Arctic Cat ZR4000 Service Manual
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Arctic Cat ZR4000 Service Manual

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Summary of Contents for Arctic Cat ZR4000

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

  • Page 2: Table Of Contents

    ZR/XF/M 4000/6000/8000 TABLE OF CONTENTS General Information/Foreword ..........2 Arctic Power Valve (APV) System ........118 Snowmobile Identification ............2 Exhaust Controlled Timing (ECT) System ......122 Recommended Gasoline and Oil ..........2 Fuel Systems ................123 Engine Break-In ............... 3 EFI System ................

  • Page 3: General Information/Foreword

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

  • Page 4: Engine Break-In

    Drive Belt sub-section in the Drive Train/Track/Brake 4000/8000 Systems section of this manual). The Arctic Cat engine (when new or rebuilt) requires a CAUTION short break-in period before the engine is subjected to heavy load conditions. Arctic Cat requires that the first...
  • Page 5 ENGINE On the standard models, the front shock springs are also individually adjustable for the terrain conditions and A normally aspirated engine will generate more horse- driving style of the operator. The spring adjuster has been power at sea level than it does at higher altitudes. The set at the factory so the correct amount of threads are reason is that the higher you go, less oxygen is available exposed between the spring adjuster and the shock hous-...

  • Page 6: Preparation For Storage

    B. Pour 29.5 ml (1 fl oz) of SAE #30 petroleum-based hours of trouble-free snowmobiling. Arctic Cat recom- oil into each spark plug hole and pull the recoil mends the following procedure: starter handle slowly about 10 times.

  • Page 7: After Break-In Checkup/Checklist

    4. Inspect the drive belt for cracks and tears. Check belt DRIVE CLUTCH/DRIVEN CLUTCH specifications. Replace if damaged or worn. Install ALIGNMENT (OFFSET) — The alignment between the drive belt. the drive clutch and driven clutch are set at the factory. Normally, no adjustment is necessary;...

  • Page 8: Engine Specifications

    Engine Specifications Crankshaft Runout/Repair Specifications 4000 Refer to the drawing; then find the letter indicating the ITEM specification and refer to the chart below the illustration. Engine Model Number AX50L9 Displacement 499 cc NOTE: The proper location for checking crankshaft ...

  • Page 9: Arctic Power Valve (Apv) System Specifications

    Arctic Power Valve (APV) System Specifications VALVE POSITION CYCLE RPM Mid-Open 67-7500 (Low/High Alt) Full-Open 77-8500 (Low/High Alt) APV CABLE LENGTH 6000/8000 36.5 mm ± 1 mm 0735-516...

  • Page 10: Electrical Specifications

    Electrical Specifications Component Test Value + Test Connections - Spark Plug Cap 4000-6000 ohms cap end cap end Oil Level Sensor Less than 1 ohm (float end down) terminal terminal Ignition Switch Less than 1 ohm (key in OFF position) terminal terminal 4000 (Normally Open Ignition) Ignition Coil...

  • Page 11: Drive Clutch/Driven Clutch-Related Specifications

    Clutch-Related Specifications 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 ALIGNMENT BAR system.
  • Page 12 Drive Gear Ratio Chain Engine RPM Sprocket Ratio 8 Tooth 50 0.380 (2.86" 49 0.429 pitch) 46 0.435 51 0.451 48 0.458 50 0.480 41 0.512 38 0.553 35 0.571 40 0.575 37 0.595 39 0.615 36 0.639 35 0.686 8 Tooth 50 0.380 (3.0"...
  • 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 50 0.380 (3.0" pitch) 49 0.429 46 0.435 51 0.451 48 0.458 50 0.480 41 0.512...

  • 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

    Cam Arm Set Screw Cam Arm 19 in.-lb ZR/XF 137” Driven Clutch (Team) Driven Shaft Wear Strip Rail 50 in.-lb Driven Clutch** (Arctic Cat) Driven Shaft End Cap Rail 80 in.-lb Movable Sheave* (Arctic Cat) Torque Bracket Mounting Block Rail...

  • Page 16: Steering And Body

    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: Steering Post (Xf Hc)

    SNO-2218 SNO-357 2. Secure the tie rod assembly to the steering post using 6. Install the expansion chamber using the existing a new M10 nut. Be sure to align the tie rod ball springs; then connect the exhaust temperature sensor joint alignment tab with the steering post.
  • Page 18 0746-793 3. Locate the hood harness connector (located under the SNO-2226B 8. Carefully remove the secondary steering post from center vent between the intake vents) and unplug the the snowmobile. connector; then move the hood slightly forward and remove the hood. 9.
  • Page 19 SNO-740A XM212A  NOTE: Verify the bushings are properly oriented 12. With the telescoping steering assembly removed (the seam should be centered front to back). from the snowmobile; press down on the adjusting block until the inner snap ring is exposed. Remove 2.

  • Page 20: Steering Post (M)

    SNO-2218 SNO-2226A 6. Secure the tie rod assembly to the steering post using 9. Connect the tie rod (B) from the adjustable steering a new M10 nut. Be sure to align the tie rod ball post to the secondary steering post using the machine joint alignment tab with the steering post.
  • Page 21 0746-800 SNO-2221A 2. Remove all six torx-head screws securing the hood. 7. Remove the torx-head screw and nut (B) securing the tie rod link to the secondary steering post; then remove the two machine screws (A) and nuts secur- ing the top of the secondary steering post to the chas- sis.
  • Page 22 2. Secure the bottom of the steering post to the lower steering support using existing thrust washer and new Nyloc Nut. Tighten to 20 ft-lb. Install Cotter Pin into steering post and spread to secure. SNO-333 12. Remove the cap screws securing the existing steering support (C) to the spar tubes (B);...

  • Page 23: Ski (Zr/Xf)

    Ski (ZR/XF) REMOVING 1. Elevate the front of the snowmobile and secure on a support stand. 2. Remove and discard the cotter pin; then remove the nut and cap screw securing the ski to the spindle. NOTE: Note the orientation of the damper for ...

  • Page 24: Ski (Xf Hc/M)

    NOTE: Note the orientation of the damper for  faster. Arctic Cat recommends that the ski wear bars be installation purposes. replaced if worn to 1/2 of original diameter.

  • Page 25: Spindle (Zr/Xf)

    Spindle (ZR/XF) Spindle (XF HC/M) 0747-904 0749-480 REMOVING REMOVING 1. Position the front of the snowmobile on a safety 1. Position the front of the snowmobile on a safety stand; then remove the ski. stand; then remove the ski. 2. Remove the cap screws and lock nuts securing the 2.

  • Page 26: Steering Tie Rod

    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. Remove both machine screws and nyloc nuts secur- ing the steering tie rod ends to the steering arm.

  • Page 27: 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 28 7. Measure the distance from the straightedge to the right-side ski wear bar bolts in two places: 7-8 in. in front of the spindle and 7-8 in. behind the spindle. Record the measurements taken for the right side. ! WARNING The measurement from the front and rear wear bar bolts to the straightedge can be equal (ski parallel to the track), but the front measurement must never be less...

