Genuine Arctic Cat Prowler, Cougar, Panther, EXT, Z, ZL, ZR, ZRT, Powder Special & Powder Extreme Snowmobiles - Service, Repair & Maintenance Shop Manual (1990-1998)
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Purchase Information
1990-1998 Arctic Cat Snowmobile Service & Repair Shop Manual - Technical Specifications
- Document Number / Seller:
- 29612 / Jessica Ramirez
- File Size:
- 59.46 MB
- File Type:
- Language:
- English
- Pages:
- 501
- Printable:
- Yes
- Estimated Download Time:
- 1.22 Minutes
- Delivery Format:
- Digital (PDF) - Instant Access
- Category:
- Snowmobile
- Brand:
- Arctic Cat
- Reviewed and Approved:
- Dec 31, 2025
Arctic Cat Models and Parts Covered in this Snowmobile Manual
- Arctic Cat Prowler (1990-1998)
- Arctic Cat Cougar (1990-1998)
- Arctic Cat Panther 440 (1990-1998)
- Arctic Cat Panther 550 (1990-1998)
- Arctic Cat EXT 550 (1990-1998)
- Arctic Cat EXT 580 (1990-1998)
- Arctic Cat EXT 600 (1990-1998)
- Arctic Cat Z 440 (1990-1998)
- Arctic Cat ZL 440 (1990-1998)
- Arctic Cat ZR 440 (1990-1998)
- Arctic Cat ZR 580 (1990-1998)
- Arctic Cat ZR 600 (1990-1998)
- Arctic Cat ZRT 600 (1990-1998)
- Arctic Cat Powder Special (1990-1998)
- Arctic Cat Powder Extreme (1990-1998)
- Arctic Cat El Tigre EXT (1990-1992)
- Arctic Cat Prowler Special (1991-1992)
- Arctic Cat Prowler II (1993-1994)
- Arctic Cat Prowler 2-Up (1995)
- Arctic Cat 440 ZR (1993)
- Arctic Cat 580 ZR (1993)
- Arctic Cat EXT 580Z (1993)
- Arctic Cat EXT 580 Mountain Cat (1993-1996)
- Arctic Cat Cougar Mountain Cat (1994-1998)
- Arctic Cat Cougar 2-Up (1996)
- Arctic Cat Cougar Deluxe (1998)
- Arctic Cat EXT 580 EFI (1995-1998)
- Arctic Cat EXT 580 EFI Mountain Cat (1995-1996)
- Arctic Cat EXT 580 EFI Deluxe (1996-1998)
- Arctic Cat EXT 580 Powder Special (1996)
- Arctic Cat ZR 580 EFI (1995-1997)
- Arctic Cat ZL 500 (1998)
- Arctic Cat ZR 500 (1998)
- Arctic Cat Pantera EFI 580 (1997-1998)
- Arctic Cat Pantera (1997-1998)
- Arctic Cat EXT 600 Touring (1998)
- Arctic Cat 600 Powder Extreme (1998)
- Arctic Cat Powder Special EFI (1997-1998)
Complete Manual Information
Arctic Cat Prowler, Cougar, Panther, EXT, Z, ZL, ZR, ZRT, Powder Series Service Manual - 1990-1998
This official service manual provides authoritative repair and maintenance protocols for a wide range of Arctic Cat snowmobile models. It covers comprehensive system overhauls, from the Suzuki-based two-stroke powerplants to advanced liquid cooling and drive architectures. Integration of low-temperature grease at all critical steering and suspension pivot points is vital for ensuring component longevity and maximum uptime in sub-zero operational environments.
Technical Applicability & Model Generations
Model Coverage by Technical Series & Engine Displacement
- Prowler & Cougar Chassis (435.8 cc / 431 cc)
- Prowler Models (1990–1995): Includes Prowler, Prowler Special, Prowler II, and Prowler 2-Up.
- Cougar Models (1991–1998): Includes Cougar, Cougar Mountain Cat, and Cougar Deluxe.
