Arctic Cat ZR 6000R CC 2015 Operators Manual
OPERATOR’S MANUAL
ZR 6000 R CROSS COUNTRY
www.arcticcat.com
Limited Warranty
Arctic Cat Inc. (hereinafter referred to as Arctic Cat) extends a limited warranty as described below on each new Arctic Cat Snowmobile it assembles and on each
genuine Arctic Cat Snowmobile part and accessory assembled and sold by an authorized Arctic Cat Snowmobile dealer. The limited warranty on an Arctic Cat
Snowmobile is extended to the original retail purchaser for the time periods described below; however, the balance of the remaining warranty may be transferred to
another party unless the purchase is for commercial use (see below). Warranty coverage is only available in the country in which the original retail purchase occurs
to the original retail purchaser resident in that country or to a transferee resident in that country of the balance of the remaining warranty.
Arctic Cat warrants only the products it assembles and/or sells and does not warrant that other products will function properly when used with an ArcticCat
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.
This repair work MUST be done by an authorized Arctic Cat Snowmobile dealer. No transportation charges, rental charges, or inconvenience costs will be paid by Arctic
Cat. The warranty is validated upon examination of said parts by Arctic Cat or an authorized Arctic Cat Snowmobile dealer. Arctic Cat reserves the right to inspect such
parts at its factory for final determination if warranty should apply.
The warranty periods are as follows:
1. For snowmobiles used for recreational purposes:
—If purchased between May 1 and November 30, warranty expires ONE (1) YEAR from December 1 of the current year.
—If purchased between December 1 and April 30, ONE (1) YEAR from the date of sale.
2. For snowmobiles used for commercial purposes (including rental operations), ONE (1) YEAR from the date of invoice and/or 5000 MILES whichever comes first
(non-transferable).
3. THIRTY (30) DAYS from date of sale of snowmobile on Arctic Cat supplied batteries.
Exclusions to this warranty include normal wear, abuse (i.e. a track run on marginal snow conditions without proper lubrication or additional idler wheels), and the
following parts:
Fuel Filter Light Bulbs Windshield Drive Belt Torn or Punctured Upholstery
Wear Bars Brake Pads Spark Plugs Drive Clutch/Driven Clutch Wear Parts
Wear Strips Shock Absorber(s) - Standard* Shock Absorber(s) - Rebuildable**
* Limited to one (1) year or 1000 miles of “normal” riding conditions - replace for defective or leaking shock, corroded or pitted shaft, peeling chrome.
** Limited to one (1) year or 1000 miles of “normal” riding conditions - rebuild for leaking shock (warranted) - replace for defective shock, corroded or pitted shaft, peeling
chrome.
The following will VOID Arctic Cat’s warranty:
1. Failure to perform the proper break-in procedure and all related maintenance, storage procedures (if stored for extended periods), and/or serviceas
recommended in the Operator’s Manual.
2. Repairs and/or adjustments by anyone other than an authorized Arctic Cat Snowmobile dealer.
3. Use of an improper fuel mixture ratio.
4. Use of improper carburetor jets.
5. Use of improper gasoline, lubricating oils, or spark plugs.
6. An accident or subjecting the snowmobile to misuse, abuse, or negligent operation.
7. Any modification, addition, or removal of parts unless instructed to do so by Arctic Cat.
8. Use of the snowmobile in any way for racing pur poses.
9. Removal of the engine for use in another vehicle.
10. Removal or mutilation of the Vehicle Identification Number or Engine Serial Number.
11. Use of parts not sold or approved by Arctic Cat.
12. Track and tunnel damage resulting from either ice stud or hooker plate installation.
13. Damage due to improper transportation.
Arctic Cat shall not be responsible for and this limited warranty excludes recovery of economic, punitive, consequential and incidental damages, lost profits, and loss
of use. Some states or provinces do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation may not apply to you. Arctic
Cat’s aggregate liability may not exceed the price of the product. The law of the State of Minnesota shall apply to all claims or disputes, exclusive of its conflicts of
law provisions.
IMPLIED WARRANTY EXCLUSION AND DISCLAIMER
To the fullest extent permitted by law, Arctic Cat excludes and disclaims all implied warranties of merchantability and fitness for a particular purpose.
If you are not satisfied with warranty service or repairs, you should contact Arctic Cat at (U.S.) 1-218-681-9851 or (Canada) 1-204-982-1656.
FOREWORD
Congratulations! You have chosen a quality Arctic Cat Snowmobile designed and manufactured to give dependable service. Be sure, as the owner/operator of an Arctic Cat Snowmobile, to become thoroughly familiar with its
basic operation, maintenance, and off-season storage procedures. Read this manual and the accompanying Snowmobile Safety Handbook before operating the snowmobile to ensure safe and proper use of your new Arctic Cat
Snowmobile. Always operate the snowmobile within your level of skill and current terrain conditions.
The Operator’s Manual, Snowmobile Safety Handbook, and snowmobile decals display the words Warning, Caution, and Note to emphasize important information. The symbol
related information. Be sure to follow the directive because it deals with the possibility of severe personal injury or
even death. A CAUTION identifies unsafe practices which may result in snowmobile-related damage. Follow
the directive because it deals with the possibility of damaging part or parts of the snowmobile. The symbol
NOTE: identifies supplementary information worthy of particular attention.
This manual covers operator-related maintenance, operating instructions, and off-season storage instructions. If
major repair or service is ever required, contact an authorized Arctic Cat Snowmobile dealer for professional service.
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.
This Operator’s Manual should be considered a permanent part of the snowmobile and must remain with the snowmobile at the time of resale. If the snowmobile changes ownership more than once, contact Arctic Cat Inc., Service
Department, P.O. Box 810, Thief River Falls, MN 56701, for proper registration information.
! WARNING identifies personal safety-
Every Arctic Cat Snowmobile meets or exceeds the standards of the Snowmobile Safety and Certification Committee and displays the SSCC decal. Arctic Cat endorses and encourages the safe use of all snowmobiles. Always wear
a helmet and eye protection. Drive with caution, observe all state and local regulations, and respect the rights of
others. ISMA members like Arctic Cat do their part to improve trails, sponsor events, and generally support the
sport of snowmobiling. As a member of the National Snowmobile Foundation, Arctic Cat Inc. promotes snowmobiling through education, charity, and research programs.
© 2014 Arctic Cat Inc.
Printed in U.S.A. September 2014
! WARNING
This snowmobile is a very high performance snowmo-
bile. Because it does accelerate rapidly and is capable
of very high speeds, it should not be operated by a
novice or an inexperienced operator. Never accelerate
rapidly or drive at high speed beyond the limits of visibility or without being totally familiar with the terrain
and what lies in front of you. Obey speed limits and
never operate at speeds that do not allow adequate
maneuvering and stopping distances. Read and study
the entire Operator’s Manual and Safety Handbook.
Failure to follow this warning could result in personal
injury to yourself or others.
Reference Information
The Arctic Cat Snowmobile has two important identification numbers. The Vehicle Identification Number
(VIN) is stamped on the side of the tunnel. The Engine
Serial Number (ESN) is stamped into the crankcase of
the engine.
These numbers are required by the dealer to complete
warranty claims properly. No warranty will be allowed
by Arctic Cat Inc. if the engine serial number or VIN is
removed or mutilated in any way.
PARTS AND ACCESSORIES
When in need of replacement parts, oil, or accessories for your Arctic Cat Snowmobile, be sure to only
use GENUINE ARCTIC CAT PARTS, OIL, AND
ACCESSORIES. Only genuine Arctic Cat parts, oil,
and accessories are engineered to meet the standards
and requirements of your Arctic Cat Snowmobile.
For a complete list of accessories, refer to the current
Arctic Cat Accessory Catalog.
To aid in service and maintenance procedures on this
snowmobile, an Illustrated Parts Manual is available
through your local Arctic Cat Snowmobile dealer.
If the snowmobile is purchased
through the Team Arctic Race
Department Racing Program, there
is no warranty.
Always provide the snowmobile name, VIN, and ESN
when contacting an authorized Arctic Cat Snowmobile
dealer for parts, service, accessories, or warranty. If
the complete engine must be replaced, ask the dealer to
notify Arctic Cat for correct registration information.
Write the appropriate information for your Arctic Cat
Snowmobile in the spaces below. Always use these
numbers when referring to your snowmobile.
