Arctic Cat ZR 6000 R Cross Country 2016 Operators Manual

2016

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 Arctic Cat
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)*

* Limited to one (1) year of “normal” riding conditions - replace for defective or leaking shock, corroded or pitted shaft, peeling chrome.

NOTE: Snowmobiles that are factory equipped with Fox, Elka, or JRI shocks and experience a shock failure of workmanship or material within the factory warranty

period must not be tampered with. Only the air pressure valve (p/n 2603-511 - Fox shocks only) is serviceable during the warranty period. Any other tampering with the
shock will void warranty.

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 service as
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 purposes.

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.

© 2015 Arctic Cat Inc.
Printed in U.S.A. September 2015

! WARNING

This snowmobile is a very high performance snowmo­bile. 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.

T o 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

Arctic Power Valve (APV) System Specifications ... 3

Electrical Specifications .......................................... 4

Component Voltage/Resistance Chart - Water

Temperature ........................................................ 4

Drive System Specifications ................................... 5

Drive Clutch/Driven Clutch Optional Components .. 5

Chain Case Performance Calibrations.................... 6

Chains and Sprockets............................................. 8

Rear Spring Selection ............................................. 8

Installed Spring Rate .............................................. 8

Front Suspension Sway Bar.................................... 9

Rebuildable Shock Tools Required ......................... 9

Optional Front Arm Shock Springs ......................... 9

Valve Stacks/Specifications .................................. 10

Rebuildable Shock Accessory Part Numbers ....... 11

Drill Bit Sizes (Number) ........................................ 12

Fraction/Decimal Chart ......................................... 12

MM/IN. Conversion ............................................... 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 ........................................................ 19

Recommended Gasoline ...................................... 20

Preoperation Checks ............................................ 20

Checking Headlight Aim........................................ 21

Track Tension/Track Alignment.............................. 21

Test Ride............................................................... 22

General Information ............................................ 23-26

Control Locations .................................................. 23

Arctic Power Valve (APV) System ......................... 24

Exhaust Controlled Timing (ECT) System ............ 25

Arctic Power Valve (APV) System ......................... 24

Testing Exhaust Temperature Sensor ................... 25

Handlebar Tilt........................................................ 25

Exhaust System .................................................... 25

Exhaust System .................................................... 25

Liquid Cooling System .......................................... 26

Drive Clutch And Driven Clutch ............................ 26

Drive Clutch/Driven Clutch Alignment ................... 26

Shock Absorbers................................................... 26

Track Studs ........................................................... 26

Towing................................................................... 26

Operating Instructions ......................................... 27-28

Starting And Stopping Engine............................... 27

Braking.................................................................. 27

Emergency Stopping............................................. 28

Lubrication................................................................ 29

Chain Case ........................................................... 29

Rear Suspension .................................................. 29

Maintenance........................................................ 30-63

Periodic Maintenance Checklist ............................ 30

Pre-Race/Practice Checklist ................................. 31

Engine................................................................... 31

Track Drive ............................................................ 50

Drive Sprockets..................................................... 51

Brake System........................................................ 52

Brake Fluid............................................................ 52

Checking Brake Lever Travel................................. 53

Bleeding Brake System......................................... 53

Checking/Changing Brake Pads ........................... 54

Drive Belt .............................................................. 55

Drive Clutch .......................................................... 56

Driven Clutch ........................................................ 57

Adjusting Rear Transfer Adjuster Cams ................ 62

Adjusting Rear Transfer Adjuster Cams ................ 62

Lights .................................................................... 62

Ski Wear Bar......................................................... 63

Rail Wear Strip...................................................... 63

Performance Tips ..................................................... 64

Preparation For Storage........................................... 65

Preparation After Storage......................................... 66

Genuine Arctic Cat Products .................................... 67

Special Tools ....................................................... 68-77

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 Synthetic Chain

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

Lube

Engine Specifications

Engine Number 0962-039
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) To le ra nce

0-15 ±20%

16-39 ±15%

40+ ±10%

DRIVE SYSTEM

Item Secured to

Drive Clutch*** Engine 51
Drive Clutch Cover Movable Sheave 120 in.-lb
Cam Arm Pin Lock Nut Cam Arm Pin
Driven Clutch** Driven Shaft
Movable Sheave* Torque Bracket
Chain Case (Cap Screw) Chassis 96 in.-lb

