 °C 21 °F 3.113 7830
74 °C 165 °F 0.361 371 -8 °C 18 °F 3.219 8490
72 °C 162 °F 0.383 393 -10 °C 14 °F 3.325 9150
70 °C 158 °F 0.405 415 -12 °C 10 °F 3.421 9422
68 °C 154 °F 0.438 445 -14 °C 7 °F 3.517 9694
66 °C 151 °F 0.471 475 -16 °C 3 °F 3.613 9966
64 °C 147 °F 0.504 505 -18 °C -0.4 °F 3.709 10238
62 °C 144 °F 0.537 535 -20 °C -4 °F 3.805 10510
60 °C 140 °F 0.570 565 -22 °C -8 °F 3.885 13688
58 °C 136 °F 0.598 609 -24 °C -11 °F 3.965 16866
56 °C 133 °F 0.626 653 -26 °C -15 °F 4.045 20044
54 °C 129 °F 0.654 697 -28 °C -18 °F 4.125 23222
52 °C 126 °F 0.682 741 -30 °C -22 °F 4.205 26400
50 °C 122 °F 0.710 785 -32 °C -26 °F 4.267 30520
48 °C 118 °F 0.759 849 -34 °C -29 °F 4.329 34640
46 °C 115 °F 0.808 913 -36 °C -32 °F 4.391 38760
44 °C 111 °F 0.857 977 -38 °C -36 °F 4.453 42880
42 °C 108 °F 0.906 1041 -40 °C -40 °F 4.515 47000
40 °C 104 °F 0.955 1105 -42 °C -44 °F 4.553 55100
38 °C 100 °F 1.023 1214 -44 °C -47 °F 4.591 63200
36 °C 97 °F 1.091 1323 -46 °C -51 °F 4.629 71300
34 °C 93 °F 1.159 1432 -48 °C -54 °F 4.667 79400
32 °C 90 °F 1.227 1541 -50 °C -58 °F 4.705 87500
30 °C 86 °F 1.295 1650
Temperature Volts Ohms Temperature Volts Ohms
100° C 212° F 0.113 555 28° C 82° F 1.230 8540
98° C 208° F 0.121 595 26° C 79° F 1.322 9530
96° C 205° F 0.128 635 24° C 75° F 1.413 10520
94° C 201° F 0.136 675 22° C 72° F 1.505 11510
92° C 198° F 0.143 715 20° C 68° F 1.596 12500
90° C 194° F 0.151 755 18° C 64° F 1.716 14020
88° C 190° F 0.162 819 16° C 61° F 1.836 15540
86° C 187° F 0.173 883 14° C 57° F 1.955 17060
84° C 183° F 0.184 947 12° C 54° F 2.075 18580
82° C 180° F 0.195 1011 10° C 50° F 2.195 20100
80° C 176° F 0.206 1075 8° C 46° F 2.323 23060
78° C 172° F 0.222 1160 6° C 43° F 2.452 26020
76° C 169° F 0.238 1245 4° C 39° F 2.580 28980
74° C 165° F 0.253 1330 2° C 36° F 2.709 31940
72° C 162° F 0.269 1415 0° C 32° F 2.837 34900
70° C 158° F 0.285 1500 -2° C 28° F 2.969 39940
68° C 154° F 0.308 1640 -4° C 25° F 3.101 44980
66° C 151° F 0.331 1780 -6° C 21° F 3.233 50020
64° C 147° F 0.353 1920 -8° C 18° F 3.365 55060
62° C 144° F 0.376 2060 -10° C 14° F 3.497 60100
60° C 140° F 0.399 2200 -12° C 10° F 3.610 76080
58° C 136° F 0.432 2410 -14° C 7° F 3.722 92060
56° C 133° F 0.465 2620 -16° C 3° F 3.835 108040
54° C 129° F 0.498 2830 -18° C -0.4° F 3.947 124020
52° C 126° F 0.531 3040 -20° C -4° F 4.060 140000
50° C 122° F 0.564 3250 -22° C -8° F 4.142 156000
48° C 118° F 0.612 3595 -24° C -11° F 4.224 172000
46° C 115° F 0.659 3940 -26° C -15° F 4.306 188000
44° C 111° F 0.707 4285 -28° C -18° F 4.388 204000
42° C 108° F 0.754 4630 -30° C -22° F 4.470 220000
40° C 104° F 0.802 4975 -32° C -26° F 4.522 261000
38° C 100° F 0.869 5490 -34° C -29° F 4.574 302000
36° C 97° F 0.937 6005 -36° C -32° F 4.625 343000
34° C 93° F 1.004 6520 -38° C -36° F 4.677 384000
32° C 90° F 1.072 7035 -40° C -40° F 4.729 425000
30° C 86° F 1.139 7550

5
Cylinder Head Volume
Specifications
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. Specifica-
tions are called out in both millimeters 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 Arc-
tic 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 sup-
ported 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 speci-
fied amount when checking runout at points D and
F. When checking runout in the center, place indi-
cator 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.).