  • Page 29: A-Arms (Zr/Xf)

    0734-408 SNO-354 ! WARNING 6. Remove the cap screw and lock nut securing the sway bar link to the lower arm. Discard the nut. The measurement taken in front of the spindle must never be less than the measurement taken behind the spindle or poor handling will be experienced.

  • Page 30: A-Arms (Xf Hc/M)

    INSPECTING 1. Inspect the arm welded areas for cracks or any signs of deterioration. 2. Inspect the bearings and axles for wear or damage. 3. Inspect the arm tubing for signs of twisting or bend- ing. 4. Inspect mounting location of the chassis for cracks or wear.

  • Page 31: Ski Shock Absorber

    INSTALLING 1. Place the upper arm into position on the chassis and secure with the cap screws, axles, and new lock nuts. Tighten to 23 ft-lb. 0749-480A 6. Remove the two cap screws and nyloc nuts securing the lower arm to the chassis; then slide the boot from the arm and remove the arm.

  • Page 32: Sway Bar (Zr/Xf)

    INSTALLING 2. Remove the cap screws securing the shock absorber to the chassis and the lower A-arm; then remove the 1. Place the sway bar into the sway bar mounting shock absorber. Account for all mounting hardware. brackets; then install the sway bar into the snowmo- bile.

  • Page 33: Seat Assembly (M Sno Pro/Hcr/Ltd)

    NOTE: On LXR/LTD models prior to lowering and 2. Position the seat foam into the seat cover by first  aligning the front of the foam with the front of the securing the seat, connect the seat heater harness con- seat base/cover (A);...

  • Page 34: Rear Bumper/Snowflap

    INSTALLING SNOWFLAP 1. Secure the snowflap to the tunnel with the torx-head screw and nut. 2. Add the appropriate rivets to secure the snowflap to the tunnel. Windshield/Console/ Headlight REMOVING SNO-511 1. Remove and retain all machine screws securing the 2.

  • Page 35: Headlight Bulb

    Headlight Bulb NOTE: The bulb portion of the headlight is fragile.  HANDLE WITH CARE. When replacing the head- light bulb, the bulb assembly must first be removed from the housing. Do not touch the glass portion of the bulb. If the glass is touched, it must be cleaned with a dry cloth before installing.
  • Page 36 4. Make a vertical mark intersecting the horizontal mark on the aiming surface directly in front of the headlight. 5. Engage the brake lever lock and start the engine. Select the headlight dimmer switch HIGH beam position. DO NOT USE LOW BEAM. 6.

  • Page 37: Engine

    1. Carefully remove the exhaust temperature sensor This engine sub-section has been organized to show a from the expansion chamber. progression for the removing/installing of the Arctic Cat 4000 engine. For consistency purposes, this sub-section 2. Remove all springs securing the expansion chamber shows a complete and thorough progression;...
  • Page 38 14. Remove the cap screws securing the MAG-side engine mount to the engine. 15. Remove the spark plug caps from the spark plugs; then remove the cylinder head vent hose. XM251A 8. Remove the cap screws securing the MAG-side front spar to the steering support and shock mount bracket;...
  • Page 39 10. Place the recoil starter into position and secure with the cap screws. Tighten in a crisscross pattern to 96 Installing in.-lb. 11. Before connecting the wiring harness plug-ins, clean the connectors and apply Dielectric Grease to the NOTE: If the engine was replaced, make sure to ...
  • Page 40 NOTE: Before installing the drive clutch, be sure to  wipe both the crankshaft and clutch mounting tapers clean using a clean towel. 24. Install the driven clutch on the driven shaft; then install drive belt (see Drive Train/Track/Brake Systems section). 25.

  • Page 41: Assembly Schematic - 4000

    Assembly Schematic - 4000 Torque Specification Tolerances Torque (ft-lb) Tolerance 0-15 ±20% 16-39 ±15% ±10% 500CC1A12...
  • Page 42 500cc_2A_15...

  • Page 43: Engine Removing/Installing - 6000

    This engine sub-section has been organized to show a clutch to the crankshaft. progression for the removing/installing of the Arctic Cat 6000 engine. For consistency purposes, this sub-section 5. Using Drive Clutch Puller and Drive Clutch Spanner shows a complete and thorough progression;...
  • Page 44 EL-004A EL-005B 10. Slide each cable end out of the slot of the clutch; then 16. Remove the two small oil hoses from the oil pump disconnect the harness from the servomotor. assembly. 11. Remove the cap screws and lock nuts securing the shock mount bracket support to the shock mount brackets;...
  • Page 45 CWI-092 22. Disconnect the lower coolant hose from the front heat exchanger; then remove the coolant hose from the heat exchanger at the rear of the engine. CWI-093 NOTE: If replacing the engine, make sure to remove  the engine support plate, exhaust manifold, and three coolant hoses for installation on the new engine.
  • Page 46 2. Install the coolant hose to the heat exchanger at the 9. Connect the knock sensor and coolant temperature rear of the engine; then connect the lower coolant sensor connectors; then install the spark plug caps. hose to the front heat exchanger. Secure the coolant temperature sensor connector with a cable tie.
  • Page 47 18. Connect the PTO-side throttle body coolant hose; then secure with a clamp. 19. Fill the cooling system (see Liquid Cooling System in the Engine-Related Items section). 120.Using the existing clamps, secure the intake flanges to the throttle bodies. 21. With the air intake boot properly positioned on the throttle bodies, secure with the existing clamps.
  • Page 48 31. Place the drive clutch with drive belt into position on 34. Place the hood into position on the front end and the crankshaft and secure with the cap screw (threads secure with the screws; then install the hood harness. coated with oil) and high-collar washer.

  • Page 49: Assembly Schematic - 6000

    Assembly Schematic - 6000 Torque Specification Tolerances Torque (ft-lb) Tolerance 0-15 ±20% 16-39 ±15% ±10% 600_14_1...
  • Page 50 600_14_2...

  • Page 51: Engine Removing/Installing - 8000

    Engine Removing/Installing - 8000 This engine sub-section has been organized to show a progression for the removing/installing of the Arctic Cat 8000 (ZR/M/XF) engine. For consistency purposes, this sub-section shows a complete and thorough progression; however, for efficiency it may be preferable to remove only those components needing to be addressed.
  • Page 52 PC188A PC186A 8. Remove the caps screws securing the PTO-side front 12. Drain the engine coolant (see Liquid Cooling System spar to the steering support and shock mount bracket; - the Engine-Related Items section). then remove the spar. 13. Loosen the clamp securing the gasline hose to the NOTE: Take care to not drop the spar inserts and throttle body and remove the hose;...
  • Page 53 16. Remove the main harness wrap and disconnect the six harness connectors. Secure the harness up and out of the way. 17. Close-off the oil hose with a clamping device; then remove the hose clamp and oil hose from the oil pump.
  • Page 54 5. Install the PTO-side chassis support to the shock mount bracket and chassis. Secure with the cap screws and carriage bolt nut. Tighten the rear chassis cap screw to 25 ft-lb, the carriage bolt nut to 12 ft-lb, and the front shock mount cap screws to 12 ft-lb. 6.
  • Page 55 22. Install the oil injection control rod to the throttle body; then verify oil-injection pump synchronization (see the Fuel Systems section). 23. Using the existing clamps, secure the intake flanges to the throttle bodies. 24. With the air intake boot properly positioned on the throttle bodies, secure with the existing clamps.
  • Page 56 39. Allow the engine to cool; then check the coolant level and add coolant as necessary. Verify the tight- ening torque of the drive clutch. CAUTION If the engine had a major overhaul or if any major com- ponent was replaced, proper engine break-in proce- dures must be followed (see the General Information section) or severe engine damage may result.

