Arctic Cat Sno Pro 120 Manuals

Manuals and User Guides for Arctic Cat Sno Pro 120. We have 1 Arctic Cat Sno Pro 120 manual available for free PDF download: Service Manual

Arctic Cat Sno Pro 120 Service Manual

Arctic Cat Sno Pro 120 Service Manual (471 pages)

Brand: Arctic Cat | Category: Snowmobiles | Size: 130.68 MB

Table of Contents

Table of Contents
2
Table of Contents
3
General Information
3
Specifications
3
General Specifications
4
Snowmobile Identification
4
Recommended Gasoline and Oil
4
Engine Break-In
4
Clutching
5
Drive Belt Break-In
5
Genuine Parts
5
Varying Altitude Operation
5
- Initial Setting Chart
  6
- M/XF High Country
  6
- Suspension
  6
- Turbocharging
  6
- Track
  7
Preparation for Storage
7
- Carburetor Jetting
  8
- Drive Belt Deflection
  8
Preparation after Storage
8
After Break-In Checkup/Checklist
8
Track Tension and Alignment
9
Engine Specifications
10
Crankshaft Runout/Repair Specifications (2-Stroke)
11
Arctic Power Valve (APV) System Specifications (800 CC)
11
Carburetor Specifications (570 CC)
11
Electrical Specifications
12
Ignition Timing Specifications (2-Stroke)
13
Drive System Specifications
14
Drive Clutch/Driven Pulley-Related Specifications
14
Drive System Components
14
Drive Belt Dimensions
14
Gear Case Performance Calibrations
15
Chain Case Performance Calibrations
16
- Sway Bars
  17
- Springs
  17
Suspension Specifications
17
Track Specifications
17
- Steering/Front Suspension/Chassis
  18
- Drive System
  18
Torque Specifications
18
Torque Conversions
19
- Engine
  21
- Engine Removing/Installing - Bearcat 570/F570/T570
  22
- Special Tools
  22
- Assembly Schematic - 570 CC
  28
- Engine Removing/Installing - F5 LXR
  30
- Assembly Schematic - 500 CC
  38
- Engine Removing/Installing - F/M/XF 800
  40
- Assembly Schematic - 800 CC
  46
- Engine Removing/Installing - Bearcat Z1 XT/TZ1
  48
- Engine Torque Patterns (1100 CC)
  61
- Assembly Schematic - 1100 CC
  62
- Engine Removing/Installing - F/M/XF 1100
  64
- Assembly Schematic - 1100 CC
  80
- Engine Servicing - 570 CC
  83
  - Crankcase
    88
  - Cylinders
    88
  - Piston Assembly
    88
  - Crankshaft
    89
  - Insulator Plates
    89
  - Removing Outer Crankshaft Bearings
    89
  - Installing Outer Crankshaft Bearings
    90
  - Reed Valve Assembly
    90
  - Cylinder Head Volume
    91
  - Cylinder Trueness
    91
  - Measuring Critical Components
    91
  - Piston-Ring End Gap
    91
  - Connecting-Rod Small End Bore
    92
  - Crankshaft Runout
    92
  - Piston Pin and Piston-Pin Bore
    92
- Engine Servicing - 500 CC
  99
- Cylinder Head
  103
- Engine Servicing - 800 CC
  115
- Engine Servicing - 1100 CC
  134
  - Servicing Components
    140
  - Valves
    140
  - Cleaning/Inspecting Piston
    143
  - Cleaning/Inspecting Piston Ring Grooves
    143
  - Removing Piston Rings
    143
  - Measuring Piston Pin Diameter
    144
  - Measuring Piston Skirt/Cylinder Clearance
    144
  - Measuring Piston-Ring End Gap
    144
  - Piston Ring/Groove Clearance
    144
  - Cleaning/Inspecting/Measuring Cylinder Block
    145
  - Installing Piston Rings
