Arctic Cat 2005 2-Stroke Snowmobile Service Manual Set (P/N 2257-150)

Together, the volumes support engine repairs that also involve clutch removal, chassis disassembly, or final track adjustment.

Text Search, Bookmarks, and Wiring Detail

Search and diagram detail: Service text is searchable, with section bookmarks and separate wiring-diagram index bookmarks. Labels inside the color wiring diagrams may not appear in text searches. Small connector labels and wire-color codes require zooming.

Supplied as one printable, 773-page PDF. The total includes the contents menu, one foreword page within Volume I, and five Notes pages.

Engine, EFI, Drivetrain, and Suspension Service

The following selected service areas show the repair coverage. Storage preparation and after-break-in checklists are other included topics.

• Engine overhaul: Step-by-step disassembly, internal inspection, reassembly, and crankcase air-leak testing, plus in-chassis top-side service for 500/600/700cc Laydown engines.

• Fuel systems: Batteryless EFI fault codes, sensor and injector checks, and fuel-pressure testing, with separate repair procedures for Mikuni VM- and TM-style carburetors.

• Electrical diagnosis: Stator and ignition-coil resistance checks, peak-voltage tests, regulator/rectifier diagnosis, electric-start troubleshooting, and model-indexed ignition, main, and hood wiring diagrams.

• Drivetrain service: Standard chain cases with or without reverse, ACT Drive gear-case overhaul, roller driven pulleys, clutch alignment, and belt-deflection adjustment.

• Brake repair: Hydraulic caliper and master-cylinder service and bleeding, plus separate disassembly and adjustment procedures for mechanical/Quick-Adjust brakes.

• Steering and body: AWS V and AWS VI/M-Series steering-post, spindle, tie-rod, ski-alignment, and front-suspension-arm procedures, with panel, tunnel, and heat-exchanger removal.

• Track and rear suspension: Skid-frame removal, slide-rail and idler-wheel repair, track tension/alignment, and rebuildable-shock servicing and recharging.

Written for service personnel performing maintenance and repair, this manual assumes workshop judgment and access to the specified measuring equipment and special tools.

Engine Inspection and Related Systems

Engine sections distinguish fan-cooled from liquid-cooled designs, 500cc APV from non-APV configurations, and 600cc STD from Laydown engines. Identification guidance distinguishes the tunnel VIN from the engine serial number on the crankcase.

Inspection data covers piston-ring end gaps, piston-skirt clearances, connecting-rod small-end bores, cylinder trueness, and crankshaft runout. The Engine Piston Travel Versus Crank Angle Chart supports timing checks; surface-plate procedures address intake-manifold insulator and adapter-plate trueness on fan-cooled models.

Reed-valve inspection, water-pump seal replacement, 370/440cc axial-fan belt service, and recoil-starter repair extend the engine-related coverage. Arctic Power Valve (APV) procedures cover cleaning, cable adjustment, and servomotor testing; the 500cc Exhaust Controlled Timing (ECT) section addresses exhaust-temperature sensor diagnosis. Cooling System Schematics distinguish heat-exchanger and hose arrangements.

The assembly cautions identify incorrect Laydown APV exhaust-valve orientation as a cause of severe engine damage. They also explain how misalignment of the oil-injection pump and its driveshaft can damage the pump.

Carburetor Adjustment and Batteryless EFI

Break-in procedures address new or rebuilt engines, while EFI fuel-designation guidance distinguishes gasoline settings. 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 EFI Analyzer Update Kit P/N 0637-243. Kokusan-mode Existing Problem Diagnosis and Memory Problem Diagnosis distinguish current from intermittent faults; separate meter and pressure-gauge procedures address components the analyzer cannot diagnose.

The EFI Component Voltage/Resistance Charts for air and water temperature support sensor testing. On batteryless EFI models, a failed throttle position sensor requires replacement of the complete throttle body assembly. The oil-pump output table contains TBA entries instead of test quantities.

Ignition and Chassis Electrical Details

The ignition-harness index lists TBA for King Cat 900 EFI, ZR 900 EFI, and ZR 900 EFI Sno Pro. Printed page 5-28 is missing, interrupting the resistance-test procedures for 500cc non-APV/570cc models.

Chassis tests cover brake-light switches, headlight dimmers, and handlebar, thumb, and passenger warmers.

Drive Components, Brakes, and Suspension Variants

Clutch and gear-case references: Drive Train Schematics (w/ACT Drive) identify the input shaft, planetary gear, and ring gear. ZR 900, Firecat, and M-Series procedures distinguish their gear-case work; troubleshooting tables address poor shifting, belt damage, and hydraulic brake faults.

Suspension matching: 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 type-specific oil-filling, bleeding, seal-service, and charging procedures.

Reference tables include bore and stroke, compression ratios, ignition timing, and component torque settings in ft-lb and kg-m. Verify the applicable factory tolerances and secure the chassis before major repairs. Running checks require the shielded stand and rotating-track precautions described in the manual.

A Preview of EFI Pressure and Throttle-Sensor Specifications

Fuel-pressure specifications distinguish 600cc STD EFI engines at 35.7–40.1 psi from 600cc Laydown, 700cc, and 900cc EFI engines at 42.8–47.3 psi.

For the engine-off Throttle Valve Angle Test, the idle-position voltage range is 0.625–0.647 V on 600cc STD EFI models. The corresponding range for 600/700cc Laydown and 900cc EFI models is 0.685–0.707 V.