Model: ____________________________________
Date of Purchase: ____________________________
VIN (Vehicle Identification Number):_____________
ESN (Engine Serial Number): ___________________
Your Arctic Cat Dealer: ________________________
Address: ____________________________________
Phone: _____________________________________
TABLE OF CONTENTS
Specifications/Charts/Patterns/Diagrams.............. 2-15
General Specifications ............................................ 2
Engine Specifications ............................................. 2
Torque Specifications .............................................. 2
Torque Conversions (ft-lb/N-m) ............................... 3
Tightening Torque (General Bolts) .......................... 3
Crankshaft Runout/Repair Specifications ............... 3
Crankshaft Runout/Repair Specifications ............... 3
Arctic Power Valve (APV) System Specifications.... 3
Component Voltage/Resistance Chart - Water
Temperature......................................................... 4
Drive System Specifications ................................... 5
Drive Clutch/Driven Clutch Optional Components .. 5
Drive Clutch Cam Arms (w/Set Screw)................... 5
Chain Case Performance Calibrations.................... 6
Chains and Sprockets............................................. 7
Rear Spring Selection Chart................................... 7
Installed Spring Rate Chart .................................... 7
Front Suspension Sway Bar.................................... 7
Rebuildable Shock Tools Required ......................... 8
Optional Front Arm Shock Springs ......................... 8
Valve Stacks/Specifications .................................... 9
Rebuildable Shock Accessory Part Numbers ....... 10
Fraction/Decimal Conversion Chart ...................... 11
Drill Bit Sizes (Number) Chart............................... 11
MM/IN. Conversion Chart ..................................... 12
Wiring Diagram - Hood Harness........................... 13
Wiring Diagram - Ignition/Main Harness (p/n 1686-
732) ................................................................... 15
Setup Instructions ............................................... 17-22
Removing Snowmobile From Crate/Handlebar
Assembly ........................................................... 17
Installing Windshield ............................................ 17
Installing Spindle/A-Arm ....................................... 17
Installing Front Shock Absorbers .......................... 17
Installing Skis ........................................................ 17
Sway Bar............................................................... 18
Brake System........................................................ 18
Ski Alignment ........................................................ 18
Recommended Gasoline ...................................... 20
Preoperation Checks ............................................ 20
Checking Headlight Aim........................................ 20
Track Tension/Track Alignment.............................. 21
Test Ride ............................................................... 22
General Information ............................................ 23-25
Control Locations .................................................. 23
Arctic Power Valve (APV) System......................... 23
Exhaust Controlled Timing (ECT) System ............ 23
Arctic Power Valve (APV) System ......................... 23
Testing Exhaust Temperature Sensor ................... 24
Handlebar Tilt........................................................ 24
Rear Bumper......................................................... 24
Exhaust System .................................................... 24
Liquid Cooling System .......................................... 24
Drive Clutch And Driven Clutch............................. 25
Drive Clutch/Driven Clutch Alignment ................... 25
Shock Absorbers................................................... 25
Track Studs ........................................................... 25
Towing ................................................................... 25
Operating Instructions ......................................... 26-27
Starting And Stopping Engine ............................... 26
Braking.................................................................. 26
Emergency Stopping............................................. 27
Lubrication................................................................ 28
Chain Case ........................................................... 28
Rear Suspension .................................................. 28
Maintenance........................................................ 29-87
Periodic Maintenance Checklist ............................ 29
Pre-Race/Practice Checklist ................................. 30
Engine................................................................... 30
Track Drive ............................................................ 49
Drive Sprockets..................................................... 50
Brake System........................................................ 51
Brake Fluid ............................................................ 51
Checking Brake Lever Travel................................. 52
Bleeding Brake System......................................... 52
Checking/Changing Brake Pads ........................... 53
Drive Belt............................................................... 54
Drive Clutch........................................................... 55
Driven Clutch......................................................... 56
Servicing Float X Evol Shock Absorbers............... 61
Rear Suspension .................................................. 77
Servicing Zero-X Shock Absorbers ....................... 78
Adjusting Rear Transfer Adjuster Cams ................ 85
Lights .................................................................... 85
Ski Wear Bar ......................................................... 86
Rail Wear Strip ...................................................... 87
Performance Tips ..................................................... 88
Preparation For Storage........................................... 89
Preparation After Storage......................................... 90
Genuine Arctic Cat Products .................................... 91
Special Tools ..................................................... 92-101
Declaration of Conformity................ Inside Back Cover
1
General Specifications
Chassis Length 307 cm (121 in.)
Height 122 cm (48 in.)
Width 125-128 cm (49.25-50.25 in.)
Spindle Center-to-Center Distance 106-109 cm (41.90-42.90 in.)
Dry Weight (approx) 225 kg (495 lb)
Gas Tank Capacity 44.3 l (11.7 U.S. gal.)
Chain Case Lubricant Capacity 355 ml (15 fl oz)
Gasoline (Recommended) 91 Octane (minimum)
Engine Oil Arctic Cat CTec2
Chain Case Lubricant Arctic Cat Chain Lube
Suspension Grease All-Temperature
Brake Fluid High-Temp DOT 4
Taillight/Brakelight Bulb p/n 3303-849
Headlight Bulb p/n 0109-724
Cooling System Capacity 3.81 l (4.0 U.S. qt)
Starting System Manual Recoil
Engine Specifications
Engine Number 0962-011
Displacement 599 cc
Bore x Stroke 73.8 x 70 mm
Compression Ratio 6.62:1
Cooling System Liquid
Ignition Timing (Engine Warm) 16.5° @ 2000 RPM 0.072”
Spark Plug (NGK) BPR9ES
Spark Plug Gap 0.028-0.031”
Piston Skirt/Cylinder Clearance 0.0041-0.0053”
Piston Ring End Gap 0.012-0.0196”
Cylinder Trueness Limit 0.004”
Piston Pin Diameter 0.8659-0.8661”
Piston Pin Bore Diameter 0.8661-0.8665”
Connecting Rod Small End Bore 1.0631-1.0634”
Connecting Rod Radial Play 0.0001-0.0008”
Crankshaft Runout (t.i.r.) 0.002”
Crankshaft End Play 0.002-0.004”
Reed Stopper Height 0.512”
Torque Specifications
NOTE: Torque specifications have the following tol-
erances:
Torque (ft-lb) Tolerance
0-15 ±20%
16-39 ±15%
40+ ±10%
DRIVE SYSTEM
Item Secured to
Drive Clutch*** Engine
Drive Clutch Cover Movable Sheave
Cam Arm Pin Lock Nut Cam Arm Pin
Cam Arm Set Screw Cam Arm
Driven Clutch** Driven Shaft
Movable Sheave* Torque Bracket
Chain Case (Cap Screw) Chassis
Torque
ft-lb
51
120 in.-lb
11
19 in.-lb
20
27
96 in.-lb
DRIVE SYSTEM
Item Secured to
Chain Case (Torx-Head Screw) Chassis
Chain Case Cover Chain Case
Brake Caliper Chassis
Outside Caliper Housing Inside Caliper Housing
Brakeline Caliper
Brakeline Master Cylinder
Brake Caliper Shield Cover
STEERING/FRONT SUSPENSION/CHASSIS
Item Secured to
Ski Spindle
Ski Wearbar
Ski Ski Handle
Handlebar Adjuster Post
Steering Support Mounting Block
Steering Tie Rod Link Steering Post
Steering Tie Rod Link Steering Arm
Steering Post Cap Riser Block
Steering Post Chassis
Steering Tie Rod Steering Arm
Tie Rod Spindle Arm
Steering Support Spar
Steering Support Upper Console
Steering Arm Chassis
A-Arm (Upper) Chassis
A-Arm (Lower) Chassis (Front)
A-Arm (Lower) Chassis (Rear)
A-Arm Spindle
Shock Absorber Spindle
Shock Absorber Chassis
Sway Bar Link A-Arm/Sway Bar Link
Sway Bar Mounting Bracket Chassis
REAR SUSPENSION
Wear Strip Rail
End Cap Rail
Mounting Block Rail
Rear Arm Rail
Rear Arm Idler Arm
Spring Slide Rail
Front Arm Rail
Coupler Block Axle Rail
Limiter Strap Rail Support
Rear Tri Hub Wheel Rear Tri Hub Wheel
Rear Wheel Axle Rail
Skid Frame Tunnel
Front Shock Rail
Rail Support Rail
Limiter Strap Front Arm
* w/Green Loctite #609
** w/Blue Loctite #243
*** w/Oil
Torque
ft-lb
12
12
25
25
25
25
96 in.-lb
Torque
ft-lb
35
8
54 in.-lb
15
8
35
20
15
55
20
32
20
30 in.-lb
8
23
65
45
45
45
45
23
9
50 in.-lb
80 in.-lb
20
45
55
20
52
40
72 in.-lb
50 in.-lb
34
55**
50
20
72 in.-lb
2
Torque Conversions
(ft-lb/N-m)
ft-lb N-m ft-lb N-m ft-lb N-m ft-lb N-m
1 1.4 26 35.4 51 69.4 76 103.4
2 2.7 27 36.7 52 70.7 77 104.7
3 4.1 28 38.1 53 72.1 78 106.1
4 5.4 29 39.4 54 73.4 79 107.4
5 6.8 30 40.8 55 74.8 80 108.8
6 8.2 31 42.2 56 76.2 81 110.2
7 9.5 32 43.5 57 77.5 82 111.5
8 10.9 33 44.9 58 78.9 83 112.9
9 12.2 34 46.2 59 80.2 84 114.2
10 13.6 35 47.6 60 81.6 85 115.6
11 15 36 49 61 83 86 117
12 16.3 37 50.3 62 84.3 87 118.3
13 17.7 38 51.7 63 85.7 88 119.7
14 19 39 53 64 87 89 121
15 20.4 40 54.4 65 88.4 90 122.4
16 21.8 41 55.8 66 89.8 91 123.8
17 23.1 42 57.1 67 91.1 92 125.1
18 24.5 43 58.5 68 92.5 93 126.5
19 25.8 44 59.8 69 93.8 94 127.8
20 27.2 45 61.2 70 95.2 95 129.2
21 28.6 46 62.6 71 96.6 96 130.6
22 29.9 47 63.9 72 97.9 97 131.9
23 31.3 48 65.3 73 99.3 98 133.3
24 32.6 49 66.6 74 100.6 99 134.6
25 34 50 68 75 102 100 136
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. From the illustration, note that three check points are called out: at
either end, out on the taper as shown, and also on the
center bearing race. The crankshaft must be supported
on the inner bearings using V blocks.
0747-810
Arctic Power Valve (APV)
System Specifications
Tightening Torque
(General Bolts)
Type of Bolt
(Grade 8.8) 5 60 in.-lb
(Grade 10.9) 6 12 ft-lb
Thread
Diameter A
(mm)
6 96 in.-lb
8 20 ft-lb
10 40 ft-lb
12 65 ft-lb
8 28 ft-lb
10 50 ft-lb
12 95 ft-lb
Tightening
Torque
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.
