Arctic Cat 2015 ZR 5000 Service Manual
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Arctic Cat 2015 ZR 5000 Service Manual

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S E R V I C E M A N U A L
ZR/XF/M/Pantera
5000/7000/9000
www.arcticcat.com

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Summary of Contents for Arctic Cat 2015 ZR 5000

  • Page 1 S E R V I C E M A N U A L ZR/XF/M/Pantera 5000/7000/9000 www.arcticcat.com...
  • Page 2 Such efficiency not only helps build consumer confidence but also saves time and labor. All Arctic Cat publications and snowmobile decals display the words Warning, Caution, and Note to emphasize impor- tant information. The symbol ! WARNING identifies personal safety-related information. Be sure to follow the directive because it deals with the possibility of severe personal injury or even death.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS General Information ............2 Fuel Systems ............. 114 Snowmobile Identification ..........2 Fuel System..............114 Recommended Gasoline and Oil ........2 Individual Components ..........114 Engine Break-In ..............2 Self-Diagnostic System/Codes ........117 Drive Belt Break-In............3 Fuel Pressure Regulator..........

  • Page 4: General Information

    These numbers are required to complete warranty claims n 6639-529 - gal.). properly. No warranty will be allowed by Arctic Cat if the engine serial number or VIN is removed or mutilated After the engine break-in period, the engine oil should be in any way.

  • Page 5: Drive Belt Break-In

    When replacement of parts is necessary, use only genuine properly. This is why the fuel ratio has to be recalibrated. Arctic Cat parts. They are precision-made to ensure high High altitude engines operate as though they have a lower quality and correct fit.
  • Page 6 Exhaust gasses are directed through the turbocharger tur- As snow cover and riding conditions change, several dif- bine wheel which is attached to the compressor through a ferent adjustments can be made to change the ride and han- common shaft. As the exhaust gasses spin the turbine, the dling characteristics for operator preference.

  • Page 7: Preparation For Storage

    Sealed batteries require charging if left for extended On the durometer scale, the higher the number, the harder non-start periods. Arctic Cat recommends trickle charg- the lugs. For riding in deep powder snow, a softer durome- ing once a month. Follow the manufacturer’s instruc- ter track works best.

  • Page 8: After Break-In Checkup/Checklist

     NOTE: If the old belt is worn but in reasonable con- Below is a list of items to check after the break-in period. The recommended mileage for this inspection is between dition, retain it with the snowmobile as a spare in 100 and 300 miles.

  • Page 9: Electrical Specifications

    ITEM Electrical Specifications Crankshaft Main Bearing Clearance 0.0007-0.0015” Crankshaft/Rod Bearing Clearance 0.0016-0.0025” Crankshaft Thrust Runout (max) 0.0043” Component Test Value + Test Connections - Crankshaft Main/Rod Journals (Bearing Surfaces) 0.0012” 5000/9000 (Normally Closed Ignition) Valve Guide Inside Diameter 0.2165-0.2170” Magneto Coil (3 tests) 0.2-0.4 ohm yellow yellow...

  • Page 10: Drive System Specifications

    None Drive System Components A list of Drive System components that are available through the Arctic Cat Service Parts Department can be found in the Quick Reference Guide. This information will be useful when doing any fine-tuning on the drive...

  • Page 11: Chain Case Performance Calibrations

    Chain Case Performance Calibrations Drive Gear Ratio Chain Engine RPM Sprocket Ratio 6200 6400 6600 6800 7000 7200 7400 7600 7800 8000 8200 8400 8600 8800 9000 Top Btm Vehicle Speed (mph) 7 Tooth 49 0.429 (3.0" pitch) 46 0.435 51 0.451 48 0.458 50 0.480...
  • Page 12 Drive Gear Ratio Chain Engine RPM Sprocket Ratio 6200 6400 6600 6800 7000 7200 7400 7600 7800 8000 8200 8400 8600 8800 9000 Top Btm Vehicle Speed (mph) 9 Tooth 49 0.429 (2.86" 46 0.435 pitch) 51 0.451 48 0.458 50 0.480 41 0.512 38 0.553...

  • Page 13: Track Specifications

    IFP SHOCK ABSORBERS Track Specifications Below is a list of IFP shock absorbers used on the front and rear suspensions of Arctic Cat snowmobiles. If replacing a shock absorber, always select a shock absorber with the same length, both collapsed and Track Tension extended.

  • Page 14: Torque Conversions

    STEERING/FRONT SUSPENSION/CHASSIS Torque Conversions Torque Item Secured to ft-lb Spindle Wearbar ft-lb ft-lb ft-lb ft-lb Ski Handle 54 in.-lb 35.4 69.4 103.4 Handlebar Adjuster Block (Standard) Post 36.7 70.7 104.7 Handlebar Adjuster (Sno Pro) Post 38.1 72.1 106.1 Steering Support Mounting Block 39.4 73.4...

  • Page 15: Steering And Body

    7000 Steering and Body This section has been organized into sub-sections for ser- vicing steering and body components; however, some components may vary from model to model. The techni- cian should use discretion and sound judgment when removing and installing components. ...
  • Page 16 9000 SNO-2221A 0746-792 6. Remove the cap screws and handlebar caps securing 3. Locate the hood harness connector (located under the center vent between the intake vents) and unplug the the handlebar to the top of the handlebar riser; then connector;...
  • Page 17 SNO-1025 SNO-1026A 7. Remove the two machine screws and nuts securing 10. Remove the steering post. the front and rear steering supports around the steer- INSPECTING ing post. 1. Inspect all welded areas for cracks or deterioration. 2. Inspect the steering post and steering-post retaining plate for cracks, bends, or wear.
  • Page 18 XM134A SNO-2219 4. Secure the top of the steering post to the steering 3. Secure the right-side steering boot to the chassis support using the existing retaining plate and nuts. using the existing push rivets. Tighten to 96 in.-lb. 5. Install the expansion chamber using the existing springs;...

  • Page 19: Ski

    INSPECTING 1. Inspect the ski for cracks or deterioration. 2. Inspect the ski for abnormal bends or cracks. 3. Inspect the wear bar for wear. 4. Inspect all hardware and the spindle bushings for wear and damage. 5. Inspect the rubber damper for damage or wear. INSTALLING 1.

  • Page 20: Ski Wear Bar

    INSTALLING faster. Arctic Cat recommends that the ski wear bars be replaced if worn to 1/2 of original diameter. REMOVING 1. Raise the front of the snowmobile and secure with a suitable stand.
  • Page 21 SNO-349 SNO-351 2. Remove the nyloc nuts securing the steering tie rod  NOTE: At this point if the technician’s objective is to ends to the spindle arms. Account for the washers remove the steering arm, the reinforcement bracket and discard both nuts. will need to be removed by drilling out the appropri- ate rivets.

  • Page 22: Ski Alignment

    2. Place the steering tie rod into position on the steering post. Secure with a new nyloc nut. Tighten to 35 ft- SNO-349 Ski Alignment SNO-351  NOTE: Make sure the tie rod tab is fully seated into CHECKING the steering post and threads of the ball joint are ...

