Arctic Cat ZR 6000 R Sno Cross 2016 Operators Manual

2016

OPERATOR’S MANUAL

ZR® 6000 R SNO CROSS

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.

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.

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 Snowmobil e. 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.

Reference Information

The Arctic Cat Snowmobile has two important identification numbers. The Vehicle Identification Number (VIN) is stamped on the side of the tunn el. The Engine Serial Number (ESN) is stamped into the crankcase of the engine.

0746-482

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.

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 ............. 2-17

General Specifications ............................................ 2

Engine Specifications ............................................. 2

Torque Specifications.............................................. 2

Engine Torque Patterns .......................................... 4

Torque Conversions (ft-lb/N-m)............................... 5

Tightening Torque (General Bolts) .......................... 5

Electrical Specifications .......................................... 5

Component Voltage/Resistance Chart - Water

Temperature ........................................................ 6

Crankshaft Runout/Repair Specifications ............... 6

Drive System Specifications ................................... 7

Drive Clutch/Driven Clutch Optional Components .. 7

Drive Clutch Cam Arms (w/Set Screw)................... 7

Chain Case Performance Calibrations.................... 8

Chains and Sprockets........................................... 10

Carburetor Specifications...................................... 10

Arctic Power Valve (APV) System Specifications . 10

Mikuni Tuning Components .................................. 11

Major Tuning Components .................................... 11

Jet Needle Taper Angles....................................... 11

Rear Spring Selection Chart ................................. 12

Installed Spring Rate Chart .................................. 12

Front Suspension Sway Bar.................................. 12

Rebuildable Shock Tools Required ....................... 12

Valve Stacks/Specifications .................................. 13

Rebuildable Shock Accessory Part Numbers ....... 14

Drill Bit Sizes (Number) Chart............................... 15

Fraction/Decimal Chart ......................................... 15

MM/IN. Conversion Chart ..................................... 15

Wiring Diagram - Hood Harness (p/n 1686-664) .. 16 Wiring Diagram - Ignition/Main Harness (p/n 1686-

