Arctic Cat Pantera 3000 Service Manual
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Arctic Cat Pantera 3000 Service Manual

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  • Page 1 SERVICE MANUAL ® ® ® ® ® www.arcticcat.com www.arcticcat.com...

  • Page 2: Table Of Contents

    ZR/XF/M/Pantera 3000/5000/7000/9000 TABLE OF CONTENTS General Information/Foreword ..........2 Fuel Systems................156 Snowmobile Identification ............. 2 Fuel System ..............156 Recommended Gasoline and Oil .......... 2 Individual Components............156 Engine Break-In ..............3 Self-Diagnostic System/Codes.......... 160 Drive Belt Break-In ..............3 Fuel Pressure Regulator ...........

  • Page 3: General Information/Foreword

    These numbers are required to complete warranty claims this manual are used for clarity purposes only and are properly. No warranty will be allowed by Arctic Cat if not designed to depict actual conditions. the engine serial number or VIN is removed or mutilated in any way.

  • Page 4: Engine Break-In

    25 miles at 3/4 throttle or less. By revving the engine up and down (but not exceeding 60 The Arctic Cat 4-stroke engine (when new or rebuilt) mph), the exposed cord on the side of a new belt will be requires a short break-in period before the engine is sub- worn down.
  • Page 5 CLUTCHING Exhaust gasses are directed through the turbocharger tur- bine wheel which is attached to the compressor through a On a normally-aspirated engine as altitude changes, common shaft. As the exhaust gasses spin the turbine, the engine horsepower changes with it. As you go up in alti- compressor is spun at very high RPM.

  • Page 6: Preparation For Storage

    Many possible variables and adjustments to the rear sus- Finally, track tension should be looked at to make sure pension exist depending on snow conditions, riding style, that it is within recommended specifications to affect the and type of terrain. These adjustments can be made to efficiency of the snowmobile.

  • Page 7: Preparation After Storage

    After the break-in period, drive belt deflection should be paring it for another season will assure many miles and checked according to the instructions given in the Drive hours of trouble-free snowmobiling. Arctic Cat recom- Train/Track/Brake Systems section of this manual. mends the following procedure: 1.
  • Page 8 DRIVE CLUTCH/DRIVEN CLUTCH  Adjust track tension and alignment ALIGNMENT — The alignment between the drive  Check throttle cable tension clutch and driven clutch are set at the factory. Normally,  Check engine idle no adjustment is necessary; however, if premature drive belt wear or poor performance is experienced, the drive ...

  • Page 9: Engine Specifications

    ITEM Connecting Rod Small End Bore (5000) 0.866-0.867” Engine Specifications Inside Diameter (9000) 0.945-0.946” Cam Lobe Height (Int) (5000) 1.487-1.489” (9000) 1.436-1.437” Cam Lobe Height (Exh) (5000) 1.432-1.433” 3000 (9000) 1.417-1.418” Camshaft Journal Outside Diameter 0.8650-0.8658” ITEM Camshaft Journal Bore Diameter 0.8666-0.8670”...

  • Page 10: Electrical Specifications

    ITEM Valve Stem Diameter (Intake) 4.475-4.490 mm (0.1762-0.1677”) Valve Stem Diameter (Exhaust) 4.460-4.475 mm (0.1756-0.1762”) Valve Guide Inside Diameter (Intake) 4.500-4.512 mm (0.1772-0.1776”) Valve Guide Inside Diameter (Exhaust) 4.500-4.512 mm (0.1772-0.1776”) Valve Guide/Stem Clearance (Intake) 0.010-0.037 mm (0.0004-0.0015”) Valve Guide/Stem Clearance (Exhaust) 0.025-0.052 mm (0.0010-0.0020”) Electrical Specifications Component...

  • Page 11: 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 12: Chain Case Performance Calibrations

    Chain Case Performance Calibrations Drive Gear Ratio Chain Engine RPM Sprocket Ratio 8800 9000 6200 6400 6600 6800 7000 7200 7400 7600 7800 8000 8200 8400 8600 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 13 Drive Gear Ratio Chain Engine RPM Sprocket Ratio 8800 9000 6200 6400 6600 6800 7000 7200 7400 7600 7800 8000 8200 8400 8600 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 14: Track Specifications

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

  • Page 15: Torque Specifications

    Rail Cam Arm Lock Nut (Team) Cam Arm Screw 50 in.-lb Rear Shock (M) Front Arm/Idler Arm Cam Arm Set Screw (Arctic Cat) Cam Arm 19 in.-lb Rear Shock (XF) Front Arm/Idler Arm Driven Clutch** (Arctic Cat) Driven Shaft Rail Support...

  • Page 16: Steering And Body

    3000/7000 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. NOTE: Whenever a part is worn excessively, ...
  • Page 17 7000 SNO-2221A 0747-529 6. Remove the cap screws and handlebar caps securing 9000 the handlebar to the top of the handlebar riser; then remove the two torx-head screws and nuts securing the top of steering post to the chassis. Account for both steering post blocks and retaining plate.
  • Page 18 SNO-2221A SNO-1027A 6. Remove the torx-head screws and handlebar caps 9. Remove both cap screws and flat washers securing securing the handlebar to the top of the handlebar the front steering support to the chassis. Remove the riser. support. SNO-1025 SNO-1026A 7.
  • Page 19 2. Secure the tie rod assembly to the steering post using a new M10 nut. Be sure to align the tie rod ball joint alignment tab with the steering post. Tighten to 35 ft-lb. SNO-2218 2. Secure the tie rod assembly to the steering post using a new M10 nut.

  • Page 20: Ski (Zr/Xf/Pantera)

    11. Install the upper and lower console; then install the seat using the existing hardware. 12. Install the hood and both access panels. NOTE: Prior to securing the hood, make sure the  air filter is seated properly into the air silencer and secured using the two rubber straps.

  • Page 21: Ski (Xf Hc/M)

    Arctic Cat recommends that the ski wear bars be NOTE: Note the orientation of the damper for ...

  • Page 22: Spindle (Zr/Xf/Pantera)

    5. Turn the handlebar fully to the right and then to the left to verify the steering moves freely. Spindle (ZR/XF/Pantera) Spindle (XF HC/M) 0747-904 REMOVING 1. Position the front of the snowmobile on a safety 0749-480 stand; then remove the ski. REMOVING 2.

  • Page 23: Steering Tie Rod

    5. Install the ski. 6. Turn the handlebar fully to the right and then to the left to verify the steering moves freely. Steering Tie Rod  NOTE: To access the steering arm, the steering tie rods must be removed. REMOVING 1.

  • Page 24: Ski Alignment

    SNO-225A SNO-353 2. Place the steering tie rod into position on the steering 5. Secure the steering tie rod to the steering tie rod post. Secure with a new nyloc nut. Tighten to 35 bracket with the screw and new nyloc nut. Tighten to ft-lb.

  • Page 25: A-Arms (Zr/Xf/Pantera)

    5. Measure the distance from the straightedge to the 2. Loosen both spindle tie rod jam nuts on the same left-side ski wear bar bolts in two places: approxi- side as the ski to be aligned. mately 7-8 in. in front of the spindle and 7-8 in. 3.

