Arctic Cat ZR/XF/M 4000, ZR/XF/M 6000, ZR/XF/M 8000 Service Manual

SERVICE MANUAL

ZR/XF/M

4000/6000/8000

www.arcticcat.com

FOREWORD

This Arctic Cat Service Manual contains service and maintenance information for certain Model Year 2015 Arctic Cat Snowmobiles (see cover). 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.

All materials and specifications are subject to change without notice.

Keep this manual accessible in the shop area for reference.

Product Service and Warranty Department Arctic Cat Inc.

General Information...................................................... 2

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

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

Engine Break-In ................................................................ 2

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 ..................................... 5

Engine Specifications........................................................ 7

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

Arctic Power Valve (APV) System Specifications ............. 8

Electrical Specifications .................................................... 9

Drive System Specifications............................................ 10

Drive Clutch/Driven Clutch-Related Specifications ......... 10

Drive System Components ............................................. 10

Chain Case Performance Calibrations.............................11

Track Specifications ........................................................ 13

Suspension Specifications .............................................. 13

Torque Conversions ........................................................ 13

Torque Specifications...................................................... 14

Steering and Body ...................................................... 15

Steering Post (ZR/XF)..................................................... 15

Ski ................................................................................... 19

Ski Wear Bar................................................................... 20

Spindle ............................................................................ 20

Steering Tie Rod ............................................................. 21

Ski Alignment .................................................................. 22

A-Arms ............................................................................ 24

Ski Shock Absorber ........................................................ 25

Sway Bar (ZR/XF)........................................................... 25

Front Bumper .................................................................. 26

Seat Assembly (ZR/XF/M STD)...................................... 26

Seat Assembly (M Sno Pro/HCR/LTD) ........................... 26

Taillight/Brakelight Assembly .......................................... 27

Rear Bumper/Snowflap................................................... 27

Windshield/Console/Headlight ........................................ 28

Headlight Bulb................................................................. 29

Adjusting Headlight Aim ................................................. 29

Engine .......................................................................... 30

Engine Removing/Installing - 4000 ................................. 30

Assembly Schematic - 4000 ........................................... 34

Engine Removing/Installing - 6000 ................................. 36

Assembly Schematic - 6000 ........................................... 42

Engine Removing/Installing - 8000 ................................. 44

Assembly Schematic - 8000 ........................................... 50

Engine Servicing - 4000.................................................. 52

Engine Servicing - 6000.................................................. 67

Engine Servicing - 8000.................................................. 81

Troubleshooting Engine .................................................. 98

Engine-Related Items ............................................... 100

Water Pump - 4000....................................................... 100

Water Pump - 6000....................................................... 103

Water Pump - 8000....................................................... 106

Pressure Testing Engine ............................................... 109

Liquid Cooling System .................................................. 109

Cooling System Schematic ............................................110

Recoil Starter .................................................................111

Arctic Power Valve (APV) System..................................112

Exhaust Controlled Timing (ECT) System .....................116

Fuel Systems ............................................................. 118

EFI System .................................................................... 118

Individual Components ..................................................118

Self-Diagnostic System/Codes (4000)........................... 122

Self-Diagnostic System/Codes (6000)........................... 122

Self-Diagnostic System/Codes (8000)........................... 122

Fuel Pressure Regulator................................................123

Throttle Body Assembly.................................................123

Throttle Cable ................................................................124

Fuel Filter (6000) ...........................................................124

Fuel Pump .....................................................................125

Troubleshooting.............................................................127

Oil-Injection Pump (4000/8000) .....................................128

Electric Oil Pump (6000)................................................129

Gas Tank .......................................................................130

Electrical Systems ....................................................132

Ignition System ..............................................................132

Throttle Position Sensor ................................................132

Electrical Resistance Tests............................................134

Testing Electric Oil Pump (6000) ...................................136

Testing Voltage Regulator..............................................136

Chassis Control Unit (CCU)/Codes (4000) .................... 137

Testing Oil Level Sensor................................................137

Testing Fuel Gauge Sender...........................................138

Emergency Stop Switch.................................................138

Starter Relay Solenoid ...................................................138

Fuse...............................................................................139

Ignition Switch ...............................................................139

Starter Motor ..................................................................139

Troubleshooting Electric Start........................................143

Ignition Timing ...............................................................143

Brakelight Switch ...........................................................144

Headlight Dimmer Switch ..............................................144

Testing Handlebar Warmer Elements ...........................145

Testing Thumb Warmer Element ...................................145

Testing Handlebar Warmer/Thumb Warmer Switch.......145

Testing Speedometer Sensor ........................................146

Testing Shift Switch .......................................................146

Testing Servomotor/Potentiometer ................................146

Troubleshooting Servomotor .........................................148

Voltage/Resistance Chart - Air Temperature (8000) ...... 150

Voltage/Resistance Chart - Air Temperature (6000) ...... 150

Voltage/Resistance Chart - Coolant Temperature .........151

Drive Train/Track/Brake Systems ............................152

Drive Belt .......................................................................152