732) ................................................................... 17

Setup Instructions ............................................... 19-25

Removing Snowmobile From Crate/Handlebar

Assembly ........................................................... 19

Installing Windshield ............................................ 19

Installing Spindle/A-Arm ....................................... 19

Installing Front Shock Absorbers .......................... 19

Installing Skis........................................................ 19

Installing Sway Bar (Optional)............................... 20

Brake System........................................................ 20

Drive Belt .............................................................. 20

Ski Alignment ........................................................ 21

Recommended Gasoline/Oil/Mixing Ratio ............ 22

Preoperation Checks ............................................ 22

Checking Headlight Aim........................................ 23

Track Tension/Track Alignment.............................. 23

Handlebar/Ski Alignment ...................................... 24

Test Ride............................................................... 25

General Information ............................................ 26-30

Control Locations .................................................. 26

Engine Break-In .................................................... 26

Diagnostic Codes/Check Engine Light.................. 26

Ignition Timing Adjustment Dial ............................ 26

Testing Ignition Timing Rotary Select Switch ........ 26

Arctic Power Valve (APV) System ......................... 27

Exhaust Controlled Timing (ECT) System ............ 27

Testing Exhaust Temperature Sensor ................... 27

ACT Hot Start System........................................... 28

Handlebar Tilt........................................................ 28

Rear Bumper......................................................... 29

Exhaust System .................................................... 29

Air-Intake Silencer................................................. 29

Liquid Cooling System .......................................... 29

Drive Clutch And Driven Clutch ............................ 29

Drive Clutch/Driven Clutch Alignment ................... 29

Drive Chain Tension.............................................. 29

Fuel Pump............................................................. 30

Shock Absorbers................................................... 30

Track Studs ........................................................... 30

Towing................................................................... 30

Operating Instructions ......................................... 31-32

Starting And Stopping Engine............................... 31

Braking.................................................................. 32

Emergency Stopping............................................. 32

Lubrication................................................................ 33

Chain Case ........................................................... 33

Rear Suspension .................................................. 33

Maintenance........................................................ 34-76

Periodic Maintenance Checklist ............................ 34

Pre-Race/Practice Checklist ................................. 35

Engine................................................................... 35

Fuel System .......................................................... 57

Servicing Carburetors ........................................... 57

Adjusting Carburetors ........................................... 62

Selecting Carburetor Main Jets............................. 63

Reed Valves .......................................................... 63

Spark Plugs........................................................... 65

Track Drive ............................................................ 65

Drive Sprockets..................................................... 67

Brake System........................................................ 68

Checking Brake Lever Travel................................. 68

Bleeding Brake System......................................... 69

Checking/Changing Brake Pads ........................... 69

Drive Belt .............................................................. 69

Drive Clutch .......................................................... 70

Driven Clutch ........................................................ 72

Ski Shock Absorber Springs ................................. 73

Adjusting Rear Arm Hole Shot Device .................. 74

Lights .................................................................... 74

Ski Wear Bar......................................................... 75

Rail Wear Strip...................................................... 75

Performance Tips ..................................................... 77

Preparation For Storage........................................... 78

Preparation After Storage......................................... 79

Genuine Arctic Cat Products .................................... 80

Special Tools ....................................................... 81-90

Declaration of Conformity................ Inside Back Cover

General Specifications

Torque Specifications

Chassis Length 315 cm (124.25 in.)

Height 120 cm (48.25 in.)

Width 128-131 cm (50.50-51.50 in.)

Spindle Center-to-Center Distance (Stance)

Dry Weight (approx) 211 kg (465 lb)

Gas Tank Capacity 26.5 l (7.0 U.S. gal.)

Chain Case Lubricant Capacity 355 ml (15 fl oz)

Gasoline (Recommended) 92 Octane (minimum)

Pre-Mix Oil (32:1 Ratio) Arctic Cat APV 2-Cycle Oil

Chain Case Lubricant Arctic Cat Synthetic 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

106-109 cm (41.90-42.90 in.)

Non-Oxygenated

Engine Specifications

Model AK60L3

Bore x Stroke 73.8 x 70 mm (2.906 x 2.755 in.)

Displacement 598.9 cc (36.54 cu. in.)

Cylinder/Head Volume Squish-Gap 1.396 mm (0.055 in.)

Cylinder/Head Volume Installed 24.81 cc (1.52 cu in.)

Cylinder/Head Volume Flat Plate 28.56 cc (1.74 cu in.)

Lighting Coil Output 13V/156W @ 3000 RPM

Ignition Type CDI/NOI

Ignition Timing Electronically Controlled/Operator Adjustable

Spark Plug Type NGK BR9EYA

Spark Plug Gap 0.7-0.8 mm (0.028-0.031 in.)

Compression Ratio 6.80:1

Piston Skirt/Cylinder Clearance Range

Piston Ring End Gap Range 0.20-0.35 mm

Cylinder Truness Limit (max) 0.1 mm (0.004 in.)

Piston Pin Diameter Range 19.995-20.000 mm

Piston Pin Bore Diameter Range 20.002-20.010 mm

Connecting Rod Small End Bore Diameter Range

Connecting Rod Radial Play Range 0.003-0.020 mm

Crankshaft Runout (t.i.r.) 0.05 mm (0.002 in.)

Crankshaft End Play Range 0.05-0.10 mm (0.002-0.004 in.)

25° BTDC @ 2000-3000 RPM (4.123 mm or 0.162 in.)

0.075-0.105 mm

0.0029-0.0041 in.

0.008-0.014 in.

0.7872-0.7874 in.

0.7875-0.7878 in.

25.003-25.011 mm

0.9844-0.9846 in.

0.0001-0.0008 in.

CHASSIS

Item Secured to

Rear Bumper Steering Suppor t Steering Suppor t Rear Spar

Rear Spar Side Spar - Right Side Spar - Right Side Spar

Side Spar - Right

Side Spar - Left Spar, Upper Front Spar, Upper Front

Tube, Support - Shock Tower

Toe Hook Clutch Guard Panel, Front Chassis Panel, Front Chassis Lower Frame - Weldment Housing, A-Arm/Shock Mounting

Mounting Bracket - Upper A-Arm

Lower Frame - Weldment Chassis Toe Stop Stirrup

Chassis 12 Chassis 12 Steering Support 23 Tunnel Support Bracket -

Rear Spar Steering Support 45 Chassis 23 Chain Case 10 Housing, A-Arm/Shock

Mounting Bracket, Exhaust Mount-

ing Spar Chassis 12 Steering Support 45 Housing, A-Arm/Shock

Mounting Housing, A-Arm/Shock

Mounting Chassis 20 Chassis 5 Lower Frame - Weldment 12 Bellcrank 5 Chassis 20 Panel, Bellcrank/Shock