  • Page 57: Assembly Schematic - 8000

    Assembly Schematic - 8000 Torque Specification Tolerances Torque (ft-lb) Tolerance 0-15 ±20% 16-39 ±15% ±10% 800_12_1...
  • Page 58 800_12_2...

  • Page 59: Engine Servicing - 4000

    Engine Servicing - 4000 This engine sub-section has been organized to show a progression for servicing of the Arctic Cat 4000 engine. 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 60 FC022 FC026 5. Remove the Allen-head cap screws securing the sta-  NOTE: When removing the cylinders, place the tor to the stator plate. Move the stator to the side to engine on its intake flanges on a drain tray to allow access the Phillips-head cap screw securing the stator residual coolant to drain from the cylinder/crankcase lead wire;...
  • Page 61 16. Remove the six screws securing the water pump cover to the crankcase and remove the cover. CAUTION Account for the O-ring gasket and the alignment DO NOT use any type of punch to drive the piston pin pins. free of the piston; damage may result. Use a piston pin 17.
  • Page 62 FC034 FC036 22. Lift the bottom half of the crankcase off the top half. 26. Using a pair of snap ring pliers, remove the snap ring securing the inner seal in the crankcase. CAUTION 27. Using the hooked end of the tool, pull the inner seal free of the crankcase.
  • Page 63 4. Place the head surface of each cylinder on the sur- face plate covered with #400 grit wet-or-dry sandpa- per. Using light pressure, move each cylinder in a figure eight motion. Inspect the surface for any indi- cation of high spots. A high spot can be noted by a bright metallic finish.
  • Page 64 NOTE: If any servicing of the connecting rods, cen- ter bearings, or oil-injection pump drive gear is neces- sary, Arctic Cat recommends the crankshaft be taken to a qualified machine shop for that service. 1. Wash the crankshaft with bearings in parts-cleaning solvent.
  • Page 65 NOTE: Install the bearings by sliding each bearing 5. To assemble, place the reed valves on the cage with  its clipped corner positioned to the lower right hand onto the crankshaft making sure the dowel-pin hole in corner of the cage. Place the reed stopper assembly the outer race is properly positioned and will align into position and secure with the screws tightened to with its hole and pin in the crankcase.
  • Page 66 PISTON-RING END GAP NOTE: Make sure the smaller reading is 0.059 in. or  less. 1. Place each piston ring in the wear portion above the exhaust port of its respective cylinder. Use the piston CYLINDER TRUENESS to position each ring squarely in each cylinder. 1.
  • Page 67 5. Position the upper crankcase half upside-down on with compressed air. two wooden blocks; then install the C-ring, the four NOTE: When the use of a lubricant is indicated, use  bearing retaining pins, and the two crankcase dowel Arctic Cat Synthetic APV 2-Cycle Oil. pins.
  • Page 68 6. Place the PTO-side crankshaft bearing into position making sure the bearing retaining pin hole is posi- tioned inward. NOTE: The bearing retaining pin hole is the hole  that doesn't go entirely through the bearing case. CM036A  NOTE: At this point if the coolant temperature sen- sor was removed, install the sensor (threads coated with white Loctite #575) and tighten to 18 ft-lb.
  • Page 69 13. Apply a thin coat of grease to the sealing surface of 16. With a new O-ring (lightly coated with oil) in place, the oil-injection pump/water pump driveshaft; then install the oil-injection pump making sure the pump place the Oil Seal Protector Tool at the end of the shaft slot and pump driven gear shaft align.
  • Page 70 NOTE: For assembling purposes, lubricate the rub-  ber side of the washer before installing. CAUTION If the rubber side of the washer is not positioned toward the impeller, a coolant leak will result. 20. Apply High-Temp Sealant to the crankcase/water pump cover seam (A);...
  • Page 71 CM195B TZ068  NOTE: Install the circlip to the inside of the piston  NOTE: The shoulder side of the washer must seat to before installing the connecting rod. the needle bearing. CAUTION Make sure the circlips are firmly seated before continu- ing with assembly.
  • Page 72 NOTE: At this point, pressure test the engine (see  Section 3). 37. Secure the stator plate to the crankcase with the Allen-head cap screws (coated with blue Loctite #243) and tighten to 96 in.-lb. 0742-746 34. Install the two cylinder O-rings (lightly coated with oil) on the top of each cylinder making sure they are correctly positioned in the grooves.
  • Page 73 FC080 FC081 42. Secure the starter pulley to the flywheel with three 43. Install the coolant supply hose to the water pump and cap screws and using the spanner wrench, tighten the cylinder hose; then install the overflow hose and cap screws evenly to 19 ft-lb;...

