Form No. 2254-023 --, 1973 EXT I MANUAL

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Form No. 2254-023--, 1973 EXTModel No. 0250-022Model No. 0250-024Model No. 0250-026(340)(440)(650)\ ,Arctic Enterprises, Inc.Printed December 1972Thief River Falls, Minnesota56701IOPERATOR'SMANUAL

TABLE OF CONTENTSPage)1Brake162Drive Pulley.162Driven Pulley17340 Specifications4Drive/Driven Pulley Offset17440 Specifications5Drive/Driven Pulley Center Distance17 - 18650 Specifications6Drive Chain18 - 19Fuel Mixing.7Drive Belt19Pre-Operating Safety Checks8Suspension19 - 20Break-In Procedure .8Track TensionStarting Instructions8-9Track Alignment20 - 219Ski Alignment .21Safety Tips .Registration.Supplemental Parts.Auxiliary Rope Starting .Maintenance and AdjustmentsCheck Before Each Race .""t':- Page2010 - 22Fuel Filter21 - 2210Spark Plug22Carb., Throttle and Synchronization10 - 11Trouble Shooting23Carburetion (Fine Tuning)11 - 14EXT Identification24Carburetor Specifications14Maintenance Log.24Lubrication .15 - 16.SAFETY TIPSJ1.Before the engine is started the operatorshould, for safety purposes, wear the prescribed safety clothing and equipment.2.Before the engine is started, check and insurethat the throttle lever is operating properly.A frozen throttle could cause serious bodilyinjury and/or damage to the snowmobile.3.After the engine has been started, insure thatthe emergency shut-off switch located aheadof the right handgrip will operate properly.4.Never use a match or cigarette lighter tocheck the fuel level. Do not smoke whilerefueling.\5.Gasoline is highly flammable. Never mix oradd fuel to the fuel tank near any open flame.6.Forbid inexperienced drivers to operate themachine. To acquaint a new driver with theoperation of the machine, reading this manualshould be a prerequisite.7.Mentally prepare yourself for each race. Inthe event of an emergency, proper reactionsshould be somewhat automatic.8.Keep feet, hands, and clothing away frommoving parts of the engine and drive train.Keep both feet on the running boards.

,.REGISTRATIONThe EXT carries absolutely no warranty either expressed or implied due to theabnormal usage of the machine.To assist all EXT owners in the performance area of racing, Arctic Enterprises, Inc.will periodically send Racing News to all EXT owners; an Illustrated Parts Manual willalso be sent. To qualify for the factory racing news, the Arctic Cat EXT RegistrationCard must be completely filled out and sent to the factory for a mailing list. Therefore, at the time of sale, your dealer should complete the Registration Card and insureall information is correct. If you should change your address, please notify the factoryas soon as possible.The engines are manufactured for optimum performance, and therefore, no modification is required.Racing News will providefication and other itemsIf the factory modifies aEXT owner, which willefficientlv.each owner with any factory modification, change in speciof general reference that will increase performance levels.component, the information will be sent to each registeredenable the modification to be performed correctly andSUPPLEMENTAL PARTS INCLUDED340 & 440650QuantityQuantityCylinder23Cylinder Gasket2323Cylinder Head Gasket23Piston Set wiRings23Piston Pin Set23Carburetor Gasket23Drive Belt11Spring (Orange)11DescriptionCylinder Head.j--./2)