  • Page 23: A-Arms

    VERIFYING 1. With the handlebar in the straight-ahead position, verify ski alignment by measuring across from the outside edge of the left-side wear bar bolts to the out- side edge of the right-side wear bar bolts (without using the straightedge) in two places: approximately 7-8 in.

  • Page 24: Ski Shock Absorber

    INSTALLING 1. Place the upper arm into position on the chassis and secure with the cap screws and new nyloc nuts. Tighten to 23 ft-lb. 2. Slide the lower arm into the boot; then place the arm into position on the chassis. Secure with the cap screws and new nyloc nuts and tighten to 55 ft-lb (front) and 45 ft-lb (rear).

  • Page 25: Sway Bar

    INSTALLING 3. Using the Shock Spring Removal Tool, remove the spring from the shock body by compressing the 1. Place the sway bar into the sway bar mounting spring; then remove the spring retainer from the top brackets; then install the sway bar into the snowmo- of the spring.

  • Page 26: Seat Cushion

    SNO-227A SNO-454A  NOTE: Be sure to connect the accessory harness.  NOTE: On models with heated seats prior to lower- ing and securing the seat, connect the seat heater harness connector. Seat Cushion PANTERA 1. Lift up both seat latches and hold them in that posi- RE MOVING tion;...

  • Page 27: Rear Bumper/Snowflap

    INSTALLING BUMPER 1. Align the holes in the bumper with the existing holes in the tunnel; then using new rivets, secure rear bum- per to the tunnel; then secure the snowflap to the rear bumper using new rivets. 2. Secure the front of the bumper to the chassis using the existing machine screws and nuts.
  • Page 28 PC108 YM-028A 4. Disconnect the gauge, electrical accessory wires, and the ignition switch. 5. Remove the two screws securing the rear of the con- sole to the hood (on the underside of the hood). 6. Loosen the two side headlight assembly screws; then remove the two front headlight assembly screws.

  • Page 29: Headlight Bulb

    Headlight Bulb Adjusting Headlight Aim The headlight can be adjusted for vertical aim of the  NOTE: The bulb portion of the headlight is fragile. HIGH/LOW beam. The geometric center of HIGH beam HANDLE WITH CARE. When replacing the headlight zone is to be used for vertical aiming.

  • Page 30: Engine

    Proceed to Ser- This engine sub-section has been organized to show a pro- vicing Top-Side Components. gression for the removing/installing of the Arctic Cat 1100 cc engine. For consistency purposes, this sub-section shows 1. Remove the seat; then disconnect the battery cables a complete and thorough progression;...
  • Page 31 9. On the 5000, remove the flange nuts securing the MAG- and PTO-side exhaust pipes to the engine and remove the exhaust and resonator pipes from the chassis.  NOTE: On the 9000, remove the three cap screws and lock nuts securing the exhaust resonator to the exhaust pipe;...
  • Page 32 12. Disconnect the harness connectors and hoses from the air bypass control valve (A) and waste gate con- trol valve (B). PC054A PC051A  NOTE: For installing purposes, note the location and routing of the harness connectors and hoses. 13. Remove the screws and turbocharger cover; then remove the waste gate control valve hose from the turbocharger noting the location of the clamp for installing purposes.
  • Page 33 17. Remove the cap screws (E) and (H) securing the side supports; then remove the supports noting the posi- tion of the cable ties and harnesses. PC056A  NOTE: At this point, removing the front fascia will aid in engine removal. 746-292C ...
  • Page 34 20. Remove the MAG-side chassis support. Account for 9000 and note the location and orientation of the resonator spring tab and resonator support bracket. PC211A 23. Disconnect the harness connectors from the coolant temperature sensor (A), oil pressure switch (B), and air pressure sensor (C).
  • Page 35 PC033A 0743-992 26. Disconnect the harness plug-ins from the ignition 30. Loosen the flange clamps securing the intake mani- coils (A) and camshaft timing sensor (B). fold to the cylinder head; then remove the manifold and throttle body assembly along with the two flanges.
  • Page 36 9000 PC243 0746-314 32. Remove the two cap screws securing the elbow fit-  NOTE: Before removing the mounting hardware ting of the oil supply hose to the engine; then secure securing the engine to the chassis, remove the the hose and fitting up and out of the way. weight of the engine from the chassis using a suit- able lift or hoist.
  • Page 37 41. Raise the engine until the studs of the lower front 5000 engine to chassis mount clear the chassis; then rotate the engine clockwise enough to clear the PTO-side engine to chassis mount and carefully lift the engine up and out of the chassis. PC037A 9000 PC040A...
  • Page 38 PC038A PC045A 3. Install the coolant hose and clamp to the tunnel heat  NOTE: To secure the engine to the chassis, use exchanger and secure the clamp. steps 5-9 and the following illustration. PC039A 4. With the front engine/chassis mount into position, lower the engine back until the engine is in line with 746-293B PTO-side...
  • Page 39 PC210A PC032B 9. Secure the PTO-side chassis support to the chassis using the cap screws (I), carriage bolt (K), and lock nuts (J). Tighten the cap screws to 25 ft-lb and the carriage bolt and lock nuts to 12 ft-lb. ...
  • Page 40 15. Install the throttle bodies and secure with the clamps; then install and secure the throttle body/coolant tank and the throttle body/cylinder head hoses. PC046A  NOTE: Steps 18-22 are for the 9000 only. 18. Install the flanges to the manifold adapter assembly ZJ018A and secure with the clamps;...
  • Page 41 SNO-741A PC028A  NOTE: On the 9000, install the harness connectors and vacuum hoses to the air bypass control valve (A) and the waste gate control valve (B) to the bracket of the PTO-side chassis support. 0743-992 22. With the wire harness properly routed, install the harness connectors to the throttle position sensor, air temperature sensor, boost sensor, and cam position sensor.
  • Page 42 PC029A 26. With the throttle cable in place, install and secure the 746-292C steering post to the steering bracket with the mount-  NOTE: For assembling purposes apply a small ing blocks, cap screws, and lock nuts. Tighten to 96 amount of silicone or tape to keep the inserts in.-lb.
  • Page 43 0741-518A PC054A  NOTE: Steps 29-32 are for the 9000 only.  NOTE: Remove any tape sealing the turbocharger. 29. Install the fascia and install the front pins (B) of the CAUTION intercooler into the brackets; then install the rear brackets (A) to the pins of the intercooler and secure Make sure there are no obstructions in the intake and the brackets to the chassis with cap screws and lock...
  • Page 44 34. With the resonator properly installed to the chassis support, install the spring securing the resonator to the mounting tab.  NOTE: With the exhaust system installed, connect the oxygen sensor to the harness connector. 5000 PC027A 39. Install and secure the lower console to the skid plate with the ¼...
  • Page 45 44. Open the coolant bleed screw on the cylinder head;  NOTE: If the warning icon does not go out, shut the then add coolant to the reservoir until coolant is visi- engine off immediately and repeat step 47; then ble at the bleed screw.

