2006 Arctic Cat Bearcat, Crossfire, Firecat, King Cat, M-Series, Panther, Sabercat, Z, and ZR Snowmobiles Service Manual (P/N 2257-431)

This 741-page PDF contains the 2006 Arctic Cat two-stroke snowmobile service manual and a color wiring-diagram appendix. The service portion totals 691 pages, including the main contents page; the appendix adds 50 wiring pages.

• Engine repair covers removal, internal disassembly, crankshaft-bearing service, piston and cylinder inspection, reassembly, and crankcase pressure testing. Separate procedures cover in-chassis top-end work on the laydown engines.
• Mikuni VM- and TM-style carburetor procedures cover teardown, inspection, rebuilding, and synchronization. Oil-injection coverage adds pump testing, synchronization, and bleeding.
• Batteryless EFI troubleshooting combines diagnostic codes, fuel-pressure checks, injector and sensor tests, and throttle-position-sensor adjustment procedures.
• Arctic Power Valve (APV) service addresses valve cleaning, seal replacement, cable adjustment, and servomotor testing. Exhaust Controlled Timing (ECT) coverage includes exhaust-temperature-sensor checks.
• Drivetrain repair covers the drive clutch, standard and ACT roller driven pulleys, and clutch alignment. Reverse-transmission service and ACT gear-case disassembly, bearing replacement, and reassembly are also covered.
• Hydraulic brake coverage includes caliper and master-cylinder overhaul and bleeding. Mechanical/Quick-Adjust brakes, steering-linkage repair, and ski alignment have their own procedures.
• Model-specific skid-frame repair includes track tension and alignment, suspension-arm and idler-wheel service, plus rebuilding and charging procedures for IFP, position-sensitive, Fox air, and Fox Zero Pro shocks.

Model and engine coverage

Fan-cooled applications include Bearcat 570, Panther 370 r/570, Z 370/370 LX, Z 440 LX, and Z 570/570 LX.

Liquid-cooled coverage includes Firecat 500/600/700, Sabercat 500/600/700 EFI, Crossfire 600/700 EFI, M5 EFI, M6 EFI, M7 carbureted/EFI, King Cat 900 EFI, and ZR 900 EFI.

Application charts distinguish Sno Pro versions, reverse-equipped Firecat r models, Sabercat LX/EXT, and M7 EFI LE. Engine identification separates the 500 carbureted AV50L5 from the 500 EFI AX50L5, and the 700 carbureted AE70L4 from the 700 EFI AD70L4. APV and non-APV configurations are addressed separately where applicable.

The electrical appendix also includes diagrams for F 120, T660, Panther 660, and Bearcat W/T turbo/non-turbo models. These additional diagrams do not add engine-overhaul coverage for those machines.

Repair access and diagnostic equipment

The water-pump repair procedure for the 500/600/700 engines requires engine removal, an important distinction from their in-chassis top-end procedures. Cooling coverage also addresses the axial fan and belt on 370/440 engines, thermostat inspection, and system draining and refilling.

For EFI diagnosis beyond an active fault code, the manual covers stored intermittent sensor faults and Kokusan Special Mode data, including engine running time, temperature-related RPM history, and fuel-mode history.

Tool references identify the EFI Analyzer 0644-342, the 0637-243 update kit for 500/600/700 applications, and TPS Adjustment Tool Kit 3639-891. The EFI TPS section goes beyond whole-throttle-body replacement, with separate adjustment and sensor-replacement procedures for out-of-warranty machines.

Engine electrical repair covers stator peak-voltage and resistance tests, ignition-timing verification, and starter-motor overhaul. Chassis tests distinguish HI/OFF/LO from variable-range handlebar and thumb warmers, with passenger warmer checks as well.

APV assembly cautions explain how incorrect valve orientation can cause severe engine damage. Flywheel-removal warnings identify crankshaft and stator-coil damage risks from incorrect puller setup.

Wiring diagrams, schematics, and reference tables

The color appendix provides harness part numbers, wire-color identification, and connector details. Examples include Ignition/Main Harness I for Crossfire 600 EFI/Sno Pro and M6 EFI, and Hood Harness III for Firecat applications.

Mechanical and diagnostic references include Cooling System Schematics, Drive Train Schematics (w/ACT Drive), Slide Rail Schematics, and the EFI Component Voltage/Resistance Chart – Air Temperature. The suspension servicing chart links each model to its matching rail, arm, and idler-wheel schematics and repair procedure.

Reference data covers torque specifications, fluid capacities, lubricant requirements, engine clearances, and wear limits. Separate application tables provide clutch calibration, belt selection and offset data, spring selection, and shock setup specifications.

Track, clutch, brake, and pressurized-shock work requires the manual’s specified supports, guards, service equipment, and component-specific safety precautions.