2009 Arctic Cat 120cc–1100cc Snowmobiles Factory Service Manual

• 2009 model coverage: Covers the 120 Sno Pro; Bearcat 570, 570 XT, and Z1 XT; Crossfire, F-Series, M-Series, and T-Series machines; and Z1/TZ1 applications with 120, 500, 570, 600, 800, 1000, and 1100 cc engines, including 1100 cc turbo configurations.
• Engine repair procedures: Documents engine removal and installation, top-side service, complete disassembly and reassembly, cylinder/piston/crankshaft inspection, 1100 cc valve and timing work, 2-stroke pressure testing, water-pump repair, and turbocharger/intercooler service.
• Fuel and electrical diagnosis: Covers 120/570 carburetors, EFI throttle bodies and injectors, fuel-pressure testing, TPS checks, ECU/CCU diagnostic codes, APV and ECT systems, peak-voltage and resistance tests, starter/magneto service, and servomotor troubleshooting.
• Drive, brake, and track work: Details drive-clutch and driven-pulley overhaul, belt deflection and clutch alignment, gear-case and reverse service, driveshaft and sprocket repair, track tension/alignment, hydraulic brake repair, fluid replacement, bleeding, and fault isolation.
• Suspension, steering, and factory data: Includes model-specific skid-frame service, ACT/Fox Air/Fox Zero Pro shock rebuilding and pressurizing, steering and ski alignment, body and chassis service, plus a 671-page PDF of assembly schematics, torque tables, test specifications, calibration charts, and exploded assembly views.

Model-Specific Factory Coverage

This 2009 Arctic Cat Snowmobiles Factory Service Manual is organized around the actual engine and chassis combinations rather than applying one generic procedure to the entire fleet. The engine section separates the 120 Sno Pro; Bearcat 570/F 570/T570; Crossfire 500/600 and M-Series 600; Crossfire 800/1000 and M-Series 800/1000; F-Series 500/600 and T-Series 500; F-Series 800/1000; and Bearcat Z1 XT/TZ1/Z1 families. Separate troubleshooting chapters cover carbureted 2-strokes, EFI 2-strokes, and 4-strokes, preventing generic procedures from being applied to the wrong configuration.

Engine chapters follow the shop progression from removal and disassembly through inspection, critical measurements, assembly, installation, and final checks. The 2-stroke sections cover cylinder-head volume and squish-gap checks, cylinder trueness, piston-to-cylinder clearance, piston-ring inspection, crankshaft runout, reed valves, oil-injection systems, APV components, and pressure testing. Selected 500/600 and larger 2-stroke families also include top-side repair procedures that can be performed without complete engine removal. The 1100 cc coverage distinguishes non-turbo and turbo components and adds valve service, camshaft and crankshaft inspection, compression and oil-pressure testing, cooling-system bleeding, and turbocharger/intercooler work.

Fuel, Electrical, and Diagnostic Content

Carbureted coverage includes pre-maintenance checks, main-jet changes, 120 and 570 cc carburetor service, throttle and choke cables, synchronization-related troubleshooting, and fuel-pump checks. The EFI section goes deeper into the fuel rail, pressure regulator, injectors, throttle-body assembly, air- and coolant-temperature sensors, TPS, ignition-timing and crankshaft-position inputs, MAP and knock sensing, and the 1100 cc Turbo wastegate control valve. Self-diagnostic codes, no-start fault isolation, fuel-pressure tests, temperature charts, and component checks are tied to the appropriate model family.

Electrical repair coverage includes the 120 cc transistorized ignition, 2-stroke and 1100 cc ignition systems, main-harness and regulator checks, CCU diagnosis, servomotor testing, peak-voltage tests, electric-start troubleshooting, starter and magneto service, warmer circuits, reverse/shift-actuator testing, and speedometer-sensor checks. Manual-listed special tools include the EFI Analyzer 0744-049, CCU Diagnostic Test Kit 0644-517, Engine Leak-Down Test Kit 0644-522, Water Pump Bearing and Seal Tool Kit 0644-502, Clutch Alignment Bars 0644-427/0644-496, and Floating Piston Installation/Location Tool Kit 0644-402. Certain 4-stroke EFI electrical component tests are expressly referred to the separate Arctic Cat Diagnostic System Manual or Laptop Diagnostic Tool. Those tests require the referenced diagnostic manual and tool rather than this volume alone.

Drivetrain, Suspension, Chassis, and Reference Data

The drivetrain section covers the 120 cc chain drive as well as the larger-model drive belt, drive clutch, driven pulley, clutch offset and parallelism, gear case, mechanical/electronic reverse components, brake disc, driveshaft, sprockets, track, and hydraulic brake system. Procedures extend through clutch and pulley disassembly, gear-case internal service, master-cylinder and caliper work, brake bleeding, track adjustment, and troubleshooting charts for belts, clutches, brakes, and track behavior.

Rear-suspension chapters are separated for the 120 Sno Pro, Bearcat XT, Crossfire, M-Series, F-Series/Z1, and Bearcat 570/T-Series. They cover skid-frame removal, arm and idler assemblies, mounting-location data, suspension setup, ACT shock service, Fox Air shock rebuilding/recharging, Fox Zero Pro service, and final shock pressurization. Steering and body coverage includes steering posts, tie rods, spindles, skis and wear bars, ski alignment, A-arms, sway bars, front shocks, consoles, belly pans, fuel tanks, seats, lighting assemblies, bumpers, racks, tunnels, and snowflaps.

The reference material includes displacement-specific engine assembly schematics and torque specifications, 1100 cc engine-case and cylinder-head torque patterns, a non-turbo/turbo oil-flow chart, cooling-system schematics, 2-stroke ignition-timing diagrams, crankshaft runout drawings, and gear-case performance calibration charts.

The manual also identifies important repair traps. APV exhaust valves are directional; installing one with the long side away from the cylinder head can cause severe engine damage. Crankshaft bearing locating holes must seat on their dowel pins before the case halves are closed, or the crankcase may not seal. Impact-tool installation can damage the drive-clutch stationary sheave; the driven pulley must not be allowed to float on its shaft, and its retaining cap screw is installed without thread-locking compound to avoid pulley or gear-case damage.

Fuel pressure, ignition voltage, rotating clutches and track, hydraulic brakes, hot cooling systems, and pressurized gas shocks require the correct tools and a properly equipped work area. The procedures are written for technicians, repair shops, and experienced owners.