Drive Clutch ...................................................................153

Driven Clutch .................................................................154

Drive Clutch/Driven Clutch ............................................159

Drive Train .....................................................................160

Drive Sprockets .............................................................166

Track Tension ................................................................168

Track Alignment.............................................................168

Brake System ................................................................169

Brake Lever/Master Cylinder Assembly ........................174

Troubleshooting Hydraulic Brake System......................175

Troubleshooting Track ...................................................176

Troubleshooting Drive Clutch/Driven Clutch..................177

Suspension................................................................ 178

Suspension Setup Basics..............................................178

Servicing Suspension ....................................................183

Wiring Diagrams........................................................ 198

General Information

NOTE: General specifications for each 2015 Arctic

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

NOTE: Some illustrations and photographs used in

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

Snowmobile

Identification

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 either Arctic Cat C-Tec2 for the 6000 or Arctic Cat APV Synthetic 2-Cycle Oil for the 4000/8000. These oils are specially formulated to be used either as an injection oil or as a pre-mix oil (for break-in) and meets all of the lubrication requirements of the Arctic Cat snowmobile engine.

CAUTION

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

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 6000/8000

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.

4000

The recommended gasoline to use is 87 octane regular unleaded. In many areas, oxygenates are added to the gasoline. Oxygenated gasolines containing up to 10% ethanol are acceptable gasolines.

When using ethanol blended gasoline, it is not necessary to add a gasoline antifreeze since ethanol will prevent the accumulation of moisture in the fuel system.

Engine Break-In

4000/8000

The Arctic Cat engine (when new or rebuilt) requires a short break-in period before the engine is subjected to heavy load conditions. Arctic Cat requires that the first tankful of fuel be premixed at a 100:1 ratio in all oilinjection models.

CAUTION

DO NOT exceed the one (1) tankful limitation of a 100:1 gas/oil break-in mixture. Continuous use of a gas/oil mixture could cause spark plug fouling and excessive carbon buildup.

During the break-in period, a maximum of 1/2 throttle is recommended; however, brief full-throttle accelerations and variations in driving speeds contribute to good engine break-in.

6000

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

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

Some customers may choose to pre-mix the first tank and if this is the case, a pre-mix ratio of 100:1 is acceptable. A pre-mix ratio of 100:1 combined with the richer fuel/ oil delivered from the electronic oil pump during breakin may cause additional smoke at start up and idle.

CAUTION

DO NOT exceed the one (1) tankful limitation of a 100:1 gas/oil break-in mixture. Continuous use of a gas/oil mixture could cause spark plug fouling and excessive carbon buildup.

During the break-in period, a maximum of 1/2 throttle (with varying throttle positions) is recommended; however, brief full-throttle accelerations and variations in driving speeds contribute to good engine break-in.

Drive Belt Break-In

Drive belts require a break-in period of approximately 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 Drive Train/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.

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.

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.

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.

The normal setting for front ski suspension is as little spring pre-load tension as possible for powder snow riding allowing the skis to float across the snow with the least amount of resistance. Trail riding will require more spring tension to carry the varying load more effectively. Many different settings and spring tensions to consider exist when adjusting for riding style and snow conditions.

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.

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.

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.

M/XF High Country

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 pre-load may be used to decrease the chance of the front end “bottoming out.” With a stiffer spring pre-load, 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 pre-load 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 pre-load 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 the Sno Pro 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 Front Shock (Ski) Rear Arm Shock

XF/ZR Sno Pro 60 psi N/A

XF High Country/M Sno Pro/M LTD

XF Cross Country

XF Cross-Tour N/A 145 psi

XF Cross-Tour OS

ZR RR

90 psi 145 psi

75 psi 145 psi

80 psi (Main

Chamber) 200 psi

(Evol Chamber)

N/A

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 0.750” up to 2.6” 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 85 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 intakes until the engine exhaust starts to smoke heavily or until the engine starts to drop in RPM. Turn engine off. Install the intake boots.

CAUTION

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

4. Plug the exhaust system outlet with a clean cloth.

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 petroleum-

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

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 an all-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.

CAUTION

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

Preparation After

Storage

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.

NOTE: After prolonged storage on the 8000, Arctic

Cat recommends one tankful of 100:1 gas/oil mixture be used in conjunction with the oil-injection system to ensure proper lubrication.

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 an all-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.

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.

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

DRIVE BELT DEFLECTION

— Drive belt deflection is very important to the snowmobile. Even if it is checked and is correct when the snowmobile is set up, it does change (more so during the break-in period). This is because the rubber engine mounts and the rubber snubber on the torque link will all take a “set” during the first 100 miles allowing the distance between the drive clutch and driven clutch to shorten. When this happens, the snowmobile will appear to have too long of a drive belt. To add to this, the drive belt wears and stretches. This sometimes leads to a reduction in low-end performance, and if not corrected, can cause premature drive belt wear.