Tor que

ft-lb

22
60
20

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 25
Brakeline Caliper 25
Brakeline Master Cylinder 25
Brake Caliper Shield Cover

Torq ue

ft-lb

12
12
25

96 in.-lb

STEERING/FRONT SUSPENSION/CHASSIS

Item Secured to

Ski Spindle 35
Ski Wearbar 12-15
Ski Ski Handle 54 in.-lb
Handlebar Adjuster Post
Steering Support Mounting Block
Steering Tie Rod Link Steering Post
Steering Tie Rod Link Steering Arm 20
Steering Post Cap Riser Block 15
Steering Post Chassis
Steering Tie Rod Steering Arm
Tie Rod Spindle Arm
Steering Support Spar
Steering Support Upper Console 30 in.-lb
Steering Arm Chassis 8
A-Arm (Upper) Chassis
A-Arm (Lower) Chassis (Front)
A-Arm (Lower) Chassis (Rear)
A-Arm Spindle 45
Shock Absorber Spindle 45
Shock Absorber Chassis 45
Sway Bar Link A-Arm/Sway Bar Link
Sway Bar Mounting Bracket Chassis

Tor que

ft-lb

15
15
35

55
20
45
45

23
65
45

23

9

REAR SUSPENSION

Wear Strip Rail 50 in.-lb
End Cap Rail 80 in.-lb
Mounting Block Rail
Rear Arm Rail
Rear Arm Idler Arm
Spring Slide Rail 20
Front Arm Rail 60
Coupler Block Axle Rail
Limiter Strap Rail Support
Rear Tri Hub Wheel Rear Tri Hub Wheel
Rear Wheel Axle Rail
Skid Frame Tunnel 55**
Front Shock Rail 50
Rail Support Rail
Limiter Strap Front Arm

* w/Green Loctite #609

20
45
55

40
72 in.-lb
50 in.-lb

34

20
72 in.-lb

** w/Blue Loctite #243
*** w/Oil

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 sp ecifi cat ion 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)
(Secondary)

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*

(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

Altitude

0-5000 120/235 lb J14-66g 180/260 lb 42°/44° 0627-083 42-4600 81-8200 23T 40T 86

Drive Clutch

Spring

Cam
Arm

Driven Clutch

Spring

Tor que

Bracket

Drive Belt

Engagement

RPM

Peak
RPM

Top Gear

Bottom

Gear

Chain

P/N DESCRIPTION P/N DESCRIPTION

Drive Clutch/Driven

Clutch-Related

Specifications

ALIGNMENT BAR

OFFSET P/N CENTER-TO-CENTER OFFSET FLOAT

0744-093 12.10” 1.500” 0.060”

Drive Clutch/Driven

Clutch Optional

Components

P/N DESCRIPTION P/N DESCRIPTION

DRIVE CLUTCH SPRINGS

0646-467 35/195 LB 0646-878 105/285 LB
0646-468 35/215 LB 0646-938 85/205 LB
0646-469 60/220 LB 0646-939 105/205 LB
0646-470 60/240 LB 0646-940 105/225 LB
0646-471 85/255 LB 0646-482 120/235 LB
0646-472 85/275 LB 0646-941 160/300 LB
0646-473 120/265 LB 0646-942 165/310 LB
0646-474 120/285 LB 0646-943 70/170 LB
0646-875 85/225 LB 0646-944 80/180 LB
0646-876 85/235 LB 0646-945 90/190 LB
0646-877 105/255 LB

