Arctic Cat ZR 6000 R SNOCROSS 2015 Operator's Manual
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Arctic Cat ZR 6000 R SNOCROSS 2015 Operator's Manual

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O P E R A T O R ' S M A N U A L
ZR 6000 R SNOCROSS
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Summary of Contents for Arctic Cat ZR 6000 R SNOCROSS 2015

  • Page 1 O P E R A T O R ’ S M A N U A L ZR 6000 R SNOCROSS www.arcticcat.com...
  • Page 2 Snowmobile or will not damage the Arctic Cat Snowmobile. Arctic Cat does not assume any liability for incidental or consequential damages. Arctic Cat will repair or replace, at its option, free of charge (including any related labor charges), any parts that are found to be warrantable in material or workmanship.
  • Page 3 At the time of publication, all information and illustrations were technically correct. Some illustrations used in this manual are used for clarity purposes only and are not designed to depict actual conditions. Because Arctic Cat Inc. constantly refines and improves its products, no retroactive obligation is incurred.
  • Page 4 No warranty will be allowed To aid in service and maintenance procedures on this by Arctic Cat Inc. if the engine serial number or VIN is snowmobile, an Illustrated Parts Manual is available removed or mutilated in any way.

  • Page 5: Table Of Contents

    Preparation For Storage ......... 108 Control Locations..........29 Preparation After Storage........109 Engine Break-In ............ 29 Genuine Arctic Cat Products ........110 Diagnostic Codes/Check Engine Light....29 Special Tools ........... 111-120 Ignition Timing Adjustment Dial ......29 Declaration of Conformity....Inside Back Cover...

  • Page 6: Specifications/Charts/Patterns/Diagrams

    Gasoline (Recommended) 92 Octane (minimum) Side Spar - Right Non-Oxygenated Chain Case Side Spar - Right Pre-Mix Oil (32:1 Ratio) Arctic Cat APV 2-Cycle Oil Housing, A-Arm/Shock Side Spar Mounting Chain Case Lubricant Arctic Cat Synthetic Chain Lube Bracket, Exhaust Mount-...
  • Page 7 STEERING AND FRONT SUSPENSION ENGINE Torque Torque Item Secured to Item Secured to ft-lb ft-lb Post, Steering Bellcrank Cylinder Head/Cover Cylinder (2 Steps) 20-25 ft- Plate, Retaining - Bellcrank Bellcrank Cylinder Crankcase (3 Steps) 14-40 ft- Steering Support Mounting Block - Steering Post Thermostat Cap Crankcase...

  • Page 8: Engine Torque Patterns

    Engine Torque Patterns Torque Conversions (ft-lb/N-m) ft-lb ft-lb ft-lb ft-lb 35.4 69.4 103.4 36.7 70.7 104.7 38.1 72.1 106.1 39.4 73.4 107.4 40.8 74.8 108.8 42.2 76.2 110.2 43.5 77.5 111.5 10.9 44.9 78.9 112.9 12.2 46.2 80.2 114.2 13.6 47.6 81.6 115.6...

  • Page 9: Electrical Specifications

    Electrical Specifications Component Voltage/ Resistance Chart - Water Temperature NOTE: The ignition system is a Normally Open Ignition (NOI). Temperature Volts Ohms Temperature Volts Ohms Resistance Test Description + Test Connections - Test Value 110 °C 230 °F 0.115 129 28 °C 82 °F 1.377 1800...

  • Page 10: Crankshaft Runout/Repair Specifications

    D and contact. From the illustration, note that Arctic Cat F. When checking runout in the center, place indi- has called out three check points: at either end, out cator on center of bearing as shown at point E.

  • Page 11: Drive Clutch/Driven Clutch Optional Components

    Drive Clutch/Driven Drive Clutch Cam Arms Clutch Optional (w/Set Screw) Components ARCTIC CAT DRIVE CLUTCH CAM ARMS Grams Grams ARCTIC CAT DRIVE CLUTCH SPRING CHART 0746-661 52.0 0746-742 83.5 Rate @ 2 9/16" Rate @ 1 5/16" Color 0746-662 52.0 0746-744 50.0...

  • Page 12: Chain Case Performance Calibrations

    Chain Case Performance Calibrations NOTE: The following table should be used as a guide only. NOTE: The above gearing options are combinations which allow acceptable chain tension. Any other combinations will not allow acceptable chain tension.

  • Page 13: Chains And Sprockets

    Chains and Sprockets Arctic Power Valve (APV) System Specifications Part Sprocket Number 2602-582 SPROCKET, REX-19T FWD-(13 WIDE/19 SPLINE) 2602-523 SPROCKET, REX-20T FWD-(13 WIDE/19 SPLINE) 2602-377 SPROCKET, REX-21T FWD-(13 WIDE/19 SPLINE) 2602-335 SPROCKET, REX-22T FWD-(13 WIDE/19 SPLINE) 2602-403 SPROCKET, REX-23T FWD-(13 WIDE/19 SPLINE) 2602-666 SPROCKET, REX-19T FWD-(13 WIDE/19 SPLINE) 2602-212 SPROCKET, REX-21T FWD-(13 WIDE/19 SPLINE) 2602-461 SPROCKET, REX-22T FWD-(13 WIDE/19 SPLINE)

  • Page 14: Mikuni Tuning Components

    Mikuni Tuning Major Tuning Components Components Listed below are pilot jets and throttle valves (slides) Main Jets according to their size. 6505-299 6505-072 67.5 6505-300 6505-077 PILOT JETS THROTTLE VALVES (SLIDES) 6505-833 6505-078 Lean 12.5 Lean 72.5 3003-189 6505-124 6505-296 6505-212 6505-270 6505-125...

