Arctic Cat 2010 Crossfire 600 User manual

Operator’s Manual
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2010
2010
Crossfire 600
Crossfire 800/Sno Pro/LE
M6
M8/Sno Pro/LE
M8 HCR
M1000 Sno Pro
Mountain/Crossover
Models

LIMITED WARRANTY
Arctic Cat Inc. (hereinafter referred to as Arctic Cat) extends a limited warranty on each new Arctic Cat
Snowmobile it manufactures and on each part and accessory manufactured or sold by Arctic Cat. The
warranty is extended to the original retail purchaser only on parts and accessories sold through an
authorized Arctic Cat Snowmobile dealer. Warranty on snowmobiles is extended to the original retail
purchaser; however, the balance of the unused warranty may be transferred to a second party.
Arctic Cat warrants only the products it manufactures 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 sale and/or 5000 MILES whichever comes first.
3. THIRTY (30) DAYS from date of sale of snowmobile on Arctic Cat supplied batteries.
4. THIRTY (30) DAYS from date of sale for all dealer installed genuine Arctic Cat service parts and
accessories.
5. UNTIL EXPIRATION OF THE NEW PRODUCT WARRANTY (paragraphs 1 and 2 above) for all
eligible replacement parts on new product.
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 Torn or Punctured Upholstery
Drive Belt Wear Bars Water Pump Belt Brake Pads
Fan Belt Spark Plugs Wear Strips Drive Clutch/Driven Pulley Wear Parts
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 main 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.
In consideration of the foregoing, any implied warranty is limited in duration to the various warranty
periods set forth. This warranty gives you specific legal rights, and you may also have other rights which
vary from state to state and country to country. Some states do not allow limitations on how long an
implied warranty lasts, so the above limitations may not apply to you.

Table of Contents
Limited Warranty ......... Inside Front Cover
Foreword ................................................ 1
Declaration of Conformity....................... 2
Snowmobile Safety Rules ...................... 3
General Information .......................... 4-17
Snowmobile Identification.................. 4
Control Locations............................... 4
Gasoline-Oil....................................... 4
Engine Break-In................................. 6
Drive Belt Break-In ............................ 6
Speedometer/Tachometer ................ 7
Diagnostic Codes
(Standard/Deluxe Gauges).......... 10
Handlebar Tilt .................................. 10
Telescopic Handlebar
(Sno Pro/Sno Pro LE Models) ...... 11
Exhaust System............................... 11
Air-Intake Silencer ........................... 11
Cooling System ............................... 12
Drive Clutch and Driven Pulley........ 12
Drive Clutch/Driven Pulley
Alignment ..................................... 12
Fuel Pump ....................................... 12
Shock Absorbers (Standard Gas).... 13
Shock Absorbers
(Rebuildable Gas)......................... 13
Deep-Lug Track ............................... 13
Track Studs (Crossfire Models)........ 14
Reverse Operation........................... 15
Removable Seat (Crossfire 600/
800 cc STD Models)..................... 16
Towing.............................................. 16
Arctic Power Valve (APV) System.... 16
Exhaust Controlled Timing (ECT)
System ......................................... 17
Operating Instructions .....................18-22
Starting and Stopping Engine ..........18
Braking.............................................19
Emergency Stopping........................21
Throttle/Ignition Monitor Switch........21
Varying Altitude Operation ...............22
Lubrication .......................................23-25
ACT Drive Gear Case ......................23
Front Suspension .............................25
Rear Suspension .............................25
Maintenance ....................................26-44
Periodic Maintenance Checklist .......26
Fuel System .....................................27
Coolant Level ...................................27
Spark Plugs......................................27
Checking/Adjusting APV Cables ......28
Hydraulic Brake System...................29
Drive Belt .........................................32
Track Tension....................................35
Track Alignment................................36
Suspension ......................................37
Lights ...............................................40
Ski Wear Bars ..................................42
Adjusting Ski Stance ........................43
Rail Wear Strips ...............................43
Performance Tips.............................45-47
Preparation For Storage ..................48-49
Preparation After Storage.....................50
U.S. EPA Emission Control
Statement/Warranty Coverage......51
Change of Address, Ownership,
or Warranty Transfer ......................53
Warranty Procedure/Owner
Responsibility.......Inside Back Cover