ARCTIC CAT 340 EXT SPECIFICATIONS4ENGINE:Model . .Cylinders.DisplacementBoreStroke. . .Horsepower .Compression RatioPeak HP R.P.M.Piston ClearanceRing End Gap .TimingIgnition Type .Lighting Coil VoltagelWattageSpark PlugPlug Gap . . . .Carburetor . . .Fuel Mixture RatioCylinder Head Torque.Crankcase Torque . .Flywheel Torque. . .Maximum Engine Operating Temp .339 cc60mm60mm60 7.5: 1 Effective95000.0045 Inch Max.0.006 - 0.012 InchTiming Mark on CrankcaseCD12 Volt/l00 WattNGK Bl0EV0.012 -0.016 InchMikuni VM-3620:116 Ft. Lbs.16 Ft. Lbs.60 Ft. Lbs.425 DegreesDRIVE PULLEY:Model.Kawasaki Spring Tension. . .Arctic Spring Tension (Green)Engagement Speed . . . . .Drive Belt Width . . . . . .Outside Drive Belt CircumferenceKawasaki & Arctic45 Lbs. Per Inch64 Lbs. Per Inch6500 R.P.M. With Gear Reduction1-1/4 Inch46-7/8 Inches (-!3/16 Inch)DRIVEN PULLEY:Model . . .Spring ColorCometRedDRIVE/DRIVEN PULLEY:Center to Center DistanceOffset . . . . . . . . .11-3/8 Inches.320 InchGEARING:With Arctic Drive PulleyWith Kawasaki Drive PulleyChain.20T/35T39T/20T70 PitchCHASSIS:Chassis MaterialBelly Pan MaterialHood Material .Length W/Skis .Height. . . .Overall Width .Track WidthTrack Length on Ground.Fuel Capacity . .Chaincase CapacityWeight. . . . . . . .AluminumFiberglassFiberglass94 Inches33 Inches33-1/2 Inches15 Inches30 Inches4-1/2 Gallons8 Ounces285 PoundsT7A340RX-12 ./

ARCTIC CAT 440 EXT SPECIFICATIONSENGINE:Model . . .Cylinders.DisplacementBoreStroke. . .Horsepower. . .Compression RatioPeak HP R.P.M.Piston ClearanceRing End Gap .TimingIgnition Type .Lighting Coil Voltage/WattageSpark PlugPlug Gap. . . .Carburetor . . .Fuel Mixture RatioCylinder Head Torque.Crankcase TorqueFlywheel Torque. . .Maximum Engine Operating Temp.436 cc68 mm60mm70 7.5: 1 Effective8500 .0.0048 Inch Max.0.008 - 0.014 InchTiming Mark on CrankcaseCD12 Volt/l00 WattNGK Bl0EV0.012 - 0.016 InchMikuni VM-4020:116 Ft. Lbs.16 Ft. Lbs.60 Ft. Lbs.425 DegreesDRIVE PULLEY:Model . . . . .Kawasaki Spring Tension.Arctic Spring TensionEngagement Speed . . .Drive Belt Width . . . .Outside Drive Belt CircumferenceKawasaki & Arctic45 Lbs. Per Inch64 Lbs. Per Inch6500 R.P.M. With Gear Reduction1-1/4 Inch46-7/8 Inches (73/16 Inch)DRIVEN PULLEY:Model.Spring ColorCometRedDRIVE/DRIVEN PULLEY:Center to Center DistanceOffset . . . . . . . . .11-3/8 Inches.320 InchGEARING:With Arctic Drive PulleyWith Kawasaki Drive Pulley.Chain.CHASSIS:Chassis MaterialBelly Pan MaterialHood Material .Length WISkis .Height. . .Overall Width .Track WidthTrack Length on Ground.Fuel Capacity . .Chaincase CapacityWeight. . . . .T7A440RX-l222T/35T35T/20T60 PitchAluminumFiberglassFiberglass94 Inches33 Inches33-1/2 Inches15 Inches30 Inches4-1/2 Gallons8 Ounces285 Pounds5

ARCTIC CAT 650 EXT SPECIFICATIONS6ENGINE:Model . .Cylinders.DisplacementBoreStroke. . .Horsepower .Compression RatioPeak HP R.P.M.Piston ClearanceRing End GapTimingIgnition TypeLighting Coil Voltage/WattageSpark Plug . . .Plug Gap.Carburetor . . . . .Fuel Mixture Ratio . .Cylinder Head Torque.Crankcase TorqueFlywheel Torque. . .Maximum Engine Operating Temp .644 cc67.5 mm60mm100 7.4:1 Effective8500 I0.0048 Inch Max.0.008 - 0.014 InchTiming Mark on CrankcaseCD12 Volt/35 WattNGK B10EV0.012 - 0.016 InchMikuni VM-4020:116 Ft. Lbs.16 Ft. Lbs.60 Ft. Lbs.425 DegreesDRIVE PULLEY:Model . . . . .Kawasaki Spring Tension.Arctic Spring Tension . .Engagement Speed . . .Drive Belt Width . . . . . .Outside Drive Belt CircumferenceKawasaki & Arctic45 Lbs. Per Inch64 Lbs. Per Inch5500 R.P.M.1-1/4 Inch46-7/8 Inches (" -3/16 Inch)DRIVEN PULLEY:Model . . .Spring ColorCometRedDRIVE/DRIVEN PULLEY:Center to Center DistanceOffset . . . . . . . . .11-3/8 Inches.320 InchGEARING:With Arctic Drive PulleyWith Kawasaki Drive PulleyChain.22T/35T35T/20T68 PitchCHASSIS:Chassis MaterialBelly Pan MaterialHood Material .Length W/Skis .Height. . . .Overall Width .Track WidthTrack Length on GroundFuel Capacity . .Chaincase CapacityWeight. . . . .AluminumFiberglassFiberglass94 Inches33 Inches33-1/2 Inches15 Inches30 Inches4-1/2 Gallons8 Ounces315 PoundsT8A650RX-13). )

