1988 Arctic Cat Cougar Service Manual

The 1988 Arctic Cat Cougar is a snowmobile featuring various engine options including the 440cc and 500cc liquid-cooled engines, slide rail suspension system, hydraulic disc brakes, and electric start. This service manual provides comprehensive technical information for maintenance, troubleshooting, and repair procedures. Below are key sections covering specifications, maintenance schedules, engine service, chassis, electrical systems, and troubleshooting.

1. Specifications 2. Maintenance Schedule 3. Engine Service 4. Fuel System 5. Drive System 6. Suspension & Steering 7. Brake System 8. Electrical System 9. Troubleshooting 10. Torque Specifications 11. Wiring Diagrams

Specifications

Technical specifications for the 1988 Arctic Cat Cougar models.

ComponentSpecification
Engine Type2-stroke, liquid-cooled
Displacement440cc / 500cc
Bore x Stroke70mm x 57mm (440cc)
CarburetorMikuni VM34
Ignition SystemCDI electronic ignition
Starting SystemElectric start with backup recoil
Track Length121 inches
Track Width15 inches
SuspensionSlide rail with hydraulic shocks
Brake SystemHydraulic disc
Fuel Capacity11.5 gallons
Oil Capacity3.2 quarts

Maintenance Schedule

Recommended maintenance intervals for optimal performance.

  1. Pre-season inspection: Check all systems before first use
  2. Every 500 miles: Change engine oil and filter
  3. Every 1,000 miles: Inspect drive belt and clutch
  4. Every 2,000 miles: Replace spark plugs
  5. Seasonal: Grease suspension and steering components
  6. Annual: Check brake fluid and hydraulic system

WARNING! Always perform maintenance with engine off and cool. Use proper safety equipment.

Engine Service

Engine maintenance and repair procedures.

  1. Compression test: Should read 120-150 PSI
  2. Spark plug gap: 0.020-0.024 inches
  3. Carburetor adjustment: Pilot screw 1.5 turns out
  4. Cooling system: Check coolant level and hoses
  5. Exhaust system: Inspect for leaks and damage

CAUTION! Engine components may be hot. Allow to cool before servicing.

Fuel System

Drive System

Drive clutch and track system maintenance.

Primary Clutch: Comet 102C, inspect weights and spring

Secondary Clutch: Arctic Cat roller, check helix and spring

Drive Belt: Replace if cracked or worn. Track: Adjust tension to 1 inch deflection. Chaincase: Check oil level and chain tension.

Suspension & Steering

Front suspension: Double A-arm with shocks. Rear suspension: Slide rail with torsion springs.

  1. Check ski alignment and carbides
  2. Inspect shock absorbers for leaks
  3. Grease all suspension pivot points
  4. Check steering play and adjust if necessary

Tip: Regular suspension maintenance improves handling and ride quality.

Brake System

Hydraulic disc brake maintenance and service.

  1. Check brake fluid level in reservoir
  2. Inspect brake pads for wear
  3. Bleed system if spongy feel
  4. Check brake lever free play
  5. Inspect brake rotor for warping

WARNING! Always test brakes after service before operation.

Electrical System

Battery: 12V 18Ah. Charging system: 240W output.

ComponentSpecification
Headlight55W halogen
Tail Light5W/21W
Stator Output240W AC
Voltage Regulator14.2V DC output
Starter Motor0.8kW

Troubleshooting

SymptomPossible CauseCorrective Action
Engine won't startFuel, spark, or compressionCheck fuel supply, spark plugs, and compression
Poor performanceClutch or carburetor issuesInspect clutch engagement, clean carburetor
OverheatingCooling system blockageCheck coolant level and cooling passages
Electrical failureBattery or charging systemTest battery voltage and stator output
Track slippingDrive belt or clutch issuesInspect drive belt and clutch components

Torque Specifications

Critical fastener torque values.

Wiring Diagrams

Complete electrical schematics for all models. Color-coded wiring for easy identification. Main harness routing and connector locations. Ground points and fuse box layout.

Service: Contact Arctic Cat dealer for technical support. Parts available through authorized dealers only.

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