After the break-in period, drive belt deflection should be checked according to the instructions given in the Drive Train/Track/Brake Systems section of this manual.

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 driven train 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.x

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 belt deflection - drive clutch/driven

clutch alignment

 Adjust track tension and alignment  Check throttle cable tension  Check oil-injection pump adjustment (4000/8000)  Check engine idle  Check coolant level  Check chain case lubricant level  Check lights (high/low beam, brakelight)  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

4000

ITEM

Engine Model Number AX50L9 Displacement 499 cc Bore x Stroke 71 x 63 Compression Ratio 6.38:1 Cooling System Liquid Ignition Timing (Engine Warm) 13° @ 2000 RPM

Spark Plug (NGK) BR9EYA Spark Plug Gap 0.028-0.031” Piston Skirt/Cylinder Clearance 0.0031-0.0041” Piston Ring End Gap 0.008-0.016” Cylinder Trueness Limit 0.004” Piston Pin Diameter 0.8659-0.8661” Piston Pin Bore Diameter 0.8661-0.8665” Connecting Rod Small End Bore 1.0631-1.0634” Connecting Rod Radial Play 0.0001-0.0008” Crankshaft Runout (t.i.r.) 0.002” Crankshaft End Play 0.002-0.004” Reed Stopper Height 0.315”

0.040”

ITEM

Piston Pin Bore Diameter 0.8661-0.8665” Connecting Rod Small End Bore 1.0631-1.0634” Connecting Rod Radial Play 0.0001-0.0008” Crankshaft Runout (t.i.r.) 0.002” Crankshaft End Play 0.002-0.004” Reed Stopper Height 0.512”

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 is still supported on the outer bearings using V blocks.

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

Spark Plug (NGK) BPR9ES Spark Plug Gap 0.028-0.031” Piston Skirt/Cylinder Clearance 0.0041-0.0053” Piston Ring End Gap 0.012-0.0196” Cylinder Trueness Limit 0.004” Piston Pin Diameter 0.8659-0.8661” Piston Pin Bore Diameter 0.8661-0.8665” Connecting Rod Small End Bore 1.0631-1.0634” Connecting Rod Radial Play 0.0001-0.0008” Crankshaft Runout (t.i.r.) 0.002” Crankshaft End Play 0.002-0.004” Reed Stopper Height 0.512”

RPM 0.072”

8000

ITEM

Engine Model Number AB80L4 Displacement 794 cc Bore x Stroke 85 x 70 Compression Ratio 6.62:1 Cooling System Liquid Ignition Timing (Engine Warm) 16.5° @ 2000

Spark Plug (NGK) BR9EYA Spark Plug Gap 0.028-0.031” Piston Skirt/Cylinder Clearance 0.0041-0.0053” Piston Ring End Gap 0.012-0.0196” Cylinder Trueness Limit 0.004” Piston Pin Diameter 0.8659-0.8661”

RPM 0.072”

728-144A

Model

4000 4.515” 2.618” 4.465” 1.062” D

8000 4.751” 2.519” 4.645” 1.181” D

± 0.006B± 0.006C± 0.015

Runout D

and F Point

± 0.002

0.196”F 0.196”

NOTE: Measure in from the shaft end the specified

amount when checking runout at points D and F. When checking runout in the center, place indicator on center of bearing as shown at point E. Maximum runout at any of the three measuring points is ± 0.002”.

6000

NOTE: The crankshaft must be supported on the

inner bearings using V blocks.

0747-810

Arctic Power Valve (APV)

System Specifications

VALVE POSITION CYCLE RPM

Mid-Open Full-Open

APV CABLE LENGTH

6000/8000 36.5 mm ± 1 mm

67-7500 (Low/High Alt) 77-8500 (Low/High Alt)

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 (float end down) terminal terminal Ignition Switch Less than 1 ohm (key in OFF position) terminal terminal

4000 (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 80.8-121 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 Chassis Control Unit* 10-15 DC Volts red/blue (low power)

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 12 DC Volts red/black (counterclockwise)

Voltage Regulator/Rectifier* 9-14.5 DC Volts red/blue black

Ignition Coil (Primary)

Charge Coil (1) 8.8-13.2 ohms black/red green/red Charge Coil (2) 8.8-13.2 ohms brown/white green/red Lighting Coil 0.08-0.12 ohm yellow yellow Ignition Timing Sensor (1) 148-222 ohms green/white brown/green Ignition Timing Sensor (2) 148-222 ohms green/white brown/green Fuel Injector 10-14 ohms terminal terminal Injection Coil 15.2-22.8 ohms blue/white blue/white Fuel Pump Coil 1.52-2.28 ohms orange orange Servomotor 12 DC Volts red/black (counterclockwise)

Voltage Regulator/Rectifier* 10-15 DC Volts

(Secondary)

* Harness plugged in

The main harness connectors must be unplugged (except on the primary coil and regulator/rectifier tests), the spark plugs removed and grounded, and by pulling the recoil starter rope briskly.

