Arctic Cat ZR-XF-M 9000 2017 Service Manual

2017

SERVICE MANUAL

www.arcticcat.com

ZR/XF/M 9000

TABLE OF CONTENTS

General Information/Foreword ..................................................	2
Snowmobile Identification .....................................................	2
Recommended Gasoline and Oil ..........................................	2
Engine Break-In ....................................................................	2
Drive Belt Break-In ................................................................	3
Genuine Parts .......................................................................	3
Preparation For Storage........................................................	3
Preparation After Storage .....................................................	4
After Break-In Checkup/Checklist .........................................	4
Engine Specifications............................................................	5
Electrical Specifications ........................................................	5
Drive Clutch/Driven Clutch-Related Specifications ...............	6
Drive System Components ...................................................	6
Drive System Specifications..................................................	6
Chain Case Performance Calibrations ..................................	7
Track Specifications ..............................................................	9
Torque Conversions ..............................................................	9
Torque Specifications ..........................................................	10
Steering and Body ....................................................................	11
Steering Post.......................................................................	11
Ski (ZR/XF) .........................................................................	12
Ski (XF HC/M).....................................................................	13
Ski Wear Bar .......................................................................	13
Spindle (ZR/XF) ..................................................................	14
Spindle (XF HC/M)..............................................................	14
Steering Tie Rod .................................................................	15
Ski Alignment ......................................................................	16
A-Arms (ZR/XF) ..................................................................	17
A-Arms (XF HC/M)..............................................................	18
Ski Shock Absorber.............................................................	20
Sway Bar.............................................................................	20
Front Bumper ......................................................................	20
Seat Assembly ....................................................................	21
Seat Cushion ......................................................................	21
Taillight/Brakelight Assembly...............................................	21
Rear Bumper/Snowflap .......................................................	22
Windshield/Console/ Headlight ...........................................	22
Adjusting Headlight Aim .....................................................	23
Engine ........................................................................................	24
Engine Removing/ Installing................................................	24
Engine Servicing .................................................................	33
Assembly Schematic - 9000................................................	55
Troubleshooting Engine.......................................................	57
Engine-Related Items ...............................................................	59
Water Pump ........................................................................	59
Pressure Testing Engine .....................................................	61
Checking Compression .......................................................	61
Changing Engine Oil/Filter ..................................................	61
Testing Oil Pressure............................................................	62
Liquid Cooling System ........................................................	62
Cooling System Schematic .................................................	63
Heat Exchanger ..................................................................	63
Air Silencer..........................................................................	65
Turbocharger/Intercooler.....................................................	65

Fuel Systems.............................................................................	70
Fuel System ........................................................................	70
Individual Components........................................................	70
Self-Diagnostic System/Codes............................................	72
Throttle Body Assembly ......................................................	73
Throttle Cable......................................................................	75
Fuel Pump...........................................................................	75
Gas Tank .............................................................................	77
Troubleshooting...................................................................	78
Electrical Systems ....................................................................	79
Ignition System....................................................................	79
Throttle Position Sensor......................................................	79
Electrical Resistance Tests .................................................	80
Voltage Regulator Tests ......................................................	81
Testing Fuel Gauge Sender ................................................	81
Emergency Stop Switch ......................................................	82
Starter Relay Solenoid ........................................................	82
Fuse ....................................................................................	82
Ignition Switch.....................................................................	82
Starter Motor .......................................................................	83
Troubleshooting Electric Start .............................................	84
Magneto ..............................................................................	84
Brakelight Switch.................................................................	86
Headlight Dimmer Switch....................................................	86
Testing Handlebar Warmer Elements ................................	86
Testing Thumb Warmer Element.........................................	87
Testing Handlebar Warmer/Thumb Warmer Switch............	87
Testing Passenger Handwarmer Switch .............................	87
Testing Passenger Handwarmer Elements .........................	88
Testing Seat Heater Switches .............................................	88
Testing Speedometer Sensor..............................................	88
Testing Gear Position Switch...............................................	89
Testing Shift Switch .............................................................	89
Testing Shift Actuator ..........................................................	89
Voltage/Resistance Chart - Air Temperature.......................	90
Voltage/Resistance Chart - Coolant Temperature...............	90
Drive Train/Track/Brake Systems ............................................	91
Drive Belt.............................................................................	91
Drive Clutch.........................................................................	91
Driven Clutch.......................................................................	93
Drive Clutch/Driven Clutch ..................................................	95
Drive Train ...........................................................................	96
Drive Sprockets.................................................................	100
Track Tension ....................................................................	102
Track Alignment.................................................................	103
Brake System (Hydraulic) .................................................	104
Brake Lever/Master Cylinder Assembly ............................	109
Troubleshooting Drive Clutch/Driven Clutch......................	111
Troubleshooting Track .......................................................	112
Troubleshooting Hydraulic Brake System..........................	112
Suspension..............................................................................	113
Suspension Setup Basics .................................................	113
Servicing Suspension .......................................................	118
FOX Air Shocks.................................................................	128

1

General

Information/Foreword

NOTE: General specifications for each 2017 Arctic

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

NOTE: Some illustrations and photographs used in this manual are used for clarity purposes only and are not designed to depict actual conditions.