Drive System
Specifications
* ± 0.188 in.
** 20 (p/n 1602-600/46 (p/n 2602-074)
NOTE: For optional drive system components,
refer to the Optional Components chart below.
Driven Clutch Optional
Components
*Lightweight driven clutch only.
Drive Clutch Spring
Chart
* Titanium
Engine type Squish-Gap
500 cc 0.059 in.
Bore x
Stroke A
± 0.15
(± 0.006)
B
± 0.15
(± 0.006)
C
± 0.4
(± 0.015) GRunoutPoints
D and F
(± .002)
71 mm x 63 mm
(2.795” x 2.480”) 114.6 mm (4.515”) 66.5 mm (2.618”) 113.4 mm (4.465”) 26.9 mm (1.062”) D 5 mm (0.196”) F 5 mm (0.196”)
Drive Clutch Cam Arm Torque Bracket
p/n Spring Color p/n Grams Degrees
0746-435 0646-229 Yellow/White 0746-826 64.0 40/38
Driven Clutch Drive Belt
p/n Spring Color p/n Length* Width*
0726-297 0648-790 Black/Light Blue 0627-047 43.547 in. 1.448 in.
Engagement/
Maximum RPM Gear Ratio Chain
Pitch p/n
3500-6000/
7900-8000 20/46** (15/13 wide) 74 (15 wide) 1602-774
Torque
Bracket Degree Spring Color Spring
Rate
0648-779* 58-46-36/58-48-36 0648-749 Black/White 160/260
0648-775* 52-42-46/52-44-46 0648-702 Red/Black 140/240
0648-773* 70-44-32/68-48-46 0648-784 Black 155/222
0648-710 70-50-46/68-48-46 0648-790 Black/Light Blue 180/260
0648-737 70-44-32/68-48-46 0648-792 Black/Orange 180/280
0648-719 68-42-34/68-44-32 — — —
0648-789* 68-48-36/64-48-41 — — —
0648-791* 48-44-36/48-42-36 — — —
p/n Rate @ 2 9/16 in.Rate @ 1 5/16 in. Color
LIGHT 0646-148 53 lb 224 lb Blue
0646-150 72 lb 188 lb Silver
0646-149 74 lb 228 lb Red
0646-376 75 lb 275 lb Gold
0646-147 114 lb 267 lb Yellow/Green
0646-373* 114 lb 267 lb Yellow/Green
0646-155 121 lb 240 lb Purple
0646-229 122 lb 285 lb Yellow/White
0646-379* 122 lb 285 lb Yellow/White
0646-035 143 lb 286 lb Orange/Black
0646-248 143 lb 290 lb Orange/White
0646-367 143 lb 250 lb Black
0646-435 143 lb 290 lb Orange Stripe
HEAVY 0646-684 158 lb 290 lb Black

6
Drive Clutch Cam Arms
NOTE: All listed cam arms are w/set screw.
** Notched Cam Arm
p/n Grams p/n Grams
0746-627 84.8 0746-703 68.0
0746-629 75.0 0746-704 51.0**
0746-658 49.0** 0746-708 51.0
0746-661 52.0 0746-710 72.0
0746-662 52.0 0746-712 77.0
0746-663 52.0 0746-713 48.0
0746-664 52.0 0746-715 77.0
0746-666 55.0 0746-716 73.0
0746-668 55.0 0746-742 83.5
0746-669 60.0 0746-744 50.0
0746-670 65.0 0746-748 46.0
0746-671 70.0 0746-749 65.0
0746-672 75.0 0746-771 44.0
0746-673 80.0 0746-772 42.0
0746-676 70.0 0746-773 85.0
0746-678 55.0 0746-786 63.0
0746-687 57.0 0746-787 44.0
0746-689 69.0 0746-788 47.5
0746-690 47.0 0746-789 42.0
0746-691 44.0 0746-791 60.0
0746-692 50.0 0746-792 47.0
0746-694 63.0 0746-793 63.0
0746-695 67.0 0746-821 82.0
0746-696 63.0 0746-822 71.5
0746-699 66.0 0746-824 66.0
0746-701 49.0 0746-825 50.0
0746-702 58.0 0746-826 64.0**

7
Chain Case
Performance
Calibrations
NOTE: The following table should be used as a guide only.
