Arctic Cat Cougar User manual

General Information
Troubleshooting
Lubrication, Maintenance and Tune-up
Adjustments for Special Use
fuel System-Carbureted Models
fuel System-fuel Injected Models
Exhaust System
Electrical Systems
Oil Injection System
Cooling System
Recoil Starter
Drive System
Brake, Driven Shaft, Dropcase and Driveshaft
front Suspension and Steering
Track and Rear Suspension
Off-season Storage
Index
Wiring Diagrams

Contents
QUICK REFERENCE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • • • • • • • • • • • • • • • • . . IX
CHAPTER ONE
GENERAL INFORMATION
Manual organization . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Notes, cautions and warnings . . . . . . . . . . . . . . . . . . . . . 2
Safety first . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Service hints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Engine and chassis serial numbers . . . . . . . . . . . . . . . . . 5
Engine operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Torque specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
RTV gasket sealant . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3
Threadlock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3
CHAPTER TWO
Gasket remover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4
Expendable supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . I4
Basic hand tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14
Precision measuring tools . . . . . . . . . . . . . . . . . . . . . . . I9
Special tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Mechanic's tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Ball bearing replacement. . . . . . . . . . . . . . . . . . . . . . . . 28
Seals
........................................ 31
Snowmobile operation. . . . . . . . . . . . . . . . . . . . . . . . . . 32
Snowmobile safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Snowmobile code
of ethics . . . . . . . . . . . . . . . . . . . . . . 34
1
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . • . • . • . . . . . . . . . . . . . . • • • • • • • • • • 45
Operating requirements . . . . . . . . . . . . . . . . . . . . . . . . . 46
Troubleshooting instruments. . . . . . . . . . . . . . . . . . . . . 46
Testing electrical components . . . . . . . . . . . . . . . . . . . . 46
Engine electrical system troubleshooting
........... 47
Voltage regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
CHAPTER THREE
LUBRICATION, MAINTENANCE AND TUNE-UP
Pre-ride checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Fluid checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Break-in procedure
............................ 72
Maintenance schedules . . . . . . . . . . . . . . . . . . . . . . . . . 73
Lubrication
................................... 74
Air cooling system
............................. 77
Liquid cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Electronic fuel injection . . . . . . . . . . . . . . . . . . . . . . . .
55
Engine ...................................... 55
Two-stroke pressure testing. . . . . . . . . . . . . . . . . . . . . . 59
Power train. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Skis and steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Track assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
72
Daily maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Weekly maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . .
85
Monthly maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Non-scheduled maintenance. . . . . . . . . . . . . . . . . . . . . 91
General inspection and maintenance. . . . . . . . . . . . . . . 98
Engine tune-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I00

CHAPTER FOUR
ADJUSTMENTS FOR SPECIAL USE
Carburetor tuning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
High-altitude clutch tuning . . . . . . . . . . . . . . . . . . . . . 133
CHAPTER FIVE
125
Gearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Spring suspension adjustment. . . . . . . . . . . . . . . . . . . 133
ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Engine number identification . . . . . . . . . . . . . . . . . . . 149
Engine lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Service precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Servicing engine in frame . . . . . . . . . . . . . . . . . . . . . . 151
Engine removal .............................. 151
Engine mounts ............................... 154
Engine installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Engine top end
............................... 158
CHAPTER SIX
Cylinder.................................... 166
Piston, piston pin, and piston rings . . . . . . . . . . . . . . 170
Reed valve assembly (1990-1991 El Tigre) ........ 180
Reed valve assembly
(437.4, 497, 594 and 599 cc
engines)............ 182
Crankcase and crankshaft . . . . . . . . . . . . . . . . . . . . . . 184
Driveshaft for coolant pump
and oil injection pump . . . . . . . . . . . . . . . . . . . . . . .
198
FUEL SYSTEM-CARBURETED MODELS • • • • . • . . . . . . . . . . . • . • • . . • . . . • . . • • . . . . 21 1
Air silencer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
Altitude compensator. . . . . . . . . . . . . . . . . . . . . . . . . . 220
CHAPTER SEVEN
Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
Throttle cable replacement . . . . . . . . . . . . . . . . . . . . . 222
FUEL SYSTEM-FUEL INJECTED MODELS • . . . . . . . . . . • • . . . . . . . . . . . . . . . . • • . . . . 227
Fuel injection system components . . . . . . . . . . . . . . . 229 Testing and troubleshooting
Testing and troubleshooting (EFI system magneto-powered). . . . . . . . . . . . . . . . 242
(EFI powered by battery). . . . . . . . . . . . . . . . . . . . . 232 Component service . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
CHAPTER EIGHT
EXHAUST SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
Exhaust system repair . . . . . . . . . . . . . . . . . . . . . . . . . 266
CHAPTER NINE
ELECTRICAL SYSTEM. • . • • • • • • • • • • • • • . . . . . . . . • . • • • . . . . . . . . . . . . • . . • • . . • • 268
Flywheel and stator assembly . . . . . . . . . . . . . . . . . . . 268
Ignition coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
CDI unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
Voltage regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
Lighting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
Instrument assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 285
CHAPTER TEN
Warning lamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
Fuel level sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
Oil level gauge ............................... 289
Electric starting motor. . . . . . . . . . . . . . . . . . . . . . . . . 289
Wiring diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
OIL INJECTION SYSTEM. • . • . • . . • • . • • • • • • • • • • • • • • • • . • . . . . . . . . . . . . . . . . • . . 295
System components. . . . . . . . . . . . . . . . . . . . . . . . . . . 295
Oil pump service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295 Component replacement . . . . . . . . . . . . . . . . . . . . . . . 296
Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297

