Arctic Cat ZR 6000R SX, ZR 6000R XC Service Manual

This vehicle can be hazardous to operate.

A snowmobile is a very high performance vehicle. 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 Snowmobile Safety Handbook.

Failure to follow this warning could result in personal injury to yourself or others. For your safety, understand and follow all the warnings contained in this Operator’s Manual and on the labels on this vehicle.

Keep this Operator’s Manual with this vehicle at all times. If you lose your manual, contact your authorized dealer for a free replacement. The labels should be considered permanent parts of the vehicle. If a label comes off or becomes hard to read, contact your authorized dealer for a free replacement. Contact Arctic Cat Service Department, P.O. Box 810, Thief River Falls, MN 56701, for proper registration information.

FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH.

The Operator’s Manual, Snowmobile Safety Handbook, and Snowmobile Decals display important information:

!

! WARNING

CAUTION

NOTE:

The Safety Alert Symbol means ATTENTION! BE ALERT! YOUR SAFETY IS INVOLVED.

WARNING identifies personal safety-related information. Follow the directive because it deals with the possibility of serious personal injury or even death.

CAUTION, without the safety alert symbol, 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.

A NOTE identifies supplementary information worthy of particular attention.

Personal Injury

•To avoid injury to yourself and others, NEVER operate the snowmobile without first reading and understanding this manual and the Snowmobile Safety Handbook; then follow the instructions and heed the warnings given.

•USE COMMON SENSE.

•DON’T DRINK and DRIVE.

•STAY IN CONTROL at ALL TIMES.

•TELL YOUR FRIENDS. If you see a friend operating a snowmobile recklessly, at excessive speeds, while intoxicated, or in other unsafe ways, don’t wait until it is too late to warn of the consequences of snowmobile misuse. Such conduct endangers everyone. TAKE AN ACTIVE ROLE IN THE SAFETY OF YOURSELF AND OTHERS.

California Proposition 65

! WARNING

The Engine Exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.

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) - Standard*		Shock Absorber(s) - Rebuildable**

* Limited to one (1) year or 1000 miles of “normal” riding conditions - replace for defective or leaking shock, corroded or pitted shaft, peeling chrome.

**Limited to one (1) year or 1000 miles of “normal” riding conditions - rebuild for leaking shock (warranted) - replace for defective shock, corroded or pitted shaft, peeling chrome.

The following will VOID Arctic Cat’s warranty:

1.Failure to perform the proper break-in procedure and all related maintenance, storage procedures (if stored for extended periods), and/or 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 gasoline, lubricating oils, or spark plugs.

5.An accident or subjecting the snowmobile to misuse, abuse, or negligent operation.

6.Any modification, addition, or removal of parts unless instructed to do so by Arctic Cat.

7.Use of the snowmobile in any way for racing purposes.

8.Removal of the engine for use in another vehicle.

9.Removal or mutilation of the Vehicle Identification Number or Engine Serial Number.

10.Use of parts not sold or approved by Arctic Cat.

11.Track and tunnel damage resulting from either ice stud or hooker plate installation.

12.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.) 218-681-9851 or (Canada) 204-982-1656.

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

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.

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.

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.

© 2018 Arctic Cat Inc.

Printed in U.S.A. October 2018

PARTS AND ACCESSORIES

When in need of replacement parts, oil, or accessories for your Arctic Cat Snowmobile, be sure to only use GENUINE ARCTIC CAT PARTS, OIL, AND ACCESSORIES. Only genuine Arctic Cat parts, oil, and accessories are engineered to meet the standards and requirements of your Arctic Cat Snowmobile. For a complete list of accessories, refer to the current Arctic Cat Accessory Catalog.

To aid in service and maintenance procedures on this snowmobile, an Illustrated Parts Manual is available through your local Arctic Cat Snowmobile dealer.

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 properly complete warranty claims. 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 .............		3-23
Specifications..........................................................		3
Torque Specifications .............................................		4
Torque Conversions (ft-lb/N-m) ..............................		4
Tightening Torque (General Bolts) .........................		5
Crankshaft Runout/Repair Specifications ...............		5
Arctic Power Valve (APV) System Specifications... 5
Electrical Specifications ..........................................		5
Component Voltage/Resistance Chart — Water
Temperature ........................................................		6
R-XC Team Drive Clutch Optional Components		.... 7
R-SX Arctic Cat Drive Clutch/Driven Clutch Optional
Components ........................................................		7
R-SX Arctic Cat Drive Clutch Cam Arms (w/Set
Screw) .................................................................		8
Chain Case Performance Calibrations ...................		9
Chains and Sprockets...........................................		11
Rear Spring Selection...........................................		11
Installed Spring Rate Chart...................................		11
Front Suspension Sway Bar .................................		11
Rebuildable Shock Tools Required ......................		12
Optional Front Arm Shock Springs — R-XC.........		12
Optional Dual Rate Spring Chart (DSR) ...............		12
Rebuildable Shock Accessory Part Numbers .......		15
Fraction/Decimal Conversion Chart......................		16
Drill Bit Sizes (Number) Chart...............................		16
Conversion Chart (mm/in.)...................................		17
Wiring Diagram — Hood Harness (R-XC) ............		19
Wiring Diagram — Ignition/Main Harness (R-XC) 21
Wiring Diagram — Ignition/Main Harness (R-SX). 23
Setup Instructions ...............................................	25-32
Removing Snowmobile from Crate/Installing
Handlebar Assembly .........................................		25
Installing Windshield ............................................		25
Installing Front Shock Absorbers..........................		25
Installing Skis (R-SX)............................................		25
Installing Skis (R-XC)............................................		26
Sway Bar ..............................................................		26
Brake System .......................................................		26
Ski Alignment........................................................		27
Recommended Gasoline ......................................		28
Preoperation Checks ............................................		29
Checking Headlight Aim .......................................		29
Track Tension/Track Alignment	(R-SX) ...............	29
Track Tension (R-XC)...........................................		31
Track Alignment (R-XC)........................................		31
Test Ride ..............................................................		32