  • Page 46: Engine Removing Installing - 7000

    Remove the resonator. Installing - 7000 This engine sub-section has been organized to show a pro- gression for the removing/installing of the Arctic Cat 1049 cc (ZR/XF) engine. For consistency purposes, this sub-sec- tion shows a complete and thorough progression; however, for efficiency it may be preferable to remove only those components needing to be addressed.
  • Page 47 11. After the oil has drained completely, install a new 16. Remove the fuse block from the coolant tank and drain plug with a new O-ring and tighten to 16 ft-lb. move it out of the way; then remove the screws securing the right- and left-side facia to the chassis.
  • Page 48 22. Remove the four nuts securing the right-side chassis support; then remove the oil hose from the right side of the engine. YM-066A 26. With all hoses and wires disconnected from the engine, move the engine forward and out the right- side of the chassis.
  • Page 49 SNO-365 SNO-364A 2. Carefully lower the engine into the chassis aligning 6. Connect the PTO-side coolant hose to the heat the rear engine mounts with the chassis mounts; then exchanger using the existing clamps; then connect loosely secure using the existing cap screws and the oil pressure switch, oil pressure sensor, and the nuts.
  • Page 50 8. Install the throttle body assembly into the intake boots on the engine. Secure using the existing clamps. Tighten to 26.4 in.-lb. 0747-939 12. Install steering post into position and secure to the YM-037A steering stop bracket with a new M10 nut. Be sure to 9.
  • Page 51 21. Position the exhaust gasket between the engine and the exhaust manifold; then secure the manifold to the engine using the existing screws. Tighten to 16 ft-lb. XM134A 15. Secure the top of the steering post to the steering support using the existing retaining plate and nuts making sure the throttle cable is routed between the YM-034 steering bushings.
  • Page 52 27. Install the seat and secure using the screw.  NOTE: On the LXR models, connect the seat heater harness connector. 28. Install the hood and both access panels. YM-033A 25. Install the gas tank assembly and connect the battery; then install the upper and lower console making sure to connect the reverse alarm.

  • Page 53: Engine Servicing - 5000/9000

    Engine Servicing - 5000/ 9000 This engine sub-section has been organized to show a progression for servicing of the Arctic Cat 1100 cc engines. For consistency purposes, this sub-section shows a complete and thorough progression; however, for efficiency it may be preferable to disassemble only those components needing to be addressed.
  • Page 54 ZJ029A 9. On the 9000, remove the four cap screws securing the manifold adapter assembly; then remove the manifold. 743-780C 6. Remove the lock nuts and washers securing the exhaust pipes to the cylinder head; then carefully remove the turbocharger and exhaust pipes assembly. If needed remove the cap screws securing the lower heat shield to the exhaust pipes and turbocharger.
  • Page 55 ZJ031A ZJ034 11. Remove the eighteen cap screws securing the mag- 14. Remove the flywheel key from the crankshaft; then neto cover to the engine; then remove the cover and remove the starter gear. account for the starter torque limiter (A), spacer (B), idler gear (D), inner spacer (C), and outer spacer (E).
  • Page 56 ZJ049B ZJ038A 19. Remove the cap screws securing the camshaft covers  NOTE: If cleaning or replacing the cylinder head to the cylinder head; then remove the covers. cover is necessary, the cam position sensor must be Remove both camshafts. Account for the dowel pins. removed.
  • Page 57 ZJ051B ZJ041A 21. Remove the six nuts and two cap screws (A) from 23. Remove the fourteen cap screws securing the oil pan outside the cylinder head; then remove the six cap to the engine; then remove the oil pan and note the screws (B) from inside the cylinder head.
  • Page 58 31. Remove the oil separator plates for the lower crank- case half and account for the eight Allen-head cap screws. ZJ052B  NOTE: Because the connecting rods and connect- ing rod caps are unique, note the I.D. marks and keep all associated parts together for assembling pur- ZJ047A poses.
  • Page 59 If valves, valve guides, or valve seats require servicing or replacement, Arctic Cat recommends the components be taken to a qualified machine shop for servicing. IO051A 1. Install the drive clutch; then using Drive Clutch Spanner Wrench, rotate the engine two full revolu- tions.
  • Page 60 SNO2152...
  • Page 61 SNO2153...
  • Page 62 B. Find the Present Shim Size (three-digit-number) at the top-side horizontal column of the table. C. Match the clearance in the vertical column with the present shim size to obtain the recommended replacement shim.  NOTE: At this point, complete steps 33-40 of Assembling in this sub-section before proceeding to step 5.
  • Page 63 Measuring Piston-Ring End Gap (Installed) 1. Place each piston ring in the wear portion of the cyl- inder. Use the piston to position each ring squarely in the cylinder.  NOTE: Remove any carbon; then clean the top of the cylinder bore before inserting the piston rings. 2.
  • Page 64 Installing Piston Rings Cleaning/Inspecting/Measuring Cylinder Block 1. Install a thin oil ring, oil ring expander, and thin oil ring in the bottom groove of the piston. Stagger the 1. Wash the cylinder block in parts-cleaning solvent. end gaps of the upper and lower thin oil rings until they are on directly opposite sides of the piston.
  • Page 65 Bearing Selection Charts To select the correct main or balancer shaft bearing insert, read the letter stamped for the bearing location on the crankcase; then read the letter stamped on the crankshaft or balancer shaft corresponding to the same bearing location. ...
  • Page 66 (A) is directed toward the crankshaft. Assembling  NOTE: Arctic Cat recommends that new gaskets, seals, and O-rings be installed whenever assembling the engine.  NOTE: For assembling purposes, use oil-dissolv- able molybdenum disulfide grease as engine-assem- bly grease.
  • Page 67 ZJ071A ZJ054A  NOTE: Prior to installing the pistons, make sure the  NOTE: Prior to installing the jets, make sure the ori- oil ring end gaps are on directly opposite sides of the fices are clear of any debris or contaminants. piston, and the compression ring end gaps are 90°...
  • Page 68 8. Lubricate the lips of the crankshaft seal with grease and install the crankshaft seal over the PTO end of the crankshaft with the spring side of the seal directed toward the crankshaft; then install the crank- shaft.  NOTE: Position the crankshaft at bottom-dead-cen- ter for assembling purposes.
  • Page 69 16. With the crankshaft at bottom-dead-center, install the 21. Install the lower crankcase half to the upper engine front counterbalancer with the single dot (B) on the case; then verify the cases are properly seated face of the crankshaft and balancer gears directly in together.
  • Page 70 28. Install the cam chain tensioner; then install the wash- ers between the engine case and guide/tensioner and secure with two Allen-head cap screws (coated with blue Loctite #243). Tighten to 84 in.-lb. 741-584A  NOTE: Prior to installing the oil pan, ensure the oil strainer is cleaned thoroughly.
  • Page 71 32. Install the flange nuts and cap screws (cap screws 1- 6 threads coated with oil); then using the pattern shown, tighten in the following sequence: A. Cap screws 1-6 initially to 18 ft-lb. B. Flange nuts 7-8 to 18 ft-lb. C.
  • Page 72 741-624A 741-580A 38. Remove the tensioner ball, spring, and bolt.  NOTE: At this point, install the spark plugs. 42. Place the starter gear on the crankshaft; then install the flywheel key. ZJ086 39. Install the cam chain tensioner adjuster by first com- pressing the locking clip;...
  • Page 73 0742-125 ZJ090A 45. With the two pins installed in the engine case, first 47. Install the coolant hose inlet fitting and secure with install the starter torque limiter (A) and spacer (B); the two cap screws. Tighten to 84 in.-lb. then install the inner spacer (C), idler gear (D), and outer spacer (E).
  • Page 74 ZJ093 746-517A  NOTE: On the 9000, install the intake flange assem-  NOTE: At this point, assembly of the 5000 engine is bly; then tighten the cap screws evenly to 96 in.-lb. complete. Steps 53-59 are for the 9000 only. 53.
  • Page 75 743-991A 59. With the turbocharger secured, install the oil feed pipe with the banjo bolts and two new crush washers on each side of the union. Tighten to 11 ft-lb. 743-780A 57. Tighten the two lock nuts (from step 53) to 30 ft-lb. 58.