FUEL MIXINGeThe correct engine lubricant and fuel mixture isvery critical to the performance of the Arctic Catengine.A 100% synthetic lubricant developed especiallyfor racing is Arctic Cat Chemilube; it possesses nopetroleum oil whatsoever. Because of its superiorlubricating characteristics, the bearings, cylinders,pistons and rings are exceptionally well protected.Plug fouling and "load up" on the line are substantially minimized.Mixing RatioeCAUTIONThe recommended fuel mixture ratio mustalways be strictly adhered to. A mixture containing an excessive amount of oil will causeextensive carbon formations on the piston,spark plugs, ports and in the exhaust system;resultants· are loss of power and pre-ignition.A fuel mixture containing too little oil willcause overheating; resultants may be pistonseizure and possible rod and bearing failure.Mixing Procedure"WARNING"When mixing gas/oil or wheri filling the snowmobile fuel tank, do not smoke.The engine that powers the EXT snowmobile is ofthe two stroke principle, which requires the lubricating oil to be mixed with the gasoline for lubricating purposes and internal engine cooling.The correct fuel mixture is five (5) gallons ofpremium gasoline (97 octane minimum) plus one(1) quart of Arctic Cat Chemilube.IINote:The correct fuel mixture ratio is20:1. Mix twenty (20) parts of a good gradepremium gasoline (97 octane minimum) with one(1) part of two cycle air cooled engine oil (ArcticCat Chemilube). This is equivalent to one (1)quart of lubricant mixed with five (5) gallons ofgasoline (97 octane minimum).ADD 2% GALLONSADD CHEMIl.UBENote: Gasoline and oil will not mix well inII extremelycold temperatures, therefore, it isrecommended that the oil be at room temperature(70 ) when mixing.1.Add 2-1/2 gallons of gasoline to a cleangasoline container.2.Add the recommended amount of oil (1quart) and shake the mixture well.3.Add an additional 2-1/2 gallons of gasolineand again, shake the mixture well.When filling the EXT fuel tank, use a funnel witha fine mesh screen to prevent the entry of dirt orother foreign particles into the fuel system.Note: When using a gas/oil mixture that hasII beensetting for some time (settling of oilmay have occurred), shake the mixture beforefilling the fuel tank.SHAKE MIXTUREADD 2% GALLONSSHAKE MIXTUREI7

PRE-OPERATING SAFETY CHECKS1.Check the cooling system. "Insure the coolingfins are clean and free from obstructions.2.Insure the exhaust system and carburetors aresecurely fastened.3.Check the operation of the throttleThe throttle control should depressexcessive effort and return freely toposition.Insure the emergencyswitch is operating properly.1.Insure that all nuts and bolts are properlytorqued.A. loose nut or bolt may causebodily injury' or serious damage to the machine.8.When the machine is operated in extremelycold weather or under slushy conditions, propthe back end of the machine up on a quickjack and open the throttle slightly, allowingthe track to turn several revolutions. Thisrotation will allow the track to clear itself,and provide the bearings, track and drivebelt proper "warm-up" before subjectingthem to full load under race conditions.control.withoutthe idleshut-off4.Check the brake control. The brake shouldfully engage when the brake lever is depressed approximately 3/4" and disengagefreely when released. If more than 3/4" ofbrake lever travel is necessary to engage thebrake, or if the brake lever bottoms on thehandle control, an adjustment is necessary.5.Check the steering to insure the skis turnfreely. If difficulty is encountered in turningthe skis, remove ice or snow from around thesteering mechanism.6.the tank after completion of race. Excessfuel will add weight, and consequently, retardthe performance of the machine during arace. . WARNING"Do not allow anyone to stand to the front orto the rear of the machine or hold up the rearof the machine when either "warming up" or"clearing" the track.Check the machine fuel supply. Carry justenough fuel to complete a race, but alwayshave a minimum of one (1) gallon remain inBREAK-IN PROCEDUREStrict adherence to the following break-in procedure will contribute to the optimum life of theengine.Note: Do not alter the gas/oil mixture duringthe break-in period (5 operating hours).subjected to heavy lugging or prolonged fullthrottle operation. During break-in, a maximumof three-fourths throttle is recommended. Varythe operating speeds but DO NOT subject the engine to constant speed operation for a prolongedtime.For the first five (5) operating hours (approximately one tank of fuel), the engine shou Id not beAfter the break-in, check the entire machine forproper operation.IISTARTING INSTRUCTIONSTO START:. WARNING .Never allow anyone to stand in front of themachine when starting or when the engine isrunning.81.Insure all Pre-Operating Safety Checks havebeen satisfactorily carried out .2.Position the emergency shut-off switch (A)in the ON position.

