2007 Arctic Cat Snowmobile 2-Stroke Service Manual (P/N 0638-313, P/N 2257-850)

• Covers 2007 Arctic Cat 2-stroke snowmobiles with 370, 500, 570, 600, 800, and 1000 cc engines: Bearcat 570; Panther 370/570; Z 370/570, with LX harness and suspension variants; Crossfire 500/600/800/1000; M6/M8/M1000; and F5/F6/F8/F1000, with LXR and Sno Pro data where applicable. 676 PDF pages.
• Details engine removal, Crossfire/M-Series top-side repair, crankcase disassembly and assembly, piston and cylinder inspection, water-pump repair, APV/ECT service, engine pressure testing, ignition timing, and final operational checks.
• Documents carburetor disassembly, cleaning, jetting, and synchronization; EFI fuel-pressure and injector diagnosis; throttle-body/TPS testing; oil-injection bleeding and synchronization; and ECU/CCU fault isolation.
• Breaks down drive-clutch and driven-pulley repair, ACT gear-case and chain-case service, reverse and non-reverse drivetrains, belt alignment and deflection, hydraulic and mechanical brake work, and system-specific troubleshooting.
• Provides model-specific steering, ski-alignment, front-suspension, track, skid-frame, and rear-suspension procedures, including ACT, position-sensitive, Fox Air, and Fox Zero Pro shock rebuilding and recharging.
• Supplies displacement-specific assembly schematics, cooling and carburetor diagrams, diagnostic charts, exploded views, factory tool P/Ns, torque/clearance/wear data, and model-specific full-page wiring diagrams.

Engine Service and Diagnostics

This Arctic Cat factory service manual separates carbureted, fan-cooled 370/570 machines from EFI, liquid-cooled 500/600/800/1000 models, then divides the engine section by the powertrain groups used in 2007: Panther 370/Z 370; Bearcat 570/Panther 570/Z 570; Crossfire 500/600 and M6; Crossfire 800/1000 and M8/M1000; F-Series 500/600; and F-Series 800/1000. The specification table identifies engine builds AA37A9, AX50L6, AA56A6, AJ60L4, AB80L1, and AB10L1 to match the correct chapter before repair.

Each group follows a workshop progression through removal, disassembly, cleaning and inspection, critical measurement, assembly, installation, and checks. Crossfire/M-Series chapters also cover top-side service with the engine installed. Measurement procedures address cylinder-head volume by the squish-gap method, cylinder trueness, piston-skirt clearance, ring end gap, piston-pin and bore condition, connecting-rod small-end bore, crankshaft runout, reed-stopper height, and reed-to-seat clearance. Assembly schematics show bolt patterns, seal direction, bearing-retaining points, and specified applications for Three Bond, High-Temp Sealant, anti-seize, and multiple Loctite grades.

Engine-related chapters extend coverage to axial-fan service, water-pump rebuilding, crankcase pressure testing, liquid-cooling drain/fill procedures, recoil starters, Arctic Power Valve service, and Exhaust Controlled Timing. The 1000 cc ignition data is separated for Crossfire/F-Series and M-Series applications instead of one common setting.

Fuel, Electrical, and Chassis Diagnostics

Carbureted Bearcat, Panther, and Z models receive carburetor specifications, schematics, overhaul procedures, cable adjustment, tuning data, and fuel-system troubleshooting. EFI coverage includes the fuel pump, regulator, injectors, throttle bodies, sensors, fuel-pressure testing, throttle-position adjustment, and analyzer-based diagnosis.

For Crossfire, F-Series, and M-Series models, the opening tables contain 11 Check Engine flash codes, 11 CCU wrench-icon codes, and two coolant-warning indications. Later chapters connect those indications to injector, APV, servomotor, knock-sensor, stator, voltage-output, tachometer, gear-position, and shift-actuator tests. Engine-electrical coverage adds displacement-specific resistance and peak-voltage charts, ignition-timing data, electric-start diagnosis, and gauge/sender checks. Chassis-electrical procedures cover brake-light and dimmer switches, warmer circuits, speedometer sensing, reverse alarms, and electronic shift controls.

Drivetrain, Brake, Steering, and Suspension Repair

Drivetrain sections separate standard chain-case systems with and without reverse from F-Series and Crossfire/M-Series ACT Drive arrangements. Covered repair work includes belts, clutches, roller driven pulleys, alignment, chain and sprocket service, performance calibration, brake-disc assemblies, hydraulic brakes, and mechanical quick-adjust brakes.

Steering and body chapters address steering posts, links, tie rods, spindles, ski alignment, suspension arms, sway bars, belly pans, tanks and seats, headlights, tunnels, bumpers, and body panels. Rear-suspension service is organized into four model-specific repair procedures: Z 370/570 and LX; Bearcat/Panther; Crossfire/M-Series; and F-Series. Related charts cover mounting locations, tracks, idler wheels, springs, sway bars, skid-frame components, and shock valving. Separate procedures document ACT, position-sensitive, Fox Air, and Fox Zero Pro shock service, including rebuilding, bleeding, nitrogen charging, and final checks.

Technical Data, Tools, and Wiring Diagrams

Named visual references include the six displacement-specific Engine Assembly Schematics, the Engine Piston Travel Versus Crank Angle Chart, the Crankshaft Runout/Repair Specifications drawing, F-Series and Crossfire/M-Series Cooling System Schematics, carburetor schematics, and model-specific harness drawings. The final 28 pages provide separate harness diagrams for Bearcat, Panther, and Z/LX models; Crossfire and M-Series standard/Sno Pro configurations; and F-Series standard, LXR, and Sno Pro configurations.

Factory tool references are tied to the procedures. Examples include Drive Clutch Pullers P/N 0644-207 and 0644-446, Flywheel Puller P/N 0744-040, Piston Pin Puller P/N 0644-328, Compression/Pressure Tester Kit P/N 0644-366, Fuel Pressure Test Kit P/N 0644-493, and Oil Seal Protector Tool P/N 0644-219.

Scope Notes and Repair Cautions

Several repair traps are called out clearly. APV exhaust valves and gaskets are directional, and incorrect positioning can cause severe engine damage. The liquid-cooled thermostat is a lock-open design, while the drive-clutch fastener must not be tightened with an impact tool because the stationary sheave can be damaged. Fuel-system work must be performed away from open flames; shock service involves high-pressure nitrogen; and running checks require secure support.

Two scope limits matter. Connecting-rod, center-bearing, or oil-injection drive-gear work on the pressed crankshaft is referred to a qualified machine shop. Operating instructions for the 800/1000 cc laptop system and 500/600 cc EFI Analyzer are in companion manuals P/N 2257-850 and 2259-020 supplied with those tools. The PDF retains related self-diagnostic setup, code interpretation, component tests, fuel-pressure procedures, and peak-voltage specifications.