  • Page 76: Assembly Schematic - 5000/9000

    Assembly Schematic - 5000/9000 Torque Specification Tolerances Torque (ft-lb) Tolerance 0-15 ±20% 16-39 ±15% ±10% 1100ccJAG12...
  • Page 77 1100ccZ1RV10...
  • Page 78 Engine Torque Patterns (5000/9000) 1100TorquePattern12...

  • Page 79: Engine Servicing - 7000

    Engine Servicing - 7000 This engine sub-section has been organized to show a progression for servicing of the Arctic Cat 7000 engines. For consistency purposes, this sub-section shows a com- plete and thorough progression; however, for efficiency it may be preferable to disassemble only those components needing to be addressed.
  • Page 80  NOTE: TDC on the compression stroke can be found when the camshaft lobes for cylinder #3 (MAG side) are turned away from each other.  NOTE: At this point if the technician’s objective is to service the valves, proceed to Servicing Components - Valves in this sub-section.
  • Page 81 11. Remove the four cap screws securing the output shaft assembly to the crankcase; then thread the drive clutch bolt into the end of the crankshaft and pull the output shaft assembly from the engine. YM-012 YM-009 12. Remove the Allen-head screws securing the water pump assembly to the crankcase;...
  • Page 82 SNO-283A YM-017A 16. Remove the eight cap screws (#3-10) and two Allen- 19. Tip the engine upside down; then remove the cap head screws (#1 and #2). Remove the head and screws securing the oil pan to the crankcase. Using a account the gasket and dowel pins.
  • Page 83 25. Straighten the locking tabs securing the cap screws securing the balancer shaft; then remove both cap screws and both balancer weights.  NOTE: To remove the cap screws (C), place a small piece of wood (B) between the balancer weight (C) and the crankcase.
  • Page 84 If valves, valve guides, or valve seats require servicing or on the surface of the existing shim; then refer to the replacement, Arctic Cat recommends the components be appropriate Tappet Shim Selection Table (Exhaust or taken to a qualified machine shop for servicing.
  • Page 85 SNO2152...
  • Page 86 SNO2153...
  • Page 87 CRANKSHAFT JOURNAL BEARING  NOTE: Do not interchange the crankshaft journal bearings. To obtain the correct crankshaft-journal-to- crankshaft-journal-bearing clearance prevent engine damage, the crankshaft journal bearings must be installed in their original positions. 1. Clean the crankshaft journal bearings, crankshaft jour- nals, and bearing portions of the crankcase.
  • Page 88 PISTON ASSEMBLY Measuring Piston-Ring End Gap (Installed) 1. Place each piston ring in the wear portion of the cyl- inder. Use the piston to position each ring squarely in the cylinder.  NOTE: Remove any carbon; then clean the top of the cylinder bore before inserting the piston rings.
  • Page 89 Taper Limit (T) 0.050 mm (0.0020 in.) Out of Round (R) 0.050 mm (0.0020 in.) SNO-292 Installing Piston Rings 1. Install the piston rings according to the illustration SNO-290 below. Stagger the end gaps of the upper and lower thin oil rings until they are on directly opposite sides “C”...
  • Page 90 (C) on the shaft end. not within specifications, the crankshaft must be replaced. Assembling  NOTE: Arctic Cat recommends new gaskets, seals, and O-rings be installed whenever assembling the engine.  NOTE: For assembling purposes, use oil-dissolv- able molybdenum disulfide grease as engine-assem- bly grease.
  • Page 91 SNO-384A SNO-296 8. With the piston rings installed, lubricate each piston and cylinder with engine oil; then with the punch marks on the top of the pistons directed towards the exhaust side of the engine, install the piston assem- blies into the cylinder using Ring Compressor and a soft hammer.
  • Page 92  NOTE: Make sure the “Y” marks (A) on the connect- ing rods face towards the right side (MAG side) of the crankshaft. Make sure the characters (B) on both the connecting rod and connecting rod cap are aligned. SNO-301 ...
  • Page 93  NOTE: If a cap screw is tightened more than the specified angle, do not loosen the bolt and then retighten it. Instead, replace the bolt with a new one and perform the procedure again.  NOTE: Do not use a torque wrench to tighten the bolt to the specified angle.
  • Page 94 28. Tighten the cylinder head bolts further to reach the specified angle 175°-185° in the proper tightening sequence as shown. Do not use a torque wrench for this step. SNO-307  NOTE: Prior to installing the cam chain tensioner, assure the chain is properly seated to the gear on the crankshaft.
  • Page 95 SNO-311A SNO-312A 33. Install the existing dowel pins into the cylinder head; 35. With the tensioner rod compressed, flip the hook (A) then install the intake and exhaust camshaft caps. over the rod (B) to secure it down. Tighten the camshaft cap screws to 86 in.-lb in two stages and in a crisscross pattern working from the inner caps out.
  • Page 96 SNO-316 SNO-317 38. Apply Three Bond Sealant onto the mating surfaces 39. Install the spark plugs. Tighten to 8.7 ft-lb. of the cylinder head cover gasket. Tighten the cylin- 40. Install the ignition coils over the spark plugs making der head cover screws in a crisscross pattern to 7.2 sure they are fully seated.

  • Page 97: Assembly Schematic - 7000

    Assembly Schematic - 7000 Torque Specification Tolerances Torque (ft-lb) Tolerance 0-15 ±20% 16-39 ±15% ±10% 1049cc_14_2...
  • Page 98 1049cc_14_1...

  • Page 99: Troubleshooting Engine

    Troubleshooting Engine Problem: Engine Does Not Start (No Spark at Spark Plugs) Condition Remedy 1. Ground connections dirty — loose 1. Check all ground connections — clean and tight 2. Wiring harness shorting — disconnected 2. Repair — replace — connect wiring harness 3.
  • Page 100 Problem: Engine Overheats Condition Remedy 1. Coolant low — absent 1. Add coolant 2. Heat exchanger obstructed 2. Remove obstruction 3. Drive system (drive clutch — driven clutch — track — 3. Troubleshoot — adjust drive system drive belt) adjusted incorrectly — worn — damaged 4.

