Table Of Contents - Arctic Cat ZR 120 Service Manual

General Information ................................................... 2
Snowmobile Identification................................... 2
Recommended Gasoline and Oil ....................... 2
Break-In Procedure ............................................ 2
Genuine Parts .................................................... 3
Drive Chain Lubrication ...................................... 3
Preparation For Storage ..................................... 3
Preparation After Storage................................... 3
Torque Conversions (ft-lb/N-m) .......................... 4
Torque Specifications ......................................... 4
Engine Torque Diagram...................................... 5
Engine Specifications ......................................... 6
Carburetor Specifications ................................... 6
Track Specifications............................................ 6
Ski Shock Spring Specifications......................... 6
Rear Arm Spring Specifications ......................... 6
Ski Shock Absorber Specifications..................... 6
Idler Wheel Dimensions ..................................... 6
Engine ........................................................................ 7
Removing ........................................................... 7
Disassembling .................................................... 8
Servicing Components ..................................... 12
Assembling....................................................... 18
Installing ........................................................... 23
Changing Oil..................................................... 24
Recoil Starter ................................................... 24
Troubleshooting Engine.................................... 26
Fuel System ............................................................. 27
Pre-Maintenance Checks ................................. 27
Carburetor ........................................................ 27
Throttle Cable................................................... 30

TABLE OF CONTENTS

Troubleshooting Fuel System ........................... 32
Electrical System...................................................... 33
Transistorized Ignition System.......................... 33
Testing Ignition Switches .................................. 34
Testing Electrical Resistances .......................... 34
Drive Chain and Sprockets....................................... 35
Track and Driveshaft................................................. 36
Brake System ........................................................... 40
Troubleshooting Track............................................... 42
Rear Suspension...................................................... 43
Removing Skid Frame ...................................... 43
End Cap............................................................ 44
Wear Strip......................................................... 44
Rear Suspension Arm/Rear Springs ................ 45
Rear Idler Wheels and Axle .............................. 45
Upper Idler Wheels ........................................... 46
Slide Rail .......................................................... 46
Installing Skid Frame ........................................ 48
Steering and Body.................................................... 49
Steering Post .................................................... 49
Ski .................................................................... 52
Ski Wear Bar..................................................... 52
Tie Rods .......................................................... 52
Spindle ............................................................. 53
Ski Alignment.................................................... 54
Front Suspension A-Arms ............................... 55
Front Suspension (Ski) Shock Absorber........... 55
Belly Pan .......................................................... 56
Seat/Cushion/Taillight Housing ........................ 57
Headlight Assembly ......................................... 58
Wiring Diagram......................................................... 59
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