Arctic Cat ZR /Riot /M/Norseman X 6000, ZR /Riot /M/Norseman X 8000 Service Manual

Service Manual

p/n: 2262-817

11/19

ZR/Riot/M/Norseman X 6000/8000

Table of Contents

General Information/Foreword ............................................... 2

Snowmobile Identification ........................................................2

Recommended Gasoline and Oil ............................................. 2

Engine Break-In ....................................................................... 3

Drive Belt Break-In ...................................................................3

Genuine Parts .......................................................................... 3

Varying Altitude Operation ....................................................... 3

Preparation for Storage............................................................ 4

Preparation after Storage......................................................... 5

After Break-In Checkup/Checklist ............................................ 6

Engine Specifications............................................................... 6

Crankshaft Runout/Repair Specifications ................................7

Arctic Power Valve (APV) System Specifications .................... 7

Electrical Specifications ...........................................................8

Drive System Specifications..................................................... 8

Drive Clutch/Driven Clutch-Related Specifications ..................8

Drive System Components ......................................................8

Chain Case Performance Calibrations..................................... 9

Track Specifications ............................................................... 11

IFP Shock Specifications .......................................................11

Torque Conversions............................................................... 11

Torque Specifications............................................................. 11

Steering and Body ................................................................. 13

Steering Post (ZR/Riot/Norseman X) ..................................... 13

Steering Post (Riot X) ............................................................15

Steering Post (M) ................................................................... 18

Ski (ZR/Riot)........................................................................... 21

Ski (Norseman X)................................................................... 21

Ski (Riot X/M) ......................................................................... 22

Ski Wear Bar.......................................................................... 22

Spindle (ZR/Riot).................................................................... 23

Spindle (Norseman X)............................................................ 23

Spindle (Riot X/M) .................................................................. 24

Steering Tie Rod .................................................................... 24

Ski Alignment ......................................................................... 26

A-Arms (ZR/Riot).................................................................... 28

A-Arms (Norseman X)............................................................ 29

A-Arms (Riot X/M) .................................................................. 31

Ski Shock Absorber................................................................ 32

Sway Bar (ZR/Riot/Norseman X) ...........................................32

Front Bumper ......................................................................... 33

Seat Assembly (ZR/Riot)........................................................ 33

Seat Assembly (Norseman X)................................................ 34

Seat Assembly (M)................................................................. 34

Taillight/Brake Light Assembly (ZR/Riot/M) ...........................35

Taillight/Brake Light Assembly (Norseman X)........................ 35

Rear Bumper/Snowflap .......................................................... 35

Windshield/Console/ Headlight ..............................................35

Headlight Bulb — Non-LED ................................................... 36

Adjusting Headlight Aim ........................................................ 37

Engine..................................................................................... 38

Engine Removing/Installing.................................................... 38

Assembly Schematic (6000) ..................................................44

Assembly Schematic (8000) ..................................................46

Engine Servicing (6000)......................................................... 48

Engine Servicing (8000 Early Build)....................................... 61

Engine Servicing (8000)......................................................... 73

Troubleshooting Engine ......................................................... 86

Engine-Related Items................................................................ 88

Water Pump........................................................................... 88

Pressure Testing Engine ....................................................... 90

Liquid Cooling System........................................................... 90

Cooling System Schematic.................................................... 91

Recoil Starter......................................................................... 91

Arctic Power Valve (APV) System......................................... 93

Troubleshooting Arctic Power Valve (APV) System .............. 99

Exhaust Controlled Timing (ECT) System ............................. 99

Fuel Systems ........................................................................100

EFI System .......................................................................... 100

Individual Components ........................................................ 100

Self-Diagnostic System/Codes ............................................ 102

Fuel Pressure Regulator...................................................... 103

Throttle Body Assembly....................................................... 103

Throttle Cable ...................................................................... 103

Fuel Pump ........................................................................... 104

Troubleshooting Fuel Systems ............................................ 106

Electric Oil Pump ................................................................. 106

Gas Tank ............................................................................. 107

Electrical Systems ...............................................................108

Ignition System .................................................................... 108

Throttle Position Sensor ...................................................... 108

Electrical Resistance Tests ................................................. 109

Testing Electric Oil Pump .................................................... 110

Testing Voltage Regulator ................................................... 110

Testing Oil Level Sensor ..................................................... 111

Testing Fuel Gauge Sender ................................................ 111

Emergency Stop Switch ...................................................... 111

Starter Relay Solenoid......................................................... 111

Fuse..................................................................................... 112

Ignition Switch ..................................................................... 112

Starter Motor........................................................................ 112

Troubleshooting Electric Start ............................................. 116

Brake Light Switch............................................................... 116

Testing Headlight Dimmer Switch ....................................... 116

Testing Handlebar Warmer Elements ................................ 117

Testing Thumb Warmer Element......................................... 117

Testing Handlebar Warmer/Thumb Warmer Switch............ 117

Testing Tether ..................................................................... 117

Testing Speedometer Sensor.............................................. 117

Testing Shift Switch ............................................................. 118

Drivetrain/Track/Brake Systems .........................................119

Drive Belt ............................................................................. 119

Drive Clutch ......................................................................... 119

Driven Clutch ....................................................................... 121

Drive Clutch/Driven Clutch .................................................. 123

Drivetrain ............................................................................. 124

Drive Sprockets ................................................................... 130

Track Tension...................................................................... 132

Track Alignment................................................................... 133

Brake System ...................................................................... 133

Brake Lever/Master Cylinder Assembly .............................. 138

Troubleshooting Hydraulic Brake System ........................... 140

Troubleshooting Track......................................................... 140

Troubleshooting Drive Clutch/Driven Clutch........................ 141

Suspension ...........................................................................142

Suspension Setup Basics.................................................... 142

Chassis and Skid Frame Mounting Locations ..................... 147

Servicing Suspension .......................................................... 150

FOX Air Shocks ................................................................... 166

Servicing IFP Shocks .......................................................... 166

General

Information/Foreword

NOTE: General specifications for each 2020 Arctic

Cat Snowmobile can be accessed from the Arctic Cat Cat Tracker Dealer Communication System.

NOTE: Some illustrations and photographs used in

this section are used for clarity purposes only and are not designed to depict actual conditions.

This Service Manual contains service and maintenance information for 2020 Arctic Cat ZR, Riot, M and Norseman X snowmobile models. The manual is designed to aid service personnel in service-oriented applications.

This manual is divided into sections. The sections cover specific snowmobile components or systems and, in addition to the standard service procedures, includes assembling, disassembling, and inspecting instructions. When using this manual as a guide, the technician should use discretion as to how much disassembly is needed to correct any given condition.

The service technician should become familiar with the operation and construction of the components or systems by carefully studying the complete manual. This will assist the service technician in becoming more aware of and efficient with servicing procedures. Such efficiency not only helps build consumer confidence but also saves time and labor.

All Arctic Cat publications and snowmobile decals display the words Warning, Caution, and Note to emphasize important information. The symbol ! WARNING identifies personal safety-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.

At the time of publication, all information, photographs, and illustrations were technically correct. Some photographs and 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.

Snowmobile Identification

The Arctic Cat Snowmobile has two important identification numbers. The Vehicle Identification Number (VIN) is stamped into the tunnel near the right-side footrest. The decal also displays pertinent production information. The Engine Serial Number (ESN) is stamped into the crankcase of the engine.

These numbers are required to complete warranty claims properly. No warranty will be allowed by Arctic Cat if the engine serial number or VIN is removed or mutilated in any way.

Recommended Gasoline

and Oil

CAUTION

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

RECOMMENDED GASOLINE

The recommended gasoline to use is 91 octane (minimum).

NOTE: If a situation arises in which 91 octane gaso-

line is not available, 87 octane gasoline can be substituted; however, do not prolong the usage of 87 octane gasoline as it will cause poor engine performance.

In many areas, oxygenates are added to the gasoline. Oxygenated gasolines containing up to 10% ethanol are acceptable gasolines.

RECOMMENDED OIL

CAUTION

Any oil used in place of the recommended oil may cause serious damage.

The recommended oil to use in the oil-injection system is Arctic Cat C-TEC2 Synthetic 2-Cycle Oil (p/n 8639-118 — quart), (p/n 7639-840 — gal.), or (p/n 6639-521 — 2.5 gal.) This oil is specially formulated to be used and meets all of the lubrication requirements of the Arctic Cat C-TEC2 snowmobile engine.

All materials and specifications are subject to change without notice.

Product Service and Warranty Department Arctic Cat Inc.

Engine Break-In

The Arctic Cat engine (when new) requires a short break-in period before the engine is subjected to heavy load conditions.