  • Page 26: A-Arms (Xf Hc/M)

    2. Remove the push rivets securing the steering boot to 2. Inspect the bearings and axles for wear or damage. the chassis; then slide the boot away from the snow- 3. Inspect the arm tubing for signs of twisting or bend- mobile.
  • Page 27 YM-137A SNO-572 3. Remove the torx-head screws securing the front skid INSPECTING plate to the chassis; then remove the front skid plate. 1. Inspect the arm welded areas for cracks or any signs 4. Remove the ski shock absorber. of deterioration. 5.

  • Page 28: Ski Shock Absorber

    3. Secure the A-arms to the spindle using one new lock nut and one new tri nut. Tighten to the lock nut 45 ft-lb and the tri-nut to 23 ft-lb.  NOTE: If the upper A-arm ball joint is being replaced, make sure the ball joint is threaded in as far as it can.

  • Page 29: Seat Assembly

    2. Release the lever securing the operator seat; then lift up and remove the front seat. Make sure to discon- Seat Assembly nect the seat heater harness. Remove the operator seat. ZR/XF/M NOTE: On models with heated seats, be sure to discon- ...

  • Page 30: Taillight/Brakelight Assembly

    2. Fold the rear edge of the cushion down and around 2. Connect the taillight harness connector; then secure the plastic base. Using a staple gun and 1/4 in. sta- the taillight to the rear rack facia with the screws. ples, staple the rear flap of the cushion to the plastic Tighten to 48 in.-lb.
  • Page 31 3. Remove the four screws securing the windshield brace to the console. Disconnect the gauge; then remove the windshield brace assembly. PC107A 8. Remove the headlight assembly. REMOVING (3000/7000) PC104A 1. Remove and retain all machine screws securing the 4. Disconnect the electrical accessory wires and igni- hood;...

  • Page 32: Headlight Bulb

    INSTALLING 5. Check headlight aim (see Adjusting Headlight Aim in this sub-section). 1. With the headlight assembly in position, install the front headlight assembly screws. Engage the side ! WARNING headlight screws in the slots and tighten until snug. Do not operate the snowmobile unless headlight beam 2.

  • Page 33: Engine

    This engine sub-section has been organized to show a 5. Remove the retaining nut from the neck of the gas progression for the removing/installing of the Arctic Cat tank and the two screws securing the upper console. 3000 engine. For consistency purposes, this sub-section Disconnect the wires from the reverse alarm, heated shows a complete and thorough progression;...
  • Page 34 14. Loosen the two hose clamps securing the air silencer to the throttle body and the intake tube; then discon- nect the ignition coils from the main harness. Remove the spark plug caps from the engine; then remove the three screws securing the air silencer to the tunnel.
  • Page 35 20. Remove the two screws securing the exhaust heat shield to the chassis support. Remove the shield. XM405A 18. Position a funnel under the water pump and out through the exhaust hole in the skid plate; then XM422A remove the cap screw and let the coolant drain into a 21.
  • Page 36 SNO-2219 25. Remove the two nuts, retaining plate, and bearing XM419 securing the top of the steering post. Remove the 30. Remove the four screws, four nuts, and bracket steering post assembly out of the chassis and set out securing the right-side chassis support; then Remove of the way.
  • Page 37 XM415A SNO-365 3. Connect the coolant hose to the heat exchanger using the existing clamp; then connect the other end of the Installing coolant hose to the water pump using the existing clamp. Tighten the coolant hose clamps to 35 in.-lb. 1.
  • Page 38 XM417A XM420A 7. Install the front spars to the chassis using the existing 11. Secure both ground wires using the existing screws cap screws. Tighten to 25 ft-lb. Install the two side and nut. Tighten securely. supports to the chassis using the existing cap screws and new nuts.
  • Page 39 20. Secure the top of the radiator through the oil cooler bracket and into the exhaust heat shield using the existing screws. Tighten securely. Connect the radia- tor fan to the main harness SNO-2219 14. Secure the right-side steering boot to the chassis using the existing push rivets.
  • Page 40 23. Secure the battery cables to the starter motor using the existing nut, star washers, and cap screw. Tighten the positive cable nut to 40 in.-lb and tighten the neg- ative cable cap screw to 96 in.-lb. XM404 27. Position the air intake silencer onto the throttle body and the intake tube.
  • Page 41 34. Add the recommended amount of oil; then add cool- ant into the filler neck. CAUTION If the engine had a major overhaul or if any major com- ponent was replaced, proper engine break-in proce- dures must followed (see General Information/Foreword section).

  • Page 42: Engine Removing/Installing - 5000/9000

    Engine Removing/Installing - 5000/9000 This engine sub-section has been organized to show a progression for the removing/installing of the Arctic Cat 1100 cc engine. For consistency purposes, this sub-sec- tion shows a complete and thorough progression; how- ever, for efficiency it may be preferable to remove only those components needing to be addressed.
  • Page 43 8. Disconnect the oxygen sensor and remove the spring securing the resonator to the chassis. 5000 PC065 11. Using a suitable vacuum pump, remove the coolant from the coolant/oil separator tank; then loosen the PC024A clamp and remove the hose from the tank and the 9000 lower heat exchanger.
  • Page 44 PC052A PC059A 15. Remove the lock nuts and screws (A) securing the rear intercooler brackets to the chassis and remove the brackets from the intercooler; then carefully pry the intercooler out from the front brackets (B) and remove the intercooler with the air bypass valve and hoses.
  • Page 45 18. Remove the cap screws and nuts securing the front spars to the steering support; then remove the torx-head screws securing the steering post bracket to the steering support. Remove the steering support. PC057A PC030 19. Remove the cap screws (F) or (G) securing the shock mounting bracket support to the shock mounting brackets;...
  • Page 46 22. Remove the throttle body coolant hoses. 5000 PC032  NOTE: Steps 25-27 are for the 5000 only. ZJ018 25. Loosen the clamps securing the air silencer to the 9000 throttle bodies; then disconnect the harness connec- tor from the air temperature sensor and remove the air silencer.
  • Page 47 743-999A PC034A 29. From the opposite side of the throttle body, discon- nect the idle speed control and the throttle cable; then remove the spark plug caps from the spark plugs. PC243 32. Remove the two cap screws securing the elbow fit- ting of the oil supply hose to the engine;...
  • Page 48 5000 0746-313 PC209A 38. Remove the cap screws securing the PTO-side 9000 engine to chassis mount (bearing bracket). 39. Disconnect the harness connectors from the regula- tor/rectifier and magneto; then remove the cap screws securing the routing clamp to the engine (5000 models) and secure the wire harness up and out of the way.
  • Page 49 PC038A PC040A PC039A PC047A 2. Tip the engine forward enough to install the cables to  NOTE: At this time, verify all components connect- the starter motor and tighten the ground cable to 19 ing the engine to the chassis are disconnected and out ft-lb and the positive cable to 42 in.-lb.
  • Page 50 4. With the front engine/chassis mount into position, 7. Secure the MAG-side engine to chassis mount using lower the engine back until the engine is in line with the two cap screws (coated with blue Loctite #243) PTO-side engine/chassis mount (bearing (E).
  • Page 51 5000 PC243 PC037A  NOTE: Make sure the O-rings are in place before 9000 installing the oil hoses. 13. Install the coolant/oil separator tank to the bracket on the engine; then install the hoses with clamps to the coolant/oil separator tank and secure the clamps. XM097A ...
  • Page 52 ZJ094A PC211A 20. With the spark plug wires routed properly, install the CAUTION spark plug caps to the spark plugs. Make sure the harness is routed away from the exhaust NOTE: Make sure the caps are firmly seated on the ...
  • Page 53 743-999A SNO-231C 24. With the battery cables and solenoid harness prop-  NOTE: At this time, secure the wire harness to the erly positioned in the channel of the gas tank assem- locations noted during disassembly. bly, install the gas tank (see the Fuel Systems section).
  • Page 54 NOTE: On the 9000, secure the front heat shield to  the chassis with the screws. PC061A 28. Install the throttle cable into the lever; then verify the throttle lever free-play is within specification. PC058A  NOTE: On the 5000, install the MAP sensor to the bracket on the MAG-side steering support.
  • Page 55 PC055A PC052A 32. Install the exhaust resonator to the chassis support and secure with the spring; then secure the resonator to the exhaust pipe and tighten the cap screws and flange nuts to 12 ft-lb. NOTE: Steps 33-34 are for the 5000 only. ...
  • Page 56 35. Install and secure the drive clutch with the cap screw (lightly coated with oil); then tighten the cap screw to 51 ft-lb. CAUTION When installing the drive clutch, do not tighten the clutch cap screw with any kind of impact tool. Tighten cap screw using a hand torque wrench only.
  • Page 57 NOTE: At this time, connect Hood Harness Exten-  sion to the hood and connect the main harness con- nector to the extension. CAUTION After running the engine to the proper operating tem- perature, shut the engine off; then inspect for any signs of coolant, gasoline, or oil leakage.

