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Arctic Cat Manuals
Toy
M4000
Service manual
Arctic Cat M4000 Service Manual
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Table of Contents
General Information/Foreword
Snowmobile Identification
Recommended Gasoline and Oil
Engine Break-In
Drive Belt Break-In
Genuine Parts
Varying Altitude Operation
Preparation for Storage
Preparation after Storage
After Break-In Checkup/Checklist
Engine Specifications
Crankshaft Runout/Repair Specifications
Arctic Power Valve (APV) System Specifications
Electrical Specifications
Drive Clutch/Driven Clutch-Related Specifications
Drive System Specifications
Drive System Components
Chain Case Performance Calibrations
Track Specifications
Suspension Specifications
Torque Conversions
Torque Specifications
Steering and Body
Steering Post (ZR/XF)
Steering Post (XF HC)
Steering Post (M)
Ski (ZR/XF)
Ski (XF HC/M)
Ski Wear Bar
Spindle (ZR/XF)
Spindle (XF HC/M)
Steering Tie Rod
Ski Alignment
A-Arms (ZR/XF)
A-Arms (XF HC/M)
Ski Shock Absorber
Sway Bar (ZR/XF)
Front Bumper
Seat Assembly (ZR/XF/M STD)
Seat Assembly (M Sno Pro/Hcr/Ltd)
Taillight/Brakelight Assembly
Rear Bumper/Snowflap
Windshield/Console/Headlight
Headlight Bulb
Adjusting Headlight Aim
Engine
Engine Removing/Installing - 4000
Assembly Schematic - 4000
Engine Removing/Installing - 6000
Assembly Schematic - 6000
Engine Removing/Installing - 8000
Assembly Schematic - 8000
Engine Servicing - 4000
Engine Servicing - 6000
Engine Servicing - 8000
Troubleshooting Engine
Engine-Related Items
Water Pump - 4000
Water Pump - 6000
Water Pump - 8000
Pressure Testing Engine
Liquid Cooling System
Cooling System Schematic
Recoil Starter
Arctic Power Valve (APV) System
Exhaust Controlled Timing (ECT) System
Fuel Systems
EFI System
Individual Components
Self-Diagnostic System/Codes (4000)
Self-Diagnostic System/Codes (6000)
Self-Diagnostic System/Codes (8000)
Fuel Pressure Regulator
Throttle Body Assembly
Throttle Cable
Fuel Filter (6000)
Fuel Pump
Troubleshooting
Oil-Injection Pump (4000/8000)
Electric Oil Pump (6000)
Gas Tank
Electrical Systems
Ignition System
Throttle Position Sensor
Electrical Resistance Tests
Testing Electric Oil Pump (6000)
Testing Voltage Regulator
Chassis Control Unit (Ccu)/Codes (4000)
Testing Oil Level Sensor
Testing Fuel Gauge Sender
Emergency Stop Switch
Starter Relay Solenoid
Fuse
Ignition Switch
Starter Motor
Troubleshooting Electric Start
Ignition Timing
Brakelight Switch
Headlight Dimmer Switch
Testing Handlebar Warmer Elements
Testing Thumb Warmer Element
Testing Handlebar Warmer/Thumb Warmer Switch
Testing Speedometer Sensor
Testing Shift Switch
Testing Servomotor/Potentiometer
Troubleshooting Servomotor
Voltage/Resistance Chart - Air Temperature (8000)
Voltage/Resistance Chart - Air Temperature (6000)
Voltage/Resistance Chart - Coolant Temperature
Drive Train/Track/Brake Systems
Drive Belt
Drive Clutch
Driven Clutch
Drive Clutch/Driven Clutch
Drive Train
Installing Chain Case
Driven Shaft/Driveshaft/Track (4000)
Drive Sprockets
Track Tension
Track Alignment
Brake System
Brake Lever/Master Cylinder Assembly
Troubleshooting Hydraulic Brake System
Troubleshooting Track
Troubleshooting Drive Clutch/Driven Clutch
Suspension
Suspension Setup Basics
Servicing Suspension
FOX Air Shocks
Servicing IFP Shock
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Table of Contents
Troubleshooting
Troubleshooting Engine
105
Troubleshooting
133
Troubleshooting Electric Start
150
Troubleshooting Servomotor
155
Troubleshooting Hydraulic Brake System
186
Troubleshooting Drive Clutch/Driven Clutch
187
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Summarization of Contents
General Information and Foreword
Recommended Gasoline and Oil
Specifies the correct gasoline octane and Arctic Cat approved oil for 4000/8000 and 6000 models.
Engine Break-In Procedures
Drive Belt Break-In
Details the break-in procedure for new drive belts to ensure proper flexibility and life.
Engine Specifications and Data
Crankshaft Runout and Repair Specifications
Provides specifications for checking crankshaft runout at various points and acceptable limits.
Drive System Specifications
Chain Case Performance Calibrations
Details chain case performance calibrations for various models and speeds.
Torque Specifications for Key Components
Drive System Torque Specifications
Lists torque specifications for drive system components like clutch and brake caliper.
Steering and Body Component Service
Steering Post (ZR/XF) Removal and Installation
Step-by-step instructions for removing and installing the steering post on ZR/XF models.
Ski Service Procedures
Ski Installation (ZR/XF)
Guides for installing the ski onto the spindle, including damper and spacer orientation.
Engine Removal and Installation
Engine Removal and Installation - 4000 Models
Detailed procedure for removing and installing the 4000 engine, including special tools.
Engine Troubleshooting Guide
Problem: Engine Does Not Start (No Spark)
Troubleshooting steps for engine no-start conditions related to lack of spark.
Fuel System Service and Components
Fuel Injector Service and Specifications
Details on fuel injector function, coding, and replacement procedures.
Electrical System Testing and Service
Throttle Position Sensor (TPS) Testing and Adjustment
Procedures for checking and adjusting the TPS for proper engine operation and fuel mixture.
Drive Train, Track, and Brake System Service
Drive Belt Inspection and Installation
Covers inspection, removal, and installation of the drive belt for optimal performance.
Drive Clutch Component Service
Procedures for disassembling, cleaning, inspecting, and assembling the drive clutch.
Suspension System Setup and Adjustment
Suspension Setup Basics
Explains suspension functions like weight transfer, track tension, and spring tension.
Adjusting Ski Shocks (Fox Float)
Guides for adjusting air pressure in Fox Float ski shocks for terrain and riding style.
Troubleshooting Hydraulic Brake System Issues
Problem: Caliper Leaks
Diagnosing and resolving issues related to caliper leaks and O-ring damage.
Problem: Loss of Brake
Troubleshooting steps for brake failure due to fluid issues or component damage.
Troubleshooting Drive Clutch and Driven Clutch
Problem: Midrange Shift-Up Too Quickly
Addresses issues where the clutch shifts too fast, resulting in lower RPM.
Servicing the Suspension System
Removing the Skid Frame
Procedure for removing the skid frame from the snowmobile chassis.
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