Target Audience:
Snowmobile owners, DIY enthusiasts, independent repair shops, and dealership technicians.
Vintage Status:
Covers a popular vintage snowmobile model, crucial for owners seeking to maintain or restore their machines.
Value Proposition:
Provides expert-level repair knowledge originally intended for factory-trained technicians, enabling significant cost savings on maintenance and repairs.
Content Focus:
Hands-on complete teardown of the specific snowmobile model and year, ensuring practical and accurate repair guidance.
Visual Aids:
Wealth of illustrations, diagrams, schematics, and pictures to ensure successful repair completion.
General Information:
External View, Machine Identification, Terms, Stage, Pre-Season Preparation, Maintenance, Periodic Maintenance, High Altitude Tuning, Tune-Up, Special Tools, Precautions Before Service
Fuel System:
Carburetor (Removal, Disassembly, Inspection, Assembly, Installation, Tuning and Adjustment, Troubleshooting), Fuel Injection System (Repair, Troubleshooting, Specifications), Intake
Chassis:
Steering (Assembly, Adjustment), Skis (Inspection, Assembly), Oil Tank, Fuel Tank
Electrical:
Ignition System (Troubleshooting, Timing, Spark Gap Test, Ignition Coil, Spark Plug, Pickup and CDI Charging Coil Test, CDI Unit), Lighting System (Headlight Beam Adjustment, Lighting Coil Test), Voltage Regulator, Charging System (Charging Circuit Test, Silicon Rectifier Checking), Electric Starting System (Starter Motor, Starter Relay Switch, Battery)
Engine:
Engine Removal, Disassembly and Inspection, Recoil Starter, Flywheel Magneto, Primary Sheave, Oil Pump, Top End, Bottom End, Assembly and Adjustment (Bottom End, Top End, Oil Pump Gear Case, Primary Sheave, Flywheel Magneto, Recoil Starter), Engine Installation, Troubleshooting
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 (Disassembly, Inspection, Assembly, Brake Adjustment), Slide Rail Suspension (Removal, Inspection, Adjustment, Installation), Drive (Removal, Inspection, Assembly), Track Adjustment
Miscellaneous:
Wiring Diagrams, Wire and Cable Routing Diagrams, Specifications, Tightening Torque, Conversion Tables, Exploded Diagrams
Suspension Systems:
Front and rear suspension systems, including slide rail suspension details, lubrication, and adjustment.
Recoil Starter:
Complete service procedures for the recoil starter assembly, including removal, inspection, and reassembly.
Major Procedures:
Complete part removal, disassembly, cleaning, inspection, assembly, and reinstallation servicing procedures.
Tuning Adjustments:
Detailed tuning and adjustment procedures for carburetors, clutches, steering, and brakes.
Wiring Diagrams:
Includes detailed electrical wiring diagrams for troubleshooting and repair of the lighting, ignition, and starting systems.
Depth:
Comprehensive, covering all aspects of maintenance and repair from basic tune-ups to major component overhauls.
Diagnostic Focus:
Provides in-depth diagnostic procedures and troubleshooting flowcharts for common issues across all major systems.
Exploded Diagrams:
Includes exploded view diagrams for all major components, aiding in part identification and reassembly.
Engine Model:
600cc Class (Specific internal code not provided in product info, but typically a twin-cylinder, 2-stroke engine for this era and model).
Horsepower Estimated:
Typically in the 90-110 HP range for a 600cc twin 2-stroke of this era.
Torque Estimated:
Not specified, but crucial for snowmobile performance.
Fuel Delivery:
Carburetor (dual carburetors likely) and potentially a Fuel Injection System (as indicated in the manual's coverage).
Oil Delivery:
Oil Injection System (indicated by 'Oil Pump' coverage).
Carburetor Data:
Specific tuning data for carburetors, including jetting, needle positions, and air screw adjustments for various conditions (e.g., altitude).
Engine Removal Procedure:
Step-by-step guide for safely removing the engine from the chassis, including necessary disconnections.
Top End Rebuild:
Procedures for cylinder, piston, and reed valve servicing, including torque specifications for cylinder head and manifold bolts.
Bottom End Rebuild:
Procedures for crankshaft, connecting rods, bearings, and seals servicing.
Periodic Maintenance:
The manual covers periodic maintenance schedules, including checks for track tension, suspension lubrication, drive belt condition, and fluid levels.
Chaincase Maintenance:
Recommended intervals for checking and changing chaincase oil and inspecting chain/sprockets.
Engine Oil:
Specific 2-stroke snowmobile oil recommendations (API-TC or JASO FD/FD certified, depending on manufacturer's specific requirements).
Chaincase Oil:
Specific gear oil for the chaincase, likely a GL-4 or GL-5 type depending on Arctic Cat specifications.
Coolant:
If liquid-cooled, specifications for antifreeze/coolant mixture. (Note: Some EXT models were fan-cooled).
Fuel Type:
Typically requires premium unleaded gasoline (91+ octane).
Common Wear Items:
Drive belts, clutch weights and springs, carbides on skis, suspension bushings, and recoil starter components are common wear items addressed in the manual.
Ignition Troubleshooting:
Detailed troubleshooting for ignition system failures, including coil, CDI unit, and charging coil tests.
Tune Up Components:
Includes spark plug replacement/cleaning, carburetor adjustment, chaincase oil change, and general inspection for optimal performance.
