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Contents
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Table of Contents
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Troubleshooting
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Bookmarks
Quick Links
FOREWORD
This Arctic Cat Service Manual contains service and maintenance information for the Model Year 2004 Arctic Cat 4-
Stroke Snowmobiles. The manual is designed to aid service personnel in service-oriented applications.
This manual is divided into sections. The sections cover specific snowmobile components or systems and, in addition
to the standard service procedures, includes assembling, disassembling, and inspecting instructions. When using this
manual as a guide, the technician should use discretion as to how much disassembly is needed to correct any given con-
dition.
The service technician should become familiar with the operation and construction of the components or systems by
carefully studying the complete manual. This will assist the service technician in becoming more aware of and efficient
with servicing procedures. Such efficiency not only helps build consumer confidence but also saves time and labor.
All Arctic Cat publications and snowmobile decals display the words Warning, Caution, and Note to emphasize impor-
tant information. The symbol ! WARNING identifies personal safety-related information. Be sure to follow the
directive because it deals with the possibility of severe personal injury or even death. The symbol ! CAUTION
identifies unsafe practices which may result in snowmobile-related damage. Follow the directive because it deals with
the possibility of damaging part or parts of the snowmobile. The symbol
tion worthy of particular attention.
At the time of publication, all information, photographs, and illustrations were technically correct. Some photographs
and illustrations used in this manual are used for clarity purposes only and are not designed to depict actual conditions.
Because Arctic Cat Inc. constantly refines and improves its products, no retroactive obligation is incurred.
All materials and specifications are subject to change without notice.
Keep this manual accessible in the shop area for reference.
Product Service and Warranty Department
Arctic Cat Inc.
© 2003 Arctic Cat Inc.
®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN
NOTE: identifies supplementary informa-
Back to TOC
December 2003
Chapters
Troubleshooting
Summary of Contents for Arctic Cat 660 cc
(Ocr-Read Summary of Contents of some pages of the Arctic Cat 660 cc Document (Main Content), UPD: 24 August 2023)
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231, 8-31 8 Drive Train Schematics 0738-421 KEY 1. Sprocket Assy 2. Sprocket 3. Spring Retainer 4. Slip Pin 5. Compression Spring 6. Cap Screw 7. Lock Nut 8. Bearing 9. Shaft Spacer 10. Chain 11. Driveshaft Exten- sion 12. Reverse Gear 13. Thrust Washer 14. Thrust Bearing 15. Retaining Ring 16. Cap Screw 17, Tab Lock Washer 18. Washer 19. Shaft Retainer 20. Spring Pin 21. Spring 22. Reverse Idler Spacer …
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143, 5-10 AO300 AO301 5. Remove the four cap screws securing the stator windings to the rectifier assembly; then remove the one screw securing the stator to the alternator housing. Remove the stator. NOTE: The stator wires will have to be straight- ened for removal. AO302 6. Remove the two cap screws and the two nuts connecting the two alternator housing covers. Prior to removing the covers, make sure to make corresponding alignment marks on the covers for asse…
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88, 3-6 3. Insert a wooden pry bar (such as a hammer handle) between the engine and the alternator, pry the alternator away from the engine, and tighten the accessory belt. 4. When the accessory belt is tensioned properly (see Checking Tension in this sub-section), tighten the adjustment screw (A) to 2.2 kg-m (16 ft-lb). 5. Tighten the pivot cap screw (B) to 5.1 kg-m (37 ft- lb). 6. Place the belt guard into positi…
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44, 2-32 GEN-0027 6. After reconditioning the valve seat, the valve seat could be narrow. In this case, recondition the valve seat using the 45° cutter. After reconditioning, thoroughly remove any burrs which may be caused by grinding. The valve seat surface should be smooth but not too glossy. Repeat the valve seat repair procedure on the remaining valve. NOTE: After reconditioning all valve seats, thor- oughly clean the seat and its vicinity. Valve Springs 1. Whe…