0.24-0.36 ohm 6800-10,200 ohms

6000 (Normally Open Ignition)

0.24-0.36 ohm 5040-7560 ohms

8000 (Normally Open Ignition)

0.24-0.36 ohm 5040-7560 ohms

11-14 AC Volts

orange/black high tension wire

red/black (high power)

black/white high tension wire

black/red (clockwise)

black/white high tension wire

black/red (clockwise)

red/blue yellow

orange/red ground

black (low power) black (high power)

white/blue ground

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

white/blue ground

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

brown brown

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.

Drive System

Specifications

Model Altitude

ZR 4000 LXR

ZR 4000 RR 0-5000 Yellow/White 63g Black/White 44°/42° 0627-083 36-4000 81-8200 21T 49T 90

XF 6000 C ross Tour 0-5000 Green 64g Black/Blue 42°/40° 0627-083 42-4600 81-8200 21T 49T 90

ZR 6000/XF 6000 CC 0-5000 Green 64g Black/Blue 42°/40° 0627-083 42-4600 81-8200 22T 48T 90

ZR 8000

M 6000

M 8000

XF 8000 LXR/Cross Tour/ Cross Country/Sno Pro

XF 8000 High Country

XF 6000 High Country

0-5000 Yellow/White 63g Black/Blue 42°/40° 0627-083 36-4000 81-8200 21T 49T 90

0-5000 Green 73.5g Black/Blue 44°/40° 0627-083 36-4000 81-8200 21T 41T 86

6-9000 Yellow/White 60g Brown 36° 0627-083 42-4600 81-8200 19T 50T 90

6-9000 Yellow/White 68g Black/Blue 36° 0627-084 42-4600 81-8200 19T 50T 90

0-3000 Green 73.5g Black/Blue 42°/40° 0627-083 36-4000 81-8200 22T 48T 90

6-9000 Yellow/White 68g Black/Blue 36° 0627-084 42-4600 81-8200 19T 50T 90

6-9000 Yellow/White 60g Brown 36° 0627-083 42-4600 81-8200 19T 50T 90

Drive

Clutch

Spring

Cam Arm

Driven Clutch Spring

Tor que

Bracket

Drive

Belt

Engagement

RPM

Peak RPM

Top

Gear

Bottom

Gear

Chain

Pitch

Drive Clutch/Driven

Clutch-Related

Specifications

ALIGNMENT BAR

OFFSET P/N CENTER-TO-CENTER OFFSET FLOAT

0644-428 12.10” 1.485” None

Drive System

Components

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)

Gear

Ratio

Top B tm

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 11 0 113 115 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 11 2 11 5 118 121 123 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 11 3 11 6 119 122 125 128 131 134 137 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 11 5 118 121 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 11 2 114 117 120 123 126 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 11 3 11 6 119 122 125 128 131 134 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 11 0 113 116 120 123 126 130 133 136 140 143 146 150 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 11 0 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 11 2 11 5 118 121 124 127 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 11 4 11 7 120 123 126 129 132 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 11 3 11 6 119 122 125 128 132 135 138 141 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

Vehicle Speed (mph)

8800 9000

Drive

Sprocket

9 Tooth

(2.52"

pitch)

9 Tooth

(2.86"

pitch)

9 Tooth

(3.0" pitch)

10 Tooth

(2.52"

pitch)

Gear

Ratio

Top B tm

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 11 3 11 5 118 121 124 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 11 2 114 117 120 123 126 129 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 11 4 11 7 120 123 126 129 132 135 138 24 35 0.686 84 102 106 109 112 115 119 122 125 129 132 135 138 142 145 148 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 11 0 113 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 11 2 115 117 120 123 126 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 11 2 115 118 122 125 128 131 134 137 140 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 11 0 112 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 11 0 113 115 11 8 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 11 2 116 119 123 126 129 133 136 140 143 146 150 153 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 11 0 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 11 2 115 118 120 123 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 11 3 11 6 119 122 125 128 131 134 137 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 11 4 11 8 121 124 127 130 133 137 140 143 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 11 3 116 119 123 126 130 133 137 140 143 147 150 154 24 35 0.686 84 114 117 121 125 128 132 136 139 143 147 150 154 158 161 165

Ratio Chain Engine RPM

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

Vehicle Speed (mph)

Track Specifications

Tra ck Tension

Model Length

ZR LXR ZR Sno Pro/El Tigre M Standard M Sno Pro/HCR/LTD 153"/162" 2.6" 2-2.25” 2-2.25" XF Standard 137" 1.25" 2-2.25” 2-2.25" XF Cross Country 141" 1.6" 2-2.25” 2-2.25” XF Cross Tour XF HC XF Sno Pro

129" 1" 2-2.25” 2-2.25" 129" 1.25" 2-2.25” 2-2.25"

153"/162" 2.25" 2-2.25" 2-2.25"

141” 1.352” 2-2.25” 2-2.25” 141" 2.25" 2-2.25” 2-2.25" 141" 1.5" 2-2.25” 2-2.25"

Lug

Height

Setup

After

Break-in

NOTE: The track tension on 129” and 137” models

should be @ 20 lb. The track tension on 141”, 153”, and 162” models should be at 12-15 lb.

