Arctic Cat Sno Pro 120 2013 Service Manual
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Arctic Cat Sno Pro 120 2013 Service Manual

Arctic Cat Sno Pro 120 2013 Service Manual

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Sno Pro 120
M D
PARTAGEZ NOTRE PASSION.

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Summary of Contents for Arctic Cat Sno Pro 120 2013

  • Page 1 Sno Pro 120 PARTAGEZ NOTRE PASSION.
  • Page 2 FOREWORD This Arctic Cat Service Manual contains service and maintenance information for the Model Year 2013 Arctic Cat Sno Pro 120 Snowmobile. The manual is designed to aid service personnel in service-oriented applications. This manual is divided into sections. The sections cover specific snowmobile components or systems and, in addition to the standard service procedures, includes assembling, disassembling, and inspecting instructions.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS General Information ........... 2 Troubleshooting Fuel System ......32 Snowmobile Identification........2 Electrical System............33 Recommended Gasoline and Oil ....... 2 Transistorized Ignition System......33 Break-In Procedure ..........3 Testing Ignition Switches ........34 Genuine Parts ............ 3 Testing Electrical Resistances ......

  • Page 5: General Information

    A number of special tools must be available to the techni- These numbers are required to complete warranty claims cian when servicing this snowmobile. properly. No warranty will be allowed by Arctic Cat Inc. if the engine serial number or VIN is removed or muti- Description lated in any way.

  • Page 6: Break-In Procedure

    After the 10 hour break-in period, the snowmo- bile may be taken to an authorized Arctic Cat Snowmo- B. Pour 10 ml (approximately two teaspoons) of bile dealer for a checkup and oil change at the discretion petroleum-based oil into the spark plug hole;...

  • Page 7: Preparation After Storage

    114.2 paring it for operation will assure many miles and hours 13.6 47.6 81.6 115.6 of trouble-free snowmobiling. Arctic Cat recommends the following procedure to prepare the snowmobile. 16.3 50.3 84.3 118.3 1. Clean the snowmobile thoroughly. Polish the exte- 17.7...

  • Page 8: Engine Torque Diagram

    NOTE: Before engine assembly, ensure all threaded areas are clean to assure an accurate torque value is achieved. Torque values have a range of ± 20%. = Torque control required = Lubricate with Arctic Cat 4-Stroke Engine Oil = Apply Loctite = Lubricate with Arctic Cat All-Temp Grease 120-ENG10...

  • Page 9: Engine Specifications

    Engine Specifications Carburetor Specifications Engine Model Number 70CL1-030 Displacement 123 cc Idle Fuel Adjuster Screw Main Jet Pilot Jet Float Height (Turns Out) No. of Cylinders Bore x Stroke 56 x 50 mm 77.5 37.5 0.63" Cooling System Spark Plug (NGK) BPR4ES Track Specifications Spark Plug Gap...

  • Page 10: Engine

    This engine section has been organized into sub-sections showing a progression for the complete servicing of the Arctic Cat 120 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 11: Disassembling

    9. At this point, scribe a line at the front of the engine 13. Remove the engine from the engine compartment. and measure the distance between the crankshaft and the driveshaft. Record the measurement for Disassembling installing purposes. 1. Remove the oil drain plug and drain the oil; then install the oil plug and tighten securely.
  • Page 12 4. Remove the two springs from the governor arm, throttle cable bracket, and retaining bracket. IO068  NOTE: If the cylinder head will be replaced, the carbu- retor studs may be removed by tightening the two nuts IO065A against each other; then using a wrench on the inside ...
  • Page 13 IO071 IO069B 12. Remove the lock nuts and rocker arm pivots secur- 16. Using a flywheel puller, remove the flywheel. ing the rocker arms to the cylinder head. 13. Remove the push rods; then remove the push rod guide plate. IO074 17.
  • Page 14 21. Rotate the crankshaft until the connecting rod cap screws are accessible. IO094B IO080A 22. 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 15: Servicing Components