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11, 1-9 1 Fraction/Decimal Conversion Chart Drill Bit Sizes (Number) Chart 8ths 16ths 32nds 64ths 64ths (cont) 1/8 = .125 1/16 = .0625 1/32 = .03125 1/64 = .015625 33/64 = .515625 1/4 = .250 3/16 = .1875 3/32 = .09375 3/64 = .046875 35/64 = .546875 3/8 = .375 5/16 = .3125 5/32 = .15625 5/64 = .078125 37/64 = .578125 1/2 = .500 7/16 = .4375 7/32 = .21875 7/64 = .109375 39/64 = .609375 5/8 = .625 9/16 = .5625 9/32 = .28125 9/64 = .140625 41/64 = .640625 3/4 = .750 11/16 = .6875 11/32 = .34375 11…
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87, 3-5 3 GR502D 5. Route the recoil rope through the rope guide of the recoil housing and through the recoil handle; then tie a knot in the rope. GR501D 6. Wind the rope counterclockwise 3-4 turns around the roller. 7. Secure the recoil starter to the engine shroud. GR304D NOTE: At this point, install the engine (see Sec- tion 2). Accessory Belt Arctic Cat recommends that the condition of the acces- sory belt be inspected monthly. CHECKING BELT T…
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4, 1-2 General Specifications Snowmobile Identification The Arctic Cat Snowmobile has two important identifica- tion numbers. The Vehicle Identification Number (VIN) is stamped into the tunnel near the right-side footrest. The Engine Serial Number (ESN) is stamped into the crank- case of the engine. 0726-383 These numbers are required to complete warranty claims properly. No warranty will be allowed by Arctic Cat Inc. if the engine serial number or VIN is removed or muti- lated in any w…
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326, 9-53 9 FC185 9. Secure the outer idler wheel mounting block with the cap screw and lock nut. Tighten to 5.5 kg-m (40 ft-lb). AG686D 10. Secure the outer and inner idler wheels to the mounting blocks with existing hardware. Tighten to 5.5 kg-m (40 ft-lb). FC151 11. Secure the crossbraces with cap screws (coated with blue Loctite #243). Tighten to 6.9 kg-m (50 ft-lb). FS051 NOTE: Apply a light coat of grease to the slide rail surface to aid …
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392, Arctic Cat 660 cc 9-119 9 Servicing Position Sensitive Shock (T660 Trail — Turbo) REMOVING/CLEANING 1. Remove the shock from the snowmobile. 2. Wash the shock body in parts-cleaning solvent; then dry with compressed air to remove sand and dirt. DISASSEMBLING 1. Remove the screw from the bladder housing on the bottom of the shock. Discharge all the pressure from the shock using the Shock Inflation Needle (p/n 0644-158). Open the valve in filler handle until all pressure i…
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353, 9-80 FS083C 16. Remove the cap screws and lock nuts securing the track adjuster bracket. AG527D 17. Twist the push nuts off the solid rivets securing the shock pads; then remove the pads. NOTE: The shock pads should be removed only if being replaced. INSPECTING NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. 1. Inspect the slide rail for cracks or unusual bends. AG529D 2. Inspect the wear strip for…
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3, 1-1 1 SECTION 1 — GENERAL INFORMATION TABLE OF CONTENTS General Specifications …………………………………….. 1-2 Snowmobile Identification ………………………………… 1-2 Recommended Gasoline and Oil ……………………… 1-2 Break-In Procedure ………………………………………… 1-3 Genuine Parts ……………………………………………….. 1-3 High Altitude Operation ………………………………………
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179, 7-20 AO167 4. Remove the lock nuts securing the A-arms to the chassis; then push the cap screws as far forward as possible. AO169A 5. Angle the rear of each A-arm downward and slide them off the cap screws. Account for two outer axles and an inner axle for each arm. A033 NOTE: If the cap screw must be removed, it will be necessary to remove the belly pan (see appro- priate Belly Pan in this section). INSPECTING NOTE: Whenever a part is worn excessively, cracked, or damag…
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318, Arctic Cat 660 cc 9-45 9 INSPECTING NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. 1. Inspect all front arm weldments for cracks or unusual bends. 2. Closely inspect all tubing for cracks or unusual bends. 3. Inspect the bearings, bushings, and front arm spac- ers for wear or damage. 4. Inspect the two rear track guide bumpers. If worn, drill out the rivets secu…
