Seat/Cushion/Taillight Housing - Arctic Cat ZR 120 Service Manual

Seat/Cushion/Taillight
Housing
KEY
1. Seat Assy 14. Decal
2. Gas Tank/Seat-Base 15. Teflon Tape
3. Cap w/Gauge 16. Shut-Off Valve
4. Seal 17. Hose Clamp
5. Seat Cover 18. Fuel Hose
6. Seat Wire 19. Fuel Filter
7. Foam 20. Hose Clamp
8. Seat Wire 21. Fuel Hose
9. Staple 22. Hose Clamp
10. Clip 23. Cable Tie
11. Vent Hose 24. Spring
12. Bushing 25. Choke Cable
13. Push Nut 26. Nut
REMOVING
1. Remove the retaining nut securing the ignition
switch to the console; then slide the switch for-
ward and out of the console.
2. Remove the screw securing the choke knob to the
cable; then remove the knob.
3. Remove the two nuts securing the choke cable to
the console; then slide the cable forward and out of
the console.
4. Pull the recoil starter rope out approximately 24";
then tie a slip-knot in the starter rope below the
console and allow the rope to slowly retract
against the starter case.
5. Remove the knot at the handle and remove the
handle; then thread the rope through the bushing in
the console.
6. Turn the gas tank shut-off valve to the CLOSED
position; then disconnect the fuel hose from the
carburetor.
! WARNING
Whenever any maintenance or inspection is made on
a fuel system when there may be fuel leakage, there
should be no welding, smoking, open flames, etc., in
the area.
7. Remove the vent hose from the top of the gas tank.
8. Raise the flap at the rear of the seat and remove the
9. Raise the rear of the seat assembly high enough to
27. Decal
28. Ignition Switch
29. Retaining Nut
30. Ignition Switch Key
10. Remove the seat assembly.
31. Cap Screw
32. Lock Nut

NOTE: If necessary, use a sharp tool to pry out all sta-
33. Washer
ples securing the seat cover to the plastic seat base;
34. Cap Nut
then remove the cover from the seat base and seat
35. Taillight Assy
foam.
36. Washer
37. Nut w/Washer
INSTALLING

NOTE: If the seat cover was removed, position the
0747-299
cover over the seat foam and plastic seat base. Check
to make sure it is positioned straight; then fold the rear
edge of the cushion down and around the base. Using a
staple gun and 1/4-in. staples, staple the rear flap of the
cushion to the base in the same areas as the original
staples were located. Position staples 1" apart. Fold the
sides of the cushion down around the bottom edge of
the base. Position the staples in the same areas as the
original staples were located.
1. Place the seat assembly into position and connect
2. Secure the seat assembly to the tunnel with wash-
3. Connect the vent hose to the top of the gas tank.
4. Thread the recoil starter rope through the bushing in
5. Untie the slip-knot at the starter case and allow it
6. Slide the choke cable through the console and
7. Slide the ignition switch into position on the con-
two cap nuts securing the seat assembly to the tun-
nel. Account for two washers.
disconnect the taillight wiring harness; then dis-
connect the taillight from the main wiring harness.
the taillight wiring harness.
ers and cap nuts.
the console and the handle; then tie a knot at the end
of the rope and pull the handle up and onto the knot.
to slowly rewind into the case.
secure with two lock nuts; then using a screw
(coated with blue Loctite #243), secure the choke
knob to the end of the cable.
sole; then secure with the retaining nut.
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