     NOTE: If the seals or bearings of the crankshaft need to be replaced, see Crankshaft Bearings in Servicing 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 damage.
  • Page 16 Measuring Valve Guide/Valve Stem 5. Rotate the valve until the valve and seat are evenly polished. Clearance 1. Using a micrometer and small bore gauge, take 6. Clean all compound residue from the valve and diameter readings on the valve stems and inside seat.
  • Page 17 Removing Piston Rings 1. Starting with the top ring, slide one end of the ring out of the ring-groove. 2. Remove each ring by working it toward the dome of the piston while rotating it out of the groove.  NOTE: Note the location of each ring for proper instal- lation.
  • Page 18 3. Piston skirt to cylinder clearance must be within 0.0006-0.0016". 4. If the piston/cylinder clearance exceeds the limit, bore the cylinder and use an oversized piston or replace both cylinder and piston. Installing Piston Rings 1. Place the oil ring expander into the bottom groove of the piston allowing the ends to contact each other.
  • Page 19 ATV-1069 IO087 4. Inspect the cylinder for pitting, scoring, scuffing, CYLINDER/CYLINDER HEAD warpage, and corrosion. If marks are found, repair  NOTE: If the cylinder/cylinder head assembly cannot the surface using the Ball Hone (see Honing Cyl- inder sub-section). be trued, they must be replaced. 5.
  • Page 20 MEASURING CONNECTING ROD BIG END SIDE CLEARANCE 1. Check the connecting rod side clearance by using a thickness gauge. If the clearance exceeds the limit, replace the connecting rod or crankshaft. 2. Clearance measurement must be within 0.008- 0.024". GEN-0034 3.

  • Page 21: Assembling

    CARBURETOR INSULATOR PLATE 1. Inspect for cracks, scoring, pitting, imperfections, or warping. 2. Inspect the sealing surfaces for trueness by placing each on the surface plate covered with #400 grit wet-or-dry sandpaper. Using light pressure, move both sides in a figure eight motion. Inspect the sealing surfaces for any indication of high spots or warping.
  • Page 22 4. With the connecting rod, end cap, and crankshaft journal lubricated with engine oil, install the con- necting rod and rod end cap to the crankshaft and secure with the cap screws. Tighten evenly to 106 in.-lb. IO091A  NOTE: Coat the cylinder wall, connecting rod bearing surface, and the crankshaft with engine oil.
  • Page 23 IO101 IO077 9. Secure the crankcase side cover to the crankcase  NOTE: When installing the governor control shaft, with the cap screws. Tighten to 16 ft-lb using the position the shaft so the flat end (A) of the shaft is following pattern.
  • Page 24 IO107 IO096A 13. Set the valve clearance to the recommended set-  NOTE: Adjust spark plug gap to specification; then ting with a feeler gauge, and while holding the install and tighten the plug to 15 ft-lb. adjustment nut, tighten the rocker arm lock nuts to 88 in.-lb.
  • Page 25 20. Rotate the flywheel until the magnet of the fly- wheel is under the legs of the ignition coil; then insert a flat 0.020" feeler gauge between the lower leg of the coil and the flywheel. IO102A ! WARNING When performing service work on the fuel system, do not smoke or allow open flames near the snowmobile.

  • Page 26: Installing

    IO104 IO062A 27. With a gasket in place on the intake tube, install 3. Align the engine with the scribed line made during the air cleaner case, and with gasket, insulator removing; then measure the distance between the plate, and cap screws, secure the case to the intake crankshaft and the driveshaft.

  • Page 27: Troubleshooting Engine

     NOTE: At this point, install the drive chain (see Drive Chain and Sprockets section). 13. Install the choke cable into the bracket and carbu- retor butterfly arm. Adjust the cable and secure with the jam nuts and pinch screw. IO060A 12.
  • Page 28 Problem: Engine Does Not Start (Fuel Does Not Ignite) Condition Remedy 1. Valve clearance poor 1. Inspect valves 2. Spark absent 2. Check for spark — see No Spark at Spark Plug sub-section 3. Compression low 3. Service engine 4. Engine flooded 4.

  • Page 29: Changing Oil

     NOTE: The engine must be removed to access the Changing Oil recoil starter (see Engine section). REMOVING/DISASSEMBLING  NOTE: The front of the snowmobile must be elevated ! WARNING until the bottom of the front bumper is approximately Always wear safety glasses when servicing the recoil 18.5"...