VALVE POSITION CYCLE RPM
Mid-Open
Full-Open
APV CABLE LENGTH
6000 36.5 mm ± 1 mm
67-7500 (Low/High Alt)
77-8500 (Low/High Alt)
0735-516
3
Electrical Specifications
Component Test Value + Test Connections -
Spark Plug Cap 4000-6000 ohms cap end cap end
Oil Level Sensor Less than 1 ohm
Ignition Switch Less than 1 ohm
Ignition Coil (Primary)
Charge Coil (1) 8.8-13.2 ohms black/red green/red
Charge Coil (2) 8.8-13.2 ohms brown/white green/red
Lighting Coil 0.08-0.12 ohm yellow yellow
Ignition Timing Sensor (1) 148-222 ohms green/white brown/green
Ignition Timing Sensor (2) 148-222 ohms green/white brown/green
Fuel Injector 10-14 ohms terminal terminal
Injection Coil 15.2-22.8 ohms blue/white blue/white
Fuel Pump Coil 1.52-2.28 ohms orange orange
Servomotor 12 DC Volts red/black
Voltage Regulator/
Rectifier*
(Secondary)
(float end down)
(key in OFF
position)
(Normally Open Ignition)
0.24-0.36 ohm
5040-7560 ohms
9-14.5 DC Volts red/blue black
* Harness plugged in
The main harness connectors must be unplugged
(except on the primary coil and regulator/rectifier
tests), the spark plugs removed and grounded, and by
pulling the recoil starter rope briskly.
NOTE: Lighting coil output is unregulated voltage.
! WARNING
Most voltages generated by the ignition system are sufficient to interrupt pacemakers! All technicians, especially those using pacemakers, must avoid contact with
all electrical connections when pulling the recoil starter
rope or after the engine has been started.
terminal terminal
terminal terminal
black/white
high tension wire
(counterclockwise)
black/red
(clockwise)
white/blue
high tension wire
black/red
(counterclockwise)
red/black
(clockwise)
Component Voltage/
Resistance Chart - Water
Temperature
Temperature Volts Ohms Temperature Volts Ohms
110 °C 230 °F 0.115 129 28 °C 82 °F 1.377 1800
108 °C 226 °F 0.129 137 26 °C 79 °F 1.459 1950
106 °C 223 °F 0.143 145 24 °C 75 °F 1.541 2100
104 °C 219 °F 0.157 153 22 °C 72 °F 1.623 2250
102 °C 216 °F 0.171 161 20 °C 68 °F 1.705 2400
100 °C 212 °F 0.185 169 18 °C 64 °F 1.806 2670
98 °C 208 °F 0.192 180 16 °C 61 °F 1.907 2940
96 °C 205 °F 0.199 191 14 °C 57 °F 2.008 3210
94 °C 201 °F 0.206 202 12 °C 54 °F 2.109 3480
92 °C 198 °F 0.213 213 10 °C 50 °F 2.210 3750
90 °C 194 °F 0.220 224 8 °C 46 °F 2.327 4170
88 °C 190 °F 0.235 240 6 °C 43 °F 2.444 4590
86 °C 187 °F 0.250 256 4 °C 39 °F 2.561 5010
84 °C 183 °F 0.265 273 2 °C 36 °F 2.678 5430
82 °C 180 °F 0.280 289 0 °C 32 °F 2.795 5850
80 °C 176 °F 0.295 305 -2 °C 28 °F 2.901 6510
78 °C 172 °F 0.317 327 -4 °C 25 °F 3.007 7170
76 °C 169 °F 0.339 349 -6 °C 21 °F 3.113 7830
74 °C 165 °F 0.361 371 -8 °C 18 °F 3.219 8490
72 °C 162 °F 0.383 393 -10 °C 14 °F 3.325 9150
70 °C 158 °F 0.405 415 -12 °C 10 °F 3.421 9422
68 °C 154 °F 0.438 445 -14 °C 7 °F 3.517 9694
66 °C 151 °F 0.471 475 -16 °C 3 °F 3.613 9966
64 °C 147 °F 0.504 505 -18 °C -0.4 °F 3.709 10238
62 °C 144 °F 0.537 535 -20 °C -4 °F 3.805 10510
60 °C 140 °F 0.570 565 -22 °C -8 °F 3.885 13688
58 °C 136 °F 0.598 609 -24 °C -11 °F 3.965 16866
56 °C 133 °F 0.626 653 -26 °C -15 °F 4.045 20044
54 °C 129 °F 0.654 697 -28 °C -18 °F 4.125 23222
52 °C 126 °F 0.682 741 -30 °C -22 °F 4.205 26400
50 °C 122 °F 0.710 785 -32 °C -26 °F 4.267 30520
48 °C 118 °F 0.759 849 -34 °C -29 °F 4.329 34640
46 °C 115 °F 0.808 913 -36 °C -32 °F 4.391 38760
44 °C 111 °F 0.857 977 -38 °C -36 °F 4.453 42880
42 °C 108 °F 0.906 1041 -40 °C -40 °F 4.515 47000
40 °C 104 °F 0.955 1105 -42 °C -44 °F 4.553 55100
38 °C 100 °F 1.023 1214 -44 °C -47 °F 4.591 63200
36 °C 97 °F 1.091 1323 -46 °C -51 °F 4.629 71300
34 °C 93 °F 1.159 1432 -48 °C -54 °F 4.667 79400
32 °C 90 °F 1.227 1541 -50 °C -58 °F 4.705 87500
30 °C 86 °F 1.295 1650
4
Drive System
Specifications
Model Altitude
ZR 6000R Cross Country
Drive
Clutch
Spring
0-5000 Green 64g Black/Blue 44°/42° 0627-083 42-4600 81-8200 23T 40T 86
Cam
Arm
Drive Clutch/Driven
Clutch-Related
Specifications
ALIGNMENT BAR
OFFSET P/N CENTER-TO-CENTER OFFSET FLOAT
0644-428 12.10” 1.485” None
Drive Clutch/Driven
Clutch Optional
Components
ARCTIC CAT DRIVE CLUTCH SPRING CHART
p/n Rate @ 2 9/16" Rate @ 1 5/16" Color
LIGHT 0646-439 50 lb 250 lb Black/White
0646-148 53 lb 224 lb Blue
0646-150 72 lb 188 lb Silver
0646-149 74 lb 228 lb Red
0646-432 74 lb 228 lb Black/Red
0646-433 75 lb 275 lb Black/Gold
0646-376 75 lb 275 lb Gold
0646-252 103 lb 315 lb Green
0646-147 114 lb 267 lb Yellow/Green
0646-373* 114 lb 257 lb Yellow/Green
0646-155 121 lb 240 lb Purple
0646-229 122 lb 285 lb Yellow/White
0646-379* 122 lb 285 lb Yellow/White
0646-035 143 lb 286 lb Orange/
0646-447
(Titanium)
0646-367 143 lb 250 lb Black
HEAVY 0646-684 158 lb 285 lb Black
0646-410 165 lb 310 lb Black/Blue
Torque
Bracket
0648-779* 58-46-36/
0648-775* 52-42-46/
0648-773* 70-44-32/
0648-789* 68-48-36/
0648-791* 48-44-36/
Degree Spring Color
58-48-36
52-44-46
68-48-46
64-48-41
48-42-36
143 lb 286 lb Pink
DRIVEN CLUTCH
0648-749 Black/White 160/260
0648-702 Red/Black 140/240
0648-784 Black 155/222
0648-790 Black/Light Blue 180/260
0648-792 Black/Orange 180/280
Black
Spring
Rate
Driven
Clutch
Spring
Torque
Bracket
Drive
Belt
Engagement
RPM
Peak
RPM
Top
Gear
Bottom
Gear
Drive Clutch Cam Arms
(w/Set Screw)
ARCTIC CAT DRIVE CLUTCH CAM ARMS
p/n Grams p/n Grams
0746-661 52.0 0746-712 77.0
0746-662 52.0 0746-713 48.0
0746-663 52.0 0746-715 77.0
0746-664 52.0 0746-716 73.0
0746-666 55.0 0746-742 83.5
0746-668 55.0 0746-744 50.0
0746-669 60.0 0746-748 46.0
0746-670 65.0 0746-749 65.0
0746-671 70.0 0746-771 44.0
0746-672 75.0 0746-772 42.0
0746-673 80.0 0746-773 85.0
0746-676 70.0 0746-786 63.0
0746-678 55.0 0746-787 44.0
0746-687 57.0 0746-788 47.5
0746-689 69.0 0746-789 42.0
0746-690 47.0 0746-791 60.0
0746-691 44.0 0746-792 47.0
0746-692 50.0 0746-793 63.0
0746-694 63.0 0746-814 83.0
0746-695 67.0 0746-821 82.0
0746-696 63.0 0746-822 71.5
0746-698 64.0 0746-824 66.0
0746-699 66.0 0746-825 50.0
0746-701 49.0 0746-826 64.0*
0746-702 57.5 0746-830 60.0
0746-703 68.0
0746-704 51.0
0746-708 51.0
0746-710 72.0
* Notched Cam Arm
Chain
Pitch
*Lightweight driven clutch only.
5
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.