  • Page 58: Engine Removing/ Installing - 7000

    Remove the resonator. This engine sub-section has been organized to show a progression for the removing/installing of the Arctic Cat 1049 cc engine. For consistency purposes, this sub-sec- tion shows a complete and thorough progression; how- ever, for efficiency it may be preferable to remove only those components needing to be addressed.
  • Page 59 746-121A NOTE: To aid in draining the oil from the tank,  position a funnel between the tank and the opening of the tunnel running board. YM-035A 16. Remove the fuse block from the coolant tank and 11. After the oil has drained completely, install a new move it out of the way;...
  • Page 60 21. Disconnect the throttle body harness from the main harness; then remove the three clamps securing the throttle body to the intake boots. Remove both cool- ant hoses. Remove the throttle body. YM-039 25. Remove the clamp securing the MAG-side coolant hose to the engine;...
  • Page 61 YM-107A SNO-364 1. Position the front engine bracket with the front 4. Tighten the rear engine cap screws and nuts to 93 engine mounts; then loosely secure using the existing ft-lb. cap screws and nuts. 5. Tighten the cap screws (A and B) to 25 ft-lb. Tighten cap screws (C) to 65 ft-lb.
  • Page 62 7. Secure the upper mounting bracket, right-side chas- sis support, and the right-side steering support to the chassis using the existing cap screws and nuts. Tighten to 20 ft-lb. Install the oil hose to the right side of the engine. YM-049 11.
  • Page 63 SNO-2219 14. Secure the right-side steering boot to the chassis YM-035A 21. Position the exhaust gasket between the engine and using the existing push rivets. the exhaust manifold; then secure the manifold to the engine using the existing screws. Tighten to 16 ft-lb. XM134A 15.
  • Page 64 25. Install the gas tank assembly and connect the battery; then install the upper and lower console making sure to connect the reverse alarm. 26. Install the drive clutch, drive belt, and the driven clutch. 27. Install the seat and secure using the screw. ...

  • Page 65: Engine Servicing - 3000

    Engine Servicing - 3000 This engine sub-section has been organized to show a progression for servicing of the Arctic Cat 3000 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 66 ROV1-013 ROV1-010 4. Remove the cam chain tensioner. Account for a gas-  NOTE: The camshaft holder and cylinder head ket and the fasteners. have matching code numbers and must remain a set. ROV1-002 KC548A 5. Remove the chain guide. KC549A 7.
  • Page 67 ROV1-021A WT471A 9. Loosen the six head bolts securing the cylinder head CAUTION to the cylinder. When removing the tappets, note the location of the tap- pet, the valve from which the tappet was removed, and the shim number of the tappet or severe engine damage may occur.
  • Page 68 Valve Clearance (Cold) 15°-25° C Intake: 0.16 mm (0.006 in.) (59°-77° F) Exhaust: 0.22 mm (0.009 in.) ROV1-043  NOTE: Only one piston circlip needs to be removed. KC534A 4. To select the correct replacement shim for an out-of-specification clearance, note the three-digit number on the surface of the existing shim;...
  • Page 69 TAPPET CLEARANCE TABLE - INTAKE KCINTAKE...
  • Page 70 TAPPET CLEARANCE TABLE - EXHAUST KCEXHAUST...
  • Page 71 WT581 WT583A 3. Remove the valve springs; then invert the cylinder CAUTION head and remove the valves. Water or parts-cleaning solvent must be used in con- junction with the wet-or-dry sandpaper or damage to CAUTION the sealing surface may result. If valves are discolored or pitted or if the seating sur- VALVE ASSEMBLY face is worn, the valve must be replaced.
  • Page 72 2. Inspect the piston for seizure marks or scuffing. If observed, replace the piston. 3. Inspect the perimeter of each piston for signs of excessive “blowby.” Excessive “blowby” indicates worn piston rings or an out-of-round cylinder. Measuring Piston-Ring End Gap (Installed) 1.
  • Page 73 ATV-1069 Measuring Connecting Rod (Small End Bore) 1. Insert a snap gauge into the upper connecting rod small end bore; then remove the gauge and measure it with micrometer. KC700RINGS 2. Rotate the rings so the ring gaps are orientated as KC544 shown and oriented to the piston pin.
  • Page 74 3. Place the cylinder head on the surface plate covered with #400 grit wet-or-dry sandpaper. Using light pressure, move the cylinder head in a figure eight motion. Inspect the sealing surface for any indication of high spots. A high spot can be noted by a bright metallic finish.
  • Page 75 Components 1. Inspect cam chain guide for cuts, tears, breaks, or chips.  NOTE: Arctic Cat recommends new gaskets be used 2. If the chain guide is damaged, it must be replaced. when assembling the engine. Measuring Camshaft Runout 1. Before installing on the connecting rod, install the inside piston circlip into the piston making sure the ...
  • Page 76 11. Install the cap screws (threads coated with oil) with the two longer bolts going in the dowel pin locations. WT131 8. Install the chain guide so it is seated at the top and bottom. WT142A 12. In the order shown, tighten the head bolts to 22 ft-lb, then to 29 ft-lb, and finally to 36 ft-lb.
  • Page 77 17. Install the intake cam shaft; then install the chain around the sprocket so the intake timing mark is par- allel with the head surface. WT143A 15. Making sure the chain stays on the crankshaft sprocket, rotate the engine to TDC. WT151 18.
  • Page 78 NOTE: Applying a small bead of silicone between  the head cover and rubber gasket will aid in assem- bling. 24. Tighten the head cover fasteners in the order shown to 7 ft-lb with the rubber washers and steel cups. WT156B 21.
  • Page 79 ROV1-116A ROV1-048 3. Remove the chain by pulling it down through the crankcase and out the PTO side. Bottom-Side Components 4. Remove the fastener securing the chain guide to the crankcase. NOTE: For efficiency, it is preferable to remove and ...
  • Page 80 ROV1-108A KC543 10. Remove the starter idler gear and shaft.  NOTE: Account for the different-lengthed fasteners for assembling purposes.  NOTE: If the technician’s objective is to service or replace the flywheel or starter gear, proceed to step 7; if not, continue to disassemble the bottom side compo- nents without removing the flywheel or starter gear.
  • Page 81 ROV1-064 ROV1-070A 13. Remove the fasteners connecting the top case half to the bottom case half. ROV1-068 17. Remove the oil passage tube and oil level stick. ROV1-077A NOTE: The fastener just above the oil filter is lon-  ger than the others. 14.
  • Page 82 NOTE: Using a rubber mallet will aid in separating  the case halves. ROV1-084  NOTE: Note the color coding on the bearings for assembling purposes. ROV1-088A  NOTE: Note the color coding on the bearings for  NOTE: Keep both the top and bottom of the con- assembling purposes.
  • Page 83 REPLACING STATOR COIL/ CRANKSHAFT POSITION SENSOR 1. Remove the three cap screws securing the stator coil and the two cap screws securing the crankshaft posi- tion sensor. ROV1-111 26. Remove the mechanical seal from the cover and the ceramic mating seal from the impeller. Servicing Bottom-Side Components ROV1-059A...
  • Page 84 Main Bearings Check the main bearings for signs of pitting, scratches, wear, or damage. If any of these conditions are found, the bearings must be replaced. CAUTION Always replace the bearings as a set; never replace one side only or severe engine damage will occur. Bearing Selection ...
  • Page 85 ROV1-084A ROV1-088A 2. Connect the mating halves of the connecting rod on 4. Place the counterbalance shaft into the case making the crankshaft making sure the gear is on the right sure the alignment marks on the counterbalance gear hand side and the oil holes are facing the intake side. and crankshaft are aligned.
  • Page 86 ROV1-092A ROV1-078A NOTE: Verify the correct positioning of the wash-   NOTE: The longer fasteners go in the holes num- ers. bered one through six. 10. Place the rubber O-ring into the oil pressure relief 7. Rotate the engine to right-side up and install the valve bore;...
  • Page 87 12. Using a gasket scraper, clean off the old gasket from the oil pan and case. Install a new gasket and two dowel pins. ROV1-063  NOTE: When installing the pump, the chain and sprocket must be on the oil pump and counterbalance shaft with the sprocket shoulder facing the oil pump.
  • Page 88 19. Using a gasket scraper, clean off the existing gasket and case from the MAG-side cover. Using a new gasket and dowel pins, install the cover making sure the coolant pump shaft is aligned with the oil pump shaft. Tighten to 7 ft-lb. 20.