This Arctic Cat Service Manual contains service and maintenance information for certain Model Year 2017 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 snowmo- bile-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.

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 or on top of the tunnel. 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.

CAUTION

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

RECOMMENDED GASOLINE

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

NOTE: If a situation arises in which 91 octane gasoline 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. Do not use gasolines containing methanol.

RECOMMENDED OIL

The recommended oil to use is Synthetic C-TEC4 Oil (p/n 6639-529 - gal.).

After the engine break-in period, the engine oil and oil filter should be changed every 2500 miles or before prolonged storage.

Engine Break-In

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

This engine does not require any pre-mixed fuel during the break-in period.

There is never a more important period in the life of the engine than the first 500 km (300 miles).

2

Since the engine is brand new, do not put an excessive load on it for the first 500 km (300 miles). The various parts in the engine wear and polish themselves to the correct operating clearances. During this period, prolonged full throttle operation or any condition that might result in engine overheating must be avoided.

Operating your snowmobile for the first time: Start the engine and let it idle for 5 minutes.

0-160 km (0–100 miles): Avoid prolonged operation above 6000 RPM.

160-500 km (100–300 miles): Avoid prolonged operation above 8000 RPM.

500 km (300 miles) and beyond: The snowmobile can now be operated normally.

NOTE: After 800 km (500 miles) of operation, the engine oil must be changed and the oil filter replaced. If any engine trouble should occur during the engine break-in period, immediately have an Arctic Cat dealer check the snowmobile.

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 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.

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.Change the engine oil and replace the air filter if necessary.

4.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.

5.With the snowmobile level, check the lubricant level in the chain case. If low, add chain lube through the fill hole (when the reverse actuator is removed).

6.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.

7.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.

8.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.

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

10.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.

CAUTION

On models with remote start, make sure to leave the battery cables disconnected. Failure to disconnect the battery cables when storing the snowmobile for a prolonged period of time (six weeks or more) will result in a discharged or damaged battery.

11.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.

3

12.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

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:

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

2.Clean the engine. 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 (see the Drive Train/Track/Brake Systems section).

NOTE: If the old belt is worn but in reasonable condition, 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.Tighten all nuts, bolts, and cap screws making sure all calibrated nuts, bolts, and cap screws are tightened to specifications.

7.If not done during preparation for storage, lubricate the rear suspension with an all-temperature grease.

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

9.Charge the battery; then connect the battery cables making sure to connect the positive cable first. Test the electric start system.

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

11.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.

DRIVE CLUTCH/DRIVEN CLUTCH ALIGNMENT — 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.

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.

Adjust track tension and alignment

Check throttle cable tension

Check engine idle

Check coolant level

Check chain case lubricant level

Check engine oil

Check lights (high/low beam, brakelight)

Check safety switch operation

Check engine compartment for any rubbing components

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

4

Engine Specifications

ITEM
Engine Model Number		8KJ
Displacement		998 cc
Compression Ratio		9.0:1
Bore x Stroke		80.0 x 66.2 mm (3.15 × 2.61”)
Cooling System		Liquid
Spark Plug (NGK)		CR8E
Spark Plug Gap		0.71-0.79 mm (0.028-0.031”)
Piston Skirt/Cylinder Clearance		0.036-0.061 mm
		(0.0014-0.0024”)
Piston Pin Diameter		20.990-20.995 mm
		(0.8264-0.8266”)
Piston Pin Bore Diameter		21.004-21.015 mm
		(0.8269-0.8274”)
Piston Pin to Piston Pin Bore Clearance		0.009-0.025 mm
		(0.0003-0.0009”)
Connecting Rod: Small End Diameter		21.005-21.027 mm
		(0.8269-0.8278”)
Crankshaft Pin/Connecting Rod Big End		0.030-0.048 mm
Clearance		(0.0012-0.0019”)
Connecting rod: Big End Diameter		41.000-41.018 mm
		(1.6142-1.6149”)
Piston Ring End Gap	(Top)	0.35-0.45 mm (0.014-0.018”)
	(2nd)	0.75-0.85 mm (0.030-0.033”)
	(Oil)	0.10-0.35 mm (0.004-0.014”)
Piston Ring/	(1st - Top)	0.030-0.065 mm
Groove Clearance	(2nd)	(0.0012-0.0026”)
	(Oil)	0.020-0.055 mm
		(0.0008-0.0022”)
		0.040-0.140 mm
		(0.0016-0.0055”)
Piston Diameter		79.95-79.96 mm
(10 mm from bottom edge)		(3.1476-3.1480”)

