Arctic Cat 2014 M 2-STROKE Service Manual
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Arctic Cat 2014 M 2-STROKE Service Manual

2014
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2014
SERVICE MANUAL
[SNOWMOBILE]

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JOHN Rollins
March 1, 2025

How to remove pistonh tie rod

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Mr. Anderson
March 1, 2025

The provided context does not contain information on removing the piston tie rod on a 2014 Arctic Cat 2-Stroke.

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Summary of Contents for Arctic Cat 2014 M 2-STROKE

  • Page 1 2014 SERVICE MANUAL [SNOWMOBILE]...
  • Page 2 Such efficiency not only helps build consumer confidence but also saves time and labor. All Arctic Cat publications and snowmobile decals display the words Warning, Caution, and Note to emphasize impor- tant information. The symbol ! WARNING identifies personal safety-related information. Be sure to follow the directive because it deals with the possibility of severe personal injury or even death.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS General Information ............2 EFI System ..............92 Snowmobile Identification ..........2 Individual Components ............92 Recommended Gasoline and Oil ........2 Self-Diagnostic System/Codes (6000)......95 Engine Break-In ..............2 Self-Diagnostic System/Codes (8000)......95 Drive Belt Break-In............2 Fuel Pressure Regulator..........96 Genuine Parts ..............

  • Page 5: General Information

    The recommended oil to use in the oil-injection system is ing 60 mph), the exposed cord on the side of a new belt either Arctic Cat C-Tec2 for the 6000 or Arctic Cat APV will be worn down. This will allow the drive belt to gain Synthetic 2-Cycle Oil for the 8000.

  • Page 6: Genuine Parts

    When replacement of parts is necessary, use only genuine A normally aspirated engine will generate more horsepower Arctic Cat parts. They are precision-made to ensure high at sea level than it does at higher altitudes. The reason is that quality and correct fit.

  • Page 7: Preparation For Storage

    M/XF High Country Track As snow cover and riding conditions change, several dif- Carefully matching the riding requirements to the type of ferent adjustments can be made to change the ride and han- track will ensure the maximum use of all available engine dling characteristics for operator preference.

  • Page 8: Preparation After Storage

    6. Fill the gas tank to its rated capacity; then add Arctic paring it for another season will assure many miles and Cat Fuel Stabilizer to the gas tank following direc- hours of trouble-free snowmobiling. Arctic Cat recom- tions on the container for the stabilizer/gasoline mends the following procedure: ratio.

  • Page 9: After Break-In Checkup/Checklist

     Check brake lever travel and adjustment After Break-In Checkup/  Grease all lubrication points Checklist Engine Specifications Certain areas require adjustment after the break-in period in order to obtain peak performance. These areas are the following. 6000 DRIVE BELT DEFLECTION — Drive belt deflection is very important to the snowmobile.

  • Page 10: Crankshaft Runout/Repair Specifications

    Crankshaft Runout/ Repair Specifications To use the specifications, first refer to the drawing; then find the letter indicating the specification and refer to the chart below the illustration. 8000  NOTE: The proper location for checking crankshaft runout is the very edge of the straight portion of the shaft where the oil seal makes contact.

  • Page 11: Electrical Specifications

    Electrical Specifications Component Test Value + Test Connections - Spark Plug Cap 4000-6000 ohms cap end cap end Oil Level Sensor Less than 1 ohm (float end down) terminal terminal Ignition Switch Less than 1 ohm (key in OFF position) terminal terminal 6000 (Normally Open Ignition) Ignition Coil...

  • Page 12: Drive System Specifications

    Drive System Components A list of Drive System components that are available through the Arctic Cat Service Parts Department can be found in the Quick Reference Guide. This information will be useful when doing any fine-tuning on the drive system.

  • Page 13: Chain Case Performance Calibrations

    Chain Case Performance Calibrations ENGINE RPM DRIVE CHAIN CHAIN RATIO 7200 7400 7600 7800 8000 8200 8400 8600 8800 SPROCKET SPROCKETS PITCH VEHICLE SPEED 0.380 0.408 0.429 0.458 0.512 0.526 10 TOOTH (2.52 PITCH) 0.553 0.571 0.575 0.595 0.639 0.686 0.380 0.408 0.429...

  • Page 14: Track Specifications

    SHOCK ABSORBERS Track Specifications Below is a list of shock absorbers used on the front and rear suspensions of Arctic Cat snowmobiles. If replacing a shock absorber, always select a shock absorber with the same length, both collapsed and extended.

  • Page 15: Torque Specifications

    REAR SUSPENSION Torque Specifications Torque Item Secured to ft-lb M/XF 141”  NOTE: Torque specifications have the following tol- Wear Strip Rail 50 in.-lb End Cap Rail 80 in.-lb erances: Mounting Block Rail Rear Wheel Axle Rail Torque (ft-lb) Tolerance Rear Arm Rail 0-15...

  • Page 16: Steering And Body

    5. Remove the push rivets securing the right-side steering Steering and Body boot to the chassis. This allows access to the two nuts securing the bottom of the steering post. This section has been organized into sub-sections for ser- vicing steering and body components; however, some components may vary from model to model.
  • Page 17 5. Install the expansion chamber using the existing springs; then connect the exhaust temperature sensor to the main harness. 6. Position the hood onto the snowmobile and connect the hood harness connector. 7. Secure the hood with the six torx-head screws and tighten securely.
  • Page 18 5. Remove the push rivets securing the right-side steering boot to the chassis. This allows access to the two nuts securing the bottom of the steering post. SNO-2225A  NOTE: On HCR models, the fixed steering post can not be separated and must be removed as an assem- XM134A bly.
  • Page 19 INSTALLING 1. Insert the telescoping steering post into the steering support along with two bushings; then secure the steering post using the existing retaining ring. XM212A 12. With the telescoping steering assembly removed from the snowmobile; press down on the adjusting block until the inner snap ring is exposed.

  • Page 20: Ski

    5. Install the secondary steering post into position and secure to the steering stop bracket with a new M10 nut. Be sure to align the steering post ball joint alignment tab with the steering stop bracket. Tighten to 43 ft-lb. SNO-2226A 9.

  • Page 21: Ski Wear Bar

    Arctic Cat recommends that the ski wear bars be replaced if worn to 1/2 of original diameter. REMOVING 1.

  • Page 22: Steering Tie Rod

    INSPECTING  NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is nec- essary. 1. Inspect the spindle for excessive wear, cracks, bends, or imperfections. 2. Inspect the A-arm bushings and axle area for wear. 3.
  • Page 23 2. Place the steering tie rod into position on the steering post. Secure with a new nyloc nut. Tighten to 35 ft- PC099C  NOTE: At this point if the technician’s objective is to remove the steering arm, the reinforcement bracket will need to be removed by drilling out the appropri- SNO-351 ate rivets.

  • Page 24: Ski Alignment

    SNO-349 729-887A Ski Alignment CHECKING  NOTE: Track tension and alignment must be properly adjusted prior to checking or adjusting ski alignment. Ski alignment must be performed on a flat, level surface. Ski toe-out must fall within the range of 1/16-1/4 in. 1.