  • Page 15: Rear Spring Selection Chart

    Rear Spring Selection Installed Spring Rate Chart Chart Below is a list of rear suspension springs and specifi- Suspension Fully Suspension Fully Extended Extended cations. A longer spring in areas (D) and (E) can be (in.-lb - Adjuster Set 1 & 1) (in.-lb - Adjuster Set 3 &...

  • Page 16: Valve Stacks/Specifications

    Valve Stacks/ Specifications Part Number Description Compression (Piston Side) Rebound (Piston Side) 3703-348/349 Ski Shock 1.300 x 0.006 in. 1.100 x 0.008 in. Extended Length: 19.14 in. Rebuild Kit - p/n 3603-420 1.300 x 0.008 in. 0.600 x 0.004 in. Collapsed Length: 13.29 in.
  • Page 17 Compression Rebound Part Number Description (Piston Side) (Piston Side) 2704-638 Rear Arm Shock** 1.600 x 0.008 in. 1.425 x 0.015 in. Extended Length: 14.59 in. Rebuild Kit - p/n 2603-013 1.600 x 0.008 in. 1.100 x 0.0045 in. Collapsed Length: 10.06 in. Rebuild Kit - p/n 3604-539 1.425 x 0.012 1.400 x 0.080 in.

  • Page 18: Rebuildable Shock Accessory Part Numbers

    Valve: [1.250 OD X 0.377 ID X 0.012 TH] NOTE: Shock Oil (p/n 5639-530) is available from 0603-889 Valve: [1.250 OD X 0.377 ID X 0.015 TH] the Arctic Cat Service Department. 0603-348 Valve: [1.300 OD X 0.377 ID X 0.006 TH] 0603-349 Valve: [1.300 OD X 0.377 ID X 0.008 TH]...

  • Page 19: Fraction/Decimal Conversion Chart

    Double Bleed Shims (DB) Fraction/Decimal AC PN Description Conversion Chart 3603-342 Valve: DB 3 PORT (1.30" OD X .375" ID .004" THK.) 3603-343 Valve: DB 3 PORT (1.30" OD X .375" ID .006" THK.) 3603-344 Valve: DB 3 PORT (1.30" OD X .375" ID .008" THK.) 8ths 16ths 32nds...

  • Page 20: Mm/In. Conversion Chart

    MM/IN. Conversion Chart .00039 .02008 .03937 2.00787 .00079 .02047 .07874 2.04724 .00118 .02087 .11811 2.08661 .00157 .02126 .15748 2.12598 .00197 .02165 .19685 2.16535 .00236 .02205 .23622 2.20472 .00276 .02244 .27559 2.24409 .00315 .02283 .31496 2.28346 .00354 .02323 .35433 2.32283 .00394 .02362 .39370 2.36220...

  • Page 21: Wiring Diagram - Hood Harness (P/N 1686-664)

    Wiring Diagram - Hood Harness (p/n 1686-664) SNO-491...
  • Page 22 NOTES...

  • Page 23: Wiring Diagram (Ignition/Main) (Harness P/N 1686-732)

    Wiring Diagram (Ignition/Main) (Harness p/n 1686-732) 0747-813...

  • Page 25: Setup Instructions

    Installing Spindle/A-Arm Setup Instructions This snowmobile has been prepared at the factory to minimize required setup items; however, there are some items and inspections that must be done at a dealership or by the owner/operator. Please pay close attention to all items on the following pages. Be sure to read these instructions thoroughly before starting to set up the snowmobile.

  • Page 26: Installing Sway Bar (Optional)

    2. If the brake fluid level is below the low mark, located to the inside of the ski and the cotter pin slot remove the reservoir cover and add Arctic Cat in the cap screw will be horizontal with the ski.

  • Page 27: Ski Alignment

    NOTE: Turning the set screw clockwise increases distance between the sheaves (increases belt deflection measurement); turning the set screw counterclockwise decreases distance between the sheaves (decreases belt deflection measurement). Ski Alignment Checking Toe-Out Range 0.0 - 12.7 mm (0 - 1/2 in.) NOTE: Track tension and alignment must be properly adjusted prior to checking or adjusting ski alignment.

  • Page 28: Recommended Gasoline/Oil/Mixing Ratio

    NOTE: The following procedure can be used to adjust the alignment of either ski. Do not use white gas or gasoline containing methanol. Only Arctic Cat approved gasoline additives should be 1. Unlock the steering tie rod by loosening jam nuts (A). used.

