2005 Arctic Cat 2-STROKE King Cat and M-Series sleds, 370–900cc Service Manual (P/N 2257-149, 2257-150)

• Covers 2005 Arctic Cat 370, 440, 500, 550, 570, 600, 700, and 900cc 2-stroke snowmobiles, including Laydown, STD, EFI, and carbureted variants.
• Engine overhaul coverage includes disassembly, internal inspection, reassembly, and crankcase air-leak testing, plus in-chassis top-side service for 500/600/700cc Laydown engines.
• Batteryless EFI diagnosis covers fault codes, sensor and injector checks, and fuel-pressure testing; carburetor repair sections distinguish Mikuni VM- and TM-style assemblies.
• Drivetrain teardown and reassembly distinguish standard chain cases with or without reverse from ACT Drive gear cases and roller driven pulleys used on ZR 900, Firecat, and M-Series models.
• Hydraulic brake repair includes caliper and master-cylinder service and bleeding, with separate disassembly and adjustment procedures for mechanical/Quick-Adjust brakes.
• Track and rear-suspension work covers skid-frame removal, slide rails, idler wheels, and track tension/alignment, plus rebuildable-shock servicing and recharging.

The 2005 Arctic Cat factory service manual was written for service personnel performing maintenance and repair. This 773-page PDF combines Volume I content and its foreword (302 pages), Volume II (470 pages), and a one-page overall contents menu. The two volumes divide engine-related work from chassis, drivetrain, and suspension service.

Volume I: Engine, Fuel, and Ignition Repair

Volume I covers break-in procedures for new or rebuilt engines and specific fuel-designation requirements for EFI models. Engine sections distinguish fan-cooled from liquid-cooled designs, 500cc APV from non-APV configurations, and 600cc STD from Laydown engines. Identification guidance separates the VIN stamped into the tunnel near the right footrest from the engine serial number on the crankcase.

Beyond engine removal and teardown, the manual addresses reed-valve inspection, water-pump seal replacement, 370/440cc axial-fan belt service, and recoil-starter repair. Arctic Power Valve (APV) coverage includes valve cleaning, cable adjustment, and servomotor testing; the 500cc Exhaust Controlled Timing (ECT) section addresses exhaust-temperature sensor diagnosis. Cooling System Schematics show the different heat-exchanger and hose arrangements.

The assembly cautions flag severe engine damage from incorrectly oriented Laydown APV exhaust valves. Misalignment between the oil-injection pump and its driveshaft can damage the pump itself.

Fuel-system work extends to carburetor synchronization, throttle and choke cable adjustment, oil-injection bleeding, and check-valve testing. EFI procedures specify the EFI Analyzer (P/N 0644-342) and Laydown update kit P/N 0637-243. Kokusan-mode Existing Problem Diagnosis and Memory Problem Diagnosis tests address current and intermittent faults; separate meter and pressure-gauge procedures cover components the analyzer cannot diagnose.

Ignition coverage includes stator and coil resistance checks, peak-voltage tests, regulator/rectifier diagnosis, and electric-start troubleshooting. The EFI Component Voltage/Resistance Charts for air and water temperature support sensor testing, while model-indexed ignition, main, and hood wiring diagrams identify the applicable harnesses.

Volume II: Chassis, Drive Train, and Rear Suspension

Steering and body sections separate AWS V from AWS VI/M-Series configurations. They cover steering-post and spindle replacement, tie rods, ski alignment, and front suspension arms. Body repair extends to panel, tunnel, and heat-exchanger removal. Chassis electrical tests address brake-light switches, headlight dimmers, and handlebar, thumb, and passenger warmers.

Clutch work includes offset and parallelism checks, belt-deflection adjustment, and spring service. Drive Train Schematics (w/ACT Drive) identify the input shaft, planetary gear, and ring gear used in gear-case service. Troubleshooting tables address poor shifting, belt damage, and hydraulic brake faults.

A model-specific Servicing Chart links each rear suspension to its slide-rail, arm, and idler-wheel schematics and one of four repair procedures. Shock sections distinguish IFP, position-sensitive, Fox Air, Fox Zero Pro, and remote-reservoir designs, with oil-filling, bleeding, seal service, and charging procedures appropriate to each type.

Component Specifications and Edition Limits

Reference data covers bore and stroke measurements, compression ratios, and ignition timing degrees. Inspection limits address piston-ring end gaps, cylinder trueness, piston-skirt clearances, and connecting-rod small-end bores. Torque settings are listed in both ft-lb and kg-m. The Engine Piston Travel Versus Crank Angle Chart and crankshaft runout drawings support timing and dimensional checks. Surface-plate procedures address intake-manifold insulator and adapter-plate trueness on fan-cooled models.

Printed page 5-28 is missing from this PDF. The oil-pump output table lists TBA instead of test quantities. The ignition-harness index also lists TBA for King Cat 900 EFI, ZR 900 EFI, and ZR 900 EFI Sno Pro.

Always verify factory tolerances and properly secure the chassis before major repair work. Follow the manual's shielded-stand and rotating-track precautions during running checks.