To we r Panel, Bellcrank/Shock

To we r Housing, A-Arm/Shock

Mounting Heat Exchanger 25 Seat, Hold-Down 20 Toe Hook 8

Tor que

ft-lb

DRIVE SYSTEM AND ELECTRICAL

Clutch, Drive**** Engine 51 Clutch, Driven* Shaft, Driven 20 CDI Plate, Air Silencer - Upper 8 Servomotor Mounting Bracket -

Voltage Regulator Electrical Panel 5 Electrical Panel Steering Support 12 Timing Select Steering Support - Right 6 Chain Case Chassis 12 Chain Case Chassis 8 Brake Caliper Brake Caliper 25 Brake Hose Master Cylinder 125 in.-lb Brake Hose Brake Caliper 25 Bridge Bolts Brake Caliper 60 Chain Case - Cover Chain Case 12 Reservoir Cover Master Cylinder 12 in.-lb Master Cylinder Clamp Master Cylinder 72 in.-lb Brake Caliper Cover, Shield 8

Servomotor

STEERING AND FRONT SUSPENSION

Item Secured to

Post, Steering Bellcrank 55 Plate, Retaining - Bellcrank Bellcrank 20 Steering Support Mounting Block - Steering

Bellcrank Lower Frame - Bellcrank

Tie Rod, Spindle/Bellcrank Bellcrank 20 Tie Rod, Spindle/Bellcrank Spindle 40 Mounting Block - Throttle - Front Mounting Block - Throttle

Lever, Throttle Axle, Lever 18 in.-lb Cap, Steering Block, Riser 15

Shock Absorber Spindle 45 Shock Absorber Chassis

Upper Arm Panel, Front Chassis 23 Upper Arm Spindle 45 Lower A-Arm - Front Lower Frame - Weldment 55 Lower A-Arm - Rear Lower Frame - Weldment 45 Lower A-Arm Spindle 45

Post

Mounting

- Rear

Tor que

ft-lb

REAR SUSPENSION

Suspension, Rear Axle, Front Arm 45 Suspension, Rear Axle, Offset Arm 45 Nosepiece Rail 80 in.-lb Wearstrip Rail 50 in.-lb Limiter Strap Front Arm 66 in.-lb Limiter Strap Limiter Strap 66 in.-lb Rail Crossbrace Axle 20 Rail Front Shock 50 Front Arm Rail 55 Front Shock Top Front Arm 45 Rear Arm Rail 45 Rear Arm Shock Idler Arm 45 Rear Arm Idler Arm 55 Rear Shock Link Rear Shock Axle 45 Spring Slide Rail 20 Offset Arm Idler Arm 55 Rear Wheel Axle (Left***, Right*) Axle Nut 60 Shock Pivot Rail 45 Rail Brace Rail 10 Rail Brace Rail 20 Rail Brace Axle, Crossbrace 20 Rail Axle, Crossbrace - Rear

Track Adjuster Rail 10 Rail Brace Pad, Shock 4

Arm

ENGINE

Item Secured to

Cylinder Head/Cover Cylinder (2 Steps) 20-25 ft-

Cylinder Crankcase (3 Steps) 14-40 ft-

Thermostat Cap Crankcase 96 in.-lb Flywheel** Crankcase 50 ft-lb Exhaust Manifold Cylinder 96 in.-lb Crankcase (6 mm)

(10 mm)

Spark Plug Cylinder 19 ft-lb Water Pump Impeller* Crankcase 96 in.-lb Coolant Temperature Sensor Crankcase 18 ft-lb APV Assemblies* Cylinder 96 in.-lb Recoil Starter Crankcase 96 in.-lb Coolant Hose - Engine/Coolant Tank Engine 11 in.-lb Coolant Hose - Engine/Coolant Tank Coolant Bottle Bypass 35 in.-lb Coolant Hose - Engine/Front

Exchanger Tank, Coolant Coolant Bottle Bypass 30 in.-lb Coolant Hose - Tunnel Exchanger/

coolant Tank Carburetor Boot Flange 5.5 in.-lb Hose, Throttle Body/Water Pump Both Ends 14 in.-lb Sensor, Exhaust Temperature Chamber, Expansion 34 Manifold, Exhaust Engine Studs 7 Intake Manifold/Reed Cage Engine 8 Servo Cable Plate Engine 44 in.-lb Engine Mount Engine Mount - Front 12 Engine Mount - Front Engine 45 Engine Mount - Front Chassis 45 Mounting Plate - MAG Engine 23 Mounting Plate - PTO Nut Plate 23 Mounting Plate - PTO Hub, Bearing Housing 12 Mounting Plate - PTO Engine 23 Lower Mount - Rear Chassis 12 Lower Mount - Rear Chassis 7 Water Pump Engine 7*****