  • Page 74: Engine Servicing - 6000

    Engine Servicing - 6000 This engine sub-section has been organized to show a progression for servicing of the Arctic Cat 6000 engine. 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 75 CWI-005A CWI-009 NOTE: For assembling purposes, note the indenta-  tion (A) of the stator plate is aligned with the harness opening (B) in the crankcase. CWI-010 11. Remove the four nuts securing the fuel rail to the back of the cylinders; then remove the fuel rail and injectors as an assembly.
  • Page 76 CWI-012 CWI-015 13. Remove the PTO-side piston-pin circlip from the 16. Remove the screws securing the intake flanges. PTO-side piston; then remove the MAG-side pis- Remove the intake manifolds and reed valve assem- ton-pin circlip from the MAG-side piston. blies. CWI-013A CWI-020 14.
  • Page 77 CWI-018A CWI-075A 18. Remove the seven screws securing the water pump cover to the crankcase and remove the cover. Account for the O-ring gasket and the alignment pins. CWI-023A 21. Tip the crankcase assembly up onto the water pump side; then remove the black torx-screw from the bot- tom of the crankcase and tip down and drain the injection oil from the center cavity into a container.
  • Page 78 NOTE: When replacing the inner water pump seals,  use the recommended Water Pump Bearing and Seal Tool Kit only. 27. Place the lower crankcase on the bench with the water pump side down. Using the long seal driver, drive the mechanical water pump seal from the crankcase.
  • Page 79 Arctic Cat recommends the crankshaft be taken to a bores. If a bore is severely damaged or gouged, the qualified crankshaft rebuild shop for that service.
  • Page 80 REED VALVE ASSEMBLY 1. Carefully pry the reed assemblies from the intake manifold and inspect the reed valves for cracks or any deterioration; then remove the screws securing the reeds. CWI-058 4. Visually inspect the springs to make sure they are in proper location on the seals.
  • Page 81 2. Position a bore gauge between the micrometer points and move it from top to bottom and side to side to find zero; then adjust the gauge to zero. CWI-056 Measuring Critical CWI-090 Components CYLINDER TRUENESS 1. Measure each cylinder in locations from front to back and side to side top and bottom of the cylinder for a total of four readings.
  • Page 82 NOTE: When the use of a lubricant is indicated, use  Arctic Cat C-Tec2 engine oil. 1. Apply a thin coat of grease to the inner seal lips of the water pump seal. 2. Using the seal driver, position the inner water pump shaft seal onto the seal driver and gently tap the seal down into position.
  • Page 83 11. Tighten cap screws (1-10) in two steps using the pat- tern shown. First tighten to 15 ft-lb; then tighten to 33 ft-lb. CWI-067 7. Place the crankshaft end bearings into position mak- ing sure the bearing retaining pin holes are posi- tioned inward.
  • Page 84 102 in.-lb. CWI-016A 17. Tip the crankcase assembly up on the water pump side; then pour Arctic Cat C-Tec2 engine oil into the center cavity of the crankshaft until the oil is level with the shoulder of the shaft (A).
  • Page 85 29. Install the cylinder O-rings (lightly coated with oil) on the top of each cylinder making sure they are cor- rectly positioned in the grooves. CWI-078A CAUTION Incorrect installation of the piston rings will result in CWI-010 engine damage. 30. Place new O-rings (lightly coated with oil) onto each 23.
  • Page 86 36. Route the stator harness through the opening in the crankcase; then secure the stator to the stator plate with the screws (coated with blue Loctite #243). Tighten to 10 ft-lb. 37. Secure the upper ignition timing sensor with cap screws (coated with blue Loctite #243).
  • Page 87 45. If the knock sensor was removed, secure it to the cyl- inder head using the existing cap screw. Tighten to 18 ft-lb. 46. After installing the engine, bleed the oil lines using the Oil Bleeding Procedure included with the CATT II Tool.

  • Page 88: Engine Servicing - 8000

    Engine Servicing - 8000 This engine sub-section has been organized to show a progression for servicing of the Arctic Cat 8000 engine. 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 89 CM142A CM145D 5. Remove the Allen-head cap screw (A) securing the  NOTE: For assembling purposes, note the indenta- stator lead wire plate to the crankcase; then remove tion (A) of the stator plate is aligned with the harness the Allen-head cap screws (B) securing the timing opening (B) in the crankcase.
  • Page 90 XM017 XM018 9. Remove the spark plugs. 12. Remove the PTO-side piston-pin circlip from the PTO-side piston; then remove the MAG-side pis- NOTE: At this point, remove the knock sensor and  ton-pin circlip from the MAG-side piston. lock plate from the cylinder head by bending the lock plate tabs down and unthreading the sensor.
  • Page 91 CM151 IO015A 17. Remove the four cap screws securing the thermostat  NOTE: Place a suitable length of rubber hose cap; then remove the cap, gasket, and thermostat. around the connecting rods to prevent the connecting rods from damaging the crankcase. 15.
  • Page 92 CAUTION DO NOT drive any tool between halves to separate the crankcase. Damage to the sealing surfaces will result. CM156A 19. Remove the cap screw securing the water pump impeller; then slide the impeller free of the shaft. Account for the washer and gasket. CM158 24.
  • Page 93 NOTE: When replacing the inner water pump seals, 3. Place the cylinder head on a Surface Plate covered  with #400 grit wet-or-dry sandpaper. Using light use the recommended Water Pump Bearing and Seal pressure, move each cylinder head in a figure eight Tool Kit only.
  • Page 94 NOTE: If any servicing of the connecting rods, cen- water or honing oil. ter bearings, or oil-injection pump drive gear is neces- sary, Arctic Cat recommends the crankshaft be taken NOTE: If scuffing or seizure marks are too deep to ...
  • Page 95 4. To assemble, place the reed valves on the cage with its clipped corner positioned to the lower right hand corner of the cage. Place the reed stopper assembly into position and secure with the screws tightened to 10 in.-lb (± 2.2 in.-lb). CM161 Inspect the crankshaft bearing area for wear.
  • Page 96 PISTON PIN Measure the piston pin diameter at each end and in the center. Acceptable piston pin measurement must be within 0.8659-0.8661 in. If any measurement varies by more than 0.001 in., the piston pin and bearing must be replaced as a set. CWI-090 CWI-079 CRANKSHAFT RUNOUT...
  • Page 97 NOTE: When the use of a lubricant is indicated, use bearing retaining pins (B), and the two crankcase Arctic Cat Synthetic APV 2-Cycle Oil. dowel pins (C). 1. Apply a thin coat of grease to the inner seal lips of the water pump seal.
  • Page 98 CM043A CM036A 7. Lubricate the inner lips of the crankshaft oil seals with grease; then slide the seals onto the crankshaft making sure the spring side of each seal faces inward. 8. Apply oil to the crankshaft bearings; then install the crankshaft into the upper crankcase half.
  • Page 99 14. Apply a thin coat of grease to the sealing surface of 17. With the new O-ring (lightly coated with oil) in the oil-injection pump/water pump driveshaft; then place, install the oil-injection pump making sure the place the Oil Seal Protector Tool at the end of the pump shaft slot (A) and pump driven gear shaft (B) shaft.
  • Page 100 19. With new gaskets, install the reed valve assemblies 23. Place the impeller into position and secure with a cap and intake flanges using the pattern shown. Tighten screw and washer. Be sure the rubber side of the to 96 in.-lb; then secure the intake flange oil hoses to washer is lubricated with a light coat of grease and the oil pump and secure with the clamps.
  • Page 101 CM157A TZ068  NOTE: The shoulder side of the washer must seat to the needle bearing. CM155A 27. Install the dowel pins into the crankcase; then place the cylinder base gasket into position on the crank- case. CM172A 30. Place each piston over the connecting rod so the indi- 28.
  • Page 102 XM021A XM022 33. In turn on each cylinder, place a piston holder (or 36. Place new O-rings (lightly coated with oil) onto each suitable substitute) beneath the piston skirt and of the head cap screws. Place four of these cap square the piston in respect to the crankcase;...
  • Page 103 NOTE: At this point, pressure test the engine (see 42. Secure the lower ignition timing sensor with two cap  screws (A) (coated with blue Loctite #243). Tighten the Engine-Related Items section). to 48 in.-lb; then install the grommet. With the stator 38.
  • Page 104 46. Secure the starter clutch while using the spanner NOTE: At this time if the coolant temperature sen-  wrench and tighten the three cap screws (from step sor was removed, install the sensor (threads coated 45) evenly to 19 ft-lb. with blue Loctite #243) and tighten to 18 ft-lb.

  • Page 105: Troubleshooting Engine

    Troubleshooting Engine Problem: Engine Does Not Start (No Spark at Spark Plugs) Condition Remedy 1. Key in the OFF position 1. Turn key to the ON position 2. Emergency stop switch in DOWN position — 2. Move switch to UP position — replace throttle control malfunctioning 3.
  • Page 106 Problem: Engine Loses Power or Runs on One Cylinder Condition Remedy 1. Sensor faulty 1. Check ECM for trouble code — repair — replace sensor 2. Spark plug fouled 2. Replace spark plugs 3. Injector faulty 3. Replace injector 4. External coil faulty 4.