Cam Lobe Height (Intake)	33.750-33.850 mm
	(1.3287-1.3327”)
Cam Lobe Height (Exhaust)	33.750-33.850 mm
	(1.3287-1.3327”)
Cam Lobe Width (Intake)	24.950-25.050 mm
	(0.9823-0.9862”)
Cam Lobe Width (Exhaust)	24.950-25.050 mm
	(0.9823-0.9862”)
Camshaft Journal Diameter	24.46-24.47 mm
	(0.9630-0.9635”)
Camshaft Journal Clearance	0.028-0.062 mm
	(0.0011-0.0024”)
Crank Pin Diameter	37.976-38.000 mm
	(1.4951-1.4961”)
Crankshaft Runout (max)	0.3 mm (0.012”)
Crankshaft Main Bearing Clearance	0.027-0.045 mm
	(0.0011-0.0018”)
Crankshaft/Rod Bearing Clearance	0.030-0.048 mm
	(0.0012-0.0019”)
Valve Stem Diameter (Intake)	4.475-4.490 mm
	(0.1762-0.1677”)
Valve Stem Diameter (Exhaust)	4.460-4.475 mm
	(0.1756-0.1762”)
Valve Guide Inside Diameter (Intake)	4.500-4.512 mm
	(0.1772-0.1776”)
Valve Guide Inside Diameter (Exhaust)	4.500-4.512 mm
	(0.1772-0.1776”)
Valve Guide/Stem Clearance (Intake)	0.010-0.037 mm
	(0.0004-0.0015”)
Valve Guide/Stem Clearance (Exhaust)	0.025-0.052 mm
	(0.0010-0.0020”)
Valve Face Width (Intake)	0.90-1.10 mm (0.035-0.043”)
Valve Face Width (Exhaust)	0.90-1.10 mm (0.035-0.043”)
VALVE TIMING (below)
Intake Open (BTDC)	35.0 degrees
Intake Closed (ABDC)	45.0 degrees
Exhaust Open (BBDC)	45.0 degrees
Exhaust Closed (ATDC)	35.0 degrees
Valve Overlap	70.0 degrees

Electrical Specifications

Component	Test Value		+ Test Connections -
	(Normally Closed Ignition)
Magneto Coil (3 tests)*	0.15-0.23 ohm	white		white
Primary Ignition Coil*	1.19-1.61 ohms
Secondary Ignition Coil*	8.5k-11.5k ohms
Crankshaft Position Sensor	336-504 ohms	light gray		dark gray
Voltage Regulator/Rectifier**	12-14.5 DC Volts	terminal		terminal
Magneto Coil (no load)	36-44 AC Volts	white		white
Ignition Switch	Less than 1 ohm (key in ON position)	terminal		terminal
* Harness plugged in	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.

5

Drive System

Specifications

Model	Drive Clutch	Cam Arm	Driven Clutch		Torque	Drive	Engagement	Peak	Top	Bottom	Chain
	Spring		Spring		Bracket	Belt	RPM	RPM	Gear	Gear	Pitch
ZR 9000	120/285 lb	J14-74g	155-220 lb		58-49-.15	0627-104	4-4200	8750	24T	50T	92
XF 9000	120/285 lb	J14-74g	155-220 lb		58-49-.15	0627-104	4-4200	8750	22T	48T	90
M 9000 King Cat	120/285 lb	J14-74g	155-220 lb		58-49-.15	0627-104	4-4200	8750	21T	52T	98

Drive Clutch/Driven

Clutch-Related

Specifications

ALIGNMENT BAR

CENTER-TO-CENTER	OFFSET	FLOAT
10.38” ± 0.020”	1.560”	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.