  • Page 101: Engine-Related Items

    Engine-Related Items  NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is nec- essary. SPECIAL TOOLS A number of special tools must be available to the techni- cian when servicing the engine-related items. Description Blind-Hole Bearing Puller 0644-500 ZJ113A...
  • Page 102  NOTE: Apply heat to the housing to aid in removing the seals. CAUTION Do not apply excessive heat to the housing or the bushing next to the bearing may be damaged. 4. Using the bearing puller, remove the bearing (F) from the inner housing.
  • Page 103 DISASSEMBLING/ASSEMBLING (7000) SNO-374A 5. Remove the rubber damper holder (A) and the rubber damper (B) from the impeller using a small flat-head screwdriver making sure not to damage the impeller SNO-372 shaft. 1. Obtain top-dead-center (TDC) by rotating the crank- shaft (clockwise) until the mark on the magneto rotor is aligned with the pointer on the magneto cover and the #3 piston is at TDC.

  • Page 104: Pressure Testing Engine

    7000 With the spark plugs removed, install the compression tester gauge with adapter into the spark plug hole; then with the throttle valve in the full-open position, crank the engine over to get the psi reading. Compression should be 213.3 psi CAUTION Do not ground the spark plug on the cylinder head cover.
  • Page 105 12. Without starting the engine, place the handlebar emergency stop switch to the RUN position and the ignition switch to the ON position. The Oil Pressure Warning Icon should illuminate immediately on the standard gauge or after the three seconds on the pre- mium gauge.

  • Page 106: Testing Oil Pressure

    Warning Icon should illuminate.  NOTE: If the warning icon does not illuminate, take the snowmobile to an authorized Arctic Cat Snowmo- bile dealer for service. If not under warranty, this ser- vice is at the discretion and expense of the 9000 snowmobile owner.

  • Page 107: Liquid Cooling System (5000/9000)

    FILLING/BLEEDING COOLING SYSTEM 1. Remove the left- and right-side access panels and hood.  NOTE: Place the hood along side the snowmobile; then using Hood Harness Extension, connect the hood to the main harness. 2. Loosen the bleed screw and add coolant into the filler neck until coolant is visible at the bleed screw;...

  • Page 108: Liquid Cooling System (7000)

    All coolant hoses and clamps should be replaced every four years. INSPECTING THERMOSTAT 1. Inspect the thermostat for corrosion, wear, or spring damage. 2. Using the following procedure, inspect the thermo- stat for proper operation. A. Suspend the thermostat in a container filled with water;...

  • Page 109: Cooling System Schematics

    Schematics closed position. CAUTION The following schematics are representative of the differ- ent styles of cooling systems in the Arctic Cat snowmo- Never heat the thermostat to the fully open position or biles. damage to the thermostat may occur. 5000...
  • Page 110 9000 0746-522 7000 0747-953...

  • Page 111: Air Silencer (5000)

    Air Silencer (5000) Air Silencer (9000) REMOVING/INSTALLING REMOVING/INSPECTING 1. Remove the right- and left-side access panels; then 1. Remove the air cleaner cover; then remove the air disconnect the hood harness and remove the hood. filter. 2. Remove the seat and gas tank (see the Fuel Systems 2.
  • Page 112 4. Remove the intercooler, air bypass valve, and air CAUTION duct as an assembly by removing the intercooler from the four mounting brackets. Do not carry the turbocharger by the hoses or by the 5. Remove the clamp securing the coolant return hose waste gate control rod.
  • Page 113 PC230A PC234A  NOTE: If the oil hose has to be removed from the engine, note the banjo bolt securing the hose to the turbocharger has the smaller feed holes. 11. Remove the lock nuts and washers securing the exhaust manifold to the cylinder head; then carefully remove the turbocharger and exhaust manifold assembly.
  • Page 114 2. Install the mounting bracket to the 9000; then with 9. Connect the coolant feed hose and oil return hose to the backing plate properly positioned as shown, the 9000, release the clamp, and secure the hoses secure the bracket to the turbocharger with the lock with the hose clamps.
  • Page 115 15. Install the intercooler, air bypass valve, and the air duct as an assembly into the four mounting brackets. 16. Secure the outlet hose, air duct, and intercooler using the existing clamps (A); then install the air filter (B) and all hoses connected to the intercooler. SNO-232A 12.

  • Page 116: Fuel Systems

     NOTE: The ECM cannot be repaired. INTRODUCTION Removing (5000/9000) The Arctic Cat EFI System operates off a series of coils 1. Remove the left-side access panel; then remove the located on the stator and is made up of the following snap ring securing the lower console.

  • Page 117: Coolant Temperature Sensor

    2. Install the ECM with mounting bracket onto the rear  NOTE: On 7000 models, the sensor is secured to belt guard until it snaps into place. the air intake assembly using two screws. 3. Connect the two wiring connectors to the ECM. Installing 4.
  • Page 118 Removing (5000/9000) WARNING Since the fuel supply hose may be under pressure, remove it slowly to release the pressure. Place an absorbent towel around the connection to absorb gasoline; then remove the hose slowly to release the pressure. Always wear safety glasses when removing the fuel hoses. 1.

  • Page 119: Self-Diagnostic System/Codes

    CRANKSHAFT POSITION SENSOR INTRODUCTION This sensor measures the location in degrees of rotation of The Service Icon is controlled by the ECM. The icon the crankshaft. A 15° resolution exists between signals. The should illuminate each time the engine is started, and it signal is triggered by teeth on the outer surface of the fly- should go out after a few seconds.

  • Page 120: Fuel Pressure Regulator

    The fuel system and the ignition system remain two sepa- Code Trouble rate systems. In a no-start situation, first determine if the P1686 Main relay circuit low problem is caused by lack of spark or by a fuel delivery P1688 Reverse relay open circuit problem or by an internal engine condition (low cylinder P1689...
  • Page 121 ASSEMBLING/INSTALLING (5000) 1. Install the fuel injectors onto the throttle body assem- bly; then secure the fuel rail and injectors to the throttle body assembly with the two screws and the retaining clips. ZJ289A 2. Loosen the throttle cable jam nut; then remove the throttle cable from the bracket and the throttle valve cam.
  • Page 122 REMOVING/DISASSEMBLING (9000) 1. Remove the hood, seat, and gas tank. 2. Disconnect the throttle cable (A); then disconnect the idle speed control (B). TZ110A  NOTE: Remove the throttle body ISC valve before using any type of cleaner to clean the throttle body. 6.
  • Page 123 9. Remove the four harness connectors from the injec- tors; then carefully remove the injectors from the fuel rail. TZ117 TZ113  NOTE: With the injectors removed, inspect the O- rings and gaskets for damage. TZ111A 4. With a new gasket for the ISC valve in place, secure the ISC valve to the throttle body and tighten securely.
  • Page 124 6. Install the hose connecting the intake pipe to the throttle body and secure with the hose clamps. 7. Install the coolant hoses to the throttle body and secure with the clamps; then install the harness con- nector to the throttle position sensor. 8.
  • Page 125 YM-047A YM-048A 2. Connect all connections of the throttle body harness to the throttle body sensors. Secure the harness to the fuel rail using cable ties. YM-048A  NOTE: For assembling purposes, note from which side the fuel injectors were removed. YM-045A ASSEMBLING/INSTALLING (7000) 3.

