PDF Service Manual Arctic Cat Snowmobiles (2013) - 11 MB
Keep your 2013 Arctic Cat snowmobile in peak condition with this official service manual.
This comprehensive guide provides detailed, step-by-step instructions for maintenance, troubleshooting, and complete overhaul procedures.
Covering engines, clutches, suspension, and electrical systems, it's the same resource used by dealership technicians.
A must-have for any serious rider or mechanic wanting to perform their own service.
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Printed in U.S.A. ®™Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701 p/n 2259-510
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16. If possible, store the snowmobile indoors. Raise the NOTE: On the 2-stroke models after prolonged stor-
track off the floor by blocking up the back end mak- age, Arctic Cat recommends one tankful of 100:1 gas/
ing sure the snowmobile is secure. Loosen the track oil mixture be used in conjunction with the oil-injec-
adjusting bolts to reduce track tension. Cover the tion system to ensure proper lubrication.
snowmobile with a machine cover or a heavy, venti-
lated tarpaulin to protect it from dirt and dust. 8. Tighten all nuts, bolts, and cap screws making sure
17. If the snowmobile must be stored outdoors, position the all calibrated nuts, bolts, and cap screws are tight-
snowmobile out of direct sunlight; then block the entire ened to specifications.
snowmobile off the ground making sure the snowmobile 9. If not done during preparation for storage, lubricate
is secure. Loosen the track adjusting bolts to reduce the rear suspension with an all-temperature grease.
track tension. Cover with a machine cover or a heavy, On the Bearcat/F-Series/T-Series, lubricate the spin-
ventilated tarpaulin to protect it from dirt, dust, and rain. dles and steering arm with an all-temperature grease.
CAUTION 10. On liquid cooled models, check the coolant level and
Avoid storing in direct sunlight and using a plastic cover as all coolant hoses and connections for deterioration or
moisture may collect on the snowmobile causing corrosion. cracks. Add properly mixed coolant as necessary.
11. On the 570 cc, clean the engine cooling fins and
vents.
Preparation After
Storage 12. On electric start models, charge the battery; then
connect the battery cables making sure to connect the
positive cable first. Test the electric start system.
Taking the snowmobile out of storage and correctly pre- 13. Inspect the entire brake system, all controls, head-
paring it for another season will assure many miles and light, taillight, brake light, ski wear bars, and head-
hours of trouble-free snowmobiling. Arctic Cat recom- light aim; adjust or replace as necessary.
mends the following procedure:
14. Adjust the track to the proper tension and alignment.
CAUTION
On the 570 cc if the gas in each carburetor float cham-
ber was not drained prior to storage, the carburetors After Break-In Checkup/
must be cleaned before starting the engine.
Checklist
1. Clean the snowmobile thoroughly. Polish the exte-
rior of the snowmobile. Certain areas require adjustment after the break-in period
2. Clean the engine. Remove the cloth from the exhaust in order to obtain peak performance. These areas are the
system. Check exhaust system and air silencer for following.
obstructions. CARBURETOR JETTING (570 cc) — Altitude, tem-
3. Inspect all control wires and cables for signs of wear or perature, and the use of oxygenated gasoline affect the
fraying. Replace if necessary. Use cable ties or tape to carburetion needed for optimum engine performance.
route wires and cables away from hot or rotating parts. The carburetor main jets must be changed in conjunction
with changes in operating altitude, oxygenated gasoline
4. Inspect the drive belt for cracks and tears. Check belt usage, and temperature.
specifications. Replace if damaged or worn. Install
the drive belt (see Section 6). DRIVE BELT DEFLECTION — Drive belt deflection is
very important to the snowmobile. Even if it is checked and is
NOTE: If the old belt is worn but in reasonable con- correct when the snowmobile is set up, it does change (more
dition, retain it with the snowmobile as a spare in so during the break-in period). This is because the rubber
case of emergency. engine mounts and the rubber snubber on the torque link will
all take a “set” during the first 100 miles allowing the distance
5. On the 570 cc, inspect the in-line fuel filter and replace if between the drive clutch and driven clutch to shorten. When
necessary; then adjust the carburetors and choke cable. this happens, the snowmobile will appear to have a too long
drive belt. To add to this, the drive belt itself wears and
! WARNING stretches somewhat leading to a low-end performance problem
and, if not corrected, causes premature drive belt wear.