CHAPTER ELEVEN
COOLING SYSTEMS. . . • • . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . 300
Fan-cooled models ............................ 300 Liquid-cooled models . . . . . . . . . . . . . . . . . . . . . . . . . 303
CHAPTER TWELVE
RECOIL STARTER . • • . . . . . • • • • • . . . . . . • • • • • • . . . . . . . . • . • • • . . . . . . • • • • . . . • 3 t4
CHAPTER THIRTEEN
DRIVE SYSTEM . . . • . . . . . . . • • . . . . . . . . . • • • • . . . . . . . . • • . • • . . . . . . . • • • • . . . .
324
Drive unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
Drive pulley assembly . . . . . . . . . . . . . . . . . . . . . . . . . 325
Driven pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
CHAPTER FOURTEEN
Drive belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
Drive pulley service. . . . . . . . . . . . . . . . . . . . . . . . . . . 334
Driven pulley service. . . . . . . . . . . . . . . . . . . . . . . . . . 345
BRAKE, DRIVEN SHAFT, DROPCASE AND DRIVESHAFT . . . . . • • • • • • • . . . . . • • • • . . . 370
Drive chain and sprockets
(models without reverse)
...................... 370
Drive chain and sprockets (models with reverse) .... 374
External chain tensioner . . . . . . . . . . . . . . . . . . . . . . . 380
CHAPTER FIFTEEN
Driven shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 I
Driveshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 384
Mechanical brake system . . . . . . . . . . . . . . . . . . . . . . 387
Hydraulic brake system
........................ 393
FRONT SUSPENSION AND STEERING. . . . . . . . . . . . . . . . . . • • • • . . . . . . . . . . • • • • . . 401
Skis ....................................... 401
Front suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
CHAPTER SIXTEEN
Steering assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422
Steering adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . 428
TRACK AND REAR SUSPENSION. . . . . . . . . . • • • . . . . • • . . . . . . . . . . . . . . . . . . . • . . 432
Rear suspension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432
Wear strips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434
End caps
.................................... 435
Shock absorbers .............................. 435
Front arm spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 457
Rear spring
.................................. 457
CHAPTER SEVENTEEN
Front arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 459
Rear arm and lower arm . . . . . . . . . . . . . . . . . . . . . . . 460
Idler wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 461
Rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 461
Track
...................................... 462
OFF-SEASON STORAGE. . . . . • • • . . . . . • • • • • . . . • • • • • . . . . . . . . • . . • . . • • • . . . . . 467
INDEX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 t
WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 473

Quick Refe.rence Data
RECOMMENDED LUBRICANTS AND FUEL
Engine oil
Coolant
Chaincase
Grease
Fuel
Brake fluid
Chaincase
Without reverse
.. 1993-199S
Cooling system
1990•1991
1992
1993
1994
Cougar
EXTS80
ZR440,ZRS80
1995
Z440
ZR440
Cougar, CougarMtn.Cat
Prowler 2-Up
EXT sao (all models)
ZR 580, ZR S80 EFI
1996
Z440
ZR440
Collgar
CougarMtn. Cat, Cougar 2-Up
EXT Sao (all models)
ZR5aO
ZRT600
ArcticCat
S0:1 Injection Oil
Glycol-basedautomotivetypeantifreeze compounded
foraluminum engines
Arctic
Cat Chain Lube
Ll)v,v~temperature grease
87 minimum octane
ArcticCatHi-Temp Brake Fluid
FLUU:)· CAPACITIES
236cc
345cc
2.4L
2.9L
2.4L
·3.3L
2.9 L
air-cooled
2.9 L
3.3L
·3.3 L
2:9L
2.9L
air-cooled
2.9.L
3.3L
3.3L
2.9L
2.9L
4.2L
(continued)
IX
8oz.
12oz.
2.Sqt.
3.0qt.
2.Sqt.
3.Sqt.
3.0qt.
a.oqt.
3.S qt.
3.Sqt.
3.0qt.
3.0qt.
3.0qt.
3.S qt.
3.Sqt.
a.oqt.
3.0qt.
·4.4qt.

