Complete Service Repair Manual Arctic Cat Snowmobile 2001 This Manual is specifically written for the do-it-yourselfer as well as the experienced mechanic. Using this repair manual is an inexpensive way to keep you vehicle working properly. Each manual provides step-by-step instructions based on the complete disassembly of the machine. The high level of detail, along with hundreds of illustrations and details guide the reader through each service and repair procedure. This is the same manual used by dealer technicians to service, repair and mantain your Arctic Cat Snowmobile 2001. Models covered: Bearcat W/T Mountain Cat 500 EFI Mountain Cat 600 Mountain Cat 600 EFI /600 EFI LE Mountain Cat 800 /800 LE Mountain Cat 1000 Pantera 580 EFI Pantera 1000 Panther 370 Panther 440 /440 esr Panther 550 Thundercat Triple Touring 600 Z 120 Z 370 /370 es Z 440 /440 es ZL 500 EFI esr ZL 550 /550 esr ZL 600 EFI /600 EFI esr /600 EFI esr LE ZL 800 esr ZR 500 /500 EFI ZR 600 ZR 600 EFI /600 EFI LE ZR 800 /800 LE ZRT 600 /600 LE ZRT 800 /800 LE ----Index of Contents:---- 1 - General Information Snowmobile Identification Recommended Gasoline and Oil Break-In Procedure Genuine Parts High Altitude Operation Drive Chain Lubrication (120 cc) Preparation For Storage Preparation After Storage After Break-In Checkup Checklist Torque Conversions Tightening Torque (General Bolts) Fraction/Decimal Conversion Chart Drill Bit Sizes (Number) Chart MM/In. Conversion Chart Servicing Symbols 2 - Engine Engine Removing Engine (Table of Contents) Disassembling Engine (Table of Contents) Servicing Components (120 cc) Cleaning and Inspecting Engine Measuring Critical Components Arctic Cat Engine Specifications Assembling Engine (Table of Contents) Assembly Schematics (Table of Contents) Installing Engine (Table of Contents) Troubleshooting Engine (120 cc) Troubleshooting Engine (Carbureted Models) Troubleshooting Engine (EFI Models) Troubleshooting Engine 3 - Axial Fan/Belt (370/440 cc) Repairing Water Pump Pressure Testing Engine Liquid Cooling System Cooling System Schematics Recoil Starter (120 cc Model) Recoil Starter Arctic Power Valve (APV) System 4 - Fuel Systems Fuel System (Carbureted) Fuel System (Batteryless EFI) Fuel System (Related Items) 5 - Electrical Systems Electrical Specifications Chart Resistance Tests Chart Electrical Specifications (Individual) Transistorized Ignition System (120 cc Model) Testing Electrical Components3 Troubleshooting/Testing Ignition System 120 cc Model EFI Models Fan Cooled Models Twin L/C & Triple Models Digital 3-D Ignition (500/580/600/800/1000 cc Models) Testing Main Wiring Harness (120 cc Model) Testing Electrical Resistances Peak Voltage Tests (Fan Cooled Models) Peak Voltage Tests (Carbureted APV Models) Peak Voltage Tests (Liquid Cooled Models) Testing Low-Oil Light Sensor Testing High Temperature Sensor Testing High Temperature Warning Light Testing Fuel Gauge Testing Fuel Gauge Sender Testing Electric Fuel Pump Electric Start Components Solenoid Charging Diode Fuse Ignition Switch - Electric Start Function Starter Motor Troubleshooting Electric Start Wire Color Code and Function Description Ignition Timing Ignition Timing Specifications Wiring Diagram Index (Ignition) Wiring Diagrams 6 - Chassis electrical Systems Brakelight Switch (Hydraulic System) Brakelight Switch (Mechanical System) Headlight Dimmer Switch Testing Handlebar Warmer Elements(ON/OFF Function) Testing Thumb Warmer Element(ON/OFF Function) Testing Handlebar Warmer Elements(HI/OFF/LO Function) Testing Thumb Warmer Element(HI/OFF/LO Function) Testing