Crankcase (2 Steps)

Front Exchanger 35 in.-lb

Exchanger/bypass 11 in.-lb

Tor que

ft-lb

96 in.-lb

13-37 ft-

MISCELLANEOUS

Taillight Lens Taillight Bracket 4 Pump, Fuel Plate, Air Silencer -

Mounting Bracket - Air Silencer Chassis 8 Mounting Bracket - Air Silencer Silencer, Air - Front

Intake Baffle Plate, Intake 8

Lower

Bumper

*w//Blue Loctite #243 ** w/Red Loctite #271 ***w/Green Loctite #620 ****w/oil *****Superflex High Temp Silicone

Engine Torque Patterns

0744-096

0738-220

738-202A

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

Ignition (NOI).

Description

Ignition Coil

Primary

Secondary

DC Power Coil 0.71-1.07 ohms red/yellow yellow/red

Lighting Coil 0.12-0.18 ohm yellow yellow

Ignition Timing

Sensor

Spark-Plug Cap 4000-6000 ohms cap end cap end

Description Test Value + Test Connections -

Voltage Regulator 11-14 AC Volts yellow brown

Regulator/Rectifier 11.2-16.8 DC Volts

Condenser 11.6-17.4 DC Volts

High Temperature

Sensor

Tether Switch Less than 1 ohm

Resistance Test

Tes t Val ue

0.27-0.41 ohm

6800-10,200 ohms

148-222 ohms green/white brown/green

(@ 2000 RPM)

305 ohms + (water

temperature at or

above 176°F)

203 ohms + (water temperature at or above 200°F)

(tether cap removed)

+ Test Connections -

orange

high tension

wire

red/blue brown/yellow

red brown

terminal #1 terminal #2

terminal terminal

black

high tension

wire

Tightening Torque (General

Bolts)

Type of Bolt

Diameter A

(mm)

(Grade 8.8) 5 60 in.-lb

6 96 in.-lb

8 20 ft-lb

10 40 ft-lb

12 65 ft-lb

(Grade 10.9) 6 12 ft-lb

8 28 ft-lb

10 50 ft-lb

12 95 ft-lb

Thread

Tightening

Torque

Electrical Specifications

NOTE: The ignition system is a Normally Open

Component Voltage/

Resistance Chart - Water

Temperature

Tem peratu re Volts Ohms Temperature Vol ts 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

To use the specifications, first refer to the drawing; then find the letter which indicates the specification and refer to the chart below the illustration. Specifications are called out in both millimeters and inches.

NOTE: We have given the proper location for

checking crankshaft runout as the very edge of the straight portion of the shaft where the oil seal makes contact. From the illustration, note that Arctic Cat has called out three check points: at either end, out on the taper as shown, and also on the center bearing race. The crankshaft is still supported on the outer bearings using V blocks. The maximum runout shouldn’t exceed 0.05 mm (0.002 in.).

728-144A

NOTE: Measure in from the shaft end the spec-

ified amount when checking runout at points D and F. When checking runout in the center, place indicator on center of bearing as shown at point E. Maximum runout at any of the 3 measuring points is ±0.05 mm (0.002 in.).

Bore X StrokeA ± 0.15

73.8 x 70 mm (2.906 x 2.756”)

(± 0.006)

119.7 mm (4.712”)

± 0.15

(± 0.006)

64 mm

(2.519”)

± 0.4

( ± 0.015)

118 mm (4.645”)30(1.181)

Point (± .002)

D 5

(0.196)

Runout

D and F

F 5

(0.196)

Crankshaft Runout/Repair

Specifications

For those who have crankshaft work sent out to another shop, it is advisable to provide them with this information.

Drive System

Specifications

DRIVE CLUTCH DRIVE SPRING CAM ARM DRIVEN CLUTCH DRIVEN SPRING

P/N P/N COLOR P/N GRAMS P/N SPRING COLOR

0746-264 0646-216 Yellow 0746-830 60.0 0726-400 0648-792 Black/Orange

DRIVE BELT

P/N Length* Width* PITCH P/N DEGREE P/N

0627-086 48.15 in.

(1223 mm)

1.45 in.