REFERENCE 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: ________________________________________
Vehicle Identification Number: ______________________________
Engine Serial Number: ____________________________________
Your Arctic Cat Dealer: ___________________________________
Address: ______________________________________________
Phone: ________________________________________________
! WARNING
A snowmobile is a very high performance vehicle. Because it does accel-
erate rapidly and is capable of very high speeds, it should not be oper-
ated by a novice or an inexperienced operator. Never accelerate rapidly
or drive at high speed beyond the limits of visibility 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 maneuver-
ing 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.
PERSONAL INJURY
• To avoid injury to yourself and others, NEVER operate the snowmobile without
first reading and understanding this manual and the Snowmobile Safety Hand-
book; then follow the instructions and heed the warnings given.
• USE COMMON SENSE.
• DON’T DRINK and DRIVE.
• STAY IN CONTROL at ALL TIMES.
• TELL YOUR FRIENDS. If you see a friend operating a snowmobile recklessly, at
excessive speeds, while intoxicated, or in other unsafe ways, don’t wait until it is
too late to warn of the consequences of snowmobile misuse. Such conduct
endangers everyone. TAKE AN ACTIVE ROLE IN THE SAFETY OF YOUR-
SELF AND OTHERS.
PARTS AND ACCESSORIES
When in need of replacement parts, oil, or accessories 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 engi-
neered to meet the standards and requirements of your Arctic Cat Snowmobile.
For a complete list of accessories, refer to the current Arctic Cat Accessory Cat-
alog. To aid in service and maintenance procedures on these snowmobiles, an
Illustrated Parts Manual and a Service Manual are available through your local
Arctic Cat Snowmobile dealer.

1
FOREWORD
Congratulations! You have chosen a quality Arctic Cat Snowmobile designed
and manufactured to give dependable service. Be sure, as the owner/operator of
an Arctic Cat Snowmobile, to become thoroughly familiar with its basic opera-
tion, maintenance, and off-season storage procedures. Read this manual and the
accompanying Snowmobile Safety Handbook before operating the snowmobile
to learn 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, Caution, and Note to emphasize important informa-
tion. The symbol ! WARNING identifies personal safety-related informa-
tion. Be sure to follow the directive because it deals with the possibility of
serious personal injury or even death. A CAUTION identifies unsafe prac-
tices 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 particu-
lar 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 service.
At the time of publication, all information and illustrations were technically cor-
rect. 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 snowmo-
bile and must remain with the snowmobile at the time of resale. If the snowmo-
bile changes ownership more than once, contact Arctic Cat Inc., Service
Department, P.O. Box 810, Thief River Falls, MN 56701, for proper registration
information. This manual was prepared by the Product Service and Warranty
Department of Arctic Cat Inc.
Every Arctic Cat Snowmobile meets or exceeds the standards of the Snowmobile
Safety and Certification Committee and displays the SSCC decal. Arctic Cat Inc.
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
snowmobiling through education, charity, and research programs.
© 2009 Arctic Cat Inc.
Printed in U.S.A.

2
DECLARATION OF CONFORMITY
Application of council directives:
Issued by European Commission.
EMC Directive 89/336/EEC
EC Machinery Directive 98/37/EC
Type of Equipment: Snowmobile
Brand Name: Arctic Cat
Model Numbers:
S2010M6D3EUSG S2010M8H3EUSG S2010M8HSPUSW S2010M8HLEUSB
S2010M8HEKUSG S2010M8HSEUSW S2010M8HHCUSG S2010M1LSEUSW
S2010CFD1EUSG S2010CFH1EUSG S2010CFHSPUSW S2010CFHLEUSB
Standards to which conformity is declared:
EMC:
MACHINERY:
EN 55012, EN 61000-6-0
EN 292-1, EN 292-2, EN 953, EN 1050, EN 954-1
Manufacturer (if not issuing agent): Arctic Cat Inc.
601 Brooks Ave. S.
Thief River Falls, MN
56701 USA

SNOWMOBILE SAFETY RULES 3
SNOWMOBILE SAFETY RULES

4 GENERAL INFORMATION
GENERAL INFORMATION
SNOWMOBILE
IDENTIFICATION
The Arctic Cat Snowmobile has two
important identification numbers. The
Vehicle Identification Number (VIN) is
stamped into the tunnel near the right-
side footrest and on a decal beneath the
seat. The decal also displays pertinent
production information. The Engine
Serial Number (ESN) is stamped into
the crankcase of the engine.
0726-383
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 muti-
lated 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.
CONTROL LOCATIONS
Shown are the typical control locations
for Arctic Cat snowmobiles. Location
of a specific control will vary accord-
ing to model.
741-633A
GASOLINE-OIL
Recommended
Gasoline (600/
1000 cc Models)
The recommended gasoline to use in
these snowmobiles is 87 octane regular
unleaded.
NOTE: For optimum perfor-
mance, do not exceed the recom-
mended 87 octane gasoline. Using
a higher octane gasoline will not
increase overall performance.
In many areas, oxygenates (either etha-
nol or MTBE) are added to the gasoline.