6
Chains and Sprockets
Part
Number
2602-582 SPROCKET, REX-19T FWD-(13 WIDE/19 SPLINE)
2602-523 SPROCKET, REX-20T FWD-(13 WIDE/19 SPLINE)
2602-377 SPROCKET, REX-21T FWD-(13 WIDE/19 SPLINE)
2602-335 SPROCKET, REX-22T FWD-(13 WIDE/19 SPLINE)
2602-403 SPROCKET, REX-23T FWD-(13 WIDE/19 SPLINE)
2602-666 SPROCKET, REX-19T FWD-(13 WIDE/19 SPLINE)
2602-212 SPROCKET, REX-21T FWD-(13 WIDE/19 SPLINE)
2602-461 SPROCKET, REX-22T FWD-(13 WIDE/19 SPLINE)
2602-405 SPROCKET, REX-35T FWD-(13 WIDE/19 SPLINE)
2602-406 SPROCKET, REX-36T FWD-(13 WIDE/19 SPLINE)
2602-371 SPROCKET, REX-37T FWD-(13 WIDE/19 SPLINE)
2602-372 SPROCKET, REX-38T FWD-(13 WIDE/19 SPLINE)
2602-522 SPROCKET, REX-41T FWD-(13 WIDE/19 SPLINE)
2602-364 SPROCKET, REX-48T FWD-(13 WIDE/19 SPLINE)
2602-363 SPROCKET, REX-49T FWD-(13 WIDE/19 SPLINE)
2602-548 SPROCKET, REX-50T FWD-(13 WIDE/19 SPLINE)
1702-406 SPROCKET, 40T TOS-ASSY
1702-405 SPROCKET, 49T TOS-ASSY
Part
Number
2602-369 CHAIN, REXNORD-84P (13 WIDE)
2062-514 CHAIN, REXNORD-86P (13 WIDE)
2602-370 CHAIN, REXNORD-90P (13 WIDE)
2602-365 CHAIN, REXNORD-84P (13 WIDE)
2602-373 CHAIN, REXNORD-90P (13 WIDE)
2602-710 CHAIN, REXNORD-86P (13 WIDE)
2602-733 CHAIN, REXNORD-92P (13 WIDE)
Sprocket
Chain
Rear Spring Selection
Chart
Below is a list of rear suspension springs and specifications. A longer spring in areas (D) and (E) can be
selected if cut off to match the original spring. The
replacement spring must match the original spring in
areas (C), (D), and (E).
P/N
1704-382/
383
(Light)
1704-384/
385
(Heavy)
1704-916/
917
2704-224/
225
1704-576/
577
2704-384/
385
2704-380/
381*
2704-382/
383**
Wire
Diameter
(A)
.359 90° 5.75 3.00 15.62 4.60 17
.375 90° 5.75 3.00 15.62 4.60 20
.405 120° 5.90 3.20 15.62 4.70 24
.437 105° 6.80 3.75 15.62 4.70 27.3
.405 90° 6.75 3.65 18.50 5.50 18.5
.405 115° 6.80 3.65 15.62 4.70 18.9
.437 92° 6.75 3.75 15.62 4.70 27.4
.405 89° 6.75 3.65 15.62 4.70 18.9
Angle
(B)
Number
of
Coils
Coil
Width
(C)
Length
(D)
Length
(E)
Degree
(In lb)
* Production (Sno Cross) **Production (Cross Country)
NOTE: The wire diameter and length of the spring
have a large influence over the valving of the
shocks.
Installed Spring Rate
Chart
Suspension Fully
P/N
1704-382/383 1360 1700
1704-384/385 1600 2001
1704-916/917 480 960
2704-224/225 1350 1890
1704-576/577 1480 1850
2704-380/381 2082 2630
2704-382/383 1550 1928
2704-384/385 567 945
P/N
1704-382/383 3740 4080
1704-384/385 4411 4812
1704-916/917 3840 4320
2704-224/225 5130 5670
1704-576/577 4070 4440
2704-380/381 5918 6466
2704-382/383 4196 4574
2704-384/385 3213 3591
(in.-lb - Adjuster Set1&1)
(in.-lb - Adjuster Set1&1)
Extended
Suspension Fully
Collapsed
Suspension Fully
Extended
(in.-lb - Adjuster Set3&3)
Suspension Fully
Collapsed
(in.-lb - Adjuster Set3&3)
0730-218
Front Suspension
Sway Bar
Sway Bar p/n Bushing p/n Description
2703-615 2603-944/945 (inc.) 11.1 mm diameter
2703-793 2603-946/947 (inc.) 12.7 mm diameter
NOTE: Sway Bar Mounting Kit (p/n 6639-001).
7
Rebuildable Shock Tools
Required
P/N 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. O.D. x 1/2 in. I.D.)
0644-543 Gas Shock Shaft Clamping Tool
0644-350 Floating Piston Location Gauge
0644-539 Inflation Needle Replacement Tip
0744-072 Float Shock Spanner Wrench
0644-584 Air Sleeve Bushing Installation Tool
0644-585 Air Sleeve Bushing Installation Tool
0644-456 Bullet Air Sleeve Bushing Installation Tool
Optional Front Arm
Shock Springs
P/N LB Length (Inches)
2704-755* 100/250 7.75
2704-228 100/250 7.75
2704-229 160/260 7.75
1704-819 230 7.50
1704-820 170 7.50
1704-821 190 7.50
1704-822 210 7.50
1704-831 250 7.50
Ice Racing Springs
2704-749 70 6
2704-750 90 6
2704-751 110 6
* Stock Spring
8
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. Rebuild Kit - p/n 3604-539 0.800 x 0.006 in. 1.125 x 0.080 in.
Stroke: 5.65 in. (Reservoir) 1.300 x 0.010 in.
1.250 x 0.010 in.
1.100 x 0.010 in.
1.000 x 0.010 in.
0.900 x 0.010 in.
Piston Orifice: 0.059 in. Piston Depth: 2.50 in. 1.125 x 0.093 in. Top out
Compression (CD Piston)
0.700 x 0.010 in.
0.700 x 0.010 in.
0.600 x 0.010 in.
0.500 x 0.006 in.
0.400 x 0.020 in. (BU)
0.400 x 0.020 in. (BU)
CD Knob @ 12 clicks from full closed; RB Knob @ 12 clicks from full closed.
Eyelets tightened to 3.9 kg-m (28 ft-lb). Piston nut tightened to 3.0 kg-m (22 ft-lb).
Tighten the shaft nut to 3.0 kg-m (22 ft-lb). Shocks charged at 250 psi (nitrogen)/80/200 psi (air).
Green Loctite #620 on shock eyelet threads.
Ground
0.620 x 0.093 in.
Backup
Part Number Description
2704-635 Front Arm Shock 1.300 x 0.008 in. 1.100 x 0.008 in.
Extended Length: 12.36 in. Rebuild Kit - p/n 3604-538 1.300 x 0.008 in. 0.600 x 0.004 in.
Collapsed Length: 8.56 in. Rebuild Kit - p/n 4604-017 0.800 x 0.004 in. (Center) 0.700 x 0.010 in.
Stroke: 3.80 in. (Reservoir) 1.300 x 0.10 (Ring) 1.125 x 0.080 in.
Piston Orifice: None Piston Depth: 1.80 in.
Compression
(Piston Side)
1.100 x 0.004 in.
1.000 x 0.004 in. 0.620 x 0.093 in.
1.000 x 0.004 in.
0.700 x 0.004 in.
1.250 x 0.093 in. (Top Out)
Rebound
(Piston Side)
(Top Out)
Backup
Compression @ 12 clicks counterclockwise from full stop.
Eyelets tightened to 3.9 kg-m (28 ft-lb). Piston nut tightened to 3.0 kg-m (22 ft-lb). Tighten shaft nut to 3.9 kg-m (28 ft-lb). Shock
charged at 250 psi. Green Loctite #620 on shock eyelet threads.
Part Number Description
2704-636 Rear Arm Shock 1.600 x 0.004 in. (DB) 1.425 x 0.015 in.
Extended Length: 14.59 in. Rebuild Kit - p/n 2603-013 1.600 x 0.010 in. 1.425 x 0.015 in.
Collapsed Length: 10.06 in. Rebuild Kit - p/n 4604-017 1.600 x 0.012 in. 1.100 x 0.012 in.
Stroke: 4.53 in. (Reservoir) 1.600 x 0.012 in. 0.950 x 0.012 in.
Piston Orifice: None Piston Depth: 2.40 in.
Compression
(Piston Side)
1.600 x 0.010 in. 1.425 x 0.012 in.
1.100 x 0.006 in. 1.350 x 0.012 in.
1.600 x 0.012 in. 0.800 x 0.020 in.
1.425 x 0.010 in. 0.800 x 0.020 in.
1.350 x 0.010 in. 0.750 x 0.080 in.
1.100 x 0.008 in. 0.750 x 0.100 in. (Backup)
1.570 x 0.128 in. (Top Out)
Rebound
(Piston Side)
CD Knob @ 12 clicks from full closed; RB Knob @ 5 clicks counterclockwise.
Shock charged at 250 psi. Green Loctite #620 on shock eyelet threads.
Eyelets tightened to 3.9 kg-m (28 ft-lb). Piston nut tightened to 3.0 kg-m (22 ft-lb).
Tighten the shaft nut to 3.9 kg-m (28 ft-lb).
9
Rebuildable Shock
Accessory Part Numbers
NOTE: When rebuilding Fox shocks, use only
Fox valves and/or pistons.