    145
  - Bearing Selection Charts
    146
  - Crankcase Stamping
    146
  - Crankshaft Stamping
    146
  - Main Bearings
    146
  - Connecting Rod Bearing Selection
    147
  - Thrust Bearing Selection
    147
  - Engine Does Not Start
    157
  - Engine Overheats
    157
- Troubleshooting Engine (2-Stroke Carbureted)
  157
  - Engine Backfires
    158
  - Engine Four-Cycles
    158
  - Engine Stops Gradually
    158
  - Engine Stops Suddenly
    158
  - Engine Does Not Start (Fuel Does Not Ignite)
    159
  - Engine Does Not Start (no Fuel at Cylinders)
    159
  - Engine Does Not Start (no Spark at Spark Plugs)
    159
- Troubleshooting Engine (2-Stroke EFI)
  159
  - Engine Four-Cycles (Floods Excessively)
    160
  - Engine Loses Power or Runs on One Cylinder
    160
- Troubleshooting Engine (4-Stroke)
  161
  - Engine Loses Power
    162
  - Engine-Related Items
    163
- Engine-Related Items
  164
- Water Pump (500 CC)
  164
- Water Pump (800 CC)
  167
- Water Pump (1100 CC)
  171
- Changing Oil/Filter (F/M/XF 1100 CC)
  173
- Checking Compression (1100 CC)
  173
- Pressure Testing Engine (2-Stroke)
  173
- Changing Oil/Filter (Bearcat/T-Series 1100 CC)
  174
- Testing Oil Pressure (1100 CC)
  175
  - DRAINING COOLING SYSTEM (800 CC)
    176
  - Liquid Cooling System
    176
- Oil Flow Chart (1100 CC)
  176
  - Draining Cooling System
    177
  - Filling Cooling System
    177
  - Inspecting Coolant Hoses and Clamps
    177
  - Inspecting Thermostat
    177
- Liquid Cooling System (1100 CC)
  177
  - Filling/Bleeding Cooling System
    178
  - Bearcat/T-Series 1100 CC (Non-Turbo)
    179
- Cooling System Schematics
  179
- Recoil Starter (500 CC)
  181
- Recoil Starter (570/800 CC)
  182
- Air Silencer (570 CC)
  183
- Air Silencer (F5 LXR)
  184
- Air Silencer (Bearcat/T-Series 1100 CC Non-Turbo)
  185
- Fuel Systems
  187
- Air Silencer (1100 CC Turbo)
  189
- Air Silencer (F/M/XF 1100 CC Non-Turbo)
  189
- Turbocharger/Intercooler (F/XF/M 1100 CC Turbo)
  189
- Turbocharger/Intercooler (T-Series 1100 CC Turbo)
  193
- Arctic Power Valve (APV) System (800 CC)
  198
  - Exhaust Valve Cables
    199
  - Lighting Coil
    199
  - Servomotor Cycles Three Times
    199
  - Voltage Regulator/Rectifier
    199
  - Cable Adjustment
    200
  - Replacing Oil Seal
    201
- Exhaust Controlled Timing (ECT) System (800 CC)
  203
- Fuel Systems
  205
- Changing Main Jets
  206
- Fuel System (Carbureted)
  206
- Pre-Maintenance Checks
  206
- Carburetor
  207
  - Electrical Systems
    212
  - Choke Cables
    213
  - Piston Valves
    213
  - Synchronizing Piston Valves
    213
  - Engine Idle Speed
    214
  - Pilot Air Screws
    214
- Throttle Cable
  214
- Choke Cable
  215
- Fuel Pump
  215
  - Preliminary Checks
    215
  - Testing Vacuum
    216
- Troubleshooting
  216
- Fuel System (EFI)
  217
- Individual Components
  217
  - Installing (Bearcat/F-Series/T-Series)
    217
  - Air Temperature Sensor
    218
  - Barometric Pressure Sensor
    218
  - Fuel Injectors
    218
  - Ignition Timing Sensor
    218
  - Throttle Position Sensor