GENERAL INFORMATION 5
Oxygenated gasolines containing up to
10% ethanol or up to 15% MTBE are
acceptable gasoline. Do not use gaso-
lines containing methanol.
Recommended
Gasoline (800 cc
Models)
The only recommended gasoline to use
in these snowmobiles is 91 octane
(minimum).
NOTE: For optimum perfor-
mance, use only 91 octane (mini-
mum) gasoline.
In many areas, oxygenates (either etha-
nol or MTBE) are added to the gasoline.
Oxygenated gasolines containing up to
10% ethanol or up to 15% MTBE are
acceptable gasoline. Do not use gaso-
lines containing methanol.
Recommended
Injection Oil
The recommended oil to use in the oil-
injection system is Arctic Cat Synthetic
APV 2-Cycle Oil. This oil is specially
formulated to be used either as an
injection oil or as a pre-mix oil (for
break-in) and meets all of the lubrica-
tion requirements of the Arctic Cat
snowmobile engine.
Filling Gas Tank
Since gasoline expands as its tempera-
ture increases, the gas tank must be
filled to its rated capacity only. Expan-
sion room must be maintained in the
tank particularly if the tank is filled
with cold gasoline and then moved to a
warm area.
Also, if the snowmobile is to remain on
a trailer after filling the gas tank, the
bed of the trailer must be maintained
level to prevent gasoline from draining
out through the gas tank vent hose.
CAUTION
Do not use white gas or gasoline
containing methanol. Only Arctic
Cat approved gasoline additives
should be used.
CAUTION
If a situation arises wherein 91
octane gasoline is not available, 87
octane gasoline can be substi-
tuted; however, do not prolong the
usage of 87 octane gasoline as it
will cause poor engine perfor-
mance.
CAUTION
Do not use white gas or gasoline
containing methanol. Only Arctic
Cat approved gasoline additives
should be used.
CAUTION
Any oil used in place of the recom-
mended oil could cause serious
engine damage.
! WARNING
Always fill the gas tank in a well-
ventilated area. Never add gasoline
to the snowmobile gas tank near
any open flames or with the engine
running. DO NOT SMOKE while fill-
ing the gas tank. Do not sit on the
snowmobile without first installing
the gas tank cap.

6 GENERAL INFORMATION
Break-In Gas/Oil
Mixing Instructions
Before mixing gasoline and oil, make
sure the oil is at room temperature (20°
C/68° F). Use a U.L. approved 22.7 l (6
U.S. gal.) gasoline container for mix-
ing the gasoline and oil. To properly
mix the fuel at a 100:1 ratio, use the
following procedure:
1. Pour gasoline into the gasoline
container until approximately half
full.
2. Pour 236 ml (8 fl oz) of the recom-
mended 2-cycle oil into the gaso-
line container.
3. Install cap on gasoline container
and shake the mixture vigorously.
4. Fill the gasoline container with
gasoline; then cap the gasoline
container and shake the mixture
vigorously.
5. Using a fine-mesh screened fun-
nel, pour the fuel mixture from the
gasoline container into the snow-
mobile gas tank.
ENGINE BREAK-IN
The Arctic Cat 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 pre-
mixed at a 100:1 ratio in all oil-injec-
tion models.
During the break-in period, a maxi-
mum of 1/2 throttle is recommended;
however, brief full-throttle accelera-
tions and variations in driving speeds
contribute to good engine break-in.
After one (1) tankful break-in period,
the snowmobile may be taken to an
authorized Arctic Cat Snowmobile
dealer for a checkup. This checkup is at
the discretion and the expense of the
snowmobile owner.
DRIVE BELT BREAK-IN
Drive belts require a break-in period of
approximately 25 miles. Drive the
snowmobile for 25 miles at 3/4 throttle
or less. By revving the engine up and
down (but not exceeding 60 mph), the
exposed cord on the side of a new belt
will be worn down. This will allow the
drive belt to gain its optimum flexibil-
ity and will extend drive belt life.
NOTE: Before starting the snow-
mobile in extremely cold tempera-
tures, the drive belt should be
removed and warmed up to room
temperature. Once the drive belt is
at room temperature, install the
drive belt (see Drive Belt sub-sec-
tion in the Maintenance section of
this manual).
CAUTION
Never mix oil and gasoline in the
snowmobile gas tank.
! WARNING
Always fill the gas tank in a well-
ventilated area. Never add gasoline
to the snowmobile gas tank near
any open flames or with the engine
running. DO NOT SMOKE while
mixing fuel or filling the gas tank.
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 consis-
tently operating in extremely cold
conditions (-26°C/-15°F or colder),
could cause spark plug fouling and
excessive carbon 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 con-
ditions.