AC PN Description
2603-499 Valve: [0.500 OD X 0.252 ID X 0.006 TH]
2603-500 Valve: [0.600 OD X 0.252 ID X 0.010 TH]
2603-501 Valve: [0.700 OD X 0.252 ID X 0.010 TH]
2603-902 Valve: [0.550 OD X 0.377 ID X 0.020 TH]
3604-171 Valve: [0.600 OD X 0.377 ID X 0.004 TH]
3604-533 Valve: [0.600 OD X 0.377 ID X 0.012 TH]
2603-224 Valve: [0.620 OD X 0.377 ID X 0.015 TH]
0603-731 Valve: [0.700 OD X 0.377 ID X 0.004 TH]
0603-330 Valve: [0.700 OD X 0.377 ID X 0.006 TH]
0603-331 Valve: [0.700 OD X 0.377 ID X 0.008 TH]
0603-332 Valve: [0.700 OD X 0.377 ID X 0.010 TH]
0603-878 Valve: [0.700 OD X 0.377 ID X 0.012 TH]
0603-884 Valve: [0.700 OD X 0.377 ID X 0.015 TH]
0603-895 Valve: [0.800 OD X 0.377 ID X 0.004 TH]
0603-333 Valve: [0.800 OD X 0.377 ID X 0.006 TH]
0603-334 Valve: [0.800 OD X 0.377 ID X 0.008 TH]
0603-335 Valve: [0.800 OD X 0.377 ID X 0.010 TH]
0603-879 Valve: [0.800 OD X 0.377 ID X 0.012 TH]
0603-885 Valve: [0.800 OD X 0.377 ID X 0.015 TH]
0603-894 Valve: [0.900 OD X 0.377 ID X 0.004 TH]
0603-336 Valve: [0.900 OD X 0.377 ID X 0.006 TH]
0603-337 Valve: [0.900 OD X 0.377 ID X 0.008 TH]
0603-338 Valve: [0.900 OD X 0.377 ID X 0.010 TH]
0603-880 Valve: [0.900 OD X 0.377 ID X 0.012 TH]
0603-886 Valve: [0.900 OD X 0.377 ID X 0.015 TH]
0603-893 Valve: [1.000 OD X 0.377 ID X 0.004 TH]
0603-339 Valve: [1.000 OD X 0.377 ID X 0.006 TH]
0603-340 Valve: [1.000 OD X 0.377 ID X 0.008 TH]
0603-341 Valve: [1.000 OD X 0.377 ID X 0.010 TH]
0603-881 Valve: [1.000 OD X 0.377 ID X 0.012 TH]
0603-887 Valve: [1.000 OD X 0.377 ID X 0.015 TH]
0603-892 Valve: [1.100 OD X 0.377 ID X 0.004 TH]
0603-342 Valve: [1.100 OD X 0.377 ID X 0.006 TH]
0603-343 Valve: [1.100 OD X 0.377 ID X 0.008 TH]
0603-344 Valve: [1.100 OD X 0.377 ID X 0.010 TH]
0603-882 Valve: [1.100 OD X 0.377 ID X 0.012 TH]
0603-888 Valve: [1.100 OD X 0.377 ID X 0.015 TH]
0603-345 Valve: [1.250 OD X 0.377 ID X 0.006 TH]
0603-346 Valve: [1.250 OD X 0.377 ID X 0.008 TH]
0603-347 Valve: [1.250 OD X 0.377 ID X 0.010 TH]
0603-883 Valve: [1.250 OD X 0.377 ID X 0.012 TH]
0603-889 Valve: [1.250 OD X 0.377 ID X 0.015 TH]
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]
0603-350 Valve: [1.300 OD X 0.377 ID X 0.010 TH]
0603-891 Valve: [1.300 OD X 0.377 ID X 0.012 TH]
0603-890 Valve: [1.300 OD X 0.377 ID X 0.015 TH]
AC PN Description
2604-647 Valve: [1.425 OD X 0.377 ID X 0.010 TH]
2604-632 Valve: [1.425 OD X 0.377 ID X 0.012 TH]
2604-633 Valve: [1.425 OD X 0.377 ID X 0.015 TH]
3604-577 Valve: [1.600 OD X 0.377 ID X 0.008 TH]
2604-631 Valve: [1.600 OD X 0.377 ID X 0.010 TH]
2604-683 Valve: [0.650 OD X 0.504 ID X 0.020 TH]
2604-469 Valve: [0.700 OD X 0.504 ID X 0.010 TH]
2604-470 Valve: [0.700 OD X 0.504 ID X 0.020 TH]
2604-471 Valve: [0.750 OD X 0.504 ID X 0.020 TH]
2604-472 Valve: [0.800 OD X 0.504 ID X 0.006 TH]
2604-473 Valve: [0.800 OD X 0.504 ID X 0.008 TH]
2604-474 Valve: [0.800 OD X 0.504 ID X 0.010 TH]
2604-475 Valve: [0.800 OD X 0.504 ID X 0.012 TH]
2604-476 Valve: [0.800 OD X 0.504 ID X 0.015 TH]
2604-477 Valve: [0.800 OD X 0.504 ID X 0.020 TH]
2604-478 Valve: [0.950 OD X 0.504 ID X 0.006 TH]
2604-479 Valve: [0.950 OD X 0.504 ID X 0.008 TH]
2604-480 Valve: [0.950 OD X 0.504 ID X 0.010 TH]
2604-481 Valve: [0.950 OD X 0.504 ID X 0.012 TH]
2604-482 Valve: [0.950 OD X 0.504 ID X 0.015 TH]
2604-483 Valve: [1.000 OD X 0.504 ID X 0.020 TH]
3604-149 Valve: [1.100 OD X 0.504 ID X 0.004 TH]
2604-484 Valve: [1.100 OD X 0.504 ID X 0.006 TH]
2604-485 Valve: [1.100 OD X 0.504 ID X 0.008 TH]
2604-486 Valve: [1.100 OD X 0.504 ID X 0.010 TH]
2604-487 Valve: [1.100 OD X 0.504 ID X 0.012 TH]
2604-488 Valve: [1.100 OD X 0.504 ID X 0.015 TH]
2604-489 Valve: [1.100 OD X 0.504 ID X 0.020 TH]
2604-684 Valve: [1.250 OD X 0.504 ID X 0.006 TH]
2604-685 Valve: [1.250 OD X 0.504 ID X 0.008 TH]
2604-686 Valve: [1.250 OD X 0.504 ID X 0.010 TH]
2604-687 Valve: [1.250 OD X 0.504 ID X 0.012 TH]
2604-688 Valve: [1.250 OD X 0.504 ID X 0.015 TH]
2604-490 Valve: [1.350 OD X 0.504 ID X 0.006 TH]
2604-491 Valve: [1.350 OD X 0.504 ID X 0.008 TH]
2604-492 Valve: [1.350 OD X 0.504 ID X 0.010 TH]
2604-493 Valve: [1.350 OD X 0.504 ID X 0.012 TH]
2604-494 Valve: [1.350 OD X 0.504 ID X 0.015 TH]
2604-495 Valve: [1.425 OD X 0.504 ID X 0.006 TH]
2604-496 Valve: [1.425 OD X 0.504 ID X 0.008 TH]
2604-497 Valve: [1.425 OD X 0.504 ID X 0.010 TH]
2604-498 Valve: [1.425 OD X 0.504 ID X 0.012 TH]
2604-499 Valve: [1.425 OD X 0.504 ID X 0.015 TH]
2604-500 Valve: [1.600 OD X 0.504 ID X 0.006 TH]
2604-501 Valve: [1.600 OD X 0.504 ID X 0.008 TH]
2604-502 Valve: [1.600 OD X 0.504 ID X 0.010 TH]
2604-503 Valve: [1.600 OD X 0.504 ID X 0.012 TH]
2604-504 Valve: [1.600 OD X 0.504 ID X 0.015 TH]
NOTE: Shock Oil (p/n 5639-530) is available from
Arctic Cat Service Department.
10
Double Bleed Shims (DB)
AC PN Description
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.)
3603-345 Valve: DB 3 PORT (1.30" OD X .375" ID .010" THK.)
3603-346 Valve: DB 3 PORT (1.30" OD X .375" ID .012" THK.)
3603-347 Valve: DB 3 PORT (1.30" OD X .375" ID .015" THK.)
3603-348 Valve: DB 3 PORT (1.30" OD X .375" ID .020" THK.)
3603-481 Valve: DB 4 PORT (1.60" OD X .502" ID .004" THK.)
3603-482 Valve: DB 4 PORT (1.60" OD X .502" ID .006" THK.)
3603-483 Valve: DB 4 PORT (1.60" OD X .502" ID .008" THK.)
3603-484 Valve: DB 4 PORT (1.60" OD X .502" ID .010" THK.)
3603-485 Valve: DB 4 PORT (1.60" OD X .502" ID .012" THK.)
3603-486 Valve: DB 4 PORT (1.60" OD X .502" ID .015" THK.)
3603-487 Valve: DB 4 PORT (1.60" OD X .502" ID .020" THK.)
Single Bleed Shims (DB)
AC PN Description
3603-469 Valve: SB 3 PORT (1.30" OD X .375" ID .004" THK.)
3603-470 Valve: SB 3 PORT (1.30" OD X .375" ID .006" THK.)
4604-038 Valve: SB 3 PORT (1.30" OD X .375" ID .008" THK.)
3603-471 Valve: SB 3 PORT (1.30" OD X .375" ID .010" THK.)
3603-472 Valve: SB 3 PORT (1.30" OD X .375" ID .012" THK.)
3603-473 Valve: SB 3 PORT (1.30" OD X .375" ID .015" THK.)
3603-474 Valve: SB 3 PORT (1.30" OD X .375" ID .020" THK.)
3603-475 Valve: SB 4 PORT (1.60" OD X .502" ID .004" THK.)
3603-410 Valve: SB 4 PORT (1.60" OD X .502" ID .006" THK.)
3603-476 Valve: SB 4 PORT (1.60" OD X .502" ID .005" THK.)
3603-477 Valve: SB 4 PORT (1.60" OD X .502" ID .010" THK.)
3603-478 Valve: SB 4 PORT (1.60" OD X .502" ID .012" THK.)
3603-479 Valve: SB 4 PORT (1.60" OD X .502" ID .015" THK.)
3603-480 Valve: SB 4 PORT (1.60" OD X .502" ID .020" THK.)
Drill Bit Sizes
(Number) Chart
Size of
No.
Drill in
Inches
1 .2280 21 .1590 41 .0960 61 .0390
2 .2210 22 .1570 42 .0935 62 .0380
3 .2130 23 .1540 43 .0890 63 .0370
4 .2090 24 .1520 44 .0860 64 .0360
5 .2055 25 .1495 45 .0820 65 .0350
6 .2040 26 .1470 46 .0810 66 .0330
7 .2010 27 .1440 47 .0785 67 .0320
8 .1990 28 .1405 48 .0760 68 .0310
9 .1960 29 .1360 49 .0730 69 .0292
10 .1935 30 .1285 50 .0700 70 .0280
11 .1910 31 .1200 51 .0670 71 .0260
12 .1890 32 .1160 52 .0635 72 .0250
13 .1850 33 .1130 53 .0595 73 .0240
14 .1820 34 .1110 54 .0550 74 .0225
15 .1800 35 .1100 55 .0520 75 .0210
16 .1770 36 .1065 56 .0465 76 .0200
17 .1730 37 .1040 57 .0430 77 .0180
18 .1695 38 .1015 58 .0420 78 .0160
19 .1660 39 .0995 59 .0410 79 .0145
20 .1610 40 .0980 60 .0400 80 .0135
No.