  • Page 29: Preoperation Checks

    To adjust track tension/track alignment, use the fol- must be just below the high mark on the brake lowing procedure. fluid reservoir. Add Arctic Cat approved brake fluid as necessary. 1. Elevate the snowmobile on a shielded safety stand high enough to use a spring scale.

  • Page 30: Handlebar/Ski Alignment

    0744-067 0740-118 8. If the idler wheels are not centered between the NOTE: Always loosen the right-side rear axle nut inner track drive lugs, adjust track alignment. when adjusting track tension/alignment. The left- side rear axle nut is secured with green Loctite ! WARNING #609 and should not be loosened or removed.
  • Page 31 8. If ski alignment is not as specified, adjust the align- 3. Using a very light hold-down strap (bungee cord) ment of the ski(s) not parallel to the straightedge. between the ski handles, apply a very light load approximately 2-4 lb pulling the skis together just Adjusting enough to pull the slack.

  • Page 32: Test Ride

    NOTE: Some operating conditions may require more toe-out than recommended; however, more toe-out causes more “drag.” ! WARNING 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. Neglecting to lock the tie rod by tightening the jam nuts may cause loss of snowmobile control and possible personal injury.

  • Page 33: General Information

    Ignition Timing Adjustment Dial General Information Control Locations RA016A 0746-486 Engine Break-In The engine (when new or rebuilt) requires a short break-in period before the engine is subjected to heavy load conditions. During the break-in period, a maximum of 1/2 throttle is recommended;...

  • Page 34: Arctic Power Valve (Apv) System

    3. Compare the reading with the timing selection in 1. Remove the actuating cables from the servo. the chart. 2. While holding the cable housing, lightly pull on one cable end to remove slack. Ignition Timing Rotary Select Switch Timing Selection ohms 3.

  • Page 35: Testing Exhaust Temperature Sensor

    Using the Hot Start Function NOTE: A disabled ECT system WILL NOT cause engine damage; however, a failed ECT system will To use the hot start function, start the engine and depress have slower throttle response and may produce the red hot start button located on the left side of the han- slightly less top-end performance.

  • Page 36: Rear Bumper

    If leakage or damage is detected and the operator does not feel qualified to service the cooling that allows the brake fluid to be below the low system, see an authorized Arctic Cat Snowmobile mark on either side of the master cylinder. dealer for this service.

  • Page 37: Drive Clutch/Driven Clutch Alignment

    Normally, no ery problems, see an authorized Arctic Cat Snowmo- adjustment is necessary as long as neither the drive bile dealer for this service.

  • Page 38: Operating Instructions

    NOTE: When the engine is being started with aid Add Arctic Cat approved brake fluid as necessary. of the choke, DO NOT COMPRESS THE THROTTLE CONTROL LEVER. If the throttle control lever is compressed, the engine will not start because the gas/air mixture will be too lean.

  • Page 39: Braking

    ! WARNING NOTE: Continued choking will cause the engine Use only Arctic Cat approved brake fluid. Never sub- to flood more. stitute or mix different types or grades of brake fluid. Brake loss can result. Check brake fluid level and pad NOTE: If the engine fails to start during the...

  • Page 40: Emergency Stopping

    6. When new brake pads are installed, a “burnishing” ! WARNING process is required. Drive the snowmobile slowly If any malfunction of the carburetor/throttle system and compress the brake lever several times until occurs (such as freezing in fluffy snow) and the the pads just start to heat up;...

  • Page 41: Lubrication

    NOTE: If excessive oil deposits are observed, the Lubrication chain case must be serviced. Also, when the oil level is at the add mark, approximately 2 fl oz of transmis- sion lube must be added to the chain case. Chain Case CAUTION The recommended amount of synthetic chain lube in the chain case is 12 fl oz.

  • Page 42: Maintenance

    Maintenance The longevity and safety of the snowmobile can be increased by making periodic checks of the items in the follow- ing checklist. Perform maintenance checks more often if the snowmobile is used under severe conditions. Periodic Maintenance Checklist EVERY EVERY EVERY INTERVAL...