  • Page 126: Throttle Cable

    6. Adjust the throttle cable tension by turning the jam nuts in the appropriate direction until 0.030-0.060 in. free-play exists in the throttle lever and the butterfly completely opens and closes. Tighten the jam nuts securely. YM-043A 5. Connect the large gray connector to the main har- ness.

  • Page 127: Fuel Pump

    SNO-700A XM282  NOTE: On the 9000, insert the filter making sure the lip sits between the tab and clamp. XM184B 2. Disconnect the gasline hose from the fuel pump. 3. Remove the hose clamps and discard; then slowly SNO-1021 remove the fuel hoses from the fuel filter.
  • Page 128 3. Disconnect the gasline hose connector hose from the  NOTE: If the fuel pump still fails to operate, the outlet of the fuel pump by pressing inward on the pump is defective and must be replaced. white connector, pressing in the black release, and REMOVING (5000/9000) finally pulling back on the hose.
  • Page 129 SNO-791 SNO-704 4. Make sure the front pickup will sit flat on the bottom 2. Carefully push the fuel pump assembly down and of the tank with no kinks in the fuel hose. back into the fuel tank until the white fuel sensor (below the fuel pump) is flush with the fuel pump mounting surface.
  • Page 130  NOTE: If the fuel pickup assembly is not being replaced, inspect the screens for any tears or obstructions. Also check the hoses and replace if necessary. INSTALLING (7000) 1. The two fuel pickups should be pressed together then carefully slide into the fuel pump opening in the gas tank;...

  • Page 131: Troubleshooting

    5. Install the seat(s). YM-086A Troubleshooting Problem: Too Rich Condition Remedy 1. Diagnostic trouble code activated 1. Replace problem sensor 2. Fuel pressure too high 2. Replace regulator 3. Fuel return hose obstructed 3. Service - replace hose - remove obstruction 4.
  • Page 132 5. Install new hose clamp over the gasline hose; then press the gasline hose fully onto the fitting. Use Fuel Hose Clamp Tool to secure the hose clamp over the gasline hose by crimping the clamps until the two clamp areas touch. SNO-506A 6.

  • Page 133: Electrical Systems

    2. Crank the engine over and check for spark. If no CATT II 0544-023 spark is present, check to make sure the throttle cable Arctic Cat Diagnostic System Manual 2256-974 is properly tensioned. Compress the throttle control Laptop Diagnostic Tool...
  • Page 134 CHECKING TPS 3. Using Throttle Position Sensor (TPS) Adjustment Tool Kit, connect its wiring harness to the TPS. Con-  NOTE: If the snowmobile is in warranty, breaking nect the red and black digital voltmeter leads to the the seal on the idle screw jam nut or the Phillips-head white and black jacks of the TPS adjustment tool.

  • Page 135: Electrical Resistance Tests (5000/9000)

    5000 ZJ254 YM-067 2. Install the screws w/ washers securing the sensor to 9000 the throttle body. Do not tighten at this time. 3. Adjust the TPS using the CATT II Tool. Instructions will be included with the tool.  NOTE: Before installing the TPS harness connector, apply dielectric grease to the connector pins.

  • Page 136: Electrical Resistance Tests (7000)

    Injection Coil 2. Connect the red meter lead to the gray wire; then connect the black meter lead to the black wire. 1. Test between the black/yellow and black wires from the injection coil. 3. Resistance must be 336-504 ohms. 2.

  • Page 137: Testing Fuel Gauge Sender

    This test should be made at the three-pin connector of the regulator/rectifier. ! WARNING Most voltages generated by the ignition system are sufficient to interrupt pacemakers! All technicians, especially those using pacemakers, must avoid con- tact with all electrical connections after the engine has been started.

  • Page 138: Fuse

    4. Disconnect the two-wire plug from the starter relay; 3. Rotate the key to the START position and verify bat- then connect the red tester lead to the green wire and tery voltage. the black tester lead to the black wire. ...
  • Page 139 YM-060 ZJ141A 4. With the armature removed from the magnet hous- DISASSEMBLING (5000/9000) ing, remove snap ring (D) from the armature. Account for shim (E) and locking plate (F). 1. Secure the starter motor in a suitable clamping device; then remove the two long cap screws from 5.
  • Page 140 7. Inspect the brass commutator end of the armature for 11. Inspect the armature for shorting using a “growler” any discolored spots or damage. If the commutator is and the following procedure. slightly discolored or damaged, the armature must be A.
  • Page 141 ZJ145 ZJ140A  NOTE: After completing step 2, ensure that the INSTALLING (7000) brushes are properly seated to the commutator. 1. Install the starter motor into the engine; then with the negative battery cable positioned to the top mounting 3. Noting the alignment marks made in disassembling, hole, install the two cap screws (threads coated with install the magnet housing;...

  • Page 142: Troubleshooting Electric Start

    2. Install the positive cable (A) to the starter motor and 4. Remove the eighteen cap screws securing the mag- tighten securely. Secure the positive and negative neto cover to the engine; then remove the cover and cables with cable ties as noted during disassembling. account for the dowel pins, the oil pump seal, and the gasket.
  • Page 143 3. Install the coolant hoses to the water pump, oil cooler, and separator tank; then secure the hoses with the clamps. 4. Secure all coolant hoses and oil hoses using the existing clamps; then secure the left-side support using the existing cap screws and nuts. Tighten securely.
  • Page 144 YM-056A SNO-380 4. Remove the cap screws securing the harness clamp 2. Install the two alignment pins in the engine for the to the magneto cover. Remove the three cap screws magneto cover; then with a new gasket, install the securing the magneto to the cover;...

  • Page 145: Brakelight Switch

    YM-055A XM206 4. Install the resonator and secure using existing hard- INSTALLING ware. 1. Press the switch into the brake lever assembly mak-  NOTE: At this point, fill and bleed the oil and cool- ing sure it is fully seated. ing systems.

  • Page 146: Testing Handlebar Warmer Elements

     NOTE: If either test does not read within specifica- Testing Handlebar tion, replace the complete control assembly. Warmer/Thumb Warmer INSTALLING Switch 1. Connect the HI/LO beam harness to the switch; then place the control assembly on the handlebar. REMOVING/TESTING 2.

  • Page 147: Testing Passenger Handwarmer Switch

    PASSENGER HEATER SWITCH - Testing Passenger Resistance Handwarmer Switch 1. Disconnect the main harness/element connector. 2. Connect one ohmmeter lead to the red/black main harness wire; then connect the other ohmmeter lead 1. Disconnect the lead wires from the switch. to the green/red main harness wire.

  • Page 148: Testing Gear Position Switch

    1. Elevate the rear of the snowmobile onto a suitable safety stand. 2. Set the meter selector to the DC Voltage position. 3. At the sensor side of the plug-in, connect the red maxiclip and meter lead to the white/orange lead; then connect the black maxiclip and meter lead to the black lead.

  • Page 149: Voltage/Resistance Chart - Air Temperature

    Voltage/Resistance Chart - Voltage/Resistance Chart - Air Temperature Coolant Temperature Temperature Volts Ohms Temperature Volts Ohms Temperature Volts Ohms Temperature Volts Ohms 100° C 212° F 0.113 28° C 82° F 1.230 8540 110° C 230° F 0.115 28° C 82°...