Size of
Drill in
Inches
No.
Size of
Drill in
Inches
No.
Size of
Drill in
Inches
Fraction/Decimal
Conversion Chart
8ths 16ths 32nds 64ths 64ths (cont)
1/8 = .125 1/16 = .0625 1/32 = .03125 1/64 = .015625 33/64 = .515625
1/4 = .250 3/16 = .1875 3/32 = .09375 3/64 = .046875 35/64 = .546875
3/8 = .375 5/16 = .3125 5/32 = .15625 5/64 = .078125 37/64 = .578125
1/2 = .500 7/16 = .4375 7/32 = .21875 7/64 = .109375 39/64 = .609375
5/8 = .625 9/16 = .5625 9/32 = .28125 9/64 = .140625 41/64 = .640625
3/4 = .750 11/16 = .6875 11/32 = .34375 11/64 = .171875 43/64 = .671875
7/8 = .875 13/16 = .8125 13/32 = .40625 13/64 = .203125 45/64 = .703125
— 15/16 = .9375 15/32 = .46875 15/64 = .234370 47/64 = .734375
— — 17/32 = .53125 17/64 = .265625 49/64 = .765625
— — 19/32 = .59375 19/64 = .296875 51/64 = .796875
— — 21/32 = .65625 21/64 = .328125 53/64 = .828125
— — 23/32 = .71875 23/64 = .359375 55/64 = .859375
— — 25/32 = .78125 25/64 = .390625 57/64 = .890625
— — 27/32 = .84375 27/64 = .421875 59/64 = .921875
— — 29/32 = .90625 29/64 = .453125 61/64 = .953125
— — 31/32 = .96875 31/64 = .484375 63/64 = .984375
11
MM/IN. Conversion Chart
mm in. mm in. mm in. mm in.
.01 .00039 .51 .02008 1 .03937 51 2.00787
.02 .00079 .52 .02047 2 .07874 52 2.04724
.03 .00118 .53 .02087 3 .11811 53 2.08661
.04 .00157 .54 .02126 4 .15748 54 2.12598
.05 .00197 .55 .02165 5 .19685 55 2.16535
.06 .00236 .56 .02205 6 .23622 56 2.20472
.07 .00276 .57 .02244 7 .27559 57 2.24409
.08 .00315 .58 .02283 8 .31496 58 2.28346
.09 .00354 .59 .02323 9 .35433 59 2.32283
.10 .00394 .60 .02362 10 .39370 60 2.36220
.11 .00433 .61 .02402 11 .43307 61 2.40157
.12 .00472 .62 .02441 12 .47244 62 2.44094
.13 .00512 .63 .02480 13 .51181 63 2.48031
.14 .00551 .64 .02520 14 .55118 64 2.51968
.15 .00591 .65 .02559 15 .59055 65 2.55905
.16 .00630 .66 .02598 16 .62992 66 2.59842
.17 .00669 .67 .02638 17 .66929 67 2.63779
.18 .00709 .68 .02677 18 .70866 68 2.67716
.19 .00748 .69 .02717 19 .74803 69 2.71653
.20 .00787 .70 .02756 20 .78740 70 2.75590
.21 .00827 .71 .02795 21 .82677 71 2.79527
.22 .00866 .72 .02835 22 .86614 72 2.83464
.23 .00906 .73 .02874 23 .90551 73 2.87401
.24 .00945 .74 .02913 24 .94488 74 2.91338
.25 .00984 .75 .02953 25 .98425 75 2.95275
.26 .01024 .76 .02992 26 1.02362 76 2.99212
.27 .01063 .77 .03032 27 1.06299 77 3.03149
.28 .01102 .78 .03071 28 1.10236 78 3.07086
.29 .01142 .79 .03110 29 1.14173 79 3.11023
.30 .01181 .80 .03150 30 1.18110 80 3.14960
.31 .01220 .81 .03189 31 1.22047 81 3.18897
.32 .01260 .82 .03228 32 1.25984 82 3.22834
.33 .01299 .83 .03268 33 1.29921 83 3.26771
.34 .01339 .84 .03307 34 1.33858 84 3.30708
.35 .01378 .85 .03346 35 1.37795 85 3.34645
.36 .01417 .86 .03386 36 1.41732 86 3.38582
.37 .01457 .87 .03425 37 1.45669 87 3.42519
.38 .01496 .88 .03465 38 1.49606 88 3.46456
.39 .01535 .89 .03504 39 1.53543 89 3.50393
.40 .01575 .90 .03543 40 1.57480 90 3.54330
.41 .01614 .91 .03583 41 1.61417 91 3.58267
.42 .01654 .92 .03622 42 1.65354 92 3.62204
.43 .01693 .93 .03661 43 1.69291 93 3.66141
.44 .01732 .94 .03701 44 1.73228 94 3.70078
.45 .01772 .95 .03740 45 1.77165 95 3.74015
.46 .01811 .96 .03780 46 1.81102 96 3.77952
.47 .01850 .97 .03819 47 1.85039 97 3.81889
.48 .01890 .98 .03858 48 1.88976 98 3.85826
.49 .01929 .99 .03898 49 1.92913 99 3.89763
.50 .01969 1.0 .03937 50 1.96850 100 3.93700
12
Wiring Diagram - Hood
Harness
(p/n 1686-706) - Cross Country
0748-009
13
NOTES
14
Wiring Diagram (Ignition/Main)
(Harness p/n 1686-732)
0747-813
15
16
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.
Removing Snowmobile From Crate/ Handlebar Assembly
Installing Spindle/A-Arm
CAUTION
Care should be taken when removing the snowmobile
from the crate. Damage that is not warrantable may
occur.
1. Remove the top and four sides of the crate.
Remove the skis from the crate sides.
2. Remove the windshield and hardware kit.
3. Remove all mounting hardware securing the
snowmobile to the crate base; then lift the snowmobile free of the crate base.
4. Swing the handlebar up and tighten the cap screws
evenly to 15 ft-lb; then check steering for maximum right/left turning capabilities. Install the handlebar pad assembly.
Installing Windshield
1. Remove the protective film from the windshield.
2. Install the expansion nuts into the speedometer
bracket; then place the windshield into position on
the console and bracket.
746-483A
1. Install the A-arms onto the spindle and secure
using new lock nuts. Tighten to 45 ft-lb.
2. Install the steering tie rod to the spindle. Tighten
lock nuts to 40 ft-lb.
Installing Front Shock Absorbers
746-484B
1. Raise the front of the snowmobile and place it on a
support stand.
2. Apply grease to the O-rings; then install the O-rings
and the spherical spacers to each side of the shock
eyelet spherical bearing. T ake care that the O-ring is
between the bearing and spherical spacers.
SNO-490
3. Secure the windshield using the screws according to
the illustration.
3. Place the upper shock into position on the frame;
then install the cap screw and flange nut. Tighten
to 45 ft-lb.
4. Install the lower shock eyelet into the lower A-arm
mounting bracket.
5. Push the cap screw through the shock eyelet and
backside of the A-arm mounting bracket; then
install the nut and tighten to 45 ft-lb.
6. Install the remaining shock absorber.
Installing Skis
1. Slide a washer onto the cap screw used to secure the
ski; then apply all-temperature grease to the shaft
portion of the cap screw and spindle axle.
17
0747-094
2. Install the spindle axle into the spindle; then position the
ski damper into the bottom of the ski making sure the
damper is properly positioned for the desired ski stance.
NOTE: The ski damper must be positioned in the ski
so it is directly under the spindle.
3. With the cap screw hole of the ski centered with the
spindle axle, slide the cap screw with washer through
the outside of the ski and spindle assemblies.
NOTE: Local laws and/or regulations as to maxi-
mum width of the ski stance may be applicable.
Always comply with the maximum width laws and/or
regulations when adjusting ski stance.
NOTE: Install the cap screw so the lock nut will be
located to the inside of the ski and the cotter pin slot
in the cap screw will be horizontal with the ski.
4. Install the remaining washer and lock nut; then
tighten the lock nut to 35 ft-lb.
NOTE: Assure that the cotter pin slot in the cap
screw is still horizontal with the ski (see illustration);
then proceed to step 7.
5. Install the cotter pin from the back side of the ski cap
screw and spread the pin.
NOTE: Repeat this sub-section on the opposite side.
Sway Bar
3. Tighten machine screws evenly to 8 ft-lb.
4. Position the sway bar link onto the lower A-arm
and the sway bar. Install the cap screws and lock
nuts. Tighten the lock nuts to 23 ft-lb.
Brake System
Checking Brake Fluid
1. With the brake fluid reservoir in a level position,
check the fluid level. The brake fluid level must be
just below the high mark.
SNO-253
2. If the brake fluid level is below the low mark,
remove the reservoir cover and add Arctic Cat
approved brake fluid until the fluid level is just
below the high mark. Install and secure the reservoir cover. Do not allow moisture to contaminate
the brake system.
CAUTION
Brake fluid is highly corrosive. Do not spill brake fluid
on any surface of the snowmobile.
! WARNING
Do not overfill the brake fluid reservoir. Overfilling the
reservoir may cause the brake system to hydraulically
lock. Use only Arctic Cat approved brake fluid.
Checking Brake Lever Operation
1. Test the operation of the hydraulic brake system
by compressing the brake lever.
SNO-2232
1. Place the sway bar into position (mounting location) of the chassis.
2. Secure the bar with the two mounting brackets,
four machine screws.
18
2. The brake lever must feel firm when compressed.
Ski Alignment
Checking
Toe-Out Range
0.0-12.7mm(0-1/2in.)
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 specified range.
1. Raise the front end of snowmobile just high
enough that the ski shocks are fully extended but
the skis are still resting on the floor.
