Arctic Cat Tigershark PWC Service Manual 1994 (P/N 2255-116)

This Arctco factory service manual (P/N 2255-116) covers the 1994 Arctic Cat Tigershark personal watercraft lineup: Barracuda, Daytona, Monte Carlo, Montego, and Montego Deluxe.

Bookmarked PDF and Wiring Diagram Detail

Chapter access and small labels: Embedded PDF bookmarks link to the table of contents, all eight sections, and the wiring diagrams. Text search is limited to the title page; the technical pages are not searchable. Small wire-color and connector labels require zooming, and some fine circuit lines are faint.

One printable English PDF with 148 pages, including one unnumbered title page.

Two-Stroke Engine and Jet Pump Service

The selected topics below outline the repair coverage. Additional procedures address storage preparation and submerged-watercraft recovery.

• Engine repair: Step-by-step removal, disassembly, inspection, and reassembly for PJ640-AC and PJ650-AC engines, including crankshaft bearings, pistons, and reed valves.

• Fuel and oil injection: Mikuni BN carburetor/fuel pump overhaul, mixture and cable adjustment, pop-off testing, oil-pump output checks, synchronization, and bleeding.

• Jet pump service: Driveshaft, bearing, and seal replacement; impeller and wear-ring inspection; housing removal; and stator venturi and steering-nozzle inspection.

• Electrical diagnosis: Ignition and charging-system tests, digital CDI replacement, starter-motor overhaul, and checks for the bilge pump module, switches, and power trim.

• Steering and controls: Steering-cable centering and replacement, steering-post service, reverse adjustment, trim-indicator adjustment, and trim-cable replacement.

• Troubleshooting charts: Symptom, condition, and remedy tables for starting faults, overheating, poor performance, cavitation, unusual vibration, and accessory-system problems.

Written for service personnel, this manual also supports service training.

Engine Overhaul and Drive-Coupler Alignment

Piston-skirt clearance views, cylinder-measurement illustrations, and crankshaft runout drawings accompany the internal inspection procedures. Component torque tables and engine torque patterns support reassembly.

The engine-shimming section includes shim sizes and part numbers and specifies the Drive Coupler Gauge (P/N 0644-204). Its alignment checks provide a measured reference after engine installation, while the vibration troubleshooting chart identifies other possible causes such as worn bearings, damaged impellers, and loose motor mounts.

The crankcase instructions warn that forcing a tool between the halves can damage their sealing surfaces.

Carburetor and Oil-Injection Diagnosis

The carburetor chart distinguishes the BN 46-42 used with PJ640-AC engines from the BN 44-40 used with PJ650-AC engines. Needle-and-seat specifications, mixture settings, and pop-off pressures are listed separately.

Fuel-pump diaphragm vacuum testing and separate fuel-system and oil-tank pressure tests help distinguish delivery faults from leakage. Oil-injection checks include measured pump output and check-valve testing.

The oil-pump installation instructions warn that misalignment between the pump shaft and the flywheel cap-screw slot can damage the pump.

Jet Pump Variants and Hull Work

The Montego uses an aluminum impeller and wear ring; the other covered models use stainless steel components. The Impeller Drive Assembly Schematic identifies the bearings, seals, spacers, stator venturi, and steering nozzle.

Bearing service references the Seal and Bearing Tool Kit (P/N 0644-183). Inspection criteria address driveshaft wear and deflection as well as impeller damage.

The hull/body section identifies fiberglass construction and gel-coat materials, with seat-sealing and molding work covered separately. Fiberglass repair work is referred to the repair kit’s instructions.

Circuit Tests and Electrical Repair Limits

Electrical resistance charts identify test connections for the ignition, charge, trigger, and lighting coils, plus the solenoid and switches. Lighting-coil output is listed as 12V/105W.

Separate wiring diagrams cover Barracuda/Daytona, Montego, and Montego Deluxe/Monte Carlo configurations. Starter service extends to brush and commutator inspection, armature testing, and starter-pinion replacement.

The trim motor is tested and replaced as a complete unit; internal rebuilding is not covered.

Since marine service involves fuel lines and high-voltage ignition systems, follow standard shop safety practices and consult a qualified technician if a procedure exceeds your experience.

Examples of Carburetor Pop-Off and Impeller Limits

For needle-valve pop-off testing, the carburetor chart specifies 19 psi ±20% for the BN 46-42/PJ640-AC combination and 55 psi ±20% for the BN 44-40/PJ650-AC combination. The testing section specifies a lubricated, wet needle and seat.

Jet-pump inspection gives a maximum impeller-tip-to-wear-ring clearance of 1.0 mm (0.040 in.), measured at the center of each blade.