  • Page 107: 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 FC118 2.
  • Page 108 FC124 FC121 8. Using the hooked end of the long seal driver, pull the 5. Remove the oil-injection pump retainer and shaft inner seal free of the crankcase. from the opposite side of the crankcase. Account for the thrust washer located between the retainer and ASSEMBLING shaft flange.
  • Page 109 FC127 FS233A 4. Using a pair of snap ring pliers, install the snap ring 7. Position the shim on the oil pump end of the shaft; securing the inner seal in the crankcase. then with the O-ring installed on the retainer, install the oil-injection pump retainer.

  • Page 110: Water Pump - 6000

    FS235A FC072B 10. Place the impeller into position and secure with a cap 12. Position the O-ring into the water pump cover; then screw and washer. Be sure the rubber side of the install the cover. Install the cap screws; then using washer is lubricated with a fine coat of oil and the pattern shown, tighten to 96 in.-lb.
  • Page 111 CWI-094A CWI-082  NOTE: When servicing the water pump, use Water  NOTE: If the impeller will not slide off the shaft, Pump Bearing and Seal Tool Kit and Oil Seal Protec- start the cap screw into the shaft and tap on the cap tor Tool.
  • Page 112 CWI-099 FS232 6. Apply a light coat of grease to the sealing surface of ASSEMBLING the pump driveshaft; then install Oil Seal Protector 1. Thoroughly clean the seal surfaces of the crankcase. Tool at the end of the shaft. Twist the shaft while pushing it through the water pump seals until the 2.

  • Page 113: Water Pump - 8000

    1. Loosen the clamps securing the coolant hoses to the water pump; then remove the hoses. CWI-096 9. Position the O-ring into the water pump cover; then install the cover. Install the cap screws; then tighten to 96 in.-lb using a crisscross pattern. XM114A 2.
  • Page 114 FS221A FS226 4. Remove the cap screw securing the impeller. 7. Using the long seal driver, drive the water pump Account for the rubber washer and gasket behind the mechanical seal from the crankcase. cap screw. FS227 8. Using a pair of snap ring pliers, remove the snap ring XM112 5.
  • Page 115 ASSEMBLING 1. Thoroughly clean the seal surfaces of the crankcase. 2. Position the oil seal onto the seal driver (spring side towards the crankshaft). Gently tap into position. FS233A FS230 3. Apply a small amount of grease to the oil seal lips. 4.

  • Page 116: Pressure Testing Engine

    FS220A XM112A 11. Position the O-ring into the water pump cover; then  NOTE: When installing the lower check valve, install the cover. Install the cap screws; then using assure that the gaskets are installed on each side of the pattern shown, tighten to 96 in.-lb. the valve.

  • Page 117: Cooling System Schematic

    The following schematic is representative of the different aid in removing all coolant from the heat exchangers. styles of cooling systems in the Arctic Cat snowmobiles. Some components may vary from model to model; there- 4. Once the coolant has completely drained, secure the fore, the technician should use discretion and sound judg- lower coolant hose using the existing clamp.

  • Page 118: Recoil Starter

    6. Carefully lift the roller free of the case making sure the main spring (I) does not disengage from the case. Recoil Starter Account for the bushing. ! WARNING Care must be taken when lifting the roller free of the case.

  • Page 119: Arctic Power Valve (Apv) System

    9. Apply a low-temperature grease to the friction plate. The APV system does not increase engine horsepower, Place the pawl activator into position on the friction but it does allow the engine to be designed for maximum plate making sure the arms of the activator are prop- top end horsepower without the losses associated with a erly positioned to the pawl.
  • Page 120 OPERATION MAINTENANCE At idle and low speed operation, the exhaust valves are The APV system requires only periodic cleaning and held in the “low port” position by the return spring. cable adjustment. The cables should be checked every When engine RPM reaches a predetermined point, the 2600 miles and adjusted as necessary.
  • Page 121 NOTE: Repeat steps 3 and 4 for each cable; then  compare the measurements to the APV Cable Length chart in the General Information section. The mea- surements must be within the specifications from the chart. If the measurements are within specifications, no adjustment is necessary (proceed to step 7).
  • Page 122 FC117 FC113 3. With the valve plate gasket properly positioned, slide ASSEMBLING/INSTALLING the exhaust valve through the valve plate and insert it into the valve stopper. Secure with the retaining screw. Tighten to 48 in.-lb. A. Exhaust Valve D. Oil Seal G.

  • Page 123: Exhaust Controlled Timing (Ect) System

    Problem: Engine loses power; no top end Condition Remedy 1. Exhaust valves sticking in 1. Remove carbon deposits, down position burrs, etc. 2. Cables adjusted too long 2. Inspect—adjust 3. Regulator/Rectifier output 3. Inspect—replace Regula- voltage out of tolerance tor/Rectifier/stator Problem: Poor acceleration;...

  • Page 124: Fuel Systems

    The Arctic Cat EFI System operates off a series of coils the sensors. The technician can determine the problem located on the stator and is made up of the following sensor by reading the code shown on the readout screen components.
  • Page 125 NOTE: On the 8000, the ECM is coded with sym- NOTE: If the coolant temperature rises above 75° C   (167° F), the temperature sensor starts to richen the bols ( ). When replacement of the ECM is nec- ...
  • Page 126 6000 SNO-738 Removing CWI-106 WARNING Removing Since the fuel supply hose may be under pressure, 1. With both access panels, hood, seat, and the gas tank remove it slowly to release the pressure. Place an absor- removed, remove the nuts securing the fuel rail to the bent towel around the connection to absorb gasoline;...

  • Page 127: Self-Diagnostic System/Codes (4000)

    FUEL PRESSURE REGULATOR The fuel pressure regulator maintains the fuel pressure at a constant specified level. EXHAUST TEMPERATURE SENSOR This platinum, thin-film sensor detects the exhaust air temperature in the exhaust system. The ECM sends cur- rent to this sensor, and (depending on the temperature) the sensor will pass a portion of that current to ground.

  • Page 128: Self-Diagnostic System/Codes (6000)

    Code Trouble P0546 Exhaust temp sensor circuit high. P1000 Oil pump flow not programmed. P1001 Injector 1 offset not programmed. P1002 Injector 2 offset not programmed. P1003 Oil pump outlier. P1004 ISC outlier. P1005 Regulator voltage circuit low. P1006 Regulator voltage circuit high. P1007 Fuel pump circuit low.

  • Page 129: Fuel Pressure Regulator

    2. Pressurize the regulator to 28-31.3 psi. Turn the pres- Deluxe Gauge sure tester shut off valve to the OFF position. Observe the gauge for several minutes and note any loss of pressure. If pressure begins to drop, the cause may be a ruptured diaphragm, worn spring, or leak- ing valve.