2. From the riding position on the snowmobile,
check that the handlebar is in a straight-forward
direction for driving.
NOTE: Steering can be centered in the chassis by
taking measurements from each side of the drag
link to a location on the chassis which would be of
equal distance from each side of the drag link.
3. Using a very light hold-down strap (bungee cord)
between the ski handles, apply a very light load
approximately 2-4 lb pulling the skis together just
enough to pull the slack.
NOTE: Track tension and alignment must be
properly adjusted prior to placing the straightedge
against the outside edge of the track.
7. Measure the distance from the straightedge to the
right-side ski edge in two places: 35.5-38.1 cm
(14-15 in.) in front of the spindle and 35.5-38.1 cm
(14-15 in.) behind the spindle. Record the measurements taken for the right side.
! WARNING
The measurement from the front and rear of ski to the
straightedge can be equal (ski parallel to the track),
but the front measurement must never be less (ski
toed-in) or poor handling will be experienced. The
front measurements to the straightedge must not
exceed the rear measurements to the straightedge (ski
toed-out) by more than 12.7 mm (1/2 in.).
8. If ski alignment is not as specified, adjust the alignment of the ski(s) not parallel to the straightedge.
4. Place a long straightedge against the outside edge
of the track so it lies near the inside edge of the
left-side ski.
729-887E
NOTE: The straightedge should be long enough to
extend from the back of the track to the front of the ski.
5. Measure the distance from the straightedge to the
left-side ski edge in two places: approximately
35.5-38.1 cm (14-15 in.) in front of the spindle and
35.5-38.1 cm (14-15 in.) behind the spindle.
Record the measurements taken for the left side.
Adjusting
NOTE: The following procedure can be used to
adjust the alignment of either ski.
1. Unlock the steering tie rod by loosening jam nuts (A).
NOTE:The inside jam nuts are left-hand thread. Care
should be taken to rotate them in the proper direction.
SNO-2233A
2. Adjust ski alignment by rotating the tie rod with a
wrench at hex-point (B).
3. When ski alignment is correct, apply blue Loctite
#243 to the jam nut threaded area and tighten to 20
ft-lb. Tighten both jam nuts against the tie rod.
729-887D
6. Place the straightedge against the outside edge of the
track so it lies near the inside edge of the right-side ski.
! WARNING
Neglecting to lock the tie rod by tightening the jam
nuts may cause loss of snowmobile control and possible personal injury.
NOTE: To allow equal rotation of the tie rod end
ball joints, secure the tie rod jam nuts with the tie
rod ends positioned 90° from each other.
19
Also, if the snowmobile is to remain on a trailer after
filling the gas tank, the bed of the trailer must be maintained level to prevent gasoline from draining out
through the gas tank vent hose.
! WARNING
Always fill the gas tank in a well-ventilated area. Never
add gasoline to the snowmobile gas tank near any
open flames or with the engine running. DO NOT
SMOKE while filling the gas tank. Do not sit on the
snowmobile without first installing the gas tank cap.
0743-088
Recommended Gasoline
CAUTION
Do not use white gas or gasolines containing methanol. Only Arctic Cat approved gasoline additives
should be used.
The recommended gasoline to use in this snowmobile
is minimum 91 octane gasoline with a maximum 10%
ethanol content.
NOTE: For optimum performance, use only 91
octane (minimum) gasoline.
CAUTION
If a situation arises wherein 91 octane non ethanol or
91 octane with maximum 10% ethanol gasoline is not
available, 87 octane gasoline can be substituted in an
emergency; however, the prolonged usage of 87
octane gasoline can cause severe engine damage.
Gasolines containing more than 10% ethanol are not
acceptable gasoline for use in this snowmobile. Do not
use gasolines containing methanol.
Engine Break-In
The Arctic Cat engine (when new or rebuilt) requires a
short break-in period before the engine is subjected to
heavy load conditions.
During the break-in period (one tank of fuel), a maximum of 1/2 throttle (with varying throttle positions) is
recommended; however, brief full-throttle accelerations and variations in driving speeds contribute to
good engine break-in.
Premixing fuel and oil during the break in period is not
required. With the oil delivery control strategy of the
electronic oil pump, the pump will automatically compensate and deliver a richer fuel-to-oil ratio during the
engine break-in period.
Some may choose to pre-mix the first tank and if this
is the case, a pre-mix ratio of 100:1 is acceptable. A
pre-mix ratio of 100:1 combined with the richer fuel/
oil delivered from the electronic oil pump during
break-in may cause additional smoke at start up and
idle.
Preoperation Checks
1. Visually check all fluid levels. Add fluids as necessary.
Recommended Injection Oil
The recommended oil to use in the oil-injection system
is Arctic Cat C-TEC2 Synthetic 2-Cycle Oil (p/n
6639-520 - 48 oz) This oil is specially formulated to be
used and meets all of the lubrication requirements of
the Arctic Cat C-TEC2 snowmobile engine.
CAUTION
Any oil used in place of the recommended oil could
cause serious engine damage.
Filling Gas Tank
Since gasoline expands as its temperature increases,
the gas tank must be filled to its rated capacity only.
Expansion room must be maintained in the tank particularly if the tank is filled with cold gasoline and then
moved to a warm area.
20
2. Visually check the entire snowmobile for any
loose fasteners. Tighten as required.
3. Start and run the engine to operating temperature.
4. Check all switches (tether, dimmer, brakelight,
emergency stop) to make sure all function properly; then visually check the headlight, taillight,
and brake light for proper illumination.
5. Test the operation of the brakes. The brake lever
must feel firm when the lever is compressed.
Inspect the brake fluid level. The brake fluid level
must be just below the high mark on the brake
fluid reservoir. Add Arctic Cat approved brake
fluid as necessary.
Checking Headlight Aim
1. Position the snowmobile on a level floor so the
headlight is approximately 8 m (25 ft) from an
aiming surface (wall or similar surface).
NOTE: There should be an “average” operating
load on the snowmobile when adjusting headlight
aim.
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 horizontal mark on the aiming surface directly in front of
the headlight.
5. Engage the brake lever lock and start the engine.
Move the headlight dimmer switch to the HIGH
beam position. DO NOT USE LOW BEAM.
6. Observe the headlight beam aim. Proper aim is
when the most intense beam is centered on the vertical mark 5 cm (2 in.) below the horizontal mark
on the aiming surface.
0745-813
7. Adjust the headlight adjustment knobs until correct aim is obtained. Shut the engine off; then disengage the brake lever lock.
Track Tension/Track Alignment
CAUTION
Track tension has been initially adjusted at the factory
for “run-up testing”; however, track tension (and track
alignment) must be adjusted at the dealership according to the following recommendations.
To adjust track tension/track alignment, use the following procedure.
1. Elevate the snowmobile on a shielded safety stand
high enough to use a spring scale.
! WARNING
The tips of the skis must be positioned against a wall
or similar object for safety.
2. At mid-point of the track (on the bottom side),
hook a spring scale around a track clip; then pull
down on the scale to 9 kg (20 lb). Measure the
deflection (distance) between the bottom of the
wear strip and the inside surface of the track clip.
Compare the measurement with the chart.
0744-068
Rear Suspension Style Setup
129 in. Track @ 20 lb 35-41 mm
Tension
(1 3/8-1 5/8 in.)
After Break-In
Tension
38-44 mm
(1 1/2-1 3/4 in.)
3. Using Axle Nut Spanner Wrench (p/n 0644-558)
from the tool kit, loosen the right-side rear axle nut.
0744-067
NOTE: Always loosen the right-side rear axle nut
when adjusting track tension/alignment. The leftside rear axle nut is secured with green Loctite
#609 and should not be loosened or removed.
4. If the distance between the bottom of the wear
strip and the inside surface of the track clip
exceeds specifications, tighten the adjusting bolts.
If the distance between the bottom of the wear
strip and inside surface of the track clip is less than
specified, loosen the adjusting bolts.
5. When proper track deflection is attained, loosen
the right-side rear axle nut just enough to apply
blue Loctite #243 to the axle threads; then tighten
the nut to 40-45 ft-lb.
CAUTION
Make certain the right-side rear axle nut is tightened
or component damage will occur.
21
6. Start the engine and accelerate slightly. Use only
enough throttle to turn the track several revolutions. Shut engine off.
! WARNING
DO NOT stand behind the snowmobile or near the
rotating track. NEVER run the track at high speed
when the track is suspended.
NOTE: Allow the track to coast to a stop. Do not
apply the brake because it could produce an inaccurate alignment condition.
7. When the track stops rotating, check the relationship
of the rear idler wheels and the inner track drive lugs.
If the rear idler wheels are centered between the inner
track drive lugs, no adjustment is necessary.
9. Loosen the right-side rear axle nut; then on the
side of the track which has the inner track drive
lugs closer to the rear idler wheel, rotate the
adjusting bolt clockwise 1-1 1/2 turns.
10. Check track alignment and make necessary adjustments until proper alignment is obtained.
NOTE: Make sure correct track tension is maintained after adjusting track alignment.
11. Loosen the right-side rear axle nut just enough to
apply blue Loctite #243 to the axle threads; then
tighten the nut to 40-45 ft-lb.
! WARNING
If the axle nut is not tightened, the adjusting bolts could
loosen causing the track to ratchet, derail, or lock.
Test Ride
Test ride the snowmobile 5 to 10 minutes. During and
after the test ride, do the following:
1. Burnish the brake pads by driving the snowmobile
slowly and compressing the brake lever repeatedly
until the pads just start to heat up; then allow them
to cool down. This process stabilizes the pad material and extends the life of the pads.
0740-118
8. If the idler wheels are not centered between the
inner track drive lugs, adjust track alignment.
! WARNING
Make sure the ignition switch is in the OFF position
and the track is not rotating before checking or adjusting the track alignment.