  • Page 25: A-Arms

    4. Apply blue Loctite #243 to each jam nut thread area; then tighten the jam nuts against the spindle tie rod.  NOTE: Repeat this procedure on each side (if nec- essary) until ski toe-out is within specification. ! WARNING Neglecting to lock the tie rod by tightening the jam nuts may cause loss of snowmobile control and possi- ble personal injury.

  • Page 26: Ski Shock Absorber

    SNO-226A XM135 4. Secure the A-arms to the spindle. 8. Remove the two cap screws and lock nuts securing the upper arm to the chassis. Discard the nuts. 5. Install the ski shock absorber. INSPECTING 6. Place the front skid plate into position; then secure with 1.

  • Page 27: Sway Bar (Zr/Xf)

    3. Install the bushings, sleeves, and spacers into each shock end; then place the shock absorber into posi- Seat Assembly tion and secure with the cap screws and lock nuts. (ZR/XF/M STD) Tighten the lock nuts to 32 ft-lb. REMOVING/INSTALLING SEAT Sway Bar (ZR/XF) ...

  • Page 28: Seat Assembly (M Sno Pro/Hcr/Ltd)

    2. Fold the rear edge of the cushion down and around 3. Remove the backing from the installation bag (p/n the plastic base. Using a staple gun and 1/4 in. sta- 1655-841); then adhere it to the gas tank making sure ples, staple the rear flap of the cushion to the plastic the bag covers the velcro on the gas tank.

  • Page 29: Rear Bumper/Snowflap

    2. Connect the taillight harness connector; then secure the taillight to the taillight support with the two torx- Windshield/Console/ head screws. Tighten to 48 in.-lb. Headlight Rear Bumper/Snowflap REMOVING 1. Remove and retain all machine screws securing the REMOVING BUMPER hood;...

  • Page 30: Headlight Bulb

    Headlight Bulb  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. Do not touch the glass portion of the bulb. If the glass is touched, it must be cleaned with a dry cloth before installing.
  • Page 31 4. Make a vertical mark intersecting the horizontal mark on the aiming surface directly in front of the headlight. 5. Engage the brake lever lock and start the engine. Select the headlight dimmer switch HIGH beam position. DO NOT USE LOW BEAM. 6.

  • Page 32: Engine

    Engine Removing/ Installing - 6000 This engine sub-section has been organized to show a 0746-793A progression for the removing/installing of the Arctic Cat 1. Carefully remove the exhaust temperature sensor 6000 engine. For consistency purposes, this sub-section from the expansion chamber.
  • Page 33 EL-002A EL-006A 8. Remove the cap screws securing the PTO-side front 13. Loosen the four clamps securing the throttle body; spar to the steering support and shock mount bracket; then lift up the throttle body and disconnect the cool- then remove the spar. ant hoses.
  • Page 34 CWI-092 CWI-093 21. Disconnect the lower coolant hose from the front 23. Remove the cap screw and two lock nuts securing heat exchanger; then remove the coolant hose from the engine support plate to the chassis; then lift the the heat exchanger at the rear of the engine. engine out of the engine compartment.
  • Page 35 2. Install the coolant hose to the heat exchanger at the 9. Connect the knock sensor and coolant temperature rear of the engine; then connect the lower coolant sensor connectors; then install the spark plug caps. hose to the front heat exchanger. Secure the coolant temperature sensor connector with a cable tie.
  • Page 36 EL-003A EL-002A 22. Insert the servomotor cable ends into the slot in the  NOTE: At this point, secure the PDM harness to the clutch; then connect the servomotor connector. shock mount bracket support using a cable tie. Secure the cables with the holder. 27.
  • Page 37 32. Check drive belt deflection (see the Drive Train/ 35. After running the engine to the proper operating tem- Track/Brake Systems section). perature, shut the engine off; then open the access panels and inspect for any signs of coolant, gasoline, 33.

  • Page 38: Assembly Schematic - 6000

    Assembly Schematic - 6000 Torque Specification Tolerances Torque (ft-lb) Tolerance 0-15 ±20% 16-39 ±15% ±10% 600_14_1...
  • Page 39 600_14_2...

  • Page 40: Engine Removing/Installing - 8000

    Engine Removing/ Installing - 8000 This engine sub-section has been organized to show a progression for the removing/installing of the Arctic Cat 8000 (ZR/M/XF) engine. For consistency purposes, this sub-section shows a complete and thorough progression; however, for efficiency it may be preferable to remove only those components needing to be addressed.
  • Page 41 PC188A PC186A 8. Remove the caps screws securing the PTO-side front 12. Drain the engine coolant (see Liquid Cooling System spar to the steering support and shock mount bracket; - the Engine-Related Items section). then remove the spar. 13. Loosen the clamp securing the gasline hose to the ...
  • Page 42 16. Remove the main harness wrap and disconnect the six harness connectors. Secure the harness up and out of the way. 17. Close-off the oil hose with a clamping device; then remove the hose clamp and oil hose from the oil pump. PC178A 22.
  • Page 43 5. Install the PTO-side chassis support to the shock mount bracket and chassis. Secure with the cap screws and carriage bolt nut. Tighten the rear chassis cap screw to 25 ft-lb, the carriage bolt nut to 12 ft-lb, and the front shock mount cap screws to 12 ft-lb. 6.
  • Page 44 21. Fill the cooling system (see Liquid Cooling System 30. Position the heat shield onto the two front locating in the Engine-Related Items section). pins (B); then secure it to the chassis with the two screws (A). Tighten securely. 22. Install the oil injection control rod to the throttle body;...
  • Page 45 38. After running the engine to the proper operating tem- 39. Allow the engine to cool; then check the coolant perature, shut the engine off; then open the access level and add coolant as necessary. Verify the tight- panels and inspect for any signs of coolant, gasoline, ening torque of the drive clutch.

  • Page 46: Assembly Schematic - 8000

    Assembly Schematic - 8000 Torque Specification Tolerances Torque (ft-lb) Tolerance 0-15 ±20% 16-39 ±15% ±10% 800_12_1...
  • Page 47 800_12_2...

  • Page 48: Engine Servicing - 6000

    Engine Servicing - 6000 This engine sub-section has been organized to show a progression for servicing of the Arctic Cat 6000 engine. For consistency purposes, this sub-section shows a com- plete and thorough progression; however, for efficiency it may be preferable to disassemble only those components needing to be addressed.
  • Page 49 CWI-005A CWI-009  NOTE: For assembling purposes, note the indenta- tion (A) of the stator plate is aligned with the harness opening (B) in the crankcase. CWI-010 11. Remove the four nuts securing the fuel rail to the back of the cylinders; then remove the fuel rail and injectors as an assembly.
  • Page 50 XM018 CWI-015 13. Remove the PTO-side piston-pin circlip from the 16. Remove the screws securing the intake flanges. PTO-side piston; then remove the MAG-side piston- Remove the intake manifolds and reed valve assem- pin circlip from the MAG-side piston. blies. CWI-013A CWI-020 14.
  • Page 51  NOTE: For assembling purposes, note that the bypass/check valve is directed up. CWI-075A CWI-018A 18. Remove the seven screws securing the water pump cover to the crankcase and remove the cover. Account for the O-ring gasket and the alignment pins.