GENERAL INFORMATION 7
SPEEDOMETER/
TACHOMETER
These snowmobiles are equipped with
different speedometer/tachometer styles.
Determine which style your model is
equipped with and use the appropriate
following information.
Indicator Icons
(Standard Gauge)
Certain models are equipped with a
standard gauge combination speedom-
eter/tachometer. Indicator icons are
incorporated within the speedometer/
tachometer. Also incorporated into the
speedometer/tachometer is a digital
readout screen.
FZ003D
A. Oil Pressure/Low Oil
B. Coolant Temperature
C. Low Fuel
D. Fuel Level
E. Service
F. High Beam
RPM/MPH (kph)
By pushing the left button once, the
RPM and MPH will be displayed (one
on the readout screen and one with the
needle). By pushing the button once
again, the functions will be reversed.
By pushing the left button (with speed
being displayed) for more than two
seconds, the display will change
between standard mph or metric kph.
Release the button when desired dis-
play appears.
With RPM displayed on the readout
screen by pushing and holding the left
button, maximum RPM will be dis-
played on the readout screen. The max-
imum RPM readout will reset when the
right button is pushed (while maximum
RPM is displayed).
Odometer/Trip-Meter
(1)/Trip-Meter (2)/
Hour-Meter
By pushing the right button, the read-
out screen will display odometer, trip-
meter (1), trip-meter (2), and hour-
meter. To reset the trip meter with the
trip meter displayed, push and hold the
right button until the display is cleared.
The hour-meter readout will not reset.
Service Icon
The icon should briefly illuminate each
time the engine is started; then it should
go out. If the icon illuminates while the
engine is running, the system is receiv-
ing input that is outside of its estab-
lished parameters. If the icon
illuminates indicating an error, take the
snowmobile to an authorized Arctic Cat
Snowmobile dealer for service. If not
under warranty, this service is at the dis-
cretion and expense of the snowmobile
owner.
CAUTION
Never run the engine with the drive
belt removed. Excessive revving of
the engine could result in serious
engine damage and drive clutch
failure.

8 GENERAL INFORMATION
Coolant Temperature
Warning Icon
If the coolant temperature is at or
above the maximum running tempera-
ture, the coolant temperature warning
icon will flash a warning (alert). If the
coolant temperature is at or above the
maximum running temperature, the
coolant temperature warning icon will
cease flashing and will remain con-
stantly illuminated.
Low Oil Warning Icon
The Low Oil Warning Icon is designed
to alert the snowmobile operator when
the oil in the oil injection reservoir gets
below a prescribed level; however, it is
highly recommended that a visual veri-
fication of the oil level in the reservoir
be done prior to operating the snowmo-
bile. Once the Low Oil Warning Icon
illuminates during operation of the
snowmobile, the operator must periodi-
cally monitor the level of oil in the res-
ervoir and must fill the reservoir the
next time gasoline is added to the gas
tank. The “alert level” of the Low Oil
Warning Icon is approximately equal to
1 tankful of gasoline under normal
operating conditions.
Indicator Icons
(Deluxe Gauge)
Certain models are equipped with a
deluxe gauge combination speedometer/
tachometer. Indicator icons are incorpo-
rated within the speedometer/tachometer.
Also incorporated into the speedometer/
tachometer is a digital readout screen.
FZ001E
A. High Beam
B. Oil Pressure/Low Oil
C. Coolant Temperature
D. Increment Button
E. Select Button
F. Decrement Button
G. Service
RPM/MPH (kph)
By pushing the increment button once,
the RPM and MPH will be displayed
(one on the readout screen and one
with the needle). By pushing the button
once again, the functions will be
reversed.
By pushing the increment button (with
speed being displayed) for more than
two seconds, the display will change
between standard mph or metric kph.
With RPM displayed on the readout
screen by pushing and holding the
increment button, maximum RPM will
be displayed on the readout screen. The
maximum RPM readout will reset
when the decrement button is pushed
(while maximum RPM is displayed).
Steady Flash
(Coolant Tempera-
ture Icon)
Coolant Temperature
Above 80° C (176° F).
Constant On
(Coolant Tempera-
ture Icon)
Coolant Temperature
Above 93° C (200° F).
CAUTION
At this point, take precautionary
measures such as changing to
loose snow terrain, shutting the
engine off (allowing the engine to
cool down), and checking coolant
level. If unable to either determine
or remedy the problem, take the
snowmobile to an authorized Arc-
tic Cat Snowmobile dealer for ser-
vice. If not under warranty, this
service is at the discretion and
expense of the snowmobile owner.

