2007 Arctic Cat 2 Stroke Snowmobiles Service Manual
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Table Of Contents:
2007 Arctic Cat 2 Stroke Snowmobiles Service Manual
Snowmobile Identification ………………………………… 1-2
Recommended Gasoline and Oil ……………………… 1-2
Break-In Procedure ………………………………………… 1-2
Genuine Parts ……………………………………………….. 1-2
High Altitude Operation …………………………………… 1-3
Preparation For Storage ………………………………….. 1-3
Preparation After Storage ……………………………….. 1-4
After Break-In Checkup (100 Miles) ………………….. 1-5
After Break-In Checkup Checklist …………………….. 1-6
Check Engine Light
(Crossfire/F-Series/M-Series Models) …………….. 1-6
Diagnostic Codes/Check Engine
(Crossfire/F-Series/M-Series Models) …………….. 1-6
Chassis Control Unit
(Crossfire/F-Series/M-Series Models) …………….. 1-7
Diagnostic Codes/Chassis Control Unit
(Crossfire/F-Series/M-Series Models) …………….. 1-7
Torque Conversions ……………………………………….. 1-8
Tightening Torque (General Bolts) ……………………. 1-8
Fraction/Decimal Conversion Chart ………………….. 1-9
Drill Bit Sizes (Number) Chart ………………………….. 1-9
MM/In. Conversion Chart ………………………………. 1-10
Servicing Symbols ……………………………………….. 1-11
Arctic Cat Engine Specifications ……………………….. 2-2
Torque Conversions ………………………………………… 2-3
Piston Replacement Guide ………………………………. 2-3
Assembly Schematics (Table of Contents) ………….. 2-4
Cylinder Head Volume Specifications ………………. 2-18
Engine Piston Travel Versus Crank Angle Chart … 2-18
Crankshaft Runout/Repair Specifications …………. 2-19
Engine – Panther 370/Z 370 ……………………………. 2-20
Engine – Bearcat 570/Panther 570/Z 570………….. 2-35
Engine – Crossfire 500/600 – M-Series 600……….. 2-57
Engine – Crossfire 800/1000 –
M-Series 800/1000……………………………………… 2-86
Engine – F-Series 500/600 ……………………………. 2-120
Engine – F-Series 800/1000 ………………………….. 2-148
Troubleshooting Engine (Carbureted Models)….. 2-178
Troubleshooting Engine (EFI Models) …………….. 2-181
Axial Fan/Belt (370 cc) …………………………………….. 3-2
Repairing Water Pump (500/600 cc) ………………….. 3-4
Repairing Water Pump (800/1000 cc) ………………… 3-8
Pressure Testing Engine ………………………………… 3-12
Liquid Cooling System …………………………………… 3-12
Cooling System Schematics …………………………… 3-15
Recoil Starter (370/500/600 cc) ………………………. 3-17
Recoil Starter (570/800/1000 cc) …………………….. 3-19
Arctic Power Valve (APV) System ……………………. 3-22
Exhaust Controlled Timing (ECT) System ………… 3-29
Fuel System (Carbureted) ………………………………… 4-2
Fuel System (EFI) …………………………………………. 4-21
Fuel System (Related Items)…………………………… 4-37
Electrical Specifications Chart ………………………….. 5-2
Electrical Specifications (Individual)…………………… 5-3
Testing Electrical Components………………………….. 5-7
Troubleshooting/Testing Ignition System
EFI Models………………………………………………….. 5-7
Fan Cooled Models ………………………………………. 5-8
Throttle Position Sensor
(EFI Models) ……………………………………………… 5-11
Testing Electrical Resistances
500/600 cc Models……………………………………… 5-12
800/1000 cc Models……………………………………. 5-14
370 cc Model……………………………………………… 5-15
570 cc Model……………………………………………… 5-17
Voltage Regulator Test (Carbureted Models) …….. 5-19
Chassis Control Unit Voltage Test (EFI Models) … 5-19
Servomotor Test ……………………………………………. 5-19
Potentiometer Test ………………………………………… 5-20
Peak Voltage Tests