Cooling system
1997
Z440
Panther 440
ZL 440,
ZR 440
·Cougar
Cougar Mtn. Cat
Panther 550
Pantera EFI
Powder Special (with carburetors)
EXT580 EFI
EXT 580 EFI DLX
Powder Special
EFI
ZR580
EXT 600, ZRT 600
Powder Extreme
1998
Z440
Panther440
ZL440,
ZR 440
ZL 500,
ZR 500
Cougar, Cougar DLX
CougarMtn. Cat
Panther550
Pantera EFI
Powder Special (with carburetors)
EXT580EFI
EXT 580 EFI DLX
Powder Special
EFI
ZR 600 (with carburetors)
EXT 600, ZRT 600
Powder Extreme
Fuel tank
1990
1992
Prowler
1993
440ZR
580ZR
1994
Cougar
ZR440
EXT580
ZR580
1995
Z440
ZR440
Cougar
ZR 580, ZR 580 EFI
1996
Z440
ZR440
ZRT 600
·•• •··· ·air-Cooled
.air*Cooled
2.9L
· 3.1 L
2.9L
2.9L
2.9L
2.91. ....
4.2L ·
2.91.
2,9L
3.1 L
4.2L
4.2L
.29;5·L
2't.3L
34L
34L
37,5L
3SL
41.1L
37;5L
. 37.5L
.37~51..··.
33.71..
.3.0qt,
3~3 qt.
3.0qt;··
.
3.0q ••
·. 3;0qt.
3.0qt.
4.~qt.
.3;()qt.
3.oqt.

Fuel tank
1997
Z440
Panther440
ZL 440, ZR 440
ZR580EFI
Cougar, CougarMountain Cat
Panther550
EXT580EFI
EXT580DLX
Pantera
Powder Special EFI
EXT600
ZRT600
PowderExtreme
1998
Z440
Panthet440
ZL 440, ZR 440
ZL500
Cougar,CougarDeluxe
CougarMountain Cat
Panther$50
EXT580EFI
EXT 580 EFI [)LX
Pantera
Powder Special EFI
EXT6()0
EXT600Touring
ZRT600
Powder Extreme
... ···. . ... ;
1998 models
1997 PoWder Special
EFI
1997 ZR 580 EFJ
All other models
FLUID CAPACITUiS fcontinued)
39.7L
39.7 L
37.5L
35.9L
34.1 L
34.1 L
39.7 L
39.7 L
39.7L
39.7L
37.5 L
37.5L
35.9 L
39.7L
39.7 L
35.7 L
35.7L
37;1 L
35.4L
35.4 L
40;1 L
40.1 L
39.7L
39.7 L
41.3 L
35.4 L
37.1 L
35.9L
SPARK PLUGS
Plug type
NGKBR9EYA
NGKBR9EYA
NGKBR9EYA
NGKBR9ES
10.5gal.
10.5 gal.
9.9 gal.
9.5 gal.
9gal.
9gal.
10.5 gal.
10.5 gal.
10.5 gal.
10.5gal.
9.9 gal.
9.9gal.
9.5 gal.
10.5gal.
10.5gal.
9.4gal.
9.4gal.
9.8 gal.
9.4 gal.
9.4 gal.
10.6gal.
10.6gal.
10.5gal.
10.5gal.
10.9gal.
9.4gat.
9.8 gal.
9.5 gal.
Gap (mm [in.])
0.7 (0.028}
0.7 (0.028}
0.7 {0.028}
.0.7 {0.028)
CARBURETOR PILOT AIR SCREW AND IDLE SPEED
1990 ....
ProWler; El TigreEXT
19$1~1992 ...
.
Cou~ar; f)rowler, El Tigre EXT
.Pilot air screw ..
turns out*
1
1
(continued)
Idle speed
rpm
2000~2500
2000~2500

Co1Jgar, ProWler
EXT550
580 ZR, EXT 580Z
1994
Cougar, Prowler
ZR 440, ZR: 580
EXT580
1995
Z 440, ZR: 440
Cougar; Prowler 2~Up
.EXT 580, ZR: 580
1996
Z440
ZR440
Cougar, Cougar ~~Up.··
EXT 580, ZR: 580
ZRT$00
1997
Z440
ZL 440, ZR: 440
Panther440 and 550 .. ·
Cougar
PowderSpecial
EXT 600, ZR:T 600; PoWder E)(treme
1998 .. .
Z440
Panther440
ZL440
ZR440
ZL500
· Panther550 ·
Cougar·
· PoWder Special• •··
EXT 600, ZR:T 600
Powder E:xtreme ·
1
1
1
.1-11/2
11/2
1
1
1
1
1-11/2
1112<
3/4
. 3/4
11/2
•.. 11/4
•· •..• ·•.• •·•··· 1 ..••.
...... 1
1
.... 11t4 .
11/2 ...
1
(continued)
Idle speed
rpm
1500
2000~2500
1500~2000
1500
1500·2000
1500-2000
1500·2000
1500-2000
1500-2000
1500-2000
1500·2000
1500·2000
1500-2000
1500·2000
1500·2000
1500-2000
1500·2000
1500-2000
1500-2000
1500-2000
1$00-2000
1500-2000
1500·2000
1500·2000
1500~2000
1500-2000
1500·20()0
1500·2000
1500·2000
1500·2000
1500-2000
*The!isted
number ittdicates.therecornmen(led initialsetting(ti.irns out from lightly seated)and is usuallycorrect
within ±118 turn. · ···· ·
Circumference
cm.pn.)
110.5-111.1
(43.50-43.74)