  • Page 89: 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 90 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 91 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 92 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 93 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 94 ZJ052B ZJ047A 32. Remove the Allen-head cap screws securing the pis-  NOTE: Because the connecting rods and connecting ton cooling jets to the upper crankcase half; then rod caps are unique, note the I.D. marks and keep all remove the jets and account for the O-rings. associated parts together for assembling purposes.
  • Page 95 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. 1. Install the drive clutch; then using Drive Clutch Spanner Wrench, rotate the engine two full revolu- tions.
  • Page 96 SNO2152...
  • Page 97 SNO2153...
  • Page 98 Cleaning/Inspecting Piston 6. With the engine at top-dead-center, measure the valve/tappet clearance of the cylinder that is on the 1. Using a non-metallic carbon removal tool, remove compression stroke; then rotate the engine another any carbon buildup from the dome of the piston. 360°...
  • Page 99 0738-532 ATV-1069 Measuring Piston Skirt/Cylinder Measuring Piston Pin Diameter Clearance Measure the piston pin diameter at each end and in the center. Measurement must be within 0.8658-0.8661 in. 1. Measure the cylinder front to back in six places using for the 5000 and 0.9447-0.9449 in. for the 9000. If mea- a cylinder bore gauge.
  • Page 100 4. Rotate the rings until the ring end gaps are 120° from one another. CAUTION Incorrect installation of the piston rings will result in engine damage. MEASURING CONNECTING ROD SMALL END BORE INSIDE DIAMETER 1. Using a small bore gauge, measure the connecting rod small end bore inside diameter.
  • Page 101 Crankcase Stamping Right Front Balancer Center Front Balancer Left Front Balancer (A or B) (A or B) (A or B) Right Main Center Main Left Main (A or B) (A or B) (A or B) Right Rear Balancer Center Rear Balancer Left Rear Balancer (A or B) (A or B)
  • Page 102 NOTE: Prior to installing the pistons, make sure the  oil ring end gaps are on directly opposite sides of the piston, and the compression ring end gaps are 90° NOTE: Arctic Cat recommends that new gaskets,  from one another. seals, and O-rings be installed whenever assembling 4.
  • Page 103 NOTE: Install a cap screw and large washer to the  cylinder head cap screw hole between pistons to avoid any chance of the pistons sliding out of the cylinder. ZJ069A CAUTION Prior to lubricating the bearings and journals, make sure all surfaces are cleaned thoroughly and dried with ZJ073A 6.
  • Page 104 NOTE: Prior to installing the oil-relief valve, make  sure the valve is free and clear of any contaminants. 14. With proper bearings selected, install the counterbal- ancer bearing halves into the upper engine case; then apply a light film of engine-assembly grease to the bearing surfaces.
  • Page 105 23. For initial tightening of the engine case cap screws, use this sequence: A. Cap screws 1-6 (10 mm) to 13 ft-lb. B. Cap screws 7-24 (8 mm) to 120 in.-lb. C. Cap screws 25-28 (6 mm) to 96 in.-lb. 24.
  • Page 106 29. Position the pistons at the top-dead-center position by rotating the crankshaft until the keyway on the crankshaft is directed upward and aligned with the cylinder. ZJ078A  NOTE: If the oil pan drain plug was removed, always install new drain plug and reservoir washers. ...
  • Page 107 741-617A 741-801A 33. With a light film of engine-assembly grease applied 36. With the cam chain properly seated to the gears of to the tappets, install the correct shim (A) and tappet the crankshaft and exhaust camshaft, install the (B) to each valve of the cylinder head as noted intake camshaft noting the timing marks (B) are during disassembling.
  • Page 108 ZJ086 ZJ036A 39. Install the cam chain tensioner adjuster by first com- 43. Install the flywheel with the cap screw and washer. pressing the locking clip; then by pushing in the ten- Using the flywheel holder wrench from Flywheel sioner shaft until completely compressed. Puller, tighten the cap screw to 88 ft-lb.
  • Page 109 742-002A ZJ031B 46. Install the two alignment pins in the engine for the 48. Install a new thermostat; then install the cover and magneto cover; then with a new gasket, install the secure with the two cap screws. Tighten to 84 in.-lb. cover and with the pattern shown, tighten the 18 cap NOTE: Make sure to install the thermostat with the ...
  • Page 110 TZ087A TZ063A 50. Install the starter motor; then secure with the cap 54. Install the lower heat shield onto the turbocharger screw. Tighten to 19 ft-lb. and exhaust manifold with the cap screws. Tighten to 60 in.-lb. 55. With the gaskets in place, install the exhaust pipes and turbocharger assembly to the engine;...
  • Page 111 743-991A 744-771B 59. With the turbocharger secured, install the oil feed  NOTE: Make sure when installing the oil feed pipe pipe with the banjo bolts and two new crush washers that the correct banjo bolt is securing the pipe to the on each side of the union.