Be sure to tighten the swivel adapter jam nuts securely. If a
jam nut isn’t tightened, the adjuster can rotate out of the After the break-in period, drive belt deflection should be
carburetor cap causing the piston valve not to return to the checked according to the instructions given in Section 6
full-closed position. of this manual.
6. Adjust the throttle cable. Inspect all fuel hoses and DRIVE CLUTCH/DRIVEN CLUTCH
oil hoses for deterioration or cracks; replace if neces- ALIGNMENT — The alignment between the drive
sary. Make sure all connections are tight. clutch and driven clutch are set at the factory. Normally,
no adjustment is necessary; however, if premature drive
7. On the 2-stroke, fill the oil-injection reservoir with the belt wear or poor performance is experienced, the drive
recommended 2-cycle oil; then inspect each spark clutch/driven clutch alignment must be checked.
plug. Replace, gap, or clean as necessary.
1-6
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STEERING/FRONT SUSPENSION/CHASSIS
Torque Specifications F/M/XF
Torque
Item Secured to
ft-lb
NOTE: Torque specifications have the following tol- Ski Spindle 35
erances: Ski Wearbar 96 in.-lb
Ski Ski Handle 54 in.-lb
Torque (ft-lb) Tolerance Handlebar Adjuster Block (Stan- Post 15
0-15 ±20% dard)
16-39 ±15% Handlebar Adjuster (Sno Pro) Post 15
40+ ±10% Steering Support Mounting Block 96 in.-lb
DRIVE SYSTEM Steering Post (F/XF/M 1100) Steering Stop Bracket 43
Bearcat/F-Series/T-Series Steering Tie Rod Steering Post 35
Torque Steering Tie Rod Steering Arm 20
Item Secured to ft-lb Steering Post Cap Riser Block 120 in.-lb
Drive Clutch *** Engine 51 Steering Post (M 800 SP/HCR) Mounting Bracket 20
Drive Clutch Cover Movable Sheave 120 in.-lb Tie Rod Steering Post 20
Cam Arm Pin Lock Nut Cam Arm Pin 11 Tie Rod Steering Tie Rod 20
Cam Arm Set Screw* Cam Arm 19 in.-lb Bracket
Drive Clutch* Ring Gear 22 Tie Rod Spindle Arm 32
Driven Clutch Input Shaft 32 Steering Support Spar 12
Movable Sheave Torque Bracket 72 in.-lb Steering Support Upper Console 30 in.-lb
Gear Case Chassis 20 Steering Arm Chassis 96 in.-lb
Gear Case Cover Gear Case 12.5 A-Arm (Upper) Chassis 23
Gear Case Drain/Fill Plug Gear Case 15 A-Arm (Lower) Chassis (Front) 55
Shift Actuator Gear Case 41 in.-lb A-Arm (Lower) Chassis (Rear) 45
Output Shaft Driveshaft 70 A-Arm Spindle 45
Brake Disc Driveshaft 120 Shock Absorber Spindle 32
Brake Caliper Chassis 20 Shock Absorber Chassis 32
Brakeline Caliper 10.5 Sway Bar Link A-Arm/Sway Bar Link 23
Brakeline Master Cylinder 21 Sway Bar Mounting Bracket Chassis 96 in.-lb
Speedometer Sensor Bracket Brake Caliper 17 Bearcat/F-Series/T-Series
F/M/XF Ski Spindle 32
Drive Clutch*** Engine 51 Ski Wearbar 108 in.-lb
Drive Clutch Cover Movable Sheave 120 in.-lb Ski Ski Handle 54 in.-lb
Cam Arm Pin Lock Nut Cam Arm Pin 11 Shock Mount Frame Suspension Mounting 96 in.-lb
Bracket
Cam Arm Set Screw Cam Arm 19 in.-lb
Steering Post* Suspension Mounting 35
Driven Clutch Driven Shaft 20 Bracket
Top Sprocket Driven Shaft 25 Steering Tie Rod Steering Post Arm 35
Movable Sheave Torque Bracket 72 in.-lb Tie Rod Spindle 30
Chain Case (Cap Screw) Chassis 96 in.-lb Steering Arm Suspension Mounting 20
Chain Case (Torx-Head Screw) Chassis 12 Bracket
Chain Case Cover Chain Case 12 Drag Link** Steering Arm 12