GENERAL INFORMATION 9
Odometer/Trip-Meter
(1)/Trip-Meter (2)/
Hour-Meter
By pushing the decrement button, the
readout screen will display odometer,
trip-meter (1), trip-meter (2), and hour-
meter. To reset the trip meter with the
trip meter displayed, push and hold the
decrement button until the display is
cleared. The hour-meter readout will
not reset.
Altimeter
By pushing the select button, the read-
out screen will display altimeter and
maximum altimeter.
The altimeter readout is based off baro-
metric pressure and may require cali-
bration as weather conditions change.
To calibrate the altimeter to an estab-
lished altitude with altimeter selected
on the display screen by pushing and
holding the select button for a mini-
mum of two seconds, the acronym
CAL will be displayed on the readout
screen for one second; then the altitude
value will flash. Push the increment
button to increase the displayed alti-
tude; push the decrement button to
decrease the displayed altitude. Push-
ing and holding a button will accelerate
the number display.
NOTE: If MPH has been selected
in the speed readout, the altitude
value will be displayed in feet. If
kph has been selected in the
speed readout, the altitude value
will be displayed in meters.
To reset the maximum altimeter read-
out with the maximum altimeter dis-
played, push and hold the select button
for a minimum of two seconds.
Service Icon
The icon should briefly illuminate each
time the engine is started; then it
should go out. If the icon illuminates
while the engine is running, the system
is receiving input that is outside of its
established parameters. If the system
icon illuminates indicating an error,
take the snowmobile to an authorized
Arctic Cat Snowmobile dealer for ser-
vice. If not under warranty, this service
is at the discretion and expense of the
snowmobile owner.
Coolant Temperature
Warning Icon
If the coolant temperature is at or
above the maximum running tempera-
ture, the coolant temperature warning
icon will flash a warning (alert). If the
coolant temperature is at or above the
maximum running temperature, the
coolant temperature warning icon will
cease flashing and will remain con-
stantly illuminated.
Steady Flash (Cool-
ant Temperature
Icon)
Coolant Tempera-
ture Above 80° C
(176° F).
Constant On
(Coolant Tempera-
ture Icon)
Coolant Tempera-
ture Above 93° C
(200° F).
CAUTION
At this point, take precautionary
measures such as changing to
loose snow terrain, shutting the
engine off (allowing the engine to
cool down), and checking coolant
level. If unable to either determine
or remedy the problem, take the
snowmobile to an authorized Arc-
tic Cat Snowmobile dealer for ser-
vice. If not under warranty, this
service is at the discretion and
expense of the snowmobile owner.

10 GENERAL INFORMATION
Low Oil Warning Icon
The Low Oil Warning Icon is designed
to alert the snowmobile operator when
the oil in the oil injection reservoir gets
below a prescribed level; however, it is
highly recommended that a visual veri-
fication of the oil level in the reservoir
be done prior to operating the snowmo-
bile. Once the Low Oil Warning Icon
illuminates during operation of the
snowmobile, the operator must periodi-
cally monitor the level of oil in the res-
ervoir and must fill the reservoir the
next time gasoline is added to the gas
tank. The “alert level” of the Low Oil
Warning Icon is approximately equal to
1 tankful of gasoline under normal
operating conditions.
DIAGNOSTIC CODES
(Standard/Deluxe
Gauges)
Diagnostic codes are activated by the
ECU and may be displayed on the
readout screen for a number of reasons.
If a code is displayed while the engine
is running, the ECU is receiving input
that is outside of its established param-
eters. If a code has been activated, take
the snowmobile to an authorized Arctic
Cat Snowmobile dealer for service. If
not under warranty, this service is at the
discretion and expense of the snowmo-
bile owner.
Additional codes are displayed on the
readout screen. Refer to the following
chart for diagnostic codes.
* On certain models.
HANDLEBAR TILT
The handlebar can be adjusted to the
position providing the operator with
the most comfort. To adjust the handle-
bar, use the following procedure:
NOTE: It may be necessary to
remove the handlebar cover for
this procedure.
1. Loosen the four lock nuts (Allen-
head cap screws on models with a
telescoping handlebar) securing
the handlebar caps and block to
the steering post.
743-442A
Code Trouble
2 Failure in injector(s).
4 Open or short circuit in barometric
pressure sensor.
5 Open or short circuit in intake air
temperature sensor.
6 Open or short circuit in water tem-
perature sensor.
7 Open or short circuit in throttle
position sensor.
12 Failure in ignition coil.
16* Incorrect adjustment/failure in
APV cable.
17* Failure in exhaust temperature
sensor.
18* Failure in servomotor.
21* Failure in knock sensor.
23* Fail-safe mode activated in knock
control system.
OCTN* Low octane gasoline.

