1991 Arctic CAT COUGAR Snowmobile Service Repair Manual
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🏷️ Basic Information Identification Make: Arctic Cat Model: Cougar Year: 1991 Codes Vehicle Type: Snowmobile Manual Type Indicator: Service Repair Manual 👋 Introduction Market Position Target Audience: Arctic Cat owners, independent repair shops, and DIY enthusiasts seeking to maintain and repair their 1991 Cougar snowmobile. Competitive Analysis Value Proposition: Provides factory-level repair information to save on professional service costs and empower owners with detailed knowledge for effective upkeep. Key Features Comprehensiveness: Covers every aspect of maintenance and repair, based on a complete teardown of the specific model and year. Usability: Written with easy-to-understand, step-by-step procedures. Technical Accuracy: Originally published by the manufacturer for dealership technicians, ensuring high accuracy and detail. 📋 Manual Details Coverage Areas Primary Coverage: Comprehensive maintenance and repair for the 1991 Arctic Cat Cougar Snowmobile. Specific Systems: Engine, Fuel System (Carburetor & Fuel Injection), Chassis, Steering, Electrical (Ignition, Lighting, Charging, Starting), Power Train (Clutches, V-Belt, Chain Case, Brake, Suspension, Drive Track). Page Count Estimated Page Count: Detailed information suggests a substantial page count, typical for a full factory service manual. Specific number not provided, but coverage implies hundreds of pages. Manual Type Type: Factory Original Manufacturer Service Repair Manual Language Language: English Format File Format: PDF Print Quality: Full Printable Zoom Capability: Yes Delivery Delivery Method: Instant Download Requirements Software Requirements: Adobe PDF Reader, WinZip Product Origin Publisher Type: Manufacturer (Original) 📖 Manual Coverage Systems Covered Engine Systems: Detailed engine removal, disassembly, inspection, assembly, and installation. Includes recoil starter, flywheel magneto, primary sheave, oil pump, top end, and bottom end. Fuel Systems: Carburetor (removal, disassembly, inspection, assembly, installation, tuning, adjustment, troubleshooting), Carburetor Tuning Data, Fuel Injection System (repair, troubleshooting, specifications), Intake. Chassis Systems: Steering (assembly, adjustment), Skis (inspection, assembly), Oil Tank, Fuel Tank. Electrical Systems: Ignition System (troubleshooting, timing, spark gap, coil, spark plug, pickup/CDI charging coil tests), Lighting System (headlight adjustment, lighting coil test, voltage regulator), Charging System (circuit test, silicon rectifier check), Electric Starting System (starter motor, relay switch, battery). Powertrain Systems: Sheave alignment, clutch tuning, clutch setting data, V-belt (removal, inspection), primary and secondary sheaves (removal, disassembly, inspection, assembly), chain case (disassembly, inspection, gearing, assembly), brake (disassembly, inspection, assembly, adjustment), slide rail suspension (removal, inspection, adjustment, installation), drive assembly, track adjustment. Procedures Included Maintenance Procedures: General Information (pre-season preparation, maintenance, periodic maintenance, tune-up), High Altitude Tuning. Repair Procedures: Step-by-step repair procedures for the entire vehicle, including component disassembly, cleaning, inspection, assembly, and reinstallation. Troubleshooting Guides: Troubleshooting sections for Fuel System, Ignition System, and Engine. Component Rebuild: Covers detailed rebuild procedures for major components like carburetors, clutches, and engine sub-assemblies. Technical Depth Depth: Highly detailed, covering complete teardowns, component-level repairs, tuning, and adjustments, as intended for dealership technicians and certified mechanics. Diagrams Illustrations: Wealth of illustrations, diagrams, schematics, and pictures to ensure successful repair work. Special Information: Special Tools, Precautions Before Service, Carburetor Tuning Data, Clutch Setting Data, Tightening Torque Specifications, Wiring Diagrams, Wire and Cable Routing Diagrams, Exploded Diagrams. Miscellaneous Sections Wiring Diagrams: Includes comprehensive wiring diagrams and wire/cable routing diagrams. Technical Data Tables: Includes specifications, tightening torque values, and conversion tables. 