  • Page 43: Pre-Race/Practice Checklist

    SNOWMOBILE. Immediately diagnose and repair any component. If the operator does not feel qualified RA001A to service the suspension, see an authorized Arctic Cat 5. Remove both clips securing the servo cables to the Snowmobile dealer for this service. servomotor. Remove the cables.
  • Page 44 NOTE: At this time, clamp or close off the gasline hose; then secure the hoses, throttle cable, and wiring harness out of the way. 10. Remove and discard the four PTO-side cap screws securing the PTO engine mounting plate to the engine.
  • Page 45 RA006A RA009 NOTE: For assembling purposes, note the loca- tion of the different-length cap screws and spacers. Disassembling Engine NOTE: It is advisable to loosen the spark plugs prior to disassembling the engine. 1. Using Flywheel Spanner Wrench (p/n 0144-007) to secure the flywheel, remove the flywheel cap screw, lock washer, and flat washer;...
  • Page 46 RS014 RS019B 3. Using Flywheel Puller (p/n 0744-040) or suitable 6. Remove the Allen-head cap screws securing the substitute, remove the flywheel from the crank- stator to the stator plate; then remove the stator shaft by tightening the puller bolt, striking the and account for the rubber grommet.
  • Page 47 RS020A RS023 8. Remove the stator plate from the engine; then NOTE: Make sure to mark the APV components remove the flange nuts securing the exhaust mani- for assembling purposes. fold. Remove the manifold and gaskets. RS024 RS021A 11. Remove the cap screws with O-rings securing the NOTE: The stator plate screws had Loctite cylinder head cover and the cylinder heads;...
  • Page 48 NOTE: When removing the cylinders, place the engine on its intake flanges on a drain tray to allow residual coolant to drain from the cylinder/ crank- case water jacket. 12. Remove the eight nuts securing the cylinders to the crankcase; then using a rubber hammer, gently tap the cylinders and remove from the crankcase by lifting them straight up off their studs.
  • Page 49 RS032A FC033 21. With its bottom side up on two support blocks, NOTE: Note the orientation of the bypass valve remove the cap screws securing the crankcase for assembling purposes. halves. NOTE: The end bearings are not pressed onto the crankshaft. 22.
  • Page 50 FC036 RS036A 28. Using a pair of snap ring pliers, remove the snap ring securing the inner seal in the crankcase. RS037 26. Remove the water pump driveshaft from the lower crankcase half. Account for the thrust washer on MS415 the outer end of the shaft.
  • Page 51 Cleaning and Inspecting Engine NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. Cylinder Heads 1. Using a non-metallic carbon removal tool, remove any carbon buildup from the combustion chambers being careful not to nick, scrape, or damage the combustion chambers or the sealing surfaces.
  • Page 52 Piston Assembly 6. Inspect the sealing surfaces of the crankcase halves for trueness by placing each crankcase half 1. Using a non-metallic carbon removal tool, remove on the surface plate covered with #400 grit wet-or- the carbon buildup from the dome of each piston. dry sandpaper.
  • Page 53 NOTE: Install the bearings by sliding each bear- ing onto the crankshaft making sure the dowel-pin hole in the outer race is properly positioned and will align with its hole and pin in the crankcase. FC039 3. Inspect the connecting-rod bearings by rotating them.
  • Page 54 Cylinder Trueness Piston-Ring End Gap 1. Measure each cylinder in the three locations from front 1. Place each piston ring in the wear portion above the to back and side to side for a total of six readings. exhaust port of its respective cylinder. Use the pis- ton to position each ring squarely in each cylinder.
  • Page 55 NOTE: When the use of a lubricant is indicated, NOTE: Maximum runout at any of the 3 measur- use Arctic Cat Synthetic APV 2-Cycle Oil. ing points is 0.002 in. 1. Apply a thin coat of grease to the inner seal lips of the water pump seal.
  • Page 56 NOTE: The seal must be installed with its spring 6. Position the shim on the oil-injection pump end of the driveshaft. side towards the crankshaft. 3. Install the snap ring securing the inner seal in the crankcase. RS043 7. Position the upper crankcase half upside-down on two wooden blocks;...
  • Page 57 FC071 NOTE: Use only Arctic Cat Three Bond Sealant (p/n 0636-070) to seal the crankcase halves. 13. Assemble the crankcase halves making sure that the crankshaft gear and water pump driveshaft gears mesh.
  • Page 58 NOTE: Secure the connecting rods with rubber bands on the cylinder studs. 16. With a new O-ring, install the oil-injection pump retainer; then install the cover plate and gasket. CM169 19. Place the impeller into position and secure with a cap screw and washer.
  • Page 59 FC072B RS033A FC072A RS032A NOTE: Sealant is only required on the crankcase 23. Install the coolant temperature sensor (coated with seam. white Loctite #575) and tighten to 18 ft-lb; then secure the sensor wire to the sensor with a cable 21.
  • Page 60 726-306A FC079A CAUTION Incorrect installation of the piston ring will result in engine damage. 27. Apply oil to the connecting-rod small end bear- ings; then install the small-end bearings. RS056A CAUTION Make sure the circlips are firmly seated and the open end is directed away from the access slot before con- tinuing with assembly.
  • Page 61 RS050 RS026A 31. Secure the cylinders with flange nuts tightening NOTE: Lubricating the cylinder O-rings with a the nuts in a crisscross pattern in 3 steps (step 1 = light coat of grease will help keep them seated in 14 ft-lb; step 2 = 24 ft-lb; step 3 = 40 ft-lb). the grooves of the cylinder and cylinder head.
  • Page 62 RS054 RS021A 35. With new O-rings on the cylinder head cover cap screws, install the cap screws and finger-tighten; then using the pattern shown, tighten the cap screws in 2 steps (step 1 = 15 ft-lb; step 2 = 25 ft- lb).
  • Page 63 40. Install the key in the crankshaft; then place the starter clutch in position and loosely secure the starter clutch with three cap screws (coated with red Loctite #271). 41. Slide the flywheel onto the crankshaft making sure the keyways match. NOTE: Before installing the flywheel, be sure to wipe the crankshaft and flywheel tapers clean using a clean towel.
  • Page 64 RA007A RA008 5. Secure the PTO-side engine mount to the engine using the four new patch-lock cap screws. Tighten to 25 ft-lb. RS074A 9. Secure the air silencer boots making sure they are properly seated to the intake bores of the carbure- tors;...
  • Page 65 11. Place the recoil starter with ground wire into posi- 15. Place the drive clutch into position on the crank- tion and secure the starter with six cap screws shaft and secure with the cap screw (lightly lubri- (threads coated with blue Loctite #243). Tighten to cated) and lock washer.