  • Page 130: Throttle Cable

    INSTALLING 6. Connect the ISC hoses to the throttle body using the clamps. 4000/8000 1. Attach the throttle cable to the throttle body; then secure with jam nut. Secure the coolant hoses to Throttle Cable throttle body assembly. 2. Place the throttle body assembly into position. Make REMOVING sure the flanges and boots are positioned properly.

  • Page 131: Fuel Filter (6000)

    3. Use Fuel Hose Clamp Tool to make sure the fuel rail side hose clamp is tight by crimping the clamps until Fuel Filter (6000) the two clamp areas touch. NOTE: The fuel filter should be replaced every 5000  miles.
  • Page 132 NOTE: If fuel pressure is not as specified, the pump  is defective and must be replaced. 5. Disconnect the fuel pump from the main wiring har- ness. 6. Connect the positive lead of a 12-volt power supply to the red wire and the negative lead of the 12-volt power supply to the black wire.

  • Page 133: Troubleshooting

    4. Make sure the front pickup will sit flat on the bottom of the tank with no kinks in the fuel hose. SNO-744  NOTE: Tip the fuel pump assembly to one side enough to allow the tool to be removed. NOTE: When the fuel pump hose assembly is ...

  • Page 134: Oil-Injection Pump (4000/8000)

    2. Place the gasket and oil-injection pump near the engine; then install the lower union bolt through a Oil-Injection Pump gasket, check valve, and gasket. (4000/8000) 3. Position the oil-injection pump on the engine making sure the oil-injection pump gear is correctly aligned with the oil-injection pump drive gear.

  • Page 135: Electric Oil Pump (6000)

    3. Attach a suitable length of clear oil-supply hose to the oil pump; then using Oil Injection Usage Tool, 2. Attach the Vacuum Test Pump hose to the check fill the hose with Arctic Cat Synthetic APV 2-Cycle valve. Oil.

  • Page 136: Gas Tank

    3. Remove all four hoses from the oil pump assembly; NOTE: If a new oil pump is being installed, be sure  then disconnect the oil pump harness and remove the to enter the A and B codes using the CATT II Tool. two screws securing the oil pump to the oil tank.
  • Page 137 XM211 XM210A INSTALLING 1. Install the gas tank; then connect the gasline hose, vent hose, and fuel pump harness. 2. Install the rear spar tubes and secure to the chassis and steering support using the four cap screws. Tighten to 23 ft-lb. XM212A 3.

  • Page 138: Electrical Systems

    If spark is now present, adjust the throttle cable tension. Description TESTING CATT II 0544-023 Arctic Cat Diagnostic System Manual 2256-974 Throttle Control Switch Laptop Diagnostic Tool 0744-048 1. Disconnect the handlebar harness connector; then...

  • Page 139: Throttle Position Sensor

    NOTE: If at any point throughout the throttle range  the meter reads no voltage (open), hold the throttle Throttle Position Sensor lever in that position. If the voltage does not return, the throttle body must be replaced. NOTE: Two-stroke engines equipped with a throttle ...

  • Page 140: Electrical Resistance Tests

    Removing 7. With the idle position set to specification, slowly compress the throttle lever to the full-open position. 1. Rotate the idle screw counterclockwise until it no The full-open specification should be observed. Gen- longer contacts the throttle shaft stop. The throttle tly snap the throttle lever open and closed several shaft should now be completely closed.
  • Page 141 Ignition Switch 1. Test between the two orange wires in the four-prong connector from the magneto.  NOTE: The console must be removed to access the ignition switch. 2. Resistance must be 1.52-2.28 ohms. Injection Coil 1. Remove the main wiring harness connectors from the ignition switch.

  • Page 142: Testing Electric Oil Pump (6000)

    6000 2. Test the resistance between the two leads from the sensor. 1. Remove the right-side access panel; then remove the lower console from the right-side skid plate and 3. Compare the resistance reading to the Voltage/Resis- secure out of the way. tance Chart - Coolant Temperature in this section.

  • Page 143: Chassis Control Unit (Ccu)/Codes (4000)

    SERVICE ICON 7. Start the engine and allow it to idle. Meter reading must be within 9-15 AC volts. The Service Icon is controlled by the CCU/ECM and may illuminate for a number of reasons. The icon should 4000 illuminate or illuminates each time the engine is started, 1.

  • Page 144: Testing Fuel Gauge Sender

    2. Set the selector to the OHMS position. 3. Connect one tester lead to one pin; then connect the other tester lead to the other pin. PC256 1. Verify the oil level is below the float; then remove the sensor from the oil reservoir by twisting and pull- ing out.

  • Page 145: Fuse

    NOTE: If a “click” is heard and more than 1 volt is If battery voltage is present at the plug-in and the starter  fails to activate, use the following procedure: indicated by the multimeter, replace the starter relay. If no “click” is heard and the multimeter continues to 1.
  • Page 146 SNO-574 SNO-573 9. Remove the eight cap screws securing the MAG side REMOVING (6000) of the starter motor to the starter motor retaining plate. Account for the negative battery cable and 1. Remove the seat and disconnect the battery; then external tooth washer.
  • Page 147 1. Attach a black jumper cable to a good ground on the starter. 2. Attach the opposite end of the black jumper cable to the negative post of a good 12V battery. 3. Attach the red jumper cable to the positive post of the battery.
  • Page 148 3. Install inner snap ring onto the starter motor (if 11. Connect both battery cables to the battery making removed during removing); then install the gear and sure both are secure; then install the seat. secure using outer snap ring making sure both snap INSTALLING (6000) rings are fully seated.
  • Page 149 7. Secure the ECM and front fascia assembly to the chassis using the existing self-tapping screws. Tighten securely. 8. Install the resonator and expansion chamber and secure using existing springs. 9. Install the hood, left-, and right-side access panels. 10. Connect both battery cables to the battery making sure both are secure;...

  • Page 150: Troubleshooting Electric Start

    4. Inspect the inner housing for tightness and cracks. If NOTE: Make sure the pinion stop is able to be  the housing shows any signs of being loose or pushed in and rotated freely when the nut is torqued. cracked, replace the pinion assembly.

  • Page 151: Brakelight Switch

    BTDC - 13° - 0.040" 4000 XM206 INSTALLING 1. Press the switch into the brake lever assembly mak- ing sure it is fully seated. 2. Position the O-ring into the reservoir; then secure the reservoir to the piston assembly using the existing screws.

  • Page 152: Testing Handlebar Warmer Elements

    INSTALLING 6. Connect the leads; then install and secure the right-side handlebar control assembly. 1. Connect the HI/LO beam harness to the switch; then place the control assembly on the handlebar. 2. Secure with the four screws. Testing Handlebar Warmer/Thumb Warmer Switch Testing Handlebar Warmer Elements...

  • Page 153: Testing Speedometer Sensor

    Testing Speedometer Sensor NOTE: The following test should be made using  MaxiClips and the Fluke Model 77 Multimeter set to the DC Volt scale. NOTE: Prior to testing the sensor, inspect the  three-wire connector on the sensor harness for con- tamination, broken pins, and/or corrosion.
  • Page 154 2. Connect the red MaxiClip and meter lead to the black/white servo terminal; then connect the black MaxiClip and meter lead to the yellow servo termi- nal. 3. Rotate the servo clutch counterclockwise. The ohms should increase as the clutch is rotated until it reaches 4700-5000 ohms.