(Carbureted Models) …………………………………… 5-20
Peak Voltage Tests (500/600 cc Models) ………….. 5-21
Peak Voltage Tests (800/1000 cc Models) ………… 5-22
Testing Low-Oil Light Sensor…………………………… 5-23
Testing High Temperature Sensor ……………………. 5-23
Testing High Temperature Warning Light ………….. 5-23
Testing Fuel Gauge ……………………………………….. 5-23
Testing Fuel Gauge Sender ……………………………. 5-24
Testing Electric Fuel Pump……………………………… 5-24
Electric Start Components
Solenoid ……………………………………………………. 5-24
Fuse …………………………………………………………. 5-24
Ignition Switch – Electric Start Function …………. 5-25
Starter Motor ……………………………………………… 5-25
Troubleshooting Electric Start ………………………. 5-32
Ignition Timing………………………………………………. 5-32
Ignition Timing Specifications
(Table of Contents) ……………………………………….. 5-32
Ignition Timing Specifications………………………….. 5-33
Brakelight Switch (Bearcat 570/Z 570)……………….. 6-2
Brakelight Switch (Panther 370/Z 370)……………….. 6-2
Brakelight Switch (EFI Models/Panther 570)……….. 6-3
Headlight Dimmer Switch
(Bearcat 570/Panther 370/Z 370/Z 570) ………….. 6-3
Headlight Dimmer Switch
(EFI Models/Panther 570)
Testing Handlebar Warmer Elements
(Panther 370/Z 370/Z 570)…………………………….. 6-4
Testing Handlebar Warmer Elements
(EFI Models/Panther 570) ……………………………… 6-5
Testing Thumb Warmer Element
(Bearcat 570/Panther 370/Z 370/Z 570) ………….. 6-5
Testing Thumb Warmer Element
(EFI Models/Panther 570) ……………………………… 6-5
Testing Handlebar Warmer Switch
(Bearcat 570/Panther 370/Z 370/Z 570) ………….. 6-5
Testing Handlebar Warmer/Thumb Warmer
Switch (EFI Models/Panther 570) …………………… 6-6
Testing Thumb Warmer Switch
(Bearcat 570/Panther 370/Z 370/Z 570) ………….. 6-6
Testing Passenger Handwarmer Switch……………… 6-6
Testing Passenger Handwarmer Elements …………. 6-6
Testing Speedometer Sensor (EFI Models) ………… 6-7
Testing Reverse Alarm Switch
(Bearcat 570/Panther 370/570)………………………. 6-7
Testing Reverse Alarm Switch
(Crossfire/F-Series/M-Series) ………………………… 6-7
Testing Shift Actuator Switch
(Crossfire/F-Series/M-Series) ………………………… 6-8
Testing Shift Actuator
(Crossfire/F-Series/M-Series) ………………………… 6-8
Steering and Body ………………………………………….. 7-2
Steering Post (Bearcat/Panther/Z) …………………….. 7-2
Steering Post
(Crossfire/M-Series)……………………………………… 7-6
Steering Post (F-Series)…………………………………… 7-8
Ski ………………………………………………………………. 7-11
Ski Wear Bar ………………………………………………… 7-12
Drag Link (Bearcat/Panther/Z) ………………………… 7-13
Drag Link (F-Series)………………………………………. 7-14
Front Tie Rods (Bearcat/Panther/Z) …………………. 7-16
Front Tie Rods
(Crossfire/M-Series)……………………………………. 7-17
Tie Rods (F-Series)……………………………………….. 7-18
Spindle (Bearcat/Panther/Z)……………………………. 7-19
Spindle (Crossfire/M-Series)…………………………… 7-20
Spindle (F-Series) …………………………………………. 7-23
Steering Tie Rod
(Bearcat/Panther/Z) ……………………………………. 7-25
Steering Tie Rod
(Crossfire/M-Series)……………………………………. 7-26
Steering Tie Rod (F-Series) ……………………………. 7-27
Ski Alignment ……………………………………………….. 7-28
Front Suspension Arms
(Bearcat/Panther/Z) ……………………………………. 7-30
Front Suspension Arms
(Crossfire/M-Series)……………………………………. 7-32
Front Suspension Arms (F-Series)…………………… 7-36
Front Suspension (Ski) Shock Absorber …………… 7-38
Sway Bar (Bearcat/Panther/Z) ………………………… 7-38