GENERAL INFORMATION 11
0743-467
2. Adjust the handlebar to operator’s
desired tilt; then tighten the lock
nuts/cap screws evenly and
securely. Check steering for maxi-
mum right/left turning capabilities.
NOTE: Do not adjust the handle-
bar to a position that allows air to
enter the brake system.
3. Recheck lock nuts/cap screws;
tighten securely.
NOTE: Recommended torque
value of lock nuts is 18 ft-lb. Rec-
ommended torque value for the
Allen-head cap screws (on models
with a telescoping handlebar) is 20
ft-lb.
TELESCOPIC
HANDLEBAR (Sno Pro/
Sno Pro LE Models)
1. From each side of the steering
post, compress the locking tabs to
unlock the handlebar.
0743-463
2. With the tabs compressed, adjust
the handlebar up or down to the
desired position; then release the
tabs to lock the handlebar in place.
EXHAUST SYSTEM
The exhaust system is designed to
reduce noise and to improve the total
performance of the engine. If any
exhaust system component is removed
from the engine and the engine is run,
severe engine damage will result.
AIR-INTAKE SILENCER
Used in conjunction with the fuel
intake system is a specially designed
air-intake silencer. The purpose of the
silencer is to quiet the intake of fresh
air. Since the fuel intake system is cali-
brated with the air-intake silencer in
place, the engine must never be run
with the silencer removed. Perfor-
mance will not be improved if the air-
intake silencer is removed. In contrast,
severe engine damage will occur.
! WARNING
Tighten lock nuts according to
specifications to prevent unex-
pected “movement” of the handle-
bar during operation over rough
terrain and DO NOT position han-
dlebar so steering (maximum right/
left turning capabilities) or throttle
and brake controls are affected. CAUTION
These snowmobiles are not
designed to be operated in dusty
conditions. Operating the snow-
mobile in dusty conditions will
result in severe engine damage.

12 GENERAL INFORMATION
COOLING SYSTEM
These snowmobiles are equipped with a
closed liquid cooling system for engine
cooling. The cooling system should be
inspected daily for leakage and damage.
Also, the coolant level should be
checked daily. If leakage or damage is
detected, take the snowmobile to an
authorized Arctic Cat Snowmobile
dealer for service. If not under warranty,
this service is at the discretion and
expense of the snowmobile owner.
When filling the cooling system reser-
voir, use an ethylene glycol-based cool-
ant/water mixture which will satisfy the
coldest anticipated weather conditions
of your area in accordance with the cool-
ant manufacturer’s recommendations.
For checking/filling cooling system,
refer to Coolant Level sub-section in
the Maintenance section of this man-
ual.
DRIVE CLUTCH AND
DRIVEN PULLEY
The drive clutch and driven pulley do
not require lubrication; therefore, no
special maintenance is required by the
snowmobile owner except for periodi-
cal cleaning (see the Periodic Mainte-
nance Checklist in this manual).
However, the drive clutch and driven
pulley should be disassembled,
cleaned, and inspected by an autho-
rized Arctic Cat Snowmobile dealer
after every 800 miles of operation or at
the end of the snowmobiling season
whichever occurs first. This service is
at the discretion and expense of the
snowmobile owner.
When operating the snowmobile at
high altitudes, it may be necessary to
change certain component parts of the
drive clutch and/or the driven pulley.
See an authorized Arctic Cat Snowmo-
bile dealer for further information.
DRIVE CLUTCH/
DRIVEN PULLEY
ALIGNMENT
The parallelism and the offset between
the drive clutch and driven pulley are
set at the factory. Normally, no adjust-
ment is necessary as long as neither the
drive clutch nor the driven pulley is
removed or disassembled. However, if
premature drive belt wear is experi-
enced or if the drive belt turns over, the
drive clutch/driven pulley alignment
must be checked. Take the snowmobile
to an authorized Arctic Cat Snowmobile
dealer for this service. If not under war-
ranty, this service is at the discretion and
expense of the snowmobile owner.
FUEL PUMP
The fuel pump is designed to provide
adequate amount of gas to the injectors
at all throttle settings. If a fuel delivery
problem is suspected, take the snow-
mobile to an authorized Arctic Cat
Snowmobile dealer. If not under war-
ranty, this service is at the discretion
and expense of the snowmobile owner.
CAUTION
DO NOT attempt to service the
drive clutch and driven pulley. The
drive clutch and driven pulley must
be serviced by an authorized Arc-
tic Cat Snowmobile dealer only.

