2008 Arctic Cat AC 120, Bearcat W/T, Panther 660, T660, Jaguar Z1 & TZ1 4-Stroke Snowmobile Service Manual (P/N 2259-007)

This 2008 Arctic Cat 4-Stroke Snowmobile Service Manual (P/N 2259-007) covers AC 120, Bearcat W/T, Panther 660, T660, Jaguar Z1/Sno Pro, and TZ1/LXR models. Engine coverage is divided into 120 cc, 660 cc non-turbo/turbo, and 1100 cc sections.

PDF Search, Bookmarks and Wiring Detail

Finding procedures and diagrams: Service text and wiring-diagram titles are searchable; labels inside the wiring drawings are not. Embedded bookmarks open all eight service sections and the wiring diagrams. Small connector numbers, pin identifiers, and wire-color labels require zooming for comfortable reading.

Supplied as one printable 490-page PDF in English, comprising 471 service-manual pages and 19 wiring-diagram pages already included in that total. The file opens at Section 1 without a separate cover or foreword.

Engine, EFI and Snowmobile Chassis Service

The following highlights are a selection of the manual’s contents. Other documented work includes recoil-starter service and headlight-aim adjustment.

• Engine repair: Step-by-step removal, teardown, component inspection, bearing selection, and reassembly procedures, with cam timing, valve adjustment, and engine troubleshooting.

• Cooling and lubrication: Coolant filling, thermostat inspection, water-pump repair, oil-pressure testing, and oil-pump/pressure-relief-valve service.

• Fuel and EFI: AC 120 carburetor overhaul, throttle-body service, throttle position sensor testing and adjustment, fuel-pump replacement, and diagnostic code charts.

• Electrical diagnosis: Starter and charging tests, starter-motor repair, alternator/magneto service, CCU codes, reverse-actuator checks, and model-specific wiring diagrams.

• Drive train and brakes: Clutch and driven-pulley repair, alignment and belt-deflection checks, chain-case and Z1 gear-case service, caliper repair, and hydraulic brake bleeding.

• Track, suspension, and steering: Skid-frame servicing, track tension and alignment, Fox shock rebuilding, steering-component inspection, and ski alignment.

The internal measurements and electrical tests make this manual suited to experienced mechanics with the specified pullers, gauges, and diagnostic equipment.

Engine Internals and Valve Service

Piston and cylinder measurements, crankshaft inspection, and bearing-selection charts support internal engine work. The 1100 cc procedures also address balancer alignment and valve-shim selection; separate 660 cc specifications distinguish turbo and non-turbo camshafts and valve clearances.

Inspection tables cover cam-lobe height, crankshaft runout, piston-pin fits, and valve stem-to-guide clearance. Assembly schematics and 15 engine torque-pattern diagrams accompany cylinder-head, crankcase, oil-pan, and intake-manifold work.

Valve-service limits: For 660 cc valves, guides, or seats requiring servicing or replacement, the manual recommends a qualified machine shop.

General service information includes VIN and engine serial number identification, break-in checks, storage preparation, and high-altitude clutching guidance. Main-jet selection guidance applies to the 120 cc carburetor.

Cooling, Oil Circuits and Turbocharger Work

Cooling System Flow/Component Schematics and Oil Flow Charts trace the 660 cc and 1100 cc circuits. Compression-testing procedures are also included.

The 660 cc material documents accessory-belt adjustment. For the 1100 cc water pump, coverage extends to disassembly and replacement of bearings and seals.

Turbocharger/intercooler removal and installation are covered for the 660 cc turbo engine, alongside separate air-silencer procedures. A turbocharger handling caution explains that spinning the unit with compressed air can damage its bearings.

EFI Codes and Electrical Testing

Diagnostic references distinguish 660 cc check-engine-light flash codes from 1100 cc ECU display codes. CCU coverage includes code retrieval and clearing, while component tests address ignition circuits, charging components, grip heaters, seat-heater switches, and reverse controls.

TPS procedures specify the TPS Adjustment Tool Kit P/N 3639-891 and Multi-TPS Test Harness P/N 1686-436. Wiring examples include the Jaguar Z1 Ignition/Main Harness and TZ1 LXR Hood Harness X, showing connector views and wire-color identification.

Diagnostic scope: Certain EFI fuel and electrical component tests refer to the separate Arctic Cat Diagnostic System Manual, P/N 2256-974, or Laptop Diagnostic Tool, P/N 0744-048. Neither that diagnostic manual nor the equipment is included.

Clutch Alignment, Gear Cases and Brakes

Conventional driven-pulley procedures apply to the non-turbo Bearcat W/T, Panther 660, and T660. ACT Roller Driven Pulley procedures are provided for the Bearcat W/T Turbo and Z1 models. These distinctions help match alignment and belt-deflection procedures to the installed drive system when investigating engagement problems or belt wear.

Chain-case reverse-linkage adjustment and Z1 ACT gear-case teardown have separate procedures. The Z1 instructions warn that allowing the driven pulley to float on its shaft can damage the pulley.

Brake coverage distinguishes the AC 120 band brake from the hydraulic systems fitted to larger models.

Rear Suspension, Steering and Body Repairs

A model-based Servicing Chart directs the reader to four track/rear-suspension repair procedures. Skid Frame Mounting Schematics support this work, including the Bearcat W/T articulating suspension.

Fox air-shock and Zero Pro sections describe teardown, rebuilding, bleeding, and recharging. Steering and chassis procedures address tie rods, drag links, suspension arms, the Z1 front-suspension mounting bracket, and body-panel removal.

Driveshaft reference: Drive-sprocket positioning uses the applicable driveshaft part number from the model’s separate parts manual to select the corresponding illustration. That parts manual is not included.

Follow the manual’s workshop safety requirements for pressurized fuel systems, spring-loaded clutch components, and nitrogen-charged shocks.

A Preview of Valve and Bearing Clearances

For cold valve checks at 59–77°F, the 660 cc tables specify exhaust lash of 0.18–0.23 mm for non-turbo engines and 0.30–0.35 mm for turbo engines.

The 1100 cc engine specifications give crankshaft main-bearing clearance as 0.016–0.040 mm, complementing the internal inspection and bearing-selection material.