The break-in period occurs in two stages. Stage One occurs during the first 18 minutes of a new engine's run time where the ECM will provide additional fuel and oil to the engine. Stage Two occurs after the completion of Stage One. However, Stage Two still provides additional fuel and oil to the engine for the remainder of 6 hours. This additional fuel and oil is less than the amount added during Stage One.

TPS must be higher than programmed thresholds to accrue time toward each break-in stage.

Premixing fuel and oil during the break in period is not required. Due to the oil delivery control strategy of the electronic oil pump, the oil pump will automatically compensate and deliver a richer fuel-oil ratio during the engine break-in period.

Drive Belt Break-In

Drive belts require a break-in period of 25 miles. Drive the snowmobile for 25 miles at 3/4 throttle or less. By revving the engine up and down (but not exceeding 60 mph), the exposed cord on the side of a new belt will be worn down. This will allow the drive belt to gain its optimum flexibility and will extend drive belt life.

NOTE: Before starting the snowmobile in extremely

cold temperatures, the drive belt should be removed and warmed up to room temperature. Once the drive belt is at room temperature, install the drive belt (see Drive Belt sub-section in the Drivetrain/Track/Brake Systems section of this manual).

CAUTION

Running the engine with the drive belt removed could result in serious engine damage and drive clutch failure.

CLUTCHING

On a normally-aspirated engine as altitude changes, engine horsepower changes with it. As you go up in altitude, the engine loses horsepower. Because of this, the continuously variable transmission (CVT) system needs to be calibrated to compensate for the horsepower loss.

At altitudes above 5000 ft, the engine loses peak horsepower but will also lose horsepower at engagement speed. For this reason, calibrating the drive system is usually needed in order to attain acceptable performance. Changing drive clutch engagement speed can be done several ways. Some of the methods will affect other characteristics of CVT operation, so you must be careful what you change. Drive clutch springs are the most common way to increase engagement speed; however, by simply changing the cam arms to a lighter weight from the heavier sea level cam arm, you will gain some engagement speed.

The driven clutch will also play a part in CVT tuning for high altitude operation. A steeper helix (torque bracket) angle in the driven clutch will mean a quicker up-shift. A shallower angle will mean a slower up-shift. If the up-shift is too quick, due to a very steep helix, RPM will be pulled down under the peak operating RPM of the engine (where the horsepower is) and performance will suffer. The engine may even bog.

ENGINE

A normally aspirated engine will generate more horsepower at sea level than it does at higher altitudes. The reason is that the higher you go, less oxygen is available for the engine to use during its combustion process. Less oxygen means it needs less fuel to obtain the correct air/fuel ratio to operate properly. This is why the fuel ratio has to be recalibrated. High altitude engines operate as though they have a lower compression ratio. This, along with less oxygen and less fuel, means that the engine generates less horsepower. All of these characteristics will become more evident the higher the altitude.

SUSPENSION

The different riding styles of the individual operator, the varying snow conditions, and the type of terrain are all factors that affect the suspension at high altitude. Trail riding versus powder snow riding versus combination riding will all require different suspension settings.

Genuine Parts

When replacement of parts is necessary, use only genuine Arctic Cat parts. They are precision-made to ensure high quality and correct fit.

Varying Altitude Operation

Operating a snowmobile at varying altitudes requires recalibration of drive system components. Consult the appropriate specification sheet on Cat Tracker Online.

Following are basic altitude theories for clutching, engine, suspension, and track.

The rear suspension has a number of spring settings that produce different riding characteristics.

The front arm spring and shock will also affect the ride and handling when either on a trail or in powder snow. A strong spring setting on this shock will cause the snowmobile to tend to “dig” more when riding in the powder snow rather than climbing up on top of the snow. But, it will work more effectively when riding on a trail. A softer spring setting will allow the front of the rear suspension to collapse much quicker and change the angle of the track to the snow. A more gradual angle will tend to raise the snowmobile up on the snow rather than digging into it.

Many possible variables and adjustments to the rear suspension exist depending on snow conditions, riding style, and type of terrain. These adjustments can be made to individualize the snowmobile to the riding style of the operator.

As snow cover and riding conditions change, several different adjustments can be made to change the ride and handling characteristics for operator preference. Located on the front suspension arm are limiter straps. They limit the amount of “fallout” the front arm can have. These straps may be adjusted in or out due to conditions and riding style. The more the straps are brought up, the more steering power the operator has due to the amount of ski pressure.

Another adjustment that can be made on the rear suspension is the front arm shock spring tension. As trail conditions change, the spring preload may be used to decrease the chance of the front end “bottoming out.” With a stiffer spring preload, the ride of the snowmobile will improve on the trail but will affect the performance in the deep powder snow. In deep powder snow, the stiffer spring preload will cause the front-end to “dig” and possibly take longer for it to plane off. Several different-rate springs are available for different riding styles and terrain conditions.

On the standard models, the front shock springs are also individually adjustable for the terrain conditions and driving style of the operator. The spring adjuster has been set at the factory so the correct amount of threads are exposed between the spring adjuster and the shock housing as an initial setting. Additional ski pressure can be obtained by tightening the spring tension; ski pressure can be decreased by relaxing spring tension. Springs with different spring rates are available for operator choice and snow conditions.

A limit exists as to how far you can preload the springs before “coil bind” takes effect where the wire on the spring actually runs into itself and causes binding. Equal adjustments should be maintained on both sides of the snowmobile. On models with float shocks, they are individually adjustable for the terrain conditions and driving style of the operator. The shocks are preset at the factory (see chart) as an initial setting; however, it is possible to “fine tune” the shocks to match the operator’s weight, riding style, and terrain conditions.

Initial Setting Chart

Model

FOX Float QS3

Front Shock

(Ski)

85 psi 35 psi 165 psi

Front Arm

Shock

Rear Arm

Shock

Checking and adjusting air pressure must be done at riding temperature (outside) and shocks are at full extension with no weight on the shock. Also, it is advisable to check air pressure when the outside temperature varies more than 25°.

NOTE: Care should be taken to have equal pressure

in the ski shocks before operating the snowmobile.

Finally, track tension should be looked at to make sure that it is within recommended specifications to affect the efficiency of the snowmobile. On models with the torque sensing link, the track is actually tightening as the suspension moves through its range of motion causing the track to sag in the middle and rub on the top part of the rear suspension arm.

TRACK

Carefully matching the riding requirements to the type of track will ensure the maximum use of all available engine power. Lug height and track durometer are the two main concerns when selecting a track for various riding styles.

Tracks exist with lug heights from 1.0” up to 3.0” to accommodate various snow conditions. Generally, the deeper the snow, the taller the lug. It must be noted that the installation of any deep-lug track may reduce top end speed and promote premature wear strip wear in marginal snow conditions.

Durometer is a measurement of how hard a rubber is. The lugs on most tracks range between 60 and 80 durometer. On the durometer scale, the higher the number, the harder the lugs. For riding in deep powder snow, a softer durometer track works best. The softer rubber allows the track to “give” a little and pack the snow creating lift rather than digging its way straight down. When hill-climbing, the harder lug of an 80 durometer track works the best due to penetrating the hard snow creating more bite.

Some tracks come with a dual durometer rating, such as a track with a 80/60 durometer rating. The lugs on this track are 80% 80 durometer rubber, and the top 20% is made of the softer 60 durometer rubber. This track is designed to be a good all-around track for riding mostly in deep powder snow but can climb the occasional hard snow hill.

Preparation for Storage

Prior to storing the snowmobile, it must be properly serviced to prevent corrosion and component deterioration.

1. Clean the seat cushion with a damp cloth and Arctic Cat Vinyl Protectant.

2. Clean the snowmobile thoroughly by hosing dirt, oil, grass, and other foreign matter from the skid frame, tunnel, hood, and belly pan. Allow the snowmobile to dry thoroughly. DO NOT get water into any part of the engine.

3. Place the rear of the snowmobile up on a shielded safety stand; then start the engine and allow to idle. Spray an Engine Storage Preserver into the intake until the engine exhaust starts to smoke heavily or until the engine starts to drop in RPM. Turn engine off.

CAUTION

Do not run the engine without the belt guard in place and secured.

4. Plug the exhaust system outlet with steel wool.

5. With the ignition switch in the OFF position:

A. Disconnect the high tension leads from the spark

plugs; then remove the plugs, connect them to the leads, and ground them on the cylinder heads.

CAUTION

Never crank the engine over without grounding the spark plugs. Damage to coils and/or ECM may result.

B.Pour 29.5 ml (1 fl oz) of SAE 30 petro-

leum-based oil into each spark plug hole and pull the recoil starter handle slowly about 10 times.

Preparation after Storage

C. Install the spark plugs and connect the high ten-

sion leads.

