Model Variant:
EXT 600 (all models/engines/trim/transmissions)
Production Years Covered:
1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998
Product Type:
Workshop Service Repair Manual
Product Format:
PDF Download
Target Audience:
Arctic Cat EXT 600 snowmobile owners, independent repair shops, and DIY enthusiasts seeking professional-grade repair information.
Advantage Over Alternatives:
Provides factory-level detail, often exceeding the scope of generic repair guides. Instant download eliminates shipping delays and costs.
Authenticity:
Original workshop manual used by local service/repair shops, ensuring accuracy and completeness.
Convenience:
Digital format allows for easy searching, printing of specific sections, and avoidance of physical damage from shop use.
Cost Savings:
Empowers users to perform their own maintenance and repairs, potentially saving hundreds or thousands of dollars in labor costs.
Engine Overhaul:
Complete engine disassembly, inspection, and reassembly procedures for the 600cc engine.
Fuel System Diagnosis And Repair:
Carburetor tuning, cleaning, rebuilding, fuel pump, fuel lines, and fuel tank service.
Ignition System:
CDI unit, ignition coils, spark plug specifications, and troubleshooting.
Electrical Diagnostics:
Comprehensive troubleshooting for lighting, starting system, charging system, and accessory circuits.
Oil Injection System:
Operation, maintenance, and troubleshooting of the automatic oil injection system.
Cooling System:
Liquid cooling system components, coolant specifications, and radiator service.
Drivetrain Components:
Drive clutch, driven clutch (primary and secondary), chain case, and drive axle service.
Suspension And Steering:
Front and rear suspension geometry, shock absorber service, ski alignment, and steering linkage.
Braking System:
Brake caliper, master cylinder, brake fluid specifications, and brake pad replacement.
Track System:
Track tension adjustment, idler wheel service, and track drive lug inspection.
Routine Maintenance:
Scheduled maintenance tasks, lubrication points, and inspection checklists.
Component Removal And Installation:
Detailed step-by-step instructions for disassembling and reassembling all major snowmobile components.
Diagnostic Procedures:
Systematic troubleshooting guides for identifying and resolving common and uncommon issues.
Rebuilds And Overhauls:
Instructions for complete rebuilds of engine, transmission, and suspension components.
Wiring Diagrams:
Color-coded and detailed wiring schematics for all electrical systems.
Off Season Storage Preparation:
Proper procedures for preparing the snowmobile for extended storage.
Depth Of Information:
Comprehensive, covering basic maintenance to complete engine and drivetrain overhauls, suitable for professional technicians and advanced DIY enthusiasts.
Diagnostic Capabilities:
Advanced diagnostic trees and troubleshooting guides for pinpointing complex issues.
Diagrams And Illustrations:
Hundreds of detailed diagrams, drawings, and photos illustrating procedures and parts.
Printable:
Yes, full printable pages
Binding Type:
Digital Download (No physical binding)
Paper Type:
Not Applicable (Digital Format)
Software Requirements:
Adobe PDF Reader, WinZip (for extraction if applicable)
Operating Systems:
Compatible with all versions of Windows & Mac
Engine Type:
Liquid-cooled, 2-stroke, parallel twin (typically a Rotax or Suzuki engine depending on specific Arctic Cat configurations of the era)
Displacement:
600cc class (exact bore and stroke would be detailed within the manual)
Horsepower Range:
Estimated 80-100 HP (peak figures vary by specific model year and tuning)
Torque Specifications:
Not explicitly provided, but torque curves and values for specific components will be in the manual.
Fuel Delivery:
Dual carburetors (e.g., Mikuni VM series, specific model number detailed in manual)
Fuel Type:
Unleaded gasoline (octane rating to be specified in manual)
Oil Type:
2-stroke engine oil (specific API/JASO rating and brand recommendations in manual)
Crankcase Lubrication:
Pre-mix or oil injection system (detailed in manual)
Length:
Specific dimensions not provided in product info, but typically around 100-115 inches.
Width:
Specific dimensions not provided in product info, but typically around 45-48 inches.
Height:
Specific dimensions not provided in product info, but typically around 40-45 inches.
Dry Weight:
Typically in the 450-550 lb range, exact figures would be in the manual.
Estimated Wet Weight:
Increased by fuel, oil, and coolant. Exact values not specified in product info.
Track Width:
Typically 15 inches wide.
Track Length:
Typically 121 or 136 inches long.
Safety Standards:
Compliance with relevant snowmobile safety standards of the era will be implicitly covered through maintenance and operation procedures.
Braking System:
Hydraulic disc brake system for reliable stopping power.
Throttle Safety:
Thumb throttle with safety switch interlock (detailed in electrical/controls).
Chassis Design:
Reinforced chassis for stability and rider protection.
Lighting:
Headlight, taillight, and brake light for visibility.
Oil Change Interval:
Specific intervals for oil injection system checks and chain case oil changes will be detailed. Typically based on mileage or operating hours.
Clutch Maintenance:
Recommendations for clutch inspection, cleaning, and belt replacement intervals based on usage.
Spark Plug Replacement:
Recommended replacement intervals and gap specifications for spark plugs will be provided.
Track Tension Adjustment:
Scheduled checks for track tension to ensure optimal performance and longevity.
Coolant Type:
Specific coolant mixture (e.g., ethylene glycol-based antifreeze) and capacity detailed in the manual.
Chain Case Oil Type:
Recommended lubricant for the chain case (e.g., SAE 80W-90 gear oil or specific Arctic Cat recommended fluid).
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid typically specified, depending on the braking system components.
Common Wear Items:
The manual will likely detail maintenance for wear items such as drive belts, carbides, sliders, and brake pads.
Engine Specific Wear:
Potential issues related to piston rings, crank seals, and exhaust power valves (if equipped) will be addressed.
Manufacturer History:
Arctic Cat, founded in 1960, has a long-standing reputation for producing high-performance snowmobiles.
Ext Series Significance:
The EXT series was a popular line for Arctic Cat, known for its versatility and performance in various snow conditions.
Manufacturing Era:
This manual covers a significant generational period for the EXT 600, indicating continuous refinement and feature updates during these years.