📊 Manual Specifications File Format Digital Format: PDF Print Quality Printability: Full Printable Binding Type Digital Binding: N/A (Digital Download) Paper Type Digital Paper Type: N/A (Digital Document) File Content Searchable Text: Implied by PDF format, but exact searchability may vary depending on the OCR quality of the original document. ⚙️ Engine Specifications Primary Engine Engine Type: Likely a 2-stroke, twin-cylinder engine based on typical Arctic Cat Cougar models of this era. Specific displacement and configuration not detailed in product info. Performance Horsepower Torque: Specific horsepower and torque figures are not provided in the product information but are covered within the tuning and adjustment sections of the manual. Fuel System Fuel Delivery: Features both Carburetor and Fuel Injection systems, with detailed repair and tuning procedures for both. Carburetor Details: Includes specific tuning data and adjustment procedures for low-speed, mid-range, and high-speed operation. Maintenance Oil System: Includes procedures for oil pump cable adjustment and oil pump disassembly/assembly. 🔧 Transmission Standard Clutch System: CVT (Continuously Variable Transmission) system with primary and secondary clutches, V-belt drive. Optional Gear Ratios: Chain case disassembly and inspection of gearing implies potential for gear ratio information or maintenance relevant to the chain drive system. Features Clutch Tuning Data: Specific data for clutch engagement and shift RPM is provided. Sheave Alignment: Procedure for ensuring correct sheave alignment for optimal power transfer and belt life. 📐 Dimensions Exterior Overall Dimensions: Specific dimensions are not provided in the product information but are likely detailed in the manual's general information or specifications section. Weights Dry Weight: Not specified in product details, but would be a key specification within the manual. Operating Weight: Not specified in product details, but would be a key specification within the manual. 🛡️ Safety Features Ratings Crash Test Results:...
Detailed information suggests a substantial page count, typical for a full factory service manual. Specific number not provided, but coverage implies hundreds of pages.
Manual Type
Type:
Factory Original Manufacturer Service Repair Manual
Language
Language:
English
Format
File Format:
PDF
Print Quality:
Full Printable
Zoom Capability:
Yes
Delivery
Delivery Method:
Instant Download
Requirements
Software Requirements:
Adobe PDF Reader, WinZip
Product Origin
Publisher Type:
Manufacturer (Original)
📖 Manual Coverage
Systems Covered
Engine Systems:
Detailed engine removal, disassembly, inspection, assembly, and installation. Includes recoil starter, flywheel magneto, primary sheave, oil pump, top end, and bottom end.
General Information (pre-season preparation, maintenance, periodic maintenance, tune-up), High Altitude Tuning.
Repair Procedures:
Step-by-step repair procedures for the entire vehicle, including component disassembly, cleaning, inspection, assembly, and reinstallation.
Troubleshooting Guides:
Troubleshooting sections for Fuel System, Ignition System, and Engine.
Component Rebuild:
Covers detailed rebuild procedures for major components like carburetors, clutches, and engine sub-assemblies.
Technical Depth
Depth:
Highly detailed, covering complete teardowns, component-level repairs, tuning, and adjustments, as intended for dealership technicians and certified mechanics.
Diagrams Illustrations:
Wealth of illustrations, diagrams, schematics, and pictures to ensure successful repair work.
Special Information:
Special Tools, Precautions Before Service, Carburetor Tuning Data, Clutch Setting Data, Tightening Torque Specifications, Wiring Diagrams, Wire and Cable Routing Diagrams, Exploded Diagrams.
Miscellaneous Sections
Wiring Diagrams:
Includes comprehensive wiring diagrams and wire/cable routing diagrams.
Technical Data Tables:
Includes specifications, tightening torque values, and conversion tables.
📊 Manual Specifications
File Format
Digital Format:
PDF
Print Quality
Printability:
Full Printable
Binding Type
Digital Binding:
N/A (Digital Download)
Paper Type
Digital Paper Type:
N/A (Digital Document)
File Content
Searchable Text:
Implied by PDF format, but exact searchability may vary depending on the OCR quality of the original document.