GENERAL INFORMATION 13
SHOCK ABSORBERS
(Standard Gas)
Each shock absorber should be visibly
checked weekly for fluid leakage,
cracks or breaks in the lower case, or a
bent plunger. If any one of these condi-
tions is detected, replacement is neces-
sary. Take the snowmobile to an
authorized Arctic Cat Snowmobile
dealer for this service. If not under war-
ranty, this service is at the discretion and
expense of the snowmobile owner.
NOTE: When the snowmobile is
operated in extremely cold weather
(-23° C/-10° F or colder), a small
amount of leakage may be present.
Unless the leakage is excessive,
replacement is not necessary.
SHOCK ABSORBERS
(Rebuildable Gas)
NOTE: The presence of a FOX
identifier (decal or embossed) on a
shock absorber body indicates a
“rebuildable” shock absorber.
 NOTE: The frequency of servicing
rebuildable shock absorbers will
vary according to the types of con-
ditions and terrain the snowmobile
has been subjected to. If riding
quality deteriorates (or seems to be
deteriorating), take the snowmobile
to an authorized Arctic Cat Snow-
mobile dealer for shock absorber
evaluation and/or servicing. This
service is at the discretion and
expense of the snowmobile owner.
Servicing rebuildable shock absorbers
is considered normal maintenance and
is the responsibility of the owner. Take
the snowmobile to an authorized Arctic
Cat Snowmobile dealer for this service.
This service is at the discretion and
expense of the snowmobile owner. Kits
are available to either stiffen or soften
gas shock valving. If changes in shock
valving are desired, see an authorized
Arctic Cat Snowmobile dealer. This
service is at the discretion and expense
of the snowmobile owner.
Each shock absorber should be visibly
checked weekly for fluid leakage,
cracks or breaks in the lower case, or a
bent plunger. If any one of these condi-
tions is detected, replacement is neces-
sary. Take the snowmobile to an
authorized Arctic Cat Snowmobile
dealer for this service. If not under war-
ranty, this service is at the discretion and
expense of the snowmobile owner.
NOTE: When the snowmobile is
operated in extremely cold weather
(-23° C/-10° F or colder), a small
amount of leakage may be present.
Unless the leakage is excessive,
replacement is not necessary.
DEEP-LUG TRACK
Some models are equipped with a deep-
lug track which is specially designed for
use in powder snow riding conditions.
When the deep-lug track is operated in
hard-packed snow conditions, it will run
slightly slower than a standard-lug track
and it will accelerate wear strip wear. To
decrease the amount of wear strip wear,
slower speeds must be maintained when
operating on hard-packed trails. Accel-
erated wear strip wear caused by operat-
ing a deep-lug track on hard-packed
snow conditions is NOT covered under
Arctic Cat Inc. warranty policy.

14 GENERAL INFORMATION
 NOTE: If operating on ice or hard-
packed snow conditions, it is rec-
ommended that Ice Scratchers (p/n
4639-958) be installed to reduce
wear strip and engine overheating.
TRACK STUDS
(Crossfire Models)
NOTE: Stud or hooker plate
installation will void track and tun-
nel warranty.
NOTE: Stud installation can be
performed by the snowmobile
owner if qualified to do so. If the
owner does not feel qualified, take
the snowmobile to an authorized
Arctic Cat Snowmobile dealer for
this service. This service is at the
discretion and expense of the
snowmobile owner.
 NOTE: To prevent tunnel damage
from the studs, Tunnel Protector Kit
(p/n 4639-968) must be installed.
For proper installation, use the follow-
ing procedure:
1. Using the stud template (see
chart), mark the desired stud pat-
tern to be used.
2. Using the proper-sized stud hole
drill bit, drill out the stud holes.
3. Push the stud through the hole
from inside the track; then place
the domed support plate and lock
nut on the exposed stud.
4. Using a wrench to secure the stud,
tighten the lock nut on the exposed
stud.
It is also recommended that whenever
studs are installed on a track, carbide
wear bars should be installed on the
skis. Carbide wear bars complement
the track studs to balance steering con-
trol under these conditions. The length
of the carbide on the wear bars should
be proportionate to the number of track
studs (i.e. small number of track studs
— short length of carbide...many track
studs — long length of carbide). The
proper proportion between the number
of studs and carbide length on the wear
bar will maintain steering balance.
! WARNING
When installing studs on a single-
ply track, it is important to use Arc-
tic Cat-approved studs (proper
head diameter). If approved studs
(proper head diameter) are not
used, studs could tear free of the
track causing possible injury or
even death. Consult an authorized
Arctic Cat Snowmobile dealer for
information.
CAUTION
If installing studs, a short Snowflap
(p/n 5639-232) must be installed or
component damage will occur.
Stud Template Chart
Track Length p/n
141 in. 4639-991
! WARNING
Always balance the snowmobile
with the proper proportion
between the number of studs and
carbide length on the wear bars.
Do not “over drive” conditions;
use common sense in all operating
conditions.
CAUTION
Do not use studs that are more
than 9.525 mm (0.375 in.) longer
than the track lug height.