Suspension

Specifications

IFP SHOCK ABSORBERS

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/XF 12.59” 18.38” 5.79” 7.00” M

Model

ZR XF M Standard 8.10” 11.25” 3.15” 5.01”

Model

ZR LXR 10.08” 14.37” 4.48” 0.90” XF LXR M Standard

Collapsed

Length

11.32” 17.18” 6.09” 7.00”

FRONT ARM

Collapsed

Length

8.16” 11.76” 3.71” 5.14”

8.56” 12.50” 3.93” 3.97”

REAR ARM

Collapsed

Length

10.32” 15.12” 4.79” 0.89”

11.10” 16.00” 5.10” 5.01”

Extended

Length

Extended

Length

Extended

Length

Stroke

Piston Depth

SPRINGS

SKI SHOCK

Model

ZR/XF

Model

ZR/XF 0.312” 8.25” 90/250 lb/

M 8000

Model

M Std/XF

REAR ARM (See Illustration Below)

Model

Wire

Diameter

0.312” 13.00” 95 lb/in. 10 NO

Wire

Diameter

0.295” 7.75” 110 lb/in. 7.0 NO

Wire

Diameter

0.375” 13.00” 175 lb/in. 10.5 NO

Wire

Diameter

.405" 90° 3.65" 6.75 18.50”

Free

Length

FRONT ARM

Free

Length

REAR ARM

Free

Length

Angle

(A)

(B)

Rate Coils Ta b

Rate Coils Tab

in.

Rate Coils Tab

Coil

Width

(C)

9.8 NO

Length

Coils

(D)

Torque Conversions

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

0730-218

Torque Specifications

NOTE: Torque specifications have the following tol-

erances:

Torque (ft-lb) Toler ance

0-15 ±20%

16-39 ±15%

40+ ±10%

DRIVE SYSTEM

Item Secured to

Drive Clutch*** Engine 51 Drive Clutch Cover Movable Sheave 120 in.-lb Ring Gear* Drive Clutch 22 Cam Arm Pin Lock Nut Cam Arm Pin Cam Arm Set Screw Cam Arm Driven Clutch** Driven Shaft Movable Sheave* Torque Bracket 27 Chain Case (Cap Screw) Chassis 96 in.-lb Chain Case (Torx-Head Screw) Chassis Chain Case Cover Chain Case Brake Caliper Chassis Outside Caliper Housing Inside Caliper Housing Brakeline Caliper 25 Brakeline Master Cylinder 25 Brake Caliper Shield Cover

STEERING/FRONT SUSPENSION/CHASSIS

Item Secured to

Ski Spindle 35 Ski Wearbar Ski Ski Handle Handlebar Adjuster Block (Stan-

dard) Handlebar Adjuster (Sno Pro) Post Steering Support Mounting Block Steering Tie Rod Link Steering Post Steering Tie Rod Link Steering Arm 20 Steering Post Cap Riser Block 15 Steering Post Chassis Steering Tie Rod Steering Arm Tie Rod Spindle Arm Steering Support Spar Steering Support Upper Console 30 in.-lb Steering Arm Chassis 8 A-Arm (Upper) (M) Chassis A-Arm (Upper) Chassis A-Arm (Lower) Chassis (Front) A-Arm (Lower) Chassis (Rear) 45 A-Arm Spindle 45 Shock Absorber (ZR, XF) Spindle 32 Shock Absorber (ZR, XF) Chassis Shock Absorber (M) Spindle Shock Absorber (M) Chassis Sway Bar Link A-Arm/Sway Bar Link 23 Sway Bar Mounting Bracket Chassis 9

* w/Green Loctite #609

Post

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

Tor que

ft-lb

19 in.-lb

12 12 25 25

96 in.-lb

Torq ue

ft-lb

54 in.-lb

55 20 32 20

9 23 65

32 24 24

REAR SUSPENSION

Item Secured to

Tor que

ft-lb

M/XF 141”

Wear Strip Rail 50 in.-lb End Cap (XF) Rail 80 in.-lb End Cap/Rail Cap Wheel (M) Rail Mounting Block Rail Rear Wheel Axle Rail Rear Arm Rail 20 Idler Arm Rear Arm 20 Front Shock Rail 50 Rear Shock Front Arm/Idler Arm Rail Support Rail Front Shock Front Arm Limiter Strap Rail Support 72 in.-lb Rail Rail Brace 12 Rear Tri Hub Wheel Rear Tri Hub Wheel 50 in.-lb Rear Shock Link Front Arm/Idler Arm Front Arm Rail Skid Frame Tunnel