  • Page 52: Cylinder Head

    26. Remove the water pump driveshaft from the lower crankcase half. Account for the thrust washer on the outer end of the shaft.  NOTE: When replacing the inner water pump seals, use the recommended Water Pump Bearing and Seal Tool Kit only.
  • Page 53 4. Place the head surface of each cylinder on the sur- Arctic Cat recommends the crankshaft be taken to a face plate covered with #400 grit wet-or-dry sandpa- qualified crankshaft rebuild shop for that service.

  • Page 54: Reed Valve Assembly

    CWI-058 IO019B 4. Visually inspect the springs to make sure they are in REED VALVE ASSEMBLY proper location on the seals. 1. Carefully pry the reed assemblies from the intake manifold and inspect the reed valves for cracks or any deterioration; then remove the screws securing the reeds.
  • Page 55 CWI-055 CWI-080 2. Position a bore gauge between the micrometer points and move it from top to bottom and side to side to find zero; then adjust the gauge to zero. CWI-056 Measuring Critical Components CWI-090 CYLINDER TRUENESS 1. Measure each cylinder in locations from front to back and side to side top and bottom of the cylinder for a total of four readings.
  • Page 56  NOTE: When the use of a lubricant is indicated, use rotate the crankshaft slowly. Note the amount of Arctic Cat C-Tec2 engine oil. crankshaft runout (total indicator reading). 1. Apply a thin coat of grease to the inner seal lips of the water pump seal.
  • Page 57 CWI-030A MS986A 8. Install the crankshaft into the upper crankcase half. Be sure the alignment hole in each bearing is posi-  NOTE: The seal must be installed with its spring tioned over its respective retaining pin in the crank- side towards the crankshaft.
  • Page 58 16. Tip the crankcase assembly up on the water pump 12. Apply a thin coat of grease to the sealing surface of side; then pour Arctic Cat C-Tec2 engine oil into the the water pump shaft; then place the Oil Seal Protec- center cavity of the crankshaft until the oil is level tor Tool at the end of the shaft.
  • Page 59 CWI-020 CWI-078A 18. With the bypass/check valve of the thermostat CAUTION directed to the 12 o’clock position, install the ther- Incorrect installation of the piston rings will result in mostat and housing; then in a crisscross pattern, engine damage. tighten the screws to 102 in.-lb. 21.
  • Page 60 26. Install each cylinder with the eight existing nuts; then secure the cylinders by tightening the cylinder base nuts to 15 ft-lb then to 38 ft-lb in a crisscross pattern. 27. Install the cylinder O-rings (lightly coated with oil) on the top of each cylinder making sure they are cor- rectly positioned in the grooves.
  • Page 61 33. Route the stator harness through the opening in the 37. Place the recoil cup in position on the flywheel and crankcase; then secure the stator to the stator plate visually center; then secure the cup with three cap with the screws (coated with blue Loctite #243). screws and tighten only until snug.

  • Page 62: Engine Servicing - 8000

    Engine Servicing - 8000 This engine sub-section has been organized to show a progression for servicing of the Arctic Cat 8000 engine. For consistency purposes, this sub-section shows a com- plete and thorough progression; however, for efficiency it may be preferable to disassemble only those components needing to be addressed.
  • Page 63 CM142A CM145D 5. Remove the Allen-head cap screw (A) securing the  NOTE: For assembling purposes, note the indenta- stator lead wire plate to the crankcase; then remove tion (A) of the stator plate is aligned with the harness the Allen-head cap screws (B) securing the timing opening (B) in the crankcase.
  • Page 64 XM017 XM018 9. Remove the spark plugs. 12. Remove the PTO-side piston-pin circlip from the PTO-side piston; then remove the MAG-side piston-  NOTE: At this point, remove the knock sensor and pin circlip from the MAG-side piston. lock plate from the cylinder head by bending the lock plate tabs down and unthreading the sensor.
  • Page 65 CM151 IO015A 17. Remove the four cap screws securing the thermostat  NOTE: Place a suitable length of rubber hose cap; then remove the cap, gasket, and thermostat. around the connecting rods to prevent the connect- ing rods from damaging the crankcase. 15.
  • Page 66 CAUTION DO NOT drive any tool between halves to separate the crankcase. Damage to the sealing surfaces will result. CM156A 19. Remove the cap screw securing the water pump impeller; then slide the impeller free of the shaft. Account for the washer and gasket. CM158 24.
  • Page 67 Cleaning and Inspecting CYLINDER HEAD 1. Using a non-metallic carbon removal tool, remove any carbon buildup from the combustion chambers being careful not to nick, scrape, or damage the com- bustion chambers or the sealing surfaces. 2. Inspect the spark-plug holes for any damaged threads.
  • Page 68 Arctic Cat recommends the crankshaft be taken to a qualified machine shop for that service. 5. Inspect the perimeter of each piston for signs of excessive “blowby.”...
  • Page 69 REED VALVE ASSEMBLY 1. Inspect the reed valves, stoppers, and valve blocks for cracks or any deterioration. FC040 4. Inspect the oil-injection pump drive gear for any signs of worn or chipped teeth. If either condition exists, replace the gear. XM227 ...
  • Page 70 Measuring Critical Components CYLINDER TRUENESS 1. Measure each cylinder in locations from front to back and side to side top and bottom of the cylinder for a total of four readings. CWI-089 3. Place the bore gauge in the cylinder and measure each cylinder in locations from front to back and side to side top and bottom of the cylinder for a total of four readings.
  • Page 71 Always wear safety glasses when drying components with compressed air.  NOTE: When the use of a lubricant is indicated, use Arctic Cat Synthetic APV 2-Cycle Oil. 0742-727  NOTE: For runout location point specifications, see 1. Apply a thin coat of grease to the inner seal lips of the water pump seal.
  • Page 72  NOTE: The seal must be installed with its spring side towards the crankshaft. 3. Install the snap ring securing the inner seal in the crankcase. CM043A 7. Lubricate the inner lips of the crankshaft oil seals with grease; then slide the seals onto the crankshaft making sure the spring side of each seal faces inward.
  • Page 73 14. Apply a thin coat of grease to the sealing surface of the oil-injection pump/water pump driveshaft; then place the Oil Seal Protector Tool at the end of the shaft. CAUTION Be very careful not to damage the seals when installing the oil pump driveshaft.
  • Page 74 17. With the new O-ring (lightly coated with oil) in 19. With new gaskets, install the reed valve assemblies place, install the oil-injection pump making sure the and intake flanges using the pattern shown. Tighten pump shaft slot (A) and pump driven gear shaft (B) to 96 in.-lb;...
  • Page 75 23. Place the impeller into position and secure with a cap screw and washer. Be sure the rubber side of the washer is lubricated with a light coat of grease and directed toward the impeller. Apply blue Loctite #243 to the threads of the cap screw and tighten to 108 in.-lb.
  • Page 76 TZ068 XM021A 33. In turn on each cylinder, place a piston holder (or  NOTE: The shoulder side of the washer must seat to suitable substitute) beneath the piston skirt and the needle bearing. square the piston in respect to the crankcase; then using a ring compressor or fingers, compress the rings and slide the cylinder over the piston.
  • Page 77  NOTE: At this point, pressure test the engine (see the Engine-Related Items section). 38. With the raised edge of the valve aligned with the channel of the cylinder, slide the APV assemblies into position in the cylinders; then secure with cap screws.
  • Page 78 42. Secure the lower ignition timing sensor with two cap 46. Secure the starter clutch while using the spanner screws (A) (coated with blue Loctite #243). Tighten wrench and tighten the three cap screws (from step to 48 in.-lb; then install the grommet. With the stator 45) evenly to 19 ft-lb.

