Arctic Cat 60 cc, 440 LC, 500, 550, 580, 600, 700, 800, and 1000 cc Snowmobile Manual, 2000 (P/N 225385)

• Covers 1999–2000 Arctic Cat snowmobiles, including 60 cc, 440 LC, 500, 550, 580, 600, 700, 800, and 1000 cc engine variants across Twin, Triple, and fan-cooled configurations.
• Original OEM publication from September 1999 (Part Number / Form Number 225385).
• Contains 216 indexed figures, 9 comprehensive section tables, and detailed assembly schematics for engine components.
• Total length: 647 pages. This two-volume reference serves as the primary service documentation for the 2000 Arctic Cat lineup.
• Explains comprehensive step-by-step procedures for batteryless EFI systems, VM and TM-style carburetors, oil-injection pumps, recoil starters, hydraulic brake networks, and rebuildable shock absorbers.
• Highlights crucial maintenance tasks involving drive clutches, driven pulleys, steering posts, FasTrack rear suspensions, throttle position sensors, ski alignment, and track tensioning.

Engine Servicing and Component Overhaul

This factory service PDF publication provides the core specifications for the 2000 Arctic Cat series, spanning displacements from the compact 60 cc up to the 1000 cc powerplants. Inside, you will find the exact mechanical progression documented for shop maintenance and complex repair. The manual outlines the removal, disassembly, inspection, and assembly phases for major sub-systems, including fuel delivery, electrical arrays, drive trains, and the track suspension. By detailing step-by-step instructions for highly involved tasks—such as rebuilding internal floating piston (IFP) shocks, bleeding hydraulic brake systems, synchronizing carburetors, and adjusting the 3-D ignition—this resource eliminates the need for expensive dealership visits. Technical sections dive strictly into component tolerances. Mechanics get factory-verified data on bore trueness, piston-ring end gap, crankshaft runout, and connecting-rod small-end bore dimensions. These metrics are essential for accurate technical evaluation and diagnostic inspection during a rebuild. Before tearing down any high-performance sled engine, reviewing the torque sequences and pressure thresholds outlined in these chapters is a necessary safety measure to prevent severe mechanical failure and potential injury during operation.

Specification Previews and Identification Data

This text lays out essential baseline values to establish a precise standard in the bay, ensuring a reliable fix for recurring faults. For example, cylinder head warpage limits are strictly capped at 0.05 mm, and throttle lever free-play must sit between 0.75 mm and 1.5 mm. The recommended engine idle speed for these specific 2000 units is set exactly at 1500 RPM, while maximum drive clutch assembly clearance is documented at 12.7 mm. To streamline the daily workflow, the manual consolidates troubleshooting efforts with direct access to exact reference materials. Having comprehensive Wiring diagrams, alongside the Main Jet Chart, Engine Piston Travel Versus Crank Angle Chart, Idler Wheel Selection Chart, Fraction/Decimal Conversion Chart, and the Arctic Cat Drive Belt Dimension Chart readily available provides a clear advantage in a busy workshop. Technicians can verify exact tolerances without breaking their concentration to search for external data.

When conducting a major repair on these specific models, mechanics must navigate several known mechanical traps. For instance, if the water pump impeller washer is installed with the rubber side facing away from the impeller, a continuous coolant leak from the crankcase bleed hole is guaranteed. Additionally, on batteryless EFI models, neglecting to manually disconnect the Fuel Designation Connector at the ECU prior to running oxygenated gasoline forces the engine into a dangerously lean condition, ultimately leading to severe piston damage. By providing structural breakdowns of chassis, electrical, and cooling specifications, this manual delivers the foundation needed to evaluate wear and tear accurately in a professional shop or a serious DIY garage.