O P E R A T O R ’ S M A N U A L

www.arcticcat.com

BEARCAT/LYNX

Limited WarrantyArctic Cat Inc. (hereinafter referred to as Arctic Cat) extends a limited warranty as described below on eachnew Arctic Cat Snowmobile it assembles and on each genuine Arctic Cat Snowmobile part and accessoryassembled and sold by an authorized Arctic Cat Snowmobile dealer. The limited warranty on an Arctic CatSnowmobile is extended to the original retail purchaser for the time periods described below; however, thebalance of the remaining warranty may be transferred to another party unless the purchase is forcommercial use (see below). Warranty coverage is only available in the country in which the original retailpurchase occurs to the original retail purchaser resident in that country or to a transferee resident in thatcountry of the balance of the remaining warranty.

Arctic Cat warrants only the products it assembles and/or sells and does not warrant that other products willfunction properly when used with an Arctic Cat Snowmobile or will not damage the Arctic Cat Snowmobile.Arctic Cat does not assume any liability for incidental or consequential damages.

Arctic Cat will repair or replace, at its option, free of charge (including any related labor charges), any partsthat are found to be warrantable in material or workmanship. This repair work MUST be done by anauthorized Arctic Cat Snowmobile dealer. No transportation charges, rental charges, or inconvenience costswill be paid by Arctic Cat. The warranty is validated upon examination of said parts by Arctic Cat or anauthorized Arctic Cat Snowmobile dealer. Arctic Cat reserves the right to inspect such parts at its factory forfinal determination if warranty should apply.The warranty periods are as follows:

1. For snowmobiles used for recreational purposes:—If purchased between May 1 and November 30, warranty expires ONE (1) YEAR from December 1of the current year.—If purchased between December 1 and April 30, ONE (1) YEAR from the date of sale.

2. For snowmobiles used for commercial purposes (including rental operations), ONE (1) YEAR from thedate of invoice and/or 5000 MILES whichever comes first (non-transferable).

3. THIRTY (30) DAYS from date of sale of snowmobile on Arctic Cat supplied batteries.Exclusions to this warranty include normal wear, abuse (i.e. a track run on marginal snow conditionswithout proper lubrication or additional idler wheels), and the following parts:

Fuel Filter Light Bulbs Windshield Drive Belt Torn or Punctured UpholsteryWear Bars Brake Pads Spark Plugs Drive Clutch/Driven Clutch Wear PartsWear Strips Shock Absorber(s) - Standard* Shock Absorber(s) - Rebuildable*** Limited to one (1) year or 1000 miles of “normal” riding conditions - replace for defective or leaking shock,

corroded or pitted shaft, peeling chrome.** Limited to one (1) year or 1000 miles of “normal” riding conditions - rebuild for leaking shock (warranted)

- replace for defective shock, corroded or pitted shaft, peeling chrome.The following will VOID Arctic Cat’s warranty:

1. Failure to perform the proper break-in procedure and all related maintenance, storage procedures (ifstored for extended periods), and/or service as recommended in the Operator’s Manual.

2. Repairs and/or adjustments by anyone other than an authorized Arctic Cat Snowmobile dealer.3. Use of an improper fuel mixture ratio.4. Use of improper carburetor jets.5. Use of improper gasoline, lubricating oils, or spark plugs.6. An accident or subjecting the snowmobile to misuse, abuse, or negligent operation.7. Any modification, addition, or removal of parts unless instructed to do so by Arctic Cat.8. Use of the snowmobile in any way for racing purposes.9. Removal of the engine for use in another vehicle.

10. Removal or mutilation of the Vehicle Identification Number or Engine Serial Number.11. Use of parts not sold or approved by Arctic Cat.12. Track and tunnel damage resulting from either ice stud or hooker plate installation.13. Damage due to improper transportation.

Arctic Cat shall not be responsible for and this limited warranty excludes recovery of economic, punitive,consequential and incidental damages, lost profits, and loss of use. Some states or provinces do not allowthe exclusion or limitation of incidental or consequential damages, so the above limitation may not apply toyou. Arctic Cat’s aggregate liability may not exceed the price of the product. The law of the State ofMinnesota shall apply to all claims or disputes, exclusive of its conflicts of law provisions.

IMPLIED WARRANTY EXCLUSION AND DISCLAIMERTo the fullest extent permitted by law, Arctic Cat excludes and disclaims all implied warranties ofmerchantability and fitness for a particular purpose.

If you are not satisfied with warranty service or repairs, you should contact Arctic Cat at (U.S.) 1-218-681-9851 or (Canada) 1-204-982-1656.

Table of ContentsLimited Warranty .....................Inside Front CoverForeword ............................................................1Declaration of Conformity...................................2Snowmobile Safety Rules ..................................3General Information ......................................4-19Snowmobile Identification.................................. 4Control Locations .............................................. 4Gasoline-Oil....................................................... 5Engine Break-In................................................. 6Drive Belt Break-In ............................................ 6Cold Drive-Away Function (5000)...................... 7Speedometer/Tachometer/Indicator Icons......... 7Diagnostic Codes (5000)................................. 11Handlebar Tilt .................................................. 12Exhaust System .............................................. 13Air-Intake Silencer ........................................... 13Cooling System (5000).................................... 13Battery (Electric Start) ..................................... 13Jump-Starting (5000)....................................... 13Drive Clutch and Driven Clutch ....................... 14Drive Clutch/Driven Clutch Alignment ............. 15Fuel Pump ....................................................... 15Shock Absorbers ............................................. 15Standard-Lug Track ......................................... 15Track Studs...................................................... 15Reverse Operation .......................................... 16Adjustable/Movable Backrest (Bearcat/Lynx2000 LT)......................................................... 17

Removable Rear Seat ..................................... 18Removable Light Bar (Bearcat XT GS) ........... 19Winch (Bearcat XT GS)................................... 19Towing ............................................................. 19

Operating Instructions .................................20-24Starting and Stopping Engine ......................... 20Braking ............................................................ 22Emergency Stopping ....................................... 23Throttle/Ignition Monitor Switch ....................... 23

Varying Altitude Operation...............................24Lubrication.................................................. 25-27Gear Case .......................................................25Front Suspension.............................................26Rear Suspension .............................................27

Maintenance............................................... 28-52Periodic Maintenance Checklist.......................28Fuel System.....................................................29Fuel System.....................................................29Checking Engine Oil Level (5000) ...................30Changing Engine Oil/Filter (5000) ...................30Coolant Level (5000)........................................32Adjusting/Calibrating Carburetors (2000) ........32Spark Plugs .....................................................35Valve Clearance (5000) ...................................36Battery (Electric Start) .....................................36Fuses...............................................................38Brake System ..................................................39Drive Belt .........................................................41Track Tension ...................................................43Track Alignment ...............................................44Suspension......................................................45Lights ...............................................................47Ski Wear Bars ..................................................51Adjusting Ski Stance (Bearcat) ........................51Rail Wear Strips ...............................................51

Performance Tips........................................ 53-55Preparation for Storage .............................. 56-57Preparation after Storage .................................58U.S. EPA Emission Control Statement/Warranty

Coverage (U.S. Only) ....................................59Change of Address, Ownership, or Warranty

Transfer..........................................................61Warranty Procedure/Owner

Responsibility .......................Inside Back Cover

Reference InformationWrite the appropriate information for your Arctic Cat Snowmobile in the spacesbelow.

Always use these numbers when referring to your snowmobile.

Model: _________________________________________________Date of Purchase: ________________________________________Vehicle Identification Number: _______________________________Engine Serial Number: _____________________________________Your Arctic Cat Dealer: ___________________________________Address: _______________________________________________Phone: _________________________________________________

! WARNINGA snowmobile is a very high performance vehicle. Because it does acceleraterapidly and is capable of very high speeds, it should not be operated by a nov-ice or an inexperienced operator. Never accelerate rapidly or drive at high speedbeyond the limits of visibility or without being totally familiar with the terrainand what lies in front of you. Obey speed limits and never operate at speeds thatdo not allow adequate maneuvering and stopping distances. Read and studythe entire Operator’s Manual and Safety Handbook.Failure to follow this warning could result in personal injury to yourself or others.

Personal Injury• To avoid injury to yourself and others, NEVER operate the snowmobile without

first reading and understanding this manual and the Snowmobile Safety Hand-book; then follow the instructions and heed the warnings given.

• USE COMMON SENSE.• DON’T DRINK and DRIVE.• STAY IN CONTROL at ALL TIMES.• TELL YOUR FRIENDS. If you see a friend operating a snowmobile recklessly, at

excessive speeds, while intoxicated, or in other unsafe ways, don’t wait until it istoo late to warn of the consequences of snowmobile misuse. Such conductendangers everyone. TAKE AN ACTIVE ROLE IN THE SAFETY OF YOUR-SELF AND OTHERS.

Parts and AccessoriesWhen in need of replacement parts, oil, or accessories for your Arctic Cat Snowmo-bile, be sure to only use GENUINE ARCTIC CAT PARTS, OIL, AND ACCESSO-RIES. Only genuine Arctic Cat parts, oil, and accessories are engineered to meet thestandards and requirements of your Arctic Cat Snowmobile. For a complete list ofaccessories, refer to the current Arctic Cat Accessory Catalog. To aid in service andmaintenance procedures on these snowmobiles, an Illustrated Parts Manual and aService Manual are available through your local Arctic Cat Snowmobile dealer.

ForewordCongratulations! You have chosen a quality Arctic Cat Snowmobile designed andassembled to give dependable service. Be sure, as the owner/operator of an ArcticCat Snowmobile, to become thoroughly familiar with its basic operation, mainte-nance, and off-season storage procedures. Read this manual and the accompanyingSnowmobile Safety Handbook before operating the snowmobile to learn safe andproper use of your new Arctic Cat Snowmobile. Always operate the snowmobilewithin your level of skill and current terrain conditions.

The Operator’s Manual, Snowmobile Safety Handbook, and Snowmobile Decalsdisplay the words Warning, Caution, and Note to emphasize important information.The symbol ! WARNING identifies personal safety-related information. Besure to follow the directive because it deals with the possibility of serious personalinjury or even death. A CAUTION identifies unsafe practices which may resultin snowmobile-related damage. Follow the directive because it deals with the possi-bility of damaging part or parts of the snowmobile. The symbol NOTE: identi-fies supplementary information worthy of particular attention.

This manual covers operator-related maintenance, operating instructions, and off-season storage instructions. If major repair or service is ever required, contact anauthorized Arctic Cat Snowmobile dealer for professional service.

At the time of publication, all information and illustrations were technically cor-rect. Some illustrations used in this manual are used for clarity purposes only andare not designed to depict actual conditions. Because Arctic Cat Inc. constantlyrefines and improves its products, no retroactive obligation is incurred.

This Operator’s Manual should be considered a permanent part of the snowmobileand must remain with the snowmobile at the time of resale. If the snowmobilechanges ownership more than once, contact Arctic Cat Inc., Service Department,P.O. Box 810, Thief River Falls, MN 56701, for proper registration information.This manual was prepared by the Product Service and Warranty Department ofArctic Cat Inc.

Every Arctic Cat Snowmobile meets or exceeds the standards of the SnowmobileSafety and Certification Committee and displays the SSCC decal. Arctic Cat Inc.endorses and encourages the safe use of all snowmobiles. Always wear a helmetand eye protection. Drive with caution, observe all state and local regulations, andrespect the rights of others. ISMA members like Arctic Cat do their part to improvetrails, sponsor events, and generally support the sport of snowmobiling. As a mem-ber of the National Snowmobile Foundation, Arctic Cat Inc. promotes snowmobil-ing through education, charity, and research programs.

© 2014 Arctic Cat Inc.

Printed in U.S.A.

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Declaration of Conformity

I, the undersigned, hereby declare that the equipment specified above conforms to thedirective(s) and standard(s) as specified.

Brad DarlingVice President/General Manager - Snowmobile Division

Application of council directives:Issued by European Commission.

EMC Directive 2004/108/ECEC Machinery Directive 2006/42/EC

Type of Equipment: SnowmobileModel Numbers:

Brand Name: Arctic Cat

S2015BCDFCUSL S2015BCDWTOSO S2015BCNWGUSO S2015BCNWTUSLS2015BCDWEOSB S2015BCDWTUSL S2015BCNWLOSB S2015LXDFCUSGS2015BCDWEUSB S2015BCDWTUSO S2015BCNWLUSB S2015LXDLTOSBS2015BCDWTOSL S2015BCNWGOSO S2015BCNWTOSL S2015LXDLTUSB

Standards to which conformity is declared:EMC: EN 55012, EN 61000-6-2 MACHINERY: EN 12100:2010Manufacturer (if not issuing agent): Arctic Cat Inc.

601 Brooks Ave. S.Thief River Falls, MN 56701 USA

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Snowmobile Safety Rules

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General InformationSnowmobile IdentificationThe Arctic Cat Snowmobile has twoimportant identification numbers. TheVehicle Identification Number (VIN) isstamped into the tunnel near the right-side footrest. The Engine Serial Number(ESN) is stamped into the crankcase ofthe engine.

0726-383

These numbers are required by the dealerto complete warranty claims properly. Nowarranty will be allowed by Arctic CatInc. if the engine serial number or VIN isremoved or mutilated in any way.

Always provide the snowmobile name,VIN, and ESN when contacting an autho-rized Arctic Cat Snowmobile dealer forparts, service, accessories, or warranty. Ifthe complete engine must be replaced,ask the dealer to notify Arctic Cat forcorrect registration information.

Control LocationsShown are the typical control locationsfor Arctic Cat snowmobiles. Location ofa specific control will vary according tomodel.

0744-441

0745-803

Bearcat 2000 LT/2000 XT/Lynx

Bearcat XT/GS

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0745-804

Gasoline-OilRecommended Gasoline

The recommended gasoline to use in thesesnowmobiles is 87 octane regularunleaded. In many areas, oxygenates areadded to the gasoline. Oxygenated gaso-lines containing up to 10% ethanol areacceptable gasolines; however, on the2000 models whenever using oxygenatedgasolines, the carburetor main jet must beone size larger than the main jet requiredfor regular unleaded gasoline. For exam-ple, if a 220 main jet is recommended forregular unleaded gasoline, a 230 main jetmust be installed if using an oxygenatedgasoline.

When using ethanol blended gasoline, it isnot necessary to add a gasoline antifreezesince ethanol will prevent the accumula-tion of moisture in the fuel system.

Recommended Injection Oil (2000)

The recommended oil to use in the oil-injection system is Arctic Cat Formula 50Injection Oil (p/n 5639-475 - qt) or (p/n5639-476 - gal.). This oil is specially for-mulated to be used either as an injectionoil or as a pre-mix oil (for break-in) andmeets all of the lubrication requirementsof the Arctic Cat snowmobile engine.

Recommended Engine Oil (5000)

The recommended oil to use is C-TEC4Synthetic Oil (p/n 6639-524 - qt) or (p/n6639-525 - gal.).

After the engine break-in period, theengine oil should be changed every 2500-3000 miles and before prolonged storage.

Filling Gas Tank

Since gasoline expands as its temperatureincreases, the gas tank must be filled toits rated capacity only. Expansion roommust be maintained in the tank particu-larly if the tank is filled with cold gaso-line and then moved to a warm area.

Also, if the snowmobile is to remain on atrailer after filling the gas tank, the bed ofthe trailer must be maintained level toprevent gasoline from draining outthrough the gas tank vent hose.

Bearcat XT LTD

CAUTIONDo not use white gas or gasolinescontaining methanol. Only Arctic Catapproved gasoline additives shouldbe used.

CAUTIONAny oil used in place of the recom-mended oil could cause seriousengine damage.

! WARNINGAlways fill the gas tank in a well-venti-lated area. Never add gasoline to thesnowmobile gas tank near any openflames or with the engine running. DONOT SMOKE while filling the gas tank.Do not sit on the snowmobile withoutfirst installing the gas tank cap.

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Break-In Gas/Oil Mixing Instructions (2000)

Before mixing gasoline and oil, make surethe oil is at room temperature (20° C/68°F). Use a U.L. approved 22.7 l (6 U.S. gal.)gasoline container for mixing the gasolineand oil. To properly mix the fuel at a 100:1ratio, use the following procedure:

1. Pour gasoline into the gasoline con-tainer until approximately half full.

2. Pour 236 ml (8 fl oz) of the recom-mended 2-cycle oil into the gasolinecontainer.

3. Install cap on gasoline container andshake the mixture vigorously.

4. Fill the gasoline container with gaso-line; then cap the gasoline containerand shake the mixture vigorously.

5. Using a fine-mesh screened funnel,pour the fuel mixture from the gasolinecontainer into the snowmobile gas tank.

Engine Break-InThe Arctic Cat engine (when new or rebuilt)requires a short break-in period before theengine is subjected to heavy load conditions.

2000

Arctic Cat requires that the first tankfulof fuel be premixed at a 100:1 ratio in alloil-injection models.

During the break-in period, a maximumof 1/2 throttle is recommended; however,brief full-throttle accelerations and varia-tions in driving speeds contribute to goodengine break-in. After one (1) tankfulbreak-in period, the snowmobile may betaken to an authorized Arctic Cat Snow-mobile dealer for a checkup. Thischeckup is at the discretion and theexpense of the snowmobile owner.

5000

This engine does not require any pre-mixed fuel during the break-in period.

To ensure trouble-free operation, carefuladherence to the following break-inguidelines will be beneficial.

* With occasional full-throttle operation.

To ensure proper engine break-in, ArcticCat recommends that the engine oil andfilter be changed after 500 miles. Thisservice is at the discretion and expense ofthe snowmobile owner.

Drive Belt Break-InDrive belts require a break-in period ofapproximately 25 miles. Drive the snow-mobile for 25 miles at 3/4 throttle or less.By revving the engine up and down (butnot exceeding 60 mph), the exposed cordon the side of a new belt will be worndown. This will allow the drive belt togain its optimum flexibility and willextend drive belt life.

NOTE: Before starting the snowmo-bile in extremely cold temperatures, thedrive belt should be removed andwarmed up to room temperature. Oncethe drive belt is at room temperature,install the drive belt (see Drive Belt sub-section in the Maintenance section).

CAUTIONNever mix oil and gasoline in thesnowmobile gas tank.

! WARNINGAlways fill the gas tank in a well-ven-tilated area. Never add gasoline to thesnowmobile gas tank near any openflames or with the engine running. DONOT SMOKE while mixing fuel or fill-ing the gas tank.

