Arctic Cat ZR 6000 R CROSS COUNTRY Operator's Manual
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Arctic Cat ZR 6000 R CROSS COUNTRY Operator's Manual

Arctic cat zr 6000 r cross country
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ZR 6000 R CROSS COUNTRY
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Summary of Contents for Arctic Cat ZR 6000 R CROSS COUNTRY

  • Page 1 O P E R A T O R ’ S M A N U A L ZR 6000 R CROSS COUNTRY www.arcticcat.com...

  • Page 2: Limited Warranty

    Snowmobile or will not damage the Arctic Cat Snowmobile. Arctic Cat does not assume any liability for incidental or consequential damages. Arctic Cat will repair or replace, at its option, free of charge (including any related labor charges), any parts that are found to be warrantable in material or workmanship.
  • Page 3 At the time of publication, all information and illustrations were technically correct. Some illustrations used in this manual are used for clarity purposes only and are not designed to depict actual conditions. Because Arctic Cat Inc. constantly refines and improves its products, no retroactive obligation is incurred.

  • Page 4: Parts And Accessories

    No warranty will be allowed the entire Operator’s Manual and Safety Handbook. by Arctic Cat Inc. if the engine serial number or VIN is Failure to follow this warning could result in personal removed or mutilated in any way.

  • Page 5: Table Of Contents

    Preparation For Storage ........... 89 Checking Headlight Aim........20 Preparation After Storage......... 90 Track Tension/Track Alignment......21 Genuine Arctic Cat Products ........91 Test Ride ............... 22 Special Tools ............. 92-101 General Information ..........23-25 Declaration of Conformity....Inside Back Cover Control Locations..........

  • Page 6: Specifications/Charts/Patterns/Diagrams

    Gasoline (Recommended) 91 Octane (minimum) Torque Item Secured to ft-lb Engine Oil Arctic Cat CTec2 Spindle Chain Case Lubricant Arctic Cat Chain Lube Wearbar Suspension Grease All-Temperature Ski Handle 54 in.-lb Brake Fluid High-Temp DOT 4 Handlebar Adjuster Post Taillight/Brakelight Bulb p/n...

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

     NOTE: The proper location for checking crankshaft Torque Conversions runout is the very edge of the straight portion of the (ft-lb/N-m) shaft where the oil seal makes contact. From the illus- tration, note that three check points are called out: at either end, out on the taper as shown, and also on the center bearing race.

  • Page 8: Component Voltage/Resistance Chart - Water Temperature

    Electrical Specifications Component Voltage/ Resistance Chart - Water Temperature Component Test Value + Test Connections - Spark Plug Cap 4000-6000 ohms cap end cap end Oil Level Sensor Less than 1 ohm terminal terminal (float end down) Temperature Volts Ohms Temperature Volts Ohms Ignition Switch...

  • Page 9: Drive System Specifications

    12.10” 1.485” None Drive Clutch/Driven Drive Clutch Cam Arms Clutch Optional (w/Set Screw) Components ARCTIC CAT DRIVE CLUTCH CAM ARMS Grams Grams ARCTIC CAT DRIVE CLUTCH SPRING CHART 0746-661 52.0 0746-712 77.0 Rate @ 2 9/16" Rate @ 1 5/16"...

  • Page 10: Chain Case Performance Calibrations

    Chain Case Performance Calibrations NOTE: The following table should be used as a guide only. NOTE: The above gearing options are combinations which allow acceptable chain tension. Any other combinations will not allow acceptable chain tension.

  • Page 11: Chains And Sprockets

    Chains and Sprockets Wire Number Coil Angle Length Length Degree Diameter Width (In lb) Coils 1704-382/ .359 90° 5.75 3.00 15.62 4.60 Part (Light) Sprocket Number 1704-384/ .375 90° 5.75 3.00 15.62 4.60 2602-582 SPROCKET, REX-19T FWD-(13 WIDE/19 SPLINE) (Heavy) 2602-523 SPROCKET, REX-20T FWD-(13 WIDE/19 SPLINE) 1704-916/ .405...

  • Page 12: Rebuildable Shock Tools Required

    Rebuildable Shock Tools Required Tool 0744-020 Inflation Needle 0644-486 Gas Shock Retaining Blocks 0644-544 Replacement Needle 0644-169 Piston Location Tool 0644-151 Nitrogen Regulator 0644-268 Bearing Cap Seal Protector 0644-403 Bearing Cap Seal Protector (1/2-in. O.D. x 3/8 in. I.D.) 0644-404 Bearing Cap Seal Protector (5/8-in. O.D. x 3/8 in. I.D.) 0644-542 Bearing Cap Seal Protector (5/8 in.