6

Chain Case Performance

Calibrations

Drive	Gear		Ratio	Chain							Engine RPM
Sprocket	Ratio
	Top	Btm			6200	6400	6600	6800	7000	7200	7400	7600	7800		8000	8200	8400	8600	8800	9000
											Vehicle Speed (mph)
7 Tooth	21	49	0.429	90	59	61	63	65	67	69	71	73	74		76	78	80	82	84	86
(3.0" pitch)
	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
8 Tooth	21	49	0.429	90	64	67	69	71	73	75	77	79	81		83	85	87	89	91	94
(2.86"	20	46	0.435	88	65	67	70	72	74	76	78	80	82		84	86	89	91	93	95
pitch)
	23	51	0.451	92	68	70	72	74	77	79	81	83	85		88	90	92	94	96	98
	22	48	0.458	90	69	71	73	76	78	80	82	84	87		89	91	93	96	98	100
	24	50	0.480	92	72	75	77	79	81	84	86	88	91		93	95	98	100	102	105
	21	41	0.512	86	77	80	82	84	87	89	92	94	97		99	102	104	107	109	112
	21	38	0.553	84	83	86	88	91	94	97	99	102	105		107	110	113	115	118	121
	20	35	0.571	82	86	89	91	94	97	100	103	105	108		111	114	116	119	122	125
	23	40	0.575	86	86	89	92	95	98	100	103	106	109		112	114	117	120	123	126
	22	37	0.595	84	89	92	95	98	101	104	107	110	112		115	118	121	124	127	130
	24	39	0.615	86	93	96	99	101	104	107	110	113	116		119	122	125	128	131	134
	23	36	0.639	84	96	99	102	105	108	112	115	118	121		124	127	130	133	136	139
	24	35	0.686	84	103	106	110	113	116	120	123	126	130		133	136	140	143	146	150
8 Tooth	21	49	0.429	90	68	70	72	74	76	79	81	83	85		87	89	92	94	96	98
(3.0" pitch)
	20	46	0.435	88	69	71	73	75	77	80	82	84	86		88	91	93	95	97	100
	23	51	0.451	92	71	73	76	78	80	83	85	87	89		92	94	96	99	101	103
	22	48	0.458	90	72	75	77	79	82	84	86	89	91		93	96	98	100	103	105
	24	50	0.480	92	76	78	81	83	85	88	90	93	95		98	100	103	105	107	110
	21	41	0.512	86	81	83	86	89	91	94	96	99	102		104	107	109	112	115	117
	21	38	0.553	84	87	90	93	96	98	101	104	107	110		112	115	118	121	124	127
	20	35	0.571	82	90	93	96	99	102	105	108	110	113		116	119	122	125	128	131
	23	40	0.575	86	91	94	97	99	102	105	108	111	114		117	120	123	126	129	132
	22	37	0.595	84	94	97	100	103	106	109	112	115	118		121	124	127	130	133	136
	24	39	0.615	86	97	100	103	106	110	113	116	119	122		125	128	132	135	138	141
	23	36	0.639	84	101	104	107	111	114	117	120	124	127		130	133	137	140	143	146
	24	35	0.686	84	108	112	115	119	122	126	129	133	136		140	143	147	150	154	157
9 Tooth	21	49	0.429	90	64	66	68	70	72	74	76	78	80		82	84	87	89	91	93
(2.52"	20	46	0.435	88	65	67	69	71	73	75	77	79	82		84	86	88	90	92	94
pitch)
	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

7

Drive	Gear		Ratio	Chain							Engine RPM
Sprocket	Ratio
	Top	Btm			6200	6400	6600	6800	7000	7200	7400	7600	7800		8000	8200	8400	8600	8800	9000
											Vehicle Speed (mph)
9 Tooth	21	49	0.429	90	73	75	77	80	82	84	87	89	91		94	96	98	101	103	105
(2.86"	20	46	0.435	88	74	76	78	81	83	85	88	90	93		95	97	100	102	104	107
pitch)
	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
9 Tooth	21	49	0.429	90	76	79	81	83	86	88	91	93	96		98	101	103	105	108	110
(3.0" pitch)
	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
10 Tooth	21	49	0.429	90	71	73	76	78	80	82	85	87	89		92	94	96	98	101	103
(2.52"	20	46	0.435	88	72	74	77	79	81	84	86	88	91		93	95	98	100	102	105
pitch)
	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

8

Track Specifications

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.

Model	Length	Lug Height
ZR	129/137”	1.25”
XF	137”	1.25”
XF High Country	141/153”	1.75”
M 9000 King Cat	162”	3.0”

NOTE: The track tension on all models should be

2-in. at 20 lb.