20 12 34

24 20 24

24 52 45

ZR/XF 137”

Wear Strip Rail End Cap Rail Mounting Block Rail Rear Arm Rail Rear Arm Idler Arm 55 Spring Slide Rail 20 Front Arm Rail Coupler Block Axle Rail Limiter Strap Rail Support Rear Tri Hub Wheel Rear Tri Hub Wheel 50 in.-lb Rear Wheel Axle Rail 34 Skid Frame Tunnel 55** Front Shock Rail Rail Support Rail Limiter Strap Front Arm

50 in.-lb 80 in.-lb

12 45

52 40

72 in.-lb

50 20

72 in.-lb

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

Shock Spring Removal Tool 0644-057

Handlebar Stand 5639-152

Steering Post Stand 5639-946

NOTE: Special tools are available from the Arctic

Cat Service Parts Department.

Steering Post (ZR/XF)

REMOVING

1. Remove the hairpin clip from the pin located at the front of the access panel. Move the panel up and off the pin; then swing the panel all the way out and unhinge the panel from the lower console.

2. Remove all six torx-head screws securing the hood.

XM134A

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.

SNO-2221A

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

0746-793

3. Locate the hood harness connector (located under the center vent and between the intake vents) and unplug the connector; then move the hood slightly forward 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-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.

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

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

7. Secure the hood with the six torx-head screws and tighten securely.

8. Install the access panels onto the lower console; then close the access panels and secure with the clip.

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.

Steering Post (XF HC/M)

REMOVING

1. Remove the hairpin clip from the pin located at the front of the access panel; then unscrew the thumb screw. Move the panel up and off the pin; then swing the panel all the way out and unhinge the panel from the lower console.

0746-800

2. Remove all six torx-head screws securing the hood.

XM134A

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

SNO-357

0746-793

3. Locate the hood harness connector (located under the center vent between the intake vents) and unplug the connector; then move the hood slightly forward 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.

XM134A

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.

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.

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).

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-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.

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-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-2225A

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

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-740A

NOTE: Verify the bushings are properly oriented

(the seam should be centered front to back).

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-2219

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

0747-617

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

13. Install the hood and both access panels.

Ski

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.

XM134A

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-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 15 ft-lb.

NOTE: Note the orientation of the damper for instal-

lation 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 all-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.

NOTE: On the ZR 4000 RR, there are two spacers

installed onto the spindle axle.

0746-796

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

REMOVING

0746-797

NOTE: The ski damper must be positioned in the ski

so it is directly under the spindle.

3. With the cap screw hole of the ski centered with the spindle axle, slide the cap screw with washer through the outside of the ski and spindle assemblies.

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

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

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

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

4. Install the remaining washer and lock nut; then tighten the lock nut to 35 ft-lb.

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

screw is still horizontal with the ski (see illustration); then proceed to step 5.

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

Ski Wear Bar

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.

0747-904

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

2. Remove the cap screw and lock nut securing the shock absorber to the spindle.

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.

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

0747-904

1. Place the shock absorber into position on the spindle. Secure with the cap screw and lock nut. Tighten to 32 ft-lb for ZR and XF models. Tighten to 24 ft-lb for M models.

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

NOTE: The weight of the snowmobile will allow the

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

SNO-353

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.

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.

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-350

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.

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.

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.

SNO-225A

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, flat washers, and nut. Tighten to 96 in.-lb.

SNO-225A

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

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

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-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.

SNO-349

Ski Alignment

CHECKING



NOTE: Track tension and alignment must be properly adjusted prior to checking or adjusting ski alignment. Ski alignment must be performed on a flat, level surface. Ski toe-out must fall within the 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.

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.

0734-408

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.

! 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.

729-887A

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.

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 nec-

essary) 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.

5. Remove the two lock nuts securing the spindle to the A-arms; then using a rubber mallet, remove the arms from the spindle. Discard the nuts.

SNO-354

6. On the ZR/XF, remove the cap screw and lock nut securing the sway bar link to the lower arm. Discard the nut.

A-Arms

REMOVING

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

2. Remove the push rivets securing the steering boot to the chassis; then slide the boot away from the snowmobile.

XM134A

3. Remove the torx-head screws securing the front skid plate to the chassis; then remove the front skid plate.

4. Remove the ski shock absorber.

XM135

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.

SNO-226A

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

INSPECTING

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

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 23 ft-lb.

2. Slide the lower arm into the boot; then place the arm into position on the chassis. Secure with the cap screws and new nyloc nuts and tighten to 55 ft-lb (front) and 45 ft-lb (rear).

PC095A

3. On the ZR/XF, secure the sway bar link to the lower arm with the cap screw and new nyloc nut. Tighten to 23 ft-lb.

NOTE: Note the number of threads exposed

between the spring adjuster and shock housing for installing purposes.