Handlebar Warmer Switch(ON/OFF Function) Testing Handlebar Warmer Switch(HI/OFF/LO Function) Testing Thumb Warmer Switch(OFF/ON Function) Testing Thumb Warmer Switch(HI/OFF/LO Function) Testing Passenger Handwarmer Switch Testing Passenger Handwarmer Elements Wire Color Code and Function Description Wiring Diagrams (Main and Hood) 7 - Steering and Body Steering Steering Post (120) Steering Post (AWS III) Steering Post (AWS V) Ski Ski (120 cc) Ski Wear Bar Drag Link Tie Rods (120 cc) Front Tie, Rods Spindle Steering Tie Rod Ski Alignment Front Suspension A-Arms (120 cc) Front Suspension Arms Front Suspension (Ski) Shock Absorber Sway Bar Console (EFI Models) Console (Carbureted Model - Style A) Console (Carbureted Models - Style B) Belly Pan Seat/Cushion/Taillight Housing (120 cc) Taillight Housing Windshield Backrest/Rack/Taillight Assembly Tunnel/Rear Bumper/Snowflap Headlight Assembly (120 cc) Headlight Assembly (1 Bulb Halogen Adjusting Headlight Aim (1 Bulb Halogen) Headlight Assembly (3 Bulb Halogen) Adjusting Headlight Aim (3 Bulb Halogen) Torque Specifications Torque Specifications (General Bolts) 8 - Drive Train and brake system Drive Train and Brake Systems Drive Chain and Sprockets (120 cc) Drive Belt Drive Clutch Driven Pulley Drive Clutch/Driven Pulley Drive Train Schematics (w/Reverse) Drive Train Schematics (w/o Reverse) Drive Train/Brake Disc (w/Reverse) Drive Train/Brake Disc (w/o Reverse) Chain Adjuster Brake System (Hydraulic) Brake Lever/Master Cylinder Assembly (Hydraulic System) Brake System (Mechanical/Quick-Adjust) Brake Control (Mechanical/Quick-Adjust) Drive System Specifications (Production) Chain Case Performance Specifications With Tension Pad Tightener System Chain Case Performance Specifications With Roller Tightener System Drive System Components Arctic Cat Cam Arms Comet Cam Arms Comet-To-Arctic Cat Cam Arm Conversion Chart Chains & Sprockets Arctic Cat Drive Belt Dimension Chart Arctic Cat Drive Belt Replacement Chart Center-To-Center/Offset Specifications Torque Specifications Troubleshooting Drive Clutch/Driven Pulley Troubleshooting Drive Belt Troubleshooting Hydraulic Brake System 9 - Track / Rear Suspension Understanding the Suspension Suspension Setup Basics Suspension Mounting Location Chart Chassis and Skid Frame Mounting Locations Servicing Chart Slide Rail Schematics Front Arm Schematics Rear Arm Schematics Idler Wheels Schematics Articulating Skid Frame Schematic Repair Procedure Drive Sprocket Location Drive Track Usage Chart Drive Track Lug Patterns Idler Wheel Selection Chart Torque Specifications Rebuildable Shock Absorber Usage Guide Rebuildable Shock Accessory Part Numbers Shock Absorber Usage Guide Rear Spring Selection Chart Front Suspension Ski Springs Front Suspension Sway Bar Rear Suspension (Front Arm Springs) Standard Shock & Spring Chart Optional Rear Arm Spring Chart Rebuildable Shock Piston Depth Chart Rebuildable Shock Tools Required Rebuildable Shock Rebuild Kits Valve Stacks Servicing IFP Style Shocks Servicing Front Arm Quick-Adjust Shock Installing Internal Travel Limiting Spacers Servicing Rebuildable Shocks & Remote Reservoir w/Clicker Bearing Cap and Shaft Seal Shaft Eyelet Ski Shocks Bottom-Out Bumper Pressurizing Rebuildable Shocks Troubleshooting Track Language: ENG File Format: PDF Requirements: Adobe PDF Reader Specifications: High quality - Fully Bookmarked - Printable Compatible: All Windows and Mac Computers All systems, maintenance and repairs are covered. Hundreds of photos & Wiring diagrams showing complete procedures of disassembly and reassembly.