(36.8 mm)

ENGAGEMENT/ MAXIMUM RPM

4900-5200/

8300-8500

GEAR RATIO

20/49

(13/13 wide)

CHAIN TORQUE BRACKET

(13 wide)

2602-760 70-44-32

68-42-32

* ± 0.188 in. (4.78 mm)

NOTE: For optional drive system components,

refer to the Optional Components chart on the

Drive Clutch Cam Arms

(w/Set Screw)

following page.

ARCTIC CAT DRIVE CLUTCH CAM ARMS

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

0646-367 50 lb 250 lb Black 0646-148 53 lb 224 lb Blue 0646-149 74 lb 228 lb Red

0646-432 74 lb 228 lb Black/Red 0646-433 75 lb 275 lb Black/Gold 0646-433 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

0646-192 120 lb 270 lb Orange

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* 143 lb 286 lb Pink

0646-684 158 lb 285 lb Black 0646-410 165 lb 310 lb Blue

HEAVY 0646-216 170 lb 330 lb Yellow

DRIVEN CLUTCH

Torq ue

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

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

*Lightweight driven clutch only.

Black

Spring

Rate

p/n Grams p/n Grams

0746-661 52.0 0746-742 83.5 0746-662 52.0 0746-744 50.0 0746-663 52.0 0746-748 46.0 0746-664 52.0 0746-749 65.0 0746-666 55.0 0746-771 44.0 0746-668 55.0 0746-772 42.0 0746-669 60.0 0746-773 85.0 0746-670 65.0 0746-786 63.0 0746-671 70.0 0746-787 44.0 0746-672 75.0 0746-788 47.5 0746-673 80.0 0746-789 42.0 0746-676 70.0 0746-791 60.0 0746-678 55.0 0746-792 47.0 0746-687 57.0 0746-793 63.0 0746-689 69.0 0746-814 83.0 0746-690 47.0 0746-821 82.0 0746-691 44.0 0746-822 71.5 0746-692 50.0 0746-824 66.0 0746-694 63.0 0746-825 50.0 0746-695 67.0 0746-826 64.0* 0746-696 63.0 0746-830 60.0 0746-698 64.0 0746-699 66.0 0746-701 49.0 0746-702 57.5 0746-703 68.0 0746-704 51.0 0746-708 51.0 0746-710 72.0 0746-712 77.0 0746-713 48.0 0746-715 77.0 0746-716 73.0

* Notched Cam Arm ** w/Set Screw

0746-843 56.5** 0746-844 53** 0746-845 48** 0746-846 57** 0746-847 64** 0746-848 62**

2602-823

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 13 8 141 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

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 13 8 141 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 15 7 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.

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

Arctic Power Valve (APV)

System Specifications

NOTE: The servo will activate once (clean

cycle) at 2500 RPM. If the servo cycles three times, cable length adjustment or valve inspection is required.

APV CABLE LENGTH

ENGINE CENTER ± 1 mm (0.039 in.)

600 cc 36.5 mm (1.437 in.)

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)

Carburetor Specifications

Main

Model Typ e

Snocross

Needle

Jet

TM-40 400 Q0

(825)

Jet

Needle

9DFH12-54-3 50 2.5 1.25

Pilot

Jet

Cut

Away

0735-516

Pilot Air

Screw (Turns

Out)

Mikuni Tuning

Components

Main Jets

Jet p/n Jet p/n

65 6505-299 370 6505-072

67.5 6505-300 380 6505-077 70 6505-833 390 6505-078

72.5 3003-189 400 6505-124 75 6505-296 410 6505-212

120 6505-270 420 6505-125 130 6505-216 430 6505-146 140 6505-217 440 6505-126 150 6505-168 450 6505-147 160 6505-064 460 6505-127 170 6505-065 470 6505-148 180 6505-056 480 6505-149 190 6505-066 490 6505-150 200 6505-144 500 6505-151 210 6505-145 510N 6506-378 220 6505-137 520 6505-530 230 6505-067 520N 6506-379 240 6505-079 530N 6506-380 250 6505-068 540 6505-531 260 6505-017 540N 6506-381 270 6505-069 550N 6506-382 280 6505-080 560 6505-172 290 6505-123 560N 6506-383 300 6505-128 580 6505-211 310 6505-136 600 6505-532 320 6505-074 640 6505-533 330 6505-070 660 6505-535 340 6505-076 680 6505-169 350 6505-071 700 6505-536 360 6505-038 720 6505-538