  • Page 13: Valve Stacks/Specifications

    Valve Stacks/ Specifications Part Number Description Compression (Piston Side) Rebound (Piston Side) 3703-346/347 Ski Shock 1.300 x 0.008 in. 1.100 x 0.008 in. Extended Length: 18.94 in. Rebuild Kit - p/n 2603-929 1.300 x 0.008 in. 0.800 x 0.004 in. Collapsed Length: 13.29 in.

  • Page 14: Rebuildable Shock Accessory Part Numbers

    Valve: [1.250 OD X 0.377 ID X 0.012 TH] NOTE: Shock Oil (p/n 5639-530) is available from 0603-889 Valve: [1.250 OD X 0.377 ID X 0.015 TH] Arctic Cat Service Department. 0603-348 Valve: [1.300 OD X 0.377 ID X 0.006 TH] 0603-349 Valve: [1.300 OD X 0.377 ID X 0.008 TH]...

  • Page 15: Fraction/Decimal Conversion Chart

    Double Bleed Shims (DB) Drill Bit Sizes AC PN Description (Number) Chart 3603-342 Valve: DB 3 PORT (1.30" OD X .375" ID .004" THK.) 3603-343 Valve: DB 3 PORT (1.30" OD X .375" ID .006" THK.) 3603-344 Valve: DB 3 PORT (1.30" OD X .375" ID .008" THK.) Size of Size of Size of...

  • Page 16: Mm/In. Conversion Chart

    MM/IN. Conversion Chart .00039 .02008 .03937 2.00787 .00079 .02047 .07874 2.04724 .00118 .02087 .11811 2.08661 .00157 .02126 .15748 2.12598 .00197 .02165 .19685 2.16535 .00236 .02205 .23622 2.20472 .00276 .02244 .27559 2.24409 .00315 .02283 .31496 2.28346 .00354 .02323 .35433 2.32283 .00394 .02362 .39370 2.36220...

  • Page 17: Wiring Diagram - Hood Harness

    Wiring Diagram - Hood Harness (p/n 1686-706) - Cross Country 0748-009...
  • Page 18 NOTES...

  • Page 19: Wiring Diagram (Ignition/Main) (Harness P/N 1686-732)

    Wiring Diagram (Ignition/Main) (Harness p/n 1686-732) 0747-813...

  • Page 21: Setup Instructions

    Installing Spindle/A-Arm Setup Instructions This snowmobile has been prepared at the factory to minimize required setup items; however, there are some items and inspections that must be done at a dealership or by the owner/operator. Please pay close attention to all items on the following pages. Be sure to read these instructions thoroughly before starting to set up the snowmobile.

  • Page 22: Sway Bar

    Always comply with the maximum width laws and/or 2. If the brake fluid level is below the low mark, regulations when adjusting ski stance. remove the reservoir cover and add Arctic Cat  approved brake fluid until the fluid level is just NOTE: Install the cap screw so the lock nut will be below the high mark.
  • Page 23 2. From the riding position on the snowmobile, 7. Measure the distance from the straightedge to the check that the handlebar is in a straight-forward right-side ski edge in two places: 35.5-38.1 cm direction for driving. (14-15 in.) in front of the spindle and 35.5-38.1 cm (14-15 in.) behind the spindle.

  • Page 24: Recommended Gasoline

    SMOKE while filling the gas tank. Do not sit on the snowmobile without first installing the gas tank cap. Engine Break-In 0743-088 The Arctic Cat engine (when new or rebuilt) requires a short break-in period before the engine is subjected to Recommended Gasoline heavy load conditions.

  • Page 25: Track Tension/Track Alignment

    2. Measure the distance from the floor to midpoint of the headlight. 3. Using the measurement obtained in step 2, make a horizontal mark on the aiming surface. 4. Make a vertical mark which intersects the horizon- tal mark on the aiming surface directly in front of the headlight.

  • Page 26: Test Ride

    6. Start the engine and accelerate slightly. Use only 9. Loosen the right-side rear axle nut; then on the enough throttle to turn the track several revolu- side of the track which has the inner track drive tions. Shut engine off. lugs closer to the rear idler wheel, rotate the adjusting bolt clockwise 1-1 1/2 turns.