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

9

Torque Specifications

NOTE: Torque specifications have the following tolerances:

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

DRIVE SYSTEM

Item		Secured to	Torque
			ft-lb
Drive Clutch	Engine		51****
Drive Clutch Cover	Movable Sheave		120 in.-lb
Cam Arm Lock Nut	Cam Arm Screw		50 in.-lb
Driven Clutch	Driven Shaft		60
Spider	Stationary Sheave		450***
Movable Sheave	Torque Bracket		72 in.-lb
Chain Case (Cap Screw)	Chassis		96 in.-lb
Chain Case (Torx-Head Screw)	Chassis		12
Chain Case Cover	Chain Case		12
Shift Actuator	Chain Case Cover		36 in.-lb
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**
STEERING/FRONT SUSPENSION/CHASSIS
Item		Secured to	Torque
			ft-lb
Ski		Spindle	35
Ski		Wearbar	8
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	15
Steering Post		Chassis	55
Steering Tie Rod		Steering Arm	20
Tie Rod		Spindle Arm	32
Steering Support		Spar	20
Steering Arm		Chassis	8
A-Arm (Upper) (XF HC/M)		Chassis	9
A-Arm (Upper) (ZR/XF)		Chassis	23
A-Arm (Lower)		Chassis (Front)	65

A-Arm (Lower)	Chassis (Rear)	45
A-Arm (Upper) (ZR/XF)	Spindle	45
A-Arm (Upper) (XF HC/M)	Spindle	23
A-Arm (Lower)	Spindle	45
Shock Absorber (ZR, XF)	Spindle	32
Shock Absorber (ZR, XF)	Chassis	32
Shock Absorber (XF HC/M)	Spindle	24
Shock Absorber (XF HC/M)	Chassis	24
Sway Bar Link	A-Arm/Sway Bar Link	23
Sway Bar Mounting Bracket	Chassis	9
REAR SUSPENSION
XF 141/153/162”
Wear Strip	Rail	50 in.-lb
End Cap	Rail	80 in.-lb
Mounting Block	Rail	12
Rear Wheel Axle	Rail	34
Rear Arm	Rail	20
Idler Arm	Rear Arm	40
Front Shock	Rail	50**
Rear Shock	Front Arm/Idler Arm	40
Rail Support	Rail	20
Front Shock	Front Arm	40
Limiter Strap	Rail Support	72 in.-lb
Rear Tri Hub Wheel	Rear Tri Hub Wheel	50 in.-lb
Rear Shock Link	Front Arm/Idler Arm	40
Front Arm	Rail	52**
Skid Frame	Tunnel	45**
ZR/XF 129”/137”
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 Tri Hub Wheel	Rear Tri Hub Wheel	50 in.-lb
Rear Wheel Axle	Rail	34
Skid Frame	Tunnel	45**
Front Shock	Rail	50**
Rail Support	Rail	20
Limiter Strap	Front Arm	72 in.-lb

*w/Green Loctite #609

**w/Blue Loctite #243

***w/Red Loctite #271

****w/Oil

10

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 special tool must be available to the technician when servicing the steering and body systems.

NOTE: When indicated for use, each special tool will be identified by its specific name, as shown in the chart below, and capitalized.

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

REMOVING

To remove the access panel and hood, use the following procedure:

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.Disconnect the hood harness on the left-side of the hood; then loosen the two quarter turns securing the front of the hood. Pull the hood forward and remove the hood.

0750-565A

3.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

4.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

5.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.

SNO-357

6.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.

11

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-763

4.Secure the top of the steering post to the steering support using the existing retaining plate, steering post blocks, and nuts. Make sure the throttle cable is positioned between the steering post blocks. Tighten to 8 ft-lb.

5.Install the handlebar riser onto the top of the steering post and secure using the existing cap screws and caps. Tighten evenly to 15 ft-lb.

6.Position the hood onto the snowmobile and connect the hood harness connector and secure the two front quarter turns.

7.Install the access panels into the skid plates; then close the access panel and secure with the two quarter turns.

Ski (ZR/XF)

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 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.

0746-796

0746-797

12

NOTE: The ski damper must be positioned in the ski so it is directly under the spindle.

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

NOTE: Local laws and/or regulations as to maximum width of the ski stance may be applicable. Always comply with the maximum width laws and/or regulations when adjusting ski stance.

NOTE: Install the cap screw so the lock nut will be located to the inside of the ski and the cotter pin slot in the cap screw will be horizontal with the ski.

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

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 (XF HC/M)

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.

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 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.

0748-903

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

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 8 ft-lb.

13

Spindle (ZR/XF)

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

Spindle (XF HC/M)

0747-904

REMOVING

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

1.Place the shock absorber into position on the spindle. Secure with the cap screw and lock nut. Tighten to 32 ft-lb.

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.

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.

0749-480

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

4.Remove two lock nuts 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.

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 and loosely secure using a new lock nut.

2.Secure the upper A-arm ball joint to the spindle using the existing machine screw and tri-nut. Tighten the machine screw to 23 ft-lb.