DR .• VE ··BELT SPEC.IFICATIONS
(continued)
Model Part No. Width
mm (in.)
1991~1992
Prowler, Cougar,
EITigreEXT 0227·032
34.1~35.7
110.5-111.1
(1.344~ 1.406) (43.5043.74)
1993
Prowler; Cougar
0227~032
34.1~5.7
110.5.-111.1 ..
(1.344-1.406) (43.50-43.74)
440ZR
0627~009 34~36
120.121
(1.339·1.417) (47.24-47.64}.
EXT 550, EXT 580 0627-012
34~36 120-121
(1.339-1.417) (47;24-47,64)
580ZR
0627-009 34-36 120.121
(1.339-1.417) (47
.,24-47 .64)
1994
Cougar, Prowler 0227-103
34~36
110.3-111.1
(1.339-1.417) (43.4343;?4}
ZR 440, EXT 580, ZR 580 0627-012
34~36
120~121
(1.339-1.41?) (47.24-47.64)
1995
Cougar, Prowler 2-Up 0627-012 34-36 120.8-121.3
(1.339-1.417) (47.5647;76)
Z440 0627-012 34-36 120.8-121.7 .
(1.339~1.417)
(47.56-47.91)
ZR 440, EXT 580,
EXT 580 EFI, ZR 580,
ZR580EFI
0627-012
34~36 120.121
(1.339-1.417) (47.24;.;47.64)
1996
Coug;;,~r 0627-012
34~36
120.121
(1.339-1.417) (47.24-47.64}
Z440
0627·012
34~36 120.8-121.7
(1;339-1.417) (47.56-47.91)
ZR 440, ZRT 600 0627·010 34-36 120.121
(1.339-1.417) (47.24-47.64)
EXT 580, EXT 580 EFI,
ZRS80 0627•012
34~6
120-121
(1.339-1.417) (47.24-47
,64}
1997
Z440 0627-012 34-36 120,121
(1.339-1.417) (47.24-47;64)
ZL440 0627-012 34-36 120.121
' (1.339-1.417) (47
,24-47.64)
··ZR440 0627-010
34~36 120.121
(1.339-1.417) (47.24-47.64}
Pan.ther440 0627-012 34-36 120-121
(1.339·1.417) (47.24-47.64)
Cougar
06277012 34-36 120-121
(1.339-1.417) (47.M--47.64)
Panther 550
0627~012 34-36 120-121
(1.339-1.417) (47.24-47.64)
Pan.tera 0627-012 34-36 120-121
(1.339-1.417) (47.24-47.64)
(continued}
xm

Model
1997
EXT580EFI
Powder Special EFt
ZR580EFI
EXT600
ZRT600
Powder Extreme·
1998
Z440
ZL440
ZR440
Panther440
ZLSOO
Cougar
Panther550
EXT580 EFI
Powder Special EFI
ZR600
·e){T600
ZRl600
0627-012
0627-012
0627-010
0627*010
0627·010
0627-010
0627-012
0627-021
0627-020
0627~1
0627•020
0627~021
0627"021
0627"021 •
0627-021
0627-020.
0627•020
0627-02()
0627~0
34-36
12~121
(1.3~1H.417')
(47.2447.64)
34•36 120·121.
(1.339-1.417) (47.24-47.64)
34-36
120~t21
.. .(1.339•1.417) (47.2447.64)
34~36
120"121 .
(1.339-1.417) (47.2447.64) •
34-36
12~121
(1.339-1.417)
.. (47;2447.64)
34-36 120·121
(1.339~1.417) (47.24-47.64)
34-36 120-121
(1.339•1.417) (47.2447;64)
34-36 120-121
(1.339·1.417) (47.2447.64)
34-36
120,;121
(1.339~1.417)
(47.24-47.64) ..
34•36 12~121
(1.339-1;41l) (47.2447;64)
34·36
.. 120·121....
(1.339-1.417) (47.2447.64)
34·36
12~121
(1.339-1.41.7) (47•
.24-47.64}
34~36
12~121
(1.339-1.417) (47,2447.64).
34~36
120-121
(1.339-1.417) (47.2447.64).
34·36
12~121
(1.339-1.417) (47.2447
.64}
34-36 120
... 121 ..
(1.339~1.417)
(47.24-47;64)
34·36
12~121
(1.339-1.417) (47:2447.64)
34*36
12~121 ..
(1 ~339-1.417).
(47~24-47.64)
34-36
12~121
(1.339-1;417) (47;2447.64)
34•36.
12~121 .....
(1.339-1.417) (47.2447.64}