  • Page 27: General Information

    2. While holding the cable housing, lightly pull on General Information one cable end to remove slack. 3. Measure the amount of exposed cable from the cable housing to the end of the cable. Control Locations 0746-486 Arctic Power Valve (APV) System This RPM and exhaust pipe temperature controlled 0735-516 servomotor (servo) actuation system adjusts the size of...

  • Page 28: Testing Exhaust Temperature Sensor

    If leakage or damage is detected and the operator does not feel qualified to service the cooling The handlebar can be adjusted to the operator’s prefer- system, see an authorized Arctic Cat Snowmobile ence. To adjust the handlebar, use the following proce- dealer for this service.

  • Page 29: Drive Clutch And Driven Clutch

    International Snowmobile Racing, Inc. regulations as they pertain to the type of racing you CAUTION participate in. Arctic Cat has a variety of studding Use Clutch Puller (p/n 0744-062). Never substitute a products available from your authorized Arctic Cat different puller or drive clutch damage will occur.

  • Page 30: Operating Instructions

    Cold seizure Add Arctic Cat approved brake fluid as necessary. and piston scuffing caused by insufficient warm-up will not be covered by warranty. Also, do not idle the engine for excessively long periods of time.

  • Page 31: Emergency Stopping

    There are several methods of stopping or slowing the snowmobile under a variety of situations. Identified in Use only Arctic Cat approved brake fluid. Never sub- the following chart are the ways a snowmobile may be stitute or mix different types or grades of brake fluid.

  • Page 32: Lubrication

    NOTE: If excessive oil deposits are observed, the Lubrication chain case must be serviced. Also, when the oil level is at the add mark, approximately 2 fl oz of transmis- sion lube must be added to the chain case. Chain Case CAUTION The recommended amount of synthetic chain lube in the chain case is 15 fl oz.

  • Page 33: Maintenance

    Maintenance The longevity and safety of the snowmobile can be increased by making periodic checks of the items in the follow- ing checklist. Perform maintenance checks more often if the snowmobile is used under severe conditions. Periodic Maintenance Checklist EVERY EVERY EVERY INTERVAL...

  • Page 34: Pre-Race/Practice Checklist

    If the operator does not feel qualified and resonator. to service the suspension, see an authorized Arctic Cat Snowmobile dealer for this service. 3. Remove the torx screw from the driven clutch and slide the driven clutch (along with the drive belt) off the driven shaft.
  • Page 35 4. Using Drive Clutch Bolt Tool, remove the torx-head screw and high-collar washer securing the drive clutch to the crankshaft. 5. Using Drive Clutch Puller and Drive Clutch Spanner Wrench, tighten the puller. Remove the drive clutch.  NOTE: If the drive clutch will not release, sharply strike the head of the puller.

  • Page 36: Special Tools

    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 37 1. Using the Flywheel Spanner Wrench to secure the flywheel, remove the flywheel cap screw and washer; then remove the cap screws securing the recoil cup. CWI-074A 6. Remove the screws securing the stator to the stator plate. Route the stator lead wire out of the crankcase; then remove the stator assembly.
  • Page 38 CWI-006A CWI-011A 9. Disconnect the coolant hose from the back of the cyl- 12. Remove the eight nuts securing the cylinders to the inder head. crankcase; then using a soft hammer, gently tap the cylinders and remove from the crankcase by lifting 10.
  • Page 39 CWI-014 CWI-081 17. Remove the four screws securing the thermostat cap; CAUTION then remove the cap, gasket, and thermostat. DO NOT use any type of punch to drive the piston pin free of the piston; damage may result. Use a piston-pin puller only.
  • Page 40 CWI-016A CWI-023A 19. Remove the cap screw securing the impeller. Account 21. Tip the crankcase assembly up onto the water pump for the rubber washer and gasket behind the cap screw. side; then remove the black torx-screw from the bot- Remove the impeller from the shaft.