  • Page 155: Troubleshooting Servomotor

    Troubleshooting Servomotor SERVO1A16...
  • Page 156 SERVO2rv16...

  • Page 157: Voltage/Resistance Chart - Air Temperature (8000)

    Voltage/Resistance Chart - Voltage/Resistance Chart - Air Temperature (8000) Air Temperature (6000) 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 100° C 212° F 0.68 182.6 28°...

  • Page 158: Voltage/Resistance Chart - Coolant Temperature

    Voltage/Resistance Chart - Coolant Temperature Temperature Volts Ohms Temperature Volts Ohms 110° C 230° F 0.115 28° C 82° F 1.377 1800 108° C 226° F 0.129 26° C 79° F 1.459 1950 106° C 223° F 0.143 24° C 75°...

  • Page 159: Drive Train/Track/Brake Systems

    REMOVING (4000 LXR) 1. With the engine off, remove the left-side access Drive Train/Track/Brake panel. Loosen the 1/4 turn on the lower console. Systems 2. Remove the cap screw, washers and sheave adjuster from the end of the driven clutch; then remove the cap screw, lock washer, and washer from the This section has been organized into sub-sections for ser- adjuster.

  • Page 160: Drive Clutch

    2. Using Drive Belt Deflection Tool, thread the tool 2. Remove the cover and spring. clockwise into the driven clutch until the movable sheave opens far enough to remove the drive belt. FC055 3. Remove the cam arm pin lock nuts; then using a small torch, apply heat to the cam arm set screws to 743-067B loosen the Loctite used in assembly.
  • Page 161 2. Remove any drive belt dust accumulation from the 1. Place the drive clutch into position on the crankshaft; stationary sheave, movable sheave, and bushings then apply a few drops of oil to the threads of the cap using parts-cleaning solvent only. screw.
  • Page 162 SNO-545 SNO-546A 3. Remove the shoulder screw, washer, and lock nut 2. Install washer onto the shoulder screw and install in securing the cam arm. Account for two thrust wash- through the clutch, thrust washers, and the cam arm. ers. Secure using new lock nut.

  • Page 163: Driven Clutch

    4. Install the drive belt. Check drive belt deflection. 4. Release the compression of the spring by removing Close the left-side access panel. the wing nut; then remove the movable sheave. 5. Remove the stationary sheave; then remove the plas- ! WARNING tic spring seat.
  • Page 164 REPLACING TORQUE BRACKET BEARING/COVER BEARING 1. Remove the snap ring. 2. Using Movable Sheave Bearing Tool, drive the bear- ing out. ! WARNING Always wear safety glasses when using the bearing driver. 3. Install the new bearing using Movable Sheave Bear- ing Tool;...
  • Page 165 XM140 CM087 7. Remove the clutch from the compressor.  NOTE: If changing cam angles, move the cam 90° to 8. Install the back-side cams; then secure with the its optional position and secure the cam with the eight screws and tighten to 24 in.-lb. torx head cap screws.
  • Page 166 Cleaning And Inspecting 1. Using a parts-cleaning solvent, wash grease, dirt, and foreign matter off all components; dry with com- pressed air. 2. Remove any drive belt dust accumulation from the stationary sheave, movable sheave, and bushings using parts-cleaning solvent only. CAUTION Do not use steel wool or a wire brush to clean compo- nents having a bushing;...
  • Page 167 CM086A SNO-547 3. Slide the movable sheave off the driven shaft. INSTALLING - ZR 4000 RR DISASSEMBLING 1. Slide the alignment washers onto the end of the driven shaft. 1. Place the movable sheave on the Driven Clutch Compressor Tool with the torque bracket facing up; 2.
  • Page 168 CLEANING AND INSPECTING 1. Using parts-cleaning solvent, wash grease, drive belt dust, and foreign matter off all components. 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).

  • Page 169: Drive Clutch/Driven Clutch

    SNO-547 0747-959 3. Secure the sheaves using the existing cap screw and CORRECTING OFFSET (ZR 4000 LXR) 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 170 (ZR 4000 RR/6000/8000) add alignment washers to the driven shaft. Drive belt length, condition, and deflection are all NOTE: Available shim washers from Arctic Cat are  important for peak performance. To check and adjust p/n 0648-850 (0.090 in.) and (p/n 0648-849 (0.030 in.).

  • Page 171: Drive Train

    3. Remove the screws securing the PTO engine mount plate to the engine and the chassis. 4. Remove the expansion chamber and the resonator; then remove the right-side footrest. 5. Remove the torx-head screw securing the belly pan to the right-side footrest support. 6.
  • Page 172 XM387 PC148A 12. Remove the inner black retaining ring; then remove NOTE: If the caliper will not slide off the driveshaft  the retaining ring and washer securing the driven easily, proceed to step 17. shaft. 17. Remove the retaining pin and the brake disc pads; then pump the brake lever 3 or 4 times then pull back and secure the lever to the handlebar using a cable tie.
  • Page 173 2. Place the driveshaft/drive sprocket assembly into the tunnel brake-end first; then into the chain case drive- shaft bearing. 3. Install the inner brake caliper assembly and secure with three cap screws and the retaining ring. Tight- ened cap screws (threads coated with blue Loctite #243) securely.
  • Page 174 14. Install the chain case cover/oil tank assembly and secure with the existing screws (threads coated with blue Loctite #243). Tighten in a crisscross pattern to 12 ft-lb. Fill the chain case with 15 oz. of Arctic Cat Chain Lube. 15. Connect the speed and oil sensor connector.

  • Page 175: Installing Chain Case

    SNO-966A YM-077A 12. Remove the sprockets and chain. NOTE: If the brake caliper was split, proceed to  CLEANING AND INSPECTING CHAIN step 4. If not, proceed to step 6. CASE 4. Install the brake disc and secure with the retaining 1.

  • Page 176: Drive Sprockets

    12. Install the chain case cover/oil tank assembly and secure with the screws. Tighten in a crisscross pat- tern to 105 in.-lb. 13. Fill the chain case with 12 oz of Arctic Cat Chain Lube. 14. Install the actuator extender; then install the reverse actuator and with a drop of blue Loctite #243 on each screw, secure the actuator to the chain case cover.
  • Page 177 2. For installing purposes, scribe a line on the drivesh- aft (A) next to the drive sprocket for proper align- ment; then scribe a line on the driveshaft directly in line with the timing arrows (B located on the inside of the sprockets) on the drive sprockets for proper sprocket timing.

  • Page 178: Track Tension

    YM-072A XM283A 4. Using a calipers, measure distances between the sprockets and from the sprockets to each end of the Track Tension driveshaft for proper location (see appropriate illus- tration). CHECKING ! WARNING DO NOT attempt to check or adjust track tension with engine running.

  • Page 179: Track Alignment

    2. If the deflection (distance between the bottom of the 3. Start the engine and accelerate slightly. Use only wear strip and the inside surface of the track clip) enough throttle to turn the track several revolutions. exceeds specifications, tighten the adjusting bolts to SHUT ENGINE OFF.