  • Page 79: Troubleshooting Engine

    Troubleshooting Engine Problem: Engine Does Not Start (No Spark at Spark Plugs) Condition Remedy 1. Key in the OFF position 1. Turn key to the ON position 2. Emergency stop switch in DOWN position — 2. Move switch to UP position — replace throttle control malfunctioning 3.
  • Page 80 Problem: Engine Loses Power or Runs on One Cylinder Condition Remedy 1. Sensor faulty 1. Check ECM for trouble code — repair — replace sensor 2. Spark plug fouled 2. Replace spark plugs 3. Injector faulty 3. Replace injector 4. External coil faulty 4.

  • Page 81: Engine-Related Items

    Engine-Related Items  NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. SPECIAL TOOLS A number of special tools must be available to the techni- cian when servicing the engine-related items. Description Blind-Hole Bearing Puller 0644-500 XM114A Coolant Cap...
  • Page 82 FS221A FS226 4. Remove the cap screw securing the impeller. Account 7. Using the long seal driver, drive the water pump for the rubber washer and gasket behind the cap screw. mechanical seal from the crankcase. XM112 FS227 5. Remove the impeller from the shaft. 8.
  • Page 83 ASSEMBLING 1. Thoroughly clean the seal surfaces of the crankcase. 2. Position the oil seal onto the seal driver (spring side towards the crankshaft). Gently tap into position. FS233A FS230 3. Apply a small amount of grease to the oil seal lips. 4.

  • Page 84: Water Pump (6000)

    FS220A XM112A 11. Position the O-ring into the water pump cover; then  NOTE: When installing the lower check valve, install the cover. Install the cap screws; then using assure that the gaskets are installed on each side of the pattern shown, tighten to 96 in.-lb. the valve.
  • Page 85  NOTE: When servicing the water pump, use Water  NOTE: If the impeller will not slide off the shaft, Pump Bearing and Seal Tool Kit and Oil Seal Protec- start the cap screw into the shaft and tap on the cap tor Tool.
  • Page 86 FS230 CWI-101 3. Apply a small amount of grease to the oil seal lips. 7. Position the shim on the retainer end of the shaft; then with the O-ring in place on the retainer, install 4. Using a pair of snap ring pliers, install the snap ring the retainer.

  • Page 87: Pressure Testing Engine

    CWI-095 XM209A 12. Secure the hoses to the water pump cover.  NOTE: Raising the rear end of the snowmobile will aid in removing all coolant from the heat exchangers. Pressure Testing Engine 4. Once the coolant has completely drained, secure the lower coolant hose using the existing clamp.

  • Page 88: Cooling System Schematic

    Cooling System Schematic The following schematic is representative of the different styles of cooling systems in the Arctic Cat snowmobiles. Some components may vary from model to model; there- fore, the technician should use discretion and sound judg- ment when servicing a particular cooling system.
  • Page 89 DISASSEMBLING 7. Inspect the handle for damage, cracks, or deteriora- tion. ! WARNING ASSEMBLING Always wear safety glasses and gloves when servic- 1. Hook the end of the main spring around the mount- ing the recoil starter. ing lug in the case. 1.

  • Page 90: Arctic Power Valve (Apv) System

     NOTE: Before tightening the cap screws, slowly pull the recoil rope until the pawl engages; then tighten The computer within the ECM has been programmed to the cap screws centering the recoil against the mag- cycle the power valves at 4500 RPM upon initial start-up. neto case.
  • Page 91 Check each of the above probable causes in the order given to locate the problem of the servomotor cycling three times in succession; then shutting down. Check for correct exhaust valve cable length specifica- tions for model being worked on in this section. Servomotor Makes No Attempt To Cycle If when running the engine the servomotor makes no attempt...
  • Page 92 MS401A FC112 3. Hold the valve stopper securely and pull the cable CAUTION back and up until it clears the top of the stopper; then Never attempt to remove or install the pulley jam nut slowly release the cable and remove it from the valve with the pulley unsecured or damage to the servomo- stopper.
  • Page 93 ASSEMBLING/INSTALLING FC112  NOTE: Note that the exhaust valve gaskets are A. Exhaust Valve D. Oil Seal G. Stopper Pin directional and must be installed correctly. B. Cover Gasket E. Gasket H. Return Spring C. Valve Plate F. Stopper I. Valve Cover 4.

  • Page 94: Exhaust Controlled Timing (Ect) System

    For example, if the headlight and taillight are disabled, Exhaust Controlled the ECM will sense a high voltage condition and activate the fail-safe mode. Adding more than 4 amps of accesso- Timing (ECT) System ries will create a low voltage condition and activate the fail-safe mode.

  • Page 95: Fuel Systems

    ECM Diagnostic Codes chart (see Self-Diagnostic System/Codes in this section). The Arctic Cat EFI System operates off a series of coils located on the stator and is made up of the following  NOTE: The ECM cannot be repaired.

  • Page 96: Fuel Injectors

    3. Disconnect the wire harness leads from the ECM;  NOTE: The input from the throttle position sensor is then remove the two cap screws securing the ECM. one of the main inputs for the ECM calculation of fuel/ Remove the ECM. air mixture ratio.
  • Page 97 1. Loosen the clamp securing the fuel supply hose to 2. Pull the fuel rail with the injectors from the cylinders the fuel rail; then remove the hose from the fuel rail. and disconnect the wiring harness from each injector. 2.

  • Page 98: Self-Diagnostic System/Codes (6000)

    E. ECM. Code Trouble P1261 Injector circuit/open - Cylinder 1b. KNOCK SENSOR P1264 Injector circuit/open - Cylinder 2b. This sensor controls engine knock or detonation. The P1329 Knock sensor loose detection. knock sensor assesses structure borne noise (vibrations) P1636 Crank angle sensor circuit. caused by rapid pressure rises (detonation) in either cyl- P1639 Exhaust valve position sensor circuit low.

