Target Audience:
Arctic Cat snowmobile owners and independent service technicians seeking comprehensive repair and maintenance information.
Manual Value:
Provides a broad range of model and year coverage in a single, easily accessible digital format, offering significant value compared to individual factory service bulletins or older, model-specific manuals.
Comprehensiveness:
Covers nearly every aspect of snowmobile maintenance and repair, from routine checks to full engine rebuilds.
Accessibility:
Instant PDF download format ensures immediate access to critical information.
Usability:
Searchable text and clickable chapters significantly improve efficiency in finding specific information.
Origin:
Note: This is not a factory manual, but a comprehensive aftermarket compilation.
Applicable Model Years:
1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998
Covered Models:
Prowler, Cougar, Panther 440, Panther 550, EXT 550, EXT 580, EXT 580 EFI, EXT 600, Z 440, ZL 440, ZR 440, ZR 580, ZR 580 EFI, ZR 600, ZR 600 EFI, ZRT 600, Powder Special, Powder Special EFI, Powder Extreme
Download Type:
Instant Download
Manual Type:
Service Manual / Repair Manual
Navigation:
Clickable Chapters
Usage Rights:
No Restrictions on Printing or Saving
Replacement Policy:
Free Replacement Offered
Coverage Scope:
Complete tear down and rebuild
Visual Aids:
Pictures and Part Diagrams
Technical Data:
Torque Specs
Maintenance:
Comprehensive Maintenance Procedures
Troubleshooting:
Detailed Troubleshooting Guides
Engine:
Engine overhaul, bore, piston, connecting rod, crankshaft, camshaft, valves, valve clearance, fuel injection, carburetor (carb), mixture screw, pilot jet, main jet, slow jet, spark plug, ignition system, stator, magneto, flywheel, coil, compression ratio, cylinder
Fuel System:
Fuel pump, fuel tank, carburetor tuning, EFI (Electronic Fuel Injection) system diagnostics
Lubrication And Fluids:
Lubrication schedules, engine oil specifications, coolant specifications, fluid capacities, flushing procedures (coolant)
Drive Train:
Drive shaft, clutch (primary and secondary), transmission, primary reduction gear, swinger, swingarm, track system, bogey wheels
Exhaust System:
Muffler, exhaust manifold, pipe installation
Suspension:
Front suspension (struts, forks, trees), rear suspension (bogey wheel system), linkage, lubrication of suspension components
Braking System:
Brake caliper, brake pads, brake rotor, hydraulic brake system, brake fluid specifications
Electrical System:
Starting system (starter motor, kick start), charging system (rectifier, regulator), battery specifications, lighting system (headlights, taillights), switches, electronic components
Bodywork And Chassis:
Hull, frame, fenders, plastic components, seat, handle bars, throttle cable, ski installation, skis
Maintenance:
Scheduled maintenance, routine checks, fluid changes, lubrication points, filter replacement
Repair:
Component disassembly and reassembly, part replacement, gasket and seal replacement, engine rebuild, transmission repair, suspension repair, electrical component repair
Troubleshooting:
Diagnosing common problems (e.g., no spark, starting issues), identifying fault codes (if applicable), step-by-step diagnostic procedures
Installation:
Installation of new parts, accessory installation (if covered), drive train component installation
Adjustment:
Carburetor adjustment, idle speed adjustment, throttle cable adjustment, clutch adjustment (if applicable)
Depth:
Detailed workshop level, covering complete engine overhauls, transmission rebuilds, and in-depth electrical system diagnostics.
Engine Displacements:
Common displacements include 440cc, 550cc, 580cc, 600cc. Specific engine families likely include Rotax-based or Suzuki-based twin-cylinder two-stroke engines commonly used by Arctic Cat during this era.
Horsepower Range:
Estimated 70-110+ HP, depending on specific engine displacement and tuning. EFI models generally offer higher, more consistent output.
Fuel Delivery:
Carbureted (Mikuni VM series or similar) and Electronic Fuel Injection (EFI) systems are covered for various models.
Ignition Type:
CDI (Capacitor Discharge Ignition) with electronic advance, typically driven by the stator and ECU for EFI models.
Cooling Method:
Liquid-cooled systems, requiring specific coolant mixtures and maintenance.
Oil Type:
Requires a high-quality 2-stroke synthetic oil specifically formulated for snowmobile engines. The manual will specify viscosity and API/JASO standards.
Typical Compression Ratio:
Likely in the range of 7.5:1 to 9.5:1, depending on the specific engine model and porting. The manual will provide exact specifications for each model.
Typical Intervals:
The manual will detail recommended service intervals for oil changes, spark plug inspection/replacement, chain case lubrication, track tension checks, and clutch servicing. These are often based on mileage, riding hours, or annual inspections.
Coolant Type:
Antifreeze/coolant mixture (e.g., 50/50 ethylene glycol based) suitable for extreme cold temperatures. Manual specifies exact type and capacity.
Brake Fluid:
DOT 3 or DOT 4 hydraulic brake fluid, depending on the system. Manual will specify.
Chain Case Oil:
Specific gear oil for the chain case, often a SAE 80W-90 or similar. Manual will provide part number and capacity.
Common Problems:
The manual is invaluable for troubleshooting common issues of this era, such as carburetor jetting problems, clutch wear, track lug wear, suspension component fatigue, and electrical gremlins (e.g., stator or rectifier failures). Specific troubleshooting charts are included.
Storage Preparation:
Detailed procedures for off-season storage, including fuel stabilization, battery care, and lubrication.
Critical Torques:
Essential torque specifications for cylinder head bolts, crankcase bolts, clutch components, suspension fasteners, and wheel hubs are provided for ensuring proper assembly and preventing component failure.