RPM x Ratio x 0.0225 x 1.12 = MPH
RPM x Ratio x 0.0213 x 1.12 = MPH
RPM x Ratio x 0.02368 x 1.12 = MPH *Production
NOTE: The above gearing options are combinations which allow acceptable chain tension. Any other
combinations will not allow acceptable chain tension.
Drive Sprocket Chain Case Performance Specifications RPM (Engine)
8-Tooth
(3.00 Pitch)
Sprockets Ratio Chain Pitch 7400 7800 8000 8200 8700
20/46 0.435 74 81.1 85.5 87.7 89.9 95.4
20/45 0.444 74 82.8 87.3 89.5 91.7 97.3
21/45 0.467 74 87.1 91.8 94.1 96.5 102.4
19/40 0.475 70 88.6 93.4 95.8 98.2 100.5
21/41 0.512 72 95.5 100.6 103.2 105.8 112.3
20/39 0.513 70 95.7 100.8 103.4 106.0 112.5
22/41 0.537 72 100.1 105.5 108.2 110.9 113.6
22/40 0.550 72 102.6 108.1 110.9 113.7 120.6
23/40 0.575 72 107.2 113.0 115.9 118.8 121.7
23/39 0.590 72 110.0 116.0 119.0 121.9 129.4
24/39 0.615 72 115.0 120.9 124.0 127.1 134.8
Drive Sprocket Chain Case Performance Specifications RPM (Engine)
9-Tooth
(2.52 Pitch)
Sprockets Ratio Chain Pitch 6000 7000 8000 9000 10,000
20/46 0.435 74 62.3 72.6 83.0 93.4 103.8
20/45 0.444 74 63.6 74.1 84.7 95.3 105.9
21/45 0.467 74 66.8 78.0 89.1 100.3 111.4
19/40 0.475 70 68.0 79.3 90.7 102.0 113.3
21/41 0.512 72 73.3 85.5 97.7 109.9 122.1
20/39 0.513 70 73.4 85.7 97.9 110.1 122.4
22/41 0.536 72 76.7 89.5 102.3 115.1 127.9
22/40 0.550 72 78.7 91.8 105.0 118.1 131.2
23/40 0.575 72 82.3 96.0 109.7 123.5 137.2
23/39 0.590 72 84.5 98.5 112.6 126.7 140.8
24/39 0.615 72 88.1 102.7 117.4 132.1 146.7
Drive Sprocket Chain Case Performance Specifications RPM (Engine)
10-Tooth*
(2.52 Pitch)
Sprockets Ratio Chain Pitch 7400 7800 8000 8200 8400 8700
20/46* 0.435 74 85.4 90.0 92.3 94.7 97.0 100.4
20/45 0.444 74 87.1 91.8 94.2 96.6 99.0 102.4
21/45 0.467 74 91.6 96.6 99.1 101.6 104.1 107.8
19/40 0.475 70 93.2 98.3 100.8 103.3 105.8 109.6
21/41 0.512 72 100.5 105.9 108.6 111.3 114.1 118.1
20/39 0.513 70 100.7 106.1 108.8 111.6 114.3 118.4
22/41 0.537 72 105.3 111.0 113.8 116.7 119.5 123.8
22/40 0.550 72 108.0 113.8 116.7 119.6 122.5 126.9
23/40 0.575 72 112.8 118.9 122.0 125.0 128.1 132.7
23/39 0.590 72 115.8 122.0 125.2 128.3 131.4 136.1
24/39 0.615 72 120.7 127.2 130.5 133.7 137.0 142.0

8
Chains and Sprockets
* Aluminum
** PTL
Rear Spring
Selection Chart
A longer spring in areas (D) and (E) can be selected if
cut off to match the original spring. The replacement
spring must match the original spring in areas (C), (D),
and (E).
