Arctic Cat ZR4000 Service Manual 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.
25. 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.
PC186A
26. Insert the servomotor cable ends into the slot in the
clutch; then connect the servomotor connector.
Secure the cables with the holder.
PC187A
27. Rotate the servomotor clockwise to remove any
slack from the cables; then install the servomotor
retaining clip. Check APV cable adjustment (see
Arctic Power Valve (APV) System in the
Engine-Related Items section).
28. Install the PTO-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.
29. Install the fascia panels (with ECM) and secure to
the chassis using the existing screws. Tighten
securely. Connect the ECM.
NOTE: At this point, secure the PDM harness to the

shock mount bracket support using a cable tie.
30. Position the heat shield onto the two front locating
pins (B); then secure it to the chassis with the two
screws (A). Tighten securely.
54
PC189A
31. Install the resonator and secure with the springs; then
place the expansion chamber and gaskets into posi-
tion and secure to the exhaust manifold and resonator
with the springs.
NOTE: When installing the manifold springs, the

long hook portion of the spring must be attached to
the exhaust manifold or premature spring failure will
result.
32. Install the exhaust temperature sensor into the expan-
sion chamber. Tighten to 34 ft-lb.
33. Place the drive clutch with drive belt into position on
the crankshaft and secure with the cap screw (threads
coated with oil) and high-collar washer. Tighten 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. Failure to
do so could result in stationary sheave damage.
NOTE: Before installing the drive clutch, be sure to

wipe both the crankshaft and clutch mounting tapers
clean using a clean towel.
34. Install the driven clutch on the driven shaft; then
install the drive
Train/Track/Brake Systems section).
35. Install the driven clutch (see Driven clutch in the
Drive Train/Track/Brake Systems section); then
check drive belt deflection (see the Drive
Train/Track/Brake Systems section).
36. Place the hood into position on the front end and
secure with the screws; then install the hood harness.
Install the side access panels.
CAUTION
Never run the engine with the hood harness discon-
nected or damage to the electrical system will result.
37. Start the engine and warm up to operating tempera-
ture; then verify that all components are functioning
properly and that coolant is circulating through the
cooling system properly.
38. After running the engine to the proper operating tem-
perature, shut the engine off; then open the access
panels and inspect for any signs of coolant, gasoline,
or oil leakage.
belt (see the Drive