3.Loosely install a new lock nut to secure the lower A-arm to the spindle; then remove the snowmobile from the support stand. Tighten to 45 ft-lb.

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.

14

5.Install the ski.

6.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-349

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

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-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.

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

15

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.

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

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

NOTE: The straightedge should be long enough to extend from the back of the track to the front of the ski.

16

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.

729-887A

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.

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 necessary) 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/XF)

REMOVING

NOTE: The front bumper must be removed.

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.

17

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.

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.

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).

SNO-354

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

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.

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.

SNO-226A

3.Secure the sway bar link to the lower arm with the cap screw and new nyloc nut. Tighten to 23 ft-lb.

SNO-764

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.

NOTE: Install the front bumper.

A-Arms (XF HC/M)

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.

18

SNO-763

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.

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

SNO-572

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, axles, and new lock nuts. Tighten to 23 ft-lb.

0749-480A

6.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

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

SNO-572

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

PC095A

19

3.Secure the A-arms to the spindle using one new lock nut and one new tri nut. Tighten to the lock nut 45 ft-lb and the tri-nut to 23 ft-lb.

NOTE: If the upper A-arm ball joint is being replaced, make sure the ball joint is threaded in as far as it can. Do not adjust outward or damage to the A-arm or ball joint can occur.

4.Using a 19 mm wrench, tighten the hex nut against the upper A-arm securely making sure to keep the ball joint level with the spindle.

5.Install the ski shock absorber and secure using the existing cap screws and new lock nuts. Tighten to 24 ft-lb.

6.Install the steering boot and secure using the existing push-rivets; then 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 the lower A-arm; then remove the shock absorber. Account for all mounting hardware.

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.

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.

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 new lock nuts. Tighten the lock nuts to 32 ft-lb for ZR/XF models and 24 ft-lb for XF HC/M models.

Sway Bar

REMOVING

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

SNO-764

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 A-arm with the cap screws and new nyloc nuts. Tighten to 23 ft-lb.

SNO-764

Front Bumper

REMOVING/INSTALLING

1.Remove both access panels and the hood.

2.Remove the eight torx screws and washers securing the front fascia and bumper to the chassis; then remove the front center fascia.

20

SNO-887

3.Remove the PDM from the PDM bracket; then remove the front bumper assembly.

4.Using a punch and a hammer, remove the center of the existing huck rivets securing the PDM bracket to the bumper.

5.Using a 1/4-in. drill bit, drill out the four huck rivets.

6.Secure the PDM bracket to the bottom side of the front bumper using the four huck rivets.

7.Position the front bumper assembly over the front of the snowmobile and align with the previous mounting locations.

8.Secure the bumper to the intercooler assembly using the existing four torx screws. Tighten securely.

9.Install the PDM into the PDM bracket; then position the front fascia and secure using the existing torx screws and washers. Tighten securely.

10.Install the hood and both access panels.

Seat Assembly

NOTE: On models with heated seats, 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.

SNO-851

2.Route the three front tabs on the seat through the console; then install the seat and secure using the cap screw.

SNO-852

NOTE: On models with heated seats prior to lowering and securing the seat, connect the seat heater harness connector.

Seat Cushion

REMOVING

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

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.

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.

Taillight/Brakelight

Assembly

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

21

SNO-511

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

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 left-side) and tip the snowmobile onto its left side.

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 rivets securing the snowflap to the tunnel; then remove the snowflap.

INSTALLING SNOWFLAP

1.Secure the snowflap to the tunnel using the appropriate rivets.

Windshield/Console/

Headlight

REMOVING

1.Remove both access panels and the hood.

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

3.Remove the six screws securing the console.

XM541A

XM542A

4.Disconnect the gauge, electrical accessory wires, and the ignition switch.

5.Remove the three screws securing the headlight to the hood; then disconnect the headlight connector. Remove the headlight.

XM543A

22

INSTALLING

1.Position the headlight onto the hood; then secure the headlight using the existing screws. Connect the headlight connector.

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.Secure the console to the headlight and the hood using the existing screws. Tighten securely.

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

5.With the windshield in position, secure the windshield to the frame using the six screws. Tighten securely.

6.Install the hood and both access panels.

Adjusting Headlight Aim

The headlight can be adjusted for vertical aim of the HIGH/LOW beam. The geometric center of HIGH beam zone is to be used for vertical aiming.

1.Position the snowmobile on a level floor so the headlight is approximately 25 ft from an aiming surface (wall or similar surface).

NOTE: There should be an “average” operating load on the snowmobile when adjusting headlight aim.