  • Page 99: Fuel Pressure Regulator

    Standard Throttle Body Assembly Gauge REMOVING  NOTE: The expansion chamber, shock mount bracket support and air silencer must be removed for this procedure (see the Engine-Related Items sec- tion). 1. Disconnect the wiring harness from each injector and from the throttle position sensor. 2.

  • Page 100: Throttle Cable

    5. Connect the wiring harness to each injector and throttle position sensor. CAUTION Verify the oil pump rod linkage is properly installed or damage to the engine will occur.  NOTE: Install the air silencer, shock mount bracket support, and the expansion chamber (see the Engine- Related Items section).
  • Page 101 4. Start the engine. Fuel pressure should be as speci- fied. 6000 58-62 psi 8000 42.8-47.3 psi  NOTE: If fuel pressure is not as specified, the pump is defective and must be replaced. 5. Disconnect the fuel pump from the main wiring har- ness.

  • Page 102: Troubleshooting

    4. Make sure the front pickup will sit flat on the bottom of the tank with no kinks in the fuel hose. SNO-744  NOTE: Tip the fuel pump assembly to one side enough to allow the tool to be removed. ...

  • Page 103: Oil-Injection Pump (8000)

    2. Place the gasket and oil-injection pump near the Oil-Injection Pump (8000) engine; then install the lower union bolt through a gasket, check valve, and gasket. 3. Position the oil-injection pump on the engine making CAUTION sure the oil-injection pump gear is correctly aligned with the oil-injection pump drive gear.
  • Page 104 Oil Injection Usage Tool, fill the 2. Attach the Vacuum Test Pump hose to the check hose with Arctic Cat Synthetic APV 2-Cycle Oil. valve.  NOTE: Do not fully insert the usage tool into hose.

  • Page 105: Gas Tank

    INSTALLING Gas Tank 1. Install the pump assembly into the oil tank and align with the two mounting holes; then secure the pump to the tank using the two screws (threads coated with REMOVING blue Loctite #243). Tighten to 60 in.-lb. 1.
  • Page 106 INSTALLING 1. Install the gas tank; then connect the gasline hose, vent hose, and fuel pump harness. 2. Install the rear spar tubes and secure to the chassis and steering support using the four cap screws. Tighten to 23 ft-lb. XM212A 3.

  • Page 107: Electrical Systems

    Description crank the engine over and check for spark. If spark is now present, adjust the throttle cable tension. CATT II Tool 0544-023 Arctic Cat Diagnostic System Manual 2256-974 TESTING Laptop Diagnostic Tool 0744-048 Throttle Control Switch...
  • Page 108 CHECKING TPS ADJUSTING TPS  NOTE: If the snowmobile is in warranty, breaking  NOTE: Adjusting the TPS is for out of warranty the seal on the idle screw jam nut or the Phillips-head snowmobiles only. screws on the TPS will void warranty. If the TPS is 6000 tested out of specification, the throttle body must be replaced.

  • Page 109: Electrical Resistance Tests

    Installing  NOTE: If, after adjusting the Throttle Position Sen- sor to the IDLE specification, the FULL-OPEN is less 1. Install the new TPS onto the throttle shaft by align- than the specified voltage, recheck the FULL- ing the “flats” on the throttle shaft cam with the CLOSED setting.

  • Page 110: Exhaust Temperature Sensor

    Injection Coil 2. Test between the two injector terminals. Resistance must be 10-14 ohms (8000) or 12 ± 6 ohms (6000). 1. Test between the two blue/white leads in the four- prong connector harness from the magneto. 3. If not within specifications, replace the injector. 2.

  • Page 111: Testing Oil Level Sensor

     NOTE: The air temperature sensor utilizes a therm- 2. Start the engine and allow it to idle. Meter reading must be within 12-15 DC volts. istor. Resistance will change as temperature varies. 3. For the AC voltage test, connect the red maxiclip and meter lead to the yellow wire in the connector;...

  • Page 112: Testing Fuel Gauge Sender

    Method #1 Testing Fuel Gauge 1. Disconnect the solenoid connector from the main Sender wiring harness. 2. Place the ohmmeter leads across the solenoid coil terminals. The ohmmeter must read 3-5 ohms.  NOTE: Before testing the sender, verify the harness from the sender to the gauge is satisfactory.

  • Page 113: Voltage Regulator Tests

    3. Remove both torx-head screws securing the front Ignition Switch facia pieces; then disconnect the ECM and remove the facia and ECM as an assembly. 4. Remove the two cap screws and nuts securing the TESTING shock mount support bracket to the chassis; then remove the mount and servomotor up and out of the CAUTION way.
  • Page 114 XM043A EL-001A 10. Remove the two cap screws (A) and one Allen-head 4. Disconnect the ECM; then remove the screws secur- screw (B) securing the starter motor to the starter ing the right and left-side fascia panels to the chassis. motor mounting bracket.
  • Page 115 3. Inspect the inner gear and housing. If the gear shows any signs of wear, replace the pinion assembly. 4. Inspect the inner housing for tightness and cracks. If the housing shows any signs of being loose or cracked, replace the pinion assembly. 5.
  • Page 116 XM044A XM040A 2. Secure the MAG-side of the starter motor to the 5. Install the drive clutch and tighten to 51 ft-lb; then retaining plate using the eight cap screws (threads install the belt and driven clutch. coated with blue Loctite #243). The washer and neg- 6.

  • Page 117: Troubleshooting Electric Start

    9. Install the hood, left-, and right-side access panels. 10. Connect both battery cables to the battery making sure both are secure; then install the seat. Troubleshooting Electric Start Problem: Hot or Smoking Wires Condition Remedy 1. System wired incor- 1.

  • Page 118: Brakelight Switch

    Brakelight Switch Headlight Dimmer Switch TESTING/REMOVING REMOVING/TESTING 1. Disconnect the brakelight switch grey and brown 1. Remove the four screws securing the left-side han- two-wire connector (located near the brake lever). dlebar control assembly; then remove the control assembly from the handlebar. 2.

  • Page 119: Testing Thumb Warmer Element

    4. In the element connector, connect the ohmmeter between the green/blue and green lead wires on the 2-stroke models or between the green/black and yel- low lead wires on the 4-stroke models. 5. The meter must read between 12.6 and 15.4 ohms. 6.

  • Page 120: Testing Shift Switch

    Testing Servomotor/ Potentiometer SERVOMOTOR  NOTE: A 12-volt battery and test leads will be needed for this test. 1. Remove the servomotor from the snowmobile. CAUTION Care must be taken not to contact the servo yellow, XM208A orange, or black/white terminals, or damage to the 1.
  • Page 121  NOTE: If the servo operates correctly and the poten- tiometer test is correct but fails to operate when con- nected ECM/regulator/rectifier designated RPM, see Troubleshooting Servomotor chart in this section. FZ088A 6. Install the servomotor.

  • Page 122: Troubleshooting Servomotor

    Troubleshooting Servomotor SERVO1A14...
  • Page 123 SERVO2rv14...