6. Fill the gas tank to its rated capacity; then add Arctic Cat Fuel Stabilizer to the gas tank following directions on the container for the stabilizer/gasoline ratio. Tighten the gas tank cap securely.

7. With the snowmobile level, check the lubricant level in the chain case. If low, add chain lube through the fill plug hole.

8. Remove the drive belt from the drive clutch/driven clutch. Lay the belt on a flat surface or slide it into a cardboard sleeve to prevent warping or distortion during storage; then clean and inspect the drive clutch and driven clutch.

9. Apply light oil to the upper steering post bushings and to the shafts of the shock absorbers; then lubricate the rear suspension with low-temperature grease.

10. Tighten all nuts, bolts, and cap screws making sure all calibrated nuts, bolts, and cap screws are tightened to specifications. Make sure all rivets holding the components together are tight. Replace all loose rivets.

11. Clean and polish the hood, console, and chassis with Cat Cleaner. DO NOT USE SOLVENTS. THE PROPELLENT WILL DAMAGE THE FINISH.

12. On electric start models, disconnect the battery cables making sure to disconnect the negative cable first; then clean the battery posts and cables.

CAUTION

Sealed batteries require charging if left for extended non-start periods. Arctic Cat recommends trickle charging once a month. Follow the manufacturer’s instructions and cautions.

13. If possible, store the snowmobile indoors. Raise the track off the floor by blocking up the back end making sure the snowmobile is secure. Loosen the track adjusting bolts to reduce track tension. Cover the snowmobile with a machine cover or a heavy, ventilated tarpaulin to protect it from dirt and dust.

14. If the snowmobile must be stored outdoors, position the snowmobile out of direct sunlight; then block the entire snowmobile off the ground making sure the snowmobile is secure. Loosen the track adjusting bolts to reduce track tension. Cover with a machine cover or a heavy, ventilated tarpaulin to protect it from dirt, dust, and rain.

Taking the snowmobile out of storage and correctly preparing it for another season will ensure many miles and hours of trouble-free snowmobiling. Arctic Cat recommends the following procedure:

1. Clean the snowmobile thoroughly. Polish the exterior of the snowmobile.

2. Clean the engine. Remove the cloth from the exhaust system. Check exhaust system and air silencer for obstructions.

3. Inspect all control wires and cables for signs of wear or fraying. Replace if necessary. Use cable ties or tape to route wires and cables away from hot or rotating parts.

4. Inspect the drive belt for cracks and tears. Check belt specifications. Replace if damaged or worn. Install the drive belt.

NOTE: If the old belt is worn but in reasonable con-

dition, retain it with the snowmobile as a spare in case of emergency.

5. Adjust the throttle cable. Inspect all fuel hoses and oil hoses for deterioration or cracks; replace if necessary. Make sure all connections are tight.

6. Fill the oil-injection reservoir with the recommended 2-cycle oil; then inspect each spark plug. Replace, gap, or clean as necessary.

7. Tighten all nuts, bolts, and cap screws making sure all calibrated nuts, bolts, and cap screws are tightened to specifications.

8. If not done during preparation for storage, lubricate the rear suspension with low-temperature grease.

9. Check the coolant level and all coolant hoses and connections for deterioration or cracks. Add properly mixed coolant as necessary.

10. On electric start models, charge the battery; then connect the battery cables making sure to connect the positive cable first. Test the electric start system.

11. Inspect the entire brake system, all controls, headlight, taillight, brake light, ski wear bars, and headlight aim; adjust or replace as necessary.

12. Adjust the track to the proper tension and alignment.

CAUTION

Avoid storing in direct sunlight and using a plastic cover as moisture may collect on the snowmobile causing corrosion.

After Break-In

Checkup/Checklist

Certain areas require adjustment after the break-in period in order to obtain peak performance. These areas are the following:

DRIVE CLUTCH/DRIVEN CLUTCH ALIGNMENT (OFFSET) — The alignment between

the drive clutch and driven clutch are set at the factory. Normally, no adjustment is necessary; however, if premature drive belt wear or poor performance is experienced, the drive clutch/driven clutch alignment must be checked. See “CHECKING OFFSET” in the Drivetrain section in this manual.

TRACK TENSION AND ALIGNMENT — A certain amount of stretch occurs on all tracks during the first 500 miles. The track must be inspected/adjusted after the first 50 to 100 miles to the specifications given in the Track Specifications sub-section of this section and periodically thereafter. If these adjustments aren’t performed, the track may “derail” which leads to track and slide rail damage.

Along with these major areas, other areas should be checked and adjusted.

Below is a list of items to check after the break-in period. The recommended mileage for this inspection is between 100 and 300 miles.

 Check drive clutch/driven clutch alignment  Adjust track tension and alignment  Check throttle cable tension  Check engine idle  Check coolant level  Check chain case lubricant level  Check lights (high/low beam, brake light)  Check safety switch operation  Check engine compartment for any rubbing com-

ponents

 Check steering hardware for tightness  Check skid frame and A-arm mounting hardware

for tightness

 Check brake lever travel and adjustment  Grease all lubrication points

Engine Specifications

6000

ITEM

Engine Number 0962-011 Displacement 599 cc Bore x Stroke 73.8 x 70 mm Compression Ratio 6.62:1 Cooling System Liquid Ignition Timing (Engine Warm) 16.5° @ 2000 RPM Spark Plug (NGK) BPR9ES Spark Plug Gap 0.028-0.031 in. Piston Skirt/Cylinder Clearance 0.0041-0.0053 in. Piston Ring End Gap 0.012-0.0196 in. Cylinder Trueness Limit 0.004 in. Piston Pin Diameter 0.8659-0.8661 in. Piston Pin Bore Diameter 0.8661-0.8665 in. Connecting Rod Small End Bore 1.0631-1.0634 in. Connecting Rod Radial Play 0.0001-0.0008 in. Crankshaft Runout (t.i.r.) 0.002 in. Crankshaft End Play 0.008 in.

8000

ITEM

Engine Number (Early Build Models) 0962-055 Engine Number 0962-109 Displacement 794 cc Bore x Stroke 85 x 70 Compression Ratio (Early Build Models) 6.48:1 Compression Ratio 6.60:1 Cooling System Liquid Ignition Timing (Engine Warm) 19° @ 1750 RPM Spark Plug (NGK) BPR9ES Spark Plug Gap 0.028-0.031 in. Piston Skirt/Cylinder Clearance 0.0041-0.0053 in. Piston Ring End Gap 0.012-0.0196 in. Cylinder Trueness Limit 0.004 in. Piston Pin Diameter 0.8659-0.8661 in. Piston Pin Bore Diameter 0.8661-0.8665 in. Connecting Rod Small End Bore 1.0631-1.0634 in. Connecting Rod Radial Play 0.0001-0.0008 in. Crankshaft Runout (t.i.r.) 0.002 in. Crankshaft End Play 0.008 in.

Crankshaft Runout/Repair

Specifications

Arctic Power Valve (APV)

System Specifications

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 is still supported on the outer bearings using V Blocks.

NOTE: The crankshaft must be supported on the

inner bearings using V Blocks.

APV CABLE LENGTH

36.5 mm ± 1 mm

0735-516

The exhaust valve cable length can be measured using a specific gauge (p/n 8639-126).

0747-810

ZR-250

Electrical Specifications

Component Test Value + Test Connections -

Spark Plug Cap 4000-6000 ohms cap end cap end Oil Level Sensor Less than 1 ohm (float end down) terminal terminal Ignition Switch Less than 1 ohm (key in OFF position) terminal terminal

6000/8000 (Normally Open Ignition)

Ignition Coil (Primary)

Charge Coil (1) 8.8-13.2 ohms black/red green/red Charge Coil (2) 8.8-13.2 ohms brown/white green/red Lighting Coil 0.08-0.12 ohm yellow yellow Ignition Timing Sensor (1) 148-222 ohms green/white brown/green Ignition Timing Sensor (2) 148-222 ohms green/white brown/green Fuel Injector 11.4-12.6 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 (6000/8000 Early Build Models) 12 DC Volts red/black (counterclockwise)

Servomotor (8000) 12 DC Volts red/brown (counterclockwise)

Voltage Regulator/Rectifier* 9-15 DC Volts red/blue black

(Secondary)

* Harness plugged in

NOTE: Lighting coil output is unregulated voltage.

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.

