2005 Arctic Cat 370, 440, 500, 550, 570, 600, 700, and 900 cc Snowmobile Service Manual Set

The foreword directs service technicians to study both volumes and use judgment when deciding how much disassembly a job requires.

Engine scope: The engine chapters cover the listed two-stroke families; this set does not include four-stroke engine overhaul.

PDF Search, Wiring Detail and Page Count

Search and wiring detail: Embedded OCR supports text searches in the service sections, with recognition errors and gaps in diagram labels. Thirteen bookmarks reach the main sections and wiring groups; small wiring labels need zooming, and some reduced-size copies remain soft.

The download is one printable, 815-page PDF. That total includes the combined contents/navigation page and Volume I's foreword.

Two-Stroke Engine, Driveline and Suspension Work

This selection of covered work is not a full contents list; other topics include axial fan/belt service and storage/return-to-service preparation.

• Engine repair: Step-by-step removal, disassembly, inspection, critical-component measurement, reassembly, installation, and troubleshooting for 370/440, 550, 570, 600 STD, 900, and 500/600/700 cc Laydown engines.

• Cooling and exhaust: Standard and Laydown water-pump repair, engine pressure testing, recoil-starter overhaul, Arctic Power Valve (APV) service, and 500 cc Exhaust Controlled Timing sensor tests.

• Fuel systems: VM/TM carburetor overhaul, jetting, and synchronization; batteryless EFI self-diagnostics and component tests; oil-injection pump synchronization, bleeding, and output testing.

• Electrical diagnosis: Ignition resistance and peak-voltage tests, timing data, electric-start diagnosis, control/warmer checks, and indexed ignition plus main/hood wiring diagrams.

• Drivetrain and brakes: Drive-clutch and driven-pulley service, ACT Roller Driven Pulley setup, model-specific chaincase/gearcase and brake-disc repair, hydraulic-brake bleeding, and mechanical/quick-adjust brake procedures.

• Steering and body: AWS V versus AWS VI/M-Series steering and front-suspension work, ski alignment, body service, and heat-exchanger removal.

• Track and shocks: Four model-mapped skid-frame repair procedures, track tension/alignment, and service for IFP, position-sensitive, Fox Air, Fox Zero Pro, and remote-reservoir shocks.

Arctic Cat designed the set for service personnel. It is also suited to experienced owners with a properly equipped shop, including pullers, electrical test equipment, precision measuring tools, and nitrogen shock equipment.

Engine Inspection and Assembly Detail

Factory tables cover bore and stroke, compression ratio, piston-and-ring replacement guidance, torque conversions, and component-specific torque data. Inspection references address cylinder-head volume, cylinder trueness, piston-to-cylinder clearance, connecting-rod limits, and crankshaft runout.

Assembly schematics accompany the covered engine families, with distinct 500 cc APV and non-APV layouts. Servicing symbols identify Loctite 242, 243, 270, 271, and 609, Three Bond, high-temperature sealant, anti-seize, and specified lubricants.

The piston-removal instructions warn of component damage if a punch is used to drive the pins out.

Carburetors, EFI and Exhaust Controls

Carburetor sections distinguish VM, standard TM, and Laydown TM arrangements, including cable/idle setup and Mikuni tuning-component selection. Cooling System Schematics and Carburetor Schematics provide related system and assembly references.

EFI fault isolation: The ECU material explains the fuel pump, injectors, five sensor inputs, throttle-body/TPS checks, and flash codes. Existing Problem Diagnosis and Memory Problem Diagnosis distinguish current and intermittent sensor faults before individual checks, helping the technician select the relevant test.

Named diagnostic tools include EFI Analyzer P/N 0644-342 and Compression/Pressure Tester Kit P/N 0644-366. The analyzer does not replace the separate coil, pump, regulator, switch, stator, and servomotor tests.

The injector cautions explain the risk of severe engine damage when code symbols or colors are mismatched. APV detail distinguishes standard, 900, and Laydown valve designs, with cleaning, cable adjustment, servomotor behavior, and separate carbureted/EFI troubleshooting.

Oil-pump testing limit: The output-test procedure is included, but the model output-specification table is marked TBA.

Driveline, Wiring and Suspension Reference

Clutch calibration charts are model- and altitude-specific, with center-to-center and offset data. Drive Train Schematics distinguish reverse, non-reverse, and ACT Drive arrangements; a separate driven-shaft PTO-end bearing procedure applies to Firecat r/Sabercat models. Clutch removal references Drive Clutch Puller P/N 0644-207.

Wiring coverage: Ignition Wiring Diagrams and Main/Hood Wiring Diagrams use model indexes. The ignition index marks King Cat 900 EFI and ZR 900 EFI/900 EFI Sno Pro entries TBA; King Cat 900 EFI has separately indexed main and hood diagrams.

Style-coded Slide Rail, Front Arm, Rear Arm, and Idler Wheel Schematics map each model to Repair Procedure 1, 2, 3, or 4, so the skid-frame instructions can be matched to the suspension being serviced. Related tables cover mounting locations, drive tracks, sprockets, shock applications, springs, rebuild kits, and rebuildable-shock specifications.

Shock service includes the applicable rebuild and recharge procedures, with Shock Inflation Needle P/N 0644-158 and Nitrogen Regulator P/N 0644-151 listed among the tools.

Safety instructions address rotating clutch/track work, hydraulic brakes, stored recoil-spring energy, and pressurized nitrogen shocks, with specified supports, protective equipment, and pressure-service tools.

Examples of EFI Pressure and Crankshaft Inspection Data

The EFI specification table lists fuel pressure of 35.7–40.1 psi for the 600 cc STD EFI engine, compared with 42.8–47.3 psi for the 600 cc Laydown and 700/900 cc EFI engines. These are separate model specifications, rather than one interchangeable pressure range.

The crankshaft repair reference gives a maximum runout of 0.05 mm (0.002 in.) with the crankshaft supported on its outer bearings in V-blocks. Its drawings identify the relevant measuring locations.