  • Page 124: Voltage/Resistance Chart - Air Temperature (8000)

    Voltage/Resistance Chart Voltage/Resistance Chart - Air Temperature (8000) - Air Temperature (6000) Temperature Volts Ohms Temperature Volts Ohms Temperature Volts Ohms Temperature Volts Ohms 100° C 212° F 0.113 28° C 82° F 1.230 8540 100° C 212° F 0.68 182.6 28°...

  • Page 125: Voltage/Resistance Chart - Coolant Temperature

    Voltage/Resistance Chart - Coolant Temperature Temperature Volts Ohms Temperature Volts Ohms 110° C 230° F 0.115 28° C 82° F 1.377 1800 108° C 226° F 0.129 26° C 79° F 1.459 1950 106° C 223° F 0.143 24° C 75°...

  • Page 126: Drive Train/Track/Brake Systems

     NOTE: When installing a new drive belt, see After Drive Train/Track/Brake Break-In Checkup - Drive Belt Break-In in the General Systems Information section. REMOVING This section has been organized into sub-sections for ser- 1. With the engine off, remove the left-side access vicing drive train, track, and brake systems;...
  • Page 127 2. Using the Drive Clutch Puller and the Drive Clutch Spanner Wrench, tighten the puller. If the drive clutch will not release, sharply strike the head of the puller. Repeat this step until the clutch releases. 3. Remove the drive clutch and drive belt from the engine compartment.

  • Page 128: Driven Clutch

    3. Secure the cam arm pins with new lock nuts and 5. Either test drive the snowmobile or run the engine tighten to 11 ft-lb. for five minutes; then verify the drive clutch cap screw torque specification. CAUTION Driven Clutch When installing cam arms, always use new lock nuts and cam arm set screws.
  • Page 129 2. Using a suitable driving tool, drive the bearing out. ! WARNING Always wear safety glasses when using the bearing driver. 3. Install the new bearing; then secure with a new snap ring. REPLACING ROLLERS 1. Bend the locking tabs down away from the shoulder bolt;...

  • Page 130: Drive Clutch/Driven Clutch

    XM140 PC112 7. Remove the clutch from the compressor.  NOTE: Premature wear will result if the spring seat 8. Install the back-side cams; then secure with the is not installed. screws and tighten to 24 in.-lb. 2. Place the stationary sheave spring seat onto the INSTALLING spring (flat side toward the spring);...

  • Page 131: Drive Train

    0747-959 0743-319 CORRECTING OFFSET  NOTE: Push down on the belt with the ruler only until the bottom of the belt flexes upward; then read 1. To correct offset, the driven clutch must be moved the amount of deflection. laterally on the input shaft. Remove the cap screw and washers securing the driven clutch.
  • Page 132 5. Place a drain pan under the chain case; then loosen 11. Install Deep Socket (p/n 0444-237) to support the the eleven screws securing the chain case cover/oil bearing housing and secure with the driven clutch tank assembly to the chain case housing starting with cap screw.
  • Page 133 CLEANING AND INSPECTING CHAIN CASE 1. Inspect sprockets and chain(s) for excessive wear or stretching. 2. Inspect bearings and gears for roughness or chipping.  NOTE: If bearing replacement is necessary, the chain case must be removed from the tunnel and an appropriate press utilized to remove and install bear- ings.
  • Page 134 9. Secure the PTO-side engine mounting plate to the crankcase with four cap screws (coated with blue Loctite #243). Tighten to 30 ft-lb. PC148A  NOTE: If the brake caliper was split, proceed to step 4. If not, proceed to step 6. PC181 10.

  • Page 135: Drive Sprockets

    (threads coated with blue Loctite #243). Tighten in a crisscross pattern to XM101 12 ft-lb. Fill the chain case with 15 oz. of Arctic Cat  NOTE: The correct combination of washers need Chain Lube.
  • Page 136 7. Inspect the track drive sprockets for wear or damage. INSTALLING  NOTE: The drive sprockets must be installed on the brake side. MS357A 2. Using a suitable press positioned against the tension-col- lar of the drive sprocket (located on the gear case) and of the driveshaft, press the drive sprockets off the driveshaft.
  • Page 137 MS361A 740-043A 3. Slide the remaining sprocket onto the driveshaft 4. Using a calipers, measure distances between the making sure the timing arrow/lines (from removing) sprockets and from the sprockets to each end of the are aligned; then using the press/fixture, press the driveshaft for proper location (see appropriate illus- sprocket to the remaining alignment line.

  • Page 138: Track Tension

    5. After proper track tension is obtained, tighten the Track Tension idler wheel axle cap screws to 34 ft-lb.  NOTE: Since track tension and track alignment are interrelated, always check both even if only one CHECKING adjustment seems necessary. ! WARNING ! WARNING DO NOT attempt to check or adjust track tension with...

  • Page 139: Brake System

    “lock.” If a track 0745-817 “locks” during operation, severe personal injury could 2. If the brake fluid level is low, add Arctic Cat approved result. brake fluid until the fluid is at the recommended level.
  • Page 140 ! WARNING Use only Arctic Cat approved brake fluid. Any substi- tute may result in a loss of brakes. 1. Slide a piece of flexible tubing over the ball of the bleeder valve and direct the other end into a con- tainer.
  • Page 141 BRAKE CALIPER/BRAKE DISC/ DRIVESHAFT BEARING Removing/Disassembling 1. Remove both access panels; then remove the drive belt and driven clutch. 2. Remove the screws securing the brake shield and foot- rest to the chassis. 3. Slide a piece of flexible tubing over the ball of the bleeder valve and direct the other end into a container.
  • Page 142  NOTE: To aid in removing the inner caliper housing, completely loosen track tension. 7. Remove the retaining ring from the driveshaft and remove the brake disc; then remove the cap screws securing the inner caliper/driveshaft bearing housing to the chassis. PC221A 10.
  • Page 143 Cleaning and Inspecting  NOTE: To aid in installing the piston, make sure the piston O-ring is properly seated in the groove of the 1. Inspect the brake pistons for gouges, cracks, pitting, caliper housing. scuffing, or corrosion. If any of these conditions exist, replace the piston.

  • Page 144: Brake Lever/Master Cylinder Assembly

    PC223A PC173A 2. Remove the two screws securing the reservoir cover 8. Install new brake pads in the caliper and secure with and remove the reservoir cover; then open the the retainer pin. bleeder valve. Allow the brake fluid to drain com- pletely.

  • Page 145: Troubleshooting Hydraulic Brake System

    3. Inspect the brake fluid hose for cracks, deterioration, 3. Install the brakelight switch (E) to the master cylin- and the condition of the fittings (threaded and com- der. pression). 4. Install the brake lever; then secure with pin (D). INSTALLING 5.