0.24-0.36 ohm 5040-7560 ohms

! WARNING

black/white high tension wire

black/red (clockwise)

brown/red (clockwise)

white/blue ground

black/red (counterclockwise) red/black (clockwise)

brown/red (counterclockwise) red/brown (clockwise)

Drive System

Specifications

Model Altitude

ZR 6000 0-5000 85/275 lb 68g 155/220 lb 48S ERI2 0627-107 42-4600 81-8200 22T 48T 90

ZR 6000 R XC 0-5000 120/265 lb 66g 155/222 lb 38S ER/40S ER 0627-107 42-4600 81-8200 23T 40T 86

ZR 8000 0-5000 180/240 lb 74g 180/240 lb 64-49-.20 ERI2 0627-111 38-4000 81-8200 21T 41T 86

Norseman X 8000 0-5000 120/265 lb 74g 155/220 lb 48S ERI2 0627-111 38-4000 81-8200 19T 50T 90

Riot 6000 0-5000 85/275 lb 68g 155/220 lb 48S ERI2 0627-107 42-4600 81-8200 22T 48T 90

Riot 8000 0-5000 120/265 lb 74g 180/240 lb 56-49-.20 ERI3 0627-111 42-4600 81-8200 22T 48T 90

Riot X 8000 0-5000 120/265 lb 74g 180/240 lb 56-49-.20 ERI3 0627-111 42-4600 81-8200 21T 49T 90

M 6000 6-8000 120/265 lb 62g 180/240 lb 48S ERI2 0627-107 42-4600 81-8200 19T 50T 96

M 8000 6-8000 85/255 lb 70g 180/240 lb 48S ERI2 0627-111 33-3400 81-8200 19T 50T 96

Drive Clutch

Spring

Cam

Arm

Drive Clutch/Driven

Driven Clutch Spring

Torque

Bracket

Drive

Belt

Engagement

RPM

Peak RPM

Top

Gear

Bottom

Gear

Drive System Components

Chain

Pitch

Clutch-Related

Specifications

ALIGNMENT BAR

Offset P/N Center-to-Center Offset Float

0744-097 12.20” 1.500” None

A list of drive system components that are available through the Arctic Cat Service Parts Department can be found in the Quick Reference Guide. This information will be useful when doing any fine-tuning on the drive system.

Chain Case Performance Calibrations

Drive

Sprocket

7 Tooth

(3.0” pitch)

8 Tooth

(2.86” pitch)

8 Tooth

(3.0” pitch)

9 Tooth

(2.52” pitch)

Gear

Ratio

Top Btm

19 50 0.380 90 52 54 56 58 59 61 63 64 66 68 69 71 73 74 76 21 49 0.429 90 59 61 63 65 67 69 71 73 74 76 78 80 82 84 86 20 46 0.435 88 60 62 64 66 68 70 72 74 75 77 79 81 83 85 87 23 51 0.451 92 62 64 66 68 70 72 74 76 78 80 82 84 86 88 90 22 48 0.458 90 63 65 67 69 71 73 76 78 80 82 84 86 88 90 92 24 50 0.480 92 66 68 71 73 75 77 79 81 83 85 88 90 92 94 96 21 41 0.512 86 71 73 75 78 80 82 84 87 89 91 93 96 98 100 103 21 38 0.553 84 76 79 81 84 86 89 91 93 96 98 101 103 106 108 111 20 35 0.571 82 79 81 84 87 89 92 94 97 99 102 104 107 109 112 114 23 40 0.575 86 79 82 84 87 90 92 95 97 100 102 105 108 110 113 115 22 37 0.595 84 82 85 87 90 93 95 98 101 103 106 109 111 114 116 119 24 39 0.615 86 85 88 90 93 96 99 101 104 107 110 112 115 118 121 123 23 36 0.639 84 88 91 94 97 100 102 105 108 111 114 117 119 122 125 128 24 35 0.686 84 95 98 101 104 107 110 113 116 119 122 125 128 131 134 137 19 50 0.380 90 57 59 61 63 65 66 68 70 72 74 76 77 79 81 83 21 49 0.429 90 64 67 69 71 73 75 77 79 81 83 85 87 89 91 94 20 46 0.435 88 65 67 70 72 74 76 78 80 82 84 86 89 91 93 95 23 51 0.451 92 68 70 72 74 77 79 81 83 85 88 90 92 94 96 98 22 48 0.458 90 69 71 73 76 78 80 82 84 87 89 91 93 96 98 100 24 50 0.480 92 72 75 77 79 81 84 86 88 91 93 95 98 100 102 105 21 41 0.512 86 77 80 82 84 87 89 92 94 97 99 102 104 107 109 112 21 38 0.553 84 83 86 88 91 94 97 99 102 105 107 110 113 115 118 121 20 35 0.571 82 86 89 91 94 97 100 103 105 108 111 114 116 119 122 125 23 40 0.575 86 86 89 92 95 98 100 103 106 109 112 114 117 120 123 126 22 37 0.595 84 89 92 95 98 101 104 107 110 112 115 118 121 124 127 130 24 39 0.615 86 93 96 99 101 104 107 110 113 116 119 122 125 128 131 134 23 36 0.639 84 96 99 102 105 108 112 115 118 121 124 127 130 133 136 139 24 35 0.686 84 103 106 110 113 116 120 123 126 130 133 136 140 143 146 150 19 50 0.380 90 60 62 64 66 68 70 72 73 75 77 79 81 83 85 87 21 49 0.429 90 68 70 72 74 76 79 81 83 85 87 89 92 94 96 98 20 46 0.435 88 69 71 73 75 77 80 82 84 86 88 91 93 95 97 100 23 51 0.451 92 71 73 76 78 80 83 85 87 89 92 94 96 99 101 103 22 48 0.458 90 72 75 77 79 82 84 86 89 91 93 96 98 100 103 105 24 50 0.480 92 76 78 81 83 85 88 90 93 95 98 100 103 105 107 110 21 41 0.512 86 81 83 86 89 91 94 96 99 102 104 107 109 112 115 117 21 38 0.553 84 87 90 93 96 98 101 104 107 110 112 115 118 121 124 127 20 35 0.571 82 90 93 96 99 102 105 108 110 113 116 119 122 125 128 131 23 40 0.575 86 91 94 97 99 102 105 108 111 114 117 120 123 126 129 132 22 37 0.595 84 94 97 100 103 106 109 112 115 118 121 124 127 130 133 136 24 39 0.615 86 97 100 103 106 110 113 116 119 122 125 128 132 135 138 141 23 36 0.639 84 101 104 107 111 114 117 120 124 127 130 133 137 140 143 146 24 35 0.686 84 108 112 115 119 122 126 129 133 136 140 143 147 150 154 157 19 50 0.380 90 57 58 60 62 64 66 68 69 71 73 75 77 79 80 82 21 49 0.429 90 64 66 68 70 72 74 76 78 80 82 84 87 89 91 93 20 46 0.435 88 65 67 69 71 73 75 77 79 82 84 86 88 90 92 94 23 51 0.451 92 67 69 72 74 76 78 80 82 85 87 89 91 93 95 98 22 48 0.458 90 68 71 73 75 77 79 82 84 86 88 90 93 95 97 99 24 50 0.480 92 72 74 76 78 81 83 85 88 90 92 95 97 99 102 104 21 41 0.512 86 76 79 81 84 86 89 91 94 96 99 101 103 106 108 111 21 38 0.553 84 82 85 88 90 93 96 98 101 104 106 109 112 114 117 120 20 35 0.571 82 85 88 91 93 96 99 102 104 107 110 113 115 118 121 124 23 40 0.575 86 86 88 91 94 97 100 102 105 108 111 113 116 119 122 124 22 37 0.595 84 89 91 94 97 100 103 106 109 112 114 117 120 123 126 129 24 39 0.615 86 92 95 98 101 104 107 109 112 115 118 121 124 127 130 133 23 36 0.639 84 95 98 101 104 108 111 114 117 120 123 126 129 132 135 138 24 35 0.686 84 102 106 109 112 115 119 122 125 129 132 135 138 142 145 148

Ratio Chain Engine RPM

6200 6400 6600 6800 7000 7200 7400 7600 7800 8000 8200 8400 8600 8800 9000

Vehicle Speed (mph)

Drive

Sprocket

9 Tooth

(2.86” pitch)

9 Tooth

(3.0” pitch)

10 Tooth

(2.52” pitch)

8 Tooth

(3.5” pitch)