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38, Arctic Cat 660 cc 2-26 MD1458 26. Remove the intake cam timing sensor. MD1477 27. Remove the timing chain cover cap screws and timing chain cover. NOTE: Note the position of the alternator adjust- ment bracket, wiring harness tab, and intake cam timing sensor for assembling purposes. MD1490 28. Remove the timing chain tensioner guide bracket cap screws, timing chain guide cap screws, and the timing chain tensioner pivot cap screw; then remove the timing chain tensioner guide b…
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325, 9-52 AG551D FC194 4. Install the rear arm limiter cap screw (A) (coated with red Loctite #271) in the appropriate hole (as noted during disassembly) and tighten to 3.2 kg-m (23 ft-lb). Install the rear arm in the appropriate hole as noted during disassembly; then secure with a cap screw (B) (coated with red Loctite #271) and lock nut. Tighten to 4.7 kg-m (34 ft-lb). FS083A FS083B 5. Install coupler block with bushing. Secure with cap screw and lock nut…
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242, 8-42 AO373A 6. Slide the MAG-side bearing onto the driveshaft (inner race flange must be positioned toward drive chain); then install the O-ring and flange plate. Secure with three carriage bolts and lock nuts. Tighten to 2.2-2.5 kg-m (16-18 ft-lb). NOTE: Prior to installation, lubricate the O-ring with Low-Temp Snowmobile Grease (p/n 0636- 593). 7. Install the brake hub key into the driven shaft keyway; then…
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25, 2-13 2 15. Remove the 6 mm cap screws securing the throttle cable bracket to the intake plenum; then remove the throttle body cable end from the throttle body. AO189 16. Remove the air silencer (see appropriate Servicing Air Silencer in Section 3). 17. Remove the fuel line clamp at the fuel filter; then remove the throttle body heater line clamp from the main return coolant line and remove the two hoses. NOTE: Use caution; the fuel line may be under pressure. AO188 18. Remove the small …
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385, Arctic Cat 660 cc 9-112 REAR SUSPENSION SPRING SELECTION CHART Below is a list of rear suspension springs and specifi- cations. This chart was compiled to assist technicians in fine-tuning the Arctic Cat rear suspension when the original springs are not satisfactory and a softer or firmer ride is desired. A longer spring in areas (D) and (E) can be selected if cut off to match the original spring. The replacement spring must match the original spring in areas (D) and (E). 0730-2…
Table of Contents for Arctic Cat 660 cc:
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2-56 MD1657 MD1611 MD1612 MD1746 47. Install the crankshaft pulley over the crankshaft key. AO333 48. Install the crankshaft pulley cap screw and tighten to 10 kg-m (72 ft-lb). MD1661 49. Install the starter mounting plate and secure it in place with the bottom cap screw and nut; then install the ring gear shield and the remaining three cap screws and one nut. Tighten the cap screws and nuts to 4.8 kg-m (35 ft-lb). MD1613 50. Install a new water pump housi
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8-42 AO373A 6. Slide the MAG-side bearing onto the driveshaft (inner race flange must be positioned toward drive chain); then install the O-ring and flange plate. Secure with three carriage bolts and lock nuts. Tighten to 2.2-2.5 kg-m (16-18 ft-lb). NOTE: Prior to installation, lubricate the O-ring with Low-Temp Snowmobile Grease (p/n 0636- 593). 7. Install the brake hub key into the driven shaft keyway; then slide the driven shaft into position through the PTO-side bearing bracket. Position the brake disc between the brake pads; then slid
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3-28 AO366 INSTALLING NOTE: It is advisable to remove the two cap screws securing the water tank to the valve cover for turbo installation purposes. 1. With the gasket in place, install the turbo onto the exhaust manifold and secure with the two 8 mm lock nuts and the two 10 mm cap screws. Tighten in a crisscross pattern to 3.6-4.2 kg-m (26-30 ft- lb). AO367 NOTE: If the water tank was removed, secure it to the valve cover with the two cap scre
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Wiring Diagram (Ignition) 660 cc Turbo (Harness p/n 3006-843) 0739-280 5-15
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2-31 2 GEN-0023 GEN-0024 NOTE: Do not grind the valves. If a valve is dam- aged, it must be replaced. 3. Lubricate each valve stem with lightweight oil; then apply a small amount of valve lapping compound to the entire seating face of each valve. 4. Attach the suction cup of a valve lapping tool to the head of the valve. 5. Rotate the valve until the valve and seat are evenly polished. 6. Clean all compound residue from the valve and seat.