Sway Bar (F-Series)………………………………………. 7-39
Front Suspension Mounting Bracket (F-Series) …. 7-39
Console (Crossfire/M-Series)………………………….. 7-43
Console (Bearcat/Panther/Z)…………………………… 7-44
Console (F-Series) ………………………………………… 7-44
Belly Pan (Bearcat/Panther/Z)…………………………. 7-44
Belly Pan (Crossfire/M-Series) ………………………… 7-51
Gas Tank/Seat Assembly
(Bearcat/Panther/Z)…………………………………….. 7-53
Gas Tank/Seat Assembly
(Crossfire/M-Series)……………………………………. 7-53
Gas Tank/Seat Assembly (F-Series) ………………… 7-54
Seat Cushion………………………………………………… 7-55
Taillight/Brakelight Assembly …………………………… 7-56
Windshield
(Bearcat/Crossfire/M-Series/Panther/Z)…………. 7-57
Windshield (F-Series — Non-Adjustable) …………. 7-58
Windshield (F-Series — Adjustable) ………………… 7-58
Backrest/Rack Assembly………………………………… 7-58
Tunnel/Rear Bumper/Snowflap
(Bearcat/Panther/Z)…………………………………….. 7-59
Tunnel/Chassis/Rear Bumper/Snowflap
(Crossfire/M-Series)……………………………………. 7-59
Tunnel/Chassis/Rear Bumper/Snowflap
(F-Series) ………………………………………………….. 7-60
Rear Storage Compartment (F-Series) …………….. 7-61
Air Silencer Assembly
(Crossfire/M-Series)……………………………………. 7-61
Headlight Assembly
(Bearcat/Panther/Z)…………………………………….. 7-61
Headlight Assembly (F-Series) ……………………….. 7-62
Headlight Assembly (Crossfire/M-Series) …………. 7-63
Adjusting Headlight Aim ………………………………… 7-64
Torque Specifications
(Bearcat/Panther/Z)…………………………………….. 7-64
Torque Specifications
(Crossfire/M-Series/F-Series) ………………………. 7-65
Torque Specifications (General Bolts) ………………. 7-66
Drive System Specifications……………………………… 8-2
Torque Specifications ………………………………………. 8-6
Drive System Components ………………………………. 8-7
Arctic Cat Cam Arms……………………………………….. 8-9
Chain Case Performance Calibrations ……………… 8-12
Gear Case Performance Calibrations
(ACT Drive – Crossfire/F-Series/M-Series) …….. 8-14
Chains & Sprockets……………………………………….. 8-15
Arctic Cat Drive Belt Dimension Chart ……………… 8-16
Arctic Cat Drive Belt Replacement Chart ………….. 8-17
Drive Clutch/Driven Pulley-Related
Specifications…………………………………………….. 8-18
Drive Train and Brake Systems ……………………….. 8-19
Drive Belt……………………………………………………… 8-19
Drive Clutch………………………………………………….. 8-19
Roller Driven Pulley (STD) ……………………………… 8-22
Drive Clutch/Driven Pulley (STD) …………………….. 8-27
ACT Roller Driven Pulley
(Crossfire/F-Series/M-Series) ………………………. 8-29
Drive Clutch/Driven Pulley
(Crossfire/F-Series/M-Series) ………………………. 8-34
Removing/Installing Drive Belt
(ACT Roller Driven Pulley) …………………………… 8-35
Drive Train/Brake Disc (Standard w/Reverse) ……. 8-35
Drive Train/Brake Disc (Standard w/o Reverse) …. 8-43
Drive Train/Brake Disc (F-Series)…………………….. 8-48
Drive Train/Brake Disc (Crossfire/M-Series)………. 8-61
Chain Adjuster………………………………………………. 8-75
Brake System (Hydraulic)……………………………….. 8-78
Brake Lever/Master Cylinder Assembly
(Hydraulic System – STD) ……………………………. 8-92
Brake Lever/Master Cylinder Assembly
(ACT/Panther 570) ……………………………………… 8-94
Brake System (Mechanical/Quick-Adjust) …………. 8-95
Brake Control (Mechanical/Quick-Adjust) ……….. 8-102
Troubleshooting Drive Clutch/Driven Pulley …….. 8-105
Troubleshooting Drive Belt ……………………………. 8-106
Troubleshooting Hydraulic Brake System………… 8-107
Understanding the Suspension …………………………. 9-2