  • Page 66: Fuel System

    In-Line Fuel Filter Arctic Cat recommends that the in-line fuel filter be checked weekly. The in-line fuel filter is located just in front of the fuel pump inlet fitting. The filter must be clean to allow the fuel hose to transmit the amount of gasoline required.
  • Page 67 RS002A RS005A 3. Using a pair of needle-nose pliers, remove the jet 6. Remove the screws securing the float assembly. needle assembly. Account for the E-clip and washer. RS007A 7. Remove the float assembly by lifting it up and out AH617D of the mixing body.
  • Page 68 RS006A AH626D 9. Move the throttle lever to the full-open position; NOTE: In the following step, only one E-clip then remove the funnel assembly. Account for the needs to be removed to free the throttle valve from gasket. the lever assembly. 12.
  • Page 69 Assembling 3. Wash all non-metallic components with soap and water. Rinse thoroughly. 1. Place the throttle valve into the mixing body making sure the cutaway faces the funnel assembly side; 4. Dry all components with compressed air only then slide the bushing assembly/plate onto the lever making sure all holes, orifices, and channels are assembly.
  • Page 70 3. Rotate the fuel mixture screw clockwise until lightly seated; then rotate the mixture screw coun- terclockwise the same number of turns as noted in disassembling for an initial setting. CAUTION Do not force the mixture screw when seating. Forcing the mixture screw may result in damage to the screw taper and/or mixing body.

  • Page 71: Adjusting Carburetors

    AH617D 0732-848 3. Slowly rotate the choke adjuster while checking the choke for free-play. As soon as all free-play has been removed from the end of the choke, stop rotating the adjuster. 4. With free-play removed from the choke, slowly rotate the adjuster again while checking the choke for free-play.

  • Page 72: Selecting Carburetor Main Jets

    Selecting Carburetor Main Jets Altitude, temperature, and the use of oxygenated or rac- ing gasoline affect the carburetion needed for optimum engine performance. The carburetor main jets must be changed in conjunction with changes in operating alti- tude and temperature. As the ambient temperature rises or as the snowmobile is operated at a higher altitude, the main jets must be replaced with leaner main jets.
  • Page 73 To remove and install the reeds, use the following pro- cedure: 1. Remove the reducer from the reed cage; then push the reed cage firmly through the stopper flange. RS010 NOTE: It is necessary to pry each retaining bar until it can be removed by hand. 4.

  • Page 74: Spark Plugs

    RS084A 0725-048 7. Place new outer reeds on the outside surface of the A. TAN or LIGHT BROWN insulator indicates cage; then press them onto the locating tabs. correct spark plugs (heat range). 8. With the outer reeds in place, push the cage firmly B.
  • Page 75 RA031A 4. Remove the pin and allen-head screws securing the brake caliper halves together; then remove the retaining ring securing the brake disc. Remove the brake disc. 0747-877 RA032A RA013 8. Remove the cap screws securing the inner caliper to the tunnel;...

  • Page 76: Drive Sprockets

    Installing 1. Place the track drive assembly into position; then install existing chain and sprockets and secure using the existing retaining ring (bottom sprocket), cap screw and washer (top sprocket). Tighten top cap screw to 25 ft-lb. 2. Tighten chain tensioner; then install chain lube. 3.

  • Page 77: Brake System

    NOTE: Prior to installing the sprockets onto the Brake System driveshaft, lightly chamfer the inside edge of the Arctic Cat recommends that the brake system (brake sprocket to avoid binding. lever, reservoir, hose, caliper, pads, and brake disc) be checked daily for fluid leakage, wear, or damage and 1.

  • Page 78: Checking Brake Lever Travel

    Do not overfill the reservoir. Overfilling the reservoir may Cat approved brake fluid. cause the brake system to hydraulically lock. Use only Arctic Cat approved brake fluid. Never substitute or mix CAUTION different types or grades of brake fluid. Brake loss can Brake fluid is highly corrosive.

  • Page 79: Drive Belt

    NOTE: Drive belts should be purchased from an. fluid from the caliper when the pistons are pushed authorized Arctic Cat Snowmobile dealer, as Arctic into the caliper for installing new brake pads. Cat drive belts are made to exact specifications Replacing the cover will prevent fluid spillage.

  • Page 80: Drive Clutch

    6. When the belt is free of driven clutch, remove the belt from the drive clutch. Installing 1. Place the belt (so the part number can be read) between the sheaves of the drive clutch. 2. With the sheaves fully apart, roll the belt over the stationary sheave.

  • Page 81: Driven Clutch

    2. Remove any drive belt dust accumulation from the stationary sheave, movable sheave, and bushings using parts-cleaning solvent only. 3. Inspect stationary sheave, movable sheave, spider, and cover for cracks or imperfections in the casting. 4. Inspect the cam arm pins for wear or bends. 5.
  • Page 82 4. Remove the movable sheave from the driven clutch shaft and account for one spacer. Cleaning And Inspecting NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. 1. Using a parts-cleaning solvent, wash grease, dirt, and foreign matter off all components;...

  • Page 83: Ski Shock Absorber Springs

    4. With Driven Clutch Compressor (p/n 0644-444), 2. With heavier springs, the front end will become compress the roller assembly enough to allow the more aggressive in the corners as more weight will snap ring to be properly secured to the shaft. be transferred to the skis when decelerating.
  • Page 84 3. Depressurize the main chamber first; then depres- surize the EVOL chamber next. NOTE: When depressurizing the chambers, a “hissing” should be noticed as air is released. Also, the shock normally contracts slightly due to the internal negative spring. NOTE: Look for oil in the air chamber which may be at the top of the bearing head assembly.
  • Page 85 8. Using a FOX nitrogen safety needle, press it through the rubber pellet to depressurize the nitro- gen charge. When the shock is fully discharged, pull the needle away in a straight, smooth motion. NOTE: At this point, inspect the nitrogen valve for signs of wear such as holes on the face of the pellet.
  • Page 86 13. Remove the air sleeve from the reservoir end of the shock. 11. Using an appropriate bearing head removing tool, unscrew the bearing head assembly from the shock. 12. Grasp the EVOL chamber end (bottom) of the shock; then gently pull the piston/shaft/bearing/ EVOL free from the shock body.
  • Page 87 16. Using an appropriate IFP removing tool, remove the IFP from the “piggy-back” body. 15. Pour the shock oil out of the shock body; then clamp the “piggy-back” body assembly in the vise.
  • Page 88 17. Remove the IFP bleed screw and set aside. 20. Using a 5/8-in. wrench, remove the LSC assembly from the eyelet, thoroughly clean the assembly, 18. Using the new seals from the appropriate seal replace the O-rings, and install the assembly into rebuild kit, replace all IFP seals.
  • Page 89 1. Using an appropriately-sized IFP removing tool, insert the tool with a “delrin rod” (or a suitable substitute) into the air sleeve and strike the rod with a hammer freeing the bushing. NOTE: To install a new DU bushing, an appropri- ate bushing installer (A), sizer (B), and machine press must be available.
  • Page 90 C. Using the machine press, press the stack until the sizer falls free within the air sleeve. Remove the installer and the sizer. 4. Apply an ample amount of petroleum grease to the “samurai” and backup seals; then place them into the air sleeve.
  • Page 91 NOTE: It is advisable to use cable ties to pre- serve the upper and lower shim stack/piston order. Disassembling Shaft Assembly 1. Using a 9/16-in. wrench, remove the shaft lock nut. 2. Using a scribe or pick tool, lift the piston and valve assembly collectively off the shaft.
  • Page 92 4. Remove the O-ring from the piston. 7. Remove and replace all O-rings and seals. 5. Install a new piston O-ring; then using an appro- priate piston band installation tool, install a new band. 6. Remove the spring from the assembly; then remove the bearing assembly.
  • Page 93  NOTE: When installing the main seal, assure that it is oriented correctly. 3. Using a shock absorber hand air pump, apply light pres- sure to the reservoir to extract the IFP. Rebuilding EVOL Reservoir 1. Install a new O-ring in the rebound eyelet assembly. 4.
  • Page 94 5. Replace the IFP seal; then amply lubricate the IFP and place it into the reservoir. 6. Thread the EVOL reservoir onto the rebound eyelet; then tighten to 12 ft-lb. 3. Install the lower and upper shim stack/piston assembly. Assembling Shaft Assembly 1.
  • Page 95  NOTE: At this point, pour 3-5 cc of float fluid between the air sleeve and shock body. Assembling Shock Absorber 1. Securely clamp the “piggy-back” body assembly in the vise; then using an appropriate air sleeve protector tool, slide the air sleeve over the body. 2.
  • Page 96 5. Install the IFP bleed screw. 4. Using an appropriate IFP installing tool, slowly press the IFP down into the oil purging the trapped air out through the bleed hole. Do not press the IFP to the bottom of the reservoir at this time.
  • Page 97 7. Assuring that the LCS adjuster screw is rotated fully open (counterclockwise), fill the shock body with Fox High V1 Race Oil; then rotate the LCS adjuster screw fully closed (clockwise). 10. Using a rubber mallet, gently tap the shaft to allow trapped air to escape from between the piston and valve shims.
  • Page 98 11. Gently lower the negative spring and spacer into the oil taking care not to let the oil overflow into the air sleeve. CAUTION Make sure the piston assembly and the rebound hole in the shaft DO NOT come out of the oil bath. If the rebound adjust hole in the shaft comes out of the oil bath, air can transfer to the underside of the piston aerating the shock.
  • Page 99 15. Slide the air sleeve down far enough to liberally lubricate the bearing head assembly. JJJJ GGGG 16. To set the IFP depth, remove the bleed screw; then using Floating Piston Location Gauge (p/n 0644-350), adjust the depth to 2.5 in. Install the bleed screw. KKKK 18.

  • Page 100: Rear Suspension

    (6 “clicks” = 1 turn). Front Arm Shock Spring The skid frame front arm shock spring is adjustable. However, Arctic Cat recommends that the shock MMMM spring be adjusted to a maximum of 6.4 mm (1/4 in.) up or down from the standard pre-load setting.

  • Page 101: Servicing Zero-X Shock Absorbers

    Servicing Zero-X Shock Absorbers NOTE: At this point, remove the set screw and discard the valve plug. Always install a new plug This procedure shows the proper method for servicing when servicing the shock absorber. the front arm shock absorber w/“piggy-back” reservoir. 4.
  • Page 102 FS334 FS337 8. Remove the shock from the vise and pour shock oil into a proper disposal container. DO NOT REUSE OLD SHOCK OIL. FS339 11. Remove the relief screw from the IFP. Discard the relief screw O-ring, IFP O-ring, and the IFP strap. FS335 9.
  • Page 103 13. Using a 5/8-in. socket, remove the damping adjuster cartridge; then clean and inspect the inboard and outboard O-rings. FS343 16. Using a 9/16-in. wrench, remove the piston nut from the end of the shaft. FS292A CAUTION Care must be taken not to scratch the cartridge when removing O-rings.
  • Page 104 FS348 FS351 2. Slide the bearing assembly over the protector tool 5. Place the shock body and eyelet in the vise with onto the shaft. the open end directed up. 6. Fill the reservoir with Shock Oil (p/n 5639-240) until approximately 3/4 full. NOTE: Allow a few minutes for oil to overflow into the shock body.
  • Page 105 11. Turn the damping adjuster to the fully open posi- tion (counterclockwise). FS354 9. Install Floating Piston Location Gauge (p/n 0644- 350) and cover the top of the tool with a towel; then FS358 slowly press the IFP into the oil until fully covered. 12.
  • Page 106 FS361 FS364 16. Install new O-rings and piston strap on the piston 18. While holding the shaft fully extended, slide the shaft assembly and lightly grease the piston strap; assembly into the shock body. then insert the piston shaft assembly into the shock NOTE: At this point, oil should overflow.
  • Page 107 FS368 FS373 24. Install the set screw (FAV3 valve assembly) and tighten only until snug; then loosen two turns. 25. Insert the needle squarely into the center of the nitrogen valve set screw and plug (taking care that the valve is directed away from face and body) and pressurize the reservoir to 250 psi.

  • Page 108: Adjusting Rear Transfer Adjuster Cams

    4. Remove the two screws securing the rear of the con- sole to the hood. 5. Lift the front of the console from the headlight assembly; then disengage the side console tabs and remove the console. FS376 27. Install the bearings and retaining rings into the eyelets. NOTE: Ensure proper shock function prior to installing on the snowmobile.

  • Page 109: Ski Wear Bar

    2. Engage the side console tabs on the headlight assem- equipped with wear bars. Ski wear bars are avail- bly; then place the front of the console over the head- able from an authorized Arctic Cat Snowmobile light assembly. and press down until it snaps in place. dealer.

  • Page 110: Rail Wear Strip

    2. Remove the lock nuts and washers securing the wear bar to the ski. Arctic Cat recommends that the wear strips be checked weekly and replaced as necessary. Measure the wear strips at 25.4 cm (10 in.) intervals. Wear strips must be 10.7 mm (0.42 in.) thick or thicker.

  • Page 111: Performance Tips

    DRIVE CLUTCH AND DRIVEN CLUTCH — Performance Tips Keeping the drive clutch and driven clutch clean should be the primary consideration of the operator. The clutch sheaves can be cleaned of any drive belt accumulation using a clean cloth and parts-cleaning Operating a high performance snowmobile requires a solvent.

  • Page 112: Preparation For Storage

    Install the chain-case cover and seal; then pour Arctic Cat Synthetic Chain Lube (p/n 5639- Prior to storing the snowmobile, it must be properly 038) into the oil level stick filler hole according to serviced to prevent corrosion and component deterio- specifications.

  • Page 113: Preparation After Storage

    Arctic Cat adjust or replace as necessary. recommends the following procedure. 7. Inspect the spark plugs. Replace, gap, or clean as CAUTION necessary.

  • Page 114: Genuine Arctic Cat Products

    6/1 gal. cially for Arctic Cat Snowmobile engines. Arctic Cat Synthetic APV 2-Cycle Oil 16 gal. 2639-510 Oil is the only oil authorized by Suzuki and Arctic Cat Synthetic APV 2-Cycle Oil 2-1/2 gal. 2639-975 2—2-1/2 gal. engineers for use in Arctic Cat Snowmobile engines.

  • Page 115: Special Tools

    0744-040 (Complete Set) p/n: 0643-086 (Body) p/n: 0643-087 (Bolt) p/n: 0423-482 (6 mm Cap Screw) p/n: 0423-483 (8 mm Cap Screw) Usage: Pull flywheel off crankshaft on all Arctic Cat 2- stroke models. 0644-291 Flywheel Spanner Wrench p/n: 0144-007 Usage: Hold starter cup while removing/installing fly- wheel nut.
  • Page 116 Oil Seal Protector Tool Spring Tool p/n: 0644-219 p/n: 0644-072 Usage: Protect the oil seal when installing the water Usage: Remove/install exhaust springs. pump driveshaft on liquid cooled 2-stroke Arctic Cat engines. 0644-072 Stud Runner 0644-219 p/n: 0644-018 (6 mm)
  • Page 117 0644-535 p/n: 0444-213 (Complete Kit) Usage: Check crankshaft runout. p/n: 0444-207 (10 mm Adapter) p/n: 0444-093 (12 mm Adapter) Usage: Test cylinder compression on all Arctic Cat engines. 0644-535 Water Pump Bearing and Seal Tool Kit 0444-213 p/n: 0644-557...
  • Page 118 90° Hex Driver (1/4-in.) Drive Clutch Puller (Arctic) p/n: 0644-550 p/n: 0744-062 Usage: Make carburetor adjustments on all twin and tri- Usage: Remove drive clutch from the crankshaft on ple cylinder engines. Also, for any hard-to-get-at hex nuts. 2010-2012 models. (A.
  • Page 119 Drive Clutch Bolt Tool (Torx #60) Track Clip Installation Tool p/n: 0644-281 p/n: 0644-194 Usage: Remove/install drive clutch bolt. Usage: Install track clips on Camoplast and Yokohama rubber tracks. 0644-281 0644-194 Driven Clutch Compressor Tool p/n: 0644-444 Track Stud Hole Drill (7 mm) p/n: 0643-095 (A.
  • Page 120 Idler Wheel Puller Kit Gas Shock Retaining Blocks (Zero Pro) p/n: 0644-570 (Complete Kit) p/n: 0644-486 p/n: 0644-401 (A. Handle) Usage: Hold shock secure during disassembly and assembly. p/n: 0644-111 (B. Insertion Tool - 1.000 in.) p/n: 0644-569 (B. Insertion Tool - 1.560 in.) p/n: 0644-120 (C.
  • Page 121 Inflation Needle Replacement Piston Location Tool p/n: 0644-544 p/n: 0644-169 Usage: Replacement needle assembly for Inflation Nee- Usage: Precisely locate the floating piston in the rebuild- dle (p/n 0744-020). able gas shock absorber. 0644-169 0644-544 Piston Location (IFP) Tool Inflation Needle Replacement Tip p/n: 0644-575 p/n: 0644-539 Usage: Precisely locate the floating piston (IFP) in the...
  • Page 122 Axle Nut Spanner Wrench Insert Holder (5/16 in.) p/n: 0644-558 p/n: 0644-315 Usage: Adjust track alignment/tension (2010-2012 Sno Usage: With Torx Bit Insert (p/n 0644-314), remove and Pro 500 and Sno Pro 600). install torx-head screws. 0644-558 0644-315 Rear Suspension Spring Tool Phillips-Head Bits (1/4 in.
  • Page 123 Replacement Rivnuts Rivnut Tool Insert Bit p/n: 0623-557 (1/4 x 20) p/n: 0644-233 (1/4 x 20) p/n: 0623-582/627 (1/4 x 20) p/n: 0644-405 (10-32) p/n: 0623-581 (5/16 x 18) p/n: 0644-430 (5/16 x 18) p/n: 0623-699 (3/8 x 16) p/n: 0644-431 (3/8 x 16) p/n: 0623-874 (8-32) Usage: With Rivnut Tool (p/n 0644-232) and Replace- ment Rivnuts, replace rivnuts.
  • Page 124 T Wrench Torx Bits (1/4 in. Hex Drive) p/n: 0644-021 p/n: 0644-312 (#25) Usage: Drive 3/8 in. square-drive sockets. p/n: 0644-393 (#27) p/n: 0644-215 (#30) p/n: 0644-313 (#40) Usage: With Quick-Disconnect Coupler (p/n 0644-308), remove and install torx-head screws. 0644-021 Torx Bit Insert (5/16 in.

  • Page 125: Declaration Of Conformity

    Declaration of Conformity Application of council directives: EMC Directive 2004/108/EC Issued by European Commission. EC Machinery Directive 2006/42/EC Type of Equipment: Snowmobile Brand Name: Arctic Cat Model Numbers: S2015ACDPRUSG Standards to which conformity is declared: EMC: EN 55012, EN 61000-6-2...
  • Page 126 Printed in U.S.A. Trademarks of Arctic Cat Inc. Thief River Falls, MN 56701 p/n 2260-442 ®TM Phone: (218) 681-9851 - U.S. (204) 982-1656 - Canada...

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