CAM ARMS

0646-918 F7-48g 0646-901 J13-90g
0646-890 F7-50g 0646-902 J14-56g
0646-881 F7-52g 0646-871 J14-58g
0646-863 F7-54g 0646-867 J14-60g
0646-882 F7-56g 0646-872 J14-62g
0646-883 F7-58g 0646-903 J14-64g
0646-862 F7-60g 0646-869 J14-66g
0646-884 F7-62g 0646-904 J14-68g
0646-864 F7-64g 0646-905 J14-70g
0646-885 F7-66g 0646-906 J14-72g
0646-886 F7-68g 0646-907 J14-74g
0646-887 F7-70g 0646-924 J14-76g
0646-888 J13-60g 0646-930 J15-52g
0646-870 J13-62g 0646-929 J15-56g
0646-889 J13-64g 0646-908 J15-58g
0646-891 J13-66g 0646-909 J15-60g
0646-892 J13-68g 0646-910 J15-62g
0646-893 J13-70g 0646-873 J15-64g
0646-865 J13-72g 0646-911 J15-66g
0646-894 J13-74g 0646-912 J15-68g
0646-895 J13-76g 0646-913 J15-70g
0646-896 J13-78g 0646-914 J13-48g
0646-897 J13-80g 0646-915 J13-50g
0646-898 J13-82g 0646-874 J13-52g
0646-899 J13-84g 0646-868 J13-54g
0646-866 J13-86g 0646-916 J13-56g
0646-900 J13-88g 0646-917 J13-58g

0745-403 ELECTRIC START 84T 0645-410 RING, DAMPENER

0745-402 ELECTRIC START 94T 1623-821 SCREW, TORX SKT

0648-856 125/200 LB 0648-862 160/235 LB
0648-857 140/200 LB 0648-863 160/250 LB
0648-858 140/215 LB 0648-864 160/270 LB
0648-859 140/230 LB 0648-865 180/270 LB
0648-860 155/220 LB 0648-866 200/280 LB
0648-861 155/240 LB 0648-876 180/240 LB

0648-873 59-43-.36 0648-899 63-47-.36
0648-878 59-45-.36 0648-900 65-47-.36
0648-879 61-43-.36 0648-901 58-49-.15
0648-880 61-45-.36 0648-902 66-49-.20
0648-881 63-43-.36 0648-905 56-48-.20
0648-882 63-45-.36

CAM, ASSY-BOSS-273-C STRAIGHT

0648-867 42S 0648-870 46S
0648-868 43S 0648-885 47S
0648-884 44S 0648-886 48S
0648-869 45S

CAM, ASSY-BOSS-273-C PROGRESSIVE-ER (REVERSE)

0648-872 65-45-.36 ER3 0648-890 63-45-.36 ER3
0648-874 67-45-.46 ER3 0648-891 63-45-.46 ER3
0648-888 65-45-.46 ER3 0648-903 64-49-.20 ER3
0648-889 67-45-.36 ER3 0648-904 66-49-.20 ER3

CAM, ASSY-BOSS-273-C STRAIGHT-ER (REVERSE)

0648-893 42S ER3 0648-896 46S ER3
0648-894 43S ER3 0648-897 47S ER3
0648-895 44S ER3 0648-898 48S ER3
0648-871 45S ER3

RING GEARS

CLUTCH

FLAT HD M8X1.25X14

DRIVEN CLUTCH SPRINGS

DRIVEN CAMS

Pitch

5

Chain Case Performance

Calibrations

NOTE: The following table should be used as a guide only.

Drive

Sprocket

8 Tooth

(2.86"

pitch)

8 Tooth

(3.0" pitch)

9 Tooth

(2.52"

pitch)

