2007 Arctic Cat 370, 570, 600, 800, 1000cc, Crossfire, F-Series, M-Series 2-Stroke Snowmobiles Service Manual (P/N 2257-764)

This January 2007 edition of the Arctic Cat Service Manual (P/N 2257-764) covers 2-stroke Crossfire, F-Series, M-Series, Panther, Bearcat, and Z snowmobiles. Separate engine sections address the 370, 500, 570, 600, 800, and 1000 classes.

PDF Search, Bookmarks and Page Layout

Search and section navigation: Service text is searchable, and ten PDF bookmarks link to the foreword and nine main sections. Illustration labels are not consistently searchable; small labels in the ignition-switch view and engine assembly drawings are easier to read when enlarged.

One printable English-language PDF contains 648 pages, including one unnumbered foreword and 647 numbered service pages. The file starts with the foreword, and printed pagination jumps from 2-4 to 2-6.

Engine, EFI, Drivetrain and Suspension Service

These selected service topics outline the repair coverage. The manual also includes seasonal storage and recoil-starter repair.

• Engine repair: Engine removal and installation, crankcase disassembly, piston and crankshaft inspection, squish-gap measurement, and engine pressure testing.
• Cooling system: Fan and belt service, water-pump repair, coolant draining and filling, hose inspection, and thermostat testing.
• Fuel and lubrication: Mikuni carburetor service and synchronization, EFI component tests, fuel-pressure checks, and oil-injection pump adjustment and bleeding.
• Exhaust controls: APV valve cleaning and cable adjustment, servomotor troubleshooting, and Exhaust Controlled Timing (ECT) sensor testing.
• Electrical diagnosis: Engine and chassis fault codes, ignition resistance and peak-voltage tests, TPS checks, electric-start repair, and switch testing.
• Drive train and brakes: Clutch cam-arm and spring replacement, driven-pulley service, ACT gear-case overhaul, chain-case repair, and hydraulic or mechanical brake service.
• Steering and suspension: Ski alignment, steering component replacement, skid-frame repair, track adjustment, and ACT, position-sensitive, and Fox shock service.

Arctic Cat wrote this manual for service personnel; its engine measurements, electrical tests, and shock service procedures require suitable shop equipment.

Engine Overhaul and APV Service

Engine chapters separate F-Series installations from Crossfire/M-Series procedures and the fan-cooled models. Step-by-step disassembly and assembly instructions accompany inspections of crankshaft bearings, reed valves where fitted, piston-to-cylinder fit, and connecting-rod clearances.

Exploded assembly schematics identify torque-controlled joints, lubrication points, and sealing requirements. The 600-class APV section warns that incorrect exhaust-valve orientation can cause severe engine damage. The engine pressure-test section also explains how excessive test pressure can damage seals.

Water Pump and Cooling System Repair

Water-pump seal replacement has separate procedures for the 500/600 and 800/1000 engines, both requiring engine removal. Both procedures specify an Oil Seal Protector Tool, P/N 0644-219.

The Cooling System Schematics show representative hose and heat-exchanger layouts, while the service text covers thermostat inspection and model-specific coolant draining.

Carburetors, EFI and Oil Injection

The carburetor section covers Mikuni VM-32 and VM-34 configurations, with Carburetor Schematics, float and jet inspection, slide synchronization, and choke adjustment. Oil-injection procedures distinguish cable-controlled and control-rod arrangements.

EFI coverage includes injector and fuel-pump tests, ECU memory diagnosis for 500/600 engines, and temperature-based sensor voltage/resistance charts.

Diagnostic-tool scope: For 800/1000 EFI testing, the text refers to the separate EFI Diagnostic System Manual, P/N 2257-850. It also references the EFI Analyzer Usage Manual, P/N 2259-020, for 500/600 models. Those additional manuals are not included in this PDF.

Ignition and Chassis Electrical Testing

Separate test tables identify electrical connections and wire colors for each engine group. Coverage extends to the chassis control unit, hand and thumb warmers, reverse alarm, and shift actuator.

The Electric Start Key Switch terminal view supports ignition-switch checks. Electrical coverage includes component illustrations and test charts; a full vehicle wiring-diagram set is not included.

ACT Drive, Brakes and Rear Suspension

Drive-train procedures distinguish standard chain cases, with or without reverse, from ACT gear cases. Clutch alignment, pulley offset, and belt deflection checks accompany the Arctic Cat Drive Belt Replacement Chart.

The rear-suspension Servicing Chart assigns each model family to one of four repair procedures, helping you select the correct skid-frame instructions before disassembly. Shock sections extend to internal inspection, valve-stack specifications, floating-piston positioning, bleeding, and recharging.

Work around the track, electrical system, and pressurized shocks requires the support, isolation, and pressure-release precautions specified for the procedure.

Specification Preview: APV Cable and Float-Arm Settings

For APV cable adjustment, the manual specifies 36.0 mm ± 1 mm for the 600 engine and 35.0 mm ± 1 mm for 800/1000 engines. These are exposed cable lengths measured with slack gently removed and the cables routed close to their installed positions.

For Mikuni VM-32 and VM-34 carburetors, float-arm height is 22–24 mm with the carburetor inverted, measured from the gasket surface to the top of the float arm.

Reference material includes cylinder-head volume specifications, the Engine Piston Travel Versus Crank Angle Chart, crankshaft runout limits, general bolt tightening tables, and torque conversions. The Piston Replacement Guide lists piston-ring and piston-and-ring-set part numbers by engine class.