CAUTIONDO NOT exceed the one (1) tankful limi-tation of a 100:1 gas/oil break-in mix-ture. Continuous use of a gas/oilmixture, unless consistently operatingin extremely cold conditions (-26°C/-15°F or colder), could cause spark plugfouling and excessive carbon buildup. A100:1 gas/oil mixture must be used inconjunction with the oil-injection sys-tem to ensure adequate engine lubrica-tion in extremely cold conditions.

CAUTIONDO NOT use premixed fuel in thesnowmobile gas tank. Engine dam-age will occur.

0-200 miles 1/2 Throttle (45 MPH-max)

200-400 miles 1/2-3/4 Throttle

400-600 miles 1/2-3/4 Throttle *

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Cold Drive-Away Function (5000)On these models, there is a “cold drive-away” function incorporated within theengine.

NOTE: On models with a StandardGauge when cold-starting theengine, the coolant temperaturewarning icon will illuminate and thereadout screen will display TEMP.With the engine in this temperaturerange, the RPM “limit” of the enginewill be below drive system engage-ment speed. As the engine warms,the TEMP display will go out, thecoolant temperature warning iconwill begin to flash, and the RPM“limit” of the engine will increaseallowing the snowmobile to movewithout full-throttle operation. Whenthe engine reaches proper operatingtemperature, the coolant tempera-ture warning icon will go out.

NOTE: On models with a DeluxeGauge when cold-starting the engine,the coolant temperature warning iconwill illuminate and the TEMP displayon the readout screen will begin toflash. With the engine in this tempera-ture range, the RPM “limit” of theengine will be below drive systemengagement speed. As the enginewarms, the coolant temperature warn-ing icon will begin to flash, the TEMPdisplay will continue to flash, and theRPM “limit” of the engine willincrease allowing the snowmobile tomove without full-throttle operation.When the engine reaches properoperating temperature, the coolanttemperature warning icon and theTEMP display will go out

.

Speedometer/Tachometer/Indicator IconsThese snowmobiles are equipped withdifferent speedometer/tachometer styles.Determine which style your model isequipped with and use the appropriatefollowing information.

Standard Gauge

Certain models are equipped with a stan-dard gauge combination speedometer/tachometer. Indicator icons are incorpo-rated within the speedometer/tachome-ter. Also incorporated into thespeedometer/tachometer is a digital read-out screen.

FZ003C

RPM/MPH (kph)

By pushing the left button once, the RPMand MPH will be displayed (one on thereadout screen and one with the needle).By pushing the button once again, thefunctions will be reversed.

By pushing the left button (with speedbeing displayed) for more than two sec-onds, the display will change betweenstandard mph or metric kph. Release thebutton when desired display appears.

CAUTIONNever run the engine with the drivebelt removed. Excessive revving ofthe engine could result in seriousengine damage and drive clutch fail-ure.

CAUTIONIt is extremely important that theengine is properly warmed up beforesubjecting the engine to high speedoperation or heavy loads. The engineshould be allowed to idle at least 3-4minutes before it is operated at morethan 1/2 throttle. In extremely coldconditions, the warm-up time will belonger. Cold seizure and piston scuff-ing caused by insufficient warm-upwill not be covered by warranty. Also,do not idle the engine for excessivelylong periods of time.

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With RPM displayed on the readout screenby pushing and holding the left button, max-imum RPM will be displayed on the readoutscreen. The maximum RPM readout willreset when the right button is pushed (whilemaximum RPM is displayed).

Odometer/Trip-Meter (1)/Trip-Meter (2)/Hour-Meter/Clock

NOTE: The clock is available onelectric start models only.

By pushing the right button, the readoutscreen will display odometer, trip-meter(1), trip-meter (2), hour-meter, and clock.To reset the trip meter with the trip meterdisplayed, push and hold the right buttonuntil the display is cleared. The hour-meter readout will not reset.

Clock (Electric Start)

With the clock selected on the readoutscreen by pushing and holding the right but-ton for two seconds, the option of selectingthe 12-hour or 24-hour clock is available.Push the left button for 12-hour display;push the right button for 24-hour display. Atthis point, the hours and minutes will beginto flash. Push the left button to change thehour display; push the right button to changethe minute display (either tap the buttons forindividual number display or push and holdthe buttons for rapid number display).

NOTE: During clock setting if nei-ther button (left, right) is pushedwithin a 5-second time period, theclock-setting mode will be exitedwith changes saved.

A. Low Oil Warning Icon (2000)

This icon is designed to alert the snowmo-bile operator when the oil in the oil injec-tion reservoir gets below a prescribedlevel; however, it is highly recommendedthat a visual verification of the oil level inthe reservoir be done prior to operating thesnowmobile. Once the Low Oil WarningIcon illuminates during operation of thesnowmobile, the operator must periodi-cally monitor the level of oil in the reser-voir and must fill the reservoir the nexttime gasoline is added to the gas tank.

The “alert level” of the Low Oil WarningIcon is approximately equal to 1 tankful ofgasoline under normal operating condi-tions.

A. Oil Pressure Warning Icon (5000)

This icon indicates engine oil pressure,not the oil level; however, if the oil levelis low, it may affect oil pressure.

The icon should illuminate each time theignition switch is turned to RUN orSTART, and it should go out when theengine starts. If the icon illuminateswhile the engine is running, oil pressurehas been lost and the engine will auto-matically shut off.

If oil pressure is lost, check the oil level(see page 30).

If the warning icon does not go out or ifthe engine does not start, take the snow-mobile to an authorized Arctic Cat Snow-mobile dealer. If not under warranty, thisservice is at the discretion and expense ofthe snowmobile owner.

B. Coolant Temperature Warning Icon (5000)

NOTE: When cold-starting theengine, the coolant temperaturewarning icon will illuminate, the read-out screen will display TEMP, andengine RPM limit will be below drivesystem engagement speed.

When the engine reaches proper operat-ing temperature, the coolant temperaturewarning icon and TEMP display willcease to flash.

If the coolant temperature rises too farabove proper operating temperature, thecoolant temperature warning icon willflash a warning (alert) and the engine will“surge” to alert the operator. If the cool-ant temperature rises to a critical pointabove proper operating temperature, thecoolant temperature warning icon willcease flashing and will remain constantlyilluminated.

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NOTE: If the coolant temperatureicon is constantly on, the engine willshut off if vehicle speed is reducedto 1.5 kph (0.9 MPH) or slower.

C. Low Fuel Indicator

The indicator illuminates whenever thegas in the gas tank is low.

D. Fuel Level Display

This bar display shows the approximateamount of gas remaining in the gas tank.

E. Service Icon

On electric start models, the icon shouldilluminate each time the key is turned toRUN or START, and it should go outwhen the engine starts. If the icon staysilluminated (on electric start models) or itilluminates while the engine is running,the system is receiving input that is out-side of its established parameters. If theicon illuminates indicating an error, takethe snowmobile to an authorized ArcticCat Snowmobile dealer for service. If notunder warranty, this service is at the dis-cretion and expense of the snowmobileowner.

F. High Beam Indicator

The indicator is on whenever the highbeam mode is selected by the headlightswitch.

G. Charging System Warning Icon (5000)

This icon is designed to warn the operatorif the battery charging system is not func-tioning. The icon should illuminate eachtime the key is turned to RUN or START,and it should go out when the enginestarts. If the icon stays illuminated or itilluminates while the engine is running,the battery is not being charged, and thesnowmobile is running on battery reservepower only.

If the Charging System Warning Iconilluminates, you should, as soon as possi-ble, take the snowmobile to an authorizedArctic Cat Snowmobile dealer for ser-vice. If not under warranty, this service isat the discretion and expense of thesnowmobile owner. The engine WILLNOT RUN without battery power.

Deluxe Gauge

Certain models are equipped with adeluxe gauge combination speedometer/tachometer. Indicator icons are incorpo-rated within the speedometer/tachome-ter. Also incorporated into thespeedometer/tachometer is a digital read-out screen.

FZ001F

RPM/MPH (kph)

By pushing the increment button once,the RPM and MPH will be displayed(one on the readout screen and one withthe needle). By pushing the button onceagain, the functions will be reversed.

By pushing the increment button (withspeed being displayed) for more than twoseconds, the display will change betweenstandard mph or metric kph.

CAUTIONAt this point, take precautionary mea-sures such as changing to loosesnow terrain, shutting the engine off(allowing the engine to cool down),and checking coolant level. If unableto either determine or remedy theproblem, take the snowmobile to anauthorized Arctic Cat Snowmobiledealer for service. If not under war-ranty, this service is at the discretionand expense of the snowmobileowner.

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With RPM displayed on the readoutscreen by pushing and holding the incre-ment button, maximum RPM will be dis-played on the readout screen. Themaximum RPM readout will reset whenthe decrement button is pushed (whilemaximum RPM is displayed).

Odometer/Trip-Meter (1)/Trip-Meter (2)/Hour-Meter

By pushing the decrement button, thereadout screen will display odometer,trip-meter (1), trip-meter (2), and hour-meter. To reset the trip meter with the tripmeter displayed, push and hold the decre-ment button until the display is cleared.The hour-meter readout will not reset.

Clock/Altimeter

By pushing the select button, the readoutscreen will display clock, altimeter, andmaximum altimeter.

To set the clock, select clock on the dis-play by pushing and holding the selectbutton for two seconds; the option ofselecting the 12-hour or 24-hour clockmode is available. Push the incrementbutton to toggle between the 12-hour dis-play and the 24-hour display. Whendesired mode is displayed, push theselect button.

At this point, the hours display will beginto flash. Push the increment button toincrease the hours; push the decrementbutton to decrease the hours. Pushing andholding a button will accelerate the num-ber display. When desired hour number isdisplayed, push the select button.

At this point, the minutes display willbegin to flash. Push the increment buttonto increase the minutes; push the decre-ment button to decrease the minutes.Pushing and holding a button will accel-erate the number display. When desiredminute number is displayed, push theselect button.

NOTE: During clock setting if nobutton (increment, decrement,select) is pushed within a 5-secondtime period, the clock-setting modewill be exited with changes saved.

NOTE: The altimeter readout isbased off barometric pressure andmay require calibration as weatherconditions change.

To set/calibrate the altimeter to an estab-lished altitude with altimeter selected onthe display screen by pushing and hold-ing the select button for a minimum oftwo seconds, the acronym CAL will bedisplayed on the readout screen for onesecond; then the altitude value will flash.Push the increment button to increase thedisplayed altitude; push the decrementbutton to decrease the displayed altitude.Pushing and holding a button will accel-erate the number display.

NOTE: If MPH has been selected inthe speed readout, the altitude valuewill be displayed in feet. If kph hasbeen selected in the speed readout,the altitude value will be displayed inmeters.

To reset the maximum altimeter readoutwith the maximum altimeter displayed,push and hold the select button for a min-imum of two seconds.

A. High Beam Indicator

The indicator is on whenever the high beammode is selected by the headlight switch.

B. Oil Pressure Warning Icon (5000)

This icon indicates engine oil pressure,not the oil level; however, if the oil levelis low, it may affect oil pressure.

The icon should illuminate each time theignition switch is turned to RUN or START,and it should go out when the engine starts.If the icon illuminates while the engine isrunning, oil pressure has been lost and theengine will automatically shut off.

If oil pressure is lost, check the oil level(see page 30).

If the warning icon does not go out or ifthe engine does not start, take the snow-mobile to an authorized Arctic Cat Snow-mobile dealer. If not under warranty, thisservice is at the discretion and expense ofthe snowmobile owner.

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C. Coolant Temperature Warning Icon (5000)

NOTE: When cold-starting theengine, the coolant temperaturewarning icon will illuminate, thereadout screen will display TEMP,and engine RPM limit will be belowdrive system engagement speed.

When the engine reaches proper operat-ing temperature, the coolant temperaturewarning icon and TEMP display willcease to flash.

If the coolant temperature rises too farabove proper operating temperature, thecoolant temperature warning icon will flasha warning (alert) the engine will “surge” toalert the operator. If the coolant temperaturerises to a critical point above proper operat-ing temperature, the coolant temperaturewarning icon will cease flashing and willremain constantly illuminated.

NOTE: If the coolant temperatureicon is constantly on, the engine willshut off if vehicle speed is reducedto 1.5 kph (0.9 MPH) or slower.

D. Service Icon

On electric start models, the icon shouldilluminate each time the key is turned toRUN or START, and it should go outwhen the engine starts. If the icon staysilluminated (on electric start models) or itilluminates while the engine is running,the system is receiving input that is out-side of its established parameters. If theicon illuminates indicating an error, takethe snowmobile to an authorized ArcticCat Snowmobile dealer for service. If notunder warranty, this service is at the dis-cretion and expense of the snowmobileowner.

E. Charging System Warning Icon (5000)

This icon is designed to warn the operatorif the battery charging system is not func-tioning. The icon should illuminate eachtime the key is turned to RUN or START,and it should go out when the engine starts.If the icon stays illuminated or it illumi-nates while the engine is running, the bat-tery is not being charged, and thesnowmobile is running on battery reservepower only.

If the Charging System Warning Iconilluminates, you should, as soon as possi-ble, take the snowmobile to an authorizedArctic Cat Snowmobile dealer for ser-vice. If not under warranty, this service isat the discretion and expense of thesnowmobile owner. The engine WILLNOT RUN without battery power.

Diagnostic Codes (5000)Diagnostic codes are activated by theECM and may be displayed on the read-out screen for a number of reasons. If acode is displayed while the engine is run-ning, the ECM is receiving input that isoutside of its established parameters.

If a code has been activated, take thesnowmobile to an authorized Arctic CatSnowmobile dealer for service. If notunder warranty, this service is at the dis-cretion and expense of the snowmobileowner.

CAUTIONAt this point, take precautionary mea-sures such as changing to loose snowterrain, shutting the engine off (allow-ing the engine to cool down), andchecking coolant level. If unable toeither determine or remedy the prob-lem, take the snowmobile to an autho-rized Arctic Cat Snowmobile dealer forservice. If not under warranty, this ser-vice is at the discretion and expense ofthe snowmobile owner.

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Handlebar TiltStandard Block Style

The handlebar can be adjusted to theoperator’s preference. To adjust the han-dlebar, use the following procedure:

NOTE: It may be necessary toremove the handlebar cover for thisprocedure.

1. Loosen the four lock nuts securingthe handlebar caps and block to thesteering post.

743-442A

2. Adjust the handlebar to operator’sdesired tilt; then tighten the locknuts evenly and securely. Checksteering for maximum right/leftturning capabilities.

NOTE: Do not adjust the handlebarto a position that allows air to enterthe brake system.

3. Tighten the lock nuts to 18 ft-lb.

Riser Block Style

The handlebar can be adjusted to theoperator’s preference. To adjust the han-dlebar, use the following procedure:

1. Loosen the four cap screws and locknuts securing the handlebar caps to theriser and the riser to the steering post.

744-439A

2. Adjust the handlebar to operator’sdesired position, tighten the capscrews evenly to 25 ft-lb, and checksteering for maximum right/leftturning capabilities.

NOTE: Do not rotate the handlebarto a position that allows air to enterthe brake system.

Code Trouble1 Failure in the fuel system.2 Failure in injector (PTO).3 Failure in injector (MAG).4 Failure in barometric pressure sensor.5 Open or short circuit in intake manifold

air temperature sensor.6 Open or short circuit in water tempera-

ture sensor.7 Open or short circuit in throttle position

sensor.8 Open or short circuit in manifold air

pressure sensor.9 Failure in crankshaft position sensor.

11 Failure in speed sensor.12 Failure in coil (MAG).13 Failure in coil (PTO).14 Failure in ISC valve.15 Failure in oxygen sensor.19 Failure in camshaft position sensor.25 Failure in shifting system/gear position

switch.26 Malfunction in air pressure sensor.29 Malfunction in shift control switch.

! WARNINGTighten lock nuts according to specifi-cations to prevent unexpected “move-ment” of the handlebar during operationover rough terrain. DO NOT positionhandlebar so steering (maximum right/left turning capabilities) or throttle andbrake controls are affected.

! WARNINGTighten lock nuts/cap screws accord-ing to specifications to prevent unex-pected “movement” of the handlebarduring operation over rough terrain.DO NOT position the handlebar sosteering (maximum right/left turningcapabilities) or throttle and brakecontrols are affected.

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Exhaust SystemThe exhaust system is designed to reducenoise and to improve the total perfor-mance of the engine. If any exhaust sys-tem component is removed from theengine and the engine is run, severeengine damage will result.

Air-Intake SilencerUsed in conjunction with the fuel intakesystem is a specially designed air-intakesilencer. The purpose of the silencer is toquiet the intake of fresh air. Since the fuelintake system is calibrated with the air-intake silencer in place, the engine mustnever be run with the silencer removed.Performance will not be improved if theair-intake silencer is removed. In con-trast, severe engine damage will occur.

Cooling System (5000)These snowmobiles are equipped with aclosed liquid cooling system for enginecooling. The cooling system should beinspected daily for leakage and damage.Also, the coolant level should be checkeddaily. If leakage or damage is detected,take the snowmobile to an authorizedArctic Cat Snowmobile dealer for ser-vice. If not under warranty, this service isat the discretion and expense of thesnowmobile owner.

Battery(Electric Start)It is extremely important that the batterybe maintained at full charge at all timesand that the battery connections be cleanand tight. If charging the battery becomesnecessary, refer to Battery sub-section inthe Maintenance section.

Jump-Starting (5000)NOTE: Arctic Cat does not recom-mend jump-starting a snowmobilewith a dead battery but rather toremove the battery, service it, andcorrectly charge it; however, in anemergency, it may be necessary tojump-start a snowmobile. If so, usethe following procedure to carefullyand safely complete this procedure.

1. On the snowmobile to be jump-started,slide any terminal boots away.

2. Inspect the battery for any signs ofelectrolyte leaks, loose terminals, orbulging sides. Leaking or bulgingbattery cases may indicate a frozenor shorted battery.

3. Inspect the vehicle to be used forjump-starting to determine if voltageand ground polarity are compatible.The vehicle must have a 12-volt DC,negative ground electrical system.

CAUTIONThese snowmobiles are not designedto be operated in dusty conditions.Operating the snowmobile in dustyconditions will result in severeengine damage.

CAUTIONOn the 5000, always turn the ignitionswitch key to the OFF position whenthe snowmobile is not being used.Leaving the ignition switch in the ONposition will result in discharging thebattery and possible damage to thebattery.

! WARNINGImproper handling or connecting of abattery may result in severe injuryincluding acid burns, electrical burns, orblindness as a result of an explosion.Always remove rings and watches.