    218
  - Crankshaft Position Sensor
    219
  - Exhaust Air Temperature (Eat) Sensor
    219
  - Fuel Pressure Regulator
    219
  - Fuel Pump Circuit
    219
  - ECU Diagnostic Codes - 4-Stroke
    220
  - Knock Sensor
    220
- Self-Diagnostic System/Codes
  220
- Wastegate Control Valve
  220
- Fuel Pressure Regulator
  221
- Throttle Body Assembly
  221
- Fuel Filter (1100 CC)
  226
- Throttle Cable
  226
- Fuel Pump (F/M/XF)
  227
- Fuel Pump (Bearcat/F-Series/T-Series)
  229
- Troubleshooting
  230
- Oil-Injection Pump
  231
  - Testing Check Valves
    232
  - Testing Pump
    232
- Gas Tank
  233
- Electrical Systems
  235
- Electrical Systems
  236
- Ignition System
  236
  - Throttle Control Switch
    236
  - Carburetor Safety Switches (570 CC)
    237
  - Main Wiring and Safety Switches
    237
  - Synchronizing Carburetor Safety Switches (570 CC)
    237
  - Checking Tps
    238
- Throttle Position Sensor
  238
- Verifying Tps Adjustment Tool
  238
- Electrical Resistance Tests
  241
  - Ignition Coil (Primary)
    241
  - Ignition Switch
    241
  - Spark-Plug Cap
    241
  - Coolant Temperature Sensor
    242
  - Exhaust Temperature Sensor
    243
  - Fuel Injector
    243
  - Magneto Coil
    243
- Voltage Regulator/Ccu Tests
  244
- Accessing CCU Codes
  245
- Chassis Control Unit (Ccu)/Codes (F5 LXR)
  245
- Clearing Fault Codes
  245
- Testing Oil Level Sensor (2-Stroke)
  245
- Emergency Stop Switch
  246
- Resistance
  246
- Starter Relay Solenoid
  246
- Testing Fuel Gauge Sender
  246
- Fuse
  247
- Ignition Switch
  247
- Starter Motor (2-Stroke)
  247
  - Assembling Pinion
    248
  - Cleaning and Inspecting Pinion
    248
  - Disassembling Pinion
    248
  - Testing Starter Motor
    248
- Starter Motor (4-Stroke)
  249
- Magneto (4-Stroke)
  252
- Troubleshooting Electric Start
  252
- Brakelight Switch
  255
- Headlight Dimmer Switch
  255
- Ignition Timing (2-Stroke)
  255
- Testing Handlebar Warmer/Thumb Warmer Switch
  256
- Testing Thumb Warmer Element
  256
- Testing Passenger Handwarmer Elements
  257
- Testing Passenger Handwarmer Switch
  257
- Testing Seat Heater Harness/Switches
  257
- Testing Gear Position Switch
  258
- Testing Shift Switch
  258
- Testing Speedometer Sensor
  258
- Servomotor/Potentiometer Test (800 CC)
  259
- Testing Shift Actuator (500/1100 CC)
  259
- Troubleshooting Servomotor
  260
- Voltage/Resistance Chart - Air Temperature
  262
- Voltage/Resistance Chart - Coolant Temperature
  262
  - 2012 Snowmobile Wiring Diagrams
    263
  - Drive Train/Track/Brake Systems
    293
- Drive Belt
  294
Rear Suspension
294
- Drive Train/Track/Brake Systems
  294
- Changing Cam Arms/Springs
  295
- Drive Clutch
  295
- Driven Pulley (Bearcat/F-Series/T-Series)
  296
- Driven Pulley (F/M/XF)
  301
  - Replacing Rollers
    302
  - Replacing Torque Bracket Bearing/Cover Bearing
    302
  - Checking Offset
    304
  - Checking Parallelism
    304
  - Correcting Offset
    304
- Drive Clutch/Driven Pulley
  304
- Drive Belt Deflection
  305
- Drive Train (Bearcat/F-Series/T-Series)
  305