Chapter One
General Information
This Clymer shop manual covers the
1990-1998 Arctic Cat Prowler, Cougar, Panther
440, Panther 550, EXT 550, EXT 580, EXT 600,
Z 440, ZL 440, ZR 440, ZR 580, ZR 600, ZRT
600, Powder Special and Powder Extreme mod-
els.
Troubleshooting, tune-up, maintenance and
repair are not difficult
if you know what tools
and equipment
to use, as well as the proper pro-
cedures. Step-by-step instructions guide you
through jobs ranging from simple maintenance
to complete engine and suspension overhaul.
This manual can be used by anyone from a
first time do-it-yourselfer
to a professional me-
chanic. Detailed drawings and clear photo-
graphs give you all the information you need
to
do the work right.
Some
of the procedures in this manual require
the use
of special tools. The resourceful me-
chanic can, in many cases, think
of acceptable
substitutes for special tools. This can be as sim-
ple as using a few pieces
of threaded rod, wash-
ers and nuts
to remove a bearing or fabricating a
tool from scrap material. However, using a sub-
stitute for a special tool is not recommended
as it
could damage the part.
If you find that a tool can
be designed and safely made, but will require
some type
of machine work, you may want to
search out a local community college or high
school that has a machine shop curriculum. In-
dustrial arts instructors sometimes welcome
outside work that can be used
as practical shop
applications for advanced students.
Tables appearing at the end
of this chapterpro-
vide useful general information for service. Ta-
bles 1-8 are at the end
of the chapter.
Table 1 lists model number coverage and en-
gine displacement.
General dimensions are listed in Table 2. Ta-
ble 3 lists vehicle weight.
Metric and U.S. standards are used throughout
this manual. U.S. to metric conversion is given
in Table 4.
Critical torque specifications are found in ta-
ble form at the end
of each chapter (as required).
The general torque specifications listed in Table
5 can be used when a torque specification is not
listed for a specific component or assembly.

2
A list of technical abbreviations are given in
Table
6.
Metric tap drill sizes can be found in Table 7.
Table 8 lists wind chill factors.
MANUAL ORGANIZATION
This chapter provides general information
useful
to snowmobile owners and mechanics. In
addition, information in this chapter discusses
the tools and techniques for preventive mainte-
nance, troubleshooting and repair.
Chapter
Two contains methods and sugges-
tions for quick and accurate diagnosis and repair
of problems. Troubleshooting procedures dis-
cuss typical symptoms and logical methods
to
pinpoint the trouble.
Chapter Three explains all the periodic lubri-
cation and routine maintenance necessary to
keep your snowmobile operating well. Chapter
Three also includes recommended tune-up pro-
cedures, eliminating the need to frequently con-
sult other chapters on the various assemblies.
Subsequent chapters describe specific sys-
tems, providing disassembly, repair, assembly
and adjustment procedures in simple step-by-
step form. If a repair is impractical for a horne
mechanic, it is indicated.
It is usually faster and
less expensive
to take such repairs to adealership
or competent repair shop. Specifications con-
cerning a specific system are included at the end
of the appropriate chapter.
NOTES, CAUTIONS AND WARNINGS
The terms NOTE, CAUTION and WARNING
have specific meanings in this manual. A NOTE
provides additional information to make a step
or procedure easier or clearer. Disregarding a
NOTE could cause inconvenience, but it would
not cause damage or personal injury.
A CAUTION emphasizes an area where
equipment damage could occur. Disregarding a
CHAPTER ONE
CAUTION could cause permanent mechanical
damage; however, personal injury is unlikely.
A WARNING emphasizes an area where per-
sonal injury or even death could result from
negligence. Mechanical damage may also occur.
WARNINGS are to be taken seriously. In some
cases, serious injury and death have resulted
from disregarding similar warnings.
SAFETY FIRST
Professional mechanics can work for years
and never sustain a serious injury.
If you observe
a few rules
of common sense and safety, you can
enjoy many safe hours servicing your own rna-
chine.
If you ignore these rules you can hurt
yourself or damage the equipment.
1. Never use gasoline as a cleaning solvent.
2. Never smoke or use a torch in the vicinity of
flammable liquids, such as cleaning solvent, in
open containers.
3. If welding orbrazing is required on the snow-
mobile, remove the fuel tank
to a safe distance,
at least 50 feet away.
4. Use the properly sized wrenches to avoid
damage to fasteners and injury to yourself.
5. When loosening a tight or stuck nut, be
guided by what would happen
if the wrench
should slip. Be careful and protect yourself ac-
cordingly.