Throttle/Piston Valves

Slide Carb. Size (mm) p/n

2.5 40 6506-273

Starter Jets

Jet p/n Jet p/n

130 6506-265 150 6506-153 135 6506-101

Jet Needles

Needle p/n Needle p/n

9DFH12-54 6506-421 9DFH3-56 6506-186

9CFH1-56 6506-116 9DEH3-56 6506-182 9DEH1-55 6506-118 9DFH1-56 6506-221 9DEH2-57 6506-115 9DFH9-59 6506-304 9EGY1-57 6506-192 9EH6-59 6506-228

9EH2-57 6506-111 9DH9-54 6506-272 9EH6-60 6506-117 9DGH18-53 6506-417

9EJ1-60 6506-384 9EH6-58 6506-290

9EJ2-60 6506-400 9EH11-60 6506-404 9DFH2-58 6506-200 9DFH4-60 6506-260 9DFH2-59 6506-201 9EFH9-60 6506-374

Inlet Needle Assemblies

Seat Diameter Carb. Size (mm) p/n

1.5 mm (Steel) 38 6506-121

1.8 mm (Steel) 38 6506-144

Pilot Jets

Jet p/n Jet p/n

17.5 6505-218 45 6506-418 20 6505-138 45 6505-278

22.5 6505-310 47.5 6506-419 25 6505-075 50 6506-420

27.5 6505-503 50 6505-262 30 6505-073 52.5 6505-261 35 6505-297 55 6505-255 35 6505-029 60 6505-642 40 6505-047 90 6505-396

Major Tuning Components

Listed below are pilot jets and throttle valves (slides) according to their size.

PILOT JETS THROTTLE VALVES (SLIDES)

Lean

Rich

12.5

15 3.5

17.5 3.0

20 2.5

22.5 2.0

25 1.5

27.5

32.5

37.5

Lean

Rich

4.0

1.0

Jet Needle Taper Angles

0734-462

Letter Angle Letter Angle

A 0°15’ I 2°15’

B 0°30’ J 2°30’

C 0°45’ K 2°45’

D1°0’L3°0’

E 1°15’ M 3°15’

F 1°30’ N 3°30’

G 1°45’ O 3°45’

H2°0’P4°0’

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).

0730-218

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

Extended

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

Suspension Fully

Collapsed

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

Suspension Fully

Extended

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

Suspension Fully

Collapsed

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

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

Coils

Coil

Width

(C)

Length

(D)

Length

(E)

Degree

(In lb)

* Production (Snocross)

NOTE: The wire diameter and length of the

spring have a large influence over the valving of the shocks.

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).

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

Valve Stacks/

Specifications

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

3703-348/349 1.300 x 0.006 in. 1.100 x 0.008 in. Extended Length: 19.14 in. 1.300 x 0.008 in. 0.600 x 0.004 in. Collapsed Length: 13.29 in. 1.300 x 0.010 in. 0.800 x 0.006 in. Stroke: 5.80 in. 1.100 x 0.012 1.125 x 0.080 in. Ground

1.250 x 0.015 (Ring) 0.0950 x 0.050 Top Out

Rebuild Kit: p/n 3603-420 1.300 x 0.010 in.

0.800 x 0.004 in. Service Set Shaft: p/n 3603-465 1.300 x 0.012 in. Sleeve Assembly: p/n 3603-290 1.300 x 0.012 in.

1.250 x 0.010 in. Piston Depth: 2.30 in. 1.000 x 0.015 in. Piston Orifice: None 1.125 x 0.093 in. Top out washer

CD Knob @ 8; RB Knob @ 2. Eyelets tightened to 3.9 kg-m (28 ft-lb) (threads coated with green Loctite #620). Piston nut tightened

2704-637 1.300 x 0.012 in. 1.100 x 0.008 in. Extended Length: 12.36 in. 1.300 x 0.012 in. 0.600 x 0.0045 in. Collapsed Length: 8.56 in. 1.300 x 0.012 in. 0.700 x 0.0045in. Stroke: 3.80 in. 1.300 x 0.012 in. 0.800 x 0.0045 in.

Rebuild Kit: p/n 4604-017 1.300 x 0.015 in.

Piston Depth: 1.80 in. 1.300 x 0.008 in. Piston Orifice: None 1.125 x 0.093 in. Top out washer

to 3.0 kg-m (22 ft-lb). Shaft nut tightened to 3.0 kg-m (22 ft-lb). Shocks charged at 350 psi (nitrogen)/150/275 psi (air).

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

1.300 x 0.012 in. 1.125 x 0.080 in. Ground

1.300 x 0.015 in.