3. Using the Shock Spring Removal Tool, remove the spring from the shock body by compressing the spring; then remove the spring retainer from the top of the spring. Inspect the shock absorber by quickly compressing and extending the shock plunger while firmly holding the shock body. Resistance must be felt in both directions.

CLEANING AND INSPECTING

1. Inspect the shock absorber seal area for signs of excessive oil leakage.

2. Inspect the shock absorber mounting eyelet, bushings, and sleeve for wear or damage.

3. Inspect the threaded shock sleeve for damage or wear. Clean the sleeve and apply a light coat of grease to the threads before installing.

INSTALLING

1. Using the shock spring tool, place the spring on the shock absorber and secure with the retainer.

2. Adjust the retainer nut (spring adjuster) (if applicable) until the specified amount of threads are exposed between the spring adjuster and the shock housing (noted in removing) as an initial setting.

XM135

4. Secure the A-arms to the spindle.

5. Install the ski shock absorber.

6. Place the front skid plate into position; then secure with the torx-head screws.

Ski Shock Absorber

REMOVING

1. Position the front of the snowmobile on a safety stand taking all pressure off the skis.

2. Remove the cap screws securing the shock absorber to the chassis and spindle; then remove the shock absorber. Account for all mounting hardware.

3. Install the bushings, sleeves, and spacers into each shock end; then place the shock absorber into position and secure with the cap screws and lock nuts. Tighten the lock nuts to 32 ft-lb.

Sway Bar (ZR/XF)

REMOVING

1. Remove the nyloc nuts and cap screws securing the sway bar link to the lower A-arm and the sway bar.

XM135

2. Remove the torx-head screws securing the sway bar mounting brackets; then pull the sway bar out of the snowmobile.

INSPECTING

1. Inspect the sway bar for any signs of twisting, fatigue, or wear.

2. Inspect the sway bar arms for cracks or damage.

3. Inspect the links, bushings, bushing retainers, and hardware for damage or wear.

INSTALLING

1. Place the sway bar into the sway bar mounting brackets; then install the sway bar into the snowmobile. Secure with the torx-head screws and tighten to 96 in.-lb.

2. Secure the sway bar links to the sway bar and lower Aarm with the cap screws and new nyloc nuts. Tighten to 23 ft-lb.

SNO-227A

Front Bumper

REMOVING/INSTALLING

1. Remove all torx-head screws securing the front bumper; then remove the bumper.

2. With the bumper in position, install all torx-head screws. Tighten securely.

Seat Assembly (ZR/XF/M STD)

REMOVING/INSTALLING SEAT

NOTE: On LXR/LTD models, be sure to disconnect

the seat heater harness before removing the seat.

1. Remove the cap screw securing the rear of the seat; then remove the seat.

NOTE: On LXR/LTD models prior to lowering and

securing the seat, connect the seat heater harness connector.

REMOVING CUSHION

1. Remove the seat assembly.

2. Using a sharp tool, pry out all staples securing the seat cover to the plastic seat base.

3. From beneath the seat foam, remove the seat wire from the two elastic loops; then remove the cover from the seat base and seat foam.

INSTALLING CUSHION

1. Position the cover over the seat foam and seat base; then pull the two elastic loops through the slots in the seat foam and secure with the seat wire. Check to make sure it is positioned straight.

2. Fold the rear edge of the cushion down and around the plastic base. Using a staple gun and 1/4 in. staples, staple the rear flap of the cushion to the plastic base in the same areas as the original staples were located. Position staples 1 in. apart.

3. Fold the sides of the cushion down around the bottom edge of the plastic seat base. Position the staples in the same area as the original staples were located.

SNO-261A

2. Route the front tab on the seat through the seat-base hold-down bracket; then install the seat and secure using the cap screw.

NOTE: Note the cushion fit. If any wrinkles are

noted, remove by pulling the cushion material in the appropriate direction before securing with staples.

4. Fold the front cushion material back and onto the plastic seat base. Check for wrinkles and secure with staples and two screws.

5. Install the seat assembly.

Seat Assembly

(M Sno Pro/HCR/LTD)

REMOVING/INSTALLING

1. Remove both torx-head screws from the side of the seat; then remove the four tabs from the seat base from the lower console. Pull back and remove the seat cover and foam.

0747-530

2. Position the seat foam into the seat cover by first aligning the front of the foam with the front of the seat base/cover (A); then wrap the rear of the seat base/cover over the rear of the seat foam (B). Cover the sides of the seat foam with the seat base/cover and secure using the velcro strap.

Taillight/Brakelight

Assembly

1. Remove the two machine screws securing the taillight to the taillight support; then disconnect the taillight harness connector.

SNO-511

2. Connect the taillight harness connector; then secure the taillight to the taillight support with the two screws. Tighten to 48 in.-lb.

SNO-1203A

3. Remove the backing from the installation bag (p/n 1655-841); then adhere it to the gas tank making sure the bag covers the velcro on the gas tank.