Gear

Ratio

Top B tm

19 50 0.380 90 57 59 61 63 65 66 68 70 72 74 76 77 79 81 83
21 49 0.429 90 64 67 69 71 73 75 77 79 81 83 85 87 89 91 94
20 46 0.435 88 65 67 70 72 74 76 78 80 82 84 86 89 91 93 95
23 51 0.451 92 68 70 72 74 77 79 81 83 85 88 90 92 94 96 98
22 48 0.458 90 69 71 73 76 78 80 82 84 87 89 91 93 96 98 100
24 50 0.480 92 72 75 77 79 81 84 86 88 91 93 95 98 100 102 105
21 41 0.512 86 77 80 82 84 87 89 92 94 97 99 102 104 107 109 112
21 38 0.553 84 83 86 88 91 94 97 99 102 105 107 110 113 115 118 121
20 35 0.571 82 86 89 91 94 97 100 103 105 108 111 114 116 119 122 125
23 40 0.575 86 86 89 92 95 98 100 103 106 109 112 114 117 120 123 126
22 37 0.595 84 89 92 95 98 101 104 107 110 112 115 118 121 124 127 130
24 39 0.615 86 93 96 99 101 104 107 110 113 116 119 122 125 128 131 134
23 36 0.639 84 96 99 102 105 108 112 115 118 121 124 127 130 133 136 139
24 35 0.686 84 103 106 110 113 116 120 123 126 130 133 136 140 143 146 150
19 50 0.380 90 60 62 64 66 68 70 72 73 75 77 79 81 83 85 87
21 49 0.429 90 68 70 72 74 76 79 81 83 85 87 89 92 94 96 98
20 46 0.435 88 69 71 73 75 77 80 82 84 86 88 91 93 95 97 100
23 51 0.451 92 71 73 76 78 80 83 85 87 89 92 94 96 99 101 103
22 48 0.458 90 72 75 77 79 82 84 86 89 91 93 96 98 100 103 105
24 50 0.480 92 76 78 81 83 85 88 90 93 95 98 100 103 105 107 110
21 41 0.512 86 81 83 86 89 91 94 96 99 102 104 107 109 112 115 117
21 38 0.553 84 87 90 93 96 98 101 104 107 110 112 115 118 121 124 127
20 35 0.571 82 90 93 96 99 102 105 108 110 113 116 119 122 125 128 131
23 40 0.575 86 91 94 97 99 102 105 108 111 114 117 120 123 126 129 132
22 37 0.595 84 94 97 100 103 106 109 112 115 118 121 124 127 130 133 136
24 39 0.615 86 97 100 103 106 110 113 116 119 122 125 128 132 135 138 141
23 36 0.639 84 101 104 107 111 114 117 120 124 127 130 133 137 140 143 146
24 35 0.686 84 108 112 115 119 122 126 129 133 136 140 143 147 150 154 157
19 50 0.380 90 57 58 60 62 64 66 68 69 71 73 75 77 79 80 82
21 49 0.429 90 64 66 68 70 72 74 76 78 80 82 84 87 89 91 93
20 46 0.435 88 65 67 69 71 73 75 77 79 82 84 86 88 90 92 94
23 51 0.451 92 67 69 72 74 76 78 80 82 85 87 89 91 93 95 98
22 48 0.458 90 68 71 73 75 77 79 82 84 86 88 90 93 95 97 99
24 50 0.480 92 72 74 76 78 81 83 85 88 90 92 95 97 99 102 104
21 41 0.512 86 76 79 81 84 86 89 91 94 96 99 101 103 106 108 111
21 38 0.553 84 82 85 88 90 93 96 98 101 104 106 109 112 114 117 120
20 35 0.571 82 85 88 91 93 96 99 102 104 107 110 113 115 118 121 124
23 40 0.575 86 86 88 91 94 97 100 102 105 108 111 113 116 119 122 124
22 37 0.595 84 89 91 94 97 100 103 106 109 112 114 117 120 123 126 129
24 39 0.615 86 92 95 98 101 104 107 109 112 115 118 121 124 127 130 133
23 36 0.639 84 95 98 101 104 108 111 114 117 120 123 126 129 132 135 138
24 35 0.686 84 102 106 109 112 115 119 122 125 129 132 135 138 142 145 148

Ratio Chain Engine RPM

6200 6400 6600 6800 7000 7200 7400 7600 7800 8000 8200 8400 8600

Vehicle Speed (mph)

8800 9000

6

Drive

Sprocket

9 Tooth

(2.86"

pitch)

10 Tooth

(2.52"

pitch)

