Arctic Cat 2018 ZR 200 Service Manual
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Arctic Cat 2018 ZR 200 Service Manual

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  • Page 2: Table Of Contents

    2018 ZR 200 Service Manual Table of Contents General Information/Foreword.......... 2 Testing Idle Switch............37 Snowmobile Identification ..........2 Testing Handlebar Warmer Elements......37 Recommended Gasoline and Oil........3 Testing Handlebar Warmer Switch ......37 Break-In Procedure ............3 Testing Headlight Switch ..........38 Genuine Parts...............

  • Page 3: General Information/Foreword

    These numbers are required to complete warranty claims Arctic Cat Inc. properly. No warranty will be allowed by Arctic Cat Inc. if the engine serial number or VIN is removed or muti- © 2017 Arctic Cat Inc. Effective November 2017 lated in any way.

  • Page 4: Recommended Gasoline And Oil

    Oil break-in. After the 10-hour break-in period, the snowmo- bile may be taken to an authorized Arctic Cat Snowmo- bile dealer for a checkup and oil change at the discretion and expense of the snowmobile owner.

  • Page 5: Preparation After Storage

    Taking the snowmobile out of storage and correctly pre- paring it for operation will ensure many miles and hours 16.3 50.3 84.3 118.3 of trouble-free snowmobiling. Arctic Cat recommends 17.7 51.7 85.7 119.7 the following procedure to prepare the snowmobile: 1.

  • Page 6: Torque Specifications

    Torque Specifications  NOTE: Torque specifications have the following tol- erances: Torque (ft-lb) Tolerance 0-15 ±20% 16-39 ±15% ±10% Torque Item Secured to ft-lb DRIVE SYSTEM Drive Clutch Engine Driven Clutch Driven Shaft Brake Bracket Bearing Holder Chassis 60 in.-lb Drop Case Sprocket Driveshaft Drop Case...

  • Page 7: Engine Torque Diagram

    NOTE: Before engine assembly, ensure all threaded areas are clean to ensure an accurate torque value is achieved. = Torque control required = Lubricate with Arctic Cat 4-Stroke Engine Oil = Apply Loctite = Lubricate with Arctic Cat All-Temp Grease...

  • Page 8: Engine Specifications

    Engine Specifications Carburetor Specifications Engine Model Number 7DHJ Idle Fuel Adjuster Screw Main Jet Pilot Jet Float Height (Turns Out) Displacement 192 cc 37.5 0.63" No. of Cylinders Bore x Stroke 70 x 50 mm Compression Ratio 8.4:1 Cooling System Spark Plug (NGK) BPR4ES Spark Plug Gap...

  • Page 9: Engine

    This engine section has been organized into sub-sections showing a progression for the complete servicing of the Arctic Cat 200 cc engine. For consistency purposes, this section shows a complete and thorough progression; however, for efficiency it may be preferable to remove and disassemble only those components needing to be addressed and to service only those components.

  • Page 10: Disassembling

    ZR-161 ZR-125 9. Remove the screws securing the clutch guard; then 13. Using a flat-blade screwdriver, press the tabs on the remove the guard. lock washer covering the nuts securing the muffler to the engine. Remove the nuts and springs securing the muffler.
  • Page 11 IO063 IO068  NOTE: If the cylinder head will be replaced, the 2. Remove the spring and hose from the governor arm. carburetor studs may be removed by tightening the 3. Remove the throttle cable and retaining bracket from two nuts against each other; then using a wrench on the engine;...
  • Page 12 IO071 IO069B 10. Remove the lock nuts and rocker arm pivots securing 14. Using a flywheel puller, remove the flywheel. the rocker arms to the cylinder head. 11. Remove the push rods; then remove the push rod guide plate. IO074 15.
  • Page 13 19. Rotate the crankshaft until the connecting rod cap screws are accessible. IO094B IO080A 20. Note the relation of the connecting rod journal to the crankshaft and mark the connecting rod and end cap for reference during installation; then remove the cap screws and connecting rod end cap.

