Arctic Cat ZR4000 Service Manual page 39

Installing
NOTE: If the engine was replaced, make sure to

install the existing engine support plate and the
exhaust manifold on the new engine. Tighten the
exhaust manifold nuts to 12 ft-lb, the M6 engine sup-
port plate cap screws to 25 ft-lb, and the M8 engine
cap screws to 35 ft-lb. Install the coolant hoses.
1. Carefully lower the engine into the engine compart-
ment.
2. Install the coolant hose to the heat exchanger at the
rear of the engine; then connect the lower coolant
hose to the front heat exchanger.
XM253A
3. Install new MAG-side engine mount "patch-lock"
cap screws. Finger-tighten only at this time.
4. Install a new "patch-lock" cap screw and new lock
nuts to secure the engine support plate to the chassis.
Finger-tighten only at this time.
5. Install four new "patch-lock" screws to secure the
PTO-side engine mounting plate. Tighten to 30 ft-lb
using a crisscross pattern.
XM257
6. Tighten the cap screw and lock nuts (from step 4) to
25 ft-lb.
7. Install the access panel to the center belly panel and
chassis and secure using the torx-head screws.
Tighten securely.
8. Tighten the cap screws (from step 3) to 25 ft-lb.
9. Install the spark plug caps; then install the cylinder
head vent hose.
38
10. Place the recoil starter into position and secure with
the cap screws. Tighten in a crisscross pattern to 96
in.-lb.
11. Before connecting the wiring harness plug-ins, clean
the connectors and apply Dielectric Grease to the
seal; then connect all harness connectors making
sure all wiring and coolant hoses are routed properly
as noted in removing.
NOTE: Use cable ties to secure the wiring harnesses

as necessary.
12. Connect the MAG-side throttle body coolant hose;
then secure with a clamp.
13. Place the throttle body assembly into position and
secure with the flange clamps; then connect the gas-
line hose to the throttle body assembly and tighten
the clamp securely.
CAUTION
When installing the throttle bodies, make sure the gas-
line hose is properly routed to avoid premature wear
and/or contact with exhaust components.
XM252
14. Connect the PTO-side throttle body coolant hose;
then secure with a clamp.
15. Fill the cooling system (see Liquid Cooling System
in the Engine-Related Items section).
16. Using the existing clamps, secure the intake flanges
to the throttle bodies.
17. With the air intake boot properly positioned on the
throttle bodies, secure with the existing clamps.
18. Install the shock mount bracket support; then using
new lock nuts, secure the support to the shock mount
brackets and tighten to 20 ft-lb.
19. Install the MAG-side front spar and secure to the
steering post and shock mount bracket using the
existing cap screws. Tighten the cap screws to 25
ft-lb.
20. Install the fascia panels (with ECM) and secure to
the chassis using the existing screws. Tighten
securely. Connect the ECM.