Gear

Ratio

Top Btm

19 50 0.380 90 64 66 68 71 73 75 77 79 81 83 85 87 89 91 93 21 49 0.429 90 73 75 77 80 82 84 87 89 91 94 96 98 101 103 105 20 46 0.435 88 74 76 78 81 83 85 88 90 93 95 97 100 102 104 107 23 51 0.451 92 76 79 81 84 86 89 91 94 96 98 101 103 106 108 111 22 48 0.458 90 78 80 83 85 88 90 93 95 98 100 103 105 108 110 113 24 50 0.480 92 81 84 86 89 92 94 97 100 102 105 107 110 113 115 118 21 41 0.512 86 87 89 92 95 98 101 103 106 109 112 115 117 120 123 126 21 38 0.553 84 93 97 100 103 106 109 112 115 118 121 124 127 130 133 136 20 35 0.571 82 97 100 103 106 109 112 115 118 122 125 128 131 134 137 140 23 40 0.575 86 97 100 104 107 110 113 116 119 122 126 129 132 135 138 141 22 37 0.595 84 101 104 107 110 114 117 120 123 127 130 133 136 140 143 146 24 39 0.615 86 104 107 111 114 118 121 124 128 131 134 138 141 144 148 151 23 36 0.639 84 108 112 115 119 122 126 129 132 136 139 143 146 150 153 157 24 35 0.686 84 116 120 123 127 131 135 138 142 146 150 153 157 161 165 168 19 50 0.380 88 67 70 72 74 76 78 80 83 85 87 89 91 94 96 98 21 49 0.429 90 76 79 81 83 86 88 91 93 96 98 101 103 105 108 110 20 46 0.435 88 77 80 82 85 87 90 92 95 97 100 102 105 107 110 112 23 51 0.451 92 80 83 85 88 90 93 96 98 101 103 106 108 111 114 116 22 48 0.458 90 81 84 87 89 92 94 97 100 102 105 108 110 113 115 118 24 50 0.480 92 85 88 91 93 96 99 102 104 107 110 113 115 118 121 124 21 41 0.512 86 91 94 97 100 103 106 108 111 114 117 120 123 126 129 132 21 38 0.553 84 98 101 104 108 111 114 117 120 123 127 130 133 136 139 142 20 35 0.571 82 101 105 108 111 114 118 121 124 128 131 134 137 141 144 147 23 40 0.575 86 102 105 109 112 115 118 122 125 128 132 135 138 142 145 148 22 37 0.595 84 106 109 112 116 119 123 126 129 133 136 140 143 146 150 153 24 39 0.615 86 109 113 116 120 123 127 130 134 137 141 144 148 151 155 159 23 36 0.639 84 113 117 121 124 128 132 135 139 143 146 150 154 157 161 165 24 35 0.686 84 122 126 130 133 137 141 145 149 153 157 161 165 169 173 177 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 19 50 0.380 90 60 62 64 66 68 70 72 73 75 77 79 81 83 85 87 21 49 0.429 90 68 70 72 74 76 79 81 83 85 87 89 92 94 96 98 20 46 0.435 88 69 71 73 75 77 80 82 84 86 88 91 93 95 97 100 23 51 0.451 92 71 73 76 78 80 83 85 87 89 92 94 96 99 101 103 22 48 0.458 90 72 75 77 79 82 84 86 89 91 93 96 98 100 103 105 24 50 0.480 92 76 78 81 83 85 88 90 93 95 98 100 103 105 107 110 21 41 0.512 86 81 83 86 89 91 94 96 99 102 104 107 109 112 115 117 21 38 0.553 84 87 90 93 96 98 101 104 107 110 112 115 118 121 124 127 20 35 0.571 82 90 93 96 99 102 105 108 110 113 116 119 122 125 128 131 23 40 0.575 86 91 94 97 99 102 105 108 111 114 117 120 123 126 129 132 22 37 0.595 84 94 97 100 103 106 109 112 115 118 121 124 127 130 133 136 24 39 0.615 86 97 100 103 106 110 113 116 119 122 125 128 132 135 138 141 23 36 0.639 84 101 104 107 111 114 117 120 124 127 130 133 137 140 143 146 24 35 0.686 84 108 112 115 119 122 126 129 133 136 140 143 147 150 154 157

Ratio Chain Engine RPM

6200 6400 6600 6800 7000 7200 7400 7600 7800 8000 8200 8400 8600 8800 9000

Vehicle Speed (mph)

Track Specifications

Torque Conversions

Model Length Lug Height

ZR 129”/137” 1.25” Riot 146” 1.35”/1.6” Riot X 146” 2.0” M Alpha One 154”/165” Norseman X 153” 2.25”

3.0”

NOTE: The track tension on all models should be

20 lb @ 2 inches.

IFP Shock Specifications

Below is a list of IFP shock absorbers used on the front and rear suspensions of Arctic Cat snowmobiles. If replacing a shock absorber, always select a shock absorber with the same length, both collapsed and extended.

SKI

Model

ZR Sno Pro/Riot 12.59” 18.38” 5.79” 7.63” Norseman X 11.30” 17.16” 5.85” 7.67” M 10.83” 16.32” 5.48” 6.90”

Model

ZR/Riot 8.54” 12.50” 3.59” 4.50” Norseman X 8.54” 12.48” 3.93” 5.51” M 8.55” 12.48” 3.94” 5.55”

Model

ZR/Riot 9.89” 13.98” 4.09” 5.70” Norseman X 10.83” 16.00” 5.16” 7.08” M 11.31” 16.99” 5.69” 7.28”

Collapsed

Length

FRONT ARM

Collapsed

Length

REAR ARM

Collapsed

Length

Extended

Length

Extended

Length

Extended

Length

Stroke

Piston

Depth

Piston

Depth

Piston

Depth

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

Torque Specifications

NOTE: Torque specifications have the following tol-

erances:

Torque (ft-lb) Tolerance

0-15 ±20%

16-39 ±15%

40+ ±10%

Item Secured to

DRIVE SYSTEM

Drive Clutch Engine 51 Drive Clutch Cover Movable Sheave 120 in.-lb Ring Gear/Damper* Drive Clutch 22 Spider Stationary Sheave 450 Spider Jam Nut Stationary Sheave 80 Cam Arm Lock Nut Cam Arm Screw 50 in.-lb Driven Clutch Driven Shaft 60 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 Brakeline Caliper 25 Brakeline Master Cylinder 25 Brake Caliper Shield Cover 96 in.-lb

Torque

ft-lb

Item Secured to

Torque

ft-lb

STEERING

Ski Spindle 35 Ski Wear Bar 15 Ski Ski Handle 54 in.-lb Handlebar Adjuster Block 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 20 Steering Post Chassis 55 Steering Tie Rod Steering Arm 20 Tie Rod Spindle Arm 32 Steering Support Spar 20 Steering Arm Chassis 8

FRONT SUSPENSION

ZR/Riot

A-Arm (Upper) Chassis 9 A-Arm (Lower) Chassis (Front) 65 A-Arm (Lower) Chassis (Rear) 45 A-Arm (Upper) Spindle 20 A-Arm (Lower) Spindle 45 Shock Absorber A-Arm 32 Shock Absorber Chassis 32 Sway Bar Link A-Arm/Sway Bar Link 23 Sway Bar Mounting Bracket Chassis** 9

Riot X/M

A-Arm (Upper) Chassis 9 A-Arm (Lower) Chassis (Front) 65 A-Arm (Lower) Chassis (Rear) 45 A-Arm (Upper) Spindle 20 A-Arm (Lower) Spindle 45 Shock Absorber A-Arm 24 Shock Absorber Chassis 24

Norseman X

A-Arm (Upper) Chassis 23 A-Arm (Lower) Chassis (Front) 65 A-Arm (Lower) Chassis (Rear) 45 A-Arm (Upper) Spindle 45 A-Arm (Lower) Spindle 45 Shock Absorber A-Arm 32 Shock Absorber Chassis 32 Sway Bar Link A-Arm/Sway Bar Link 23 Sway Bar Mounting Bracket Chassis** 9

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

Item Secured to

Torque

ft-lb

REAR SUSPENSION

137”/146”

Wear Strip Rail 50 in.-lb End Cap Rail 80 in.-lb Coupler Block Axle** Rail 40 Front Arm** Rail 52 Front Slider Axle** Tunnel 41 Front Shock Rail 45 Front Shock Front Arm 40 Limiter Strap Front Arm 72 in.-lb Limiter Strap Limiter Strap 72 in.-lb Offset Arm Idler Arm 20 Idler Arm** Rear Arm 55 Rear Wheel Axle** Rail 35 Rear Arm Rail 45 Rear Shock Front Arm/Idler Arm 30 Rear Arm Offset Arm 45 Spring Slide Rail 20 Offset Arm** Tunnel 45

Alpha One 154”/165”

Wear Strip Rail 50 in.-lb Idler Wheel Rail/Shaft 13 Front Arm Rail 52 Front Shock Front Arm 24 Front Shock Rail 45 Rear Arm Rail 13 Rear Arm Idler Arm 24 Track Guide Rear Arm 24 in.-lb Rear Axle Rail 24 Rear Shock Idler Arm 24 Rear Shock Rear Shock Pivot 24 Rear Shock Link Rear Shock Pivot 24 Rear Shock Link Idler Arm 24 Limiter Strap Front Arm 72 in.-lb Limiter Strap Rail 15 Shock Limiter Pad Rail 24 in.-lb

Norseman X

Wear Strip Rail 50 in.-lb End Cap Rail 80 in.-lb Mounting Block Rail 12 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 Rear Wheel Axle Rail 34 Skid Frame** Tunnel 55 Front Shock Front Arm 40 Front Shock Rail 50 Rail Support Rail 20 Limiter Strap Front Arm 72 in.-lb Limiter Strap Rail Support 72 in.-lb

** w/Blue Loctite #243

Steering and Body

This section has been organized into sub-sections for servicing steering and body components; however, some components may vary from model to model. The technician should use discretion and sound judgment when removing and installing components.