Gear

Ratio

19 50 0.380 90 64 66 68 71 73 75 77 79 81 83 85 87 89 91 93
21 49 0.429 90 73 75 77 80 82 84 87 89 91 94 96 98 101 103 105
20 46 0.435 88 74 76 78 81 83 85 88 90 93 95 97 100 102 104 107
23 51 0.451 92 76 79 81 84 86 89 91 94 96 98 101 103 106 108 111
22 48 0.458 90 78 80 83 85 88 90 93 95 98 100 103 105 108 110 113
24 50 0.480 92 81 84 86 89 92 94 97 100 102 105 107 110 113 115 118
21 41 0.512 86 87 89 92 95 98 101 103 106 109 112 115 117 120 123 126
21 38 0.553 84 93 97 100 103 106 109 112 115 118 121 124 127 130 133 136
20 35 0.571 82 97 100 103 106 109 112 115 118 122 125 128 131 134 137 140
23 40 0.575 86 97 100 104 107 110 113 116 119 122 126 129 132 135 138 141
22 37 0.595 84 101 104 107 110 114 117 120 123 127 130 133 136 140 143 146
24 39 0.615 86 104 107 111 114 118 121 124 128 131 134 138 141 144 148 151
23 36 0.639 84 108 112 115 119 122 126 129 132 136 139 143 146 150 153 157
24 35 0.686 84 116 120 123 127 131 135 138 142 146 150 153 157 161 165 168
19 50 0.380 90 63 65 67 69 71 73 75 77 79 81 83 85 87 89 91
21 49 0.429 90 71 73 76 78 80 82 85 87 89 92 94 96 98 101 103
20 46 0.435 88 72 74 77 79 81 84 86 88 91 93 95 98 100 102 105
23 51 0.451 92 75 77 80 82 84 87 89 92 94 96 99 101 104 106 108
22 48 0.458 90 76 78 81 83 86 88 91 93 96 98 100 103 105 108 110
24 50 0.480 92 80 82 85 87 90 92 95 97 100 103 105 108 110 113 115
21 41 0.512 86 85 88 90 93 96 99 101 104 107 109 112 115 118 120 123
21 38 0.553 84 92 94 97 100 103 106 109 112 115 118 121 124 127 130 133
20 35 0.571 82 95 98 101 104 107 110 113 116 119 122 125 128 131 134 137
23 40 0.575 86 95 98 101 104 108 111 114 117 120 123 126 129 132 135 138
22 37 0.595 84 98 102 105 108 111 114 118 121 124 127 130 133 137 140 143
24 39 0.615 86 102 105 108 112 115 118 122 125 128 132 135 138 141 145 148
23 36 0.639 84 106 109 113 116 119 123 126 130 133 137 140 143 147 150 154
24 35 0.686 84 114 117 121 125 128 132 136 139 143 147 150 154 158 161 165

Ratio Chain Engine RPM

NOTE: The above gearing options are combinations which allow acceptable chain tension. Any other
combinations will not allow acceptable chain tension.

7

Chains and Sprockets

p/n Sprocket

2602-943 18T FWD (13 WIDE/19 SPLINE)
2602-823 19T FWD (13 WIDE/19 SPLINE)
2602-824 20T FWD (13 WIDE/19 SPLINE)
2602-825 21T FWD (13 WIDE/19 SPLINE)
2602-826 22T FWD (13 WIDE/19 SPLINE)
2602-827 23T FWD (13 WIDE/19 SPLINE)

2602-828 19T FWD (15 WIDE/19 SPLINE)
2602-829 21T FWD (15 WIDE/19 SPLINE)
2602-830 22T FWD (15 WIDE/19 SPLINE)

2602-831 35T (13 WIDE/34 SPLINE)
2602-833 36T (13 WIDE/34 SPLINE)
2602-834 37T (13 WIDE/34 SPLINE)
2602-836 38T (13 WIDE/34 SPLINE)
2602-745 41T (13 WIDE/34 SPLINE)
2602-790 48T (13 WIDE/34 SPLINE)
2602-758 49T (13 WIDE/34 SPLINE)
2602-746 50T (13 WIDE/34 SPLINE)
2602-940 53T (13 WIDE/34 SPLINE)
2602-941 54T (13 WIDE/34 SPLINE)

2602-874 48T (13 WIDE/34 SPLINE) ALUM
2602-875 49T (13 WIDE/34 SPLINE) ALUM
2602-876 50T (13 WIDE/34 SPLINE) ALUM
2602-939 50T (13 WIDE/34 SPLINE) ALUM

0730-218

Wire

P/N

1704-382/383
(Light)

1704-384/385
(Heavy)