GENERAL INFORMATION
6. When replacing afastener, make sure you use
one with the same measurements and strength
as
the old one. Incorrect or mismatched fasteners
can result in damage to the snowmobile and
possible personal injury. Beware
of fastener kits
that are filled with inexpensive and poorly made
nuts, bolts, washers and cotter pins. Refer to
Fasteners in this chapter for additional informa-
tion.
7. Keep all hand and power tools in good con-
dition. Wipe greasy and oily tools after using
Left
...
FRONT Right
...
REAR
3
them. They are difficult to hold and can cause
injury. Replace orrepair worn or damaged tools.
8. Keep your work area clean and uncluttered.
9. Wear safety goggles during all operations
involving drilling, grinding, using a cold chisel
or anytime you feel unsure about the safety of
your eyes. Wear safety goggles anytime you
clean parts using solvent or compressed
air.
10. Keep an approved fire extinguisher (Figure
1) nearby. Be sure it is rated for gasoline (Class
B) and electrical (Class C) fires.
11. If drying bearings or other rotating parts
with compressed air, never allow the air jet to
rotate the bearing or part. The air
jet is capable
of rotating them at speeds far in excess of those
for which they were designed. The bearing or
rotating part is very likely to disintegrate and
cause serious injury and damage.
To prevent
bearing damage when using compressed air,
hold the inner bearing race (Figure 2) with your
hand.
SERVICE HINTS
Most of the service procedures covered in this
book are straightforward and can be performed
by anyone reasonably handy with tools.
It is
suggested, however, that you consider your own
capabilities carefully before attempting any op-
eration involving major disassembly.
1. Front, as used in this manual, refers to the
front
of the snowmobile; the front of any com-
ponent is the end closest
to the front of the
snowmobile. The left and right sides refer
to the
position
of the parts as viewed by a rider sitting
and facing forward. For example, the throttle
control is on the right side. These rules are sim-
ple, but confusion can cause a major inconven-
ience during service (Figure 3).
2. When disassembling any engine or drive
component, markthe parts for location and mark
all parts that mate together. Small parts, such as
bolts, can beidentified by placing themin plastic

4
sandwich bags (Figure 4). Seal the bags and
labelthem withmasking tape and a marking pen.
3. Finished surfaces should be protected from
physical damage or corrosion. Keep fuel off
painted surfaces.
4. Use penetrating oil on frozen ortight bolts to
help loosen them, then strike the bolt head a few
times with a hammer and punch (use a screw-
driver on screws). Avoid the use
of heat where
possible, as itcan warp, melt oraffect the temper
of parts. Heatalso ruins finishes, especially paint
and plastics.
5. No parts removed or installed, other than
bushings and bearings, in the procedures given
in this manual should require unusual force dur-
ing disassembly orassembly.
If a part is difficult
to remove or install, find out why before pro-
ceeding.
6. Cover all openings after removing parts or
components to prevent the entrance
of debris or
small objects.
7. Read each procedure completely while look-
ing at the actual parts before starting ajob. Make
sure you thoroughly understand what is to be
done and then carefully follow the procedure,
step by step.
8. Recommendations are occasionally made to
refer service or maintenance to a snowmobile
dealerora specialistin a particularfield. In these
cases, the work will be done more quickly and
economically than
if you performed the job
yourself.
9. In procedural steps, the term replace means
to discard a defective part and replace it with a
new or exchange unit. Overhaul means to re-
move, disassemble, inspect, measure, repair or
replace defective parts, reassemble and install
major systems or parts.
10. Someoperations requiretheuse of ahydrau-
lic press. It is wiser to have these operations
performed by a shop equipped for such work,
than to try to do the job yourself with makeshift
equipment that may damage your machine.
CHAPTER ONE
11. Repairs go much faster and easier if your
machine is clean before you begin work. There
are many special cleaners on the market, like
Bel-Ray Degreaser, for washing the engine and
related parts. Follow the manufacturer's direc-
tions on the container for the best results. Clean
all oily or greasy parts with cleaning solvent as
you remove them.
WARNING
Never use gasoline as a cleaning agent.
It presents an extreme fire hazard. Be
sure to work
in a well-ventilated area
when using cleaning solvent. Keep afire
extinguisher, rated
for gasoline fires,
handy
in any case.
12. Much of the labor charges for repairs made
by dealers are for the time involved during the
removal, disassembly, assembly, and reinstalla-
tion
of other parts in order to reach the defective