NOTE: Whenever a part is worn excessively,

cracked, or damaged in any way, replacement is necessary.

SPECIAL TOOLS

A number of special tools must be available to the technician when servicing the steering and body systems.

Description p/n

Handlebar Stand 5639-152

Steering Post Stand 5639-946

NOTE: Special tools are available from the Arctic

Cat Service Parts Department.

Steering Post

(ZR/Riot/Norseman X)

SNO-763

6. Remove the nut (A) securing the bottom of the existing steering post to the steering stop bracket; then remove the nut (B) securing the steering tie rod assembly to the steering post. Discard both nuts.

REMOVING

1. Rotate the two quarter turns to the vertical position; then pull the top of the side panel out and up and off the skid plate.

2. Remove the Torx screw securing the front of the hood to the chassis; then loosen the two quarter turns securing the hood.

0752-484

3. Disconnect the hood harness and remove the hood.

4. Disconnect the exhaust temperature sensor from the main harness; then remove all springs securing the expansion chamber. Remove the expansion chamber.

5. Remove the push rivets securing the right-side steering boot to the chassis. This allows access to the two nuts securing the bottom of the steering post.

SNO-2221A

7. Remove the cap screws and handlebar caps securing the handlebar to the top of the handlebar riser; then remove the two nuts securing the top of steering post to the chassis. Account for both steering post blocks and retaining plate.

SNO-357

8. Carefully remove the steering post from the snowmobile.

INSTALLING

1. Install steering post into position and secure to the steering stop bracket with a new M10 nut. Be sure to

align the steering post ball joint alignment tab with the steering stop bracket. Tighten to 43 ft-lb.

SNO-2218

2. Secure the tie rod assembly to the steering post using a new M10 nut. Be sure to align the tie rod ball joint alignment tab with the steering post. Tighten to 35 ft-lb.

SNO-2219

3. Secure the right-side steering boot to the chassis using the existing push rivets.

SNO-357

6. Install the expansion chamber using the existing springs; then connect the exhaust temperature sensor to the main harness.

7. Position the hood onto the snowmobile and connect the hood harness connector.

8. Secure the hood with the six Torx-head screws and tighten securely.

9. Install the access panels onto the lower console; then close the access panels.

10. Install three cable ties to secure the handlebar harness to the riser block.

NOTE: Do not secure the brakeline hose with the

lower cable tie.



NOTE: Make sure when securing the harness or hoses

to the riser that all cable tie locks are directed inward.

SNO-763

4. Secure the top of the steering post to the steering support using the existing retaining plate and nuts. Tighten to 96 in.-lb.

5. Install the handlebar riser and handlebar to the top of the steering post and secure using the existing caps and screws. Tighten evenly to 20 ft-lb.

746-214A

CAUTION

With the handlebar secured and the cable installed, check maximum right/left turning capabilities to ensure that the throttle cables, brakeline hose, and harness wires are routed so they do not become pinched or stretched.

NOTE: After installing and adjusting the handlebar, ver-

ify that the throttle lever free-play is within specification.

Steering Post (Riot X)

REMOVING

1. Rotate the two quarter turns to the vertical position; then pull the top of the side panel out and up and off the skid plate.

2. Remove the Torx screw securing the front of the hood to the chassis; then loosen the two quarter turns securing the hood.

0752-484

3. Disconnect the hood harness and remove the hood.

SNO-2221A

7. Remove the Torx-head screw and nut securing the tie rod link to the secondary steering post; then remove the two machine screws and nuts securing the top of the secondary steering post to the chassis. Account for both steering post blocks and retaining plate.

4. Disconnect the exhaust temperature sensor from the main harness; then remove all springs securing the expansion chamber. Remove the expansion chamber.

5. Remove the push rivets securing the right-side steering boot to the chassis. This allows access to the two nuts securing the bottom of the steering post.

SNO-763

SNO-2226B

8. Carefully remove the secondary steering post from the snowmobile.

9. Remove and discard the cotter pin (C) and nyloc nut (B) securing the steering post to the lower steering support bracket. Account for a thrust washer (A).

SNO-2225A

10. Remove the two cap screws securing the existing steering support (C) to the front spar tubes (B); then remove the two cap screws securing the steering support to the side support tubes (A). Retain all cap screws and nuts.

SNO-2227A

11. Remove the two cap screws securing the rear portion of the steering support to the rear spar tubes.

XM212A

12. With the telescoping steering assembly removed from the snowmobile; press down on the adjusting block until the inner snap ring is exposed. Remove the snap ring.

SNO-740A

INSPECTING

1. Inspect all welded areas for cracks or deterioration.

2. Inspect the steering post and steering-post retaining plate for cracks, bends, or wear.

3. Inspect the adjuster caps and mounting block for cracks or wear.

INSTALLING

1. Insert the telescoping steering post into the steering support along with two bushings; then secure the steering post using the existing retaining ring.

SNO-739A

13. Remove the retaining ring securing the bottom side of the steering post; then remove the post from the steering support. Account for two bearings.

SNO-740A

NOTE: Verify the bushings are properly oriented

(the seam should be centered front to back).

2. Install the adjusting block onto the steering post and secure using the existing snap ring.

SNO-739A

3. Install the steering post assembly onto the front and rear spar tubes and into the thrust washer (A) and the lower steering post support. Secure with a new nyloc nut (B) and a new cotter pin (C). Tighten to 20 ft-lb and spread the cotter pin to secure.

SNO-2225A

4. Secure the steering support to the front and rear spar tubes using the existing cap screws. Tighten to 25 ft-lb.

5. Install the secondary steering post into position and secure to the steering stop bracket with a new M10 nut. Be sure to align the steering post ball joint

alignment tab with the steering stop bracket.

Tighten to 43 ft-lb.

SNO-763

8. Secure the top of the steering post to the steering support using the existing retaining plate and new nuts (A). Tighten to 96 in.-lb.

SNO-2218

6. Secure the tie rod assembly to the steering post using a new M10 nut. Be sure to align the tie rod ball joint alignment tab with the steering post. Tighten to 35 ft-lb.

SNO-2226A

9. Connect the tie rod (B) from the adjustable steering post to the secondary steering post using the machine screw and nut. Tighten to 20 ft-lb.

10. Install the expansion chamber using the existing springs; then connect the exhaust temperature sensor to the main harness.

11. Position the handlebar to the desired position; then secure using the existing cap and all eight screws. Tighten evenly to 20 ft-lb.

0752-485

12. Install the console; then install the gas tank and seat using the existing hardware.

SNO-2219

7. Secure the right-side steering boot to the chassis using the existing push rivets.

13. Install the hood and both access panels.

14. Secure the front right of the handlebar pad to the steering post using a push pin (A); then secure the left side using a push mount cable tie (B) along with the wiring harness.

XM590

CAUTION

NOTE: After installing and adjusting the handle-

bar, verify that the throttle lever free-play is within specification.

Steering Post (M)

REMOVING

1. Rotate the two quarter turns to the vertical position; then pull the top of the side panel out and slide the panel forward. Remove the panel.

2. Remove the Torx screw securing the front of the hood to the chassis; then loosen the two quarter turns securing the hood.

SNO-763

SNO-2221A

7. Remove the Torx-head screw and nut (B) securing the tie rod link to the secondary steering post; then remove the two machine screws (A) and nuts securing the top of the secondary steering post to the chassis. Account for both steering post blocks and retaining plate.

0752-484

3. Disconnect the hood harness and remove the hood.

4. Disconnect the exhaust temperature sensor from the main harness; then remove all springs securing the expansion chamber. Remove the expansion chamber.

5. Remove the push rivets securing the right-side steering boot to the chassis. This allows access to the two nuts securing the bottom of the steering post.

SNO-346A

8. Carefully remove the secondary steering post from the snowmobile.

9. Tie the recoil rope in a loose knot to prevent the rope from going into the recoil; then remove the recoil handle from the recoil rope.

10. Remove the eight machine screws and caps securing the handlebar and riser to the fixed steering post assembly.

0747-883

11. Remove and discard the cotter pin securing the fixed steering post; then remove and discard the lock nut but retain the thrust washer.