  • Page 41: Cylinder Head

    FC036 CWI-076 28. Using a pair of snap ring pliers, remove the snap ring CAUTION securing the inner seal in the crankcase. DO NOT drive any tool between halves (sealing surface) 29. Using the hooked end of the tool, pull the inner seal to separate the crankcase.
  • Page 42 Arctic Cat recommends the crankshaft be taken to a ure eight motion until a uniform bright metallic fin- qualified crankshaft rebuild shop for that service.
  • Page 43 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 44 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 45 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 46 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 47 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 48 CWI-020 CWI-078A 19. 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. 22.
  • Page 49 27. 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. 28. 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 50 35. Route the stator harness through the opening in the crankcase; then secure the stator to the stator plate with the screws (coated with blue Loctite #243). Tighten to 10 ft-lb. 36. Secure the upper ignition timing sensor with cap screws (coated with blue Loctite #243).
  • Page 51 1. Carefully lower the engine into the engine compartment. 12. Before connecting the wiring harness plug-ins, clean the connectors and apply Dielectric Grease to the 2. Install the coolant hose to the heat exchanger at the seal; then connect all harness connectors making rear of the engine;...
  • Page 52 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 53: Track Drive

    32. Check drive belt deflection. 33. Place the hood into position on the front end and secure with the screws; then install the hood harness. Install the side access panels. CAUTION Never run the engine with the hood harness discon- nected or damage to the electrical system will result.

  • Page 54: Drive Sprockets

    PC148A RA027A 9. Pull the driveshaft out to the left; then drop out of 1. For installing purposes, scribe a line on the drive- tunnel right side first. shaft (A) next to the drive sprocket for proper align- ment; then scribe a line on the driveshaft directly in NOTE: At this point, inspect the bearings for line with the timing arrows (B) on the drive sprock- wear or roughness.

  • Page 55: Brake System

    0747-025 Brake System Arctic Cat recommends that the brake system (brake lever, reservoir, hose, caliper, pads, and brake disc) be checked daily for fluid leakage, wear, or damage and for proper operation. Also, the brake fluid level must be checked every time before starting the engine.

  • Page 56: Checking Brake Lever Travel

    Use only Arctic Cat approved brake fluid. Never substitute or mix 1. Remove the reservoir cover and fill the reservoir to different types or grades of brake fluid. Brake loss can the high mark with Arctic Cat approved brake fluid.

  • Page 57: Checking/Changing Brake Pads

    4. Repeat step 3 until the brake fluid flows free of air 4. Using a pair of pliers, pull one brake pad out of the bubbles. caliper assembly. NOTE: It may be necessary to refill the reservoir NOTE: Changing one pad at a time will prevent during the bleeding process.

  • Page 58: Drive Belt

    NOTE: Drive belts should be purchased from an. Drive Train/Track/Brake authorized Arctic Cat Snowmobile dealer, as Arctic Systems Cat drive belts are made to exact specifications and of quality material. Belts made by other manu- facturers may not be of the same specifications or...

  • Page 59: Drive Clutch

    6. When the belt is free of driven clutch, remove the belt from the drive clutch. Installing 1. Place the belt (so the part number can be read) between the sheaves of the drive clutch. 2. With the sheaves fully apart, roll the belt over the stationary sheave.

  • Page 60: Driven Clutch

    2. Remove any drive belt dust accumulation from the stationary sheave, movable sheave, and bushings using parts-cleaning solvent only. 3. Inspect stationary sheave, movable sheave, spider, and cover for cracks or imperfections in the casting. 4. Inspect the cam arm pins for wear or bends. 5.
  • Page 61 4. Remove the movable sheave from the driven clutch shaft and account for one spacer. Cleaning And Inspecting NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. 1. Using a parts-cleaning solvent, wash grease, dirt, and foreign matter off all components;...

  • Page 62: Drive Train

    4. With Driven Clutch Compressor (p/n 0644-444), 4. Remove the resonator; then remove the right-side footrest. compress the roller assembly enough to allow the snap ring to be properly secured to the shaft. 5. Remove the torx-head screw securing the belly pan to the right-side footrest support.
  • Page 63 14. Remove the skid frame assembly. 15. Remove the brake shield and the left-side footrest.  NOTE: DO NOT split the brake caliper unless neces- sary service work is required. 16. Remove the cap screws securing the inner caliper to the tunnel;...
  • Page 64 3. Clean all interior chain case surfaces and compo- 6. Install the skid frame (see the Suspension section). nents in cleaning solvent and dry using compressed 7. Install the brake shield and left-side footrest. Tighten air. the cover cap screws to 8 ft-lb. ! WARNING ...