SNO-1206

4. Slide the rear of the seat cover with foam over the rear of the gas tank; then slide the four tabs into the four holes in the lower console and secure to the tunnel using two self-tapping screws. Do not over tighten.

NOTE: To ease the installation of the seat cover,

carefully pry up the rear of the gas tank so the seat cover can easily slide around the rear of the gas tank.

Rear Bumper/Snowflap

REMOVING BUMPER

1. Remove and retain only the two machine screws securing the rear of the skid frame assembly.

2. Place cardboard or a suitable substitute on the floor to protect the snowmobile from being scratched; then install Steering Post Stand for the standard steering models or Handlebar Stand for the adjustable steering models into the lower holes in the handlebar riser (from the leftside) and tip the snowmobile onto its left side.

CAUTION

The stand must be used when tipping the snowmobile onto the right side. Failure to use the stand may damage the oil fill neck.

3. Swing the skid frame assembly away from the chassis; then using a 3/16-in. drill bit, remove all rivets securing the left-side of the bumper; then repeat for opposite side.

4. Remove and retain the two machine screws and nuts securing the front of the existing bumper to the chassis.

5. Remove the two rivets securing the snowflap to the bumper. Remove the bumper.

INSTALLING BUMPER

1. Align the holes in the bumper with the existing holes in the tunnel; then using new rivets, secure rear bumper to the tunnel; then secure the snowflap to the rear bumper using new rivets.

2. Secure the front of the bumper to the chassis using the existing machine screws and nuts. Tighten securely.

3. Install skid frame assembly using two existing machine screws. Tighten securely.

REMOVING SNOWFLAP

1. Drill out the four rivets securing the snowflap to the tunnel; then remove the torx-head screw and nut.

2. Remove the snowflap.

INSTALLING SNOWFLAP

1. Secure the snowflap to the tunnel with the torx-head screw and nut.

2. Add the appropriate rivets to secure the snowflap to the tunnel.

Windshield/Console/

Headlight

REMOVING

1. Remove and retain all machine screws securing the hood; then disconnect the console harness and carefully remove the hood assembly.

2. Remove the four screws securing the windshield to the console; then remove the windshield.

3. Remove the four screws securing the windshield brace to the console. Disconnect the gauge; then remove the windshield brace assembly.

PC108

PC106A

7. Loosen the two side headlight assembly screws (A); then remove the two front headlight assembly screws (B).

PC104A

4. Disconnect the electrical accessory wires and ignition switch.

5. Remove the two screws securing the rear of the console to the hood.

6. Lift the front of the console from the headlight assembly; then disengage the side console tabs and remove the console.

PC107A

8. Remove the headlight assembly.

INSTALLING

1. With the headlight assembly in position, install the front headlight assembly screws. Engage the side headlight screws in the slots and tighten until snug.

2. Engage the side console tabs on the headlight assembly; then place the front of the console over the headlight assembly and press down until it snaps in place.

3. Install the two screws securing the rear of the console to the hood. Tighten only until snug.

4. Place the windshield brace assembly into position and secure to the console with the four screws. Tighten until snug.

5. Connect the gauge; then connect the electrical accessory wires and the ignition switch.

+ 181 hidden pages

Arctic Cat ZR/XF/M 4000, ZR/XF/M 6000, ZR/XF/M 8000 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

FOREWORD

TABLE OF CONTENTS

General Information

RECOMMENDED OIL

Recommended Gasoline

4000

Engine Break-In

4000/8000

6000

Drive Belt Break-In

Genuine Parts

CLUTCHING

ENGINE

SUSPENSION

M/XF High Country

TRACK

Preparation For Storage

Engine Specifications

4000

6000

8000

6000

Electrical Specifications

Track Specifications

IFP SHOCK ABSORBERS

SPRINGS

Torque Conversions

Torque Specifications

Steering and Body

SPECIAL TOOLS

Steering Post (ZR/XF)

REMOVING

INSTALLING

Steering Post (XF HC/M)

REMOVING

INSPECTING

INSTALLING

REMOVING

INSPECTING

INSTALLING

REMOVING

INSTALLING

Spindle

REMOVING

Ski Wear Bar

INSPECTING

INSTALLING

Steering Tie Rod

REMOVING

INSPECTING

INSTALLING

Ski Alignment

CHECKING

ADJUSTING

VERIFYING

A-Arms

REMOVING

INSPECTING

INSTALLING

CLEANING AND INSPECTING

INSTALLING

Ski Shock Absorber

REMOVING

Sway Bar (ZR/XF)

REMOVING

INSPECTING

INSTALLING

Front Bumper

REMOVING/INSTALLING

Seat Assembly (ZR/XF/M STD)

REMOVING/INSTALLING SEAT

REMOVING CUSHION

INSTALLING CUSHION

REMOVING/INSTALLING

Rear Bumper/Snowflap

REMOVING BUMPER