2005 Arctic Cat 370, 440, 500, 550, 570, 600, 700, and 900 cc Snowmobile Service Manual (PN 0639-130)

This 815-page PDF combines Arctic Cat's two-volume Model Year 2005 snowmobile service manual, dated October 2004. Volume I covers general information, engines and related systems, fuel, and engine/chassis electrical work; Volume II covers steering and body, drive train and brakes, and track/rear suspension. Arctic Cat designed the set for service personnel, and its assumed use of pullers, electrical test equipment, precision measuring tools, and nitrogen shock equipment makes it best suited to technicians and experienced owners with a properly equipped shop.

• Document scope: One combined contents/navigation page, 381 pages of Volume I material, and 433 pages of Volume II material.

• Model coverage: Model charts identify Bearcat 570, Pantera 550 and 600 EFI, Panther 370 and 570, plus Z 370/370 LX, Z 440 LX, and Z 570/570 LX. They also cover Sabercat 500/600/700, Firecat 500/600/700, King Cat 900, M5, M6, M7, M7 LE, and ZR 900, including the listed EFI, R, LX, EXT, and Sno Pro variants.

• Engine repair: Separate removal, disassembly, cleaning and inspection, critical-component measurement, reassembly, installation, and troubleshooting coverage for 370/440, 550, 570, 600 STD, 900, and 500/600/700 cc Laydown engines, with distinct 500 cc APV and non-APV assembly schematics.

• Water pump and exhaust-control work: Standard and Laydown water-pump repair, engine pressure testing, liquid-cooling schematics, recoil-starter overhaul, Arctic Power Valve cable and valve service, and 500 cc Exhaust Controlled Timing sensor testing.

• Fuel and electrical diagnosis: VM- and TM-style carburetor jetting and overhaul, batteryless EFI self-diagnostics and component tests, oil-injection synchronization and bleeding, ignition-system resistance and peak-voltage testing, timing data, electric-start diagnosis, and indexed ignition plus main/hood wiring diagrams.

• Drive train and brakes: Drive-clutch and driven-pulley service, ACT Roller Driven Pulley setup, model- and altitude-specific clutch calibration charts, center-to-center and offset data, reverse/non-reverse/ACT Drive schematics, model-specific chaincase and brake-disc repair, hydraulic-brake bleeding, and mechanical/quick-adjust brake procedures.

• Steering, body, and suspension: AWS V versus AWS VI/M-Series steering and front-suspension work, body and heat-exchanger removal, model-to-schematic rear-suspension mapping, four track/skid-frame repair procedures, and service coverage for IFP, position-sensitive, Fox Air, Fox Zero Pro, and remote-reservoir shocks, including the applicable rebuild and recharge procedures.

Engine, Fuel, and Control-System Detail

Factory engine tables cover bore and stroke, compression ratio, a piston-and-ring replacement guide, cylinder-head volume, cylinder trueness, piston-to-cylinder clearance, connecting-rod inspection limits, crankshaft runout, torque conversions, and component-specific torque data. The manual also shows engine assembly schematics for the 370/440, 550, 570, 600 STD, 900, and Laydown families. Its servicing symbols identify where Loctite 242, 243, 270, 271, and 609, Three Bond, high-temperature sealant, anti-seize, or specified lubricants are required.

Carbureted coverage distinguishes VM, standard TM, and Laydown TM arrangements through specification tables, jet changes, removal, internal inspection, reassembly, cable and idle setup, synchronization, tuning-component selection, and fault isolation. The batteryless EFI chapter explains the ECU, fuel pump, injectors, five sensor inputs, self-diagnostic flash codes, throttle-body and TPS checks, and the recommended EFI Analyzer test sequence. APV material covers standard, 900, and Laydown valve designs, cable adjustment, cleaning, servomotor behavior, and separate carbureted/EFI troubleshooting.

Drivetrain, Wiring, and Suspension Reference

Named diagrams include Cooling System Schematics, Carburetor Schematics, and the model-indexed Ignition Wiring Diagrams and Main/Hood Wiring Diagrams. Driveline reference separates schematics with reverse, without reverse, and with ACT Drive. Suspension coverage uses style-coded Slide Rail, Front Arm, Rear Arm, and Idler Wheel Schematics, then maps each model to Repair Procedure 1, 2, 3, or 4. Related tables cover mounting locations, drive tracks, sprockets, shock applications, springs, rebuild kits, and rebuildable-shock specifications.

EFI diagnosis calls for EFI Analyzer P/N 0644-342 and Compression/Pressure Tester Kit P/N 0644-366. Other named shop tools include Drive Clutch Puller P/N 0644-207, Shock Inflation Needle P/N 0644-158, and Nitrogen Regulator P/N 0644-151.

Coverage Limits and Repair Cautions

The engine chapters cover the listed two-stroke families; this set does not include a four-stroke engine overhaul section. The oil-injection pump output-test procedure is present, but the model output-specification table is left TBA. The ignition diagram index also marks the King Cat 900 EFI and ZR 900 EFI/900 EFI Sno Pro harness entries as TBA, although their main and hood harness diagrams are indexed separately.

The manual warns that driving piston pins out with a punch can damage components and that substituting an EFI injector with a different code symbol or color can cause severe engine damage. Safety instructions are especially relevant around rotating clutch and track work, hydraulic brakes, stored recoil-spring energy, and pressurized nitrogen shocks; these jobs require the specified supports, protective equipment, and pressure-service tools.