Primary Coverage:
Maintenance, Repair, Troubleshooting, and Specifications for the 1996 Arctic Cat Cougar Mountain Cat Snowmobile
Specific Systems:
Engine, Fuel System (Carburetor & Fuel Injection), Chassis, Steering, Skis, Oil Tank, Fuel Tank, Electrical System (Ignition, Lighting, Charging, Starting), Power Train (Clutches, Drive, Track), Brake System, Slide Rail Suspension
Estimated Page Count:
Likely 200-400 pages based on typical service manual scope for this era and complexity.
Type:
Factory Service Manual / Workshop Manual
Format:
PDF (Digital Download)
Engine Systems:
Engine removal, disassembly, inspection, assembly, installation, recoil starter, flywheel magneto, primary sheave, oil pump, top end, bottom end, oil pump gear case. Troubleshooting for engine issues.
Fuel Systems:
Carburetor (removal, disassembly, inspection, assembly, installation, tuning, adjustment, troubleshooting, data), Fuel Injection System (repair, troubleshooting, specifications), Intake system.
Chassis And Suspension:
Chassis overview, steering (assembly, adjustment), skis (inspection, assembly), oil tank, fuel tank, slide rail suspension (removal, inspection, adjustment, installation), drive system (removal, inspection, assembly), track adjustment.
Electrical Systems:
Ignition system (troubleshooting, timing, spark gap test, ignition coil, spark plug, pickup and C.D.I. charging coil test, C.D.I. unit), Lighting system (headlight beam adjustment, lighting coil test, voltage regulator), Charging system (charging circuit test, silicon rectifier check), Electric starting system (starter motor, starter relay switch, battery).
Power Train:
Sheave alignment, clutch tuning, clutch setting data, charging clutch engagement and shift RPM, V-belt (removal, inspection), primary sheave (removal, disassembly, inspection, assembly), secondary sheave (removal, inspection, assembly), chain case (disassembly, inspection, gearing, assembly), brake system (disassembly, inspection, assembly, adjustment).
Maintenance:
Pre-season preparation, periodic maintenance, tune-up procedures, oil pump cable adjustment, starter cable adjustment, throttle cable adjustment, high altitude tuning.
Repair And Rebuild:
Complete teardown and reassembly procedures for all major components, including engine internals, clutches, suspension, and electrical components.
Troubleshooting:
Detailed troubleshooting guides for engine performance, fuel system issues, electrical faults, and drive train problems.
Technical Adjustments:
Carburetor tuning (low speed, mid-range, high speed), ignition timing, spark plug gap, brake adjustment, clutch settings, V-belt tension, track adjustment.
Wiring Diagrams:
Includes complete wiring diagrams and wire/cable routing diagrams for the electrical system, crucial for troubleshooting lighting, ignition, and starting circuits.
Specifications Tables:
Contains comprehensive specification tables, including tightening torques for critical fasteners, conversion tables, and dimensional data.
Depth:
Comprehensive, covering everything from basic adjustments and maintenance to complete engine and component rebuilds. Includes diagnostic procedures and technical specifications essential for certified technicians and experienced DIY mechanics.
Special Tools:
Lists any special tools required for specific repairs, such as clutch pullers, flywheel pullers, and specialized engine tools, enabling correct and safe procedures.
Exploded Diagrams:
Features exploded diagrams that visually break down components, aiding in correct assembly and identification of parts during disassembly and reassembly.
Engine Type:
Likely a 2-stroke, liquid-cooled twin-cylinder engine, common for this era and model designation. Specific displacement and model designation (e.g., 600cc, 700cc) would be detailed within the manual.
Horsepower Torque:
Specific horsepower and torque figures for the 1996 Cougar Mountain Cat models would be detailed in the manual's specifications section. Generally, performance snowmobiles of this era offered around 90-120 HP depending on engine size.
Carburetion Type:
Dual carburetors, likely Mikuni or Keihin, with specific jetting, needle, and air screw settings provided for various conditions and altitudes.
Fuel Type Recommendation:
Typically premium unleaded gasoline, often with a specific octane rating recommended. The manual would specify this.
Oil Mixture System:
Likely an oil injection system with an automatic oil pump, ensuring proper pre-mix of oil and fuel. The manual details oil pump calibration and cable adjustments.
Ignition System Type:
CDI (Capacitor Discharge Ignition) system with detailed testing procedures for coils, pickup, and CDI unit.
Periodic Checks:
Detailed schedule covering daily, weekly, monthly, and annual checks. Includes pre-ride inspection, track tension, chain case oil, coolant levels, and brake function.
Engine Service:
Intervals for spark plug replacement, carburetor cleaning/syncing, compression testing, and top-end inspection would be specified.
Clutch Maintenance:
Recommendations for clutch inspection, cleaning of sheave faces, and V-belt inspection for wear and checking length.
Engine Oil:
Specific Arctic Cat 2-stroke oil or equivalent meeting their specifications. The manual will detail the oil injection system's oil type.
Chain Case Oil:
Specific gear oil grade and capacity for the chain case would be provided (e.g., SAE 80W-90 GL-5).
Coolant:
If liquid-cooled, the type and mixture ratio of antifreeze/coolant for the cooling system would be specified.
Common Wear Items:
Typical wear items for this era include V-belts, carbides on skis, hyfax (sliders), clutch buttons/rollers, and possibly crank seals if not properly maintained. The manual helps diagnose and replace these.
Carburetor Troubleshooting:
Common issues like plugging jets, worn needles, or incorrect adjustments are thoroughly covered, especially for the dual carburetor setup.