  • Page 150: Drive Train/Track/Brake Systems

     NOTE: Ensure the shims and O-ring are not Drive Train/Track/Brake removed from the adjuster. Systems This section has been organized into sub-sections for ser- vicing drive train, track, and brake systems; however, some components may vary from model to model. The technician should use discretion and sound judgment when removing and installing components.
  • Page 151 2. Using the Drive Clutch Puller and the Drive Clutch Spanner Wrench, tighten the puller. If the drive clutch will not release, sharply strike the head of the puller. Repeat this step until the clutch releases. 3. Remove the drive clutch and drive belt from the engine compartment.

  • Page 152: Driven Clutch

    3. Secure the cam arm pins with new lock nuts and 5. Either test drive the snowmobile or run the engine tighten to 11 ft-lb. for five minutes; then verify the drive clutch cap screw torque specification. CAUTION Driven Clutch When installing cam arms, always use new lock nuts and cam arm set screws.
  • Page 153 2. Using a suitable driving tool, drive the bearing out. ! WARNING Always wear safety glasses when using the bearing driver. 3. Install the new bearing; then secure with a new snap ring. REPLACING ROLLERS 1. Bend the locking tabs down away from the shoulder bolt;...

  • Page 154: Drive Clutch/Driven Clutch

    XM140 PC112 7. Remove the clutch from the compressor.  NOTE: Premature wear will result if the spring seat 8. Install the back-side cams; then secure with the is not installed. screws and tighten to 24 in.-lb. 2. Place the stationary sheave spring seat onto the INSTALLING spring (flat side toward the spring);...

  • Page 155: Drive Train

    0747-959 0743-319 CORRECTING OFFSET  NOTE: Push down on the belt with the ruler only until the bottom of the belt flexes upward; then read 1. To correct offset, the driven clutch must be moved the amount of deflection. laterally on the input shaft. Remove the cap screw and washers securing the driven clutch.
  • Page 156 4. On 5000 and 9000 models, remove the clamp secur- 9. Remove the snap ring from the driveshaft; then ing the oil separator line; then remove the line from remove the reverse chain and sprockets. Account for the oil tank elbow fitting. a thrust washer behind the upper sprocket.
  • Page 157  NOTE: If the driven shaft and driveshaft are going to serviced, proceed to Cleaning and Inspecting Chain Case. If bearings and chain or case assembly are to be replaced, remove the driven clutch; then proceed to step 12. 12. Remove the left-side chassis support. 13.
  • Page 158 CLEANING AND INSPECTING CHAIN CASE 1. Inspect sprockets and chain(s) for excessive wear or stretching. 2. Inspect bearings and gears for roughness or chipping.  NOTE: If bearing replacement is necessary, the chain case must be removed from the tunnel and an appropriate press utilized to remove and install bear- ings.
  • Page 159 12. Install the drive clutch and tighten the clutch cap screw to 51 ft-lb; then install the driven clutch and drive belt. Tighten to 20 ft-lb (threads coated with blue Loctite #243). 13. With the driveshaft installed into the chain case, install the existing thrust washer and secure with the silver snap ring making sure it is fully seated into the groove closest to the bearing.
  • Page 160 21. Install the chain case cover/oil tank assembly and secure with the screws. Tighten in a crisscross pat- tern to 14 ft-lb. 22. Fill the chain case with 12 oz of Arctic Cat Chain Lube.  NOTE: Make sure the gear position sensor wires are...

  • Page 161: Drive Sprockets

    27. Connect the harness to the gear position sensor; then 2. For installing purposes, scribe a line on the drive- secure the connector to the main harness using a shaft (A) next to the drive sprocket for proper align- Cable Tie (A). ment;...
  • Page 162 4. Using a calipers, measure distances between the sprockets and from the sprockets to each end of the driveshaft for proper location (see appropriate illus- tration). XF 7000 LXR/Sno Pro/LTD ZR 7000 LXR/Sno Pro/Sno Pro LTD/ Pantera YM-075B  NOTE: Prior to installing the sprockets onto the driveshaft, lightly chamfer the inside edge of the sprocket to avoid binding.

  • Page 163: Track Tension

    5. Install the retaining plate seal onto the drive shaft; then install the existing snap ring making sure it is installed into the groove of the shaft. 0748-447 2. If the deflection (distance between the bottom of the wear strip and the inside surface of the track clip) exceeds specifications, tighten the adjusting bolts to YM-074A take up excessive slack in the track.

  • Page 164: Brake System (Hydraulic)

    2. Position the tips of the skis against a wall; then using a shielded safety stand, raise the rear of the snowmo- bile off the floor making sure the track is free to rotate. ! WARNING The tips of the skis must be positioned against a wall or similar object for safety.

  • Page 165: Changing Brake Fluid

    0745-817  NOTE: It may be necessary to refill the reservoir a 2. If the brake fluid level is low, add Arctic Cat approved brake fluid until the fluid is at the recom- number of times to eliminate all air bubbles in the mended level.
  • Page 166 1. With the handlebar in the highest position, remove the reservoir cover and fill the reservoir with approved brake fluid. CAUTION Brake fluid is highly corrosive. Do not spill brake fluid on any surface of the snowmobile. ! WARNING Use only approved brake fluid. Any substitute may result in a loss of brakes.
  • Page 167 CAUTION Brake fluid is highly corrosive. Do not spill brake fluid on any surface of the snowmobile. 4. Open the bleeder valve and compress the brake lever several times to drain the reservoir of fluid. 5. Remove the brake hose from the caliper. Use an absorbent towel to collect any remaining brake fluid.
  • Page 168 PC174 PC221A 10. Remove the two screws securing the caliper halves. Discard the seal. PC148A 8. If the bearing will be replaced, remove the snap ring; then using a suitable press, remove the bearing from PC219A the housing. PC173 11. Remove the pistons (A) and O-rings (B); then dis- PC200 card the O-rings.
  • Page 169 Cleaning and Inspecting  NOTE: To aid in installing the piston, make sure the piston O-ring is properly seated in the groove of the 1. Inspect the brake pistons for gouges, cracks, pitting, caliper housing. scuffing, or corrosion. If any of these conditions exist, replace the piston.

  • Page 170: Brake Lever/Master Cylinder Assembly

    8. Install new brake pads in the caliper and secure with the retainer pin. 745-759A 4. Remove the pin (D) securing the brake lever to the master cylinder. PC195 9. Bleed the brake system. 5. Using a small screwdriver, compress the tabs of the brakelight switch (E) to release it from the master 10.

  • Page 171: Troubleshooting Track

    Troubleshooting Track Problem: Track Edge Frayed — Drive Lugs Worn Condition Remedy 1. Track alignment adjusted incorrectly 1. Align — replace track Problem: Track Worn Adjacent to Outer Drive Lugs Condition Remedy 1. Track tension adjusted incorrectly 1. Adjust track tension 2.