Shift Actuator (1100 cc) Chain Case Cover 36 in.-lb Tie Rod Drag Link 35
Brake Caliper Chassis 25 Tie Rod End Drag Link 35
Outside Caliper Housing Inside Caliper Housing 25 A-Arm Suspension Mounting 32
Bracket
Brakeline Caliper 25
A-Arm (Upper) Spindle 32
Brakeline Master Cylinder 25
Lower A-Arm Retainer** Spindle 13
Brake Caliper Shield Cover 96 in.-lb
Spindle Arm** Spindle 30
Adapter Sleeve Ring Nut Driven Shaft 50
Sway Bar Mounting Bracket Suspension Mounting 120 in.-lb
Bracket
Shock Absorber Shock Mounting Frame 32
Upper Bearing Bracket Support Plate 96 in.-lb
Shock Absorber Spindle 32
Rear Bumper Chassis 96 in.-lb
Rear Rack (BC XT) Tunnel 20
Front Bumper (BC XT) Suspension Mounting 32
Bracket
Front Bumper (BC XT) Shock Mounting Bracket 120 in.-lb
* w/Green Loctite #609
** w/Blue Loctite #243
*** w/Oil
1-16
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Assembly Schematic -
570 cc
Torque Specification Tolerances
Torque (ft-lb) Tolerance
0-15 ±20%
16-39 ±15%
40+ ±10%
570-ENG12
2-8
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Assembly Schematic -
500 cc
Torque Specification Tolerances
Torque (ft-lb) Tolerance
0-15 ±20%
16-39 ±15%
40+ ±10%
500CC1A12
2-18
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3. Remove the two screws securing the handlebar
Engine Removing/ close-off panel (B); then remove the three screws (C)
securing the left- and right-side rear spar panels to
Installing - the seat support tubes. Remove the screws (D) secur-
Bearcat Z1 XT/TZ1 ing the front spar panels to the front bumper; then
remove the spar panels.
NOTE: On the turbo model, only the console and
This engine section has been organized into sub-sections
showing a progression for the removing/installing of the Arc- cap screws (E) securing the left-front spar panel have
tic Cat 1100 cc (Bearcat Z1 XT/TZ1) engine. For consistency to be removed.
purposes, this section shows a complete and thorough pro-
gression; however, for efficiency it may be preferable to 4. Remove the seat (see Section 8).
remove only those components needing to be addressed. 5. Disconnect oxygen sensor connector; then remove
Also, some components may vary from model to model. The the springs securing the exhaust pipe and resonator
technician should use discretion and sound judgment. to the engine and chassis. Remove the exhaust
NOTE: Some illustrations and photographs used in assembly and account for exhaust gaskets and
this section are used for clarity purposes only and springs.
are not designed to depict actual conditions. NOTE: On the non-turbo models, the hairpin clip
and tab washer must be removed to remove the reso-
NOTE: Whenever a part is worn excessively, cracked,
nator from the chassis.
or damaged in any way, replacement is necessary.
SPECIAL TOOLS
A number of special tools must be available to the techni-
cian when servicing the engine.
Description p/n
Drive Clutch Puller 0744-062
Exhaust Spring Pliers 0644-391
Exhaust Spring Pliers 0644-397
Drive Belt Deflection Tool 0644-412
Drive Clutch Spanner Wrench 0644-136
Drive Clutch Bolt Tool 0644-281
NOTE: Special tools are available from the Arctic TZ101A
Cat Service Parts Department. 6. Remove the negative cable from the battery; then
remove the positive cable. Remove the hardware
securing the battery to the tray; then remove the bat-
Removing tery.