! WARNINGAny time service is performed on a bat-tery, the following must be observed:keep sparks, open flame, cigarettes, orany other flame away. Always wearsafety glasses. Protect skin and cloth-ing when handling a battery. When ser-vicing a battery in an enclosed space,keep the area well-ventilated.

! WARNINGIf any of these conditions exist, DONOT attempt to jump-start, boost, orcharge the battery. An explosioncould occur causing serious injury.

CAUTIONAlways make sure the electrical sys-tems are of the same voltage andground polarity prior to connectingjumper cables. If not, severe electricaldamage may occur.

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4. Move the vehicle to be used for thejump-start close enough to ensurethe jumper cables easily reach; thenset and lock the brakes, shut off allelectrical accessories, and turn theignition switch OFF.

NOTE: Make sure all switches onthe snowmobile to be jump-startedare turned OFF.

5. Disconnect all external accessoriessuch as cell phones, GPS units, andradios on both vehicles.

6. Attach one clamp of the positive(red) cable to the positive (+) termi-nal (1) of the dead battery (C) beingcareful not to touch any metal withthe other clamp; then attach theother clamp of the positive (red)cable to the positive (+) terminal (2)of the good battery (B).

0744-527

NOTE: Some jumper cables may bethe same color but the clamps or endswill be color-coded red and black.

7. Attach one clamp of the negativejumper cable (black) to the negative (-)terminal (3) of good battery (B); thenattach the other clamp of the negative(black) jumper cable (4) to an unpaintedmetal surface (A) on the engine orframe well away from the dead batteryand fuel system components.

8. Stand well away from the dead bat-tery and start the vehicle with thegood battery. Allow the vehicle torun for several minutes applyingsome charge to the dead battery.

9. Start the snowmobile with the deadbattery and allow it to run for severalminutes before disconnecting thejumper cables.

10. Remove the jumper cables in oppo-site order of hook-up (4, 3, 2, 1). Becareful not to short cables againstbare metal.

NOTE: Have the battery and elec-trical system checked prior to oper-ating the snowmobile again.

Drive Clutch and Driven ClutchThe drive clutch and driven clutch do notrequire lubrication; therefore, no specialmaintenance is required by the snowmo-bile owner except for periodical cleaning(see the Periodic Maintenance Checklistin the Maintenance section).

However, the drive clutch and drivenclutch should be disassembled, cleaned,and inspected by an authorized ArcticCat Snowmobile dealer after every 800miles of operation or at the end of thesnowmobiling season whichever occursfirst. This service is at the discretion andexpense of the snowmobile owner.

CAUTIONFailure to disconnect electronicaccessories during jump-startingmay cause system damage due topower spikes.

! WARNINGNever make the final connection to a bat-tery as a spark could ignite hydrogengases causing an explosion of the bat-tery resulting in acid burns or blindness.

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When operating the snowmobile at highaltitudes, it may be necessary to changecertain component parts of the driveclutch and/or the driven clutch. See anauthorized Arctic Cat Snowmobile dealerfor further information.

Drive Clutch/Driven Clutch AlignmentThe parallelism and the offset between thedrive clutch and driven clutch are set at thefactory. Normally, no adjustment is neces-sary as long as neither the drive clutch northe driven clutch is removed or disassem-bled. However, if premature drive belt wearis experienced or if the drive belt turns over,the drive clutch/driven clutch alignmentmust be checked. Take the snowmobile toan authorized Arctic Cat Snowmobiledealer for this service. If not under war-ranty, this service is at the discretion andexpense of the snowmobile owner.

Fuel PumpThe fuel pump is designed to provide ade-quate amount of gas to the carburetors(2000) or to the injectors (5000) at all throt-tle settings. If a fuel delivery problem is sus-pected, take the snowmobile to anauthorized Arctic Cat Snowmobile dealer. Ifnot under warranty, this service is at the dis-cretion and expense of the snowmobileowner.

Shock AbsorbersEach shock absorber should be visiblychecked weekly for fluid leakage, cracks orbreaks in the lower case, or a bent plunger.If any one of these conditions is detected,replacement is necessary. Take the snow-mobile to an authorized Arctic Cat Snow-mobile dealer for this service. If not underwarranty, this service is at the discretion andexpense of the snowmobile owner.

NOTE: When the snowmobile isoperated in extremely cold weather (-23° C/-10° F or colder), a smallamount of leakage may be present.Unless the leakage is excessive,replacement is not necessary.

Standard-Lug TrackAccelerated wear strip wear caused byoperating on ice or hard-packed snowconditions is NOT covered under ArcticCat Inc. warranty policy.

Track Studs NOTE: Stud or hooker plate installa-tion will void track and tunnel warranty.

NOTE: Arctic Cat does not recom-mend studding a track with a 1.5inch lug or greater.

NOTE: Stud installation can be per-formed by the snowmobile owner ifqualified to do so. If the owner doesnot feel qualified, take the snowmo-bile to an authorized Arctic Cat Snow-mobile dealer for this service. Thisservice is at the discretion andexpense of the snowmobile owner.

CAUTIONDO NOT attempt to service the driveclutch and driven clutch. The driveclutch and driven clutch must be ser-viced by an authorized Arctic CatSnowmobile dealer only.

CAUTIONIf installing studs on a Bearcat 2000LT with a single-ply track, studs witha head diameter of at least 28.6 mm(1.125 in.) must be used.

! WARNINGWhen installing studs on a single-plytrack, it is important to use Arctic Cat-approved studs (proper head diame-ter). If approved studs (proper headdiameter) are not used, studs couldtear free of the track causing possibleinjury or even death. Consult anauthorized Arctic Cat Snowmobiledealer for information.

CAUTIONIf installing studs, a Short Snowflap(p/n 5639-232) must be installed orcomponent damage will occur.

CAUTIONTo prevent tunnel damage from thestuds, Tunnel Protector Kit (p/n 4639-771) for the Bearcat 2000 LT/Lynx or(p/n 5639-143) for the Bearcat 5000 XTmust be installed.

15

For proper installation, use the followingprocedure:

1. Using the appropriate stud template(see chart), mark the desired studpattern to be used.

2. Using the proper-sized stud holedrill bit, drill out the stud holes.

3. Push the stud through the hole frominside the track; then place thedomed support plate and lock nut onthe exposed stud.

4. Using a wrench to secure the stud,tighten the lock nut on the exposed stud.

It is also recommended that wheneverstuds are installed on a track, carbidewear bars should be installed on the skis.Carbide wear bars complement the trackstuds to balance steering control underthese conditions. The length of the car-bide on the wear bars should be propor-tionate to the number of track studs (i.e.small number of track studs — shortlength of carbide...many track studs —long length of carbide). The proper pro-portion between the number of studs andcarbide length on the wear bar will main-tain steering balance.

Reverse OperationThe engine reverse function offers theoperator the convenience of being able toback up the snowmobile rather than havingto turn the snowmobile around by hand.This feature, under most situations, shouldnot be used to free a stuck snowmobile asit will tend to dig the skis deeper into thesnow. Always use minimal speed whenoperating in reverse and come to a com-plete stop before shifting from either for-ward to reverse or reverse to forward.

Shifting Into Reverse

741-438A

NOTE: Correct drive belt tension(deflection) is important for thereverse function to operate properly. Ifthe belt is too tight, difficulty inengaging reverse will be experienced.

1. Always warm up the engine for 2-3minutes prior to shifting into reverse.

2. Shift only with the engine at idleRPM and the snowmobile com-pletely stopped. The reverse func-tion will not engage if engine isabove idle RPM.

NOTE: The system will not shiftuntil the button is released.

Stud Template ChartModel p/n

Bearcat 2000 LT 5639-461Bearcat XT 5639-609

Lynx 2000 LT 5639-160

! WARNINGAlways balance the snowmobile withthe proper proportion between thenumber of studs and carbide lengthon the wear bars. Do not “over drive”conditions; use common sense in alloperating conditions.

CAUTIONDo not use studs that are more than9.525 mm (0.375 in.) longer than thetrack lug height.

! WARNINGDo not operate a snowmobile withloose studs as they may be thrownfrom the track. Always use a shieldedsafety stand whenever performingany maintenance or adjustments.

! WARNINGDO NOT stand behind the snowmo-bile or near the rotating track. NEVERrun the track at high speed when thetrack is suspended.

16

3. On the Bearcat 5000 XT if attemptingto shift into reverse at too high engineRPM (above idle RPM), the reversefunction will be cancelled and thecoolant temperature warning icon willflash. This indicates the reverseswitch button was pressed at too highRPM. The operator must reduceengine RPM below 4000 and pressthe button a second time.

Operating in Reverse

1. When reverse is engaged, a reverse iconwill illuminate in the speedometer/tachometer and a reverse alarm sounds.

2. On the 2000 models, the reversefunction will cancel if operated inreverse longer than 45 seconds.Whenever the reverse function hasbeen cancelled, the engine must berun in the forward mode for a mini-mum of 60 seconds at 2000 RPMbefore the reverse function can beused again.

NOTE: While operating in reverse, a“rev-limiter” will activate at 6000 RPM.

3. To shift into forward, stop the snow-mobile and allow the engine to idle(under 3000 RPM); then press thereverse button and release. The for-ward selection will be complete.

4. After shifting from reverse to for-ward (or from forward to reverse),apply the throttle slowly and evenlyto allow the driven clutch to engageproperly.

5. The reverse function is cancelledwhenever the engine is shut off.

NOTE: An alarm will sound whenthe snowmobile is operated inreverse.

Adjustable/Movable Backrest (Bearcat/Lynx 2000 LT)The backrest is designed for maximumcomfort and safety. When riding double,the backrest must be in the passenger seatposition.

To change the height of the backrest,loosen the adjuster screw, move the back-rest up or down to the desired position,and tighten the adjuster screw to lock thebackrest in place.

744-610A

When riding single, the backrest can bemoved to the forward seat position.

To move the backrest, loosen, but do notremove, the cap screw at the rear of seat,install/adjust the passenger seat, andtighten the cap screw securely.

CAUTIONNever shift into reverse while thesnowmobile is moving forward as it ishard on the driven clutch torquebracket and the cam rollers.

CAUTIONNever engage the electric starter orpull the recoil starter rope when theengine is running or when operatingin reverse. Damage to the engine and/or either the electric start or recoilstart system will occur.

! WARNINGDo not use high speed when backingup. Control could be lost and injurycould occur.

CAUTIONDo not use high speed when backingup. Damage to the drive belt anddriven clutch components may occur.

CAUTIONAfter reversing in deep powder snowconditions, make sure the snowflapdoes not become “caught up” in thetrack. Track and/or snowflap damagemay occur.

! WARNINGMoving the backrest to the forwardseat position limits the seatingcapacity to one person only.

17

NOTE: If moving the backrest tothe forward seat position, the pas-senger seat must be removed.

Removable Rear SeatBearcat 2000 LT/Lynx 2000 LT

These snowmobiles are equipped with aremovable rear seat to allow for addi-tional cargo space when no passenger isbeing carried.

NOTE: If additional cargo is beingadded, maximum weight on the snow-mobile (operator/passenger/cargo)should not exceed the maximum limi-tation set for each snowmobile. Seethe chart in the Suspension - Over-load Springs sub-section in the Main-tenance section for details. Also, theoverload springs should be engaged.

To remove the rear seat, rotate the seatlatch either clockwise or counterclock-wise and hold it in that position; then liftand remove the seat from the tunnel.

742-593B

To install the seat, use the following pro-cedure:

1. Place the seat into position on thetunnel.

2. Rotate the seat latch either clock-wise or counterclockwise and hold itin that position; then slide the seatforward, allow it to settle into posi-tion, and release the latch to lock theseat securely.

Bearcat XT

These snowmobiles are equipped with aremovable rear seat (and on the LTD, aremovable third seat) to allow for addi-tional cargo space when no passenger isbeing carried.

NOTE: If additional cargo is beingadded, maximum weight on thesnowmobile (operator/passenger/cargo) should not exceed the maxi-mum limitation set for each snowmo-bile. See the chart in the Suspension- Overload Springs sub-section inthe Maintenance section for details.Also, the overload springs should beengaged.

To remove the rear seat (and third seat onthe LTD), use the following procedure:

1. Remove the four pins securing the rearseat to the seat/Speedrack mount.

743-329A

NOTE: On the LTD, also remove thetwo pins securing the third seat to theseat/Speedrack mount; then lift thethird seat up and away.

0745-131

2. Lift on the back of the rear seat andmove it rearward to remove it fromthe mount.

To install the rear seat (and on the LTD, thethird seat), use the following procedure:

! WARNINGMake sure the rear seat is securelylocked in place before carrying a pas-senger or personal injury may result.

18

1. Place the rear seat into position onthe mount making sure the four pinholes are properly aligned with themounting location on mount.

2. Install the four pins making surethey are properly seated.

NOTE: On the LTD, place the thirdseat into position on the mount mak-ing sure the two pin holes are prop-erly aligned with the mountinglocation on the mount; then installthe two pins making sure they areproperly seated.

Removable Light Bar (Bearcat XT GS)This snowmobile is equipped with aremovable light bar. To remove andinstall, use the following procedure.

1. Disconnect the light bar harnessconnector; then remove the four pinssecuring the bar to the mount.

0745-805

2. Remove the light bar.

3. Place the light bar into position on themount; then secure with the four pins.

4. Connect the light bar harness con-nector.

Winch (Bearcat XT GS)This snowmobile is equipped with awinch. There are two mounting locations.The front mounting location is for actualuse of the winch (see the winch guide)and should not remain in this locationwhen operating the snowmobile. Thetunnel mounting location is for “storing”the winch when not in use and shouldremain in this location when operatingthe snowmobile.

To relocate the winch, use the followingprocedure.

1. Remove the receiver pin and the hair-pin clip securing the winch.

0745-806

2. Place the winch in the desired posi-tion; then secure it with the hairpinclip and the receiver pin.

NOTE: When operating the snow-mobile, always have the winch in thetunnel mounting location securedwith the hairpin clip and the receiverpin.

TowingIf the snowmobile is to be towed byanother snowmobile, do not tow usingthe loops in the skis. The tow rope shouldbe attached to the spindles.

! WARNINGMake sure the rear seat (and on theLTD, the third seat) is securely lockedin place with the pins before carryinga passenger or personal injury mayresult.

19

Operating InstructionsStarting and Stopping EngineIt is imperative that the brake system bechecked for wear and proper operation andthat all safety checks found in the accompa-nying Snowmobile Safety Handbook beperformed before attempting to start theengine. Also, on the 2000 models, be surethe correct carburetor main jets for theoperating temperature, altitude, and gas-oline are being used. After the engine hasbeen started, check the headlights (high andlow beam), taillight, and brakelight to besure they are working properly and adjustedcorrectly. Make sure all lights are clean toprovide maximum illumination. The head-light and taillight must be clean and must beilluminated whenever the engine is running.

1. Test the operation of the brake systemby compressing the brake lever. Thebrake lever must feel firm when com-pressed; then while holding the brakelever in the compressed position, mea-sure the distance between the brakelever and the handlebar. The distancemust be greater than 2.54 cm (1 in.).

741-328C

2. Check the fluid level in the reservoir.The brake fluid level must be visiblein the sight glass. Add Arctic Catapproved brake fluid as necessary.

NOTE: If the sight glass appearsdark, there is a sufficient amount offluid in the reservoir.

3. Test the throttle control lever bycompletely compressing and releas-ing it several times. The leverMUST return to the idle positionquickly and completely.

4. Move the emergency stop switch tothe UP or RUN position.

5. Insert key into ignition switch; thenrotate key to the RUN position.

6. On the 2000 models for a coldengine, move the choke lever to thefull-choke position. If the engine iswarm, choking is normally not nec-essary.

0725-001

NOTE: On the 2000 models whenthe engine is being started with aidof the choke, DO NOT COMPRESSTHE THROTTLE CONTROL LEVER. Ifthe throttle control lever is com-pressed, the engine will not startbecause the gas/air mixture will betoo lean. To start a warm engine,however, the throttle control levermay have to be compressed slightly.

NOTE: On the 5000 models when acold engine is being started, DO NOTCOMPRESS THE THROTTLE CON-TROL LEVER. If the throttle controllever is compressed, the engine willnot start because the fuel/air mixturewill be too lean.

7. On the 2000 models if using the recoil,pull the recoil handle slowly until resis-tance is felt; then give a short quickpull. Repeat until the engine starts.

! WARNINGDo not start the engine if the brake sys-tem is not functioning properly. Servicethe brake system or have it properlyrepaired prior to operating the snowmo-bile. Serious personal injury or evendeath may occur if the brake system isnot operating properly.

CAUTIONOn the 5000 models, always checkthe coolant level before starting theengine.

20

NOTE: In extremely cold weather, pullthe recoil handle slowly two to threetimes to begin the starting procedure.

NOTE: Rotate the key to theSTART position; then when theengine starts, release the key.

8. On the 2000 models when the enginestarts, allow it to warm up for approxi-mately 30 seconds with the choke leverin full-choke position. After the 30-sec-ond warm-up, move the choke lever tothe middle position. The choke levershould be moved to the OFF positionwhen engine is warm. Slight throttlecontrol lever compression may be nec-essary after the engine starts and duringwarm-up. Idle the engine several min-utes until the engine has reached nor-mal operating temperature.

9. On the 5000 models, a “cold drive-away” function is incorporatedwithin the engine. This function isactive until the engine reaches oper-ating temperature.

10. Flooding — On the 2000 models if theengine does not start when the choke isbeing used but seems ready to start,move the choke lever to the OFF posi-tion. Engage the brake lever lock; thencompress the throttle control lever fullyand try to start the engine. When theengine starts, release the throttle con-trol lever immediately. After the warm-up, release the brake lever lock.

NOTE: Continued choking willcause the engine to flood more.

NOTE: On the 2000 models if theengine fails to start during the attemptwith the throttle control lever com-pressed, remove the spark plugs andclean and dry them thoroughly orinstall a new set of properly gapped,recommended spark plugs.

11. Flooding — On the 5000 models ifthe engine does not start but seemsready to start, engage the brake leverlock; then compress the throttle con-trol lever fully and try to start theengine. When the engine starts,release the throttle control leverimmediately. After the warm-up,release the brake lever lock.

NOTE: On the 5000 models if sparkplugs must be replaced, take thesnowmobile to an authorized ArcticCat Snowmobile dealer for inspec-tion and service. This service is atthe discretion and expense of thesnowmobile owner.