  • Page 112: Assembly Schematic - 5000/9000

    Assembly Schematic - 5000/9000 Torque Specification Tolerances Torque (ft-lb) Tolerance 0-15 ±20% 16-39 ±15% ±10% 1100ccJAG12...
  • Page 113 1100ccZ1RV10...
  • Page 114 Engine Torque Patterns (5000/9000) 1100TorquePattern12...

  • Page 115: 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 116 YM-006 YM-081 6. Remove the Allen-head screws securing the MAG 8. Remove the starter gear and shaft. cover to the crankcase taking note the location of the black screw. YM-007 9. Remove the cap screw securing the flywheel to the crankshaft.
  • Page 117 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 15. Remove the cap screws securing the camshaft covers to the cylinder head;...
  • Page 118 YM-016A YM-019 18. Remove the four cap screws securing the rear engine 21. Remove the five cap screws securing the oil pump to mounting brackets to the crankcase. Remove the the crankcase. Account for two dowel pins. brackets. YM-020A 22. Loosen the cap screws in decreasing numerical order YM-017A of the embossed numbers on the crankcase.
  • Page 119 SNO-614 SNO-383A 26. Remove the snap ring securing the water pump drive  NOTE: The indicator mark (A) on the connecting gear; then remove the gear and shaft and account for rod cap will always point to the MAG end of the a spacer and a bearing.
  • Page 120 If valves, valve guides, or valve seats require servicing or 5. After verifying proper valve/tappet clearance, install replacement, Arctic Cat recommends the components be the timing inspection plug to the magneto case and taken to a qualified machine shop for servicing.
  • Page 121 SNO2152...
  • Page 122 SNO2153...
  • Page 123 4. Make sure that the “Y” mark (A) on the connecting rod faces towards the right side (AC magneto rotor side) of the crankshaft. SNO-660 NOTE: The numbers (A) stamped into the crank-  shaft web and the numbers on the connecting rods are used to determine the replacement big end bearing SNO-618A sizes.
  • Page 124 NOTE: The numbers stamped into the crankshaft  web and the numbers stamped into the lower crank- case are used to determine the replacement crank- shaft journal bearing sizes. SNO-298 3. Put a piece of Plastigauge® on each crankshaft jour- nal.
  • Page 125 NOTE: Whenever a piston, rings, or pins are out of Fit new piston ring into piston groove and measure clear-  ance between ring and ringland by using feeler gauge. tolerance, they must be replaced. Measurement must be within the following specifica- Cleaning/Inspecting Piston tions.
  • Page 126 NOTE: If out of specification, replace the crankcase  and the piston and piston rings as a set. Measuring Piston Skirt Diameter 1. Measure the piston skirt diameter (A) with a micrometer. Be sure to measure 8.0 mm (0.31 in.) from the bottom edge of the piston (B).
  • Page 127 2. If any journal is badly damaged or has wear that is spline (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-dissolvable ...
  • Page 128 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 129 NOTE: Make sure the “Y” marks (A) on the con-  necting 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 130 21. Position the oil pump chain around the crankshaft; then install the oil pump driven gear and secure using the existing cap screw. Tighten to 11ft-lb. SNO-303  NOTE: If a cap screw is tightened more than the specified angle, do not loosen the bolt and then retighten it.
  • Page 131 SNO-307 SNO-625 28. Install the magneto cover and secure using the exist-  NOTE: Prior to installing the cam chain tensioner, ing allen-head screws. Tighten to 8.7 ft-lb. assure the chain is properly seated to the gear on the crankshaft. NOTE: Apply blue Loctite #243 to the black ...
  • Page 132 SNO-308 SNO-311A 33. Tighten the Allen-head screws #1 and #2 to 104 37. Install the existing dowel pins into the cylinder head; in.-lb. then install the intake and exhaust camshaft caps. Tighten the camshaft cap screws to 86 in.-lb in two 34.
  • Page 133 SNO-626A SNO-315A 39. Insert the timing chain tensioner rod little by little so 41. Apply Three Bond Sealant onto the mating surfaces that the circlip (A) is seated into the groove (B). of the cylinder head cover and cylinder head cover gasket.

  • Page 134: Assembly Schematic - 7000

    Assembly Schematic - 7000 Torque Specification Tolerances Torque (ft-lb) Tolerance 0-15 ±20% 16-39 ±15% ±10% 1049cc_16_2...
  • Page 135 1049cc_16_1...

  • Page 136: 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 137 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 138: 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. NOTE: When indicated for use, each special tool ...
  • Page 139 WT572 WT575 8. Using an appropriate press, remove the rubber seal CAUTION and mechanical seal as an assembly. It is critical while pressing the seal into position to press on the outer diameter of the seal to avoid damag- ing the mechanical seal. 3.
  • Page 140 DISASSEMBLING/ASSEMBLING (5000/9000) ZJ112A 3. Remove the separator tank breather hose to gain access to the water pump; then remove the water inlet hose from the water pump. 0742-104 1. Secure the water pump in a suitable support device; then remove the two Phillips-head screws (A) secur- ing the inner/outer pump housings.
  • Page 141 8. Place the mechanical seal (D) into the inner housing; then using the appropriate-sized installation tool, drive the seal into the housing until the lip of the seal is properly seated. 9. Install the ceramic seal (C) onto the impeller shaft with the ceramic face of the seal facing away from the impeller.
  • Page 142 SNO-375A SNO-279A 2. Remove the screws securing the water pump cover to INSTALLING (7000) the water pump; then remove the impeller. 1. Apply tap water or coolant to the outer surface of the 3. Remove the water pump seal (A) from the water new oil seal;...

  • Page 143: Pressure Testing Engine

    5. While holding the throttle in the full-open position, crank the engine over with the electric starter until the gauge stops climbing (five to 10 compression strokes). Compression should be as shown in the chart. PSI (WOT) Cylinder #1/Cylinder #2 6.
  • Page 144 If it does, proceed to step 10. If the warning icon does not illuminate, take the snowmobile to an authorized Arctic Cat Snowmobile dealer for service. If not under warranty, this service is at the discretion and expense of the snowmobile owner.
  • Page 145 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 146: Testing Oil Pressure

    NOTE: If the warning icon does not illuminate, take  5. With the engine running at 3000 RPM and the cool- the snowmobile to an authorized Arctic Cat Snowmo- ant at approximately 195° F (cooling fan cycling), bile dealer for service. If not under warranty, this ser- the pressure gauge must show 5.27-6.68 kg/cm...

  • Page 147: Liquid Cooling System (5000/9000)

    ASSEMBLING/INSTALLING 1. Place the rotors into the crankcase making sure the Liquid Cooling System dowel pin is in the groove of the rotor. (5000/9000) 2. Place the cover onto the crankcase. 3. Secure the pump with the two cap screws coated The liquid cooling system consists of a heat exchanger, with blue Loctite #243.

  • Page 148: Liquid Cooling System (3000/7000)

    NOTE: If the coolant level in the filler neck sud- 3. Remove the hose clamp securing the coolant hose to  the bottom of the radiator; then remove the hose and denly drops when the bleed screw is loosened, an pour coolant into a container.

  • Page 149: Cooling System Schematics

    2. Using the following procedure, inspect the thermo- stat for proper operation. Cooling System Schematics The following schematics are representative of the differ- ent styles of cooling systems in the Arctic Cat snowmo- biles. 3000 0749-693...
  • Page 150 5000 0746-354 9000 0746-522...