  • Page 30: Fuel System

    REMOVING Fuel System  NOTE: Before removing the carburetor, be sure the gas tank shut-off valve is in the OFF position. This section has been organized for servicing the fuel 1. Remove the screws securing the air cleaner cover system. The technician should use discretion and sound to the air cleaner case and account for the filter and judgment when removing/disassembling and assembling/ retaining plate.
  • Page 31 4. Remove the float pin (D) securing the float (E) to 7. Place the carburetor insulator on a surface plate the carburetor body; then remove the float and covered with #400 grit wet-or-dry sandpaper. needle jet assembly (F). Move the insulator over the surface plate using a figure eight motion.
  • Page 32 ASSEMBLING 2. Install the choke cable and secure the cable with the jam nuts and pinch screw. 3. Install the fuel supply hose on the carburetor. 4. Place the gasket and air cleaner assembly into position on the carburetor; then secure with the flanged nuts and cap screw.

  • Page 33: Throttle Cable

    Speed Control Screw IO110B Throttle Cable 0744-949 The maximum speed of the snowmobile can be reduced The correct throttle cable adjustment is when (with the by adjusting the speed control screw. engine OFF) the carburetor throttle is completely open (against its limit) while the throttle lever lightly contacts To reduce the maximum speed, rotate the speed control the handlebar grip.
  • Page 34 3. Remove the C-clip securing the cable in the throt- 6. Inspect the throttle cable for damage or fraying. tle control; then remove the cable from the throttle INSTALLING control. 1. Route the cable through the slot in the throttle con- trol and insert the cable into the throttle control.

  • 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

    As the flywheel turns faster, the primary current Electrical System increases, and the terminal voltage of the circuit consist- ing of the resistor (R) and the transistor (TR1) increases. This increases the working voltage at the connection of the series circuit (r1 + r2) connected in parallel to the pri- TESTING COMPONENTS mary circuit.

  • Page 37: Testing Ignition Switches

    D. Defective tether 3. Connect one tester lead to one end of the cap and the other tester lead to other end of the cap. Testing Ignition Switches 1. Disconnect the engine wires from the main wiring harness. 2. At the main wiring harness engine connector, connect the red tester lead to the violet wire;...

  • Page 38: Drive Chain And Sprockets

    Drive Chain and Sprockets REMOVING 1. Remove the self-tapping screws securing the front clutch shield and rear sprocket cover; then remove from the engine compartment. Note the position of the hood cable.  NOTE: It will be necessary to reinstall the hood cable once the guard is removed.

  • Page 39: Track And Driveshaft

    4. Inspect the keyways in the driveshaft, chain 4. Compress and hold the brake lever; then install the sprocket, and clutch for wear or damage. cap screw (coated with red Loctite #271) and washer securing the chain sprocket. Tighten the 5.
  • Page 40 4. Remove the cap screws securing the upper idler 3. Inspect the track for cuts, gouges, or wear. wheel assembly to the tunnel; then remove the 4. Inspect the keyways in the driveshaft and in the assembly from the tunnel. chain sprocket for wear or damage.
  • Page 41 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 0744-947 track tension be checked once a month and adjusted accordingly.
  • Page 42 Excessive wear to the idler wheels, drive lugs, and track 5. If the distances from the rear idler wheels to the will occur if the track is improperly aligned. Arctic Cat inner track drive lugs are not the same on both recommends that the track alignment be checked once a sides, an adjustment is necessary.

  • Page 43: Brake System

    Brake System REMOVING AND INSPECTING A998 6. Disconnect the brake cable from the lever; then slide the brake cable out of the lever. 1. Lock Nut 8. Washer 15. Retainer Pin 2. Bushing 9. Cap Screw 16. Washer 3. Rivet 10.
  • Page 44 6. Secure the brake cable to the steering post with a cable tie; then install the handlebar pad. 7. Install the hood cable and the front clutch shield. CHECKING BRAKE LEVER TRAVEL 1. Compress the brake lever fully. 2. Check the distance between the brake lever and the lever stop.

  • Page 45: Troubleshooting Track

    Troubleshooting Track Problem: Track Edge Frayed — Drive Lugs Worn Condition Remedy 1. Track alignment adjusted incorrectly 1. Align — replace track Problem: Track Worn Adjacent to Outer Drive Lugs Condition Remedy 1. Track tension adjusted incorrectly 1. Adjust track tension 2.

  • Page 46: Rear Suspension

    This is essentially what weight transfer is all about — the Rear Suspension shift of weight to the rear of the machine for positive traction and good acceleration or to the front of the machine for positive handling and cornering control. GENERAL INFORMATION REAR ARM SPRING TENSION Quick acceleration and the ability to go through the turns...