- Panther Utility Series (431 cc / 550 cc)
- Panther 440 (1997–1998): Air-cooled utility configuration.
- Panther 550 (1997–1998): Liquid-cooled performance utility.
- EXT & El Tigre Performance Chassis (529 cc – 594 cc)
- El Tigre EXT (1990–1992): High-output early generation.
- EXT Series (1993–1998): Includes EXT 550, 580, 580Z, 580 EFI, 580 Mountain Cat, and EXT 600 Touring.
- Z, ZL, ZR & ZRT Racing/Trail Series (435.8 cc – 599 cc)
- Z/ZL/ZR 440 Series (1993–1998): Lightweight performance configurations.
- ZR 580 & 600 Series (1993–1998): Carbureted and EFI performance models.
- ZRT 600 Triple (1996–1998): High-displacement triple-cylinder architecture.
- Powder Mountain Series (580 cc – 594 cc)
- Powder Special & Powder Extreme (1996–1998): Dedicated deep-snow configurations in carbureted and EFI variants.
Operational Parameters & Service ROI
- Optimized Performance: Step-by-step synchronization of carbureted and fuel-injected systems ensures peak horsepower delivery and fuel efficiency across varied altitudes.
- Safety Assurance: Detailed inspection procedures for throttle-ignition safety switches and brake system integrity minimize the risk of mechanical failure during remote operation.
- Enhanced Longevity: Precise torque sequences and clearance specifications prevent premature wear on engine top-ends and drive clutches.
- Parts Accuracy: Utilization of engine and chassis Vehicle Identification Number (VIN) locations facilitates the procurement of exact replacement components.
Document Metadata
- Documentation Type: Full Service/Workshop Manual
- Page Count: 490+ Pages
- **Technical
Technical Depth & Factory Benchmarks
Ignition & Charging System Calibration Data
- Ignition Charge Coil Resistance: 160 ohms (Typical for most 1994-1997 ZR/EXT models).
- Lighting Coil Output: 0.22 ohms (Yellow to Yellow) for carbureted two-cylinder models.
- Spark Plug Gap: 0.7 mm (0.028 in.) utilizing NGK BR9ES or BR9EYA depending on EFI or Carbureted configuration.
- Timing Specifications: Variable by displacement; requires use of Arctco Ignition Analyzer or equivalent strobe timing equipment for precision adjustment.
Visual Navigation Aids
- Electrical Architecture: Comprehensive full-page wiring diagrams covering all model years and EFI/Carbureted variations.
- System Schematics: Detailed illustrations of the liquid cooling circuit, including thermostat bypass and heat exchanger flow paths.
- Drive Unit Overhaul: Exploded views of the drive and driven pulley assemblies, highlighting shim locations and spring orientations.
Table of Contents
- Chapter One: General Information (Tools, Fasteners, Safety)
- Chapter Two: Troubleshooting (Engine, Power Train, Electrical)
- Chapter Three: Lubrication, Maintenance, and Tune-up
- Chapter Four: Adjustments for Special Use (Altitude Tuning, Gearing)
- Chapter Five: Engine (Overhaul, Cylinders, Pistons, Crankshaft)
- Chapter Six: Fuel System - Carbureted Models
- Chapter Seven: Fuel System - Fuel Injected Models (EFI)
- Chapter Eight: Exhaust System
- Chapter Nine: Electrical Systems (Ignition, Lighting, Instrumentation)
- Chapter Ten: Oil Injection System
- Chapter Eleven: Cooling System (Air and Liquid Coed)
- Chapter Twelve: Recoil Starter
- Chapter Thirteen: Drive System (Clutches, Belts)
- Chapter Fourteen: Brake, Driven Shaft, and Dropcase
- Chapter Fifteen: Front Suspension and Steering
- Chapter Sixteen: Track and Rear Suspension
- Chapter Seventeen: Off-season Storage
Operational Limits & Specifications
Torque Sequences & Fluid Capacities
- Fan Intake Nut Torque: 25–40 N.m (18–30 ft.-lb.).