  • Page 151: Air Silencer

    7000 0747-953 5. Secure the air silencer to the tunnel using the three screws. Tighten securely. Air Silencer 6. Install the gas tank (see the Fuel Systems section) and seats. REMOVING/INSTALLING (3000) 7. Install the hood, connect the hood harness, and 1.

  • Page 152: Turbocharger/Intercooler (9000)

    3. Loosen all three hose clamps securing the intake boots to the throttle body; then disconnect the air Turbocharger/Intercooler temp sensor. Remove the air intake assembly. (9000) ! WARNING The rotating components in a turbocharger turn at speeds of 150,000 RPM. Any imbalance could cause rapid disintegration resulting in bodily injury or death.
  • Page 153 3. Remove all clamps (A) securing the outlet hose, air duct, and intercooler; then remove the air filter (B) and all hoses connected to the intercooler. SNO-232A  NOTE: To aid in the removal of the assembly from step 6, drill out the rivet (A) securing the rear heat shield to the left spar tube.
  • Page 154 PC236 TZ093A 10. Remove the three lock nuts and washers securing the 2. Inspect the waste gate linkage for signs of wear or bracket of the turbocharger to the engine; then loosen damage. the lock nuts securing the mounting bracket to the INSTALLING turbocharger.
  • Page 155 PC231 PC230A 6. Install the three lock nuts securing the turbocharger mounting bracket to the engine. Tighten the nuts to 30 ft-lb and bend each tab to secure the nut. PC233A 11. Secure the left-side front spar to the chassis; then install the two cap screws and nuts securing shock mount support bracket.
  • Page 156 13. Secure the front left-side facia to the chassis using the existing torx-head screws. 14. Secure the front heat shield using the existing torx-head screws; then secure the coolant return hose (A). SNO-231A 17. Connect the oxygen sensor; then install the cap screws, nuts, new gasket, and spring securing the resonator to the chassis.

  • Page 157: Fuel Systems

    INTRODUCTION NOTE: The ECM cannot be repaired.  The Arctic Cat EFI System operates off a series of coils Removing (3000) located on the stator and is made up of the following 1. Remove both access panels; then remove the hood.

  • Page 158: Coolant Temperature Sensor

    Installing (3000) NOTE: Make sure all connectors are clean and  tight. Apply dielectric grease to all connector seals. 1. Secure the ECM to the chassis using the existing four nuts. Tighten securely; then press the connector into 2. Install the air intake assembly to the throttle body the ECM and rotate the connector arm down until it and the radiator.

  • Page 159: Fuel Injectors

    IGNITION TIMING SENSOR 4. Connect the gasline to the fuel rail. This sensor is triggered by teeth precisely mounted to the 5. Connect the wiring harness to the injectors. Cable tie flywheel flange. Each time a tooth rotates past the sensor, as needed.

  • Page 160: Fuel Pressure Regulator

    EXHAUST AIR TEMPERATURE (EAT) 2. Disconnect the wiring harness from each injector. SENSOR 3. Remove the cap screws and washers securing the This platinum, thin-film sensor detects the exhaust air fuel rail to the throttle body assembly; then remove temperature in the exhaust system. The ECM sends cur- the rail from the injectors.

  • Page 161: Self-Diagnostic System/Codes

    Code Trouble Self-Diagnostic Open or short circuit and/or loose knock sensor circuit. Failure in injector (PTO secondary). System/Codes Failure in injector (MAG secondary). Failure in shifting system/gear position switch. Malfunction in air pressure sensor circuit. 5000/9000 Malfunction in shift control switch. ...

  • Page 162: Fuel Pressure Regulator

    Code Trouble Code Trouble P0113 Intake Air Temperature Sensor P2307 Ignition Coil “C” Primary Control Circuit High Circuit High U0155 Lost communication with the ECM P0114 Intake Air Temperature Sensor U1000 Vehicle not registered or invalid PIN Circuit Intermittent U1001 Vehicle not registered and vehicle limits enabled P0115 Engine coolant temp sensor 1 circuit...
  • Page 163 XM426 XM404 4. Loosen the nut securing the throttle cable; then 3. Position the air intake silencer onto the throttle body remove the cable and the throttle body assembly. and the intake tube. Secure using the existing hose clamps. Tighten to 35 in.-lb. 4.
  • Page 164 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 165 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 166 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 167 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 168 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-047A YM-045A 3. Install the throttle cable to the bracket on the throttle body assembly and to the throttle valve cam; then secure the cable with the jam nut.

  • Page 169: Throttle Cable

    CAUTION Compress the throttle control lever to ensure free move- ment. If the throttle cable sticks or binds, correct the problem before starting the engine. Fuel Pump TESTING 1. Remove the seat(s); then remove the upper and lower console panels. YM-049 2.
  • Page 170 YM-050C SNO-702 3. Connect Fuel Pressure Test Kit to the fuel pump and  NOTE: If the fuel pickup assembly is not being fuel hose. replaced, inspect the screens for any tears or obstruc- tions. Also check the hoses and replace if necessary. 4.
  • Page 171 6. Connect the fuel pump harness connector to the main harness and secure to the snap ring with a cable tie; then secure the gasline hose to the fuel pump making sure it locks into place. 7. Install the upper and lower consoles using existing machine screws;...

  • Page 172: Troubleshooting

    4. Carefully remove the fuel pump and fuel pickup 2. Install the retaining ring over the fuel pump and assembly from the gas tank noting the orientation of secure the fuel pump to the gas tank assembly using the fuel pump outlet for assembling purposes. the existing torx-head screws.

  • Page 173: Gas Tank

    Gas Tank ZR/XF/M (REMOVING) 1. Remove the access panels, hood, and the seat. 2. Remove the lower console. 3. Disconnect the reverse alarm; then remove the two machine screws securing the upper console. 4. Remove and retain all four cap screws securing the rear spar tubes to the chassis and steering support.
  • Page 174 8. Install the rear spar tubes and secure using the exist- ing cap screws. Tighten to 23 ft-lb. 9. Install the operator’s seat, passenger’s seat, and the storage box lid. YM-110A 7. Install the right- and left-side rack fascia using the existing hardware.

  • Page 175: Electrical Systems

    If spark is Description now present, adjust the throttle cable tension. CATT II 0544-023 Arctic Cat Diagnostic System Manual 2256-974 TESTING Laptop Diagnostic Tool 0744-048 Throttle Control Switch...
  • Page 176 5000/9000 NOTE: The Test Harness must be plugged into the  analyzer for testing voltage. Always verify battery 1. Disconnect the harness connector from the TPS. voltage is at least 4.9 DC volts before testing TPS. 2. Loosen the screw(s) of the throttle position sensor to CHECKING TPS allow adjustment.
  • Page 177 Installing 9000 1. Install the new TPS onto the throttle shaft; then rotate the sensor until properly positioned on the throttle body. 2. Install the screws w/ washers securing the sensor to the throttle body. Do not tighten at this time. 3.

  • Page 178: Electrical Resistance Tests (3000)

    CRANKSHAFT POSITION SENSOR 3. Adjust the TPS using the CATT II Tool. Instructions will be included with the tool. 1. Set the meter selector to the OHMS position. NOTE: Before installing the TPS harness connector,  2. Connect the red tester lead to the brown wire; then apply dielectric grease to the connector pins.