STARTING INSTRUCTIONS3.Make sure the tether pin (B) is inserted in thetether switch.4.Pull the starter plunger (e) on both carburetors fully upward. DO NOT HOLD THROTTLE OPEN WHEN STARTING.Note: The engine will not start if the throttleis held slightly open when the starter plungeris actuated (upward position). If the throttle isopened, the carburetors starting systems will bebypassed and an insufficient amount of fuel willnot allow the engine to start.II5.Grasp recoil starter handle (D) and pullslowly until recoil mechanism engages. Uponengagement, give a short, quick pull.eeCAUTIONTo avoid damaging the recoil starter mechanism, DO NOT pull the recoil rope to its limitor release rope from an extended position.6.When the engine starts, immediately compressthe throttle and rev the engine to a fast idle(approximately 3000 RPM) for "warm-up".7.Allow a cold engine to idle ("warm-up") forapproximately thirty (30) seconds beforeoperating the machine.Push both starterplungers fully downward after the "warmup".eeCAUTIONIdling of a warm engine for more than thirty(30) seconds may cause excessive carbon formations, plug fouling and flooding. Placing acold engine under heavy load conditions (highRPM) may cause damage to the pistons andcylinders.9

AUXILIARY ROPE STARTINGIe Arctic Cat engine used in the EXT is equippedwith an auxiliary starting pulley, accessible byremoving the recoil starter should a failure occur.The starting rope IS located in the tool pouch; keepthe rope with the machine at all times.MAINTENANCE AND ADJUSTMENTSCheck Before Each Race5.Rotate the idle adjusting screws (A) an additional two (2) turns clockwise.6.Loosen the jam nuts (B) on both throttlecables and rotate the swivel adapter counterclockwise until all slack has been removedfrom the throttle cable. Lock the jam nutsand swivel adapter into position.Improper maintenance may lead to costly repairs,or a major breakdown. The following items shouldbe checked or serviced before each race: A) DriveBelt; B) Drive/Driven Pulley Offset; C) Drive/Driven Pulley Center to Center Distance; D) Track;E) Suspension; F) Brake; G) Electrical Connections; H) Carburetion; I) Oil Level in Gear Reduc" 'n Case and J) Proper Nut and Bolt Torque.Carburetor, Throttle and Synchronization AdjustmentThe engine used in the EXT employs Mikuni carburetors for precise fuel/air mixture metering. TheMikuni carburetor is built with a fixed main jet,and therefore, no high speed adjustment is necessary. To insure optimum engine performance,both carburetors must be equally adjusted (SYNCHRONIZED).1.Open the hood.2.Rotate the idle adjusting screws (A) counterclockwise until the idle adjusting screw tipis flush with the side of the carburetor bore.7.Loosen the jam nuts (B) on both throttlecables and rotate the swivel adapter until thethrottle slide fu Ily seats in the recess of thecarburetor bore.Lock the jam nuts andswivel adapter into position.Look into the throat of all carburetorsand slowly compress the handlebar-mountedthrottle lever. All throttle slides must beginIfto rise at precisely the same instant.throttle slide movement does not occur asspecified, repeat steps 2 - 6.8.Carefully rotate both pilot air screws (C)clockwise until a slight seating resistance isfelt.9.Rotate both pilot air screws (C) one (1)revolution counterclockwise.3.Rotate both idle adjusting screws (A) clockwise until the screws contact the throttleslide. At that instant, the throttle slide willbegin to rise.10