  • Page 146: 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 147: Troubleshooting Drive Clutch/Driven Clutch

    Troubleshooting Drive Clutch/Driven Clutch Problem: Midrange Shift-Up (Too Quickly - Lowers RPM) Condition Remedy 1. Drive clutch spring weak 1. Replace drive clutch spring 2. Driven clutch spring weak 2. Replace driven clutch spring 3. Driven clutch spring preload tension inadequate 3.

  • Page 148: Suspension

    Suspension  NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is nec- 0728-180 essary. Under acceleration when the center of gravity is trans- ferred to the rear of the machine, the rear suspension col- SPECIAL TOOLS lapses slightly.
  • Page 149  NOTE: When softening the ski springs, also soften If the spring tension is adjusted too stiff, the track angle at the front of the skid frame is steep. This steep angle the rear to match entire suspension. prevents the snowmobile from getting up on plane and slows down by 5 to 8 mph.
  • Page 150 The rear arm shock spring is adjustable for the terrain con- First, with the coupler system, ski lift under acceleration is ditions and driving style and weight of the operator. The greatly reduced which provides improved handling. Sec- spring adjuster nut has been set at the factory so the cor- ond, when riding through rough terrain, the rear suspension rect amount of threads are exposed between the adjuster arm receives some needed assistance from the front arm...
  • Page 151 Chassis and Skid Frame Mounting Locations The suspensions have several possible mounting loca- CAUTION tions in the slide rails and tunnel. However, Arctic Cat recommends that when disassembling and assembling All stock mounting locations must be used. If any the suspension, all stock mounting locations be used as alterations to the skid frame are made, shock absorber shown in the following illustrations.
  • Page 152 M Models 0747-413...

  • Page 153: Servicing Suspension

    Servicing Suspension This sub-section has been organized so each procedure can be completed individually and efficiently.  NOTE: Some components may vary from model to model. The technician should use discretion and sound judgment when removing and installing com- ponents. ...
  • Page 154 Idler Wheels/Mounting Blocks REMOVING 1. Remove the cap screw and lock nut securing the idler wheel to the idler wheel mounting block; then remove the cap screw and lock nut securing the mounting block to the slide rail. 739-884A CLEANING AND INSPECTING 1.
  • Page 155 8. Remove the cap screws, washer, and lock nut from Front Arm Assembly the front shock axle; then from one side, tap the assembly forward far enough for the axle assembly to clear the slide rails. Account for an axle, two spac- ers, and two shim washers.
  • Page 156 2. Remove the cap screw and lock nut securing the upper front shock absorber eyelet to the front arm. Pull the shock eyelet free of the bracket. Account for two spacers and two O-rings. 3. Remove the cap screw (A) and axle (B) securing the front arm to the rails Account for two washers.
  • Page 157 Rear Arm Assembly (F)  NOTE: To service the rear arm assembly on the RR models, proceed to Rear Arm Assembly (RR) in this sub-section. REMOVING 1. With the skid frame removed using the Rear Suspen- sion Spring Tool, remove the spring from the adjust- ing cam.
  • Page 158 10. Remove the cap screw and lock nut securing the rear arm to the slide rail. Account for the serrated axles and axle tube. FZ101A 3. With the sleeves installed, install the shock absorber link to the lower mounting hole of the rear shock pivot;...
  • Page 159 5. Slide the sleeve and spring onto the idler arm. 6. Place the spring slide and slide block (with spring in slide block) into position on the slide rail. Secure with a cap screw and washer. Tighten to 20 ft-lb. 7.
  • Page 160 INSTALLING 1. Slide the axle tube into the rear arm; then position the rear arm with the holes in the slide rails. Secure using existing cap screws (threads coated with blue Loctite #243. Tighten to 20 ft-lb. FZ034 3. Loosen the cap screws and lock nuts securing the offset arm assembly to the idler arm;...
  • Page 161 FZ048A XM003A 3. Remove the cap screws and lock nuts securing the rear  NOTE: When tightening the offset arm lock nuts, arm shock absorber and shock link to the offset arm. tighten the upper lock nut first to ensure an even clamp load.
  • Page 162 XM007A XM006A 3. With the sleeves installed, place the shock absorber CLEANING AND INSPECTING and shock link between the offset arm bracket. 1. Clean the bearings with a clean cloth. Secure with the cap screws and lock nuts. Tighten securely. 2.
  • Page 163 XM002 FZ104 6. Turn the slide rail onto the side the idler wheel was 2. Loosen the track adjusting bolts then carefully installed in (from step 5); then with a block of wood remove the rear axle assembly from the skid frame. placed under the inner carriage axle/idler arm, install a wave washer.
  • Page 164 Slide Rails REMOVING  NOTE: When replacing one or both slide rails is necessary, remove one slide rail at a time. The remaining slide rail will then hold the crossbraces, axles, and brackets in their correct assembly order. Always mark the mounting hole locations during dis- assembly to speed up the assembly process and to prevent any damage.
  • Page 165 8. Remove the cap screw securing the front arm to the slide rail. FZ103A  NOTE: At this point, the slide rail should be free of FZ061A the skid frame components and can be removed. 9. Remove the cap screw from the rear arm limiter. ...
  • Page 166  NOTE: Tighten the rear idler wheel axle only until 9. Secure the outer idler wheel mounting block with the cap screw and lock nut. Tighten to 20 ft-lb; then secure snug until the skid frame has been installed and track the outer and inner idler wheels to the mounting blocks tension has been adjusted;...

  • Page 167: Rebuilding/Recharging Fox Air Shocks

    7. Tip the snowmobile onto the other side; then align the offset arm assembly with the appropriate hole in the tunnel. Secure the rear arm assembly with a cap screw, lock washer, and flat washer. AT THIS TIME, TIGHTEN ONLY UNTIL SNUG. ...
  • Page 168 AG260 FS142  NOTE: The eyelet must be heated up to 300° for the  NOTE: The air chamber should only be hand-tight. Loctite to soften. 3. Drain the oil from the air chamber. 3. Using a wrench, unscrew the eyelet from the shaft. 4.
  • Page 169 11. Remove the shock rod/piston assembly from the shock body. FS147 8. Using a 5/64-in. Allen-wrench, remove the set screw from the bearing cap. FS151 12. Drain the oil from the shock body into a suitable con- tainer. 13. Using an appropriate piston removal tool, remove the floating piston.
  • Page 170 FS154 FS157 2. Carefully install the floating piston into the shock 5. Lubricate the O-ring on the underside of the end cap body until it is below the threads. with shock oil. FS155 FS158 3. Using Floating Piston Location Gauge, install the 6.
  • Page 171 8. Using Spanner Wrench, tighten the bearing cap. FS164 11. Using a 3/16-in. Allen-wrench, tighten the PC246 nitrogen bladder.  NOTE: When tightening the bearing cap, note air and excess oil being bled from the hole in the cap. 9. Install the bleed ball and set screw into the bearing cap.