12. To shut off the engine, turn the igni-tion key to the OFF position or pushthe emergency stop switch to theDOWN position.

CAUTIONTo avoid damaging the recoil starter, DONOT pull the recoil rope to its limit orrelease the recoil handle from anextended position. Allow the rope torewind slowly.

CAUTIONDo not continuously run the starterfor more than 5 seconds at a time.

CAUTIONIt is extremely important that the engineis properly warmed up before subject-ing the engine to high speed operationor heavy loads. The engine should beallowed to idle at least 3-4 minutesbefore it is operated at more than 1/2throttle. In extremely cold conditions,the warm-up time will be longer. Coldseizure and piston scuffing caused byinsufficient warm-up will not be coveredby warranty. Also, do not idle the enginefor excessively long periods of time.

CAUTIONOn the 5000 models, always turn theignition switch key to the OFF posi-tion when the snowmobile is notbeing used. Leaving the ignitionswitch in the ON position will result indischarging the battery and possibledamage to the battery.

21

BrakingThe following items are items that theoperator must be familiar with whenoperating this snowmobile and itshydraulic brake system. Important addi-tional information on the proper mainte-nance of the brake system is found in theMaintenance section.

1. Use the brakes wisely. Each time thebrakes are applied in all hydraulicbrake systems (including automotiveapplications), heat is transferred to thebrake fluid. The amount of heat trans-ferred during high speed stops and/orrepetitive use may be high enough toboil the brake fluid and cause thebrakes to either fade or may cause anunexpected loss of brakes.

If this occurs, the brake fluid requiresa cool-down period before the brakeswill again function properly. Thiscool-down period will vary dependingupon the ambient air temperature andthe temperature of the brake fluid. Ifloss of brakes has occurred because ofhigh fluid temperatures, do not oper-ate the snowmobile until the cool-down period has expired and brakelever firmness has returned.

2. Be sure to maintain the brake fluid atthe proper level and take care not toget any moisture in the system asmoisture in the brake fluid lowers theboiling point. If the brake fluid is everboiled (by high speed stops or repeti-tive use) or if moisture is allowed toenter the system, it must be changed.Never substitute or mix different typesor grades of brake fluid.

3. Never ride the brake. Even main-taining minimal pressure on thebrake lever will cause the brake padsto drag on the disc and may overheatthe brake fluid.

4. The brake lever lock is not a parkingbrake and should not be applied forperiods exceeding 5 minutes.NEVER OPERATE THE SNOW-MOBILE WITH THE BRAKELEVER LOCK ENGAGED.

5. Pumping the brake lever is permissi-ble; however, if pumping the brakelever more than twice is necessary toobtain the necessary stopping power,immediately take the snowmobile toan authorized Arctic Cat Snowmo-bile dealer for service. If not underwarranty, this service is at the discre-tion and expense of the snowmobileowner.

6. When new brake pads are installed, a“burnishing” process is required. Drivethe snowmobile slowly and compressthe brake lever several times until thepads just start to heat up; then allowthem to thoroughly cool down. Thisprocess stabilizes the pad material andextends the life of the pads.

! WARNINGExcessive, repetitive use of thehydraulic brake for high speed stopswill cause overheating of the brakefluid and premature brake pad wearwhich will result in an unexpectedloss of brakes.

! WARNINGUse only Arctic Cat approved DOT 4brake fluid. Never substitute or mixdifferent types or grades of brakefluid. Brake loss can result. Checkbrake fluid level and pad wear beforeeach use. Brake loss can result insevere injury or even death.

! WARNINGThe brake lever lock is not a parkingbrake and should not be applied forperiods exceeding 5 minutes. Thebrake lever lock maintains the brakelever in the compressed position andmaintains pressure against the brakedisc; however, after a period of time,the pressure applied to the brake discmay relax below the amount requiredto hold the snowmobile stationary.

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Emergency StoppingThere are several methods of stopping orslowing the snowmobile under a varietyof situations. Identified in the followingchart are the ways a snowmobile may bebrought to a stop and the effectivenessunder normal conditions.

Throttle/Ignition Monitor SwitchThe throttle control is equipped with amonitor switch for safety purposes whichwill stop the engine when a loss of returnspring force occurs. If ice forms in thethrottle system or if there is some othermalfunction of the throttle system result-ing in a loss of return spring force, themonitor switch will stop the engine whenthe throttle control lever is released.

If the snowmobile engine stops abruptlywhen the throttle control lever is releasedand the activation of the monitor switch issuspected, use the following procedure:

1. Rotate the ignition key to the OFFposition.

2. Remove ice and snow from thethrottle system and wait 5-10 min-utes for the engine heat to thaw icefrom the throttle system.

3. Test the throttle control lever bycompressing and releasing it severaltimes. The lever MUST return to theidle position quickly and completely.

NOTE: If the throttle control leveroperates properly and the enginedoes not start, compress the throttlelever slightly (approximately 1/8throttle) and try starting the engine.If the engine now starts and stopswhen the throttle lever is released,take the snowmobile to an autho-rized Arctic Cat Snowmobile dealerfor service. If not under warranty,this service is at the discretion andexpense of the snowmobile owner.

4. If the throttle control lever operatesproperly, rotate the ignition key tothe RUN position and go throughnormal starting procedures.

NOTE: On the 2000 models if thethrottle control lever operates prop-erly and the engine does not start,either a malfunctioning monitorswitch or a misadjusted magnetic car-buretor switch may be the problem.Take the snowmobile to an authorizedArctic Cat Snowmobile dealer for ser-vice. If not under warranty, this ser-vice is at the discretion and expenseof the snowmobile owner. However, ifa dire emergency exists wherein theengine must be started, disconnectthe carburetor safety switch connec-tors. If disconnection of the carbure-tor safety switch connectors isneeded to start the engine, take thesnowmobile to an authorized ArcticCat Snowmobile dealer for service assoon as possible. If not under war-ranty, this service is at the discretionand expense of the snowmobileowner.

NOTE: On the 2000 models toaccess the switch connectors, openthe left-side access panel andremove the belt guard; then locatethe switch on the left-side of the car-buretor and trace the wire to the con-nector.

Item Function ConditionEmergencyStop Switch

interrupts igni-tion circuit

ALL

Throttle/IgnitionMonitor Switch

interrupts igni-tion circuit

ALL

Ignition Switch interrupts igni-tion circuit

ALL

Brake slows the drivesystem

ALL

Choke (2000) floods the engine 1/2 throt-tle or less

! WARNINGIf any malfunction of the throttle sys-tem occurs (such as freezing in fluffysnow) and the monitor switch doesnot shut off the engine, press downon the emergency stop switch IMME-DIATELY to stop the engine. DO NOTstart the engine until the malfunctionin the throttle system has beenlocated and corrected.

! WARNINGIf the throttle control lever does notwork properly, DO NOT ATTEMPT TOSTART THE ENGINE.

23

0743-448

NOTE: On the 5000 models if thethrottle control lever operates prop-erly and the engine does not start, amalfunctioning monitor switch maybe the problem. Take the snowmo-bile to an authorized Arctic CatSnowmobile dealer for service. If notunder warranty, this service is at thediscretion and expense of the snow-mobile owner. However, if a direemergency exists wherein theengine must be started, disconnectthe throttle monitor switch located inthe right-side handlebar control.

NOTE: On the 5000 models if discon-nection of the throttle monitor switch isneeded to start the engine, take thesnowmobile to an authorized Arctic CatSnowmobile dealer for service as soonas possible. If not under warranty, thisservice is at the discretion andexpense of the snowmobile owner.

NOTE: The monitor switch is nowbypassed. All other ignition/electricalfeatures (ignition switch, emergencystop switch, headlight, taillight, andbrakelight) will operate properly.

Varying Altitude OperationOperating a snowmobile at varying alti-tudes requires changes in performancecomponents. These changes affect drivetrain components and carburetion com-ponents (2000).

The altitude information decal is locatedon the belt guard of the snowmobile(Lynx 2000). On the Bearcat 2000 LT/Lynx 2000 LT the information is incorpo-rated into the Carburetor Jet Chart decalon the belt guard.

NOTE: Just as important as cali-brating the snowmobile for higher alti-tudes is recalibrating the snowmobilewhen going to lower altitudes. Alwaysconsult the altitude decal.

NOTE: Carburetion and drive trainchanges can be made by the snowmo-bile owner if qualified to do so. If theowner does not feel qualified, take thesnowmobile to an authorized Arctic CatSnowmobile dealer for this service.This service is at the discretion andexpense of the snowmobile owner.

! WARNINGUnder no circumstances should dis-connection of the throttle control wir-ing harness be used as a substitutefor the monitor switch during normaloperation of the snowmobile. Per-sonal injury and damage could occurif the throttle system malfunctions orif the operator is unable to stop theengine in an emergency. If the snow-mobile must be operated with a dis-connected throttle control wiringharness, EXTREME CAUTION MUSTBE TAKEN. NEVER EXCEED 10 MPHWITH THE THROTTLE CONTROLWIRING HARNESS DISCONNECTED.

CAUTIONOn the 2000 models, carefully followthe Carburetor Jet Chart recommen-dations for proper altitude calibra-tion.

24

LubricationGear CaseIt is very important that the gear case beflushed and the lubricant be replacedafter each season of use. Arctic Cat rec-ommends that the flushing and replacingbe done prior to off-season storage.

NOTE: Flushing the gear case andreplacing the lubricant can be doneby the snowmobile owner if qualifiedto do so. If the owner does not feelqualified, take the snowmobile to anauthorized Arctic Cat Snowmobiledealer for this service. This serviceis at the discretion and expense ofthe snowmobile owner.

To flush the gear case and replace thelubricant, use the following procedure:

1. Open the left-side access panel; thenremove the panel and the belt guard.

2. Remove the drive belt (see Drive Beltsub-section in the Maintenance sec-tion); then remove the driven clutch.

NOTE: If excessive oil deposits arenoticed, take the snowmobile to anauthorized Arctic Cat Snowmobiledealer for service. If not under war-ranty, this service is at the discretionand expense of the snowmobile owner.

3. Using Handlebar Stand (p/n 5639-152) or a suitable substitute, tip thesnowmobile onto its right side.

NOTE: It is recommended that thegas tank be nearly empty (less than1/4 full) when tipping the snowmo-bile.

4. Remove the drain plug from the gearcase; then install a drain adapter fit-ting with hose into the drain plughole.

0743-456

0741-334

NOTE: To aid in draining the lubri-cant, it is advisable to fashion a drainadapter by acquiring a fitting - GearCase Drain Fitting (p/n 0644-552) - anda length of 3/8-in. hose.

5. Tip the snowmobile back to theupright position; then place a drainpan on the floor next to the drainhose and tip the snowmobile towardits left side far enough to allow thelubricant to drain from the gear caseinto the drain pan.

NOTE: It is critical that the snow-mobile is on a level surface toensure the lubricant drains properlyand completely.

6. Secure the snowmobile in this posi-tion until the lubricant is completelydrained.

7. When the lubricant has completelydrained from the gear case, tip thesnowmobile back to the upright posi-tion, remove the drain adapter, andinstall and securely tighten the drainplug; then remove the check/fill plug.

8. Pour Arctic Cat ACT Drive FlushFluid (p/n 4639-333) into the check/fill hole; then install the plug.Tighten securely.

2000

CAUTIONIt is critical that all of the old lubricantbe drained from the gear case prior toflushing the gear case.

CAUTIONDo not add more or less than the rec-ommended amount (6 fl oz) of flushfluid to the gear case.

5000

25

9. Install the driven clutch; then installthe drive belt (see Drive Belt sub-section in the Maintenance section)and the belt guard.

10. Install the left-side access panel;then close the access panel.

11. Position the tips of the skis against awall; then using a shielded safetystand, raise the rear of the snowmo-bile off the floor making sure thetrack is free to rotate.

12. Start the engine and accelerateslightly. Use only enough throttle toturn the track several revolutions.SHUT ENGINE OFF.

13. Open the left-side access panel; thenremove the panel and the belt guard.

14. Remove the drive belt (see Drive Beltsub-section in the Maintenance sec-tion); then remove the driven clutch.

15. Using Handlebar Stand (p/n 5639-152) or a suitable substitute, tip thesnowmobile onto its right side.

16. Remove the drain plug from the gearcase; then install the drain adapter fit-ting with hose into the drain plug hole.

17. Tip the snowmobile back to theupright position; then place a drainpan on the floor next to the drainhose and tip the snowmobile towardits left side far enough to allow theflush fluid to drain from the gearcase into the drain pan.

18. Secure the snowmobile in this posi-tion until the flush fluid is com-pletely drained.

19. When the fluid has completelydrained from the gear case, tip thesnowmobile back to the uprightposition, remove the drain adapter,and install and securely tighten thedrain plug; then remove the check/fill plug.

20. Pour the exact amount of Arctic CatSynthetic ACT Gear Case Fluid intothe check/fill hole; then install theplug. Tighten securely.

21. Install the driven clutch; then installthe drive belt (see Drive Belt sub-section in the Maintenance section)and the belt guard.

22. Install the left-side access panel;then close the access panel.

Front SuspensionNOTE: Arctic Cat recommendsthat Arctic Cat All-Temp Grease (p/n4639-365) be used for this proce-dure.

It is very important that the front suspen-sion is greased on a monthly basis usingall-temperature grease. The front suspen-sion should also be greased after traile-ring the snowmobile on an open trailer.Pump grease into the spindle grease fit-ting (both sides) until grease is notedcoming out of the top and bottom of thespindle. Wipe excess grease from thespindle.

! WARNINGThe tips of the skis must be positionedagainst a wall or similar object.

! WARNINGDO NOT stand behind the snowmo-bile or near the rotating track. NEVERrun the track at high speed when thetrack is suspended.

CAUTIONIt is critical that all of the flush fluidbe drained from the gear case prior tofilling with new lubricant.

CAUTIONThe correct lubricant to use in thegear case is Arctic Cat Synthetic ACTGear Case Fluid (see chart). Any sub-stitute may cause serious damage tothe drive system.

Gear Case Lubricant

Model p/n Amount5000 4639-628 354 ml (12 fl oz)

2000 5639-219 444 ml (15 fl oz)

CAUTIONDo not add more or less than the rec-ommended amount of lubricant to thegear case or damage to the gear casewill occur. Oil level should be at theOil Fill Level on the gear case cover.

26

741-335A

On the Lynx 2000, turn the handlebar tothe right; then from the right side, pumpgrease into the steering arms until greaseis noted coming out of either end of thearms. Wipe excess grease from the arms.

0741-440

Rear SuspensionThis procedure should be done every 40operating hours.

NOTE: Arctic Cat recommendsthat Arctic Cat All-Temp Grease (p/n4639-365) be used for this proce-dure.

1. Shut engine off and wait for all mov-ing parts to stop.

2. With the gas tank nearly empty (lessthan 1/4 full) and using HandlebarStand (p/n 5639-152) or a suitablesubstitute, lay the snowmobile on itsleft side.

3. Lubricate the grease fittings with all-temperature grease.

0741-376

NOTE: Illustrated are the generallocations of grease fittings. Actuallocations will vary from model tomodel.

27

MaintenancePeriodic Maintenance Checklist

Item Interval Page RemarksBrake System Daily 39 Check for binding, leakage, and proper operation;

lever firmness, travel, caliper, disc, and padsCooling System - Liquid(5000)

Daily 13,32 Check for leakage, damage, obstructions, coolantlevel

Oil System Daily — Check for leakage, damage, and injection/engineoil level

Engine Oil (5000) 2500 Mi/Seasonal

30 Change oil and filter

Battery Daily 13,36 Check for proper charge and tight connectionsStop Switch Daily — Check for proper operationHoses Daily — Check for damage, leakage, and wearHeadlight & Taillight/Brakelight Daily 47-50 Check for proper operation and cleanlinessSteering System Daily — Check for proper operation, tightness of bolts, and

bindingThrottle Control System Daily 23 Check for binding, sticking, proper operation, throt-

tle cable tension, and wearDrive Belt Daily

Monthly41 Check for wear, cracks, and fraying

Check length and width dimensionsSki Wear Bars Daily 51 Check for wear and damageCarburetors (2000) Seasonal 32-34 Inspect/clean as necessaryElectrical Wiring Weekly — Check for wear, damage, and tight connectionsExhaust System Weekly 13 Check for damage, leakage, and obstructionsNuts, Bolts, Fasteners Weekly — Check tightnessRecoil Starter Weekly — Check rope for wear, fraying, and proper operationShock Absorbers Weekly 15,45 Check for fluid leakage and damageSpark Plugs (2000) Weekly 35 Check center electrode insulator color, carbon,

and gapValve Clearance (5000) 5000 Mi/

Seasonal36 Check/adjust

Suspension Weekly 45 Check for damage, loose components, and properadjustment

Track Tension/Alignment Weekly 43,44 Check/adjust as necessaryWear Strips Weekly 51 Check for wear and damageWires & Cables Weekly — Check for wear, damage, and frayingFuel System - Tank, Pump,In-Line Filter, & Vent Hose

Weekly — Check for damage, wear, obstructions, and leak-age

Fuel Filter (5000) 5000 Mi/2 years

— Replace

Air Silencer (2000) Seasonal — Inspect/cleanGear Case Seasonal 25 Flush and change drive fluid prior to storageHeat Exchangers Monthly — Check for wear, leakage, and damageDrive Clutch/Driven Clutch Monthly 14,15 Check for damage, binding, and wear/remove

drive belt, clean drive clutch/driven clutch withcompressed air, and clean sheaves with suitableparts-cleaning solvent

Front & Rear Suspension Monthly 26,27 Grease

28

The longevity and safety of the snowmo-bile can be increased by making periodicchecks of the items in the precedingchecklist.

If, at any time, abnormal noises, vibra-tions, or improper working conditions ofany component of this snowmobile aredetected, DO NOT OPERATE THESNOWMOBILE. Take the snowmobileto an authorized Arctic Cat Snowmobiledealer for inspection and adjustment orrepair. If not under warranty, this serviceis at the discretion and expense of thesnowmobile owner.

The snowmobile should be taken to anauthorized Arctic Cat Snowmobile dealerat the end of each snowmobiling seasonfor general inspection and for off-seasonstorage servicing. This inspection andservicing is at the expense of the snow-mobile owner.

Fuel System

In-Line Fuel Filter (2000)

Arctic Cat recommends that the in-linefuel filter be checked weekly. The in-linefuel filter is located just in front of thefuel pump inlet fitting. The filter must beclean to allow the fuel hose to transmitthe amount of gasoline required.