⚙️ Engine Specifications
Primary Engine
Engine Type:
Likely a 2-stroke, twin-cylinder engine based on typical Arctic Cat Cougar models of this era. Specific displacement and configuration not detailed in product info.
Performance
Horsepower Torque:
Specific horsepower and torque figures are not provided in the product information but are covered within the tuning and adjustment sections of the manual.
Fuel System
Fuel Delivery:
Features both Carburetor and Fuel Injection systems, with detailed repair and tuning procedures for both.
Carburetor Details:
Includes specific tuning data and adjustment procedures for low-speed, mid-range, and high-speed operation.
Maintenance
Oil System:
Includes procedures for oil pump cable adjustment and oil pump disassembly/assembly.
🔧 Transmission
Standard
Clutch System:
CVT (Continuously Variable Transmission) system with primary and secondary clutches, V-belt drive.
Optional
Gear Ratios:
Chain case disassembly and inspection of gearing implies potential for gear ratio information or maintenance relevant to the chain drive system.
Features
Clutch Tuning Data:
Specific data for clutch engagement and shift RPM is provided.
Sheave Alignment:
Procedure for ensuring correct sheave alignment for optimal power transfer and belt life.
📐 Dimensions
Exterior
Overall Dimensions:
Specific dimensions are not provided in the product information but are likely detailed in the manual's general information or specifications section.
Weights
Dry Weight:
Not specified in product details, but would be a key specification within the manual.
Operating Weight:
Not specified in product details, but would be a key specification within the manual.
🛡️ Safety Features
Ratings
Crash Test Results:
N/A for snowmobiles of this era in the context of automotive safety ratings.
Active Features
Braking System:
Includes brake disassembly, inspection, assembly, and adjustment procedures.
Passive Features
Throttle Control:
Includes throttle cable adjustment procedure.
Safety Precautions
Service Precautions:
Manual includes 'Precautions Before Service' for safe working practices.
💡 Technology Features
Infotainment
Features:
Basic instrumentation typical for the era (speedometer, tachometer, possibly engine temp or oil light), no advanced infotainment.
Driver Assistance
Features:
No electronic driver assistance features expected for this model year and type of vehicle.
Electrical Advancements
Ignition System Type:
CDI (Capacitor Discharge Ignition) system, with detailed testing procedures for components like the CDI unit and charging coils.
Lighting System:
Includes procedures for headlight beam adjustment and testing of lighting coils.
🔧 Maintenance
Service Intervals
Periodic Maintenance:
Manual covers 'Periodic Maintenance' and 'Pre-Season Preparation', implying a structured maintenance schedule is detailed within.
Fluid Specifications
Oil Type:
Specific oil types for the engine and chain case are likely detailed in the Engine and Power Train sections, especially relating to oil pump and chain case lubrication.
Coolant Type:
If liquid-cooled, coolant specifications would be included, but this is not explicitly mentioned. Air-cooled models are common for this era.
Known Issues
Common Wear Items:
The manual's detailed inspection procedures for clutches, drive belts, suspension components, and engine parts would address common wear items for a snowmobile of this age.
Tune Up
Tune Up Procedures:
Comprehensive tune-up procedures, including carburetor adjustments and ignition system checks, are detailed.
High Altitude
Altitude Tuning:
Specific procedures for 'High Altitude Tuning' are provided, crucial for engine performance at different elevations.
📚 Vehicle History
Brand Heritage
Arctic Cat Legacy:
Arctic Cat has a long-standing heritage in snowmobile manufacturing, known for performance and innovation in the off-road and winter recreation sectors.
Model Evolution
Cougar Lineage:
The Cougar model was a significant part of Arctic Cat's lineup in the late 1980s and early 1990s, often positioned as a performance-oriented or touring machine. This 1991 model represents a specific iteration of that lineage.
Production
Manufacturing Era:
Produced during the 1991 model year, a period of evolving snowmobile technology.
🏆 Awards & Recognition
Recognitions
Industry Awards:
Specific awards for the 1991 Cougar are not detailed in the product information, but Arctic Cat models from this era were generally well-regarded for their performance within the snowmobile community.
Certifications
Manufacturing Standards:
Manual produced to meet manufacturer's standards for dealership service.
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