General Information ............................................	33-37
R-SX Control Locations ........................................	33
R-XC Control Locations ........................................	33
Deluxe Digital Gauge (R-XC)................................	33
Power Sports Gauge (R-SX).................................	34
ACT Hot Start System (R-SX)...............................	34
Diagnostic Codes..................................................	35
Arctic Power Valve (APV) System ........................	35
Exhaust Controlled Timing (ECT) System ............	36
Handlebar Tilt........................................................	36
Exhaust System ....................................................	36
Liquid Cooling System ..........................................	37
Drive Clutch and Driven Clutch.............................	37
Drive Clutch/Driven Clutch Alignment...................	37
Shock Absorbers...................................................	37
Track Studs...........................................................	37
Towing ..................................................................	37
Operating Instructions .........................................	38-39
Starting and Stopping Engine ...............................	38
Braking..................................................................	38
Emergency Stopping.............................................	39
Lubrication................................................................	40
Chain Case ...........................................................	40
Rear Suspension ..................................................	40
Maintenance........................................................	41-76
Periodic Maintenance Checklist............................	41
Pre-Race/Practice Checklist .................................	42
Engine...................................................................	42
Track Drive............................................................	61
Drive Sprockets.....................................................	62
Brake System........................................................	63
Brake Fluid............................................................	63
Checking Brake Lever Travel................................	64
Bleeding Brake System.........................................	64
Checking/Changing Brake Pads ...........................	65
Drive Belt ..............................................................	65
Driven Clutch ........................................................	69
Lights ....................................................................	75
Ski Wear Bar.........................................................	75
Rail Wear Strip......................................................	76
Performance Tips.....................................................	77
Genuine Arctic Cat Products....................................	77
Preparation for Storage............................................	78
Preparation after Storage.........................................	79
Special Tools.......................................................	80-89
Declaration of Conformity.........................................	90

2

Specifications

ENGINE

	ZR 6000R-XC	ZR 6000R-SX
Engine Number	0962-079	0962-073
Bore x Stroke	73.8 x 70 mm (2.906 x 2.756 in.)	73.8 x 70 mm (2.906 x 2.756 in.)
Displacement	599 cc (36.55 cu in.)	599 cc (36.55 cu in.)
Compression Ratio	6.62:1	6.8:1
Cooling System	Liquid	Liquid
Ignition Timing (Engine Warm)	16.5° @ 2000 RPM 0.072”	16.5° @ 2000 RPM 0.072”
Spark Plug	NGK BPR9ES	NGK BPR9ES
Spark Plug Gap	0.0276-0.0307 in.	0.0276-0.0307 in.
Piston Skirt/Cylinder Clearance	0.0030-0.0039 in.	0.0030-0.0039 in.
Piston Ring End Gap	0.0118-0.0177 in.	0.0118-0.0177 in.
Cylinder Trueness Limit	0.0019 in.	0.0019 in.
Piston Pin Diameter	0.7872-0.7874 in.	0.7872-0.7874 in.
Piston Pin Bore Diameter	0.7875-0.7877 in.	0.7875-0.7877 in.
Connecting Rod Small End Bore	0.9844-0.9847 in.	0.9844-0.9847 in.
Connecting Rod Radial Play	0.0005-0.0015 in.	0.0005-0.0015 in.
Crankshaft Runout (t.i.r)	0.0000-0.0079 in.	0.0000-0.0079 in.
	DRIVE
Track Width	38 cm (15 in.)	38 cm (15 in.)
Track Length (Overall)	328 cm (129 in.)	345 cm (136 in.)
Track Lug Height	31.8 mm (1.25 in.)	44.5 mm (1.75 in.)
Track Deflection (Tension)	2 in. @ 20 lb	2 in. @ 20 lb
Drive Clutch Spring	120/265 lb (p/n 0646-473)	170/330 lb (p/n 0646-216)
Cam Arms	J14-66 (p/n 0646-869)	60 Gram (p/n 0646-830)
Driven Clutch Spring	155/222 lb (p/n 0648-953)	180/280 lb (p/n 0648-792)
Torque Bracket	38 ER/40S ER (p/n 0648-951)	70-44-32 (p/n 0648-823)
Top Gear	23T (p/n 2602-967)	20T (p/n 3602-169)
Bottom Gear	40T (p/n 1702-402)	49T (p/n 1702-403)
Chain	86P (p/n 2602-743)	90P (p/n 2602-760)
	CHASSIS
Length (Overall)	307.3 cm (121 in.)	315 cm (124.25 in.)
Height (Overall)	116.2 cm (45.75 in.)	113.06 cm (44.5 in.)
Width (Overall)	121.2 cm (47.75 in.)	127.6 cm (50.25 in.)
Ski Center-to-Center Distance	110.5 cm (43.5 in.)	106-109 cm (41.9-42.9 in.)
Dry Weight (approx)	215.9 kg (476 lb)	205 kg (452 lb)
	MISCELLANEOUS
Gas Tank Capacity (Rated)	40.01 l (10.56 U.S. gallon)	10.2 l (2.7 U.S. gallon)
Chain Case Lubricant Capacity	355 ml (12 fl oz)	355 ml (12 fl oz)
Injection Oil Reservoir Capacity	3.04 l (3.6 U.S. qt)	Premix (40:1 ratio)
Cooling System Capacity	5.71 l (6.0 U.S. qt)	3.8 l (4.0 U.S. qt)
Gasoline (Recommended)	91 Octane Unleaded	91 Octane (non-oxygenated) Minimum
Engine Oil	Arctic Cat Synthetic C-TEC2	Arctic Cat Synthetic C-TEC2
Chain Case Lubricant	Arctic Cat Synthetic Chain Lube	Arctic Cat Synthetic Chain Lube
Suspension Grease	Low-Temperature	Low-Temperature
Brake Fluid	High-Temp DOT 4	High-Temp DOT 4
Drive Belt Part Number	0627-107	0627-120
Drive Belt Projected width	38.3 mm (1.507 in.)	37.2 mm (1.464 in.)
Drive Belt Circumference	123.0 cm (48.425 in.)	122.3 ± .457 cm (48.150 ± .180 in.)
Headlight Bulb Part Number	LED	0609-956