  • Page 14: Servicing Components

    NOTE: If the seals or bearings of the crankshaft  need to be replaced, see Crankshaft Bearings in Ser- vicing Components. Servicing Components Thoroughly clean all non-electrical components in parts- cleaning solvent; then remove any carbon buildup from the cylinder head, piston dome, valves, and valve seats. Visually inspect all engine components for wear or dam- age.
  • Page 15 Measuring Valve Guide/Valve Stem Valve Springs Clearance 1. When the valve springs are weak, the valve and valve seat fail to form a good seal, thus allowing gas 1. Using a micrometer and small bore gauge, take to leak past the valve seat causing a loss of power. diameter readings on the valve stems and inside the Whether or not a valve spring is weak can be deter- guides.
  • Page 16 Measuring Camshaft End Running Using a ring-groove cleaning tool, clean carbon from the ring-grooves. Be sure to position the ring with its tapered Surfaces side up. 1. Using an outside micrometer, measure the running surfaces of each end of the camshaft. The measure- CAUTION ment should be at least 0.592".
  • Page 17 Measuring Piston Skirt/Cylinder 3. Position the thin oil ring gaps 90° from the gap of the oil ring expander and 180° from each other. Clearance 4. Install the middle and top compression ring with the 1. Measure the cylinder front to back in six places using I.D.
  • Page 18 2. Inspect the spark plug hole for any damaged threads. 2. Inspect the cylinder for pitting, scoring, scuffing, and Repair damaged threads using a “heli-coil” insert. corrosion. If marks are found, repair the surface using the Ball Hone. 3. Place the cylinder head on the Surface Plate covered with #400 grit wet-or-dry sandpaper.
  • Page 19 GEN-0031 GEN-0038 3. If not within specification, either straighten the 3. Measure the crank pin/connecting rod clearance. crankshaft or replace it. Measurement must be within 0.0002-0.0008". MEASURING CONNECTING ROD BIG END SIDE CLEARANCE 1. Check the connecting rod side clearance by using a thickness gauge.

  • Page 20: Assembling

    Installing 1. Lubricate the piston pin, connecting rod, and piston pin bore with engine oil; then install the piston to the 1. Secure the crankcase and press the new bearing into connecting rod and secure the piston pin with the cir- the boss of the crankcase and crankcase cover.
  • Page 21 NOTE: When installing the connecting rod to the 7. Install the washer onto the governor control shaft and  slide the shaft up into position from inside the crank- crankshaft, rotate the crankshaft so the rod journal is case far enough to install the hairpin clip. in the 6 o’clock position to allow access for installing the rod end cap.
  • Page 22 IO077 IO107 9. Secure the crankcase side cover to the crankcase 13. Set the valve clearance to the recommended setting with the cap screws. Tighten to 16 ft-lb using the fol- with a feeler gauge, and while holding the adjust- lowing pattern.
  • Page 23 IO096A IO099 NOTE: Adjust spark plug gap to specification; then  21. Loosen the ignition coil mounting cap screws (from install and tighten the plug to 15 ft-lb. step 16) enough to allow the coil to draw against the feeler gauge. Tighten the cap screw enough to hold 17.

  • Page 24: Installing

    ZR-165 ONS-033  NOTE: When securing the governor control shaft (A), turn it clockwise until it stops; then tighten the control arm cap screw (B) to 72 in.-lb. ONS-034 2. Place the engine assembly into position in the engine compartment. ZR-163 3.
  • Page 25 13. Position the bearings on each side of the steering post; then secure the steering post to the chassis using the existing cap screws, retainer, and lock nuts. Tighten to 96 in.-lb. ONS-029 5. Position the engine alignment tool onto the crank- shaft and install over the driven shaft on the drop- case.
  • Page 26 ZR-144 ZR-164 19. Secure the air cleaner cover to the air cleaner with 16. Install the fuel supply hose on the carburetor using the screws. Tighten to 30-36 in.-lb. the clamp. ZR-168 ZR-143 17. Pull the choke cable knob out completely; then hold 20.

  • Page 27: Changing Oil

    22. Secure using the cap screw and washer. Tighten to 20 ft-lb. Recoil Starter CAUTION When installing the drive clutch, do not tighten the cap screw with any kind of impact tool. Tighten cap screw using a hand torque wrench only. Failure to do so could result in sheave damage.
  • Page 28 ASSEMBLING/INSTALLING 2. Install the ratchet arms; then install the drive plate and secure it with the shoulder screw. Tighten to 57 1. Install the reel assembly with rope wound in the in.-lb. appropriate direction (noted during disassembling). 3. Route the recoil rope through the rope guide of the recoil housing and through the recoil handle;...

  • Page 29: Troubleshooting Engine

    Troubleshooting Engine Problem: Engine Does Not Start (No Spark at Spark Plug) Condition Remedy 1. Ground connections dirty — loose 1. Check all ground connections — clean and tight 2. Wiring harness shorting — disconnected 2. Repair — replace — connect wiring harness 3.

  • Page 30: Fuel System

    Arctic Cat recommends that the in-line fuel filter be checked once a month. The filter is located in the fuel hose between the gas tank and fuel pump. The only cleaning possible is to back-flush the filter using clean gasoline.
  • Page 31 CLEANING CAUTION DO NOT place any non-metallic components in parts- cleaning solvent or carburetor cleaner because damage or deterioration will result. 1. Place all metallic components in a wire basket and submerge in carburetor cleaner. 2. Soak for approximately 30 minutes; then rinse with fresh parts-cleaning solvent.
  • Page 32 ASSEMBLING A739 8. Inspect the condition of the throttle return spring. CHECKING FLOAT HEIGHT 1. Remove the cap screw securing the float chamber; then remove the float chamber from the carburetor and account for the rubber gasket. 744-959A 1. Install the nozzle (H) and main jet (G) into the carbu- 2.
  • Page 33 3. Pull the choke cable knob out completely; then hold the butterfly closed in the carburetor. Tighten the set screw to 6 in.-lb. 744-921Y Throttle Stop Screw This screw controls the seating position of the throttle valve which in turn determines the proper idle speed. ZR-169 Rotate the screw clockwise to increase engine idle speed 4.

  • Page 34: Throttle Cable

    Throttle Cable REMOVING AND INSPECTING 1. Compress the throttle lever to the WOT position; then using a small pliers, remove the throttle cable from the lever. 2. Remove the C-clip securing the throttle cable to the control; then remove the throttle cable. 3.

  • Page 35: Troubleshooting Fuel System

    Troubleshooting Fuel System Problem: Carburetor Too Rich (0-1/4 Opening) Condition Remedy 1. Choke valve will not seat 1. Adjust — service — replace choke cable — assembly 2. Idle fuel adjuster screw out of adjustment 2. Adjust idle fuel adjuster screw 3.

  • Page 36: Electrical System

    The current flowing through the primary winding (2) is thus interrupted, and rapid change occurs in the magnetic Electrical System flux across the ignition coil. The result is a high surge voltage in the secondary winding (3). SPARK ADVANCE CHARACTERISTIC TESTING COMPONENTS As noted above, the unit circuit detects a voltage and Following are testing procedures for specific electrical...

  • Page 37: Testing Electrical Resistances

    2. At the main wiring harness engine connector, con- 3. Connect one tester lead to one end of the cap and the nect the red tester lead to the violet wire; then con- other tester lead to other end of the cap. nect the black tester lead to the engine ground (brown wire).

  • Page 38: Testing Rps Switch

    Testing RPS Switch Testing Handlebar Warmer Elements 1. Disconnect the RPS switch connector coming out from the rear throttle control housing; then connect NOTE: Resistance will vary due to temperature;  the ohmmeter leads to the yellow wire and black therefore, this test should be made at room tempera- wire.

  • Page 39: Testing Headlight Switch

    3. With the handwarmer toggle in the ON position, con- 3. With the headlight toggle in the LOW BEAM posi- nect one ohmmeter lead to pin and the other ohmme- tion, connect one ohmmeter lead to pin and the other ter lead to pin.

  • Page 40: Drive Train/Track/Brake Systems

    Drive Train/Track/Brake Systems This section has been organized into sub-sections for ser- vicing drive train, track, and brake systems; however, some components may vary from model to model. The technician should use discretion and sound judgment when removing and installing components. NOTE: Whenever a part is worn excessively, ...
  • Page 41 2. Remove the movable sheave from the stationary sheave; then remove the spring. ONS-036 NOTE: Available roller weight kits from Arctic Cat  3. Remove the movable sheave cover and the six roller are p/n 0646-987 (18g — Blue), p/n 0646-988 (14g —...

  • Page 42: Driven Clutch

    4. Install the drive belt. 5. Inspect spring for distortion, crystallization, or breaks. ! WARNING 6. Inspect the driven cam and movable sheave bearings Never operate the engine without the belt guard/access for wear. If wear is present, replace the bracket or sheave.

  • Page 43: Drive Clutch/Driven Clutch

    3. To move the driven clutch outward on the shaft, add alignment washers to the driven shaft. NOTE: Available shim washers from Arctic Cat are  p/n 0648-835 (0.039 in.) and (p/n 0648-836 (0.020 in.). 4. Arrange washers to obtain the correct offset; then install driven clutch and belt and secure using the cap screw and washer.
  • Page 44 ZR-155 ZR-149 4. Place the dropcase downward bracing only the case and not the lower pulley; then apply heat to the case around the lower pulley. 5. Using a suitable press or an adequate press tool, press the lower pulley from the bearing. ASSEMBLING NOTE: The bearings within the dropcase and the ...

  • Page 45: Track

    If the track is too loose, it may slap against the tunnel causing wear, or it may ratchet on the track drive sprockets. Arctic Cat recommends that the track tension be checked once a month and adjusted accordingly.
  • Page 46 Excessive wear to the idler wheels, drive lugs, and track will occur if the track is improperly aligned. Arctic Cat recommends that the track alignment be checked once a week or whenever the track tension is adjusted.

  • Page 47: Brake System

    SNO-949 ZR-157 2. Check track alignment and continue adjustment until 3. Remove the two screws securing the brake caliper proper alignment is obtained. assembly  NOTE: Make sure correct track tension is main- tained after adjusting track alignment (see TRACK TENSION section).
  • Page 48 4. Squeeze the brake lever. This will center the caliper on the disc. Tighten the cap screws (threads coated with blue Loctite #243) to 80 in-lb. Release the brake lever and verify that the caliper is centered over the disc. If the caliper is not centered, adjust the mount- ing location as needed.
  • Page 49 1. Open the hood; remove the four screws securing the console/seat assembly and slide the console/seat rearward and out of the way. 2. Remove the pin securing the brake pads; then remove the pads. Account for the brake pad clip. ZR-102 ...

  • Page 50: Troubleshooting Track

    11. With the master cylinder still in the downward posi- tion, apply light pressure to the syringe before removing the syringe from the fitting. Remove the bleed fitting. Quickly replace the bleed port screw. Tighten to 12 in.-lb. Clean any excess brake fluid from the caliper using isopropyl alcohol.

  • Page 51: Rear Suspension

    This section has been organized so each procedure can be completed individually and efficiently. The technician Rear Suspension should use discretion and sound judgment when remov- ing and installing components. GENERAL INFORMATION Removing Skid Frame Quick acceleration and the ability to go through the turns with power are the most important handling qualities.

  • Page 52: Wear Strip

    3. Clean both the slide rail area and the end cap. Using 4. Place the straightedge along the side of the slide rail. compressed air, clean the areas of dirt and gravel. If rail is found to be bent, it must be replaced. INSTALLING ! WARNING NOTE: Use a file to remove any sharp edges on the...

  • Page 53: Rear Idler Wheels And Axle

    INSPECTING Rear Idler Wheels and Axle 1. Inspect all rear arm weldments for cracks or unusual bends. 2. Inspect all tubing for cracks or unusual bends. 3. Inspect the axles for wear or damage. 4. Inspect the upper and lower bearings for wear or damage.

  • Page 54: Slide Rail

    Slide Rail SNO-974 3. Remove the cap screw securing the rear suspension arm to the support bracket. 4. Remove the cap screws and lock nuts securing the 744-844A rear suspension arm support bracket. SNO-994 REMOVING SNO-975 NOTE: When replacing one or both slide rails is 5.

  • Page 55: Installing Skid Frame

    2. Inspect the wear strip for wear. The wear strip must be 0.42'' thick or thicker. If the wear strip measure- ment is less than specified, replacement of both wear strips is necessary. INSTALLING 1. Install the rear axle housing and adjuster bushing; then secure with cap screws and lock nuts.

  • Page 56: Steering And Body

    Steering and Body Steering Post REMOVING 1. Remove the handlebar pad. 2. Remove the screw securing the emergency stop ONS-024 switch to the handlebar; then remove the switch. 8. Cut the cable ties securing the cables to the steering post. 9.
  • Page 57 NOTE: Use additional wrench to keep tie rod end 3. Place the upper steering post bearings into position  on the steering post and secure the steering post/ shaft from turning while removing the tie rod lock bearing assembly to the support with the bearing nut.

  • Page 58: Ski

    INSPECTING bar will wear faster. Arctic Cat recommends that the ski 1. Inspect the ski for cracks or deterioration. wear bars be checked once a week and replaced if worn to 1/2 of original diameter.

  • Page 59: Spindle

    3. Secure the outer tie rod to the spindle with a washer and new lock nut (coated with blue Loctite #243). Tighten to 15 ft-lb. ZR-116 2. Open the hood; then remove the tie rod from the steering post. ZR-116 4.

  • Page 60: Ski Alignment

    NOTE: The spindle should not be disassembled. It 4. Measure the distance from the straightedge to the  left-side ski wear bar bolts in two places: approxi- will only be sold as an assembly. mately 18-20 cm (7-8 in.) in front of the spindle and INSTALLING 18-20 cm (7-8 in.) behind the spindle.

  • Page 61: Front Suspension A-Arms

    NOTE: Repeat this procedure on each side (if neces- 2. Remove the cap screws and lock nuts securing the  shock to the chassis bracket and the lower A-arm; sary) until ski toe-out is within specification. then remove the shock. Account for the upper shock VERIFYING bushing.

  • Page 62: Belly Pan

    SNO-983 SNO-985 INSPECTING 4. Secure the belly pan to the chassis using new rivets; then secure the tie-rod boots to the chassis using new 1. Inspect the A-arm welded areas for cracks or any rivets. signs of deterioration. 2. Inspect the axles for wear or damage. 3.

  • Page 63: Seat Assembly

    ONS-022 CAUTION When removing the rear portion of the seat base from SNO-986 the tunnel, use caution not to break the tabs on the bot- NOTE: The tie rod boots do not need to be removed.  tom of the seat base. 5.

  • Page 64: Gas Tank/Fuel Pump Assembly

    ONS-023 ONS-021 3. Place the seat assembly into position over the gas WARNING tank and connect the taillight wiring harness. Since the gas hose may be under pressure, remove it slowly to release the pressure. Place an absorbent towel CAUTION around the connection to absorb gasoline;...

  • Page 65: Headlight Assembly

    8. Secure the front of the seat base using the existing hardware. Tighten securely. 9. Install the gas cap; then close and latch the hood. Headlight Assembly REMOVING  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.

  • Page 66: Wiring Diagram

    Wiring Diagram 0752-220...
  • Page 67 NOTES...
  • Page 68 NOTES...
  • Page 69 NOTES...

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