  • Page 65: Servicing Float X Evol Shock Absorbers

    (threads coated with blue Loctite #243). Tighten in a crisscross pattern to NOTE: When depressurizing the chambers, a 12 ft-lb. Fill the chain case with 15 oz. of Arctic Cat “hissing” should be noticed as air is released. Chain Lube.
  • Page 66 5. Remove the shock from the vise, invert it, and clamp it in the vise by the reservoir eyelet. 6. Unthread the air sleeve from the EVOL chamber by hand and slide it down the body. 7. Using a 5/64-in. hex key, remove the button screw from the nitrogen pellet valve.
  • Page 67 10. Using a 5/64-in. hex key, carefully loosen the bleed set screw; then remove the ball bearing and set it aside. NOTE: It is advisable to use a small magnet to 9. Press down on the reservoir end cap; then using a remove the ball bearing from the hole.
  • Page 68 14. Using a scribe or pick tool, remove the “samurai” and back-up seals from the air sleeve. CAUTION Care must be taken not to score or damage any of the aluminum sealing surfaces. 13. Remove the air sleeve from the reservoir end of the shock.
  • Page 69 17. Remove the IFP bleed screw and set aside. 18. Using the new seals from the appropriate seal rebuild kit, replace all IFP seals. 16. Using an appropriate IFP removing tool, remove the IFP from the “piggy-back” body. 19. Pour the shock oil out of the “piggy-back” body assembly.
  • Page 70 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. 20. Using a 5/8-in. wrench, remove the LSC assembly from the eyelet, thoroughly clean the assembly, replace the O-rings, and install the assembly into the eyelet.
  • Page 71 3. At this point, the inside diameter of the new bush- ing must be re-sized. NOTE: To install a new DU bushing, an appropri- ate bushing installer (A), sizer (B), and machine A. Insert the sizer into the air sleeve. press must be available.
  • Page 72 C. Using the machine press, press the stack until the sizer falls free within the air sleeve. Remove the installer and the sizer. Disassembling Shaft Assembly 1. Using a 9/16-in. wrench, remove the shaft lock nut. 4. Apply an ample amount of petroleum grease to the “samurai”...
  • Page 73 NOTE: It is advisable to use cable ties to pre- 4. Remove the O-ring from the piston. serve the upper and lower shim stack/piston order. 5. Install a new piston O-ring; then using an appro- priate piston band installation tool, install a new band.
  • Page 74 7. Remove and replace all O-rings and seals.  NOTE: When installing the main seal, assure that it is oriented correctly. 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 2.
  • Page 75 5. Replace the IFP seal; then amply lubricate the IFP and place it into the reservoir. 6. Thread the EVOL reservoir onto the rebound eyelet; then 3. Using a shock absorber hand air pump, apply light pres- tighten to 12 ft-lb. sure to the reservoir to extract the IFP.
  • Page 76 Assembling Shock Absorber 1. Securely clamp the “piggy-back” body assembly in the vise; then using an appropriate air sleeve protector tool, slide the air sleeve over the body. 3. Install the lower and upper shim stack/piston assembly.  NOTE: Care must be taken that the preserved shim stack/piston assembly be installed correctly.
  • Page 77  NOTE: At this point, pour 3-5 cc of float fluid between the air sleeve and shock body. 2. Assuring that the LCS adjuster screw is rotated fully open (counterclockwise), fill the “piggy-back” reservoir with Fox High V1 Race Oil almost to the rim. 4.
  • Page 78 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 79 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 80 15. Slide the air sleeve down far enough to liberally lubricate the bearing head assembly. CCCC 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. Install the bleed screw. DDDD 14.

  • Page 81: Rear Suspension

    MMMM JJJJ NNNN Rear Suspension KKKK 18. Using an appropriate inflation needle, charge the The Sno Pro 600 is equipped with a compression adjust- reservoir to 250 psi (p/n 3703-064/065). able remote reservoir shock in the rear suspension sys- tem. This system utilizes front arm limiter straps. 19.