MAINTENANCE AND ADJUSTMENTS10.The idle speed may not be suitable for normaloperation, even though the carburetors aresynchronized.To check the engine forproper idle, proceed as follows:A.Run the engine until normal engineoperating temperature is achieved.B.If the engine will not idle or if a higheridle RPM is desired, rotate the idleadjusting screws (A) clockwise until thedesired idle is obtained.r ! i -') , i Note:Set both idle adjusting screws (A)equally. If the idle adjusting screws are notadjusted equally, it will be necessary to repeatsteps 2·8.II11.Close the hood.Carburetion (Fine Tuning)1.CH ECK F LOAT LEVE L '- The fuel level inthe float chamber is governed by the projection of the two float arms. If there is dirtbetween the needle valve and seat preventingthe valve from closing, if there is wear ordamage in the needle valve area or if thefloatts) is punctured, fuel overflow mayoccur. Conversely, if the needle sticks to theseat, a very limited amount of fuel will flowinto the float chamber.A.Remove the float chamber body andgasket from the main body of the carburetor and invert the carburetor.B.Measure the distance (0) from the gasket surface to the top edge of the floatarm. For the Mikuni VM-36 carburetor,the distance should be .693 inch or17 .8mm: for a VM-40 carburetor, thedistance should be .693 inch or 17.8mm.When an adjustment of the float arm isnecessary, bend only the float armactuating tab.6'---f\. "--2.SELECT MAl N JET - Main jets for the EXTwill have an approximate graduated rangefrom 370 to 390. In this graduated range,main jet sizes are increased in steps of ten:370, 380 and 390. The larger the number,the greater diameter of the jet orifice and asa result, a richer fuel/air mixture.A.Run the machine on a flat hard-packedarea at full throttle. If the engine drags,or labors at full throttle, the main jetorifice (size) is too large. To remedy,install the next smaller size jet and repeat full throttle operation on a flathard-packed area. Continue changingjets until the engine runs efficiently atfull throttle as explained previously.Check the condition of the spark plug(see Spark Plug, page 22).B.If the engine runs efficiently at fullthrottle to begin with, the jet shouldstill be checked for proper size; the jetmay be contributing to a lean condition.If this condition does exist, install amain jet which is two sizes larger. Runthe machine on a flat hard-packed area;when the engine drags, use the nextlower sized main jet. Engine should nowoperate efficiently. Check the conditionof the spark plug (see Spark Plug, page22).11

MAINTENANCE AND ADJUSTMENTSF.Shut the engine off.G.When the desired idle speed has beenattained, cautiously rotate the pilot airscrew in andat the same time, count thenumber of turns required to seat thescrew. .eeCAUTIONDO NOT force the pilot air screw; doing somay cause damage to the screw or seat.3.ADJUST PI LOT AI R SCR EW (A) - Throttleslide must be resting against the idle speedadjusting screw before any adjustment isinitiated. Observe this condition by lookinginto the bore of the carburetor.A.Prop the back end of the machine up ona Quick Jac and start the engine.8.Slowly rotate the idle speed adjustingscrew (8) in until the engine begins toid Ie faster.C.Slowly back the idle speed adjustingscrew (8) out until the engine begins todie out.D.E.12Perform steps C, D and E until theproper engine idle speed is attained.I.If it takes 1 turn or less, the pilot jetis too small and must be replaced by alarger pilot jet. If it takes 2-1/2 turns ormore, the pilot jet is too large and mustbe replaced by a smaller pilot jet.Note: Pilot jets will have an approximategraduated range from 30 to 35.In thisgraduated range, pilot jet sizes are increased insteps of five: 25, 30 and 35. The larger thenumber, the greater diameter of the jet orifice andas a result, a richer fuel/air mixture.J.4.IIThe pilot air screw adjustment shouldrange from 1 to 2-1/2 turns out fromthe full seated position.IIRotate the pilot air screw (A) in or outuntil the engine runs smoothly.Note: Rotating the pilot air screw in willrichen the fuel/air mixture and rotating outwill lean

1973 EXT Form No. 2254-023 Model No. 0250-022 (340) Model No. 0250-024 (440) Model No. 0250-026 (650) I OPERATOR'S MANUAL--, \ , Printed December 1972 Arctic Enterprises, Inc. Thief River Falls, Minnesota 56701

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