  • Page 179: Electrical Resistance Tests (5000/9000)

    Air Temperature Sensor Electrical Resistance Tests  NOTE: The component temperature must be known before conducting this test. Allow the engine to (5000/9000) reach room temperature. 1. Disconnect the wiring harness from the air tempera- NOTE: Replace any component that does not have a ...

  • Page 180: Voltage Regulator Tests

    3. Compare the resistance reading to the Voltage/Resis- tance Chart - Coolant Temperature in this section. Air Temperature Sensor NOTE: The component temperature must be  known before conducting this test. Allow the engine to reach room temperature. 1. Disconnect the wiring harness from the air tempera- ture sensor.

  • Page 181: Emergency Stop Switch

    2. Disconnect the fuel gauge sender unit from the main NOTE: An in-line ammeter would measure between  wiring harness; then connect the ohmmeter leads to 2 and 4 amps of solenoid coil current flow with the the two black sender wires. battery connected.

  • Page 182: Starter Motor

    2. Using the ohmmeter, test the connections indicated in the following chart. If the meter reads more than one ohm of resistance between connected terminals or less than 1 ohm of resistance on non-connected terminals, the switch must be replaced. XM427 3.
  • Page 183 XM425 XM404 5. Position the air intake silencer onto the throttle body INSTALLING and the intake tube. Secure using the existing hose 1. Apply a small amount of grease to the O-ring seal on clamps. Tighten to 35 in.-lb. the starter motor; then install the starter into the 6.
  • Page 184 3. Remove cap screw (A) securing the positive cable to the starter motor; then remove the two cap screws (B) and remove the starter motor. ZJ152A 3. Remove the bearing housing (A) and the magnet housing (B) with armature from the brush assembly (C).
  • Page 185 3. Inspect the brush holder assembly and brushes for 10. Inspect the commutator for shorting using a multi- damage or wear. Using a caliper, measure the length of meter and the following procedure. the brushes. If brush measurement is less than 0.40 in., A.
  • Page 186 NOTE: Prior to installing the bearing housing, posi-  tion the locking plate with the tabs (A) of the locking plate aligned with the cap screw ears (B) of the starter motor. ZJ143  NOTE: The brushes must be fully compressed to allow enough room to install the armature.

  • Page 187: Troubleshooting Electric Start

    5. Install the positive cable to the battery; then install 3. Remove the fasteners securing the stator and the the seat. crankshaft position sensor in place; then remove the stator. INSTALLING (5000/9000) 1. Install the starter motor to the engine; then with the ground cable positioned to the top mounting hole, install the two cap screws (B) and tighten to 19 ft-lb.
  • Page 188 ZJ149A INSTALLING (5000/9000) SNO-728 3. To gain access to the magneto cover, remove the 1. Place the magneto into position on the cover; then remaining coolant hoses from the water pump, oil install and tighten the three cap screws to 84 in.-lb. cooler, and separator tank.
  • Page 189 1. Disconnect the connector for the oxygen sensor; then remove the cap screws, nuts, and springs securing the resonator. 2. Remove the cap screws and nuts securing the MAG-side chassis support; then remove all clamps and hoses to gain access to the magneto cover. 741-583A ...

  • Page 190: Brakelight Switch

    INSTALLING (7000) 1. Place the magneto into position on the cover; then install and tighten the three cap screws (threads coated with blue Loctite #243) to 7.2 ft-lb. With the harness routed properly, install the timing sensor and harness clamp and tighten (threads coated with blue Loctite #243) to 7.2 ft-lb.

  • Page 191: Headlight Dimmer Switch

    XM207 CM109A 4. With the switch in the HI beam position, connect one ohmmeter lead to pin (B) and the other ohmmeter lead to pin (C). The meter must read 1 ohm or less resistance. NOTE: If either test does not read within specifica- ...

  • Page 192: Testing Thumb Warmer Element

    4. With the thumb warmer toggle in the high position, connect one ohmmeter lead to pin (C) and the other Testing Thumb Warmer ohmmeter lead to pin (A). The meter must read 1 Element ohm or less resistance. NOTE: If either test does not read within specifica- ...

  • Page 193: Testing Seat Heater Switches

    3. For the HI position, connect one ohmmeter lead to the green/blue wire from the element; then connect Testing Speedometer the other ohmmeter lead to the green wire from the Sensor element. The meter must read between 9.5-11.5 ohms. NOTE: The following test should be made using ...

  • Page 194: Testing Shift Switch

    Testing Shift Switch Testing Shift Actuator NOTE: The switch is located on the right-side han- NOTE: The actuator is located on the chain case.   dlebar control. To access the switch, the control 1. Disconnect the actuator two-wire connector; then assembly must be disassembled.

  • Page 195: 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 196: Drive Train/Track/Brake Systems

    NOTE: When installing a new drive belt, see After  Break-In Checkup/Checklist - Drive Belt Break-In in Drive Train/Track/Brake the General Information/Foreword section. Systems REMOVING (3000) 1. With the engine off, remove the left-side access panel. Loosen the 1/4 turn on the lower console. This section has been organized into sub-sections for ser- 2.

  • Page 197: Drive Clutch

    REMOVING (5000/7000/9000) 1. Loosen the screws securing the cover. Remove every other cap screw and lock washer from the cover; then 1. Set the brake lever lock; then remove the left-side while firmly holding the cover, remove the three access panel. Loosen the 1/4 turn on the lower con- remaining screws and lock washers equally.
  • Page 198 Cleaning And Inspecting 1. Using parts-cleaning solvent, wash grease, dirt, and foreign matter off all components; dry with com- pressed air. ! WARNING Always wear safety glasses when using compressed air to dry components. 2. Remove any drive belt dust accumulation from the stationary sheave, movable sheave, and bushings using parts-cleaning solvent only.
  • Page 199 6. Inspect rollers for damage or wear. 3. Remove the drive clutch from the engine compart- ment. Assembling Disassembling NOTE: The drive clutch rotates counterclockwise  and the shoulder screw should be installed in the NOTE: Note the timing marks on the cover, spider, ...

  • Page 200: Driven Clutch

    CAUTION When installing the drive clutch, do not tighten the cap screw with any kind of impact tool. Tighten cap screw using a hand torque wrench only. Failure to do so could result in stationary sheave damage. 3. Check alignment between the drive clutch and driven clutch.
  • Page 201 CAUTION Do not use steel wool or a wire brush to clean driven clutch components. A wire brush or steel wool will cause the sheaves to be gouged (thus, the drive belt may not slide properly between sheaves). Decreased performance and possible accelerated drive belt wear will result.
  • Page 202 XM142 SNO-547 6. Install new Screws securing the movable sheave. 3. Slide the moveable sheave off the driven shaft. Tighten in a crisscross pattern to 27 ft-lb. DISASSEMBLING 1. Place the moveable sheave on the Driven Clutch Compressor Tool with the torque bracket facing up; then install the compressor flange and handle against the torque bracket.
  • Page 203 CAUTION Do not use steel wool or a wire brush to clean driven clutch components. A wire brush or steel wool will cause the sheaves to be gouged (thus, the drive belt may not slide properly between sheaves). Decreased performance and possible accelerated drive belt wear will result.