2.Measure the distance from the floor to midpoint of the headlight.

3.Using the measurement obtained in step 2, make a horizontal mark on the aiming surface.

4.Make a vertical mark intersecting the horizontal mark on the aiming surface directly in front of the headlight.

5.Engage the brake lever lock and start the engine. Select the headlight dimmer switch HIGH beam position. DO NOT USE LOW BEAM.

6.Observe the headlight beam aim. Proper aim is when the most intense beam is centered on the vertical mark 5 cm (2 in.) below the horizontal mark on the aiming surface.

7.Adjust the headlight using the adjusting screw on the backside of the headlight housing until correct aim is obtained. Shut the engine off; then disengage the brake lever lock.

0750-309

23

Engine

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 performing service procedures in this engine section.

NOTE: When indicated for use, each special tool will be identified by its specific name, as shown in the chart below, and capitalized.

Description	p/n
Drive Clutch Bolt Tool	0644-281
Drive Clutch Puller	0744-062
Drive Clutch Spanner Wrench	0644-136
Engine Lift Plate	0744-073
Hood Harness Extension	1686-659

NOTE: Special tools are available from the Arctic

Cat Service Parts Department.

CAUTION

Never attempt to substitute any other drive clutch puller for the recommended puller or severe clutch or crankshaft damage will occur.

Engine Removing/ Installing

This engine sub-section has been organized to show a progression for the removing/installing of the Arctic Cat 998 cc engine. For consistency purposes, this sub-section shows a complete and thorough progression; however, for efficiency it may be preferable to remove only those components needing to be addressed. Also, some components may vary from model to model. The technician should use discretion and sound judgment.

Removing

NOTE: While removing the engine, note all cable tie locations.

1.Remove both access panels; then loosen the two quarter turns securing the hood. Disconnect the hood harness and pull the hood forward and off of the snowmobile.

2.Remove the seat; then remove the gas cap and retaining nut from the neck of the gas tank. Remove the eight screws securing the console. Remove the console.

YM-176A

3.Remove the gas tank assembly.

4.Remove the cap screw from the secondary sheave and slide the secondary sheave (along with the drive belt) off the driven shaft. Account for alignment washers and sheave adjuster.

5.Remove the cap screw and washer securing the primary sheave to the crankshaft.

6.Using Primary Sheave Puller, tighten the puller. Remove the primary sheave.

NOTE: If the primary sheave will not release, sharply strike the head of the puller. Repeat this step until the sheave releases.

7.Remove the torx-head screws and both access plates from beneath the snowmobile.

8.Place a drain pan beneath the engine oil drain screw; then remove the screw and allow the oil to drain completely. After the oil has drained, install the drain plug and tighten to 10 N-m (1 kg-m, 7.2 ft-lb).

YM-152A

9.Remove the four torx-head screws securing the right-side footrest to the tunnel and the support; then with a drain pan in position, remove the drain plug from the oil tank.

24

746-121A

NOTE: To aid in draining the oil from the reservoir, position a funnel between the tank and the opening of the tunnel running board.

10.After the oil has drained completely, install the drain plug with a new O-ring and tighten to 22 N-m (2.2 kg-m, 16 ft-lb).

11.Using a suitable vacuum pump, remove the coolant from the coolant filler neck and the reservoir tank.

12.Remove the five screws and washers securing the turbo heat shield to the turbo. Remove the shield.

YM-181

13.Remove the cap screws and washers securing the heat shield to the manifold.

YM-155

14.Apply a small amount of penetrating lubricant to the threads of the two clamp threads; then remove the two nuts securing the exhaust pipe clamps. Remove the clamps and the pipe.

YM-182A

15.Remove the six torx screws securing the resonator to the turbo; then remove the spring securing the resonator. Remove the resonator and account for a gasket.

NOTE: A long T50 ball head torx bit (p/n 0644-623) will be needed to remove the torx screws.

YM-154

16.Remove the screws and washers securing the exhaust heat shield to the tunnel.

YM-157

17.Remove the hose clamps securing hoses to the turbo, intake manifold, intercooler, and the air bypass valve. Remove both hoses.

25

SNO-835A

18.Remove the steering post assembly; then remove the two cap screws and nuts securing the vapor tank to the right-side support.

19.Remove the cap screws securing the front spars to the chassis; then remove the cap screws and nuts securing the right-side support to the chassis. Remove the steering support as an assembly.

SNO-836

20.Remove the screws securing the air silencer to the clutch guard; then disconnect the hose from the top of the engine and the waste gate hose. Remove the air silencer assembly.