1704-916/917 .405 120° 5.90 3.20 15.62 4.70 24
2704-224/225 .437 105° 6.80 3.75 15.62 4.70 27.3
1704-576/577 .405 90° 6.75 3.65 18.50 5.50 18.5
2704-384/385 .405 115° 6.80 3.65 15.62 4.70 18.9
2704-380/381 .437 92° 6.75 3.75 15.62 4.70 27.4
2704-382/383* .405 89° 6.75 3.65 15.62 4.70 18.9

Diameter

Angle

(A)

.359 90° 5.75 3.00 15.62 4.60 17

.375 90° 5.75 3.00 15.62 4.60 20

(B)

# of

Coils

Coil

Width

(C)

Length

(D)

Length

(E)

Degree

(In lb)

* Production (Cross Country)



NOTE: The wire diameter and length of the spring

have a large influence over the valving of the shocks.

1702-402 40T TOS-ASSY
1702-403 49T TOS-ASSY

p/n Chain

2602-837 84P (13 WIDE)
2602-743 86P (13 WIDE)
2602-760 90P (13 WIDE)
2602-744 92P (13 WIDE)
2602-944 96P (13 WIDE)

2602-838 84P (15 WIDE)
2602-839 86P (15 WIDE)
2602-840 90P (15 WIDE)
2602-841 92P (15 WIDE)
2602-945 98P (15 WIDE)

Rear Spring Selection

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).

Installed Spring Rate

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 Set 1 & 1)

(in.-lb - Adjuster Set 1 & 1)

Extended

Suspension Fully

Collapsed

Suspension Fully

Extended

(in.-lb - Adjuster Set 3 & 3)

Suspension Fully

Collapsed

(in.-lb - Adjuster Set 3 & 3)

8

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

2703-794 2603-948/949 (inc.) 14.3 mm diameter

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 Dual Rate

Spring Chart (DSR)

Dual
Rate

100/200 200 lb x 2.15" 200 lb x 6” 1” 1.70”

90/200 170 lb x 2.20” 200 lb x 6” 1” 1.65”

80/200 140 lb x 2.40” 200 lb x 6” 1” 1.80”

50/200 70 lb x 2.55” 200 lb x 6” 1” 1.65”

110/250 200 lb x 2.15” 250 lb x 6” 1” 1.52”

100/250 170 lb x 2.20” 250 lb x 6” 1” 1.50”

90/250 140 lb x 2.40” 250 lb x 6” 1” 1.75”

55/250 70 lb x 2.55” 250 lb x 6” 1” 1.60”

120/300 200 lb x 2.15” 300 lb x 6” 1” 1.40”

110-300 170 lb x 2.20” 300 lb x 6” 1” 1.40”

95/300 140 lb x 2.40” 300 lb x 6” 1” 1.60”

55/300 70 lb x 2.55” 300 lb x 6” 1” 1.55”

Ride-in

Spring

p/n 3704-037 p/n 3704-038 0.5” 2.70”

p/n 3704-036 p/n 3704-038 0.5” 2.50”

p/n 3704-035 p/n 3704-038 0.5” 2.65”

p/n 3704-033 p/n 3704-038 0.5” 2.30”

p/n 3704-037 p/n 3704-039 0.5” 2.41”

p/n 3704-036 p/n 3704-039 0.5” 2.33”

p/n 3704-035 p/n 3704-039 0.5” 2.50”

p/n 3704-033 p/n 3704-039 0.5” 2.25”

p/n 3704-037 p/n 3704-040 0.5” 2.25”

3704-036 p/n 3704-040 0.5” 2.20”

3704-035 p/n 3704-040 0.5” 2.35”

p/n 3704-033 p/n 3704-040 0.5” 2.15”

Take-over

Spring

Communication

Length

Transition

Poin t

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

9

Valve Stacks/

Specifications

Ski Shock Part Number Compression (Piston Side) Rebound (Piston Side)

3703-346/347 1.300 x 0.008 in. (SB) 1.100 x 0.008 in.
Extended Length: 18.94 in. 1.300 x 0.008 in. 0.800 x 0.004 in.
Collapsed Length: 13.29 in. 0.800 x 0.006 in. 1.125 x 0.080 in. Ground
Stroke: 5.65 in. 1.300 x 0.010 in.