0730-218
* Production
NOTE: The wire diameter and length of the spring
have a large influence over the valving of the
shocks.
Installed Spring Rate
Chart
WIDE CHAIN (13 Link)
PITCH P/N
70 1602-419
72 1602-420
74 1602-473
WIDE CHAIN (15 Link)
70 1602-578
72 1602-773
74 1602-774
WIDE CHAIN (17 Link)
70 1602-805
72 1602-904
74 1602-806
WIDE SPROCKET (w/13 Link Chain)
NUMBER OF TEETH INSIDE SPLINE P/N
19 15 1602-412
20 15 1602-413
21 15 2602-215
22 15 2602-244
23 15 2602-216
24 15 2602-254
39 15 1602-414
39 16 2602-217
40 15 1602-415
40* 16 2602-245
40 16 2602-218
41 15 1602-416
41 16 2602-219
42 15 1602-417
43 15 1602-418
44 15 1602-481
45 16 2602-223
45 15 1602-482
46 16 2602-074
46* 16 2602-224
WIDE SPROCKET (w/15 Link Chain)
19 15 1602-548
20 15 1602-600
21 15 1602-685
23 15 2602-109
39 16 1602-686
42 16 1602-687
43 16 1602-549
44 16 1602-688
45 16 1602-689
46 16 1602-690
WIDE SPROCKET (w/17 Link Chain)
19 15 1602-796
20 15 1602-735
21 15 1602-797
43 16 1602-734
44 16 1602-802
45 16 1602-803
46 16 1602-804
46** 16 1602-925
46* 16 1602-811
P/N Wire Diameter
(A) Angle
(B) Number
of
Coils
Coil
Width
(C) Length
(D) Length (E) Degree (In lb)
1704-916/
917 .405 120° 5.90 3.20 15.62 4.70 24
1704-382/
383*
(Light)
.359 90° 5.75 3.00 15.62 4.60 17
1704-384/
385
(Heavy)
.375 90° 5.75 3.00 15.62 4.60 20
P/N Suspension Fully
Extended
(In lb - Adjuster
Set 1 & 1)
Suspension Fully
Extended
(In lb - Adjuster
Set 3 & 3)
1704-382/383 1360 1700
1704-384/385 1600 2000
1704-916/917 482 964
P/N Suspension Fully
Collapsed
(In lb - Adjuster
Set 1 & 1)
Suspension Fully
Collapsed
(In lb - Adjuster
Set 3 & 3)
1704-382/383 3740 4080
1704-384/385 4400 4800
1704-916/917 3856 4338

9
Front Suspension
Sway Bar (Optional)
NOTE: Sway Bar Mounting Kit (p/n 5639-635).
Ski Shock Springs
* Production
Rebuildable Shock
Tools Required
PART NUMBER
(Sway Bar) PART NUMBER (Bushing) DESCRIPTION
4639-961 2603-803 (inc.) 11.1 mm diameter
4639-962 2603-804 (inc.) 12.7 mm diameter
4639-963 2603-775 (inc.) 14.3 mm diameter
Part No. Free
Length Rate (lb/in.) Active Coils Total Coils
2703-385 13.00 in. 175 8.50 10.50
2703-386 13.00 in. 160 8.00 10.00
2703-387 13.00 in. 190 8.50 10.50
2703-406* 13.00 in. 145 8.24 10.24
P/N Tool
0744-020 Inflation Needle
0644-486 Gas Shock Retaining Blocks
0644-544 Replacement Needle
0644-169 Piston Location Tool
0644-151 Nitrogen Regulator
0644-268 Bearing Cap Seal Protector
0644-403 Bearing Cap Seal Protector
(1/2-in. O.D. x 3/8 in. I.D.)
0644-404 Bearing Cap Seal Protector
(5/8-in. O.D. x 3/8 in. I.D.)
0644-542 Bearing Cap Seal Protector
(5/8 in. O.D. x 1/2 in. I.D.)
0644-543 Gas Shock Shaft Clamping Tool
0644-350 Floating Piston Location Gauge
0644-539 Inflation Needle Replacement Tip

10
Valve Stacks/
Specifications
Eyelets tightened to 28 ft-lb. Piston nut tightened to 22 ft-lb.