1.100 x 0.008 (Center)

1.250 x 0.012 (Ring)

1.300 x 0.015 in.

0.900 x 0.008 in.

0.800 x 0.006 in.

* Compression (Initial Setting): Full Open. 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 350 psi. Green Loctite #620 on shock eyelet threads.

Rear Arm Shock Part Number* Compression (Piston Side) Rebound (Piston Side)

2704-965 1.600 x 0.008 in. 1.425 x 0.015 in. Extended Length: 14.39 in. 1.600 x 0.008 in. 1.100 x 0.0045 in. Collapsed Length: 10.06 in. 1.425 x 0.012 1.400 x 0.080 in. Top Out Stroke: 4.33 in. 1.600 x 0.15 (Ring) 0.750 x 0.100 in. Backup

1.600 x 0.008 in. Rebuild Kit: p/n 4604-017 1.100 x 0.0045 in.

1.600 x 0.012 in. Piston Depth: 2.30 in. 1.600 x 0.012 in. Piston Orifice: None 1.600 x 0.012 in.

1.600 x 0.012 in.

1.425 x 0.012 in.

1.350 x 0.012 in.

1.250 x 0.012 in.

1.100 x 0.008 in.

1.000 x 0.010 in.

1.570 x 0.128 in. Top Out

** Low speed compression 18 positions counterclockwise from full stop. Rebound 6 clicks counterclockwise from full stop. Shock charged at 350 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).

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 the Arctic Cat Service Department.

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 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 Chart

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

Wiring Diagram - Hood

Harness (p/n 1686-664)

SNO-491

Wiring Diagram -

Ignition/Main Harness

(p/n 1686-732)

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

NOTES

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 dea lership 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 snow-

mobile 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

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

746-484A

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.

0746-485

1. Install the expansion nuts into the speedometer bracket; then place the windshield into position on the console and bracket.

2. Secure the windshield using the four torx-head screws.

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.

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

maximum 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.

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.

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.

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.

Installing Sway Bar (Optional)

NOTE: Sway Bar Kit (p/n 5639-998/999).



SNO-2232

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.

2. The brake lever must feel firm when compressed.

Drive Belt

Installing Belt

1. Set the brake lever lock; then remove the left-side access panel.

2. Using Drive Belt Deflection Tool (p/n 0644-424), thread the tool clockwise into the driven clutch until the movable sheave opens far enough to install the drive belt.

743-067B

3. Place the belt (so the part number can be read) between the sheaves of the drive clutch.

4. With the sheaves fully apart, roll the belt over the stationary sheave.

5. With the drive belt properly positioned in the drive clutch and driven clutch, turn the belt tool counterclockwise, release the brake lever lock, and roll the belt back and forth to allow the driven clutch sheaves to fully close.

6. After the belt is installed properly, install the leftside access panel.

Checking/Adjusting Deflection

Drive belt length, condition, and deflection are all important for peak performance. To check and adjust drive belt deflection, use the following procedure.

1. With the engine off; remove the hood and left-side access panel.

2. Make sure the drive belt is sitting at the top of the driven clutch sheaves.

Ski Alignment

Checking

Toe-Ou t R a n g 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 t he 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 th e outside edge of the track so it lies near the inside edge of the left-side ski.

3. Place a straightedge on the top of the drive belt. The straightedge should reach from the driv e clutch to t he top of the driven clutch.

4. Using a stiff ruler centered between the drive clutch and driven clutch, push down on the drive belt just enough to remove all slack and note the amount of deflection. The deflection should be approximately

15.9-22.2 mm (5/8-7/8 in.).

NOTE: The amount of deflection should be

experimented with or tested to obtain best startline performance.

NOTE: Push down on the belt with the ruler

only until the bottom of the belt flexes upward; then read the amount of deflection.

5. To correct drive belt deflection, loosen the jam nut on the belt width adjuster on the stationary sheave.

6. Using an Allen wrench, adjust the set screw as needed.

NOTE: Turning the set screw clockwise

increases distance between the sheaves (increases belt deflection measurement); turning the set screw counterclockwise decreases distance between the sheaves (decreases belt deflection measurement).

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 l eft 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 (1415 in.) in front of the spindle and 3 5.5-38.1 cm (1415 in.) behind the spindle. Record the measurements taken for the right side.

! 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.

! 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.

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.

0743-088

Recommended Gasoline/Oil/Mixing Ratio

The recommended gasoline to use is non-oxygenated 91 minimum octane.