  • Page 172: Troubleshooting Drive Clutch/Driven Clutch

    Troubleshooting Drive Clutch/Driven Clutch Problem: Midrange Shift-Up (Too Quickly - Lowers RPM) Condition Remedy 1. Drive clutch spring weak 1. Replace drive clutch spring 2. Driven clutch spring weak 2. Replace driven clutch spring 3. Driven clutch spring preload tension inadequate 3.

  • Page 173: Suspension

    Suspension SPECIAL TOOLS A number of special tools must be available to the techni- cian when servicing the rear suspension. Description Shock Absorber Air Pump 2603-614 Idler Wheel Puller Kit 0644-570 Rear Suspension Spring Tool 0144-311 Handlebar Stand 5639-152 0728-180 Steering Post Stand 5639-946 Under acceleration when the center of gravity is trans-...
  • Page 174 2. With stiffer springs, the front end will become more 4. Remove the pump valve from the shock air valve. aggressive in the corners as more weight will be  NOTE: As the pump valve is being removed from transferred to the skis when decelerating. Also, more the shock, the sound of air loss is from the pump weight is transferred to the rear on acceleration and hose, not from the shock.
  • Page 175 UP position. The spring ten- sion blocks lock in an over-center position when engaged.  NOTE: Arctic Cat recommends that the overload springs be engaged whenever a load on the snowmo- bile (operator/passenger/cargo) exceeds 136 kg (300 lb).
  • Page 176 To either engage or disengage the spring tension blocks, use a spark plug socket and a screwdriver to adjust the spring block to the desired position. Make sure both spring blocks are in the same position (either engaged or disengaged). 744-457A...
  • Page 177 Chassis and Skid Frame Mounting Locations The suspensions have several possible mounting loca- CAUTION tions in the slide rails and tunnel. However, Arctic Cat recommends that when disassembling and assembling All stock mounting locations must be used. If any the suspension, all stock mounting locations be used as alterations to the skid frame are made, shock absorber shown in the following illustrations.
  • Page 178 M Models 0747-413 Pantera Models 0748-835...

  • Page 179: Servicing Suspension

    Servicing Suspension This sub-section has been organized so each procedure can be completed individually and efficiently.  NOTE: If service work is needed on any FOX shock, the shock will have to be removed and sent to FOX or any FOX distributor for any service work. For FOX shock information log on to www.ridefox.com.
  • Page 180 Idler Wheels/Mounting Blocks REMOVING 1. Remove the cap screw and lock nut securing the idler wheel to the idler wheel mounting block; then remove the cap screw and lock nut securing the mounting block to the slide rail. 739-884A CLEANING AND INSPECTING 1.
  • Page 181 ZJ271A MS006A 3. Remove the lock nut and cap screw securing the rear D. Install the snap ring making sure the “sharp side” shock pivot to the front arm. is directed away from the bearing. XM004A MS007A 4. Remove the cap screws securing the front arm to the INSTALLING rails.
  • Page 182 INSTALLING 1. With the rubber bushing in place, install the axle into the lower shock eyelet bushing assembly; then install the two shim washers and two spacers. ZJ271A  NOTE: Do not over-tighten the shock absorber cap screw as the shock eyelet must be free to pivot. 8.
  • Page 183 INSPECTING 3. Remove the two cap screws securing the front arm to the rails Account for two washers. 1. Inspect all front arm weldments for cracks or unusual bends; then inspect the front arm mounting brackets for cracks and for elongated holes. 2.
  • Page 184 REMOVING 1. With the skid frame removed using the Rear Suspen- sion Spring Tool, remove the spring from the adjust- ing cam. ! WARNING Care must be taken when removing the spring or dam- age or injury could result. 2. Mark the offset arm and the idler arm for assembly purposes.
  • Page 185 10. Remove the cap screw and lock nut securing the rear arm to the slide rail. Account for the serrated axles and axle tube. FZ101A 3. With the sleeves installed, install the shock absorber link to the lower mounting hole of the rear shock pivot;...
  • Page 186 6. Place the spring slide and slide block (with spring in slide block) into position on the slide rail. Secure with a cap screw and washer. Tighten to 20 ft-lb. 7. With wheel insertion tool, install the rear upper idler wheel on the idler arm.
  • Page 187 XM090A FZ034 3. Loosen the cap screws and lock nuts securing the INSTALLING offset arm assembly to the idler arm; then remove the 1. Slide the axle tube into the rear arm; then position offset arm assembly. Account for a flanged axle, the rear arm with the holes in the slide rails.
  • Page 188 7. Align the marks on the idler arm to the centerline of 2. Remove the cap screw and lock nut securing the the offset arm assembly. Secure the offset arm to the upper shock eyelet to the idler arm; then remove the idler arm with cap screws and lock nuts.
  • Page 189 XM007A XM006A 3. With the sleeves installed, place the shock absorber CLEANING AND INSPECTING and shock link between the offset arm bracket. Secure with the cap screws and lock nuts. Tighten 1. Clean the bearings with a clean cloth. securely. 2.
  • Page 190 Rear Arm Assembly (Pantera) REMOVING 1. Remove the skid frame; then remove the slide spring from the adjusting cam. ! WARNING Care must be taken when removing the spring or dam- age or injury could result. 2. Mark the offset arm and the idler arm for assembly XM002 purposes.
  • Page 191 9. Remove the cap screw securing the rear arm to the idler arm. Account for the aluminum axle. YM-121  NOTE: Do not over-tighten the shock absorber cap FZ101A screw as the shock eyelet must be free to pivot. 10. Remove the cap screw and lock nut securing the rear ...

  • Page 192: Installing Skid Frame

    ASSEMBLING REAR AXLE YM-120  NOTE: When tightening the offset arm lock nuts, SNO-2239A tighten the upper lock nut first to ensure an even 1. If the rear idler wheels were separated, install both clamp load. Make sure the flared side of the bushing wheels onto the axle and secure using the existing is directed outward.
  • Page 193 5. Push the rear of the skid frame and the track into the 8. At this time, place the snowmobile to the upright tunnel. position; then tighten all cap screws to 40 ft-lb. 6. Align the rear arm assembly with the appropriate 9.

  • Page 194: Special Tools

    Servicing IFP Shock SPECIAL TOOLS A number of special tools must be available to the techni- cian when servicing the rear suspension. Description Floating Piston Location Gauge Tool 0644-350 Floating Piston Depth Tool 0644-575 Inflation Needle Tool 0744-020 Rear Suspension Spring Tool 0144-311 ZR-017 Shock Body Clamping Tool...
  • Page 195 ZR-011 ZR-014  NOTE: Placing the valve stack on a screwdriver when removing from the shock rod will allow the shims and valve to stay in order. 5. Remove the bearing end cap. 6. Items to inspect: A. Shock rod for straightness, nicks, or burrs. B.
  • Page 196 ZR-008 ZR-003 5. Fill shock body with new synthetic shock oil to 8. With shock oil around the seals in the bearing cap bottom of threads. and on the shock rod, slowly compress the shock rod until the shock eyelet bottoms out. Pressurize the shock with nitrogen to 200 psi and until the shock eyelet fully extends.
  • Page 206 Printed in U.S.A. Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701 p/n 2260-468...

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