If the in-line fuel filter is obstructed, gas-oline flow will be restricted; therefore,the filter must be replaced. To removeand install the in-line fuel filter, use thefollowing procedure:

1. Pinch off the fuel hose between thegas tank and fuel filter.

2. Remove and discard the clamps;then pry the fuel hoses off the in-linefuel filter and remove the filter.

NOTE: The in-line fuel filter mustbe replaced if obstructed. Filters areavailable from an authorized ArcticCat Snowmobile dealer.

3. Install the new in-line fuel filter (ifnecessary) in the fuel hose so thearrow on the filter points toward thefuel pump. Make sure the fuel hosesfit tightly on the filter. If the existingfuel hose does not fit tightly on the fil-ter, cut 6 mm (1/4 in.) from the end ofthe fuel hose; then install on the filterand secure with new clamps.

728-272B

In-Line Fuel Filter (5000)

Arctic Cat recommends that the in-linefuel filter be replaced every 5000 miles.The in-line fuel filter is located justinside the left-side access panel. The fil-ter must be clean to allow the fuel hose totransmit the amount of gasoline required.

If the in-line fuel filter is obstructed, gas-oline flow will be restricted; therefore,the filter must be replaced. To removeand install the in-line fuel filter, use thefollowing procedure:

NOTE: Before removing the fuel fil-ter, take note of the filter inlet andoutlet for installing purposes.

! WARNINGWhenever any maintenance orinspection is made on the fuel systemin which there may be fuel leakage,there should be no welding, smoking,open flames, etc., in the area.

! WARNINGThe fuel hoses must fit tightly on thefuel filter. If the fuel hose lengthdoesn’t permit this procedure,replace the fuel hose. Also, afterinstalling the fuel hoses on the filter,check to be sure that the fuel hosesdo not contact any hot or rotatingcomponents.

! WARNINGSince the fuel supply hose may beunder pressure, always wear safetyglasses; then remove the hose slowlyto release the pressure. Place anabsorbent towel around the connec-tion to absorb the fuel.

29

1. Open the left-side access panel; thenremove the fuel filter from thebracket.

2. Remove the hose clamps and dis-card; then slowly remove the fuelhoses from the fuel filter. Dispose ofthe excess fuel from the filter prop-erly.

3. Inspect the fuel hoses thoroughly forany signs of cracking, cuts, or wearpoints.

4. Place the new hose clamps on thefuel hoses; then with the fuel pumpinlet and outlet noted, connect thefuel hoses to the fuel filter. Securewith the hose clamps.

5. Secure the new fuel filter to the fuelfilter bracket; then start the engineand inspect the fuel hoses and filterfor any signs of leaks.

Gasoline Additives

Fuel de-icer can be used for all models.Also, periodic use of an injector cleanerfor the 5000 models is recommendedespecially in the last tank of gasolinebefore storage. Arctic Cat Fuel Stabilizer(p/n 0436-907) should also be added tothe last tank of gasoline before storage.

Fuel Pickup Valves (5000)

If ever there is a restricted fuel flow and apickup valve is suspected, take the snow-mobile to an authorized Arctic Cat Snow-mobile dealer for this service. If not underwarranty, this service is at the discretionand expense of the snowmobile owner.

Checking Engine Oil Level (5000)

1. Park the snowmobile on a level sur-face; then start the engine and allowit to warm up for 5-10 minutes, or ifthe snowmobile was operated, allowthe engine to idle for approximately30 seconds.

NOTE: The snowmobile must beon a level surface for this procedure.

2. Shut the engine off; then remove theoil level stick from the oil reservoir.Wipe the stick clean.

ZJ002A

3. Insert the oil level stick into the oilreservoir without threading it in andremove. Read the oil level shown onthe stick. The oil level should be nearthe middle of or on the high end ofthe NORMAL range on the stick.

0741-490

NOTE: To attain an accurate oillevel reading, do not thread the stickinto the reservoir.

4. If steps 1-3 were followed and theoil level is at or below the ADDmark, add up to 1/2 qt of recom-mended engine oil.

5. Repeat steps 3-4 until the oil level iswithin the recommended range onthe oil level stick.

Changing Engine Oil/Filter (5000)

NOTE: Recycle or properly dis-pose of the used engine oil.

1. Using a putty knife, remove thebelly pan plug.

CAUTIONMake sure the fuel filter is properlyseated into the holder located on thetunnel behind the driven shaft.

! WARNINGCare must be taken if a hot drain plugis removed by hand. Burning couldoccur.

30

2. Park the snowmobile on a level sur-face; then start the engine and allowit to warm up for 5-10 minutes, or ifthe snowmobile was operated, allowthe engine to idle for approximately30 seconds.

3. Shut the engine off; then place drainpans beneath both engine oil drainplugs (crankcase and oil reservoir).

ZJ003A

4. Remove the drain plugs and allowthe oil to drain completely.

NOTE: At this point, remove thestrainer from the oil reservoir toallow the oil to drain completely.

5. After the oil has drained completely,install the oil strainer, drain plugs,and washers and tighten to 16 ft-lb.

NOTE: Always install a new Oil PanDrain Plug Gasket (p/n 3402-011) anda new Reservoir Drain Plug O-Ring (p/n 1670-926) when changing the oil.

6. Install a new belly pan plug.

7. Using an appropriate oil filter wrench,loosen (but do not remove) the oil fil-ter and allow the oil to drain from thefilter; then remove the filter.

8. Apply a light coat of fresh engine oilto the seal of the new oil filter.

9. Install the new oil filter by turning theoil filter by hand until the seal has con-tacted the oil filter mounting surface;then tighten the oil filter to 15 ft-lb.

10. Pour 2.9 l (3 U.S. qt) of the recom-mended engine oil into the oil reservoir.

11. Open the air bleed bolt located onthe oil pump (beneath the coolanttank) to purge air from the oil hose.

ZJ004A

NOTE: When air can no longer beheard purging from oil pump bleed,tighten the bleed bolt to 7.5 ft-lb.

12. Without starting the engine, placethe handlebar emergency stopswitch to the RUN position and theignition switch to the ON position.The Oil Pressure Warning Iconshould illuminate.

NOTE: If the warning icon does notilluminate, take the snowmobile toan authorized Arctic Cat Snowmo-bile dealer for service. If not underwarranty, this service is at the dis-cretion and expense of the snowmo-bile owner.

13. If the warning icon illuminates (fromstep 12), start the engine. The warningicon should go out within five sec-onds. If it does, proceed to step 14.

NOTE: If the warning icon does notgo out, shut the engine off immedi-ately and repeat step 11; then placethe ignition switch to the ON posi-tion and repeat step 13. If the warn-ing icon does not go out, take thesnowmobile to an authorized ArcticCat Snowmobile dealer for service. Ifnot under warranty, this service is atthe discretion and expense of thesnowmobile owner.

14. Shut the engine off and pour theremaining amount (0.9 l or 1 U.S.qt) of recommended oil into the oilreservoir; then proceed to theChecking Engine Oil Level (5000)sub-section in this section to verifyand finalize the procedure.

CAUTIONDo not attempt to start the enginewith the bleed bolt open.

31

Coolant Level (5000)NOTE: Use a good quality, ethyleneglycol-based, automotive-type coolant.

NOTE: Always check the coolantlevel with the engine cold.

NOTE: The hood must be removedfor this procedure.

Locate the FULL COLD mark on thecoolant reservoir (located in the forwardengine compartment below the hoodhinge bracket).

If the coolant is below the FULL COLDmark, add coolant to the reservoir until atthe FULL COLD mark.

Adjusting/Calibrating Carburetors (2000)

0745-141

The carburetors have been adjusted/cali-brated at the factory for average ridingconditions; however, altitude, tempera-ture, and general wear may necessitatecertain carburetor adjustments.

Carburetor adjustments critically affectengine performance; therefore, the fol-lowing three external adjustments andtwo internal calibrations can be made oneach carburetor.

NOTE: The following external car-buretor adjustments may be done bythe snowmobile owner if qualified todo so. If the owner does not feelqualified, take the snowmobile to anauthorized Arctic Cat Snowmobiledealer for this service. This serviceis at the discretion and expense ofthe snowmobile owner.

Adjusting Choke Cable (External)

1. Be sure the ignition switch key is inthe OFF position and the brake leverlock is set.

2. Slide the insulators away from theadjusters; then loosen the jam nutsecuring each choke cable adjuster.Rotate each choke cable adjusterclockwise until free-play is noted inthe choke lever.

3. Slowly rotate one choke cableadjuster counterclockwise whilechecking the choke lever for free-play. As soon as all free-play hasbeen removed from the end of thelever, stop rotating the adjuster.

4. With free-play removed from the lever,slowly rotate each choke cable adjusteronce again clockwise while checkingthe choke cable lever for free-play.Adjust until 3 mm (1/8 in.) free-playbetween front bottom edge of lever andhousing is attained. Securely tightenthe adjuster jam nut; then slide theinsulators onto the adjusters.

CAUTIONIf the coolant is below the FULLCOLD mark and if coolant has beenadded, immediately inspect for leak-age and/or damage. If leakage ordamage is detected, take the snow-mobile to an authorized Arctic CatSnowmobile dealer for service. If notunder warranty, this service is at thediscretion and expense of the snow-mobile owner.

CAUTIONFor information on altitude operation,see Varying Altitude Operation sub-section in the Operating Instructionssection.

CAUTIONMake sure to perform these adjust-ment/calibration procedures on bothcarburetors.

32

732-848B

NOTE: If a carburetor choke cableis adjusted too tight when the enginereaches operating temperature, theair/fuel mixture will be incorrect andthe engine will idle poorly and mayoperate only on one cylinder.

Synchronizing Throttle Cable/Piston Valves (External)

1. Remove the air-intake silencer bootsfrom the silencer to access the intakebores.

2. Rotate the idle speed screws coun-terclockwise until all spring tensionis removed.

3. Slide the insulators away from theadjusters; then loosen the jam nutsecuring each throttle cable adjuster.Rotate each adjuster clockwise untileach piston valve bottoms in the pis-ton valve bore.

4. In turn on each carburetor, place afinger lightly against the side of thepiston valve; then rotate the carbure-tor adjuster counterclockwise untilslight upward movement of thevalve is noted.

5. Check to make sure the valves startto open at the exact same moment byplacing a thumb and finger againstthe valves; then lightly compress thethrottle lever.

NOTE: If an individual piston valvestarts to open before another, rotatethe adjuster on the valve which islifting first clockwise, just enough tosynchronize the valves. Recheck byrepeating steps 2-5.

6. With the piston valves synchronized,tighten the adjuster jam nutssecurely; then slide the insulatorsonto the adjusters.

NOTE: There must be free-play inthe throttle lever.

7. In turn on each carburetor, place afinger against the piston valve.Rotate the idle speed screw clock-wise until it contacts the valve.

8. Compress the throttle lever to the full-open position; then rotate each idlespeed screw clockwise 2 completeturns. Release the throttle lever.

NOTE: There must be 0.75-1.5 mm(0.030-0.060 in.) free-play between thethrottle lever and the control housing.

9. At this point, there must be 0.75-1.5mm (0.030-0.060 in.) of cable free-play gap in the throttle lever. If thereis no cable free-play in the throttlelever, the throttle safety switches willnot function properly, and the enginewill cut out in the idle position.

0741-518

NOTE: If cable free-play gap is notcorrect, rotate each adjuster anequal amount until recommendedfree-play is achieved. Each pistonvalve must be resting against the tipof its idle speed screw.

NOTE: If throttle cable free-play isincorrect, the carburetor safetyswitches will be activated prema-turely and the engine will not start.

! WARNINGBe sure to tighten the adjuster jamnuts securely. If an adjuster jam nut isnot tightened, the adjuster can rotateout of the carburetor cap causing thepiston valve not to return to the full-closed position.

33

Fine-Tuning Pilot Air Screws and Idle Speed Screws (External)

1. While counting the rotations, care-fully rotate the pilot air screwsclockwise until lightly seated.

2. Rotate the pilot air screws counter-clockwise the exact number of rota-tions ± 1/4 turn from the seatedposition as an initial setting.

3. Install the air-intake silencer bootstaking care that the boots are properlypositioned and that the boots are not“folded” in the air-intake silencercausing a restriction of air flow.

4. With the snowmobile on a shieldedsafety stand, start the engine, releasethe brake lever lock, and thoroughlywarm up.

NOTE: Make engine idle adjustmentonly after the engine has reached run-ning temperature. Since the idle speedscrews have not been fine-tuned, slightthrottle pressure may be necessary tokeep the engine running. Allow engineto warm up for 2-3 minutes.

5. After the engine has been thor-oughly warmed up, fine-tune thepilot air screws (equally) and theidle speed screws (equally) until theengine runs smoothly.

NOTE: Engine idle should bewithin a range of 1600-1700 RPM.

6. Test the throttle control lever bycompressing and releasing it severaltimes. The lever must return to theidle position quickly and completely.

Calibrating Main Jets/Pilot Jets/Jet Needle E-Clips (Internal)

Altitude, temperature, and the use of oxy-genated gasoline affect the carburetionneeded for optimum engine performance.The carburetor main jets must bechanged in conjunction with changes inoperating altitude, oxygenated gasolineusage, and temperature. Also, the pilotjets and jet needle E-clip positions mayhave to be changed with changes in oper-ating altitude. To change pilot jets and E-clip positions, the carburetors must beremoved and disassembled (float cham-ber, etc.). Arctic Cat highly recommendsthat this service be done by an authorizedArctic Cat Snowmobile dealer only.

NOTE: The following internal car-buretor calibrations may be done bythe snowmobile owner if qualified todo so. If the owner does not feelqualified, take the snowmobile to anauthorized Arctic Cat Snowmobiledealer for this service. This serviceis at the discretion and expense ofthe snowmobile owner.

CAUTIONDo not force a pilot air screw whenrotating it clockwise; damage to thepilot air screw needle tip will result.

! WARNINGDO NOT stand behind the snowmo-bile or near the rotating track. NEVERrun the track at high speed when thetrack is suspended.

! WARNINGIf a tachometer is not available, caremust be taken not to adjust engineidle speed too high.

CAUTIONIt is important that the pilot air screwsare adjusted equally and that the idlespeed screws are adjusted equally.

! WARNINGDO NOT operate the snowmobilewhen any component in the throttlesystem is damaged, frayed, kinked,worn, or improperly adjusted. If thesnowmobile is operated when thethrottle system is not functioningproperly, personal injury could result.

CAUTIONFor information on altitude operation,see Varying Altitude Operation sub-section in this manual.

34

As the ambient temperature rises or asthe snowmobile is operated at a higheraltitude, the main jets must be replacedwith leaner main jets. The original equip-ment (production) main jets may need tobe changed (depending on the type ofgasoline you are using, your operatingaltitude, and temperature). A CarburetorJet Chart decal is located on the beltguard of the snowmobile. It should benoted that when selecting the propermain jets, it is better to be too rich ratherthan too lean. To change carburetor mainjets, use the following procedure:

NOTE: Refer to Illustration 0745-141 in this section for location ofcomponents.

1. Loosen each carburetor flangeclamp and remove each carburetorfrom the intake flange and boot.

2. Remove each drain screw and O-ring from the carburetor float cham-ber and drain the gas into a smallcontainer or shop towels.

3. Using the main jet wrench (from thetool kit), thread the main jet out ofeach carburetor. Account for the baf-fle ring. Install the new main jet andthe existing baffle ring. Tighten themain jet securely.

4. Install each drain screw and O-ring;then tighten securely.

5. Install and secure the carburetors.

Spark Plugs5000

NOTE: If spark plugs must bereplaced, take the snowmobile to anauthorized Arctic Cat Snowmobiledealer for inspection and service.This service is at the discretion andexpense of the snowmobile owner.

2000

NOTE: Always use the recom-mended spark plugs in the engine.See the appropriate specificationssheet for correct spark plug gap.

Varying terrain conditions and operatingusage may require spark plugs of a differentheat range. For example, sustained cross-country riding will usually require colderheat-range spark plugs while trail riding orother continual slow speed operation willusually require hotter heat-range spark plugs.

Removing/Installing Spark Plugs

1. Remove the spark plug caps fromthe plugs.

2. Using a spark plug wrench, removethe plugs.

3. Install the plugs and finger-tighten.

4. Tighten the spark plugs to 19 ft-lb;then install the spark plug caps.

Checking Spark Plugs

To see if the spark plugs being used are ofthe proper heat range (after the snowmo-bile has been operated under normal driv-ing conditions), remove the spark plugsand examine the condition of the centerelectrode insulator of each spark plug.

AO352A

! WARNINGWhenever any maintenance is per-formed on the fuel system, thereshould be no welding, smoking, openflames, etc., in the area.

CAUTIONUse only GENUINE Mikuni brass mainjets. Also, if using an oxygenatedgasoline (up to 10% ethanol), the car-buretor main jet must be one sizelarger than the main jet required forregular unleaded gasoline.

CAUTIONA main jet which is too small willcause severe engine damage. Enginedamage caused by lean jetting WILLNOT BE covered by Arctic Cat Inc.warranty policy.

35

A. TAN or LIGHT BROWN insula-tor indicates correct spark plugs(heat range).

B. LIGHT GRAY or WHITE insula-tor indicates over-heating of theengine. This condition is caused bya too lean condition or incorrectspark plugs (heat range too hot).

C. BLACK insulator indicates fuelin the combustion chamber is notburning completely. This condi-tion is caused by a too rich con-dition, too much oil, or incorrectspark plugs (heat range too cold).

NOTE: If the center electrode insu-lators are light gray, white, or blackand if the carburetor adjustments(2000), oil-injection pump synchroni-zation, and ignition timing are correct,different heat-range spark plugs maybe necessary. Authorized Arctic CatSnowmobile dealers have detailedspark plug information. Consult adealer before changing spark plugs,as incorrect heat-range spark plugscould cause poor engine performanceor engine damage.

Valve Clearance (5000)After 5000 miles or prior to seasonalstorage, valve clearance should bechecked and adjusted as necessary.

NOTE: Take the snowmobile to anauthorized Arctic Cat Snowmobiledealer for inspection and service.This service is at the discretion andexpense of the snowmobile owner.

Battery (Electric Start)These standard and sealed batteries afterbeing in service require regular cleaningand recharging in order to deliver peak per-formance and maximum service life. Thefollowing procedures are recommendedfor cleaning and maintaining standard andsealed batteries. Always read and followinstructions provided with battery char-gers and battery products.