  • Page 82: Servicing Zero-X Shock Absorbers

    The skid frame front arm shock spring is adjustable. NOTE: Some illustrations and photographs used However, Arctic Cat recommends that the shock in the following sub-sections are used for clarity spring be adjusted to a maximum of 6.4 mm (1/4 in.) purposes and are not designed to depict actual up or down from the standard pre-load setting.
  • Page 83 NOTE: At this point, remove the set screw and discard the valve plug. Always install a new plug when servicing the shock absorber. 4. Depress the reservoir end cap and remove the end cap retaining ring. FS334 8. Remove the shock from the vise and pour shock oil into a proper disposal container.
  • Page 84 13. Using a 5/8-in. socket, remove the damping adjuster cartridge; then clean and inspect the inboard and outboard O-rings. FS337 FS292A CAUTION Care must be taken not to scratch the cartridge when removing O-rings. NOTE: At this point, inspect the re-flow check valve for smooth operation and for not being bent or deformed.
  • Page 85 FS343 FS348 16. Using a 9/16-in. wrench, remove the piston nut 2. Slide the bearing assembly over the protector tool from the end of the shaft. onto the shaft. FS344 FS349 17. Slide the piston assembly onto a T-handle wrench 3.
  • Page 86 FS351 FS354 5. Place the shock body and eyelet in the vise with 9. Install Floating Piston Location Gauge (p/n 0644- the open end directed up. 350) and cover the top of the tool with a towel; then slowly press the IFP into the oil until fully covered. 6.
  • Page 87 11. Turn the damping adjuster to the fully open posi- tion (counterclockwise). FS361 16. Install new O-rings and piston strap on the piston shaft assembly and lightly grease the piston strap; FS358 then insert the piston shaft assembly into the shock 12.
  • Page 88 FS364 FS368 18. While holding the shaft fully extended, slide the assembly into the shock body. NOTE: At this point, oil should overflow. If not, add recommended oil. FS369 21. While holding the IFP with the location gauge, install and tighten the relief screw. FS365 19.

  • Page 89: Adjusting Rear Transfer Adjuster Cams

    FS373 FS376 24. Install the set screw (FAV3 valve assembly) and 27. Install the bearings and retaining rings into the eyelets. tighten only until snug; then loosen two turns. NOTE: Ensure proper shock function prior to 25. Insert the needle squarely into the center of the installing on the snowmobile.

  • Page 90: Ski Wear Bar

    If the glass is touched, it must be cleaned with a the ski wear bar will wear faster. To maintain positive dry cloth before installing. steering characteristics, Arctic Cat recommends that the ski wear bars be checked before each use and 1. Disconnect the headlight harness connector from the replaced if worn beyond 1/2 of the original diameter.

  • Page 91: Rail Wear Strip

    2. Remove the lock nuts (and washers on the Sno Cross model) securing the wear bar to the ski. Arctic Cat recommends that the wear strips be checked weekly and replaced as necessary. Measure the wear strips at 25.4 cm (10 in.) intervals. Wear strips must be 10.7 mm (0.42 in.) thick or thicker.

  • Page 92: Performance Tips

    DRIVE CLUTCH AND DRIVEN CLUTCH — Performance Tips Keeping the drive clutch and driven clutch clean should be the primary consideration of the operator. The clutch sheaves can be cleaned of any drive belt accumulation using a clean cloth and parts-cleaning Operating a high performance snowmobile requires a solvent.

  • Page 93: Preparation For Storage

    Install the chain-case cover and seal; then pour Arctic Cat Synthetic Chain Lube (p/n 5639- Prior to storing the snowmobile, it must be properly 038) into the oil level stick filler hole according to serviced to prevent corrosion and component deterio- specifications.

  • Page 94: Preparation After Storage

    Arctic Cat adjust or replace as necessary. recommends the following procedure. 7. Inspect the spark plugs. Replace, gap, or clean as CAUTION necessary.

  • Page 95: Genuine Arctic Cat Products

    6/1 gal. cially for Arctic Cat Snowmobile engines. Arctic Cat Synthetic APV 2-Cycle Oil 16 gal. 2639-510 Oil is the only oil authorized by Suzuki and Arctic Cat Synthetic APV 2-Cycle Oil 2-1/2 gal. 2639-975 2—2-1/2 gal. engineers for use in Arctic Cat Snowmobile engines.