CAUTION

When operating this snowmobile on the 91 minimum octane non-oxygenated gasoline, the ignition timing dial must be set to -3° or severe engine damage may occur.

CAUTION

Do not use white gas or gasoline containing methanol. Only Arctic Cat approved gasoline additives should be used.

The recommended oil to use as a pre-mix for engines with variable exhaust valves is Arctic Cat Synthetic APV 2-Cycle Oil. This oil is specially formulated to be used as a pre-mix oil and meets all of the lubrication requirements of the Arctic Cat Snowmobile engine.

CAUTION

Any oil used in place of the recommended oil could cause serious engine damage and could lead to carbon buildup on the exhaust valves.

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 thread ed area and tighten to 20 ft-lb. Tighten both jam nuts against the tie rod.

To properly mix fuel at a 32:1 ratio, pour 594 ml (20 fl oz) of recommended oil into 19 l (5 U.S. gal.) of gasoline.

! WARNING

Always fill the fuel tank in a well-ventilated area. Never add gasoline to the snowmobile fuel tank near any open flames or with the engine running. DO NOT SMOKE while filling the fuel tank.

Preoperation Checks

1. V isually check all fluid levels. Add fluid s as necessary.

2. Visually check the enti re snowmobile for any loose fasteners. Tighten as required.

3. Start and run th e engi ne to operating temperature.

4. Check all switches (tether, dimmer, brakelight, emer gency stop) to make sure all function properly; then visually check the headlight, taillight, and brake l ight 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 head light is approximately 8 m (25 ft) from an aiming surface (wall or similar surface).

NOTE: There should be an “average” operat-

ing 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.

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), h ook 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

Setup Tension After Break-In Tension

35-41 mm (1 3/8-1 5/8 in.) 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.

0745-813

7. Adjust the headlight adjustment kn obs 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.

T o adjust track tensio n/track alig nment, u se the fol lowing procedure.

0749-498

NOTE: Always loosen the right-side rear axle

nut when adjusting track tension/alignment. The left-side 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 spec ifications, 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, l oosen 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 lu gs. If the rear idler wheels are centered between the inner track drive lugs, no adjustment is necessary.

Handlebar/Ski Alignment

Checking

Toe-Ou t R a n g e

4.0 - 12.7 mm (1/8 in. - 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 t he 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.

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.

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

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.

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.

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 l eft 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.

! WARNING

8. If ski alignment is not as specified, adjust the alignment of the ski(s) not parallel to the straightedge.

Adjusting

NOTE: The following procedure can be used to

adjust the alignment of either ski.

1. Unlock the steering tie rod by loosening the jam nuts (A).

NOTE: The inside jam nuts are left-hand

thread. Care should be taken to rotate them in the proper direction.

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 1215 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.

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.

Verifying

1. Verify ski alignment by measuring across from the outside edge of the left-side ski to the outside edge of the right-side ski (without using the straightedge) 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.

734-408B

2. The measurement from in front of the spindle to the outer edge of the ski (without using the straightedge) must not exceed the rear measurement by more than

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

NOTE: Some operating conditions may require

more toe-out than recommended; however, more toe-out causes more “drag.”

! WARNING

The measurement taken in front of the spindle must never be less than the measurement taken behind the spindle or poor handling will be experienced. Neglecting to lock the tie rod by tightening the jam nuts may cause loss of snowmobile control and possible personal injury.

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 all ow th em to cool down. This process stabilizes the pad material and extends the life of the pads.

0743-088

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).

+ 67 hidden pages

Arctic Cat ZR 6000 R Sno Cross 2016 Operators Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

If the snowmobile is purchased through the Team Arctic Race Department Racing Program, there is no warranty.

Reference Information

Torque Specifications

Engine Specifications

Engine Torque Patterns

Electrical Specifications

Carburetor Specifications

Major Tuning Components

Jet Needle Taper Angles

Installed Spring Rate Chart

Front Suspension Sway Bar

Double Bleed Shims (DB)

Single Bleed Shims (DB)

Fraction/Decimal Chart

MM/IN. Conversion Chart

Removing Snowmobile From Crate/ Handlebar Assembly

Installing Spindle/A-Arm

Installing Windshield

Installing Front Shock Absorbers

Installing Skis

Brake System

Installing Sway Bar (Optional)

Drive Belt

Ski Alignment

Recommended Gasoline/Oil/Mixing Ratio

Preoperation Checks

Checking Headlight Aim

Track Tension/Track Alignment

Handlebar/Ski Alignment

Test Ride