  • Page 172: Servicing Fox Float X Evol Front Shock Absorbers

    FS168 FS173 16. Slide the air chamber onto the shock body. ! WARNING 17. Add 1 cc of Fox Float Fluid into the chamber. Do not exceed 150 psi in the shock. 21. Install the valve cap. Servicing Fox Float X EVOL Front Shock Absorbers Disassembling Shock Absorber...
  • Page 173 3. Depressurize the main chamber first; then depres- surize the EVOL chamber next. NOTE: When depressurizing the chambers, a “hissing” should be noticed as air is released. Also, the shock normally contracts slightly due to the internal negative spring. 4. Using a strap wrench at the very end of the sleeve, loosen, but do not remove, the air sleeve.
  • Page 174 10. Using a 5/64-in. hex key, carefully loosen the bleed set screw; then remove the ball bearing and set it aside. 9. Press down on the reservoir end cap; then using a scribe or a pick tool, remove the reservoir snap ring.
  • Page 175 12. Grasp the EVOL chamber end (bottom) of the 14. Using a scribe or pick tool, remove the “samurai” shock; then gently pull the piston/shaft/bearing/ and back-up seals from the air sleeve. EVOL free from the shock body. Set this entire assembly aside.
  • Page 176 17. Remove the IFP bleed screw and set aside. 16. Using an appropriate IFP removing tool, remove the IFP from the “piggy-back” body. 18. Using the new seals from the appropriate seal rebuild kit, replace all IFP seals.
  • Page 177 Replacing Air Sleeve DU Bushing NOTE: The DU bushing must be replaced if it is significantly worn or damaged. 19. Pour the shock oil out of the “piggy-back” body assembly. 1. Using an appropriately-sized IFP removing tool, insert the tool with a “delrin rod” (or a suitable substitute) into the air sleeve and strike the rod with a hammer freeing the bushing.
  • Page 178 NOTE: To install a new DU bushing, an appropri- ate bushing installer (A), sizer (B), and machine press must be available. 2. Place the new DU bushing partially into the air sleeve and place the installer on top of it; then using the machine press, press the bushing into the air sleeve.
  • Page 179 4. Apply an ample amount of petroleum grease to the “samurai” and backup seals; then place them into the air sleeve. 3. At this point, the inside diameter of the new bush- ing must be re-sized. A. Insert the sizer into the air sleeve. B.
  • Page 180 NOTE: It is advisable to use cable ties to pre- serve the upper and lower shim stack/piston order. 2. Using a scribe or pick tool, lift the piston and valve assembly collectively off the shaft. 3. Using a sharp blade, cut the piston band; then remove the band and discard.
  • Page 181 4. Remove the O-ring from the piston. 5. Install a new piston O-ring; then using an appro- 7. Remove and replace all O-rings and seals. priate piston band installation tool, install a new band. 6. Remove the spring from the assembly; then remove the bearing assembly.
  • Page 182 Rebuilding EVOL Reservoir 1. Install a new O-ring in the rebound eyelet assembly.  NOTE: It may be advisable to use a cable tie to aid in removing the main seal. 2. Remove the EVOL reservoir from the rebound eyelet assembly;...
  • Page 183 Assembling Shaft Assembly 1. With the shaft assembly clamped in the vise, install the bottom-out bumper. 4. Pour approximately 2 cc of float fluid into the reservoir 2. Place the Bearing Cap Seal Protector (p/n 0644-268) onto (down its side) to provide lubrication for installing the IFP. the shaft, amply lubricate the protector, and install the bearing assembly onto the shaft.
  • Page 184  NOTE: Care must be taken that the preserved shim stack/piston assembly be installed correctly. 4. Thread the lock nut onto the shaft; then tighten to 18 ft-lb. Set the shaft assembly aside.  NOTE: At this point, pour 3-5 cc of float fluid between the air sleeve and shock body.
  • Page 185 4. Using an appropriate IFP installing tool, slowly press the IFP down into the oil purging the trapped air out through the bleed hole. Do not press the IFP to the bottom of the reservoir at this time. ! WARNING Cover the top of the tool to prevent oil from squirting upwards.
  • Page 186 7. Assuring that the LCS adjuster screw is rotated fully open (counterclockwise), fill the shock body with Fox High V1 Race Oil; then rotate the LCS adjuster screw fully closed (clockwise). 5. Install the IFP bleed screw.  NOTE: It is allowable to leave some oil trapped in the reservoir above the piston.
  • Page 187 11. Gently lower the negative spring and spacer into the oil taking care not to let the oil overflow into the air sleeve. CAUTION Make sure the piston assembly and the rebound hole in the shaft DO NOT come out of the oil bath. If the rebound adjust hole in the shaft comes out of the oil bath, air can transfer to the underside of the piston aerating the shock.
  • Page 188 CCCC FFFF 15. Slide the air sleeve down far enough to liberally lubricate the bearing head assembly. DDDD 14. Install the bleed set screw; then using a 5/64 in. hex key, tighten the set screw. GGGG 16. To set the IFP depth, remove the bleed screw; then using Floating Piston Location Gauge (p/n 0644-350), adjust the depth to 2.5 in.
  • Page 189 IIII LLLL 20. Using a high-pressure hand air pump, pressurize the shocks to 225 psi EVOL/125 psi Main. JJJJ MMMM KKKK 18. Using an appropriate inflation needle, charge the reservoir to 250 psi. 19. Using an appropriate strap wrench, tighten the air sleeve into the rebound eyelet assembly.

  • Page 190: Servicing Mono-Tube Shock Absorbers

    Servicing Mono-Tube Shock Absorbers ! WARNING Before starting, read through all of these instructions first to become familiar with the procedure. Make sure the work area is clean and all of the necessary tools are available. These shocks contain high pressure nitrogen gas.
  • Page 191 12. Loosen and remove the nitrogen valve from the body. FS016 ! WARNING Point the nitrogen valve away from face and body to FS014 13. Remove the shock body from the vise; then invert avoid injury when discharging or charging the shock. the shock body and place it on a folded shop towel 6.
  • Page 192 19. Hold the tip of a screwdriver against the end of shaft; then hold the piston assembly under the top-out plate and lift upwards. FS011 CAUTION Care must be taken when using a scribe to remove a FS009 seal. Always spear the seal with the point of the scribe.
  • Page 193 FS015 FS007 7. Using Floating Piston Location Gauge, install the 10. Install the new, well greased O-ring onto the IFP. floating piston while using the inflation needle to 11. Replace the bearing bleed screw O-ring. vent the shock body. ASSEMBLING ...
  • Page 194 13. As the bearing assembly is being threaded down, it 21. Insert the needle squarely into the center of the nitro- will contact the damping piston assembly and pull it gen valve (taking care that the valve is directed away down into the shock body with it.

  • Page 195: Pressurizing Rebuildable Shocks

    1. Insert the Inflation Needle into the shock bladder; Pressurizing Rebuildable then open the valve on the filler handle. Shocks 2. Turn the nitrogen tank valve open and slowly rotate the regulator T-handle inward until the gauge reads 200 lb of pressure; then close filler valve and remove To pressurize the gas shock absorber, a regulator system inflation needle.
  • Page 196 Printed in U.S.A. Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701 p/n 2259-956...

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