GENERAL INFORMATION
part. It is frequently possible to perform the
preliminaryoperations yourselfandthentake the
defective unit
to the dealer for repair at consid-
erable savings.
13. If special tools are required, make arrange-
ments to get them before you start. It is frustrat-
ing and time-consuming to get partly into a job
and then be unable
to complete it.
14. Make diagrams (take a video or Polaroid
picture) wherever similar-appearing parts are
found orparts mustbeinstalled in a certain order
or location. For instance, crankcase bolts may
have differing lengths. A faulty memory can
resultin costly mistakes. Laying outpartsin their
proper order is a good practice, but
if the parts
are disturbed the exercise is a waste
of time.
15. When assembling parts, be sure all shims
and washers are replaced exactly
as they came
out.
16. Whenever a rotating part butts against a
stationary part, look for a shim or washer. Use
new gaskets if there is any doubt about the con-
dition
of the old ones. A thin coat of silicone
sealant on non-pressure type gaskets may help
them seal more effectively.
17. Ifit is necessary to make a cover gasket and
you do not have a suitable old gasket to use
as a
guide, you can use the outline
of the cover and
gasket material to make a new gasket. Apply
engine oil to the covergasket surface. Thenplace
the cover on the new gasket material and apply
5
pressure with your hands. The oil will leave a
very accurate outline on the gasket material that
can be cut around.
CAUTION
If purchasing gasket material, measure
the thickness
of the old gasket (at an
uncompressedpoint)
and purchase gas-
ket material with the same approximate
thickness.
18. Heavy grease can be used to hold small parts
in place
if they tend to fall out during assembly.
Be sure to keep grease and oil away from elec-
trical components.
19. A carburetor is best cleaned by disassem-
bling it and cleaning the parts in hot soap and
water. Never soak gaskets and rubber parts in
commercial carburetor cleaners. Never use wire
to clean out jets and air passages because that
will damage them easily. Use compressed air to
blow out the carburetoronly
if the float has been
removed first.
20. Take your time and do the job right. Do not
forget that anewly rebuilt engine mustbe broken
in just like a new one.
ENGINE AND CHASSIS
SERIAL NUMBERS
Arctic Cat snowmobiles are identified by
frame and engine identification numbers. The
frame orVehicle Identification Number (VIN) is
stampedon the right side
of the tunneljustbelow
the front of the seat (Figure 5). The engine
number is stamped on the side
of the crankcase
as shown in Figure6. The engine model number
is also listed on a decal located on the fan or
magneto housing
as shown in Figure 7.
Write all the serial numbers and model num-
bers applicable
to your machine in the front of
this book. Take the serial numbers and model
numbers with you when you orderparts from the
dealer. Always order parts by year and engine
and machine numbers.
If possible, compare the

6
old parts with the new ones before purchasing
them.
If the parts are not alike, have the parts
manager explain the reason for the difference
and insist on assurance that the new parts will fit
and will be correct.
ENGINE OPERATION
The following is a general discussion of a
typical two-stroke piston-ported engine. The
same principles apply to engines with reed type
intake valves, exceptthatduring theintakecycle,
the fuel/air
mh l~c:re passes through the openreed
valve assembly into the crankcase. During this
discussion, assume the crankshaft is rotating
counterclockwise as in Figure 8. As the piston
travels downward, a transfer port (A) between
the crankcase and the
cy Iinder is uncovered. The
exhaust gases leave the cylinder through the
exhaust port (B), which is also opened by the
downward movement
of the piston. A fresh
fuel/air charge, which has been previously com-
pressed slightly, travels from the crankcase (C)
to the cylinder through the transfer port (A) as
the port opens. Since the incoming charge is
underpressure, itrushes into thecylinderquickly
and helps to expel the exhaust gases from the
previous cycle.
Figure9 illustrates the nextphase of thecycle.
As the crankshaft continues to rotate, the piston
moves upward, closing the exhaust and transfer
ports. As the piston continues upward, the
air/fuel mixture in the cylinder is compressed;
Notice also thata vacuum is createdin the crank-
case at the sametime. Furtherupward movement
of the pistonuncovers the intakeport(D). Afresh
fuel-air charge is then drawn into the crankcase
through the intake port because
of the vacuum
created by the upward piston movement.
The third phase is shown in Figure 10. As the
pistonapproaches top deadcenter, the sparkplug
fires, igniting the compressed mixture. The pis-
ton is then driven downward by the expanding
CHAPTER ONE
gases. Every downward stroke of the piston is a
power stroke.
When the top
of the piston uncovers the ex-
haust port, the fourth phase begins, as shown in
Figure 11. The exhaust gases leave the cylinder
®

GENERAL INFORMATION
through the exhaustport. As the piston continues
downward, the intake port (or reed valves) are
closed and the mixture in the crankcase is com-
pressed in preparation for the next cycle.
®
7
TORQUE SPECIFICATIONS
Torque specifications throughout this manual
are given in Newton-meters (N.m) and foot-
pounds (ft.-lb.). Table 5 lists general torque
specificationsfor nuts andboltsthatare notlisted
in the respective chapters. To use the table, first
determine the size
of thenutorboltby measuring
it with a verniercaliper. Figures 12 and 13 show
how to do this.
FASTENERS
The materials and designs of the various fas-
teners used on your snowmobile are not deter-
mined by pure chance or accident. Fastener
material, size, and thread type are carefully se-
lected to decrease the possibility
of physical
failure. Fastener design determines the type
of
tool required to move the fastener (Figure 14).
Nuts, bolts and screws are manufactured in a
wide range
of thread patterns. To join a nut and
bolt, the diameters
of the bolt and the hole in the
nut must be the same and the threads on both
parts must also be the same.
The best way to tell
if the threads on two
fasteners are matchedis to tumthe nutonthebolt
(or the bolt into the threaded hole in a piece
of
equipment) with fingers only. Be sure both
pieces are clean.
If much force is required, check
the thread condition on each fastener.
If the
condition
of threads on both parts is goodbut the