  • Page 204: Drive Clutch/Driven Clutch

    SNO-547 0747-959 3. Secure the sheaves using the existing cap screw and CORRECTING OFFSET (3000) washer making sure the washer is cupped toward the 1. To correct offset, the driven clutch must be moved sheave. Tighten to 60 ft-lb; then install the drive belt. laterally on the input shaft.
  • Page 205 Drive belt length, condition, and deflection are all important for peak performance. To check and adjust  NOTE: Available shim washers from Arctic Cat are drive belt deflection, use the following procedure. p/n 0648-850 (0.090 in.) and (p/n 0648-849 (0.030 in.).

  • Page 206: Drive Train

    Drive Train REMOVING CHAIN CASE/DRIVEN SHAFT/DRIVESHAFT/TRACK CAUTION If the chain or sprockets on 7000 models need to be replaced for any reason, only use the correct chain or sprocket as shown in the POGA Reference Guide. Using different chains or sprockets than those listed will cause damage due to the different tooth profiles.
  • Page 207 SNO-966A NOTE: On 7000 models, loosen the tensioning cap 0748-259  6. To drain the chain lube, place a drain pan under the screw enough so the tension is removed from the chain case; then loosen the eleven screws securing chain.
  • Page 208 XM091A PC163A 14. On 7000 models, once the cap screws and nuts secur- 16. Remove the inner snap ring; then from the left side, ing the left-side chassis support are removed, care- carefully remove the driven shaft assembly keeping fully remove the support and driveshaft. the bearing 90°...
  • Page 209 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 210 YM-054 PC085A 12. Install the drive clutch and tighten the clutch cap  NOTE: On 7000 models, turn the chain tension screw to 51 ft-lb; then install the driven clutch and adjustment bolt clockwise until it is finger tight; then drive belt.
  • Page 211 YM-100 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 YM-102 Lube.  NOTE: To verify everything is installed correctly, ...

  • Page 212: Drive Sprockets

    SNO-1247A YM-074A 26. Install the actuator and secure using the existing 2. For installing purposes, scribe a line on the drivesh- three torx screws (B) (threads coated lightly with aft (A) next to the drive sprocket for proper align- blue Loctite #243). Tighten to 36 in-lb. ment;...
  • Page 213 3. Inspect the driveshaft for damaged splines or NOTE: When pressing new sprockets on the drive-  stripped threads. shaft, align the sprocket alignment marks or the 4. Inspect the seals for any breaks or damage. sprockets won’t be timed correctly. 5.

  • Page 214: Track Tension

    0748-447 YM-074A 2. If the deflection (distance between the bottom of the wear strip and the inside surface of the track clip) Track Tension exceeds specifications, tighten the adjusting bolts to take up excessive slack in the track. 3. If the distance between the bottom of the wear strip CHECKING and the inside surface of the track clip is less than specified, loosen the adjusting bolts to increase the...

  • Page 215: 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 216: Changing Brake Fluid

    Repeat the compression until brake fluid flows free of air bubbles and appears clean. 0745-817 2. If the brake fluid level is low, add Arctic Cat NOTE: It may be necessary to refill the reservoir a  approved brake fluid until the fluid is at the recom- number of times to eliminate all air bubbles in the sys- mended level.
  • Page 217 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 218 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 219 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 the housing. PC219A PC173 11. Remove the pistons (A) and O-rings (B); then dis- PC200 card the O-rings.
  • Page 220 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 221: Brake Lever/Master Cylinder Assembly

    2. Remove the two screws securing the reservoir cover and remove the reservoir cover; then open the bleeder valve. Allow the brake fluid to drain com- pletely. 3. Place an absorbent towel around the connection to absorb brake fluid. Remove the banjo-fitting bolt (A) securing the brake fluid hose (B) to the master cylin- der.

  • Page 222: Troubleshooting Drive Clutch/Driven Clutch

    3. Install the brakelight switch (E) to the master cylin- 5. Place the reservoir cover onto the reservoir; then der. secure with the two screws. 4. Install the brake lever; then secure with pin (D). 6. Bleed the brake system. Troubleshooting Drive Clutch/Driven Clutch Problem: Midrange Shift-Up (Too Quickly - Lowers RPM)

  • Page 223: 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 224: Suspension

    Suspension SPECIAL TOOLS A number of special tools must be available to the techni- cian when servicing the rear suspension. NOTE: When indicated for use, each special tool  will be identified by its specific name, as shown in the chart below, and capitalized.
  • Page 225 3. If the springs are too stiff for general riding condi- 5. Install the air valve cap onto the shock. tions and style, the ride comfort is gone. FRONT ARM SPRING TENSION Spring Tension Too Soft Having very light front arm spring tension is desirable. 1.
  • Page 226 UP position. The spring ten- sion blocks lock in an over-center position when engaged. NOTE: Arctic Cat recommends that the overload  727-720A springs be engaged whenever a load on the snowmobile NOTE: When making any changes to the front or ...
  • Page 227 The suspensions have several possible mounting loca- tions in the slide rails and tunnel. However, Arctic Cat recommends that when disassembling and assembling the suspension, all stock mounting locations be used as shown in the following illustrations.
  • Page 228 141”/153”/162” “ 0747-413 Pantera/3000 Models 0748-835...

  • Page 229: 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 230 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 231 MS007A XM004A 4. Remove the cap screws securing the front arm to the INSTALLING rails. 1. Secure the mounting block on the slide rail with a 5. Remove the front arm and account for the front arm cap screw and lock nut. Tighten to 10 ft-lb. axle.
  • Page 232 CM246A ZJ271A 2. Place the front arm shock axle assembly into position  NOTE: Do not over-tighten the shock absorber cap on the skid frame making sure the spacers and wash- screw as the shock eyelet must be free to pivot. ers are properly positioned.
  • Page 233 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 234 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 235 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 236 5. Slide the sleeve and spring onto the idler arm. 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.
  • Page 237 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 238 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 239 XM007A XM006A 3. With the sleeves installed, place the shock absorber CLEANING AND INSPECTING and shock link between the offset arm bracket. 1. Clean the bearings with a clean cloth. Secure with the cap screws and lock nuts. Tighten securely. 2.
  • Page 240 ! 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. 3. Loosen the cap screws and lock nuts securing the offset arm assembly to the idler arm; then remove the offset arm assembly.
  • Page 241 FZ101A YM-121 10. Remove the cap screw and lock nut securing the rear NOTE: Do not over-tighten the shock absorber cap  arm to the slide rail. Account for the serrated axles screw as the shock eyelet must be free to pivot. and axle tube.

  • Page 242: 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 243: Fox Air Shocks

    NOTE: To aid in centering the front arm with the  hole in the tunnel, position the skid frame and track at a 45° angle to the bottom of the tunnel. 5. Push the rear of the skid frame and the track into the tunnel.
  • Page 244 NOTE: When indicated for use, each special tool 2. Using a 1-in. wrench, loosen the bearing assembly  and remove the shock rod and valve assembly from will be identified by its specific name, as shown in the the shock body. chart below, and capitalized.
  • Page 245 D. Piston strap for cuts, chipped or nicked edges, or 3. Using tape measure, make sure the floating piston is excessive wear. at the correct depth in the shock body (according to the chart in the specifications section of the manual). E.
  • Page 246 ZR-006 ZR-018 7. Slide the bearing cap down to the shock body and 9. Install the screw into the shock body. into the oil; then while holding the shock rod in place, begin to thread the cap into the body. As the cap threads into the body, oil will escape.
  • Page 247 NOTES...
  • Page 248 Printed in U.S.A. Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701 p/n 2260-851...

This manual is also suitable for:

Pantera 5000Pantera 7000Pantera 9000

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