NOTE: Battery maintenance maybe done by the snowmobile owner ifqualified to do so. If the owner doesnot feel qualified, take the snowmo-bile to an authorized Arctic CatSnowmobile dealer for this service.This service is at the discretion andexpense of the snowmobile owner.

To remove and charge the battery, use thefollowing procedure:

1. Remove the negative battery cable;then remove the positive cable andon the standard battery, the batteryvent tube. Remove the battery fromthe snowmobile. Care should betaken not to damage the vent tube.

CAUTIONIf a spark plug is light gray, white, orblack and another is tan or lightbrown, take the snowmobile to anauthorized Arctic Cat Snowmobiledealer for inspection and service. Ifnot under warranty, this service is atthe discretion and expense of thesnowmobile owner.

CAUTIONIt is critical that the checking/adjust-ing valve clearance be done at therecommended intervals or severeengine damage may occur.

! WARNINGAny time service is performed on abattery, the following must beobserved: Keep sparks, open flame,cigarettes, or any other flame away.Always wear safety glasses. Protectskin and clothing when handling bat-teries. When servicing battery inenclosed space, keep the area well-ventilated. Make sure battery ventingis not obstructed.

! WARNINGBattery posts, terminals, and relatedaccessories contain lead and leadcompounds, chemicals known to thestate of California to cause cancerand reproductive harm. Wash handsafter handling.

! WARNINGAvoid spillage and contact with skin,eyes, and clothing.

CAUTIONDo not charge the battery while it is inthe snowmobile with the battery ter-minals connected.

36

2. Thoroughly wash the battery withsoap and water.

NOTE: If battery posts or cableends have a build-up of white/greenpowder residue, apply water andbaking soda to neutralize acid; thenflush off with warm soapy water.

3. Using a wire brush, clean the batteryposts and cable ends removing allcorrosive buildup. Replace dam-aged cables or cable ends.

4. On a standard battery, add clean dis-tilled water to bring fluid level to theUPPER level line.

5. Using a multimeter, test the batteryvoltage. The meter must read no lessthan 12.5 DC Volts for a fullycharged battery.

NOTE: At this point if the meterreads as specified, the battery maybe returned to service (see step 9).

6. If the meter reads less than specifiedvoltage, charge the battery using thefollowing guidelines.

A. When using an automatic batterycharger, always follow the char-ger manufacturer’s instructions.

B. When using a constant-currentbattery charger, use the follow-ing Battery Charging Chart.

NOTE: If the battery voltage is 11.5DC Volts or less, some chargers may“cut off” and fail to charge. If thisoccurs, connect a fully chargedbooster battery in parallel (positive topositive and negative to negative) fora short period of time with the chargerconnected. After 10-15 minutes, dis-connect the booster battery leavingthe charger connected and the char-ger should continue to charge. If thecharger “cuts off,” replace the battery.

7. After charging the battery for thespecified time, remove the batterycharger and allow the battery to sitfor 1-2 hours.

8. Connect the multimeter and test thebattery voltage. The meter shouldread no less than 12.5 DC Volts. Ifthe voltage is as specified, the bat-tery is ready for service.

NOTE: If voltage in step 8 is belowspecifications, charge the battery anadditional 1-5 hours; then retest.Recheck electrolyte level (standardbattery) and the battery is ready forservice.

9. Place the battery into position in thesnowmobile; then coat the batteryposts and cable ends with a lightcoat of multi-purpose grease.

CAUTIONDo not remove seal strip on a sealedbattery.

! WARNINGBattery acid is harmful if it contactseyes, skin, or clothing. Care must betaken whenever handling a battery.

CAUTIONNever use electrolyte (sulfuric acid)to “top off” the battery. Use only dis-tilled water or severe battery damagemay occur.

CAUTIONNever exceed the standard chargingrate.

! WARNINGAn overheated battery could explodecausing severe injury or death.Always monitor charging times andcharge rates carefully. Stop chargingif the battery becomes very warm tothe touch. Allow it to cool beforeresuming charging.

Battery Charging Chart(Constant-Current Charger)

BatteryVoltage

(DC)

ChargeState

Charge TimeRequired (at 1.5-

2.0 Amps)

12.5 (mini-mum)

100% None

12.2-12.4 75%-99% 3-6 hours

12.0-12.2 50%-74% 5-11 hours

11.0-11.9 25%-49% 13 hours (minimum)

11.5 or less 0-24% 20 hours (minimum)

37

10. Connect the battery cables (positivecable first).

Fuses

Fuses protect the snowmobile electricalsystem from overloading. If electricalparts in the snowmobile are not working,the system may have been overloaded andcaused a blown fuse. Before repairing orreplacing any electrical part, check theappropriate fuses. If a fuse blows (opens acircuit), all the parts of the snowmobilethat use that circuit will not work.

Once which fuse to check has been deter-mined, perform the following steps:

1. Open the right-side access panel;then on the 5000 models, remove thefuse panel cover (the fuse panel islocated behind the battery). On the2000 models, remove the fuseholder cover and disconnect thefuse.

IO001A

ZJ306A

IO121A

NOTE: On the 5000 models, thereare spare fuses inside the fusepanel.

IO002A

NOTE: On the Bearcat XT GS, thetowing accessories fuses arelocated beneath the seat.

2. Remove the suspected fuse.

3. Look through the clear side of thefuse to see if the element inside isburned or separated. If it is, the fuse isblown and should be replaced with afuse of the correct amperage rating.

4. On the 5000 models, install the fusepanel cover and close the right-sideaccess panel. On the 2000 models,install the fuse holder cover.

Even after replacing a fuse, it may con-tinue to blow if the cause of the overloadis not determined. If the fuse continues toblow, take the snowmobile to an autho-rized Arctic Cat Snowmobile dealer forservice. If not under warranty, this ser-vice is at the discretion and expense ofthe snowmobile owner.

CAUTIONBefore installing the battery, make surethe ignition switch is in the OFF position.

CAUTIONConnecting cables in reverse (posi-tive to negative and negative to posi-tive) can cause serious damage tothe electrical system.

5000

Lynx 2000

! WARNINGAlways replace a fuse with one hav-ing the same specified amperage rat-ing. Using a fuse with a higher ratingcan cause severe wire damage andcould start a fire.

Bearcat 2000 LT/Lynx 2000 LT

38

Brake SystemArctic Cat recommends that the brakesystem (brake lever, fluid reservoir, hose,caliper, pads, and brake disc) be checkeddaily for fluid leakage, wear, or damageand for proper operation. Also, the brakefluid level must be checked every timebefore starting the engine. The brakefluid must be visible in the sight glass.

Checking/Adding Brake Fluid

1. With sight glass reservoir in a levelposition, check the fluid level. Thebrake fluid level must be visible inthe sight glass.

NOTE: If the sight glass appearsdark, there is a sufficient amount offluid in the reservoir.

741-328A

2. If the brake fluid is not visible in thesight glass, remove the reservoir coverand add Arctic Cat approved DOT 4brake fluid until the fluid is at the rec-ommended level. Install and secure thereservoir cover. Do not allow moistureto contaminate the brake system.

Changing Brake Fluid

The brake fluid must be changed on a reg-ular basis and whenever the brake fluid hasbeen overheated or contaminated. Thebrake fluid should be changed every 1000miles or at the end of the snowmobilingseason, whichever occurs first. Take thesnowmobile to an authorized Arctic CatSnowmobile dealer for this service. Thisservice is at the discretion and expense ofthe snowmobile owner.

Checking Brake Lever Travel

Before each use, check the brake levertravel using the following procedure:

1. Compress the brake lever fully.

NOTE: Do not pump the brakelever as it will produce an inaccuratereading.

2. Measure the distance between thebrake lever and the handlebar. Thedistance must be greater than 2.54cm (1 in.).

741-328B

3. If the resultant distance is less thanspecified, take the snowmobile to anauthorized Arctic Cat Snowmobiledealer for service. If not under war-ranty, this service is at the discretionand expense of the snowmobile owner.

! WARNINGDO NOT operate the snowmobilewhen the brake lever lock is engagedor when any component in the brakesystem is damaged, worn, oradjusted improperly. If the snowmo-bile is operated and the brake systemis not functioning properly, severepersonal injury could result.

CAUTIONBrake fluid is highly corrosive. Do notspill brake fluid on any surface of thesnowmobile.

! WARNINGDo not overfill the brake fluid reser-voir. Overfilling the reservoir maycause the brake system to hydrauli-cally lock. Use only Arctic Catapproved DOT 4 brake fluid. Neversubstitute or mix different types orgrades of brake fluid. Brake loss canresult. Brake loss can result in severeinjury or even death.

39

Bleeding Brake System

If the brake lever feels spongy when applied,the brake system may need to be bled. Tobleed the brake, use the following procedure:

NOTE: The brake system may bebled by the snowmobile owner ifqualified to do so. If the owner doesnot feel qualified, take the snowmo-bile to an authorized Arctic CatSnowmobile dealer for this service.This service is at the discretion andexpense of the snowmobile owner.

1. Remove the reservoir cover and fillthe reservoir with Arctic Catapproved DOT 4 brake fluid.

2. Slide a piece of flexible tubing overthe ball of the bleeder valve anddirect the other end into a container.

739-269B

3. Slowly compress the brake lever andhold. Open the bleeder valve torelease the fluid and air. When thefluid stops, close the bleeder valve;then release the brake lever.

4. Repeat step 3 until the brake fluidflows free of air bubbles.

NOTE: It may be necessary to refillthe reservoir during the bleedingprocess.

5. When the brake fluid is free of all airand the brake lever feels firm whencompressed, fill the reservoir; theninstall and secure the cover. Removethe tube from the bleeder valve.

Checking/Changing Brake Pads

The condition of the brake pads must bechecked daily and changed if worn ordamaged. To check and change the brakepads, use the following procedure:

NOTE: The brake pads may bechanged by the snowmobile owner ifqualified to do so. If the owner doesnot feel qualified, take the snowmo-bile to an authorized Arctic CatSnowmobile dealer for this service.This service is at the discretion andexpense of the snowmobile owner.

NOTE: When installing new brakepads, always install them as a set.Never install just one pad or usebrake pads which have been used inanother snowmobile.

1. Measure the thickness of both brakepads. Brake pad thickness must begreater than 5.0 mm (0.20 in.). If brakepad thickness is less than specified,replacement of both pads is necessary.

0739-269

2. Remove the pin/hairpin clip securingthe brake pads to the caliper assembly.

3. Remove the brake fluid reservoir cover;then remove most of the brake fluidfrom the reservoir. Install the cover.

! WARNINGDo not operate the snowmobile if thecompressed distance between thebrake lever and the handlebar is lessthan 2.54 cm (1 in.). Brake loss mayoccur. Brake loss can result in severepersonal injury.

CAUTIONBrake fluid is highly corrosive. Do notspill brake fluid on any surface of thesnowmobile.

! WARNINGUse only Arctic Cat approved DOT 4brake fluid. Any substitute may resultin a loss of brakes.

40

NOTE: The above procedure willallow room for the fluid from the cali-per when the pistons are pushedinto the caliper for installing newbrake pads. Replacing the cover willprevent fluid spillage.

4. Using a pair of pliers, pull one brakepad out of the caliper assembly.

NOTE: Changing one pad at a timewill prevent one piston from pushingout the other piston from the caliper.

5. Using a flat-blade tool, slowly andcarefully push the piston into thecaliper.

6. Position the new brake pads into thecaliper.

7. Repeat steps 4-6 for the other pad;then secure the pads with the pin/hairpin clip.

8. Remove the reservoir cover andremove the remaining fluid; then fillthe reservoir with fresh fluid andinstall the cover.

9. Pump the brake lever to ensure cor-rect positioning of the brake pads;then release.

10. Remove the reservoir cover and fill thereservoir to the proper level with freshbrake fluid; then install the cover.

NOTE: When new brake pads areinstalled, a “burnishing” process isrequired. Drive the snowmobile slowlyand compress the brake lever severaltimes until the pads just start to warmup; then allow them to cool down. Thisprocedure stabilizes the pad materialand extends the life of the pads.

Drive BeltThe drive belt transfers power from thedrive clutch to the driven clutch. If thebelt is worn, cracked, or stretched, maxi-mum power will not be transmitted andthe belt could also fail and therefore mustbe replaced. Periodic checks (at leastonce a month under normal usage) of twodrive belt specifications are essential.

1. Measure the outside circumferenceof the drive belt. The belt should bewithin the recommended range incircumference (see appropriate spec-ifications sheet).

2. Measure the outside width of thedrive belt. The belt should be withinthe recommended range in width.

3. Check the belt for cracking, fraying, etc.

If any of the specifications or conditionsare unsatisfactory, replace the drive belt.

NOTE: Drive belts should be pur-chased from an authorized Arctic CatSnowmobile dealer, as Arctic Cat drivebelts are made to exact specificationsand of quality material. Belts made byother manufacturers may not be of thesame specifications or quality and,therefore, usage could result in poorperformance and premature belt failure.

NOTE: Before starting the snowmo-bile in extremely cold temperatures,the drive belt should be removed andwarmed up to room temperature.Once the drive belt is at room temper-ature, install the drive belt.

Also, new drive belts have a break-in periodof approximately 25 miles. After installing anew drive belt, drive the snowmobile for 25miles at 3/4 throttle or less. By revving theengine up and down (but not exceeding 60mph), the exposed cord on the side of a newbelt will be worn down. This allows thedrive belt to gain its optimum flexibility andwill extend drive belt life.

Checking/Adjusting Drive Belt Deflection

0743-319

The drive belt must have the proper fit inthe drive clutch and driven clutch. Tocheck for proper drive belt fit, use thefollowing procedure.

CAUTIONNever run the engine with the drivebelt removed. Excessive revving of theengine could result in serious enginedamage and drive clutch failure.

41

1. Place a straightedge on the top of thedrive belt. The straightedge shouldreach from the drive clutch to the topof the driven clutch.

NOTE: Make sure the drive belt isall the way out in the driven clutchbefore checking drive belt deflection.

2. Using a stiff ruler centered betweenthe drive clutch and driven clutch,push down on the drive belt justenough to remove all slack and notethe amount of deflection. The deflec-tion should be within the range of28.5-31.8 mm (1 1/8-1 1/4 in.).

3. To correct drive belt deflection,remove the sheave adjuster from theclutch, remove or add shim washersto the adjuster, and install the adjuster.

NOTE: Adding shim washers willdecrease belt deflection and remov-ing shim washers will increase beltdeflection. Available shim washersfrom Arctic Cat are p/n 0648-714(0.090 in.) - one included in the toolkit, p/n 0648-715 (0.030 in.), and p/n0648-716 (0.060 in.).

NOTE: Removing/adding shim wash-ers may be done by the snowmobileowner if qualified to do so. If the ownerdoes not feel qualified, take the snow-mobile to an authorized Arctic CatSnowmobile dealer for this service.This service is at the discretion andexpense of the snowmobile owner.

Removing Drive Belt

NOTE: Changing a drive belt canbe done by the snowmobile owner ifqualified to do so. If the owner doesnot feel qualified, take the snowmo-bile to an authorized Arctic CatSnowmobile dealer for this service.This service is at the discretion andexpense of the snowmobile owner.

1. Turn ignition key to the OFF positionand wait for all moving parts to stop.

2. Set the brake lever lock.

3. Open the left-side access panel; thenremove the belt guard.

4. Remove the cap screw, lock washer,washer, and sheave adjuster from theend of the driven clutch.

0743-395

NOTE: Verify the shims and O-ringare not removed from the adjuster.

5. Remove the lock washer and flatwasher from the cap screw andreverse the sheave adjuster.

0744-551

6. Install the sheave adjuster and capscrew into the driven clutch; thentighten the cap screw until the mov-able sheave opens far enough toallow the belt to be removed.

7. Remove the drive belt from the drivenclutch first; then from the drive clutch.

NOTE: Before installing the drivebelt, use a suitable cleaning solventto thoroughly clean the sheaves.

Installing Drive Belt

NOTE: If a new drive belt is beinginstalled, see Drive Belt Break-Insub-section in the General Infor-mation section.

1. Place the drive belt (so the part num-ber can be read and the arrows arefacing the front of the snowmobile)between the sheaves of the driveclutch first; then between thesheaves of the driven clutch.

42

2. Remove the sheave adjuster and installit in its original position (beveled sideout); then install the cap screw, lockwasher, washer, and sheave adjusterback into the driven clutch. Tighten thecap screw to 32 ft-lb.

3. Install the belt guard; then close theleft-side access panel.

4. Release the brake lever lock.

Track TensionTrack tension is directly related to theoverall performance of the snowmobile. Ifthe track is too loose, it may slap againstthe tunnel causing wear or it may “ratchet”on the track drive sprockets. If extremelyloose, the idler wheels may climb over thetrack lugs forcing the track against the tun-nel causing the track to “lock.”

Arctic Cat recommends that the track ten-sion be checked daily during the first 300miles of operation and once a week there-after and adjusted according to need. Thetrack will stretch and take a “set” duringbreak-in. Track deflection must be main-tained within the recommended range.

Checking Track Tension

1. Remove excess ice and snow buildupfrom the track, track drive sprockets,and the inside of the skid frame.

2. Elevate the snowmobile on ashielded safety stand high enough touse a spring scale.

3. At mid-point of the track (on the bot-tom side), hook a spring scale around atrack clip; then pull down on the scaleto the recommended pressure. Measurethe deflection (distance) between thebottom of the wear strip and the insidesurface of the track clip. Compare themeasurement with the chart.

743-191A

Adjusting Track Tension

NOTE: To ensure proper track ten-sion adjustment, perform all adjust-ments on both sides of thesnowmobile.

1. Loosen the rear idler wheel adjust-ing bolt jam nuts.

739-636B

NOTE: On the Bearcat XT, the rearaxle cap screws must also be loosened.

CAUTIONDo not apply Loctite to the drivenclutch cap screw or component dam-age may occur.

! WARNINGNever operate the snowmobile with-out the belt guard/access panelsecured in place.

! WARNINGTrack tension must be properly main-tained. Personal injury could result ifa track is allowed to become exces-sively loose.

! WARNINGDO NOT attempt to check or adjusttrack tension with engine running.Turn ignition key to the OFF position.Personal injury could result from con-tact with a rotating track.

Model SetupTension

AfterBreak-InTension

Bearcat 2000 LT/Lynx/Lynx LT @ 20 lb

44-51 mm(1.75-2 in.)

51-57 mm(2-2.25 in.)

Bearcat XT/GS @ 10 lb 44-51 mm(1.75-2 in.)

44-51 mm(1.75-2 in.)