  • Page 180: Brake System

    NOTE: Field test the track under actual conditions 2. If the brake fluid level is low, add Arctic Cat  approved brake fluid until the fluid is at the recom- and after the field test, check track alignment and mended level. Install and secure the reservoir cover.
  • Page 181 CHECKING AND REPLACING BRAKE NOTE: It may be necessary to refill the reservoir a  number of times to eliminate all air bubbles in the sys- PADS tem. 1. Remove the brake shield; then remove the retaining pin securing the brake pads. 4.
  • Page 182 BRAKE CALIPER/BRAKE 7. Remove the retaining ring from the driveshaft and remove the brake disc; then remove the cap screws DISC/DRIVESHAFT BEARING securing the inner caliper/driveshaft bearing housing Removing/Disassembling to the chassis. 1. Remove both access panels; then remove the drive belt and driven clutch.
  • Page 183 10. Remove the two screws securing the caliper halves. 3. Inspect the piston bore of the inner and outer brake Discard the seal. calipers for gouges, cracks, pitting, scuffing, or cor- rosion. If any of these conditions exist, replace the caliper.

  • Page 184: Brake Lever/Master Cylinder Assembly

    ZJ239A PC195 4. Install the snap ring securing the bearing in the cali- 9. Bleed the brake system (see Bleeding Brake System per housing. in this sub-section). 10. Install the brake shield and footrest; then install the drive belt (see Drive Belt in this section) and driven clutch.
  • Page 185 2. Inspect the master cylinder reservoir and cover for cracks and leakage. NOTE: The master cylinder is a non-serviceable  component. If any wear or damage is detected, the master cylinder must be replaced. 3. Inspect the brake fluid hose for cracks, deterioration, and the condition of the fittings (threaded and com- pression).

  • Page 186: Troubleshooting Hydraulic Brake System

    Troubleshooting Hydraulic Brake System Problem: Caliper Leaks Condition Remedy 1. Caliper O-ring deteriorated — severed 1. Replace O-ring 2. Piston — O-ring damaged 2. Repair piston — replace piston — O-ring Problem: Lever Spongy — Bottoms Out Condition Remedy 1. Brake system air bubbles present 1.

  • Page 187: 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 188: Suspension

    Under acceleration when the center of gravity is trans- ferred to the rear of the machine, the rear suspension col- Suspension lapses slightly. This brings the rear arm point downward and with the front arm stationary, the teeter-totter effect reduces the pressure on the skis, position A. ...
  • Page 189 ADJUSTING SKI SHOCKS (Fox Float) NOTE: Adding air pressure will increase the air  spring force; reducing air pressure will decrease air The float shocks are individually adjustable for the ter- spring force. rain conditions and driving style of the operator. The ski shocks are initially preset at the factory (see the General ! WARNING Information section).
  • Page 190 When riding in sticky snow (springtime or warm days) or hill climbing on hard snow, it may be desirable to stiffen the front arm spring tension. When this is done, weight is transferred back quicker. The problem with too much front arm spring tension is that the feel of the snowmo- bile becomes very short.
  • Page 191 2. Rotate the coupler blocks to the desired position 3. Place a 4-in. block of wood under the rear of the sus- making sure both are set the same. pension just in front of the rear idler wheels to assist in collapsing the suspension.
  • Page 192 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 alter-...
  • Page 193 M/141” High Country Models 0747-414...

  • Page 194: Servicing Suspension

    Servicing Suspension This sub-section has been organized so each procedure can be completed individually and efficiently. NOTE: Some components may vary from model to  model. The technician should use discretion and sound judgment when removing and installing com- ponents. ...
  • Page 195 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 196 INSTALLING 1. Place the front arm shock axle assembly into position on the skid frame making sure the spacers and wash- ers are properly positioned. Secure with the cap screw, washer, and a new lock nut. Tighten to 40 ft-lb. 2.
  • Page 197 7. Secure the limiter straps to the front arm with cap screws, washers, and lock nuts. Tighten to 72 in.-lb. Front Arm Assembly (RR) REMOVING 1. With the skid frame removed, remove the cap screws (A) and lock nuts securing the limiter straps to the front arm.
  • Page 198 9. Remove the cap screw securing the rear arm to the idler arm. Account for the aluminum axle. FZ035A 4. Remove the idler wheel. NOTE: Use the Idler Wheel Puller Kit to remove  FZ101A 10. Remove the cap screw and lock nut securing the rear the wheel.
  • Page 199 FZ103A 0742-877 2. Install the rear arm onto the idler arm with an alumi- 4. With the sleeves installed, install the shock absorber num axle and two cap screws. Tighten to 40 ft-lb. link to the lower mounting hole of the idler arm along with the cap screw and lock nut;...
  • Page 200 REMOVING 1. With the skid frame removed using the Rear Suspen- sion Spring Tool, remove the springs from the adjust- ing cams. ! 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 201 7. Align the marks on the idler arm to the centerline of the offset arm assembly. Secure the offset arm to the idler arm with cap screws and lock nuts. Tighten to 20 ft-lb. XM090A INSTALLING 1. Slide the axle tube into the rear arm; then position the rear arm with the holes in the slide rails.
  • Page 202 2. Remove the cap screw and lock nut securing the upper shock eyelet to the idler arm; then remove the cap screw and lock nut securing the rear shock link to the idler arms. XM007A CLEANING AND INSPECTING 1. Clean the bearings with a clean cloth. 2.
  • Page 203 XM006A XM002 3. With the sleeves installed, place the shock absorber 6. Turn the slide rail onto the side the idler wheel was and shock link between the offset arm bracket. installed in (from step 5); then with a block of wood Secure with the cap screws and lock nuts.
  • Page 204 Installing Skid Frame 1. Using a piece of cardboard on the floor to protect against scratching and an appropriate handle- bar/steering post stand, tip the snowmobile onto one side. 2. Pull the track away from the tunnel and spread open; then place the skid frame into the track.

  • Page 205: Fox Air Shocks

    FOX Air Shocks AIR LEAKAGE POINTS NOTE: When attaching the air pump, the hose and  gauge will fill with air from the air chamber resulting in a lower air pressure reading than the shock was originally set at. This is normal. 1.
  • Page 206 4. Clamp the shock rod and valve assembly in bench vise; then remove the nut securing the valve stack. ZR-004 ZR-011 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.
  • Page 207 2. Install the valve stack onto the shock rod; then secure using the existing nut. Tighten to 15 ft-lb. ZR-008 5. Fill shock body with new synthetic shock oil to bot- tom of threads. ZR-014 ZR-010 ZR-007 3. Using Piston Location (IFP) Tool or a tape measure, 6.
  • Page 208 9. Install the screw into the shock body. ZR-003 8. With shock oil around the seals in the bearing cap and on the shock rod, slowly compress the shock rod ZR-004 10. Compress the shock eyelet until it bottoms out; then until the shock eyelet bottoms out.
  • Page 209 NOTES...
  • Page 210 Printed in U.S.A. Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701 p/n 2260-847...

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