Tighten the shaft nut to 22 ft-lb. Shocks charged at 250 psi. Green Loctite #620 on shock eyelet threads.
Eyelets tightened to 28 ft-lb. Piston nut tightened to 22 ft-lb. Tighten shaft nut to 28 ft-lb. Shock charged at 250 psi. Green Loctite #620
on shock eyelet threads.
\
Shock charged at 250 psi. Green Loctite #620 on shock eyelet threads.
Eyelets tightened to 28 ft-lb. Piston nut tightened to 22 ft-lb.
Tighten the shaft nut to 28 ft-lb.
Part Number Description Compression (Piston Side) Rebound (Piston Side)
2703-809 Ski Shock 1.300 x 0.006 in. 1.100 x 0.006 in.
Extended Length: 20.12 in. Rebuild Kit - p/n 2604-815 1.300 x 0.006 in. 0.600 x 0.004 in.
Collapsed Length: 13.93 in. 1.300 x 0.006 in. 0.700 x 0.004 in.
Stroke: 6.19 in. 0.900 x 0.004 in. 0.900 x 0.004 in.
1.250 x 0.008 in. 1.125 x 0.080 in.
Top out plate
1.100 x 0.008 in.
1.000 x 0.008 in. 0.620 x 0.093 in.
Backup washer
0.900 x 0.008 in.
0.800 x 0.008 in.
0.700 x 0.008 in.
Piston Orifice: 0.035 in. Piston Depth: 2.26 in. 1.125 x 0.093 in.
Top out washer
Part Number Description Compression
(Piston Side) Rebound (Piston Side)
2704-039 Front Arm Shock 1.300 x 0.010 in. 1.100 x 0.008 in.
Extended Length: 12.34 in. Rebuild Kit - p/n 2604-815 1.300 x 0.010 in. 0.600 x 0.004 in.
Collapsed Length: 8.55 in. 1.300 x 0.010 in. 0.700 x 0.004 in.
Stroke: 3.79 in. 1.300 x 0.008 in. 0.900 x 0.004 in.
1.300 x 0.008 in. 1.125 x 0.080 in.
Top out plate
1.100 x 0.008 in.
1.000 x 0.008 in. 0.620 x 0.093 in.
Backup washer
0.900 x 0.010 in.
0.800 x 0.010 in.
0.700 x 0.010 in.
Piston Orifice: 0.035 in. Piston Depth: 0.685 in. 1.125 x 0.093 in.
Top out washer
Part Number Description Compression
(Piston Side) Rebound (Piston Side)
2704-040 Rear Arm Shock 1.600 x 0.008 in. 1.425 x 0.012 in.
Extended Length: 14.48 in. Rebuild Kit - p/n 2604-880 1.600 x 0.008 in. 1.000 x 0.004 in.
Collapsed Length: 10.08 in. 1.600 x 0.012 in. (Ring) 1.400 x 0.080 in.
Ground flat Top out plate
Stroke: 4.40 in. 1.425 x 0.006 in. (Center)
1.600 x 0.008 in. 0.620 x 0.093 in.
Backup washer
1.000 x 0.010 in.
1.600 x 0.010 in.
1.600 x 0.010 in.
1.425 x 0.010 in.
1.300 x 0.008 in.
1.100 x 0.008 in.
0.900 x 0.008 in.
0.800 x 0.004 in.
Piston Orifice: 0.055 in. Piston Depth: 5.70 in. 1.570 x 0.093 in.
Top out washer

11
Rebuildable Shock
Accessory Part
Numbers
NOTE: When rebuilding Fox shocks, use only
Fox valves and/or pistons.
NOTE: Shock Oil (p/n 5639-240) for the 500 cc
shocks is available from Arctic Cat Service Depart-
ment.