7. Remove the hose clamp from the coolant hose (A)
1. Remove the hood and the right- and left-side access connecting the water pump to the right side of the oil
panels. cooler; then clamp off the coolant hose. With a drain
pan positioned under the coolant hose, remove the
2. Remove the two torx-head cap screws (A) securing hose from the water pump; then release the clamp.
the console to the chassis; then lift up the rearward Tip the hose downward allowing the coolant to drain
end of the console and disconnect the console har- completely.
ness plug-in. Remove the console.
TZ074A
8. Using Drive Clutch Bolt Tool, remove the 12-mm
Allen-head cap screw and washer securing the drive
743-945A clutch to the crankshaft.
2-28
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22. Install the close-off cover to the front end with the NOTE: To aid in coolant bleeding procedure, do not
two cap screws (A) noting the mounting tab (non- secure the upper heat shield to the manifold at this
turbo only) (B) is installed with the right-side cap point.
screw. Tighten cap screws securely.
26. Connect the air bypass hose and the air bypass con-
trol valve hose to the intake pipe and secure with the
clamps.
ZJ020A
NOTE: On the Bearcat Z1 XT, install the close-off
panel; then with the mounting tab (A) on the left front
743-983A
cap screw, secure the panel with the four cap screws.
27. Install the hose from the waste gate control valve to
the elbow fitting of the turbocharger and secure with
the clamp.
TZ078A
23. Place the resonator into position in the chassis and
install the two springs securing the resonator to the TZ086B
chassis; then install the exhaust pipe and secure to
the manifold and resonator with six springs. 28. Position the intercooler into the grommets of the
mounting bracket; then connect the intercooler hoses
NOTE: On the non-turbo models, secure the resonator to the turbo and to the intake plenum. Tighten all
to the upper frame with the tab washer and hairpin clip. hose clamps securely.
24. Connect the harness plug-in for the oxygen sensor. 29. Connect the harness connector to the ECM.
NOTE: Steps 25-28 are for the turbo model only.
25. Install the upper heat shield; then connect the coolant
return hose to the turbo and secure with the hose clamp.
TZ072A
NOTE: Before installing the drive clutch, be sure to
wipe both the crankshaft taper and clutch mounting
taper clean using a clean towel.
TZ060A
2-38
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NOTE: On the turbo models, the shock mounting
Turbo
bracket support, left front spar, and heat shield are
removed as an assembly.
20. Remove the MAG-side chassis support. Account for
and note the location and orientation of the resonator
spring tab and resonator support bracket.
PC211A
23. Disconnect the harness connectors from the coolant
temperature sensor (A), oil pressure switch (B), and
air pressure sensor (C).
PC210A
21. Clamp off the coolant bypass hose and remove the
hose from the water pump; then add a length of hose to
the bypass hose and route the hose out of the exhaust
opening of the skid plate. Drain the remaining coolant.
PC028A
24. Loosen the clamps and remove the drain and vent
hoses and the throttle body coolant hose from the
coolant/oil separator tank; then remove the tank from
the bracket on the engine.
PC026A
22. Remove the throttle body coolant hoses.
PC032
NOTE: Steps 25-27 are for the non-turbo models
only.
25. Loosen the clamps securing the air silencer to the
ZJ018B throttle bodies; then disconnect the harness connec-
tor from the air temperature sensor and remove the
air silencer.
2-48
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33. Position the exhaust pipes and resonator into the
chassis and install and secure the MAG and PTO
exhaust flanges (with new gaskets) to the cylinder
head with the flange nuts. Tighten evenly to 17 ft-lb.
34. With the resonator properly installed to the chassis
support, install the spring securing the resonator to
the mounting tab.
NOTE: With the exhaust system installed, connect
the oxygen sensor to the harness connector.
Non-Turbo
PC027A
39. Install and secure the lower console to the skid plate
with the ¼ turn screws; then install the upper console
over the gas tank and install and tighten the retaining
nut to the neck of the gas tank.
PC024A
0746-324
40. Connect the wires to the reverse alarm; then install
the two screws securing the console to the steering
bracket.