- Chaincase Lubricant Capacity: 236 cc (8 oz.) for standard models; 345 cc (12 oz.) for 1993-1995 variants.
- Cooling System Capacity: Varies from 2.4 L (2.5 qt.) on Cougar models to 4.2 L (4.4 qt.) on ZRT and Powder Extreme triples.
- Track Tension Deflection: Requires 9 kg (20 lbs.) of force at the midpoint of the slider shoe for accurate measurement.
- Recommended Lubricants: Arctic Cat 50:1 Injection Oil; Glycol-based automotive antifreeze (aluminum-safe); Low-temperature grease (NLGI No. 2 equivalent).
Download Instructions for Arctic Cat Snowmobile Manual
Frequently Asked Questions - Arctic Cat Snowmobile Manual
What does this Arctic Cat manual cover?
This comprehensive service manual covers detailed repair procedures, maintenance schedules, troubleshooting guides, and technical specifications for Genuine Arctic Cat Prowler, Cougar, Panther, EXT, Z, ZL, ZR, ZRT, Powder Special & Powder Extreme Snowmobiles - Service, Repair & Maintenance Shop Manual (1990-1998). It includes information for the following models: - Arctic Cat Prowler (1990-1998) - Arctic Cat Cougar (1990-1998) - Arctic Cat Panther 440 (1990-1998) - Arctic Cat Panther 550 (1990-1998) - Arctic Cat EXT 550 (1990-1998) - Arctic Cat EXT 580 (1990-1998) - Arctic Cat EXT 600 (1990-1998) - Arctic Cat Z 440 (1990-1998) - Arctic Cat ZL 440 (1990-1998) - Arctic Cat ZR 440 (1990-1998) - Arctic Cat ZR 580 (1990-1998) - Arctic Cat ZR 600 (1990-1998) - Arctic Cat ZRT 600 (1990-1998) - Arctic Cat Powder Special (1990-1998) - Arctic Cat Powder Extreme (1990-1998) - Arctic Cat El Tigre EXT (1990-1992) - Arctic Cat Prowler Special (1991-1992) - Arctic Cat Prowler II (1993-1994) - Arctic Cat Prowler 2-Up (1995) - Arctic Cat 440 ZR (1993) - Arctic Cat 580 ZR (1993) - Arctic Cat EXT 580Z (1993) - Arctic Cat EXT 580 Mountain Cat (1993-1996) - Arctic Cat Cougar Mountain Cat (1994-1998) - Arctic Cat Cougar 2-Up (1996) - Arctic Cat Cougar Deluxe (1998) - Arctic Cat EXT 580 EFI (1995-1998) - Arctic Cat EXT 580 EFI Mountain Cat (1995-1996) - Arctic Cat EXT 580 EFI Deluxe (1996-1998) - Arctic Cat EXT 580 Powder Special (1996) - Arctic Cat ZR 580 EFI (1995-1997) - Arctic Cat ZL 500 (1998) - Arctic Cat ZR 500 (1998) - Arctic Cat Pantera EFI 580 (1997-1998) - Arctic Cat Pantera (1997-1998) - Arctic Cat EXT 600 Touring (1998) - Arctic Cat 600 Powder Extreme (1998) - Arctic Cat Powder Special EFI (1997-1998).
Is this manual suitable for beginners?
Yes, this Arctic Cat manual is designed for both professional technicians and DIY enthusiasts. It includes step-by-step procedures with clear illustrations and safety guidelines for Snowmobile maintenance and repair.
What file format will I receive?
You will receive this manual as a PDF file (59.46 MB), which is compatible with all devices. The manual is fully searchable and printable for your convenience.
How quickly can I access the manual after purchase?
You'll receive instant access to your Arctic Cat Snowmobile manual immediately after payment completion. The download link is valid for 3 days, with lifetime re-download guarantee.
Can I print specific sections of the manual?
Absolutely! This digital manual allows you to print any section you need, from individual pages to complete chapters, making it perfect for workshop use.
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