AC PN Description
2603-499 Valve: [0.500 OD X 0.252 ID X 0.006 TH]
2603-500 Valve: [0.600 OD X 0.252 ID X 0.010 TH]
2603-501 Valve: [0.700 OD X 0.252 ID X 0.010 TH]
3604-171 Valve: [0.600 OD X 0.377 ID X 0.004 TH]
2603-224 Valve: [0.620 OD X 0.377 ID X 0.015 TH]
3604-533 Valve: [0.600 OD X 0.377 ID X 0.012 TH]
0603-731 Valve: [0.700 OD X 0.377 ID X 0.004 TH]
0603-330 Valve: [0.700 OD X 0.377 ID X 0.006 TH]
0603-331 Valve: [0.700 OD X 0.377 ID X 0.008 TH]
0603-332 Valve: [0.700 OD X 0.377 ID X 0.010 TH]
0603-878 Valve: [0.700 OD X 0.377 ID X 0.012 TH]
0603-884 Valve: [0.700 OD X 0.377 ID X 0.015 TH]
0603-895 Valve: [0.800 OD X 0.377 ID X 0.004 TH]
0603-333 Valve: [0.800 OD X 0.377 ID X 0.006 TH]
0603-334 Valve: [0.800 OD X 0.377 ID X 0.008 TH]
0603-335 Valve: [0.800 OD X 0.377 ID X 0.010 TH]
0603-879 Valve: [0.800 OD X 0.377 ID X 0.012 TH]
0603-885 Valve: [0.800 OD X 0.377 ID X 0.015 TH]
0603-894 Valve: [0.900 OD X 0.377 ID X 0.004 TH]
0603-336 Valve: [0.900 OD X 0.377 ID X 0.006 TH]
0603-337 Valve: [0.900 OD X 0.377 ID X 0.008 TH]
0603-338 Valve: [0.900 OD X 0.377 ID X 0.010 TH]
0603-880 Valve: [0.900 OD X 0.377 ID X 0.012 TH]
0603-886 Valve: [0.900 OD X 0.377 ID X 0.015 TH]
0603-893 Valve: [1.000 OD X 0.377 ID X 0.004 TH]
0603-339 Valve: [1.000 OD X 0.377 ID X 0.006 TH]
0603-340 Valve: [1.000 OD X 0.377 ID X 0.008 TH]
0603-341 Valve: [1.000 OD X 0.377 ID X 0.010 TH]
0603-881 Valve: [1.000 OD X 0.377 ID X 0.012 TH]
0603-887 Valve: [1.000 OD X 0.377 ID X 0.015 TH]
0603-892 Valve: [1.100 OD X 0.377 ID X 0.004 TH]
0603-342 Valve: [1.100 OD X 0.377 ID X 0.006 TH]
0603-343 Valve: [1.100 OD X 0.377 ID X 0.008 TH]
0603-344 Valve: [1.100 OD X 0.377 ID X 0.010 TH]
0603-882 Valve: [1.100 OD X 0.377 ID X 0.012 TH]
0603-888 Valve: [1.100 OD X 0.377 ID X 0.015 TH]
0603-345 Valve: [1.250 OD X 0.377 ID X 0.006 TH]
0603-346 Valve: [1.250 OD X 0.377 ID X 0.008 TH]
0603-347 Valve: [1.250 OD X 0.377 ID X 0.010 TH]
0603-883 Valve: [1.250 OD X 0.377 ID X 0.012 TH]
0603-889 Valve: [1.250 OD X 0.377 ID X 0.015 TH]
0603-348 Valve: [1.300 OD X 0.377 ID X 0.006 TH]
0603-349 Valve: [1.300 OD X 0.377 ID X 0.008 TH]
0603-350 Valve: [1.300 OD X 0.377 ID X 0.010 TH]
0603-891 Valve: [1.300 OD X 0.377 ID X 0.012 TH]
0603-890 Valve: [1.300 OD X 0.377 ID X 0.015 TH]
2603-902 Valve: [0.550 OD X 0.377 ID X 0.020 TH]
AC PN Description
2604-647 Valve: [1.425 OD X 0.377 ID X 0.010 TH]
2604-632 Valve: [1.425 OD X 0.377 ID X 0.012 TH]
2604-633 Valve: [1.425 OD X 0.377 ID X 0.015 TH]
3604-577 Valve: [1.600 OD X 0.377 ID X 0.008 TH]
2604-631 Valve: [1.600 OD X 0.377 ID X 0.010 TH]
2604-683 Valve: [0.650 OD X 0.504 ID X 0.020 TH]
2604-469 Valve: [0.700 OD X 0.504 ID X 0.010 TH]
2604-470 Valve: [0.700 OD X 0.504 ID X 0.020 TH]
2604-471 Valve: [0.750 OD X 0.504 ID X 0.020 TH]
2604-472 Valve: [0.800 OD X 0.504 ID X 0.006 TH]
