Arctic Cat ZR 120 Service Manual
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Arctic Cat ZR 120 Service Manual

Arctic cat 2014 snowmobile service manual
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2014
SERVICE MANUAL
[SNOWMOBILE]

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Bill goldstone
February 5, 2025

Is the ignition shut off by closing a ground or opening a ground

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1 comments:
Mr. Anderson
February 10, 2025

The ignition on the Arctic Cat ZR 120 shuts off by closing a ground. The troubleshooting section mentions inserting an auxiliary ground wire into the black wire of the main harness connector and touching it to the engine to stop the engine, indicating that grounding shuts off the ignition.

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Summary of Contents for Arctic Cat ZR 120

  • Page 1 2014 SERVICE MANUAL [SNOWMOBILE]...
  • Page 2 FOREWORD This Arctic Cat Service Manual contains service and maintenance information for the 2014 Arctic Cat ZR 120 Snowmo- bile. 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 ..........2 Testing Ignition Switches ........34 Genuine Parts ............ 3 Testing Electrical Resistances ......

  • Page 5: General Information

    These numbers are required to complete warranty claims General Information properly. No warranty will be allowed by Arctic Cat Inc. if the engine serial number or VIN is removed or muti- lated in any way.  NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary.

  • Page 6: Genuine Parts

    After the 10 hour break-in period, the snowmo- petroleum-based oil into the spark plug hole; then bile may be taken to an authorized Arctic Cat Snowmo- pull the recoil starter handle slowly about five bile dealer for a checkup and oil change at the discretion times.

  • Page 7: Torque Conversions (Ft-Lb/N-M)

    3. Check all control wires and cables for signs of Torque Specifications wear or fraying. Replace if necessary. Use cable ties or tape to route wires and cables away from hot or rotating parts. Torque 4. Inspect the drive chain and drive chain tightener. Item ft-lb Replace if necessary.

  • 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 Clearance polished. 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.

  • Page 20: Crankshaft Runout

    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: Changing Oil

    Changing Oil  NOTE: The front of the snowmobile must be elevated until the bottom of the front bumper is approximately 18.5" from the floor so the engine is in a level position when checking/changing the oil. Also, assure the engine is “cooled down”...
  • Page 28 INSPECTING  NOTE: The engine must be removed to access the recoil starter (see Engine section). 1. Inspect the spring retaining notch in the recoil housing and inspect the loop of the spring for wear REMOVING/DISASSEMBLING or cracking. ! WARNING ...

  • 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

    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

    5. Inspect the chain and chain sprocket for wear or 4. Compress and hold the brake lever; then install the damage. cap screw (coated with red Loctite #271) and washer securing the chain sprocket. Tighten the 6. Inspect the driveshaft sprockets for wear or damage. cap screw to 20 ft-lb;...
  • Page 40 4. Remove the cap screws securing the upper idler 4. Inspect the keyways in the driveshaft and in the wheel assembly to the tunnel; then remove the chain sprocket for wear or damage. assembly from the tunnel. 5. Inspect the chain and chain sprocket for damage or wear.

  • Page 41: Track Tension

    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: Track Alignment

    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: Checking Brake Lever Travel

    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 section has been organized so each procedure can be Rear Suspension completed individually and efficiently. The technician 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 47: End Cap

    End Cap REMOVING 1. Remove the lock nut, washers, and cap screw securing the end cap. 0743-189  NOTE: A wear strip can be removed and installed without removing the skid frame. To do this, remove the machine screw and lock nut securing the wear strip at the front of the slide rail;...

  • Page 48: Rear Suspension Arm/Rear Springs

    3. Using a straightedge, inspect the slide rail for any unusual bends. Place the straightedge along the bottom surface of the slide rail. If the rail is found to be bent, it must be replaced. 4. Place the straightedge along the side of the slide rail.

  • Page 49: Upper Idler Wheels

    DISASSEMBLING INSPECTING 1. With the skid frame removed, remove the cap 1. Inspect each idler wheel for cracks or damage. screws and flat washers securing the outer idler 2. Rotate the idler wheel bearing (by hand) and wheels. Remove the idler wheels from the axle and inspect for binding or roughness.
  • Page 50 AG297D AO161 2. Remove the cap screw securing the cross-brace axle 8. Remove the slide rail from the skid frame. to the slide rail. INSPECTING 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.

  • Page 51: Installing Skid Frame

    AO162 AO161 4. Secure the rear arm to the support bracket with the 7. Place the end cap onto the rail and secure with the cap screw. Tighten securely. cap screw, washers, and lock nut. Tighten to 78 in.- Installing Skid Frame 1.

  • Page 52: Steering And Body

    Steering and Body Steering Post REMOVING  NOTE: Perform steps 1-8 for both the brake and throt- tle cables. 1. Remove the handlebar pad. A980 4. Remove the C-clip securing the throttle cable in 2. Remove the C-clips securing the brake and throttle the throttle control;...
  • Page 53 INSTALLING IO059A 10. Pull the steering post up and out of the lower bear- ing. 11. Remove the lock nuts and cap screws securing the tie rods to the steering post. 1. Steering Post 11. Pad Cover 22. Hex Nut 2.
  • Page 54 5. Tighten the upper and lower retainer cap screws securely. A982 9. Seat each cable drum into its lever recess; then secure each with a pin and C-clip. A026  NOTE: Check all fasteners to ensure they are tight. Turn the handlebar full-left and full-right several times to ensure free movement.

  • Page 55: Ski

    Arctic Cat recommends that the ski 2. Inspect the ball joints and tie rods for cracks or wear bars be checked once a week and replaced if worn unusual bends.

  • Page 56: Spindle

    3. Wash the ball joint in parts-cleaning solvent. Dry 3. Remove the lock nut securing the tie-rod ball joint with compressed air. Inspect the ball joint pivot to the spindle (account for the washer); then area for wear. Apply an all-temperature grease to remove the ball joint from the spindle.

  • Page 57: Ski Alignment

    3. Inspect the suspension arm axle area for wear. 4. Secure the spindle in a vise. Rotate the spindle clockwise and counterclockwise. The movement should be smooth and free. If the spindle movement is rough or binding, grease the spindle with an all- temperature grease.

  • Page 58: Front Suspension A-Arms

    4. While holding the straight ski in position, rotate the tie rod until the measurement between the skis is within specifications. 5. When the ski alignment is correct, apply blue Loc- tite #243 to the jam nut threaded areas and tighten each jam nut securely against the tie rod.

  • Page 59: Belly Pan

    3. Using the Shock Spring Removal Tool, remove the spring from the shock body by compressing the spring; then remove the spring retainer from the top of the spring. Inspect the shock absorber by quickly compressing and extending the shock plunger while firmly holding the shock body.

  • Page 60: Seat/Cushion/Taillight Housing

    7. Remove the vent hose from the top of the gas tank. Seat/Cushion/Taillight Housing A044 8. Raise the flap at the rear of the seat and remove the two cap nuts securing the seat assembly to the tun- nel. Account for two washers. 9.

  • Page 61: Headlight Assembly

    8. Connect the fuel hose to the carburetor and turn the gas tank shut-off valve to the OPEN position. Headlight Assembly REMOVING  NOTE: The bulb portion of the headlight is fragile. HANDLE WITH CARE. When replacing the headlight bulb, the bulb assembly must first be removed from the housing.

  • 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 2259-960...

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