  - Removing Gear Case/Track Driveshaft
    305
  - Vertical Parallelism
    305
  - Disassembling Gear Case
    310
- Drive Train (F/M/XF 800)
  317
- Drive Train (F/M/XF 1100)
  321
- Drive Sprockets
  329
- Track Tension
  332
- Track Alignment
  333
- Brake System (Hydraulic)
  334
  - Checking Brake Lever Travel
    334
  - Bleeding Brake System
    335
  - Changing Brake Fluid
    335
  - Checking and Adding Brake Fluid
    335
- Brake Lever/Master Cylinder Assembly
  347
- Troubleshooting Track
  348
  - Caliper Leaks
    349
  - Lever Spongy — Bottoms out
    349
  - Oscillation Feedback in Lever
    349
- Troubleshooting Hydraulic Brake System
  349
  - Driven Pulley Vibrates
    350
  - Excessive Belt Deposits
    350
  - Midrange Shift-Up
    350
- Troubleshooting Drive Clutch/Driven Pulley
  350
  - Heavier or Stiffer Springs
    352
  - Ski Shock Absorber Springs
    352
- Suspension Setup Basics
  352
  - Understanding the Suspension
    352
  - Adjusting Ski Shocks
    353
  - Front Arm Spring Tension
    353
  - Spring Tension too Soft
    353
  - Adjusting Rear Arm Coupler
    354
  - Front Arm Limiter Straps
    354
  - Rear Arm Shock Spring (M/Xf)
    354
  - Rear Arm Spring Tension
    354
  - End Caps
    355
  - Removing Skid Frame
    355
- Servicing Suspension (Bearcat XT)
  355
  - Wear Strips
    355
  - Shock Pads
    356
  - Idler Wheels/Mounting Blocks
    357
  - Articulating Skid Frame
    372
  - Installing Skid Frame
    373
- Servicing Suspension (F/M/XF)
  375
- Rear Arm Assembly (M/XF)
  381
- Servicing Suspension (Bearcat 570/T-Series)
  389
- Servicing Suspension (F-Series)
  407
- Rebuilding/Recharging Fox Air Shocks
  424
- Servicing Fox Zero Pro Shock Absorbers
  429
- Pressurizing Rebuildable Shocks
  434
- Steering and Body
  435
- Steering and Body
  436
- Steering Post (F/M/XF)
  436
- Steering Post (Bearcat/F-Series/T-Series)
  439
- Ski
  442
- Drag Link (Bearcat/F-Series/T-Series)
  443
- Ski Wear Bar
  443
- Tie Rods (Bearcat/F-Series/T-Series)
  445
- Spindle (Bearcat/F-Series/T-Series)
  446
- Spindle (F/M/XF)
  448
- Steering Tie Rod (F/M/XF)
  450
- Steering Tie Rod (Bearcat/F-Series/T-Series)
  451
- Ski Alignment
  452
- A-Arms (F/M/XF)
  454
- A-Arms (Bearcat/F-Series/T-Series)
  456
- Ski Shock Absorber
  457
- Series)
  458
- Sway Bar (F-Series/T-Series)
  458
- Sway Bar (F/XF)
  458
- Front Bumper (F/M/XF)
  462
- Seat Assembly (F/M/XF)
  462
- Seat Assembly (Bearcat/F-Series/T-Series)
  463
- Seat Cushion
  463
- Taillight/Brakelight Assembly
  464
- Backrest/Rack Assembly (Bearcat)
  465
- Rear Bumper/Snowflap (Bearcat/F-Series/T-Series)
  465
  - Installing Bumper
    466
  - Installing Snowflap
    466
- Rear Bumper/Snowflap (F/M/XF)
  466
- Removing Snowflap
  466
- Headlight Assembly (Bearcat/F-Series/T-Series)
  467
- Windshield/Console (Bearcat/F-Series/T-Series)
  467
  - Installing Console
    468
  - Installing Windshield
    468
  - Removing Console
    468
  - Removing Windshield
    468
- Adjusting Headlight Aim
  469
- Headlight Bulb (F/M/XF)
  469

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