GENERAL INFORMATION 15
REVERSE OPERATION
The reverse function offers the opera-
tor the convenience of being able to
back up the snowmobile rather than
having to turn the snowmobile around
by hand. This feature, under most situ-
ations, should not be used to free a
stuck snowmobile as it will tend to dig
the skis deeper into the snow. Always
use minimal speed when operating in
reverse and come to a complete stop
before shifting from either forward to
reverse or reverse to forward.
Shifting Into Reverse
741-438A
NOTE: Correct drive belt tension
(deflection) is important for the
reverse function to operate prop-
erly. If the belt is too tight, diffi-
culty in engaging reverse will be
experienced (the reverse function
will make up to three attempts to
engage into reverse, and if the
function is not completed after the
third attempt, the engine will shut
down).
1. Always warm up the engine for 2-
3 minutes prior to shifting into
reverse. The reverse function is
cancelled when engine tempera-
ture is below -22° F (-30° C) or
above 176° F (80° C).
2. Shift only with the engine at idle
RPM and the snowmobile com-
pletely stopped. The reverse func-
tion will not engage if engine
speed is above 4000 RPM.
NOTE: If attempting to shift into
reverse at too high engine RPM
(above 4000 RPM), the reverse
function will be cancelled and the
coolant temperature warning icon
will flash. This indicates the
reverse switch button was pressed
at too high RPM. The operator
must reduce engine RPM below
4000 and press the button a sec-
ond time.
3. Upon pressing the reverse switch
button, the reverse function will
make up to three attempts to
engage into reverse. If the function
is not completed after the third
attempt, the engine will shut down.
Operating in Reverse
1. When reverse is engaged, a
reverse icon will illuminate in the
speedometer/tachometer and a
reverse alarm will sound.
! WARNING
Do not operate a snowmobile with
loose studs as they may be thrown
from the track. Always use a
shielded safety stand whenever
performing any maintenance or
adjustments.
! WARNING
DO NOT stand behind the snowmo-
bile or near the rotating track.
NEVER run the track at high speed
when the track is suspended.
CAUTION
Never shift into reverse while the
snowmobile is moving forward as
it is hard on the driven pulley
torque bracket and the cam rollers.
CAUTION
Never engage the electric starter or
pull the recoil starter rope when the
engine is running or when operating
in reverse. Damage to the engine
and/or either the electric start or
recoil start system will occur.

16 GENERAL INFORMATION
2. If the throttle lever is compressed
before complete reverse engage-
ment, the engine may shut down.
Always wait for the reverse icon to
illuminate and the reverse alarm to
sound before backing up.
3. If reverse is used for longer than
five minutes continuously, the
engine will shut down.
NOTE: While operating in
reverse, a “rev-limiter” will activate
at 6000 RPM.
4. After shifting from reverse to for-
ward (or from forward to reverse),
apply the throttle slowly and
evenly to allow the driven pulley
to engage properly.
5. The reverse function is cancelled
whenever the engine is shut off.
REMOVABLE SEAT
(Crossfire 600/800 cc
STD Models)
These snowmobiles are equipped with
a removable seat. To remove the seat,
use the following procedure:
1. Inside the rear storage compart-
ment on the bottom of the seat-
base, rotate the latch cover away
from the right-side locking pin.
2. Lift on the back of the seat and
move it rearward to remove it
from the tunnel.
To install the seat, use the following
procedure:
1. Slide the front of the seat into
position on the tunnel; then lower
the rear of the seat onto the lock-
ing pins.
2. Press down on the rear of the seat
until the retaining clips snap into
place on the locking pins; then rotate
the latch cover until it snaps into
place on the right-side locking pin.
TOWING
If the snowmobile is to be towed by
another snowmobile, do not tow using
the loops in the skis. The tow rope
should be attached to the spindles.
ARCTIC POWER VALVE
(APV) SYSTEM
This RPM controlled servomotor
(servo) actuated system adjusts the size
of the exhaust ports to provide peak per-
formance throughout the RPM range.
! WARNING
Do not use high speed when back-
ing up. Control could be lost and
injury could occur.
CAUTION
Do not use high speed when back-
ing up. Damage to the drive belt
and driven pulley components may
occur.
CAUTION
After reversing in deep powder
snow conditions, make sure the
snowflap does not become
“caught up” in the track. Track
and/or snowflap damage may
occur.
! WARNING
Make sure the seat is securely
locked in place or personal injury
may result.
CAUTION
The correct engine oil to use is
Arctic Cat Synthetic APV 2-Cycle
Oil (p/n 4639-348). Any substitute
may cause an APV malfunction.