NOTE: On the LXR/LTD models, connect the har-
ness connector to the seat heater switch before
PC241A securing the upper console.
35. Install and secure the drive clutch with the cap screw
(lightly coated with oil); then tighten the cap screw 41. Connect the battery cables (positive first) and the
ground wire to the battery; then connect the solenoid
to 51 ft-lb. harness to the solenoid.
CAUTION
When installing the drive clutch, do not tighten the
clutch cap screw with any kind of impact tool. Tighten
cap screw using a hand torque wrench only. Failure to
do so could result in stationary sheave damage.
36. Install the drive belt (see Section 6); then install and
secure the driven clutch (see Section 6).
37. Install the rear belt guard and connect the two har-
ness connectors to the ECM; then lock the fuse block
into the bracket of the front belt guard.
38. Install the gas tank (see Section 4).
XM015A
NOTE: On the LXR/LTD models, connect the seat
heater harness connector.
42. Install the seat (see Section 8).
43. Elevate the front of the snowmobile until the tunnel
heat exchangers are angled upward towards the engine.
2-58
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4. Place the head surface of each cylinder on the sur-
face plate covered with #400 grit wet-or-dry sandpa-
per. Using light pressure, move each cylinder in a
figure eight motion. Inspect the surface for any indi-
cation of high spots. A high spot can be noted by a
bright metallic finish. Correct any high spots before
assembly by continuing to move the cylinder in a fig-
ure eight motion until a uniform bright metallic fin-
ish is attained.
CAUTION
Water or parts-cleaning solvent must be used in con-
junction with the wet-or-dry sandpaper or damage to
the sealing surface may result.
MD2491
4. Place the cylinder head on a Surface Plate covered PISTON ASSEMBLY
with #400 grit wet-or-dry sandpaper. Using light 1. Using a non-metallic carbon removal tool, remove
pressure, move each cylinder head in a figure eight the carbon buildup from the dome of each piston.
motion. Inspect the sealing surface for any indication
of high spots. A high spot can be noted by a bright 2. Take an old piston ring and snap it into two pieces;
metallic finish. Correct any high spots before assem- then grind the end of the old ring to a 45° angle and
bly by continuing to move the cylinder head in a fig- to a sharp edge. Using the sharpened ring as a tool,
ure eight motion until a uniform bright metallic clean carbon from the ring-grooves. Be sure to posi-
finish is attained. tion the ring with its tapered side up.
CAUTION
Improper cleaning of the ring-grooves by the use of the
wrong type of ring-groove cleaner will result in severe
damage to the piston.
3. Inspect each piston for cracks in the piston pin and
skirt areas.
4. Inspect each piston for seizure marks or scuffing. If
scuffing or seizure marks are too deep, replace the
piston.
5. Inspect the perimeter of each piston for signs of
excessive “blowby.” Excessive “blowby” indicates
worn piston rings or an out-of-round cylinder.
MD2492
CRANKCASE
CAUTION
Water or parts-cleaning solvent must be used in con- 1. Wash the crankcase halves in parts-cleaning solvent.
junction with the wet-or-dry sandpaper or damage to
NOTE: Before washing the crankcase halves, make
the sealing surface may result.
sure the four bearing dowel pins have been removed
and accounted for.
CYLINDERS
1. Using a non-metallic carbon removal tool, remove 2. Inspect the crankcase halves for scoring, pitting,
carbon buildup from the exhaust ports. scuffing, or any imperfections in the casting.
2. Wash the cylinders in parts-cleaning solvent. 3. Inspect all threaded areas for damaged or stripped
threads.
3. Inspect the cylinders for pitting, scoring, scuffing,
and corrosion. If marks are found, repair the surface 4. Inspect the bearing areas for cracks or excessive
with a Ball Hone and honing oil. bearing movement. If evidence of excessive bearing
movement is noted, the crankcase must be replaced.
NOTE: To produce the proper 45° crosshatch pat-
tern, maintain a low drill RPM. If honing oil is not 5. Inspect the bearing dowel pins for wear.
available, use a lightweight, petroleum-based oil. 6. Inspect the sealing surfaces of the crankcase halves