2. Allow the engine to cool; then visually check coolant level. Add coolant as necessary.
3. Recheck track alignment and tension.
4. Check the engine compartment and underneath the
snowmobile for any signs of fluid leaks (gas, coolant).
22
General Information
Control Locations
0746-486
Arctic Power Valve (APV) System
2. While holding the cable housing, lightly pull on
one cable end to remove slack.
3. Measure the amount of exposed cable from the
cable housing to the end of the cable.
This RPM and exhaust pipe temperature controlled
servomotor (servo) actuation system adjusts the size of
the exhaust ports to provide peak performance
throughout the RPM range.
At low RPM, the exhaust valves are held in the
DOWN position by return springs. This gives the
engine a “low port” exhaust design calibrated to provide maximum low RPM power.
739-152A
At high RPM, the exhaust valves are raised. This creates a “high port” exhaust design calibrated to provide
maximum performance at high RPM.
0735-516
4. Repeat steps 2 and 3 on the other cable; then compare the measurements.
NOTE: Measurements must be within a range of
36.5 mm ± 1 mm.
NOTE: The measurements must be equal and
within the specifications. If the measurements are
within specifications, no adjustment is necessary.
If they are not within specifications, proceed to
step 5.
5. Loosen the jam nut on the cable adjuster to be
adjusted; then using the adjusting nuts, lengthen or
shorten the housing as needed.
6. While holding the adjusting nut in place, tighten
the jam nut securely.
7. Install the actuating cables to the servo.
CAUTION
If excessive adjustment is required to attain synchronization, the entire adjustment procedure should be
repeated.
739-152B
To adjust the APV system, use the following procedure:
1. Remove the actuating cables from the servo.
Exhaust Controlled Timing (ECT) System
This system automatically adjusts the ignition timing
to provide maximum performance through a variety of
operating conditions. The ECM unit receives input on
engine RPM (demand) and exhaust pipe temperature
(engine condition) and adjusts the ignition timing
accordingly. This system is not adjustable and is maintenance free.
If a system fault is suspected, disconnect the exhaust
pipe temperature sensor; then use an ohmmeter to
check continuity of the exhaust pipe temperature sensor located in the expansion chamber. A reading of
either 0 ohm or infinity indicates a failed sensor.
23
NOTE: A disabled ECT system WILL NOT cause
engine damage; however, a failed ECT system will
have slower throttle response and may produce
slightly less top-end performance.
Testing Exhaust Temperature Sensor
1. Disconnect the sensor harness; then remove the
sensor from the exhaust pipe.
2. Suspend the sensor (only up to the threads) in a
container filled with automatic transmission oil;
then slowly heat the oil on a hot plate.
3. Using a fluid thermometer, closely monitor the oil
temperature, and using a digital multimeter with
the leads connected to the sensor leads, observe
the resistance reading.
4. The resistance must be within the temperature
range (see chart).
Exhaust Temperature Sensor
° F ° C ohms
77 25 219.6
122 50 238.5
212 100 275.9
302 150 312.7
5. If the resistance and temperature are not within
specifications, replace the sensor.
NOTE: Do not adjust the handlebar to a position
that allows the brake fluid to be below the low
mark on either side of the master cylinder.
! WARNING
Tighten cap screws according to specifications to pre-
vent unexpected “fold-down” of the handlebar during
operation over rough terrain. DO NOT offset the handlebar so steering capabilities are altered or throttle
and brake controls will be affected.
Rear Bumper
The rear bumper can be removed and replaced. To remove/
install a rear bumper, use the following procedure.
1. On the inside of the tunnel, drill out all rivets and
remove both screws and nuts securing the rear
bumper to both sides of the tunnel.
2. Remove the existing bumper and install the new
one aligning the holes with the holes in the brackets; then rivet the rear bumper to both sides of the
tunnel. Secure the front of the bumper using the
existing machine screws and nuts.
Exhaust System
The exhaust system is designed to reduce noise and to
improve the total performance of the engine. If any
exhaust system component is removed from the engine
and the engine is run, severe engine damage will result.
NOTE: Before replacing the sensor, repeat the
test to confirm results.
Handlebar Tilt
The handlebar can be adjusted to the operator’s preference. To adjust the handlebar, use the following procedure:
1. Loosen the eight cap screws securing the handlebar
caps to the riser and the riser to the steering post.
SNO-2236
2. Adjust the handlebar up or down to operator’s
desired tilt, tighten the cap screws evenly to 15 ftlb, and check steering for maximum right/left turning capabilities.
Liquid Cooling System
The cooling system should be inspected daily for leakage and damage. Also, the coolant level should be
checked daily. If leakage or damage is detected and the
operator does not feel qualified to service the cooling
system, see an authorized Arctic Cat Snowmobile
dealer for this service.
When filling the cooling system, use a coolant/water
mixture which will satisfy the coldest anticipated
weather conditions of your area in accordance with the
coolant manufacturer’s recommendations. While the
cooling system is being filled, air pockets may
develop; therefore, fill the bottle and run the engine for
five to ten minutes after the initial fill (until the thermostat opens); then add more coolant if necessary. Fill
the coolant tank and take the snowmobile for a test
ride. Let the engine cool down; then recheck the coolant level and add if necessary.
NOTE: Use a good quality, glycol-based, automotive-type antifreeze.
CAUTION
After operating the snowmobile for the initial 5-10 minutes, stop the engine, allow the engine to cool down,
and check the coolant level. Add coolant as necessary.
24
Drive Clutch And Driven Clutch
Shock Absorbers
The drive clutch and driven clutch do not require lubrication; therefore, no special maintenance is required
by the snowmobile owner. However, the drive clutch
and driven clutch should be disassembled, cleaned,
and inspected before each race.
NOTE: A small amount of grease should be
applied to the driven shaft before installing the
driven clutch.
When operating the snowmobile at high altitudes, it
may be necessary to change certain component parts
of the drive clutch. If the operator does not feel qualified to change clutch components, see an authorized
Arctic Cat Snowmobile dealer for this service.
CAUTION
Use Clutch Puller (p/n 0744-062). Never substitute a
different puller or drive clutch damage will occur.
Drive Clutch/Driven Clutch Alignment
The parallelism and the offset between the drive clutch
and driven clutch are set at the factory. Normally, no
adjustment is necessary as long as neither the drive
clutch nor the driven clutch is removed or disassembled. However, if premature drive belt wear is experienced or if the drive belt turns over, the drive clutch/
driven clutch alignment must be checked. If the operator does not feel qualified to align the clutch/clutch,
see an authorized Arctic Cat Snowmobile dealer for
this service.
Each shock absorber should be visibly checked daily for
excessive fluid leakage, cracks or breaks in the lower
case, a bent plunger, and wear or leakage in the hoses. If
any one of these conditions is detected, replacement is
necessary. If the operator does not feel qualified to service or replace shock absorbers, see an authorized Arctic Cat Snowmobile dealer for this service.
Track Studs
NOTE: The track on this snowmobile is not
equipped with studs. For additional information,
see the 2015 POGA Reference Guide.
The decision to install studs should be made only after
reviewing the International Snowmobile Racing, Inc.
regulations as they pertain to the type of racing you
participate in. Arctic Cat has a variety of studding
products available from your authorized Arctic Cat
Snowmobile dealer.
Towing
If this snowmobile is to be towed by another snowmobile, do not tow using the loops in the skis. The tow
rope should be attached to the lower A-arms.
25
Operating Instructions
Starting And Stopping Engine
It is imperative that the hydraulic brake system be
checked for wear and proper operation and that all
safety checks found in the accompanying Snowmobile
Safety Handbook be performed before attempting to
start the engine. After the engine has been started,
check the headlights (high and low beam), taillight,
and brakelight to be sure they are working properly
and adjusted correctly. Make sure all lights are clean to
provide maximum illumination. The headlight and
taillight must be clean and must be illuminated whenever the engine is running.
1. Test the operation of the hydraulic brake system
by compressing the brake lever. The brake lever
must feel firm when compressed; then while holding the brake lever in the compressed position,
measure the distance between the brake lever and
the handlebar. The distance must be greater than
2.54 cm (1 in.).
! WARNING
Do not start the engine if the brake system is not functioning properly (if the lever feels spongy, if the brake
lever can be compressed to within 2.54 cm (1 in.) of
the handlebar, or if the brake fluid level is not correct).
Service the brake system or have it properly repaired
prior to operating the snowmobile. Serious personal
injury or even death may occur if the brake system is
not operating properly.
3. Test the throttle control lever by completely compressing and releasing it several times. The lever
MUST return to the idle position quickly and completely.
CAUTION
Always check the coolant level before starting the
engine.
4. Move the emergency stop switch to the RUN position.
5. Assure that the tether switch cap is secured to the
tether switch.
7. Pull the recoil handle slowly until resistance is
felt; then give a short quick pull. Repeat until the
engine starts.
0745-816
2. Check the brake fluid level in the master cylinder
reservoir. The brake fluid level must be just below
the high mark on the master cylinder reservoir.
Add Arctic Cat approved brake fluid as necessary.
SNO-253
CAUTION
To avoid damaging the recoil starter, DO NOT pull the
recoil rope to its limit or release the recoil handle from
an extended position. Allow the rope to rewind slowly.
CAUTION
It is extremely important that the engine is properly
warmed up before subjecting the engine to high speed
operation or heavy loads. Do not idle the engine for
excessively long periods of time. The engine should
be allowed to idle at least 1-2 minutes before it is operated at more than 1/2 throttle. In extremely cold conditions, the warm-up time will be longer. Cold seizure
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.
8. To shut off the engine, either depress the emergency stop switch to the OFF position or pull the
tether switch cap off the tether switch.
Braking
Operating a snowmobile with hydraulic brakes is different from operating a snowmobile with mechanical
brakes. The following items are items that the operator
must be familiar with when operating this snowmobile
and its hydraulic brake system.
NOTE: Important additional information on the
proper maintenance of the brake system is found
in the maintenance section of this manual.
26
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