43

743-323A

2. If the deflection (distance betweenthe bottom of the wear strip and theinside surface of the track clip)exceeds specifications, tighten theadjusting bolts to take up excessiveslack in the track.

3. If the distance between the bottom ofthe wear strip and the inside surfaceof the track is less than specified,loosen the adjusting bolts to increasethe slack in the track.

4. Check track alignment (see TrackAlignment sub-section in this sec-tion).

5. After proper track tension isobtained, tighten the adjusting boltjam nuts against the axle housings.

NOTE: On the Bearcat XT, tightenthe rear axle cap screws to 20 ft-lb.

NOTE: Since track tension andtrack alignment are interrelated,always check both even if only oneadjustment seems necessary.

Track AlignmentProper track alignment is obtained whenthe rear idler wheels are equal distancefrom the inner track drive lugs. Excessivewear to the idler wheels, drive lugs, andtrack will occur if the track is improperlyaligned. Arctic Cat recommends that thetrack alignment be checked once a weekor whenever the track tension is adjusted.

Checking Track Alignment

1. Remove excess ice and snowbuildup from the track, track drivesprockets, and the inside of the skidframe.

2. Position the tips of the skis against awall; then using a shielded safetystand, raise the rear of the snowmo-bile off the floor making sure thetrack is free to rotate.

3. Start the engine and accelerateslightly. Use only enough throttle toturn the track several revolutions.SHUT ENGINE OFF.

NOTE: Allow the track to coast to astop. DO NOT apply the brakebecause it could produce an inaccu-rate alignment condition.

4. When the track stops rotating, checkthe relationship of the rear idlerwheels and the inner track drive lugs.If the rear idler wheels are centeredbetween the inner track drive lugs, noadjustment is necessary.

! WARNINGIf jam nuts are not tightened properly,the adjusting bolts could loosencausing the track to becomeextremely loose and, under someoperating conditions, allow the idlerwheels to climb over the track lugsforcing the track against the tunnelcausing the track to “lock.” If a track“locks” during operation, severe per-sonal injury could result.

! WARNINGMake sure the ignition key is in theOFF position and the track is notrotating before checking or adjustingtrack alignment. Personal injurycould result if contact is made with arotating track.

! WARNINGThe tips of the skis must be posi-tioned against a wall or similar object.

! WARNINGDO NOT stand behind the snowmo-bile or near the rotating track. NEVERrun the track at high speed when thetrack is suspended.

44

725-070A

5. If the idler wheels are not centeredbetween the inner track drive lugs,an adjustment is necessary.

Adjusting Track Alignment

1. On the side of the track which hasthe inner track drive lugs closer tothe rear idler wheel, loosen theadjusting bolt jam nut; then rotatethe adjusting bolt clockwise 1 to 1 1/2 turns.

739-636B

NOTE: On the Bearcat XT, the rearaxle cap screws must also be loos-ened.

743-323A

2. Check track alignment and continueadjustment until proper alignment isobtained.

NOTE: Make sure correct tracktension is maintained after adjust-ing track alignment.

3. After proper track alignment isobtained, tighten the adjusting boltjam nut against the axle housing.

NOTE: On the Bearcat XT, tightenthe rear axle cap screws to 20 ft-lb.

4. Field test the track under actual con-ditions.

5. After the field test, check the align-ment of the track. If additional adjust-ment is necessary, repeat AdjustingTrack Alignment procedure.

SuspensionThe suspension should be adjusted forthe operational needs and riding prefer-ence of the operator.

The front shock springs determine theamount of ski pressure and the reactionof the front suspension to rough terrain.The amount of ski pressure can also bechanged by adjusting the length of theskid frame front arm limiter straps.

The rear springs influence the load carry-ing capability of the snowmobile andshould be adjusted for the weight and rid-ing preference of the operator.

Adjusting Front (Ski) Shock Springs (Bearcat XT)

The front (ski) shock springs are individ-ually adjustable for the terrain conditionsand driving style of the operator. Thespring adjuster/adjuster nut has been setat the factory so the correct amount ofthreads are exposed between the adjuster/nut and the threaded shock housing/bodyas an initial setting. Additional ski pres-sure can be obtained by tightening thespring tension; ski pressure can bedecreased by relaxing spring tension.

! WARNINGIf jam nuts are not tightened properly,the adjusting bolts could loosencausing the track to becomeextremely loose and, under someoperating conditions, allow the idlerwheels to climb over the track lugsforcing the track against the tunnelcausing the track to “lock.” If a track“locks” during operation, severe per-sonal injury could result.

45

NOTE: Equal adjustments shouldbe maintained on both sides of thesnowmobile.

To adjust spring tension, rotate the entirespring in whichever direction is desired.If after adjusting spring tension you notethe snowmobile front end wants to pitch,relax the spring tension on the side that ispitching. If both sides are pitching, relaxthe spring tension on both sides.

NOTE: The spring adjuster willnormally rotate with the spring.

734-501B

Adjusting Skid Frame Front Arm (Bearcat XT)

On these models, the skid frame front armshock spring tension and the limiter strapsare adjustable. However, Arctic Cat rec-ommends that the shock spring be main-tained at the factory preset of 1/8-1/4 in.preload. Tightening the skid frame frontarm shock spring may cause improper bal-ance and may ruin the handling features ofthe snowmobile.

The length adjustment of the front armlimiter straps determines the weight dis-tribution between the front of the skidframe and the skis. Tightening the limiterstrap (shortening the strap) will pull upon the front of the skid frame and willincrease ski pressure. Loosening the lim-iter strap (lengthening the strap) lowersthe front of the skid frame and decreasesski pressure.

When customizing the amount of skipressure, be sure to adjust both strapsequally and do not over-adjust the limiterstraps to adversely affect steering andoperator control of the snowmobile.Some experimentation may be requireduntil the proper adjustment for the opera-tor’s individual style is obtained.

NOTE: If the limiter straps areadjusted, it is highly recommended thatat least a minimum of 1/8 in. preload onthe shock spring be maintained.

Adjusting Rear Spring Pre-Load

Proper adjustment of rear spring pre-loadis necessary to get the most desirableride. The chart is designed to help in set-ting up rear spring pre-load; however,riding style is the single greatest factor indetermining rear spring requirements.

NOTE: These cam position set-tings are suggestions only. Personalriding style will greatly influencecam position settings. Spend time todetermine setting preferences.

Rear spring pre-load adjustment is accom-plished by rotating the adjusting cams.Position 3 provides the stiffest ride, andposition 1 is for the light driver or slow-speed trail riding. Position 2 is for theaverage operator under normal conditions.Always rotate the cam from the lighterposition to the heavier position.

741-450A

! WARNINGDo not adjust the front arm limiterstraps to a point at which steeringand operator control of the snowmo-bile are adversely affected.

Rider Weight (lb) Cam Position

Up to 180 1

180-240 2

Over 240 3

CAUTIONNever force the adjustment camsfrom the low position to the highposition. Cam damage may occur.

46

To rotate an adjusting cam, use the sparkplug wrench from the tool kit. Rotate thewrench until the cam is in the desiredposition. To stiffen the ride, rotate the camso as to raise the spring end. Make theappropriate adjustment on the other cam.

Articulating Skid Frame (Bearcat XT)

The rear articulating portion of the skidframe has two skid frame adjusters whichcontrol the amount of travel in the rearsuspension.

These two adjusters have been pre-set atthe factory and should require no furtheradjustment.

If adjustment is ever required, rotate thetwo adjusters equally to permit 12.5-25mm (1/2-1 in.) travel of the articulatingportion of the suspension.

0743-323

NOTE: Tightening the adjusterswill stiffen the articulating skid frametravel; loosening the adjusters willsoften the travel.

Overload Springs

Some models have overload springs builtinto the rear suspension. When either car-rying a heavy load or riding 2-up, theoverload springs should be engaged byrotating the spring tension blocks to theUP position. The spring tension blockslock in an over-center position whenengaged.

NOTE: Arctic Cat recommendsthat the overload springs beengaged whenever a load on thesnowmobile (operator/passenger/cargo) exceeds 136 kg (300 lb).

To either engage or disengage the springtension blocks, use a spark plug socketand a screwdriver to adjust the springblock to the desired position. Make sureboth spring blocks are in the same posi-tion (either engaged or disengaged).

744-457A

LightsFor the correct headlight bulb and/or tail-light/brakelight LED, see the appropriatespecifications sheet.

Removing and Installing Taillight/Brakelight (Lynx 2000)

These models are equipped with an LEDtaillight/brakelight. If the LED fails, itmust be replaced. To remove and installthe LED, use the following procedure.

NOTE: To access the harness con-nector and the two self-tappingscrews securing the taillight to thesnowflap, compress the two flangedtabs (located on the under-side ofthe tunnel) and carefully pry up onthe front of the taillight/snowflap.

CAUTIONThere are weight limitations for thesesnowmobiles. If additional cargo isbeing added, maximum weight on thesnowmobile (operator/passenger/cargo) should not exceed the maxi-mum limitation set for each snowmo-bile. See chart for details. Also, theoverload springs should be engaged.

Maximum Weight Limitations

Bearcat 2000 LT 170 kg 375 lb

Bearcat 2000 XT 272 kg 600 lb

Bearcat 5000 XT 272 kg 600 lb

Lynx 2000 LT 170 kg 375 lb

47

0744-462

1. Disconnect the taillight harness con-nector.

2. Remove the two self-tapping screwssecuring the taillight to the snowflap.

3. Secure the taillight to the snowflapwith the two self-tapping screws;then connect the taillight connector.

4. Secure the front of the snowflap tothe tunnel by carefully tapping thesnowflap until the two flanged tabssnap into place.

Removing and Installing Taillight/Brakelight (Bearcat XT)

1. Remove the four pins securing therear seat to the seat/Speedrack mount.

743-329A

NOTE: On the LTD, also removethe two pins securing the third seatto the seat/Speedrack mount; thenlift the third seat up and away.

0745-131

2. Lift on the back of the rear seat andmove rearward to remove it from themount.

3. Compress the latch on the right sideof the front seat and lift the front seataway; then disconnect the taillightharness connector.

743-444A

4. Loosen (but do not remove) thethree right-side seat/Speedrackmount cap screws.

5. Carefully route the harness connec-tor through the hole in the storagecompartment panel; then remove theharness from beneath the seat/Spee-drack mount.

6. Remove the two self-tapping screwssecuring the taillight to the bumper;then route the harness out of thebumper and remove the taillight.

7. Route the taillight harness throughthe bumper; then secure the taillightto the bumper with the two self-tap-ping screws.

8. Carefully route the harness beneath theSpeedrack mount and through the holein the storage compartment panel; thenconnect the harness connector.

9. Tighten the three right-side mountcap screws; then lower the front seat.

10. Place the rear seat into position onthe mount making sure the four pinholes are properly aligned with themounting location on the mount.

11. Install the four pins making surethey are properly seated.

48

NOTE: On the LTD, place the thirdseat into position on the mount makingsure the two pin holes are properlyaligned with the mounting location onthe mount; then install the two pinsmaking sure they are properly seated.

Removing and Installing Taillight/Brakelight Bulb (Bearcat 2000 LT/Lynx 2000 LT)

1. Remove the torx-head cap screwssecuring the taillight access panel.

742-467A

2. Disconnect the harness connectorand remove housing.

3. Push in on the socket and rotate itcounterclockwise to remove it fromthe housing.

4. Remove the old bulb by pulling itstraight out of the socket.

5. Install the new bulb in the socket bypushing it straight in.

6. Push the socket into the housing androtate it clockwise to lock into place.

7. Connect the harness connector.

8. Secure the access panel with thetorx-head cap screws.

Removing Headlight Bulb

NOTE: The bulb portion of headlightis fragile. HANDLE WITH CARE. Whenreplacing the headlight bulb, the bulbassembly must first be removed fromthe housing. Do not touch the glassportion of the bulb. If the glass istouched, it must be cleaned with a drycloth before installing.

To access the headlight bulbs, use the fol-lowing procedure:

1. Remove the two torx-head screwslocated to the outside of the head-light adjustment knobs; then removethe single torx-head screw frombeneath the console (locatedbetween the headlights).

743-439A

2. Remove the cap screw and lock nutsecuring the front of the headlightassembly to the air-intake silencer.

3. Lift the front of the console enoughto allow the headlight housing to beremoved; then remove the housing.

4. Remove the bulb from the headlighthousing and disconnect the wiringharness from the bulb.

741-329A

! WARNINGMake sure the rear seat (and on the LTD,the third seat) is securely locked in placewith the pins before carrying a passen-ger or personal injury may result.

49

Installing Headlight Bulb

1. Plug the wiring harness into theheadlight bulb.

2. Insert the bulb into the headlighthousing.

3. Lift the front of the console enoughto allow the headlight housing to beinstalled; then install the housingmaking sure the forks of the housinggo into the grommets on top of theair-intake silencer. Secure with thecap screw and lock nut.

743-439A

4. Position the console onto the air-intakesilencer; then secure with the singletorx-head screw beneath the console(located between the headlights).

5. Install the two torx-head screws locatedto the outside of the headlight adjust-ment knobs; then tighten securely.

6. Check headlight aim (see AdjustingHeadlight Aim in this sub-section).

Adjusting Headlight Aim

The headlight can be adjusted for verticalaim of the HIGH/LOW beam. The geo-metric center of HIGH beam zone is to beused for vertical aiming.

1. Position the snowmobile on a levelfloor so the headlight is approxi-mately 8 m (25 ft) from an aimingsurface (wall or similar surface).

NOTE: There should be an “aver-age” operating load on the snowmo-bile when adjusting headlight aim.

2. Measure the distance from the floorto midpoint of the headlight.

3. Using the measurement obtained instep 2, make a horizontal mark onthe aiming surface.

4. Make a vertical mark which intersectsthe horizontal mark on the aiming sur-face directly in front of the headlight.

5. Engage the brake lever lock and startthe engine. Move the headlight dim-mer switch to the HIGH beam posi-tion. DO NOT USE LOW BEAM.

6. Observe the headlight beam aim.Proper aim is when the most intensebeam is centered on the vertical mark5 cm (2 in.) below the horizontalmark on the aiming surface.

0741-448

7. Adjust the headlight using theadjustment knobs until correct aim isobtained. Shut the engine off; thendisengage the brake lever lock.

CAUTIONDo not touch the glass portion of thebulb. If the glass portion is touched, itmust be cleaned with a dry clothbefore installing.

! WARNINGDo not operate the snowmobileunless headlight beam is adjustedproperly. An incorrectly adjustedbeam will not provide the operatorthe optimum amount of light.

50

Ski Wear BarsThe ski wear bar is a replaceable barattached to the underside of the ski. The pur-pose of the wear bar is to assist in turningthe snowmobile, to minimize ski wear, andto maintain good steering control. If thesnowmobile is operated primarily in deepsnow, ski wear bar wear will be minimal;however, if the snowmobile is operated onterrain where the snow cover is minimal, theski wear bar will wear faster. To maintainpositive steering characteristics, Arctic Catrecommends that the ski wear bars bechecked before each use and replaced ifworn beyond 1/2 of the original diameter.Ski wear bars are available from an autho-rized Arctic Cat Snowmobile dealer.

Removing Ski Wear Bars

1. Using Front End Lift (p/n 5639-151),elevate the front of the snowmobile.

2. Remove the lock nuts securing thewear bar to the ski.

0743-185

3. Remove the wear bar from the ski.

Installing Ski Wear Bars

1. Move the wear bar into position onthe bottom of the ski.

NOTE: If installing a double-offsetwear bar for normal steering capabil-ities, the carbide edge should bedirected to the inside of the ski.

2. Align the wear bar studs with theholes in the ski; then install the locknuts. Tighten to 11-15 ft-lb.

Adjusting Ski Stance (Bearcat)NOTE: Local laws and/or regula-tions as to maximum width of the skistance on these snowmobiles maybe applicable. Always comply withthe maximum width laws and/or reg-ulations when adjusting ski stance.

NOTE: Ski stance can be increased/decreased by 6.3 cm (2.5 in.).

1. Place the front of the snowmobile ona support stand.

2. Remove the cotter pin; then removethe slotted nut and cap screw secur-ing the ski assembly to the spindle.Remove the ski. Account for therubber damper, inserts, and washers.

3. To increase ski stance, place both skistance spacers to the outside of spindle.

4. To decrease ski stance, place both skistance spacers to the inside of spindle.

5. Apply an all-temperature grease to thenon-threaded portion of the capscrew; then slide the cap screwthrough the ski accounting for the rub-ber damper, inserts, and washers.

NOTE: Install the cap screw so theslotted nut will be located to theinside of the ski.

6. Apply red Loctite #271 to thethreads of the cap screw; thentighten the nut to 45 ft-lb.

7. Place the cotter pin into the ski capscrew and spread the pin.

8. Repeat procedure for the other ski.

Rail Wear StripsArctic Cat recommends that the wear stripsbe checked weekly and replaced as neces-sary. Measure the wear strips at 25.4 cm(10 in.) intervals. Wear strips must be 10.7mm (0.42 in.) thick or thicker.

If wear strip measurements are less thanspecified, replacement of both wear stripsis necessary to prevent premature trackclip wear and possible track damage.Take the snowmobile to an authorizedArctic Cat Snowmobile dealer for thisservice. This service is at the discretionand expense of the snowmobile owner.

! WARNINGOperating the snowmobile withexcessively worn ski wear bars mayresult in a loss of steering control.

51

Each time a new set of wear strips areinstalled, they should be tempered. Temperthe wear strips by driving the snowmobilefor approximately a mile on a hard packtrail; then immediately drive into deep snowand allow the wear strips to cool. Repeat theprocedure (warming up the wear strips; thencooling them down) two or three times.

NOTE: The rail wear strips will wearrapidly if the snowmobile is operatedon terrain on which the snow cover isminimal. Loose snow is required tocool and lubricate the wear strips andprevent accelerated wear.

0743-189

52

Performance TipsOperating a high performance snowmo-bile requires a special attention that is notrequired by a low performance snowmo-bile. Often, a minor adjustment willresult in a large increase in performance.This section is intended to highlightminor conditions that adversely affectperformance and the adjustments neededto correct them. Be sure, however, tothoroughly read and understand thisentire manual especially the section onspark plugs, track tension and alignment,and suspension.