Suspension Setup Basics ………………………………… 9-3
Suspension Mounting Location Chart ………………… 9-6
Torque Specifications ………………………………………. 9-6
Chassis and Skid Frame
Mounting Locations………………………………………. 9-7
Servicing Chart …………………………………………….. 9-10
Repair Procedure 1 ……………………………………….. 9-10
Repair Procedure 2 ……………………………………….. 9-40
Repair Procedure 3 ……………………………………….. 9-72
Repair Procedure 4 ……………………………………… 9-104
Drive Sprocket Locations ……………………………… 9-133
2007 Idler Wheel Selection Chart ………………….. 9-137
2007 Non-Rebuildable Shock Absorber
Specifications Chart ………………………………….. 9-137
2007 Front Suspension Ski Springs
Specifications Chart ………………………………….. 9-138
2007 Front Suspension Sway Bar
Specifications Chart ………………………………….. 9-138
2007 Rear Suspension Specifications Charts….. 9-138
Shock & Spring Chart – 2007 Models……………… 9-139
2007 Track Specifications Chart…………………….. 9-140
Track Warranty Guidelines ……………………………. 9-140
Rebuildable Shock Tools Required…………………. 9-141
2007 Rebuildable Shock Specifications ………….. 9-141
Servicing ACT Shock …………………………………… 9-145
Servicing Position Sensitive Shock ………………… 9-148
Rebuilding/Recharging Fox Air Shocks …………… 9-152
Servicing Fox Zero Pro Shock Absorbers ……….. 9-158
Shaft Eyelet ………………………………………………… 9-163
Pressurizing Rebuildable Shocks…………………… 9-163
Troubleshooting Track ………………………………….. 9-164
Description:
2007 Arctic Cat 2 Stroke Snowmobiles Service Manual
- This Arctic Cat Service Manual contains service and maintenance information for the Model Year 2007 Arctic Cat 2-Stroke Snowmobiles.
- This manual is designed to aid service personnel in service-oriented applications. This manual is divided into sections.
- The sections cover specific snowmobile components or systems and, in addition to the standard service procedures, includes assembling, disassembling, and inspecting instructions.
- When using this manual as a guide, the technician should use discretion as to how much disassembly is needed to correct any given condition.
- The service technician should become familiar with the operation and construction of the components or systems by carefully studying the complete manual.
- This will assist the service technician in becoming more aware of and efficient with servicing procedures. Such efficiency not only helps build consumer confidence but also saves time and labor.
- All Arctic Cat publications and snowmobile decals display the words Warning, Caution, and Note to emphasize important information. The symbol ! WARNING identifies personal safety-related information.
- Be sure to follow the directive because it deals with the possibility of severe personal injury or even death. The symbol ! CAUTION identifies unsafe practices which may result in snowmobile-related damage. Follow the directive because it deals with the possibility of damaging part or parts of the snowmobile.
- The symbol ? NOTE: identifies supplementary information worthy of particular attention. At the time of publication, all information, photographs, and illustrations were technically correct. Some photographs and 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.
Please Note:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]