  • Page 47: End Cap

    INSTALLING 1. Position the end cap on the slide rail; then align the hole in the end cap with the hole in the slide rail. 2. Secure with a cap screws, washers, and new lock nut. Tighten to 78 in.-lb. Wear Strip ...

  • Page 48: Rear Suspension Arm/Rear Springs

    2. Using a pipe wrench and starting from either end, hook the edge of the wear strip with the pipe wrench jaw and twist the wear strip off the slide rail. Move the pipe wrench 3" and again twist the wear strip off the rail.

  • Page 49: Rear Idler Wheels And Axle

    ASSEMBLING 6. Inspect the springs for excessive wear, cracks, or imperfections. 1. In order, slide the axle through the rear axle hous- ing; then place a spacer on the axle. Slide the axle ASSEMBLING through the opposite axle housing. 1. Apply a light coat of grease to the axles and the bushing areas.

  • Page 50: Slide Rail

    Slide Rail  NOTE: The skid frame must be removed for this pro- cedure (see Removing Skid Frame sub-section). AO160 3. Remove the cap screw securing the rear suspen- sion arm to the support bracket. 4. Remove the cap screws and lock nuts securing the rear suspension arm support bracket.

  • Page 51: Installing Skid Frame

    1. Inspect the slide rail for cracks or unusual bends. 2. Inspect the wear strip for wear. The wear strip must be 0.42'' thick or thicker. If the wear strip measurement is less than specified, replacement of both wear strips is necessary. AO159 5.

  • Page 52: Steering And Body

    3. Position the front of the skid frame into the tunnel and align the front axle with the appropriate mounting holes in the tunnel. Secure the axle to the tunnel with the cap screws (coated with blue Loctite #243). Thread the cap screws in only half way.
  • Page 53  NOTE: Use an additional wrench to keep the tie rod end shaft from turning while removing the tie rod lock nut. 12. Remove the steering post from the engine com- partment. 13. Remove the two cap screws and lock nuts securing the lower steering post bearing retainer;...
  • Page 54  NOTE: Use an additional wrench to keep the tie rod 8. Route the throttle cable through the slot in the throttle control and insert the cable end into the end shaft from turning while tightening the tie rod lock throttle control.

  • Page 55: Ski

    A979 bar will wear faster. Arctic Cat recommends that the ski wear bars be checked once a week and replaced if worn to 1/2 of original diameter.

  • Page 56: Spindle

    2. Remove the tie rod from the steering post (see 5. Lock the jam nuts against the tie rod; then adjust steps 9-12 of Steering Post - Removing sub-sec- ski alignment (see Ski Alignment sub-section). tion). ! WARNING 3. Loosen the jam nuts securing the tie rod; then Neglecting to lock the jam nuts against the tie rod may remove the ball joints from the tie rod.

  • Page 57: Ski Alignment

    IO119B ZJ296A 6. Inspect the tie-rod ball joint in place. If damage, 3. Place the lower shock eyelet w/shock bushings wear, or unusual bends are noted, loosen the jam into the shock mounting bracket. Secure with the nut; then remove the ball joint from the tie rod. cap screw and lock nut.

  • Page 58: Front Suspension A-Arms

     NOTE: Ski alignment is correct when the skis are par- allel to each other (equal measurements front and rear) or when the skis have up to a maximum of 1/4" toe out (front measurement 1/4" more than rear measurement). 3.

  • Page 59: Front Suspension (Ski) Shock Absorber

    1. Slide the A-arms onto the cap screws and swing them up into position on the front end; then secure with lock nuts. Tighten to 30 ft-lb. 2. Install the spindle (see Spindle sub-section). Front Suspension (Ski) Shock Absorber REMOVING 1.

  • Page 60: Seat/Cushion/Taillight Housing

    2. Inspect the two belly pan threaded bosses and 4. Pull the recoil starter rope out approximately 24"; ensure they are in good shape. then tie a slip-knot in the starter rope below the console and allow the rope to slowly retract INSTALLING against the starter case.

  • Page 61: Headlight Assembly

    INSTALLING 1. Peel back the rubber headlight socket cap; then push in and turn the headlight socket counterclock-  NOTE: If the seat cover was removed, position the wise and remove it from the headlight housing. cover over the seat foam and plastic seat base. Check 2.

  • Page 62: Wiring Diagram

    Wiring Diagram 0744-204...
  • Page 63 NOTES...
  • Page 64 Printed in U.S.A. Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701 p/n 2259-514 ®™...

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