2000 Arctic Cat Snowmobile Service Manual Set, Volumes I & II (P/N 225385)

This Arctic Cat service manual set covers 1999–2000 snowmobiles, with engine procedures for the 60 cc model, fan-cooled twins, and liquid-cooled twin and triple configurations through 1000 cc. The September 1999 publication brings together the engine, chassis, drivetrain, and suspension sections assigned to Volumes I and II.

• Engine repair: Engine removal, crankcase disassembly, cylinder and piston inspection, crankshaft measurements, assembly schematics, and installation procedures.

• Cooling and recoil starters: Water-pump repair for twin and triple engines, engine air-leak testing, cooling-system service, and recoil-starter overhaul.

• Fuel systems: VM- and TM-style carburetor service, synchronization, oil-injection pump adjustment and bleeding, and batteryless EFI troubleshooting.

• Electrical diagnosis: Ignition and charging tests, digital 3-D ignition, starter-motor service, ECU trouble codes, and model-indexed wiring diagrams.

• Drivetrain and brakes: Drive-clutch and driven-pulley service, alignment checks, chain-case repair with and without reverse, and hydraulic and mechanical brake procedures.

• Steering and track: AWS III and AWS V steering-post service, ski alignment, FasTrack rear-suspension work, and track tension and alignment.

• Rebuildable shocks: IFP, front-arm quick-adjust, remote-reservoir, and clicker-shock service, including bleeding, seal replacement, and nitrogen charging.

The manual is written for service personnel and assumes familiarity with snowmobile components, workshop inspection methods, and the specialized equipment used in the procedures.

Engine Inspection and Cooling-System Repair

The engine sections follow removal, disassembly, inspection, assembly, and installation, with separate procedures for the different engine configurations. Inspection coverage includes cylinder trueness, piston-ring end gap, piston clearance, crankshaft runout, and connecting-rod small-end bore dimensions.

Assembly schematics accompany the engine work. The Engine Piston Travel Versus Crank Angle Chart supports the ignition-timing references, while torque tables and tightening patterns distinguish engine sizes and fastener locations.

Water-pump procedures separate twin, 600 cc triple, and 800/1000 cc designs. The manual identifies incorrect impeller-washer orientation as a cause of coolant leakage, including leakage from the crankcase bleed hole on the illustrated configuration.

Carburetors, Oil Injection, and Batteryless EFI

Carburetor coverage distinguishes VM- and TM-style assemblies, including disassembly, cleaning, synchronization, choke adjustment, and idle adjustment. Application-specific main-jet selection refers to the Main Jet Chart decal on the snowmobile.

Batteryless EFI coverage includes ECU self-diagnostics, LED trouble codes, fuel-pressure regulator testing, and temperature-sensor voltage/resistance charts. These tests help separate fuel-delivery faults from sensor and electrical faults before components are replaced.

Specialized equipment includes EFI Analyzer P/N 0644-212 and Fuel Pressure Tester P/N 0644-203. The throttle-position sensor section specifies complete throttle-body replacement for a failed sensor. Fuel Designation Connector guidance also addresses the risk of severe engine damage when the EFI fuel setting does not match oxygenated gasoline.

Ignition Tests and Model-Specific Wiring

Electrical sections distinguish fan-cooled engines, liquid-cooled twins and triples, EFI ignition, and digital 3-D ignition on 700/800/1000 cc models. Resistance tests, peak-voltage specifications, and ignition-analyzer procedures accompany starter and charging-system diagnosis.

The wiring indexes link listed models to their ignition, Main Harness, and Hood Harness diagrams. Wire Color Code and Function Description tables explain the circuits, helping the technician select and interpret the appropriate diagram.

Clutches, Brakes, Steering, and Suspension

Drive-clutch and driven-pulley procedures include offset, parallelism, and belt-deflection checks. Separate chain-case procedures address reverse and non-reverse assemblies. Brake coverage distinguishes hydraulic, mechanical, and mechanical quick-adjust systems, with hydraulic bleeding and component inspection.

Steering and suspension sections cover steering posts, linkage, skis, rear skid frames, and rebuildable shocks. Shock references include piston depths, valve stacks, and usage guides. The Arctic Cat Drive Belt Dimension Chart and Idler Wheel Selection Chart support component identification; the Fraction/Decimal Conversion Chart provides a separate shop reference.

For running tests, follow the manual’s shielded-track-stand precautions and keep clear of rotating clutches, belts, and track components.

A Sample of the Engine Air-Leak Test Limits

The engine leak-test limits illustrate a small selection of the workshop specifications in this set. The sealed-engine test specifies 8 psi crankcase pressure and a maximum pressure loss of 1 psi per minute.

These are air-leak test figures, rather than cylinder compression readings. The procedure pairs them with leak-location checks and a warning that excessive test pressure can damage engine seals.

Search, Chapter Bookmarks, and PDF Contents

Text access and diagram detail: The main text is searchable, with ten embedded bookmarks covering the foreword and nine main sections. Many wiring-diagram labels are outside the searchable text. Small labels in the checked diagrams are readable when enlarged.

The download contains one printable, English-language, 647-page PDF combining both volumes. Its page allocation is:

The Volume I count already includes the foreword, overall table of contents, and two blank preliminary pages.