3

Torque Specifications

NOTE: Torque specifications have the following tolerances:

Torque (ft-lb)	Tolerance
0-15	±20%
16-39	±15%
40+	±10%

DRIVE SYSTEM

	Item	Secured to	Torque
			ft-lb
	Drive Clutch	Engine	51
	Drive Clutch Cover	Movable Sheave	120 in.-lb
	Cam Arm Pin Lock Nut (SX)	Cam Arm Pin	11
	Cam Arm Lock Nut (XC)	Cam Arm Screw	50 in.-lb
	Cam Arm Set Screw (SX)	Cam Arm	19 in.-lb
	Movable Sheave*	Torque Bracket	120 in.-lb
	Chain Case (Cap Screw)	Chassis	96 in.-lb
	Chain Case (Torx-Head Screw)	Chassis	12
	Chain Case Cover	Chain Case	12
	Brake Caliper	Chassis	25
	Outside Caliper Housing	Inside Caliper Housing	25
	Brake Line	Caliper	25
	Brake Line	Master Cylinder	25
	Brake Caliper	Shield Cover	96 in.-lb
	STEERING/FRONT	SUSPENSION/CHASSIS
	Item	Secured to	Torque
			ft-lb
	Ski	Spindle	35
	Ski	Wearbar	8
	Ski	Ski Handle	54 in.-lb
	Handlebar Adjuster	Post	15
	Steering Support	Mounting Block	8
	Steering Tie Rod Link	Steering Post	35
	Steering Tie Rod Link	Steering Arm	20
	Steering Post Cap	Riser Block	15
	Steering Post	Chassis	55
	Steering Tie Rod	Steering Arm	20
	Tie Rod	Spindle Arm	32
	Steering Support	Spar	20
	Steering Support	Upper Console	30 in.-lb
	Steering Arm	Chassis	8
	A-Arm (Upper)	Chassis	23
	A-Arm (Lower)	Chassis (Front)	65
	A-Arm (Lower)	Chassis (Rear)	45
	A-Arm	Spindle	45
	Shock Absorber	Spindle	45
	Shock Absorber	Chassis	45
	Sway Bar Link	A-Arm/Sway Bar Link	23
	Sway Bar Mounting Bracket	Chassis	9

REAR SUSPENSION

	Item	Secured to	Torque
			ft-lb
	Wear Strip	Rail	50 in.-lb
	End Cap	Rail	80 in.-lb
	Mounting Block	Rail	20
	Rear Arm	Rail	45
	Rear Arm	Idler Arm	55
	Spring Slide	Rail	20
	Front Arm	Rail	52
	Coupler Block Axle	Rail	40
	Limiter Strap	Rail Support	72 in.-lb
	Skid Frame	Tunnel	55**
	Front Shock	Rail	50
	Rail Support	Rail	20
	Limiter Strap	Front Arm	72 in.-lb

* w/Green Loctite #609 ** w/Blue Loctite #243

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

4

Tightening Torque

(General Bolts)

		Thread	Tightening
	Type of Bolt	Diameter A
			Torque
		(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

Crankshaft Runout/

Repair Specifications

To use the specifications, first refer to the drawing; then find the letter indicating the specification and refer to the chart below the illustration.

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

APV CABLE LENGTH

6000	36.5 mm ± 1 mm

0735-516

Electrical Specifications

Component	Test Value	+ Test Connections -
Spark Plug Cap	4000-6000 ohms	cap end	cap end
Oil Level Sensor	Less than 1 ohm	terminal	terminal
	(float end down)
Ignition Switch	Less than 1 ohm	terminal	terminal
	(key in OFF
	position)
	(Normally Open	Ignition)
Ignition Coil (Primary)	0.24-0.36 ohm	black/white	white/blue
(Secondary)	5040-7560 ohms	high tension wire	high tension wire
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	black/red
		(counterclock-	(counterclock-
		wise)	wise)
		black/red	red/black
		(clockwise)	(clockwise)
Voltage Regulator/	9-14.5 DC Volts	red/blue	black
Rectifier*

* 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 the recoil starter rope briskly pulled.

5

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.

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

6

R-XC Team Drive 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
				DRIVEN CLUTCH
Torque		Degree		Spring			Color				Spring
Bracket											Rate
0648-779*		58-46-36/		0648-749			Black/White				160/260
		58-48-36
0648-775*		52-42-46/		0648-702			Red/Black				140/240
		52-44-46
0648-773*		70-44-32/		0648-784				Black			155/222
		68-48-46
0648-789*		68-48-36/		0648-790			Black/Light Blue				180/260
		64-48-41
0648-791*		48-44-36/		0648-792			Black/Orange				180/280
		48-42-36

* Lightweight driven clutch only.

R-SX Arctic Cat Drive

Clutch/Driven Clutch

Optional Components

ARCTIC CAT DRIVE CLUTCH SPRING CHART

	p/n	Rate @ 2 9/16”Rate @ 1 5/16”		Color
LIGHT	0646-439	50 lb	250 lb	Black/White
	0646-148	53 lb	224 lb	Blue
	0646-150	72 lb	188 lb	Silver
	0646-149	74 lb	228 lb	Red
	0646-432	74 lb	228 lb	Black/Red
	0646-433	75 lb	275 lb	Black/Gold
	0646-376	75 lb	275 lb	Gold
	0646-252	103 lb	315 lb	Green
	0646-147	114 lb	267 lb	Yellow/Green
	0646-373*	114 lb	257 lb	Yellow/Green
	0646-155	121 lb	240 lb	Purple
	0646-229	122 lb	285 lb	Yellow/White
	0646-379*	122 lb	285 lb	Yellow/White
	0646-035	143 lb	286 lb	Orange/
				Black
	0646-447	143 lb	286 lb	Pink
	(Titanium)
	0646-367	143 lb	250 lb	Black
	0646-684	158 lb	285 lb	Black
HEAVY	0646-410	165 lb	310 lb	Black/Blue
		DRIVEN CLUTCH

Torque	Degree	Spring	Color	Spring
Bracket				Rate
0648-779* 58-46-36/		0648-749	Black/White	160/260
	58-48-36
0648-775* 52-42-46/		0648-702	Red/Black	140/240
	52-44-46
0648-773* 70-44-32/		0648-784	Black	155/222
	68-48-46
0648-789* 68-48-36/		0648-790	Black/Light Blue	180/260
	64-48-41
0648-791* 48-44-36/		0648-792	Black/Orange	180/280
	48-42-36

*Lightweight driven clutch only.

7

R-SX Arctic Cat Drive

Clutch Cam Arms

(w/Set Screw)

ARCTIC CAT DRIVE CLUTCH CAM ARMS

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

* Notched Cam Arm

8

Chain Case Performance

Calibrations

NOTE: The following table should be used as a guide only. The vehicle speeds should be based on 12% overdrive.

	Drive	Gear		Ratio	Chain							Engine RPM
	Sprocket	Ratio
		Top	Btm			6200	6400	6600	6800	7000	7200	7400	7600	7800	8000	8200	8400	8600	8800	9000
											Vehicle Speed (mph)
	8 Tooth	19	50	0.380	90	57	59	61	63	65	66	68	70	72	74	76	77	79	81	83
	(2.86"
		21	49	0.429	90	64	67	69	71	73	75	77	79	81	83	85	87	89	91	94
	pitch)
		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
	8 Tooth	19	50	0.380	90	60	62	64	66	68	70	72	73	75	77	79	81	83	85	87
	(3.0" pitch)
		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
	9 Tooth	19	50	0.380	90	57	58	60	62	64	66	68	69	71	73	75	77	79	80	82
	(2.52"
		21	49	0.429	90	64	66	68	70	72	74	76	78	80	82	84	87	89	91	93
	pitch)
		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

9

	Drive	Gear		Ratio	Chain							Engine RPM
	Sprocket	Ratio
		Top	Btm			6200	6400	6600	6800	7000	7200	7400	7600	7800	8000	8200	8400	8600	8800	9000
											Vehicle Speed (mph)
	9 Tooth	19	50	0.380	90	64	66	68	71	73	75	77	79	81	83	85	87	89	91	93
	(2.86"
		21	49	0.429	90	73	75	77	80	82	84	87	89	91	94	96	98	101	103	105
	pitch)
		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
	10 Tooth	19	50	0.380	90	63	65	67	69	71	73	75	77	79	81	83	85	87	89	91
	(2.52"
		21	49	0.429	90	71	73	76	78	80	82	85	87	89	92	94	96	98	101	103
	pitch)
		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

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

10

Chains and Sprockets

p/n	Sprocket
3602-170	19T FWD (13 WIDE/19 SPLINE) – Optional
3602-169	20T FWD (13 WIDE/19 SPLINE) – R-SX
2602-966	21T FWD (13 WIDE/19 SPLINE) – Optional
3602-171	22T FWD (13 WIDE/19 SPLINE) – Optional
2602-967	23T FWD (13 WIDE/19 SPLINE) – R-XC
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)
2602-874	48T (13 WIDE/34 SPLINE) ALUM
2602-875	49T (13 WIDE/34 SPLINE) ALUM
2602-876	50T (13 WIDE/34 SPLINE) ALUM
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)
2602-839	86P (15 WIDE)
2602-840	90P (15 WIDE)
2602-841	92P (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).

0730-218

	Wire	Angle	# of	Coil	Length	Length	Degree
p/n	Diameter			Width
	(A)	(B)	Coils	(C)	(D)	(E)	(In lb)
1704-382/383	.359	90°	5.75	3.00	15.62	4.60	17
(Light)
1704-384/385	.375	90°	5.75	3.00	15.62	4.60	20
(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

* Production (R-XC) ** Production (R-SX)

NOTE: The wire diameter and length of the spring have a large influence over the valving of the shocks.

Installed Spring Rate

Chart

p/n	Suspension Fully	Suspension Fully
	Extended	Extended
	(in.-lb – Adjuster Set 1 & 1)	(in.-lb – Adjuster Set 3 & 3)
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	Suspension Fully	Suspension Fully
	Collapsed	Collapsed
	(in.-lb – Adjuster Set 1 & 1)	(in.-lb – Adjuster Set 3 & 3)
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

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.)	14.7 mm diameter

NOTE: Sway Bar Mounting Kit (p/n 6639-001).

11

Rebuildable Shock Tools

Required

p/n	Tool
0744-020	Inflation Needle
0644-486	Gas Shock Retaining Blocks
0644-544	Replacement Needle
0644-169	Piston Location Tool
0644-151	Nitrogen Regulator
0644-268	Bearing Cap Seal Protector
0644-403	Bearing Cap Seal Protector (1/2-in. O.D. x 3/8 in. I.D.)
0644-404	Bearing Cap Seal Protector (5/8-in. O.D. x 3/8 in. I.D.)
0644-542	Bearing Cap Seal Protector (5/8 in. O.D. x 1/2 in. I.D.)
0644-543	Gas Shock Shaft Clamping Tool
0644-350	Floating Piston Location Gauge
0644-539	Inflation Needle Replacement Tip
0744-072	Float Shock Spanner Wrench
0644-584	Air Sleeve Bushing Installation Tool
0644-585	Air Sleeve Bushing Installation Tool
0644-456	Bullet Air Sleeve Bushing Installation Tool

Optional Front Arm

Shock Springs — R-XC

p/n	lbs	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

Optional Front Arm

Shock Springs — R-SX

p/n	lbs	Length (Inches)
3704-094	90/250	8.25
3704-095	135	8.25
3704-152	300	7
3704-351	200	7
3704-352	225	7
3704-353*	250	7
3704-354	275	7

* Stock Spring

Optional Dual Rate

Spring Chart (DSR)

Dual	Ride-in	Take-over	Communication	Transition
Rate	Spring	Spring	Length	Point
100/200	200 lb x 2.15"	200 lb x 6”	1”	1.70”
	p/n 3704-037	p/n 3704-038	0.5”	2.70”
90/200	170 lb x 2.20”	200 lb x 6”	1”	1.65”
	p/n 3704-036	p/n 3704-038	0.5”	2.50”
80/200	140 lb x 2.40”	200 lb x 6”	1”	1.80”
	p/n 3704-035	p/n 3704-038	0.5”	2.65”
50/200	70 lb x 2.55”	200 lb x 6”	1”	1.65”
	p/n 3704-033	p/n 3704-038	0.5”	2.30”
110/250	200 lb x 2.15”	250 lb x 6”	1”	1.52”
	p/n 3704-037	p/n 3704-039	0.5”	2.41”
100/250*	170 lb x 2.20”	250 lb x 6”	1”	1.50”
	p/n 3704-036	p/n 3704-039	0.5”	2.33”
90/250	140 lb x 2.40”	250 lb x 6”	1”	1.75”
	p/n 3704-035	p/n 3704-039	0.5”	2.50”
55/250	70 lb x 2.55”	250 lb x 6”	1”	1.60”
	p/n 3704-033	p/n 3704-039	0.5”	2.25”
120/300	200 lb x 2.15”	300 lb x 6”	1”	1.40”
	p/n 3704-037	p/n 3704-040	0.5”	2.25”
110-300	170 lb x 2.20”	300 lb x 6”	1”	1.40”
	3704-036	p/n 3704-040	0.5”	2.20”
95/300	140 lb x 2.40”	300 lb x 6”	1”	1.60”
	3704-035	p/n 3704-040	0.5”	2.35”
55/300	70 lb x 2.55”	300 lb x 6”	1”	1.55”
	p/n 3704-033	p/n 3704-040	0.5”	2.15”

* Stock Spring (R-XC)

12

Valve Stacks/Specifications (R-XC)

Ski Shock Part Number	Compression (Piston Side)	Rebound (Piston Side)
3703-813	1.300 x 0.008 in. (DB)	1.100 x 0.010 in.
Extended Length: 18.98 in.	1.300 x 0.006 in.	0.800 x 0.006 in.
Collapsed Length: 13.28 in.	1.300 x 0.006 in.	1.125 x 0.080 in. (Backup)
Stroke: 5.7 in.	0.800 x 0.008 in.	0.750 x 0.080 in. (Backup)
	1.300 x 0.008 in.	0.750 x 0.080 in. (Backup)
Rebuild Kit: p/n 3603-522	1.250 x 0.008 in.	0.750 x 0.080 in. (Backup)
	1.100 x 0.008 in.
	1.000 x 0.008 in.
	0.900 x 0.008 in.
	0.800 x 0.008 in.
IFP Depth: 1.8 in.	1.125 x 0.093 in. (Top Out)
Piston Orifice: None

QS3 @ 2nd Setting; 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.

Front Arm Shock Part Number	Compression (Piston Side)	Rebound (Piston Side)
3704-348	1.300 x 0.010 (SB)	1.100 x 0.010 in.
Extended Length: 12.41 in.	1.300 x 0.006 in.	1.100 x 0.010 in.
Collapsed Length: 8.63 in.	1.300 x 0.006 in.	1.000 x 0.010 in.
Stroke: 3.78 in.	1.300 x 0.006 in.	0.900 x 0.010 in.
	0.700 x 0.006	0.800 x 0.010 in.
Rebuild Kit: p/n 4604-189	1.300 x 0.008 in.	0.700 x 0.010 in.
	1.250 x 0.008 in.	0.620 x 0.080 in. (Backup)
	1.100 x 0.008 in.	0.620 x 0.080 in. (Backup)
	1.000 x 0.008 in.
IFP Depth: 1.4 in.	0.800 x 0.008 in.
Piston Orifice: None	0.700 x 0.008 in.
	1.125 x 0.080 in. (Top Out)

QS3 @ 2nd Setting. 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	Compression	Rebound (Piston Side)
		(Piston Side)
	3704-342	1.600 x 0.004 in. (XSB)	1.425 x 0.015 in.
	Extended Length: 14.44 in.	1.600 x 0.010 in.	1.425 x 0.015 in.
	Collapsed Length: 10.02 in.	1.600 x 0.010 in.	1.425 x 0.012 in.
	Stroke: 4.42 in.	1.100 x 0.006 in.	1.350 x 0.012 in.
		1.600 x 0.012 in.	1.100 x 0.012 in.
	Rebuild Kit: p/n 4604-160	1.600 x 0.012 in.	0.950 x 0.012 in.
		1.600 x 0.012 in.	0.800 x 0.020 in.
		1.425 x 0.010 in.	0.800 x 0.020 in.
		1.350 x 0.010 in.	0.750 x 0.080 in. (Backup)
		1.100 x 0.008 in.	0.750 x 0.100 in. (Backup)
	Piston Depth: 2.10 in.	1.570 x 0.128 in. (Top Out)
	Piston Orifice: None

QS3 @ 2nd Setting; RB Knob @ 4 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).

13

Valve Stacks/Specifications (R-SX)

Ski Shock Part Number	Compression (Piston Side)	Rebound (Piston Side)
3703-948/949	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: 5.85 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.
	1.300 x 0.012 in.
	1.300 x 0.012 in.
	1.250 x 0.010 in.
IFP Depth: 2.30 in.	1.000 x 0.015 in.
Piston Orifice: None	1.125 x 0.093 in. (Top Out Washer)

Low Speed Compression Knob @ 8 clicks counterclockwise from full stop; RB Knob @ 5 clicks counterclockwise from full stop. Eyelets tightened to 3.9 kg-m (28 ft-lb) (threads coated with Green Loctite #620). Piston nut tightened 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)
3704-466	1.600 x 0.004 in. SB	1.425 x 0.008 in.
Extended Length: 12.34 in.	1.600 x 0.008 in.	0.850 x 0.004 in.
Collapsed Length: 8.29 in.	1.600 x 0.008 in.	1.400 x 0.080 in. (Top Out)
Stroke: 4.05 in.	1.425 x 0.008 in.	0.750 x 0.080 in. (Backup)
	1.600 x 0.012 in. (Ring)
Rebuild Kit: p/n 4604-318	1.600 x 0.008 in.
	1.420 x 0.008 in.
	1.350 x 0.008 in.
	1.200 x 0.008 in.
	1.000 x 0.008 in.
IFP Depth: 1.80 in.	1.570 x 0.080 in. (Top Out Washer)
Piston Orifice: None

LowSpeedCompression(InitialSetting):18clicksfromfullyclosed.Eyeletstightenedto3.9kg-m(28ft-lb).Pistonnuttightenedto3.0kg-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)
3704-467	1.600 x 0.004 in. (XSB)	1.425 x 0.015 in.
Extended Length: 14.39 in.	1.600 x 0.008 in.
Collapsed Length: 10.06 in.	1.600 x 0.010	1.400 x 0.080 in. (Top Out)
Stroke: 4.32 in.	1.425 x 0.012 in.
	1.600 x 0.015 (Ring)	1.400 x 0.080 in. (Top Out)
	1.600 x 0.008 in.
Rebuild Kit: p/n 4604-017	1.100 x 0.0045 in.
	1.600 x 0.012 in.
IFP 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.
	1.600 x 0.012 in.
	1.600 x 0.012 in.
	1.600 x 0.012 in.
	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 8 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).

14

Rebuildable Shock

Accessory Part Numbers

NOTE: When rebuilding FOX shocks, use only

FOX valves and/or pistons.

Acc p/n	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]

Acc p/n

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.

15

Double Bleed Shims (DB)

Acc p/n

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)

Acc p/n

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.)

Fraction/Decimal

Conversion Chart

8ths	16ths	32nds	64ths	64ths (cont)
1/8 = .125	1/16 = .0625	1/32 = .03125	1/64 = .015625	33/64 = .515625
1/4 = .250	3/16 = .1875	3/32 = .09375	3/64 = .046875	35/64 = .546875
3/8 = .375	5/16 = .3125	5/32 = .15625	5/64 = .078125	37/64 = .578125
1/2 = .500	7/16 = .4375	7/32 = .21875	7/64 = .109375	39/64 = .609375
5/8 = .625	9/16 = .5625	9/32 = .28125	9/64 = .140625	41/64 = .640625
3/4 = .750	11/16 = .6875	11/32 = .34375	11/64 = .171875	43/64 = .671875
7/8 = .875	13/16 = .8125	13/32 = .40625	13/64 = .203125	45/64 = .703125
—	15/16 = .9375	15/32 = .46875	15/64 = .234370	47/64 = .734375
—	—	17/32 = .53125	17/64 = .265625	49/64 = .765625
—	—	19/32 = .59375	19/64 = .296875	51/64 = .796875
—	—	21/32 = .65625	21/64 = .328125	53/64 = .828125
—	—	23/32 = .71875	23/64 = .359375	55/64 = .859375
—	—	25/32 = .78125	25/64 = .390625	57/64 = .890625
—	—	27/32 = .84375	27/64 = .421875	59/64 = .921875
—	—	29/32 = .90625	29/64 = .453125	61/64 = .953125
—	—	31/32 = .96875	31/64 = .484375	63/64 = .984375

Drill Bit Sizes

(Number) Chart

	Size of		Size of		Size of		Size of
No.	Drill in	No.	Drill in	No.	Drill in	No.	Drill in
	Inches		Inches		Inches		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

16

Conversion Chart

(mm/in.)

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

17

NOTES

18

Wiring Diagram —

Hood Harness (R-XC)

(p/n 1686-856, 1686-857)

RED/BLU

VLT/BLK

#2 #1

8

			1	SPEEDOMETER/TACHOMETER
			2	CONNECTOR, MAIN HARNESS
			3	CONNECTOR, KEYSWITCH
			4	OUTLET, 12V ACCESSORY
			5	HEADLIGHT, LED
			6	HEADLIGHT, HALOGEN B
			7	HEADLIGHT, HALOGEN A
			8	ALARM, REVERSE
				CIRCUIT DIAGRAM"
			SWITCH	TERMINAL	TERMINAL	TERMINAL	TERMINAL
	C	B	FUNCTION	"A"	"B"	"C"	"D"
			OFF
	D	A
1			ON
	2		START
		3

6	5	4	3	2	1								1		2	3	4	5	6	7	8
																									D	A
12	11	10	9	8	7								9		10 11										C	B
																	12	13	14	15	16
12 11 10 9	8	7	6	5 4		3	2	1	1 2 3 4 5 6 7							8 9 10 11 12 13 14 15 16									D C B A
<![if ! IE]> <![endif]>(Reverse Alarm) VLT/BLK	<![if ! IE]> <![endif]>(Can L) GRY/YEL	<![if ! IE]> <![endif]>(Can H) WHT/GRY	<![if ! IE]> <![endif]>(Fuel level Sensor) GRY	<![if ! IE]> <![endif]>(Hi Beam Power) BLU	<![if ! IE]> <![endif]>(Low Oil) BRN	<![if ! IE]> <![endif]>(Battery (+)) RED/WHT	<![if ! IE]> <![endif]>((-)) BLK/VLT	<![if ! IE]> <![endif]>(Speedo/Tach Power) RED/BLU	<![if ! IE]> <![endif]>(Low Power DC) RED/BLU	<![if ! IE]> <![endif]>(Gauge (-)) BLK/VLT	<![if ! IE]> <![endif]>(Battery (+)) RED/WHT	<![if ! IE]> <![endif]>(Low Oil) BRN	<![if ! IE]> <![endif]>(Hi Beam Power) BLU	<![if ! IE]> <![endif]>(Fuel Level Sensor) GRY	<![if ! IE]> <![endif]>(Can H) WHT/GRY		<![if ! IE]> <![endif]>(Can L) GRY/YEL		<![if ! IE]> <![endif]>(Starter Solenoid) BLK/YEL	<![if ! IE]> <![endif]>(Keyswitch Ground) BLK/BLU	<![if ! IE]> <![endif]>(Lo Beam Power) WHT	<![if ! IE]> <![endif]>(Keyswitch (+)) VLT/RED	<![if ! IE]> <![endif]>(Starter Solenoid) BLK/YEL	<![if ! IE]> <![endif]>(Ground) BLK	<![if ! IE]> <![endif]>(Keyswitch Ground) BLK/BLU	<![if ! IE]> <![endif]>(Keyswitch (+)) VLT/RED

			HALOGEN					LED
			HEADLIGHT				HEADLIGHT
<![if ! IE]> <![endif]>BLU (Hi Beam)	<![if ! IE]> <![endif]>WHT (Lo Beam)	<![if ! IE]> <![endif]>BLK (Ground)	<![if ! IE]> <![endif]>BLU (Hi Beam)	<![if ! IE]> <![endif]>WHT (Lo Beam)	<![if ! IE]> <![endif]>BLK (Ground)	<![if ! IE]> <![endif]>WHT(Lo Beam Power)	<![if ! IE]> <![endif]>BLU(Hi Beam Power)	<![if ! IE]> <![endif]>BLK(Ground)	<![if ! IE]> <![endif]>RED/BLU(Low Power DC)	<![if ! IE]> <![endif]>RED/BLU (Power)	<![if ! IE]> <![endif]>BLK (Ground)
	B			B
			C		A	1	2	3	4
C		A
										#1
											#2
							2	1
							4	3		+	-
										#1	#2
	C	A		C	A
	B			B

5

NOTES:

1. CONNECTORS SHOWN FROM MATING SURFACE SIDE.

2.	BLK	A	INDICATES WIRE SPLICE, THIS EXAMPLE
			INDICATES BLK SPLICE A.

	4	3
			4
	2	1
1	2	3	4
<![if ! IE]> <![endif]>Lo Beam LEDs	<![if ! IE]> <![endif]>Hi Beam LEDs	<![if ! IE]> <![endif]>Ground	<![if ! IE]> <![endif]>Lighting LEDs
			<![if ! IE]> <![endif]>Accent

76

0752-740

19

Wiring Diagram —

Hood Harness (R-SX)

(p/n 1686-880)

1

2

													1	2		3
			6	5	4	3	2	1
			12	11	10	9	8	7					4	5		6
12	11	10	9	8	7	6	5	4	3	2	1	1	2	3	4	5	6
				<![if ! IE]> <![endif]>(CAN Lo) GRY/YEL	<![if ! IE]> <![endif]>(CAN Hi) WHT/GRY		<![if ! IE]> <![endif]>(Hi Beams) BLU			<![if ! IE]> <![endif]>(Chassis Gnd) BLK	<![if ! IE]> <![endif]>(Fused DC Power) RED/BLU	<![if ! IE]> <![endif]>(Fused DC Power) RED/BLU	<![if ! IE]> <![endif]>(Headlight Fused AC Power) YEL/VLT	<![if ! IE]> <![endif]>(CAN Hi) WHT/GRY	<![if ! IE]> <![endif]>(CAN Lo) GRY/YEL	<![if ! IE]> <![endif]>(Chassis Gnd) BLK	<![if ! IE]> <![endif]>(Warmer Switch) GRN/VLT

<![if ! IE]> <![endif]>YEL/VLT

<![if ! IE]> <![endif]>GRN/VLT

<![if ! IE]> <![endif]>BLU

<![if ! IE]> <![endif]>WHT

<![if ! IE]> <![endif]>BLK

#1	#2	#1	#3
			#2
OPEN @ OFF
CLOSED @ ON
5			BLU + YEL/VLT = HI BEAMS ON
			WHT + YEL/VLT = LO BEAMS ON

4

1CONNECTOR, SPEEDOMETER

2CONNECTOR, MAIN HARNESS

3HEADLIGHT

4SWITCH, HEADLIGHT

5SWITCH, WARMER

NOTES:

1.CONNECTORS SHOWN FROM MATING SURFACE SIDE. WHERE APPLICABLE.

2. BLK	INDICATES WIRE SPLICE, THIS EXAMPLE
	INDICATES BLK SPLICE.

<![if ! IE]> <![endif]>(Hi Beam)	<![if ! IE]> <![endif]>(Lo Beam)	<![if ! IE]> <![endif]>(Grounnd)
<![if ! IE]> <![endif]>BLU	<![if ! IE]> <![endif]>WHT	<![if ! IE]> <![endif]>BLK
	B

CA

C A

B

3

0752-739

20

Wiring Diagram —

Ignition/Main Harness

(R-XC)

(p/n 1686-833)

(Insert 0752-737 11 x 17 in color here.)

Wiring Diagram —

Ignition/Main Harness

(R-SX)

(p/n 1686-876)

(Insert 0752-738 11 x 17 in color here.)

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/ Installing Handlebar Assembly

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.Place the windshield into position on the console and secure using the six plastic rivets.

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.

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 (R-SX)

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.

0752-635

0752-634

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.

25