2604-473 Valve: [0.800 OD X 0.504 ID X 0.008 TH]
2604-474 Valve: [0.800 OD X 0.504 ID X 0.010 TH]
2604-475 Valve: [0.800 OD X 0.504 ID X 0.012 TH]
2604-476 Valve: [0.800 OD X 0.504 ID X 0.015 TH]
2604-477 Valve: [0.800 OD X 0.504 ID X 0.020 TH]
2604-478 Valve: [0.950 OD X 0.504 ID X 0.006 TH]
2604-479 Valve: [0.950 OD X 0.504 ID X 0.008 TH]
2604-480 Valve: [0.950 OD X 0.504 ID X 0.010 TH]
2604-481 Valve: [0.950 OD X 0.504 ID X 0.012 TH]
2604-482 Valve: [0.950 OD X 0.504 ID X 0.015 TH]
2604-483 Valve: [1.000 OD X 0.504 ID X 0.020 TH]
3604-149 Valve: [1.100 OD X 0.504 ID X 0.004 TH]
2604-484 Valve: [1.100 OD X 0.504 ID X 0.006 TH]
2604-485 Valve: [1.100 OD X 0.504 ID X 0.008 TH]
2604-486 Valve: [1.100 OD X 0.504 ID X 0.010 TH]
2604-487 Valve: [1.100 OD X 0.504 ID X 0.012 TH]
2604-488 Valve: [1.100 OD X 0.504 ID X 0.015 TH]
2604-489 Valve: [1.100 OD X 0.504 ID X 0.020 TH]
2604-684 Valve: [1.250 OD X 0.504 ID X 0.006 TH]
2604-685 Valve: [1.250 OD X 0.504 ID X 0.008 TH]
2604-686 Valve: [1.250 OD X 0.504 ID X 0.010 TH]
2604-687 Valve: [1.250 OD X 0.504 ID X 0.012 TH]
2604-688 Valve: [1.250 OD X 0.504 ID X 0.015 TH]
2604-490 Valve: [1.350 OD X 0.504 ID X 0.006 TH]
2604-491 Valve: [1.350 OD X 0.504 ID X 0.008 TH]
2604-492 Valve: [1.350 OD X 0.504 ID X 0.010 TH]
2604-493 Valve: [1.350 OD X 0.504 ID X 0.012 TH]
2604-494 Valve: [1.350 OD X 0.504 ID X 0.015 TH]
2604-495 Valve: [1.425 OD X 0.504 ID X 0.006 TH]
2604-496 Valve: [1.425 OD X 0.504 ID X 0.008 TH]
2604-497 Valve: [1.425 OD X 0.504 ID X 0.010 TH]
2604-498 Valve: [1.425 OD X 0.504 ID X 0.012 TH]
2604-499 Valve: [1.425 OD X 0.504 ID X 0.015 TH]
2604-500 Valve: [1.600 OD X 0.504 ID X 0.006 TH]
2604-501 Valve: [1.600 OD X 0.504 ID X 0.008 TH]
2604-502 Valve: [1.600 OD X 0.504 ID X 0.010 TH]
2604-503 Valve: [1.600 OD X 0.504 ID X 0.012 TH]
2604-504 Valve: [1.600 OD X 0.504 ID X 0.015 TH]

12
Wiring Diagram
Hood Harness (p/n 1686-587)
0744-201

Wiring Diagram (Ignition/Main)
(Harness p/n 1686-628)
0745-605
13

14
NOTES

15
Setup Instructions
This snowmobile has been prepared at the factory to
minimize required setup items; however, there are
some items and inspections that must be done at a
dealership or by the owner/operator. Please pay close
attention to all items on the following pages. Be sure to
read these instructions thoroughly before starting to set
up the snowmobile.
REMOVING SNOWMOBILE FROM
CRATE/HANDLEBAR ASSEMBLY
1. Remove the top and four sides of the crate.
Remove the skis from the crate sides.
2. Remove the windshield and hardware kit.
3. Remove all mounting hardware securing the
snowmobile to the crate base; then lift the snow-
mobile free of the crate base.
4. Swing the handlebar up and tighten the cap screws
evenly and securely; then check steering for maxi-
mum right/left turning capabilities. Install the han-
dlebar pad assembly.