1.250 x 0.010 in. 0.620 x 0.093 in. Backup

Rebuild Kit: p/n 3603-420 1.100 x 0.010 in.

1.000 x 0.010 in.
Service Set Shaft: p/n 3603-465 0.900 x 0.010 in.
Sleeve Assembly: p/n 3603-290 1.125 x 0.093 in. Top out

Piston Depth: 2.30 in.

Piston Orifice: None 0.700 x 0.010 in.

Compression (CD Piston)

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) (green Loctite #620 on threads). Piston nut tightened to 3.0 kg-m (22 ft-lb).
Tighten shaft nut to 3.0 kg-m (22 ft-lb). Shocks charged at 250 psi (nitrogen)/80/200 psi (air).

Front Arm Shock Part Number Compression (Piston Side) Rebound (Piston Side)

2704-635 1.300 x 0.008 in. 1.100 x 0.008 in.
Extended Length: 12.36 in. 1.300 x 0.008 in. 0.600 x 0.004 in.
Collapsed Length: 8.56 in. 0.800 x 0.004 in. 0.700 x 0.010 in.
Stroke: 3.80 in. 1.300 x 0.010 1.125 x 0.080 in. (Top Out)

1.100 x 0.004 in.
Rebuild Kit: p/n 4604-017 1.000 x 0.004 in. 0.620 x 0.093 in. Backup

1.000 x 0.004 in.

0.700 x 0.004 in.

1.250 x 0.093 in. (Top Out)
Piston Depth: 1.80 in.
Piston Orifice: None

Compression @ 12 clicks counterclockwise from full stop. Eyelets tightened to 3.9 kg-m (28 ft-lb) (green Loctite #620 on threads).
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.

Rear Arm Shock Part Number

2704-636 1.600 x 0.004 in. (DB) 1.425 x 0.015 in.
Extended Length: 14.59 in. 1.600 x 0.010 in. 1.425 x 0.015 in.

Rebuild Kit: p/n 4604-017 1.100 x 0.006 in. 1.350 x 0.012 in.
(Reservoir) 1.600 x 0.012 in. 1.100 x 0.012 in.
Collapsed Length: 10.06 in. 1.600 x 0.012 in. 0.950 x 0.012 in.
Stroke: 4.52 in. 1.600 x 0.012 in. 0.800 x 0.020 in.

Piston Depth: 2.40 in. 1.570 x 0.128 in. (Top Out)
Piston Orifice: None

Compression

(Piston Side)

1.600 x 0.010 in. 1.425 x 0.012 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)

Rebound (Piston Side)

CD Knob @ 12 clicks from full closed; RB Knob @ 5 clicks counterclockwise. Shock charged at 250 psi.
Eyelets tightened to 3.9 kg-m (28 ft-lb) (green Loctite #620 on threads). Piston nut tightened to 3.0 kg-m (22 ft-lb).

Tighten the shaft nut to 3.9 kg-m (28 ft-lb).

10

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.

11

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)

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 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

MM/IN. Conversion

mm in. mm in. mm in. mm in. mm in.

.01 .00039 .41 .01614 .81 .03189 21 .82677 61 2.40157
.02 .00079 .42 .01654 .82 .03228 22 .86614 62 2.44094
.03 .00118 .43 .01693 .83 .03268 23 .90551 63 2.48031
.04 .00157 .44 .01732 .84 .03307 24 .94488 64 2.51968
.05 .00197 .45 .01772 .85 .03346 25 .98425 65 2.55905
.06 .00236 .46 .01811 .86 .03386 26 1.02362 66 2.59842
.07 .00276 .47 .01850 .87 .03425 27 1.06299 67 2.63779
.08 .00315 .48 .01890 .88 .03465 28 1.10236 68 2.67716
.09 .00354 .49 .01929 .89 .03504 29 1.14173 69 2.71653
.10 .00394 .50 .01969 .90 .03543 30 1.18110 70 2.75590
.11 .00433 .51 .02008 .91 .03583 31 1.22047 71 2.79527
.12 .00472 .52 .02047 .92 .03622 32 1.25984 72 2.83464
.13 .00512 .53 .02087 .93 .03661 33 1.29921 73 2.87401
.14 .00551 .54 .02126 .94 .03701 34 1.33858 74 2.91338
.15 .00591 .55 .02165 .95 .03740 35 1.37795 75 2.95275
.16 .00630 .56 .02205 .96 .03780 36 1.41732 76 2.99212
.17 .00669 .57 .02244 .97 .03819 37 1.45669 77 3.03149
.18 .00709 .58 .02283 .98 .03858 38 1.49606 78 3.07086
.19 .00748 .59 .02323 .99 .03898 39 1.53543 79 3.11023
.20 .00787 .60 .02362 1.0 .03937 40 1.57480 80 3.14960
.21 .00827 .61 .02402 1 .03937 41 1.61417 81 3.18897
.22 .00866 .62 .02441 2 .07874 42 1.65354 82 3.22834
.23 .00906 .63 .02480 3 .11811 43 1.69291 83 3.26771
.24 .00945 .64 .02520 4 .15748 44 1.73228 84 3.30708
.25 .00984 .65 .02559 5 .19685 45 1.77165 85 3.34645
.26 .01024 .66 .02598 6 .23622 46 1.81102 86 3.38582
.27 .01063 .67 .02638 7 .27559 47 1.85039 87 3.42519
.28 .01102 .68 .02677 8 .31496 48 1.88976 88 3.46456
.29 .01142 .69 .02717 9 .35433 49 1.92913 89 3.50393
.30 .01181 .70 .02756 10 .39370 50 1.96850 90 3.54330
.31 .01220 .71 .02795 11 .43307 51 2.00787 91 3.58267
.32 .01260 .72 .02835 12 .47244 52 2.04724 92 3.62204
.33 .01299 .73 .02874 13 .51181 53 2.08661 93 3.66141
.34 .01339 .74 .02913 14 .55118 54 2.12598 94 3.70078
.35 .01378 .75 .02953 15 .59055 55 2.16535 95 3.74015
.36 .01417 .76 .02992 16 .62992 56 2.20472 96 3.77952
.37 .01457 .77 .03032 17 .66929 57 2.24409 97 3.81889
.38 .01496 .78 .03071 18 .70866 58 2.28346 98 3.85826
.39 .01535 .79 .03110 19 .74803 59 2.32283 99 3.89763
.40 .01575 .80 .03150 20 .78740 60 2.36220 100 3.93700

12

Wiring Diagram - Hood

Harness

(p/n 1686-706) - Cross Country

0748-009A

13

NOTES

14

Wiring Diagram - Ignition/

Main Harness

(p/n 1686-732)

(Insert 0747-813 11 x 17 in color here.)

15

NOTES

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. Take 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

0748-628

Sway Bar

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.

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.

0748-629

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.

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.

18

! 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.

2. The brake lever must feel firm when compressed.

Ski Alignment

Checking

Toe - O u t Rang e

0.0 - 12.7 mm (0 - 1/2 in.)



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.

4. Place a long straightedge against the outside edge
of the track so it lies near the inside edge of the
left-side 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.

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.

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 par allel to the straightedge.

Adjusting

NOTE: The following procedure can be used to
adjust the alignment of either ski.

729-887E



NOTE: The straightedge should be long enough to

extend from the back of the track to the front of the 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

19

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.

! WARNING

Neglecting to lock the tie rod by tightening the jam
nuts may cause loss of snowmobile control and possi­ble personal injury.

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.

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.

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.

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.

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.

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

20

1. Visually check all fluid levels. Add fluids as nec­essary.

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

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.

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.

! 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

0745-813

7. Adjust the headlight adjustment knobs until cor­rect aim is obtained. Shut the engine off; then dis­engage the brake lever lock.

Rear Suspension Style Setup

129 in. Track @ 20 lb 35-41 mm

Ten sio n

(1 3/8-1 5/8 in.)

After Break-In

Tensio n

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

21

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.

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.

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.

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.

2. Allow the engine to cool; then visually check cool­ant level. Add coolant as necessary.

22

3. Recheck track alignment and tension.

4. Check the engine compartment and underneath the
snowmobile for any signs of fluid leaks (gas, cool­ant).

0740-118