DRIVE BELT — This link between theengine and drive train is often the mostneglected component. The drive belt musthave the proper fit in the drive clutch anddriven clutch. Proper fit is when the topsurface of the drive belt is flush with thetop or up to 1/16 in. higher than the drivenclutch sheaves (with the sheaves fullyclosed). If drive belt deflection is abovespecification, the snowmobile will bog andlack power at engagement and will have aslower maximum speed. For good perfor-mance, proper belt deflection is critical. Tocorrect this condition, first determine if thedrive belt is within specifications andreplace if worn or too long. Always runthe drive belt in the same direction.Installing the drive belt so the part num-ber can be read will ensure that the drivebelt is always run the same direction.

DRIVE BELT DEFLECTION — Drivebelt length, condition, and deflection areall important for peak performance. Tocheck and adjust drive belt deflection,remove the belt guard; then use the fol-lowing procedure.

NOTE: It may be necessary toremove a shim washer from betweenthe driven clutch sheaves to allowthe driven clutch to close tighter.Adding shim washers will decreasebelt deflection and removing shimwashers will increase belt deflection.Available shim washers from ArcticCat are p/n 0648-714 (0.090 in.) - oneincluded in the tool kit, p/n 0648-715(0.030 in.), and p/n 0648-716 (0.060in.).

NOTE: Removing/adding shimwashers may be done by the snow-mobile owner if qualified to do so. Ifthe owner does not feel qualified,take the snowmobile to an autho-rized Arctic Cat Snowmobile dealerfor this service. This service is at thediscretion and expense of the snow-mobile owner.

1. Turn the engine off; then open theaccess panel.

2. Make sure the drive belt is sitting atthe top of the driven clutch sheaves.

3. Place a straightedge on top of thedrive belt. The straightedge shouldreach from the driven clutch to thetop of the driven clutch.

4. Using a stiff ruler centered betweenthe drive clutch and driven clutch,push down on the drive belt justenough to remove all slack. Note theamount of deflection on the ruler atthe bottom of the straightedge. Thedeflection should be at 1 1/4 in.

0743-319

NOTE: Push down on the belt withthe ruler only until the bottom of thebelt flexes upward; then read theamount of deflection.

5. To correct drive belt deflection,remove the sheave adjuster from theclutch, remove or add shim washersto the adjuster, and install theadjuster.

NOTE: Adding shim washers willdecrease belt deflection; removingshim washers will increase beltdeflection.

6. Install the belt guard; then close theaccess panel.

53

DRIVE CLUTCH AND DRIVENCLUTCH — Keeping the drive clutchand driven clutch clean should be the pri-mary consideration of the operator. Thedrive clutch and driven clutch can becleaned of any drive belt accumulationusing compressed air. The sheaves can becleaned using a clean cloth and parts-cleaning solvent.

DRIVE CLUTCH/DRIVEN CLUTCHOFFSET — If premature drive belt wearis experienced or if the drive belt turnsover, offset must be checked. Also, offsetmust be checked whenever either thedrive clutch or driven clutch is serviced.

NOTE: For checking offset, it isnecessary to use Clutch AlignmentBar (p/n 0644-496). This special toolcan be purchased from an autho-rized Arctic Cat snowmobile dealer.

To check offset, use the following proce-dure.

1. Open the left-side access panel; thenremove the belt guard.

2. Install the clutch alignment barbetween the drive clutch sheaves.

3. Allow the bar to rest on the driveclutch shaft and against the outsideedge of the driven clutch stationarysheave.

NOTE: The alignment bar mustextend beyond the front edge of thedrive clutch.

4. With the bar against the outside edgeof the driven clutch stationarysheave at points A and B, the barshould just clear the inside edge ofthe stationary sheave of the driveclutch and rest on the stationaryshaft at point C with a maximum0.060 in. clearance at point C. Atthis point, measurement betweenpoints A and C should be 1.507 in.(with a maximum 0.060 in. clear-ance). If the bar either will not clearthe inside edge or is more than thespecified amount, the offset must becorrected.

0745-177

NOTE: If the offset is out of speci-fication, take the snowmobile to anauthorized Arctic Cat Snowmobiledealer for drive system evaluationand/or servicing. This service is atthe discretion and expense of thesnowmobile owner.

DRIVE CLUTCH/DRIVEN CLUTCHPARALLELISM — If premature drivebelt wear is experienced or if the drivebelt turns over, parallelism must bechecked. Also, parallelism must bechecked whenever either the drive clutchor driven clutch is serviced.

NOTE: For checking parallelism, itis necessary to use Clutch Align-ment Bar (p/n 0644-509). This specialtool can be purchased from anauthorized Arctic Cat Snowmobiledealer.

To check parallelism, use the followingprocedure.

1. Remove the drive belt; then open thedriven sheaves and place clutchalignment bar between the sheaves.Release the sheaves.

2. Check the parallelism of the driveclutch/driven clutch using the paral-lelism bar and reference points Xand Y with the parallelism barbetween the driven sheaves. Using acaliper or a machinist’s scale, mea-sure X and Y from the back side ofthe parallelism bar to the back sideof the drive clutch sheave. Measure-ment Y must be 0.060 in. ± 0.020 in.more than measurement X, but Ymust not exceed measurement X bymore than 0.100 in.

54

0744-609

3. If parallelism is not within specifica-tions, the parallelism must be cor-rected by first loosening all theengine mounting bolts (left side,front, and right top rear). Then, prythe front of the engine towards theMAG-side of the engine compart-ment. Next, tighten the left-sidemounting bolts followed by the frontand right-top rear bolts. Re-checkthe parallelism. If still out of specifi-cation, repeat correction procedure.

CARBURETOR MAIN JETS(2000) — Proper carburetion is abso-lutely necessary to obtain peak perfor-mance. Since ambient temperature andoperating altitude both affect the main jetsize needed for optimum engine perfor-mance, the main jets MUST be changedwhenever the temperature changes 20° For whenever operating altitude varies bymore than 1000 feet. The Carburetor JetChart on the belt guard of the snowmo-bile identifies the proper main jets to useunder all operating temperatures and alti-tudes. Follow the Carburetor Jet Chartcarefully to obtain peak engine perfor-mance and avoid engine damage.

GASOLINE — It is not necessary toexceed the recommended 87 octane gaso-line. Using a higher octane gasoline willnot increase overall performance.

55

Preparation for StoragePrior to storing the snowmobile, it must beproperly serviced to prevent corrosion andcomponent deterioration. An authorizedArctic Cat Snowmobile dealer should per-form this service; however, the owner/operator can perform this service ifdesired. This service is at the discretionand expense of the snowmobile owner. Toprepare the snowmobile for storage, ArcticCat recommends the following procedure:

1. Clean the seat cushion with a dampcloth and a Vinyl Protectant.

2. Clean the snowmobile thoroughly byhosing dirt, oil, grass, and other foreignmatter from the skid frame, tunnel,hood, and belly pan. Allow the snow-mobile to dry thoroughly. DO NOT getwater into any part of the engine.

NOTE: On the 5000 models,change the engine oil and replacethe air filter if necessary; then pro-ceed to step 6.

3. Place the rear of the snowmobile upon a shielded safety stand.

4. Carefully pry the intake boots partiallyover the carburetor/throttle body inlets;then start the engine and allow to idle.

5. Spray an Engine Storage Preserverinto the intakes until the engineexhaust starts to smoke heavily oruntil the engine starts to drop inRPM. Turn engine off. Install theintake boots.

6. Plug the exhaust system outlet witha clean cloth.

7. With the ignition switch in the OFFposition:

A. Disconnect the high tensionleads from the spark plugs; thenremove the plugs, connect themto the leads, and ground them onthe cylinder heads.

B. Pour 29.5 ml (1 fl oz) of SAE#30 petroleum-based oil intoeach spark plug hole and pull therecoil starter handle slowly about10 times.

C. Install the spark plugs and con-nect the high tension leads.

NOTE: On the 2000 models, drainthe gas from each carburetor floatchamber.

8. Fill the gas tank to its rated capacity;then add Arctic Cat Fuel Stabilizer(p/n 0436-907) to the gas tank fol-lowing directions on the containerfor the stabilizer/gasoline ratio.Tighten the gas tank cap securely.

9. Flush the gear case and replace thelubricant.

10. Remove the drive belt from the driveclutch/driven clutch. Lay the belt ona flat surface or slide it into a card-board sleeve to prevent warping ordistortion during storage.

11. Clean and inspect the drive clutchand driven clutch.

12. Apply light oil to the upper steeringpost bushing and shafts of the shockabsorbers.

13. Lubricate the rear suspension, spin-dles, and steering arms with all-tem-perature grease.

14. Tighten all nuts, bolts, and capscrews making sure all nuts, bolts,and cap screws are tightenedsecurely. Make sure all rivets hold-ing the components together aretight. Replace all loose rivets.

CAUTIONDo not do steps 3-5 on the 5000 mod-els; severe engine damage couldresult.

CAUTIONDo not run the engine without the beltguard in place and secured.

CAUTIONDo not do step 7 on the 5000 models;severe engine damage could result.

CAUTIONNever crank the engine over withoutgrounding the spark plugs. Damageto coils and/or CDI/ECM may result.

56

15. Clean and polish the hood, console,and chassis with Cat Cleaner (p/n4639-371). DO NOT USE SOL-VENTS. THE PROPELLANTWILL DAMAGE THE FINISH.

NOTE: On electric start models,disconnect the battery cables makingsure to disconnect the negative cablefirst; then clean the battery posts andcables. Charge the battery.

16. If possible, store the snowmobileindoors. Raise the track off the floorby blocking up the back end makingsure the snowmobile is secure.Loosen the track adjusting bolts toreduce track tension. Cover thesnowmobile with a machine cover ora heavy tarpaulin to protect it fromdirt and dust.

17. If the snowmobile must be stored out-doors, position the snowmobile out ofdirect sunlight; then block the entiresnowmobile off the ground makingsure the snowmobile is secure. Loosenthe track adjusting bolts to reducetrack tension. Cover with a machinecover or a heavy tarpaulin to protect itfrom dirt, dust, and rain.

CAUTIONSealed batteries require charging ifleft for extended non-start periods.Arctic Cat recommends trickle charg-ing once a month. Follow the manu-facturer’s instructions and cautions.

CAUTIONAvoid storing in direct sunlight andusing a plastic cover as moisture maycollect on the snowmobile causingcorrosion.

57

Preparation after StorageTaking the snowmobile out of storageand correctly preparing it for another sea-son will assure many miles and hours oftrouble-free snowmobiling. Arctic Catrecommends the following procedure:

1. Clean the snowmobile thoroughly.Polish the exterior of the snowmobile.

2. Clean the engine. Remove the clothfrom the exhaust system. Checkexhaust system and air-intakesilencer for obstructions.

3. Inspect all control wires and cablesfor signs of wear or fraying. Replaceif necessary. Use cable ties or tape toroute wires and cables away fromhot or rotating parts.

4. Inspect the drive belt for cracks andtears. Check belt specifications.Replace if damaged or worn. Installthe drive belt.

NOTE: If the old belt is worn but inreasonable condition, retain it withthe snowmobile as a spare in case ofemergency.

NOTE: On the 2000 models,inspect the in-line fuel filter andreplace if necessary.

5. Inspect all fuel hoses and oil hosesfor deterioration or cracks; replace ifnecessary. Make sure all connectionsare tight; then on the 2000 models,fill the oil-injection reservoir with therecommended 2-cycle oil.

NOTE: After prolonged storage ofthe 2000 models, Arctic Cat recom-mends one tankful of 100:1 gas/oil mix-ture be used in conjunction with the oil-injection system to ensure proper lubri-cation.

6. On the 2000 models, inspect thespark plugs. Replace, gap, or cleanas necessary.

7. Verify the condition of and theadjustment of the carburetors andchoke cable (on the 2000 models)and throttle cable (on all models).

8. Tighten all nuts, bolts, and capscrews making sure all nuts, bolts,and cap screws are tightenedsecurely.

9. If not done during preparation forstorage, lubricate the rear suspen-sion, spindles, and steering armswith all-temperature grease.

10. On the 5000 models, check the cool-ant level and all coolant hoses andconnections for deterioration orcracks. Add properly mixed coolantas necessary.

11. On the 2000 models, clean theengine cooling fins and vents.

12. On electric start models, charge thebattery until fully charged; then con-nect the battery cables making sureto connect the positive cable first.Test the electric start system.

13. Inspect the entire brake system, allcontrols, headlight, taillight, brake-light, ski wear bars, and headlightaim; adjust or replace as necessary.

14. Adjust the track to the proper tensionand alignment.

CAUTIONOn the 2000 models if the gas in eachcarburetor float chamber was notdrained prior to storage, the carbure-tors must be cleaned before startingthe engine.

! WARNINGOn the 2000 models, be sure to tightenthe swivel adapter jam nuts securely. Ifa jam nut isn’t tightened, the adjustercan rotate out of the carburetor capcausing the throttle valve not to returnto the full-closed position.

58

U.S. EPA Emission Control Statement/Warranty Coverage (U.S. Only)

STATEMENT/WARRANTYArctic Cat warrants to the original retail purchaser, and each subsequent purchaser, that all U.S. EPA-certified Arctic Cat snowmobiles are designed, built, and equipped to conform to all U.S. EPA EmissionControl Regulations. Please read the following information completely.

Your authorized Arctic Cat snowmobile dealer will repair or replace any defective emission-relatedcomponent at no cost to you during the warranty period. You may have non-warranty service performedby any repair establishment that uses equivalent components. The regulations provide significant civilpenalties for tampering that causes your snowmobile to no longer meet U.S. EPA emission standards.

Arctic Cat further warrants that the engine and its emission-related components are free from defects inmaterials or workmanship that could cause the engine to fail to comply with applicable regulationsduring the warranty period.

If you have any questions about this information, or the emission warranty coverage statement, contactyour local authorized Arctic Cat snowmobile dealer.

WARRANTY PERIODThe emission warranty period for this snowmobile begins on the same date as the standard warrantycoverage and continues for 30 months or 2500 miles, whichever comes first.

COMPONENTS COVEREDThe emissions warranty covers major emissions control components and emission-related componentslisted as follows:

Engine Management and Sensors Fuel/Air SystemBarometric Pressure Sensor Fuel InjectorsCamshaft Position Sensor Fuel Pressure RegulatorEngine Control Module (ECM) Fuel PumpEngine Coolant Temperature Sensor Carburetor(s)Intake Air Temperature Sensor Manifold Absolute Pressure SensorAir BypassValveOxygen SensorThrottle Position Sensor Crankcase Ventilation System

ISC Valve

Ignition System Miscellaneous Items Used in AforementionedSystemsIgnition Coil ConnectorsKnock Sensor System SwitchesCrankshaft Position Sensor GrommetsExhaust Temperature Sensor ClampsCapacitive Discharge Ignition (CDI) Module HosesMagneto Pick-Up TiesSpark Plugs Gaskets

Wiring

OWNER'S RESPONSIBILITIESThe owner of any snowmobile warranted under this Arctic Cat Emission Control Statement isresponsible for the proper maintenance and use of the snowmobile in accordance with Arctic Cat’srecommendations in the Operator's Manual.

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NOTES

60

Change of Address, Ownership, or Warranty Transfer

Arctic Cat Inc. keeps on file the current name and address of theowner of this vehicle. This allows Arctic Cat to reach the currentowner with any important safety information which may benecessary to protect customers from personal injury or propertydamage. Please make sure a copy of this form is completed andreturned to Arctic Cat Inc. if you move or if the vehicle is sold toanother party.

This form may also be used to transfer the unused portion of theoriginal warranty to a second party. In order to transfer warranty,fill out this form completely; then return a copy of this form toArctic Cat Inc. Arctic Cat will then process the application andissue warranty for the balance of the time remaining of theoriginal warranty. Warranty coverage is only available in thecountry in which the original retail purchase occurs to theoriginal retail purchaser resident in that country or to atransferee resident in that country of the balance of theremaining warranty.

Address Change

Ownership Change

Warranty Transfer

CHANGE OF ADDRESS/OWNERSHIP/WARRANTY TRANSFER TO:

Name ________________________________________

Address ______________________________________

City/State (Province)/Zip Code (Postal Code) __________

Phone # ( ) __________________________________

Year and Model _________________________________

Vehicle Identification Number (VIN) _________________

61

Fold Back Once

CHANGE OF ADDRESS/OWNERSHIP

ARCTIC CAT INC.PRODUCT SERVICE AND

WARRANTY DEPT.P.O. BOX 810

THIEF RIVER FALLS, MN 56701

PlaceStampHere

Warranty Procedure/Owner Responsibility

At the time of sale, an Owner Registration form is to be completed by the sellingdealer and consumer. The receipt of the registration form by Arctic Cat is a condi-tion precedent to warranty coverage. It is the selling dealer’s responsibility to retainand/or submit the appropriate copies of the form to the appropriate place(s) to initi-ate warranty coverage.

The dealer will furnish to the consumer a signed copy of the form which must bepresented to the dealer when requesting warranty service. The registration form isthe consumer’s proof of ownership and warranty eligibility. The form is usedby the dealer to validate the warranty claim. Retain your copy of the form andkeep it in a safe place.

When warranty repair is suspected, the snowmobile should be taken to the sellingdealer, who has the primary responsibility to perform warranty repairs. Subject tothe limitations set forth in the Limited Warranty, in the event the selling dealer hasceased to do business, you have moved, or you are in a location away from yourselling dealer, warranty may be performed by any authorized Arctic Cat Snowmo-bile dealer.

The authorized Arctic Cat Snowmobile dealer will examine the snowmobile or partto determine if, in his opinion, a warrantable condition exists. If a warrantable con-dition appears to exist, the dealer will repair or replace, at Arctic Cat’s option, freeof charge, including any related labor costs, all parts that are found to be warrant-able and any other parts which the warrantable part caused to be damaged. You, theconsumer, will then be asked to sign a warranty form to ensure Arctic Cat that thewarranty work was actually performed.

It is the consumer’s responsibility to maintain and service the snowmobile in accor-dance with Arctic Cat’s recommendations in the Operator’s Manual. To protectyourself and your snowmobile, follow all safety and service tips. Arctic Cat willNOT warrant repairs required as a result of not performing standard operatormaintenance, storage procedures, and service as outlined in the Operator’sManual.

Should you have any questions concerning the warranty, contact an authorized Arc-tic Cat Snowmobile dealer.

Arctic Cat Inc., P.O. Box 810, Thief River Falls, MN 56701 (218) 681-8558

Printed in U.S.A. Trademarks of Arctic Cat Inc. Thief River Falls, MN 56701 p/n 2260-225Phone: (218) 681-9851 - U.S./(204) 982-1656 - Canada

®TM