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9-103 9 DRIVE TRACK USAGE CHART (cont) * This track can only be used on AWS V chassis with a Torque Sensing Link Rear Suspension. P/N Length Width Rail Center # Lugs in Center Belt Bar Design Rating Lug Height 1602-188 136” 15” 8.84” Four Wave 2 .725” 1609-191 144” 15” 8.84” Four Aggressive Wave 4 1.25” 1602-225 151” 15” 8.84” Four Aggressive Wave 4 1.25” 1602-226 121” 15” 8.84” Four
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3-1 3 SECTION 3 — ENGINE-RELATED ITEMS TABLE OF CONTENTS Engine-Related Items………………………………………. 3-2 Recoil Starter (120 cc Model)……………………………. 3-2 Accessory Belt ……………………………………………….. 3-5 Liquid Cooling System …………………………………….. 3-6 Cooling System Schematics …………….
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7-30 AL181D 10. Remove the front belly pan-to-nosepiece torx- head screws. AL182D 11. Remove the belly pan from the frame. INSPECTING RIGHT-SIDE 1. Inspect for gouges, cuts, and tears. 2. Inspect all belly pan threaded bosses that they are in good shape. INSTALLING RIGHT-SIDE 1. Place the belly pan assembly in position in the frame. 2. Install the nosepiece torx-head screws to the front belly pan. AL182D 3. Install the nosepiece Phillips-head screw to the front belly pan. AL181D 4. I
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7-16 NOTE: Replacing the ski bolt bushings is diffi- cult. The existing bushings will be damaged dur- ing removal. Be careful, however, not to damage the spindle when removing the bearing. Press the new bushings into the spindle. INSTALLING 1. Place the upper and lower suspension arm ends with bushings in position into the spindle. Secure with cap screws and lock nuts. Tighten to 4.2 kg-m (30 ft-lb). 2. Place the steering tie-rod ball joint into position (threads coated with green Loctite #609) on the spindle arm as
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7-23 7 NOTE: Note the number of threads exposed between the spring adjuster and shock housing for installing purposes. 3. Using the Shock Spring Removal Tool (p/n 0644- 057), remove the spring from the shock body by compressing the spring; then remove the spring retainer from the top of the spring. Inspect the shock absorber by quickly compressing and extending the shock plunger while firmly holding the shock body. Resistance must be felt in both directions. CLEANING AND INSPECTING NOTE: Whenever a part is worn excessively, cracked, or damaged in any way,
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2-21 2 25. Remove the crankshaft. GM124D 26. Remove the cap screws securing the oil level sensor plate to the crankcase; then remove the plate. GM126D Disassembling Engine (660 cc Models) 1. Remove three cap screws holding the grooved belt cover; then remove the belt cover. Remove the cap screw holding the oil level stick tube in place; then remove the tube and the oil level stick. 2. Remove the coolant filler neck and hose ass
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Arctic Cat Bearcat 660 Snowmobile 2007 Models
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Models Covered: Jaguar Z1, Panther 660, Panther 660 Touring, Panther 660 Trail, T 660, T 660 Turbo, T 660 Trail, T 600 Turbo Touring, T 600 Turbo Touring LE, T 660 Turbo Trail, T 660 Turbo Trail LE, Bearcat 660, Bearcat 660 WideTrack, Bearcat 660 Turbo, Bearcat 660 Turbo Widetrack, Bearcat 660 Turbo Widetrack Straight Rail, Bearcat 660 Turbo Widetrack Articulating Rail, AC 120, Youth 120
Table of Contents: General Information / Specifications, Engine, Engine-Related Items, Fuel Systems, Engine Electrical Systems, Chassis Electrical Systems, Steering and Body, Drive Train & Brake Systems, Track / Rear Suspension, Color Wiring Diagrams
Part Numbers: 2257-768, 2257-905
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