NOTE: Recommended torque value for the cap
screws is 30 ft-lb.
INSTALLING WINDSHIELD
0745-366
1. Remove the protective film from the windshield.
2. Place the windshield (A) onto the hood making
sure that all the windshield tabs are in the slots.
3. Open the hood and install the windshield O-rings
(B).
4. With the windshield in place, install the expansion
nuts (C) into the hood; then install the machine
screws (D) and the snap caps (E).
INSTALLING SPINDLE/A-ARM
743-066B
1. Install the A-arms onto the spindle and secure with
washers and lock nuts. Tighten lock nuts to 45 ft-lb.
2. Install the steering tie rod to the spindle as shown in
illustration. Install the lock nut and tighten to 40 ft-lb.
INSTALLING FRONT SHOCK
ABSORBERS
744-874A
1. Raise the front of the snowmobile and place it on a
support stand.
2. Place the upper shock into position on the frame;
then install the cap screw and flange nut. Tighten
to 40 ft-lb.
3. Install the lower shock eyelet into the lower A-arm
mounting bracket.
4. Push the cap screw through the shock eyelet and
backside of the A-arm mounting bracket; then
install the nut and tighten to 40 ft-lb.
5. Install the remaining shock absorber.
INSTALLING SKIS
1. Raise the front of the snowmobile and place it on a
support stand or tip the snowmobile onto its side
using a handlebar support stand.
2. Slide a washer onto the cap screw used to secure
the ski; then apply all-temperature grease to the
non-threaded portion of the cap screw.
CAUTION
Care should be taken when removing the snowmobile
from the crate. Damage that is not warrantable may
occur.

16
3. With the rubber ski damper and damper plate
installed in the ski saddle, place the ski into posi-
tion on the spindle axle and install the spacer
(positioning the spacer for the desired ski stance).
NOTE: Maximum ski stance can be attained by
placing the spacer to the outside of the spindle;
minimum ski stance can be attained by placing the
spacer to the inside of the spindle. The spring
slide option can be attained by not installing the
spacer on either location.

NOTE: Local laws and/or regulations as to maximum
width of the ski stance on this snowmobile may be
applicable. Always comply with the maximum width
laws and/or regulations when adjusting ski stance.
4. Slide the cap screw with washer through the out-
side of the ski and spindle assemblies.
NOTE: Install the cap screw so the lock nut and
slide spring washer will be located to the inside of
the ski.
5. Install the slide spring washer.
6. Install the lock nut. Tighten the lock nut to 40-45
ft-lb.
7. Install the slide spring to the washer and spindle.
8. Install the remaining ski using steps 2-7.
INSTALLING SWAY BAR (Optional)
NOTE: Sway Bar Mounting Kit (p/n 5639-635).
0744-862
1. Place the sway bar into position (mounting loca-
tion) of the chassis.
2. Secure the bar with the two mounting brackets,
four cap screws, and four washers.
3. Tighten cap screws evenly to 96 in.-lb.
NOTE: The washers must be positioned between
the chassis and the mounting brackets.
4. Position the sway bar link onto the lower A-arm
and the sway bar. Install the cap screws and lock
nuts. Tighten the lock nuts to 20 ft-lb.
OIL-INJECTION PUMP
SYNCHRONIZATION
NOTE: Verify the mark on the control arm is
aligned with alignment mark on the oil-injection
pump boss in the full-open position. If the marks
are not aligned, adjust synchronization by loosen-
ing the jam nuts on the adjuster. Rotate the jam
nuts until properly aligned. Tighten jam nuts.
742-331A
NOTE: When the cable adjusting nut is adjusted
correctly, the throttle lever will move approxi-
mately 1/8 in. before the oil-injection pump control
arm begins to move.
CHECKING/ADJUSTING THROTTLE
LEVER FREE-PLAY (Tension)
NOTE: Prior to checking/adjusting free-play,
assure that the throttle cable is properly seated in
the throttle control housing.
1. Check the throttle cable free-play gap between the
throttle lever and the control housing.
2. On all models, there must be 0.75-1.5 mm (0.030-
0.060 in.) throttle cable free-play.
0741-518
NOTE: If throttle cable free-play is incorrect,
adjust the throttle cable jam nuts (at the throttle
body bracket) until recommended free-play is
attained.