  • Page 96: Special Tools

    0744-040 (Complete Set) p/n: 0643-086 (Body) p/n: 0643-087 (Bolt) p/n: 0423-482 (6 mm Cap Screw) p/n: 0423-483 (8 mm Cap Screw) Usage: Pull flywheel off crankshaft on all Arctic Cat 2- stroke models. 0644-291 Flywheel Spanner Wrench p/n: 0144-007 Usage: Hold starter cup while removing/installing fly- wheel nut.
  • Page 97 Oil Seal Protector Tool Spring Tool p/n: 0644-219 p/n: 0644-072 Usage: Protect the oil seal when installing the water Usage: Remove/install exhaust springs. pump driveshaft on liquid cooled 2-stroke Arctic Cat engines. 0644-072 Stud Runner 0644-219 p/n: 0644-018 (6 mm)
  • Page 98 0644-535 p/n: 0444-213 (Complete Kit) Usage: Check crankshaft runout. p/n: 0444-207 (10 mm Adapter) p/n: 0444-093 (12 mm Adapter) Usage: Test cylinder compression on all Arctic Cat engines. 0644-535 Water Pump Bearing and Seal Tool Kit 0444-213 p/n: 0644-557...
  • Page 99 90° Hex Driver (1/4-in.) Drive Clutch Puller (Arctic) p/n: 0644-550 p/n: 0744-062 Usage: Make carburetor adjustments on all twin and tri- Usage: Remove drive clutch from the crankshaft on ple cylinder engines. Also, for any hard-to-get-at hex nuts. 2010-2012 models. (A.
  • Page 100 Drive Clutch Bolt Tool (Torx #60) Track Clip Installation Tool p/n: 0644-281 p/n: 0644-194 Usage: Remove/install drive clutch bolt. Usage: Install track clips on Camoplast and Yokohama rubber tracks. 0644-281 0644-194 Driven Clutch Compressor Tool p/n: 0644-444 Track Stud Hole Drill (7 mm) p/n: 0643-095 (A.
  • Page 101 Idler Wheel Puller Kit Gas Shock Retaining Blocks (Zero Pro) p/n: 0644-570 (Complete Kit) p/n: 0644-486 p/n: 0644-401 (A. Handle) Usage: Hold shock secure during disassembly and assembly. p/n: 0644-111 (B. Insertion Tool - 1.000 in.) p/n: 0644-569 (B. Insertion Tool - 1.560 in.) p/n: 0644-120 (C.
  • Page 102 Inflation Needle Replacement Piston Location Tool p/n: 0644-544 p/n: 0644-169 Usage: Replacement needle assembly for Inflation Nee- Usage: Precisely locate the floating piston in the rebuild- dle (p/n 0744-020). able gas shock absorber. 0644-544 0644-169 Piston Location (IFP) Tool Inflation Needle Replacement Tip p/n: 0644-539 p/n: 0644-575 Usage: Precisely locate the floating piston (IFP) in the...
  • Page 103 Axle Nut Spanner Wrench Insert Holder (5/16 in.) p/n: 0644-558 p/n: 0644-315 Usage: Adjust track alignment/tension (2010-2012 Sno Usage: With Torx Bit Insert (p/n 0644-314), remove and Pro 500 and Sno Pro 600). install torx-head screws. 0644-558 0644-315 Rear Suspension Spring Tool Phillips-Head Bits (1/4 in.
  • Page 104 Replacement Rivnuts Rivnut Tool Insert Bit p/n: 0623-557 (1/4 x 20) p/n: 0644-233 (1/4 x 20) p/n: 0623-582/627 (1/4 x 20) p/n: 0644-405 (10-32) p/n: 0623-581 (5/16 x 18) p/n: 0644-430 (5/16 x 18) p/n: 0623-699 (3/8 x 16) p/n: 0644-431 (3/8 x 16) p/n: 0623-874 (8-32) Usage: With Rivnut Tool (p/n 0644-232) and Replace- ment Rivnuts, replace rivnuts.
  • Page 105 T Wrench Torx Bits (1/4 in. Hex Drive) p/n: 0644-021 p/n: 0644-312 (#25) Usage: Drive 3/8 in. square-drive sockets. p/n: 0644-393 (#27) p/n: 0644-215 (#30) p/n: 0644-313 (#40) Usage: With Quick-Disconnect Coupler (p/n 0644-308), remove and install torx-head screws. 0644-021 Torx Bit Insert (5/16 in.
  • Page 106 NOTES...

  • Page 107: Declaration Of Conformity

    Declaration of Conformity Application of council directives: EMC Directive 2004/108/EC Issued by European Commission. EC Machinery Directive 2006/42/EC Type of Equipment: Snowmobile Brand Name: Arctic Cat Model Numbers: S2015ACDCCUSG Standards to which conformity is declared: EMC: EN 55012, EN 61000-6-2...
  • Page 108 Printed in U.S.A. Trademarks of Arctic Cat Inc. Thief River Falls, MN 56701 p/n 2260-495 ®TM Phone: (218) 681-9851 - U.S. (204) 982-1656 - Canada...

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