YM-185A

21.Remove the two cap screws and spacers securing the intake manifold and throttle body to the engine; then remove the three clamps securing the intake boots to the throttle body. Remove the intake manifold.

SNO-837

22.Remove the clamp securing the intake duct to the PTO-side of the turbo.

23.Remove the hose clamp securing the coolant hose to the vapor tank; then remove the hose clamp securing the coolant hose from the bottom of the turbo.

YM-164

24.Remove the clamp securing the oil return hose to the crankcase; then remove the oil delivery hose to the cylinder. Account for two washers.

YM-165A

26

YM-163

25.Remove the four cap screws and four nuts securing the right-side chassis support to the chassis. Remove the turbo and support assembly.

26.Remove the three screws and one nut securing the clutch guard; then remove the screws and nuts securing the left-side chassis support. Rotate the support up to gain access to the rear engine cap screw.

YM-160

29.Remove the clamp securing the MAG-side coolant hose to the engine; then disconnect the oil pressure switch and the oil pressure sensor.

30.With all hoses and wires disconnected from the engine, move the engine forward and out the right-side of the chassis.

31.Remove the throttle body assembly once the engine is removed.

Installing

NOTE: Before installing the engine, be sure the starter motor and cables are installed and secured to the engine.

YM-186

27.Remove all six cap screws and nuts securing the front engine bracket; then remove the bracket. Remove the cap screw and nut securing the ground wire to the engine.

SNO-364

28.Remove the cap screw and nut securing the rear of the engine to the chassis.

YM-162

NOTE: If the thermostat-to-heat exchanger coolant hose was removed, make sure it is properly routed and installed onto the heat exchanger. Tighten to 4 N-m (0.4 kg-m, 35 in.-lb).

YM-159

27

1.Position the front engine bracket with the front engine mounts; then loosely secure using the existing cap screws and new nuts.

SNO-365

2.Carefully lower the engine into the chassis aligning the rear engine mounts with the chassis mounts; then loosely secure using the existing cap screw and a new nut.

SNO-364A

6.Connect the oil pressure switch and the oil pressure sensor to the main harness.

7.Connect the coolant hose from the heat exchanger to the water pump and secure using the existing hose clamp. Tighten to 4 N-m (0.4 kg-m, 35 in.-lb).

NOTE: All wires, cables, and hoses must be installed on the inside of the coolant hose and the PTO-side bracket.

CAUTION

Make sure the top clamp is routed like the image below so the clamp does not come in contact with the primary sheave.

YM-160

3.Loosely secure the front engine mounting bracket to the chassis using the existing cap screws and new nuts; then loosely secure the ground cable to the engine using the existing cap screw and a new nut.

YM-161

NOTE: Route the positive and negative battery cables up and over the engine mounts.

8. Install the throttle body assembly into the three intake boots and secure using the existing clamps. Tighten to 3 N-m (0.3 kg-m, 26 in.-lb).

SNO-364

4.Tighten the rear engine cap screw and nut to 126 N-m (12.8 kg-m, 93 ft-lb).

5.Tighten the cap screws (A and B) to 34 N-m (3.5 kg-m, 25 ft-lb). Tighten cap screws (C) to 88 N-m (8.9 kg-m, 65 ft-lb). Tighten cap screw (D) to 41 N-m (4.2 kg-m, 30 ft-lb).

YM-168

28

9.Install the throttle body coolant hoses to the engine and the water pump. Secure using the existing clamps.

10.Install the intake manifold assembly onto the throttle body assembly and secure using the existing clamps. Tighten to 2.4 N-m (0.24 kg-m, 20 in.-lb).

11.Secure the manifold bracket to the engine using the existing cap screws and spacers. Tighten to 10 N-m (1.0 kg-m, 7.2 ft-lb).

YM-169

12.Position the right-side rear spar with the chain case assembly; then install the existing cap screws through the chain case and the spar.

13.With the turbo installed onto the MAG-side mounting bracket; secure the assembly to the chassis using the existing screws and nuts. Tighten to 27 N-m (2.8 kg-m, 20 ft-lb).

YM-163

14.Connect the lower coolant hose on the backside of the turbo to the oil cooler. Secure using the existing hose clamp. Tighten to 3.5 N-m (0.35 kg-m, 35 in.-lb.

YM-164

15.Secure the oil return hose to the crankcase using the existing clamp; then secure the oil delivery hose to the cylinder using the existing banjo bolt and new washers. Tighten to 10 N-m (1.0 kg-m, 7.2 ft-lb).

YM-165A

YM-163

NOTE: Make sure the distance (A) between the oil delivery hose and the turbo is 3.0 mm (0.12 in.).

SNO-821

29