8
fasteners jam, the threads are not compatible. A
thread pitch gauge (Figure 15) can also be used
to determine pitch. Arctic Cat snowmobiles are
manufactured with ISO metric fasteners. ISO
metric threads are cut differently than those of
standard American fasteners (Figure 16).
Most threads are cut so that the fastener must
be turnedclockwiseto tightenit. Thesearecalled
right-hand threads. Some fasteners have left-
hand threads and must be turned counterclock-
wise to be tightened. Left-hand threads are used
in locations where normal rotation
of the equip-
ment would tend to loosen a right-hand threaded
fastener.
ISO Metric Screw Threads
ISO (International Organization for Stand-
ardization) metric threads come in coarse, fine
and constant pitch threads. The ISO coarse pitch
is used for most common fastener applications.
The fine pitch thread is used on certain precision
tools and instruments. The constant pitch thread
CHAPTER ONE
is used mainly on machine parts and not for
fasteners. Itis also usedonall metric thread spark
plugs.
ISO metric threads are specified by the capital
letter M followed by the diameter in millimeters
and the pitch (or the distance between each
thread) in millimeters separated by the sign "x".
For example a M8 x 1.25 bolt is one that has a
diameter
of 8 millimeters with a distance of 125
millimeters between each thread. The measure-
ment across two flats on the head
of the bolt
(Figure 11) indicates the proper wrench size to
be used, but it is not an indication
of thread size.
Figure13showshow to determineboltdiameter.
American Threads
American threads come in a coarse or fine
thread. Because both coarse and fine threads are
used for general use, it is important to match the
threads correctly so you do not strip the threads
and damage one or both fasteners.
® 0
CD
CD
CD
CD
Hex Flat Oval Fillister Round
MACHINE SCREWS
CD
ffi
@ ®
Slotted Phillips Allen Fluted (splined)
OPENINGS FOR TURNING TOOLS

GENERAL INFORMATION
American fasteners are normally described by
diameter, threads perinch and length.
For exam-
ple, 3/8-16 x 2 indicates a bolt 3/8 inch in diame-
ter with 16 threads per inch, 2 inches long. The
measurement across two flats on the head
of the
bolt
or screw indicates the proper wrench size to
@
9
be used. Figure 13 shows how to determine bolt
diameter.
NOTE
If purchasing a bolt from a dealer or
parts store, you must know how to spec-
ify bolt length. Correctly measure
bolt
length by measuring the length starting
from underneath the
bolt head to the end
of the bolt (Figure 17).
Machine Screws
There are many different types
of machine
screws.
Figure 18 shows a number of screw
heads requiring different types
of turning tools.
Heads are also designed to protrude above the
metal (round)
or to be slightly recessed in the
metal (flat). See
Figure 19.
Bolts
Commonly called bolts, the technical name
for these types
of fasteners is cap screw. Metric
®
® OPENING FOR TURNING TOOLS
Slotted Phillips Allen Internal torx External torx
?\~~~~

10
bolts are describedby the diameterandpitch (the
distance between each thread).
Nuts
Nuts are manufactured in a variety
of types
and sizes. Most are hexagonal (six-sided) and fit
on bolts, screws and studs with the same diame-
ter and pitch.
Figure 20 shows several types of nuts. The
commonnutis generallyusedwith alockwasher.
A self-locking nut usually has a nylon insert that
prevents the nut from loosening and no lock-
washer is required. Wing nuts are designed for
fast removal by hand and are used for conven-
ience in noncritical locations.
To indicate the size of a metric nut, manufac-
turers specify the diameter
of the opening and
the thread pitch. This is similar to bolt specifica-
tions, but without the length dimension. The
CHAPTER ONE
measurement across two flats on the nut indi-
cates the proper wrench size to be used.
Self-Locking Fasteners
Several types
of bolts, screws and nuts incor-
porate a system that develops an interference
between the bolt, screw, nut or tapped hole
threads. Interference is achieved in one
of the
following ways: by distorting threads, coating
threads with dry adhesive ornylon, distorting the
top
of an all-metal nut or using a nylon insert in
the center or at the top
of a nut.
Self-locking fasteners offer greater holding
strength and better vibration resistance. Some
self-locking fasteners can be reused
if they are in
good condition. Others, like the nylon insert nut,
form an initial locking condition when the nut is
first installed. The nylon forms closely
to the bolt
thread pattern, thus reducing any tendency for
the nut to loosen. When the nut is removed, the
® MACHINE SCREWS
Hex Flat Oval Fillister Round
Common nut Self-locking
nut
Folding
Plain
Wing nut Internal tooth External tooth