INSTALLING

1. Position steering post assembly over the spar tubes, both side supports and into the lower steering support; then secure the assembly using existing cap screws and nuts. Tighten cap screws to 23 ft-lb.

SNO-334

2. Secure the bottom of the steering post to the lower steering support using existing thrust washer and new nyloc nut. Tighten to 20 ft-lb. Install Cotter Pin into steering post and spread to secure.

SNO-333

12. Remove the cap screws securing the existing steering support (C) to the spar tubes (B); then remove the two cap screws securing the steering support to the side support tubes (A). Retain all cap screws but discard all nuts.

SNO-2218

INSPECTING

1. Inspect all welded areas for cracks or deterioration.

2. Inspect the steering post and steering-post retaining plate for cracks, bends, or wear.

3. Inspect the adjuster caps and mounting block for cracks or wear.

SNO-333

3. Install the secondary steering post into position and secure to the steering stop bracket with a new M10 nut. Be sure to align the steering post ball joint

alignment tab with the steering stop bracket.

Tighten to 43 ft-lb.

SNO-2218

4. Secure the tie rod assembly to the steering post using a new M10 nut. Be sure to align the tie rod ball joint alignment tab with the steering post. Tighten to 35 ft-lb.

SNO-2219

5. Secure the right-side steering boot to the chassis using the existing push rivets.

11. Position the handlebar to the desired position; then secure using the existing cap and all eight screws. Tighten evenly to 20 ft-lb.

0747-883

12. Install the hood and both access panels.

13. Install three cable ties to secure the handlebar harness to the riser block.

14. Secure the handlebar wires going to the main harness down the middle left side of the riser using two large cable ties.

SNO-763

6. Route the recoil rope behind the lower steering support and up through the new steering support and through the existing recoil handle. Tighten rope in a knot.

7. Secure the top of the secondary steering post to the steering support using the existing steering post blocks, machine screws and nuts. Tighten to 8 ft-lb.

8. Connect the tie rod from the secondary steering post to the fixed steering post using existing machine screw and new nyloc nut. Tighten to 20 ft-lb.

SNO-346

9. Connect the tie rod (B) from the adjustable steering post to the secondary steering post using the machine screw and nut. Tighten to 20 ft-lb.

XM594

15. With the handlebar turned fully to the right, secure the brake cable to the riser using a large cable tie; then install the handlebar pad making sure the wires are tucked under the pad. Secure to the front of the riser using a large cable tie.

XM595

10. Install the expansion chamber using the existing springs; then connect the exhaust temperature sensor to the main harness.

CAUTION



NOTE: After installing and adjusting the handlebar, verify that the throttle lever free-play is within specification.

Ski (ZR/Riot)

REMOVING

1. Elevate the front of the snowmobile and secure on a support stand.

2. Remove and discard the cotter pin; then remove the nut and cap screw securing the ski to the spindle.

NOTE: Note the orientation of the damper for

installation purposes.

3. Remove the ski. Account for the rubber damper and washers.

INSPECTING

1. Inspect the ski for cracks or deterioration.

2. Inspect the ski for abnormal bends or cracks.

3. Inspect the wear bar for wear.

4. Inspect all hardware and the spindle bushings for wear and damage.

5. Inspect the rubber damper for damage or wear.

INSTALLING

1. Slide a washer onto the cap screw used to secure the ski; then apply low-temperature grease to the shaft portion of the cap screw and spindle axle.

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.

ONS-171

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 regarding

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.

NOTE: Ensure that the cotter pin slot in the cap

screw is still horizontal with the ski.

5. Install a new cotter pin from the back side of the ski cap screw and spread the pin.

Ski (Norseman X)

REMOVING

1. Elevate the front of the snowmobile and secure on a support stand.

ONS-139

2. Remove and discard the cotter pin; then remove the nut and cap screw securing the ski to the spindle.

3. Remove the ski. Account for the rubber damper and washers.

INSPECTING

1. Inspect the ski for cracks or deterioration.

2. Inspect the ski for abnormal bends or cracks.

3. Inspect the wear bar for wear.

4. Inspect all hardware and the spindle bushings for wear and damage.

5. Inspect the rubber damper for damage or wear.

INSTALLING

NOTE: Before installing the skis, make sure the car-



bide of the split wear bar will be installed toward the inside of the ski when installed on the snowmobile.

1. Slide a washer onto the ski cap screw; then apply low-temperature grease to the cap screw shaft and spindle axle.

0748-981

2. Install the spindle axle into the spindle; then position the ski damper into the ski grooves making sure the grooved side of the damper is installed rearward.

3. Install the spacers and washers onto the spindle axle as follows:

INSPECTING

1. Inspect the ski for cracks or deterioration.

2. Inspect the ski for abnormal bends or cracks.

3. Inspect the wear bar for wear.

4. Inspect all hardware and the spindle bushings for wear and damage.

5. Inspect the rubber damper for damage or wear.

INSTALLING

1. Slide a washer onto the cap screw used to secure the ski; then apply low-temperature grease to the shaft portion of the cap screw and spindle axle.

2. Install the spindle axle and spacers 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.

Standard ski stance (one on each side of the spindle)

Minimum ski stance (both on the inside of the spindle)

Maximum ski stance (both on the outside of the spindle)

4. 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.

NOTE: Local laws and/or regulations as to maxi-

mum width of the ski stance may be applicable. Always comply with the maximum width laws and/or regulations when adjusting ski stance.

NOTE: Install the cap screw so the lock nut will be

located to the inside of the ski and the cotter pin slot in the cap screw will be horizontal with the ski.

5. Install the remaining washers and lock nut; then tighten the lock nut to 35 ft-lb. Ensure the cotter pin slot in the cap screw is still horizontal with the ski.

6. Install the cotter pin from the back side of the ski cap screw and spread the pin. Repeat for opposite ski.

Ski (Riot X/M)

0752-477

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: 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.

5. Install a new cotter pin from the back side of the ski cap screw and spread the pin.

Ski Wear Bar

REMOVING

1. Elevate the front of the snowmobile and secure on a support stand.

2. Remove and discard the cotter pin; then remove the nut and cap screw securing the ski to the spindle.

NOTE: Note the orientation of the damper for

installation purposes.

3. Remove the ski. Account for the rubber damper, axle, spacers and washers.

The ski wear bar is a replaceable bar attached to the underside of the ski. If the snowmobile is operated primarily in deep snow, ski wear bar wear will be minimal; however, if the snowmobile is operated on terrain where the snow cover is minimal, the ski wear bar will wear faster. Arctic Cat recommends that the ski wear bars be replaced if worn to 1/2 of original diameter.

REMOVING

1. Raise the front of the snowmobile and secure with a suitable stand.

2. Remove the lock nuts securing the wear bar to the ski; then remove the wear bar.

INSTALLING

1. Install the wear bar into the ski making sure it is fully seated using a rubber mallet.

2. Secure the wear bar with lock nuts. Tighten to 96 in.-lb.

Spindle (ZR/Riot)

NOTE: The weight of the snowmobile will allow the

ball joint to seat into the spindle before tightening the nut.

4. Place the tie rod with washer into position on the spindle arm. Secure with a new lock nut. Tighten to 32 ft-lb.

5. Install the ski using the existing hardware and new cotter pin. Tighten the cap screws to 35 ft-lb.

6. Turn the handlebar fully to the right and then to the left to verify the steering moves freely.

Spindle (Norseman X)

ONS-185

REMOVING

1. Position the front of the snowmobile on a safety stand; then remove the ski.

2. Remove the lock nut securing the tie rod to the spindle arm. Account for the washer on the top side.

3. Remove the shoulder screw and the tri-nut securing the upper A-arm to the spindle; then remove the lock nut securing the spindle to the lower A-arm. Using a rubber mallet, remove the spindle from the lower A-arm.

INSPECTING

1. Inspect the spindle for excessive wear, cracks, bends, or imperfections.

2. Inspect the A-arm bushings and axle area for wear.

3. Inspect the ski spindle axle and bearings for wear, damage, or loose fit. Replace the bearings as a set.



NOTE: Replacing the ski bolt bushings is difficult. The existing bushings will be damaged during removal. Be careful, however, not to damage the spindle when removing the bushings. Press the new bushings into the spindle.

INSTALLING

1. Install the lower A-arm into the spindle; then loosely secure with a new lock nut.

2. Position the upper A-arm end with the top of the spindle; then secure the A-arm end to the spindle using the existing shoulder screw and tri-nut. Tighten to 20 ft-lb.

3. Remove the snowmobile from the support stand. Tighten the lower A-arm nut to 45 ft-lb.

ONS-186

REMOVING

1. Position the front of the snowmobile on a safety stand; then remove the ski.

2. Remove the cap screws and lock nuts securing the shock absorber. Account for two axles.

3. Remove the lock nut securing the tie rod to the spindle arm. Account for the washer on the top side.

4. Remove the two lock nuts securing the spindle to the upper and lower A-arms; then using a rubber mallet, remove the arms from the spindle.

5. Remove the spindle.

INSPECTING

1. Inspect the spindle for excessive wear, cracks, bends, or imperfections.

2. Inspect the A-arm bushings and axle area for wear.

3. Inspect the ski spindle axle and bearings for wear, damage, or loose fit. Replace the bearings as a set.



INSTALLING

1. Place the shock absorber into position. Secure with the cap screws and new lock nuts. Tighten to 32 ft-lb.

2. Install the upper and lower A-arms into the spindle and loosely secure with new lock nuts; then remove the snowmobile from the support stand. Tighten both lock nuts to 45 ft-lb.

NOTE: The weight of the snowmobile will allow the

ball joints to seat into the spindle before tightening the nuts.

3. Place the tie rod with washer into position on the spindle arm. Secure with a new lock nut. Tighten to 32 ft-lb.

4. Install the ski.

5. Turn the handlebar fully to the right and then to the left to verify the steering moves freely.

Spindle (Riot X/M)

INSTALLING

1. Install the lower A-arm into the spindle and loosely secure using a new lock nut.

2. Loosely secure the upper A-arm ball joint to the spindle using the existing machine screw and the tri-nut. Raise the spindle so the upper A-arm is level; then tighten the screw securing the ball joint to the spindle to 20 ft-lb.

3. Install the shock and secure using the existing cap screws and lock nuts. Tighten to 24 ft-lb.

4. Remove the snowmobile from the support stand. Tighten lower A-arm lock nut to 45 ft-lb.

NOTE: The weight of the snowmobile will allow the

lower ball joint to seat into the spindle before tightening the nut.

5. Place the tie rod with washer into position on the spindle arm. Secure with a new lock nut. Tighten to 32 ft-lb.

6. Install the ski.

7. Turn the handlebar fully to the right and then to the left to verify the steering moves freely.

0749-480

REMOVING

1. Position the front of the snowmobile on a safety stand; then remove the ski.

2. Remove the two cap screws and nuts securing the shock to the chassis and to the lower A-arm.

3. Remove the lock nut securing the tie rod to the spindle arm. Account for the washer on the top side.

4. Remove the machine screw and tri-nut securing the upper A-arm ball joint to the spindle.

5. Remove the lock nut securing the spindle to the lower A-arm; then using a rubber mallet, remove the lower arm from the spindle.

INSPECTING

1. Inspect the spindle for excessive wear, cracks, bends, or imperfections.

2. Inspect the A-arm bushings and axle area for wear.

3. Inspect the ski spindle axle and bearings for wear, damage, or loose fit. Replace the bearings as a set.

Steering Tie Rod

NOTE: To access the steering arm, the steering tie

rods must be removed.

REMOVING

1. Remove both machine screws and nyloc nuts securing the steering tie rod ends to the steering arm. Discard both nuts.

SNO-349

2. Remove the nyloc nuts securing the steering tie rod ends to the spindle arms. Account for the washers and discard both nuts.



NOTE: Replacing the ski bushings is difficult. The existing bushings will be damaged during removal. Be careful, however, not to damage the spindle when removing the bushings. Press the new bushings into the spindle.

SNO-353

5. Remove the lock nut securing the steering tie rod to the steering post. Discard the nut.

SNO-351

NOTE: At this point if the technician’s objective is

to remove the steering arm, the reinforcement bracket will need to be removed by drilling out the appropriate rivets.

6. Remove all Torx-head screws securing the front skid plate to the chassis; then remove the cap screw and nut securing the steering arm to the chassis. Account for two washers and two bushings.

ONS-189

ONS-270

3. Slide the steering tie rod out of the steering boot and out of the snowmobile.

4. Remove the screw and lock nut securing the steering tie rod end to the steering arm. Discard the nut.

SNO-829A

INSPECTING

1. Inspect the ball joints for damaged threads or wear.

2. Inspect the tie rod for damage, unusual bends, or wear.

INSTALLING

1. Secure steering arm into position and secure using the existing cap screw and flat washers, and new nut. Tighten to 96 in.-lb.

SNO-350

SNO-829A

2. Place the steering tie rod into position on the steering post. Secure with a new nyloc nut. Tighten to 35 ft-lb.

SNO-351

NOTE: Make sure the tie rod tab is fully seated into

the steering post and threads of the ball joint are above the nut when tightened correctly.

3. Place the tie rod end into position on the steering tie rod bracket. Secure with a new nyloc nut. Tighten to 20 ft-lb.

ONS-189

SNO-350

4. Slide the steering tie rod through the steering boot and into the snowmobile; then place the steering tie rod into the spindle arm with the washer. Secure with a new nyloc nut. Tighten to 32 ft-lb.

SNO-353

ONS-270

5. Secure the steering tie rod to the steering tie rod bracket with the screw and new nyloc nut. Tighten to 20 ft-lb.

SNO-349

Ski Alignment

CHECKING

NOTE: Track tension and alignment must be prop-



erly 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 range of 1/16-1/4 in.

1. Raise the front end of snowmobile just high enough to keep the skis from contacting the floor.

2. Turn the handlebar to the straight-ahead position. Visually inspect the handlebar for being centered and in the straight-ahead position.

3. With the handlebar in the straight-ahead position, secure the handlebar to prevent the alignment from becoming disturbed during the remainder of the alignment procedure.

NOTE: Track tension and alignment must be prop-

erly adjusted prior to placing the straightedge against the outside edge of the track.

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 wear bar bolts in two places: 7-8 in. in front of the spindle and 7-8 in. behind the spindle. Record the measurements taken for the right side.

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

729-887B

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 wear bar bolts in two places: approximately 7-8 in. in front of the spindle and 7-8 in. behind the spindle. Record the measurements taken for the left side.

! WARNING

The measurement from the front and rear wear bar bolts 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 wear bar bolt measurement to the straightedge must not exceed the measurement from the rear wear bar bolt to the straightedge (ski toed-out) by more than 5/32 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.

NOTE: The rivets securing the steering boots will

have to be removed in order to adjust the inner tie rod ends.

1. Secure the steering tie rod in the centered position.

2. Loosen both spindle tie rod jam nuts on the same side as the ski to be aligned.

3. Using a wrench on the spindle tie rod “flats,” rotate the spindle tie rod until recommended specification is attained.

729-887A

4. Apply blue Loctite #243 to each jam nut thread area; then tighten the jam nuts against the spindle tie rod.

NOTE: Repeat this procedure on each side (if neces-

sary) until ski toe-out is within specification.

! WARNING

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

VERIFYING

1. With the handlebar in the straight-ahead position, verify ski alignment by measuring across from the outside edge of the left-side wear bar bolts to the outside edge of the right-side wear bar bolts (without using the straightedge) in two places: approximately 7-8 in. in front of the spindle and 7-8 in. behind the spindle.

2. The measurement from in front of the spindle to the outer edge of the wear bar bolts (without using the straightedge) must not exceed the rear measurement by more than 1/16-1/4 in. toe-out.

0734-408

! 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.

A-Arms (ZR/Riot)

REMOVING

1. Elevate the front of the snowmobile and secure using a suitable support stand.

2. Remove the Torx-head screws securing the front skid plate to the chassis; then remove the front skid plate.

3. Remove the eight push rivets securing the steering boot to the chassis; then slide the boot away from the chassis.

ONS-190

6. Remove the cap screw and lock nut securing the sway bar link to the lower arm.

SNO-764

7. Remove the two cap screws and nyloc nuts securing the lower arm to the chassis; then slide the boot from the arm and remove the arm.

8. Remove the two cap screws and lock nuts securing the upper arm to the chassis.

INSPECTING

1. Inspect the arm welded areas for cracks or any signs of deterioration.

SNO-763

4. Remove the ski shock.

5. Remove the shoulder screw and tri-nut securing the upper A-arm, and the lower lock nut securing the lower A-arm. Using a rubber mallet, remove the lower arm from the spindle. Discard the lower lock nut.

2. Inspect the bearings and axles for wear or damage.

3. Inspect the arm tubing for signs of twisting or bending.

4. Inspect mounting location of the chassis for cracks or wear.

INSTALLING

1. Place the upper arm into position on the chassis and secure with the cap screws and new nyloc nuts. Tighten to 9 ft-lb.

+ 146 hidden pages

Arctic Cat ZR /Riot /M/Norseman X 6000, ZR /Riot /M/Norseman X 8000 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual