Arctic Cat ZR/XF/M Pantera/Notseman 3000, ZR/XF/M Pantera/Notseman 7000, ZR/XF/M Pantera/Notseman 9000 Service Manual

ZR/XF/Pantera/Norseman/M 4-Stroke

Table of Contents

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

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

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

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

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

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

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

Preparation for Storage......................................................... 5

Preparation After Storage ..................................................... 5

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

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

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

Drive System Specifications.................................................. 9

Drive Clutch/Driven Clutch-Related Specifications ...............9

Drive System Components ................................................... 9

Chain Case Performance Calibrations................................ 10

Track Specifications ............................................................ 12

Suspension Specifications .................................................. 12

Torque Conversions ............................................................ 12

Torque Specifications .......................................................... 13

Steering and Body .................................................................... 14

Steering Post....................................................................... 14

Ski (ZR/XF/Pantera)............................................................ 15

Ski (Norseman) ................................................................... 16

Ski (XF HC/M) ..................................................................... 17

Ski Wear Bar....................................................................... 17

Spindle (ZR/XF/Pantera/Norseman) ................................... 17

Spindle (XF HC/M) .............................................................. 18

Steering Tie Rod ................................................................. 18

Ski Alignment ...................................................................... 20

A-Arms (ZR/XF/Pantera/Norseman) ................................... 21

A-Arms (XF HC/M) .............................................................. 22

Ski Shock Absorber............................................................. 23

Sway Bar............................................................................. 24

Front Bumper ...................................................................... 24

Seat Assembly (ZR/XF/Norseman/M)................................. 24

Seat Assembly (Pantera) .................................................... 25

Seat Cushion ...................................................................... 25

Taillight/Brake Light Assembly (ZR/XF/Norseman/M) ......... 25

Taillight/Brake Light Assembly (Pantera)............................. 26

Rear Bumper/Snowflap ....................................................... 26

Windshield/Console/ Headlight ........................................... 26

Headlight Bulb..................................................................... 27

Adjusting Headlight Aim ..................................................... 27

Engine ........................................................................................ 28

Engine Removing/Installing — 3000 ................................... 28

Engine Removing/Installing — 7000 ................................... 37

Engine Removing/Installing — 9000 ................................... 43

Engine Servicing — 3000 ................................................... 52

Engine Servicing — 7000/9000 .......................................... 76

Assembly Schematic — 7000 ............................................. 96

Assembly Schematic — 9000 ............................................. 98

Troubleshooting Engine..................................................... 100

Engine-Related Items ............................................................. 102

Water Pump ...................................................................... 102

Pressure Testing Engine ................................................... 105

Checking Compression ..................................................... 105

Changing Oil/Filter ............................................................ 106

Testing Oil Pressure.......................................................... 109

Liquid Cooling System (3000/7000) .................................. 109

Liquid Cooling System (9000) ........................................... 110

Cooling System Schematics ............................................. 111

Heat Exchanger (9000) ..................................................... 113

Air Silencer........................................................................ 114

Turbocharger/Intercooler (9000)........................................ 116

Fuel Systems........................................................................... 120

Fuel System ...................................................................... 120

Individual Components...................................................... 120

Self-Diagnostic System/Codes.......................................... 123

Fuel Pressure Regulator ................................................... 124

Throttle Body Assembly .................................................... 124

Throttle Cable.................................................................... 127

Fuel Pump......................................................................... 127

Gas Tank ........................................................................... 128

Electrical Systems .................................................................. 130

Ignition System.................................................................. 130

Throttle Position Sensor.................................................... 130

Electrical Resistance Tests (3000) .................................... 132

Electrical Resistance Tests (7000) .................................... 133

Voltage Regulator Tests .................................................... 134

Testing Fuel Gauge Sender .............................................. 134

Emergency Stop Switch .................................................... 135

Starter Relay Solenoid ...................................................... 135

Fuse .................................................................................. 135

Ignition Switch ................................................................... 135

Starter Motor ..................................................................... 136

Troubleshooting Electric Start ........................................... 140

Magneto ............................................................................ 140

Brake Light Switch ............................................................ 141

Headlight Dimmer Switch.................................................. 142

Testing Handlebar Warmer Elements .............................. 142

Testing Thumb Warmer Element....................................... 143

Testing Handlebar Warmer/Thumb Warmer Switch .......... 143

Testing Passenger Handwarmer Switch ........................... 143

Testing Passenger Handwarmer Elements ....................... 144

Testing Seat Heater Switches ........................................... 144

Testing Speedometer Sensor............................................ 144

Testing Gear Position Switch............................................. 145

Testing Shift Switch ........................................................... 145

Testing Shift Actuator ........................................................ 145

Testing Heated Shield Outlet............................................. 145

Voltage/Resistance Chart — Air Temperature .................. 146

Voltage/Resistance Chart — Coolant Temperature ..........146

Drive Train/Track/Brake Systems .......................................... 147

Drive Belt........................................................................... 147

Drive Clutch....................................................................... 148

Driven Clutch..................................................................... 151

Drive Clutch/Driven Clutch ................................................ 155

Drive Train ......................................................................... 156

Drive Sprockets................................................................. 161

Track Tension .................................................................... 163

Track Alignment................................................................. 164

Brake System (Hydraulic) ................................................. 165

Brake Lever/Master Cylinder Assembly ............................ 170

Troubleshooting Drive Clutch/Driven Clutch...................... 172

Troubleshooting Track ....................................................... 173

Troubleshooting Hydraulic Brake System.......................... 173

Suspension.............................................................................. 174

Suspension Setup Basics ................................................. 174

Chassis and Skid Frame Mounting Locations ................... 177

Servicing Suspension ....................................................... 178

FOX Air Shock................................................................... 191

Servicing IFP Shock.......................................................... 191

General

Information/Foreword

NOTE: General specifications for each 2018 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 2018 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 supple- mentary information worthy of particular attention.

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 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, adding a gasoline antifreeze is not necessary since ethanol will prevent the accumulation of moisture in the fuel system.

RECOMMENDED OIL (3000)

The recommended oil to use is Synthetic 0W-40 Oil in all temperatures and conditions.

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.

OILCHARTJ

After the engine break-in period, the engine oil and filter should be changed every 2500-3000 miles and before prolonged storage.

RECOMMENDED OIL (7000/9000)

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 filter should be changed every 2500 miles or before prolonged storage.

Engine Break-In

Drive Belt Break-In

3000

The Arctic Cat 4-stroke 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.

CAUTION

DO NOT use premixed fuel in the snowmobile gas tank. Engine damage will occur.

To ensure trouble-free operation, careful adherence to the following break-in guidelines will be beneficial.

0-200 miles 1/2 Throttle (30 mph max)

200-400 miles 1/2-3/4 Throttle

400-600 miles

* With occasional full-throttle operation.

1/2-3/4 Throttle

To ensure proper engine break-in, Arctic Cat recommends that the engine oil and filter be changed after 500 miles or after one month, whichever comes first. This service is at the discretion and expense of the snowmobile owner.

7000/9000

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).

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 15 minutes.

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.

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.

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.

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.

Other more complicated methods exist such as engagement notches and changing the position of the cam arm center of gravity in relation to the roller. This is called “tucking the weight” and can be used, but, like the engagement notch, it can hurt belt life.

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. If you have a helix that is too shallow, the engine may over-rev or have poor acceleration. Usually, angles shallower than the sea level calibrations work best. The driven spring will also affect driven clutch tuning. Tighten the spring, and RPM will increase. Loosen the spring, and RPM will decrease. The spring should be used to fine-tune and complement the helix selection.

Carburetor calibration changes for high altitude operation will have an effect on the CVT system and how it operates. Understanding the basics of CVT operation is important in order to make the correct high altitude CVT calibration changes.

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

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

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

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.

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

TRACK

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

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

Durometer is a measurement of how hard a rubber is. The lugs on most tracks range between 60 and 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.

9. 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.

10. 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.

11. 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.

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. 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.

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

5. 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.

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

7. 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.

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

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 ensure many miles and hours of trouble-free snowmobiling. Arctic Cat recommends the following procedure:

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

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

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

4. Inspect the drive belt for cracks and tears. Check belt specifications. Replace if damaged or worn. Install the drive belt (see the Drive Train/Track/Brake Systems section).

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. 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 a low-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 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 a too long drive belt. To add to this, the drive belt itself wears and stretches somewhat leading to a low-end performance problem and, if not corrected, causes 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 — 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.

 Check drive belt deflection - drive clutch/driven

clutch alignment

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

ponents

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

for tightness

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

Engine Specifications

3000

ITEM

Displacement 700 cc Compression Ratio 10.5:1 Bore x Stroke 76.9 x 75.3 mm (3.03 × 2.96”) Cooling System Liquid Spark Plug (NGK) CR8EB Spark Plug Gap 0.6-0.8 mm (0.023-0.031 in.) Valve Face Diameter (Intake)

Valve/Tappet Clearance (Intake) (Cold Engine) (max) (Exhaust)

Valve Guide/Stem Clearance (Intake) (max) (Exhaust)

Valve Guide Inside Diameter (max) 4.532 mm Valve Head Thickness (min) 2.3 mm Valve Seat Angle 45° +15’/+30’ Valve Spring Free Length (min) 38.7 mm Valve Spring Tension @ 31.5 mm 19.0 kg (42 lb) Cam Lobe Height (min) 36.5 mm Camshaft Journal Oil Clearance (max) 0.07 mm Camshaft Journal Holder (Right/Center)

Inside Diameter (Left) Camshaft Journal Outside (Right/Center)

Diameter (Left) Camshaft Runout (max) 0.05 mm Cylinder Head/Cover Distortion (max) 0.05 mm Piston/Cylinder Clearance 0.14 mm Cylinder Bore (max) 76.965 mm Piston Diameter (10 mm from skirt end) 76.825 mm Piston Ring Free End Gap (min) (1st/2nd) 12.5 mm Cylinder Trueness (max) 0.05 mm Piston Ring End Gap Installed (1st/2nd)

(max) (Oil) Piston Ring to Groove Clearance (max) 0.1 mm Piston Ring Groove Width (1st/2nd)

Piston Ring Thickness (1st/2nd) 1.170-1.195 mm Piston Pin Bore (max) 18.018 mm Piston Pin Outside Diameter (min) 17.984 mm Connecting Rod: Small End Bore (max) 18.044 mm Crankshaft Runout (max) 0.03 mm

(Exhaust)

7000

ITEM

Engine Model Number 8KH Displacement 1049 cc Compression Ratio 11:1 Bore x Stroke 82.04 x 66.29 mm (3.23 × 2.61”) Cooling System Liquid Spark Plug (NGK) CR9E Spark Plug Gap 0.71-0.79 mm (0.028-0.031”) Piston Skirt/Cylinder Clearance 0.036-0.061 mm

Piston Pin Diameter 18.991-19.000 mm

Piston Pin Bore Diameter 19.004-19.015 mm

Piston Pin to Piston Pin Bore Clearance 0.004-0.024 mm

Connecting Rod: Small End Diameter 19.005-19.027 mm

Crankshaft Pin/Connecting Rod: Big End Clearance

Connecting Rod: Big End Diameter 41.000-41.018 mm

31.6 mm

27.9 mm

0.16 mm

0.22 mm

0.08 mm

0.10 mm

21.94-22.04 mm

17.44-17.48 mm

21.96-21.98 mm

17.48-17.53 mm

0.65 mm

0.85 mm

1.202-1.204 mm

(Oil)

2.501-2.503 mm

(0.0014-0.0024”)

(0.7477-0.7480”)

(0.7482-0.7486”)

(0.0002-0.0009”)

(0.7482-0.7491”)

0.033-0.050 mm (0.0013-0.0020”)

(1.6142-1.6149”)

ITEM

Piston Ring End Gap (Top) (2nd) (Oil)

Piston Ring/ (1st /Top) Groove Clearance

Piston Diameter (8 mm from bottom edge)

Cam Lobe Height (Intake)

Cam Lobe Width (Intake/Exhaust)24.85 mm (0.9783”) Camshaft Journal Diameter 24.46-24.47 mm

Camshaft Journal Clearance 0.028-0.062 mm

Crank Pin Diameter 37.976-38.000 mm

Crankshaft Runout (max) 0.3 mm (0.012”) Crankshaft Main Bearing Clearance 0.027-0.045 mm

Crankshaft/Rod Bearing Clearance 0.032-0.050 mm

Valve Stem Diameter (Intake)

Valve Guide Inside Diameter (Intake)

Valve Guide/Stem Clearance (Intake)

(Exhaust)

0.35-0.45 mm (0.014-0.018”)

0.70-0.80 mm (0.028-0.031”)

0.10-0.35 mm (0.004-0.014”)

0.030-0.070 mm (0.0012-0.0028”)

(2nd)

0.020-0.060 mm (0.0008-0.0024”)

(Oil)

0.040-0.110 mm (0.0016-0.0043”)

81.95-81.97 mm (3.2264-3.2270”)

34.50 mm (1.3583”)

34.00 mm (1.3356”)

(0.9630-0.9635”)

(0.0011-0.0024”)

(1.4951-1.4961”)

(0.0011-0.0018”)

(0.0013-0.0020”)

4.475-4.490 mm (0.1762-0.1677”)

4.460-4.475 mm (0.1756-0.1762”)

4.500-4.512 mm (0.1772-0.1776”)

0.010-0.037 mm (0.0004-0.0015”)

0.025-0.052 mm (0.0010-0.0020”)

9000

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

Piston Pin Bore Diameter 21.004-21.015 mm

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

Crankshaft Pin/Connecting Rod: Big End Clearance

Connecting Rod: Big End Diameter 41.000-41.018 mm

Piston Ring End Gap (Top) (2nd) (Oil)

Piston Ring/ (1st/Top) Groove Clearance (2nd)

Piston Diameter (10 mm from bottom edge)

Cam Lobe Height (Intake)

(Exhaust)

Cam Lobe Width (Intake/Exhaust) 24.950-25.050 mm

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

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 Clearance

Valve Stem Diameter (Intake)

Valve Guide Inside Diameter (Intake)

Valve Guide/Stem Clearance (Intake)

Valve Face Width (Intake/Exhaust) 0.90-1.10 mm (0.035-0.043”)

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

— Cold (Intake)

(Exhaust)

VALVE TIMING (below)

(0.8264-0.8266”)

(0.8269-0.8274”)

(0.8269-0.8278”)

0.030-0.048 mm (0.0012-0.0019”)

(1.6142-1.6149”)

0.35-0.45 mm (0.014-0.018”)

0.75-0.85 mm (0.030-0.033”)

0.10-0.35 mm (0.004-0.014”)

0.030-0.065 mm (0.0012-0.0026”)

0.020-0.055 mm (0.0008-0.0022”)

(Oil)

0.040-0.140 mm (0.0016-0.0055”)

79.95-79.96 mm (3.1476-3.1480”)

33.750-33.850 mm (1.3287-1.3327”)

(0.9823-0.9862”)

(1.4951-1.4961”)

0.15-0.22 mm (0.0059-0.0087”)

0.21-0.25 mm (0.0083-0.098”)

4.475-4.490 mm (0.1762-0.1677”)

4.460-4.475 mm (0.1756-0.1762”)

4.500-4.512 mm (0.1772-0.1776”)

0.010-0.037 mm (0.0004-0.0015”)

0.025-0.052 mm (0.0010-0.0020”)

Electrical Specifications

Component Test Value + Test Connections -

3000 (Normally Closed Ignition)

Spark Plug Cap 5000 ohms Ignition Coil Resistance (primary) Less than 1 ohm Ignition Coil Primary Voltage Battery Voltage Stator Coil (crankshaft position sensor)

Resistance (AC generator) Crankshaft Position Sensor 1.5 AC Volts or more AC Generator Output (no load) 65 AC volts @ 4000 RPM Ignition Timing 10° BTDC @ 1500 RPM Ignition Switch Less than 1 ohm (key in ON position) terminal terminal

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 blue/white green/white 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

100-150 ohms Less than 1 ohm

7000/9000 (Normally Closed Ignition)

NOTE: Lighting coil output is unregulated voltage.

Most voltages generated by the ignition system are sufficient to interrupt pacemakers! All technicians, especially those using pacemakers, must avoid contact with all electrical connections.

! WARNING

Drive System

Specifications

Model Altitude

ZR 3000 0-5000 Black/Blue 63g Black/Blue 36° 0627-081 38-4000 85-8600 19T 50T 90

Norseman 3000 0-3000 Black/Blue 63g Black/Blue 36° 0627-081 38-4000 85-8600 19T 50T 90

ZR 7000 0-5000 60/220 lb 62g 140-200 lb 64-51-.20 0627-110 38-4000 85-8600 21T 49T 90

ZR 9000 0-5000 120/285 lb J14-74g 155-220 lb 58-49-.15 0627-112 4-4200 8750 22T 48T 90

XF 7000 0-5000 60/200 lb 62g 140-200 lb 64-51-.20 0627-110 38-4000 85-8600 21T 49T 90

XF 9000 0-5000 120/285 lb J14-74g 155-220 lb 58-49-.15 0627-112 4-4200 8750 22T 48T 90

Pantera 3000 0-5000 Black/Blue 63g Black/Blue 36° 0627-081 28-3000 85-8600 19T 50T 90

Pantera 7000 0-5000 60-220 lb 62g 140-200 lb 64-51-.20 0627-110 38-4000 85-8600 21T 49T 90

M 9000 6-8000 120/285 lb J14-74g 155-220 lb 58-49-.15 0627-112 4-4200 8750 21T 52T 98

Drive Clutch

Spring

Cam Arm

Drive Clutch/Driven

Driven Clutch Spring

Torq ue

Bracket

Drive

Belt

Engagement

RPM

Peak RPM

Top

Gear

Bottom

Gear

Chain

Pitch

Drive System Components

Clutch-Related

Specifications

ALIGNMENT BAR

Offset P/N Center-to-Center Offset Float

0644-246 (3000) 11.567” ± 0.020” 1.485” None 0744-097 (7000) 10.30” ± 0.020” 1.530” None 0744-097 (9000) 10.38” ± 0.020” 1.530” None

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

Chain Case Performance

Calibrations

Drive

Sprocket

7 Tooth

(3.0" pitch)

8 Tooth

(2.86" pitch)

8 Tooth

(3.0" pitch)

9 Tooth

(2.52" pitch)

Gear

Ratio

Top B tm

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

Ratio Chain Engine RPM

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

Vehicle Speed (mph)

8800 9000

Drive

Sprocket

9 Tooth

(2.86" pitch)

9 Tooth

(3.0" pitch)

10 Tooth

(2.52" pitch)

Gear

Ratio

Top B tm

21 49 0.429 90 73 75 77 80 82 84 87 89 91 94 96 98 101 103 105 20 46 0.435 88 74 76 78 81 83 85 88 90 93 95 97 100 102 104 107 23 51 0.451 92 76 79 81 84 86 89 91 94 96 98 101 103 106 108 111 22 48 0.458 90 78 80 83 85 88 90 93 95 98 100 103 105 108 110 113 24 50 0.480 92 81 84 86 89 92 94 97 100 102 105 107 110 113 115 118 21 41 0.512 86 87 89 92 95 98 101 103 106 109 112 115 117 120 123 126 21 38 0.553 84 93 97 100 103 106 109 112 115 118 121 124 127 130 133 136 20 35 0.571 82 97 100 103 106 109 112 115 118 122 125 128 131 134 137 140 23 40 0.575 86 97 100 104 107 110 113 116 119 122 126 129 132 135 138 141 22 37 0.595 84 101 104 107 110 114 117 120 123 127 130 133 136 140 143 146 24 39 0.615 86 104 107 111 114 118 121 124 128 131 134 138 141 144 148 151 23 36 0.639 84 108 112 115 119 122 126 129 132 136 139 143 146 150 153 157 24 35 0.686 84 116 120 123 127 131 135 138 142 146 150 153 157 161 165 168 21 49 0.429 90 76 79 81 83 86 88 91 93 96 98 101 103 105 108 110 20 46 0.435 88 77 80 82 85 87 90 92 95 97 100 102 105 107 110 112 23 51 0.451 92 80 83 85 88 90 93 96 98 101 103 106 108 111 114 116 22 48 0.458 90 81 84 87 89 92 94 97 100 102 105 108 110 113 115 118 24 50 0.480 92 85 88 91 93 96 99 102 104 107 110 113 115 118 121 124 21 41 0.512 86 91 94 97 100 103 106 108 111 114 117 120 123 126 129 132 21 38 0.553 84 98 101 104 108 111 114 117 120 123 127 130 133 136 139 142 20 35 0.571 82 101 105 108 111 114 118 121 124 128 131 134 137 141 144 147 23 40 0.575 86 102 105 109 112 115 118 122 125 128 132 135 138 142 145 148 22 37 0.595 84 106 109 112 116 119 123 126 129 133 136 140 143 146 150 153 24 39 0.615 86 109 113 116 120 123 127 130 134 137 141 144 148 151 155 159 23 36 0.639 84 113 117 121 124 128 132 135 139 143 146 150 154 157 161 165 24 35 0.686 84 122 126 130 133 137 141 145 149 153 157 161 165 169 173 177 21 49 0.429 90 71 73 76 78 80 82 85 87 89 92 94 96 98 101 103 20 46 0.435 88 72 74 77 79 81 84 86 88 91 93 95 98 100 102 105 23 51 0.451 92 75 77 80 82 84 87 89 92 94 96 99 101 104 106 108 22 48 0.458 90 76 78 81 83 86 88 91 93 96 98 100 103 105 108 110 24 50 0.480 92 80 82 85 87 90 92 95 97 100 103 105 108 110 113 115 21 41 0.512 86 85 88 90 93 96 99 101 104 107 109 112 115 118 120 123 21 38 0.553 84 92 94 97 100 103 106 109 112 115 118 121 124 127 130 133 20 35 0.571 82 95 98 101 104 107 110 113 116 119 122 125 128 131 134 137 23 40 0.575 86 95 98 101 104 108 111 114 117 120 123 126 129 132 135 138 22 37 0.595 84 98 102 105 108 111 114 118 121 124 127 130 133 137 140 143 24 39 0.615 86 102 105 108 112 115 118 122 125 128 132 135 138 141 145 148 23 36 0.639 84 106 109 113 116 119 123 126 130 133 137 140 143 147 150 154 24 35 0.686 84 114 117 121 125 128 132 136 139 143 147 150 154 158 161 165

Ratio Chain Engine RPM

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

Vehicle Speed (mph)

8800 9000

Track Specifications

Model Length Lug Height Track Tension

ZR 129" 1" 20lb @ 2” ZR Sno Pro 129" 1.25" 20lb @ 2” Pantera 146” 1.25” 20lb @ 2” XF CrossTrek 137” 1.6” 20lb @ 2” XF CrossTour 146” 1.35” 20lb @ 2” XF Cross Country 137” 1.75” 20lb @ 2” XF High Country 141"/153” 2.25" 20lb @ 2” XF Sno Pro 141" 1.50" 20lb @ 2” M 162” 3.0” 20 lb @ 2”

Suspension Specifications

SPRINGS

SKI SHOCK

Model

ZR/XF/Pantera 0.331” 13.00” 120 lb/in. 9.6 NO

Model

ZR/XF 0.312” 8.25” 90/250

Pantera 0.312” 7.75” 110 lb/in. 7 NO

Model

XF 137” 0.375” 13.00” 175 lb/in. 10.5 NO

REAR ARM (See Illustration Below)

Model

ZR/XF 137” .394" 90° 3.65" 6.75 18.50” Pantera .405” 80° 3.65” 6.75 18.50”

SNO-832

Wire

Diameter

Wire

Diameter

Wire

Diameter

Wire

Diameter

Free

Length

FRONT ARM

Free

Length

REAR ARM

Free

Length

Angle

(A)

(B)

Rate Coils Ta b

lb/in.

Rate Coils Ta b

Coil

Width

(C)

9.8 NO

Length

Coils

(D)

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/Pantera 12.59” 18.38” 5.79” 7.00”

Model

ZR/Pantera 8.14” 11.74” 3.59” 4.50” XF 8.55” 12.50” 3.94” 4.91”

Model

ZR 9.89” 13.98” 4.09” 5.70” XF/Pantera 10.32” 15.12” 4.80” 6.13”

Collapsed

Length

FRONT ARM

Collapsed

Length

REAR ARM

Collapsed

Length

Extended

Length

Extended

Length

Extended

Length

Stroke

Piston

Depth

Piston

Depth

Piston

Depth

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

Torque Specifications

NOTE: Torque specifications have the following tol-

erances:

Torque (ft-lb) Tol er 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 Cam Arm Lock Nut (Arctic Cat) Cam Arm Pin 11 Cam Arm Lock Nut (Team) Cam Arm Screw 50 in.-lb Cam Arm Set Screw (Arctic Cat) Cam Arm 19 in.-lb Driven Clutch** (Arctic Cat) Driven Shaft 20 Driven Clutch (Team) Driven Shaft 60 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

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

Tor que

ft-lb

Tor que

ft-lb

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

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 52** Rear Shock Front Arm/Idler Arm 24 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 Fron t A rm 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

Steering and Body

3000/7000

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.

To remove the access panel and hood on 9000 models, use steps 4-5:

4. 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.

5. 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.

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 on 3000 and 7000 models, use steps 1-3:

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.

0750-565A

6. 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

7. 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.

0747-529

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.

SNO-2221A

8. 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

9. Carefully remove the steering post from the snowmobile.

INSTALLING

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

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

SNO-2218

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

SNO-763

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

5. Install the 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; then install the access panels.

Ski (ZR/XF/Pantera)

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.

SNO-2219

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

INSPECTING

1. Inspect the ski for cracks or deterioration.

2. Inspect the ski for abnormal bends or cracks.

3. Inspect the wear bar for wear.

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

5. Inspect the rubber damper for damage or wear.

INSTALLING

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

2. Install the spindle axle into the spindle; then position the ski damper into the bottom of the ski making sure the damper is properly positioned for the desired ski stance.

0746-796

INSPECTING

1. Inspect the ski for cracks or deterioration.

2. Inspect the ski for abnormal bends or cracks.

3. Inspect the wear bar for wear.

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

5. Inspect the rubber damper for damage or wear.

INSTALLING

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



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

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

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 regarding

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

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

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

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

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

screw is still horizontal with the ski (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 (Norseman)

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.

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

0748-981

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

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

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

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

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

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

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

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

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

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

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

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

Ski (XF HC/M)

Ski Wear Bar

REMOVING

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

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

NOTE: Note the orientation of the damper for

installation purposes.

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

INSPECTING

1. Inspect the ski for cracks or deterioration.

2. Inspect the ski for abnormal bends or cracks.

3. Inspect the wear bar for wear.

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

5. Inspect the rubber damper for damage or wear.

INSTALLING

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

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

REMOVING

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

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

INSTALLING

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

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

Spindle

(ZR/XF/Pantera/Norseman)

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.

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.

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

Spindle (XF HC/M)

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.

5. Install the ski.

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

0749-480

REMOVING

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

2. Remove the 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.

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.

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

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-350

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

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 ft-lb.

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-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.

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.

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.

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 prop-



erly adjusted prior to checking or adjusting ski alignment. Ski alignment must be performed on a flat, level surface. Ski toe-out must fall within the range of 1/16-1/4 in.

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.

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

! 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.

! 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.

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 neces-

sary) until ski toe-out is within specification.

! WARNING

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

A-Arms

(ZR/XF/Pantera/Norseman)

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.

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.

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

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.

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)

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).

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.

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-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

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.

PC095A

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.

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.

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.

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).

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/Pantera models and 24 ft-lb for XF HC and 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.

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/Norseman/M)



NOTE: On models with heated seats, be sure to discon-

nect the seat heater harness before removing the seat.

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

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-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.

SNO-227A

NOTE: On models with heated seats prior to lower-

ing and securing the seat, connect the seat heater harness connector.

SNO-764

Seat Assembly

(Pantera)

REMOVING/INSTALLING

1. Lift up both seat latches and hold them in that position; then lift sure to disconnect the accessory harness.

0748-449

2. Release the lever securing the operator seat; then lift up and remove the front seat. Make sure to disconnect the seat heater harness. Remove the operator seat.

and remove the passenger seat. Make

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.

0748-419

3. To install the operator seat, route the front tab on the operator seat through the seat-base hold-down bracket; then secure the rear of the operator seat using the lever.

4. To install the passenger seat, position the front of the seat base tabs under the loops in the seat frame; then press down and secure using the two seat latches.

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/Brake Light

Assembly

(ZR/XF/Norseman/M)

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

SNO-454A

NOTE: Be sure to connect the accessory harness.

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.

Taillight/Brake Light

Assembly (Pantera)

1. Remove the storage box lid; then remove the machine screws securing the taillight to the rear rack fascia. Disconnect the taillight harness connector.

XM098

2. Connect the taillight harness connector; then secure the taillight to the rear rack fascia with the screws. Tighten to 48 in.-lb. Install the storage box lid.

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

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

3. Remove the four screws securing the console.

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.

YM-028A

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

5. Remove the two screws securing the rear of the console to the hood (on the underside of the hood).

6. Loosen the two side headlight assembly screws; then remove the two front headlight assembly screws.

YM-029A

7. 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. Check headlight aim (see Adjusting Headlight Aim in this sub-section).

! WARNING

Do not operate the snowmobile unless headlight beam is adjusted properly. An incorrectly adjusted beam will not provide the operator the optimum amount of light.

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

6. With the windshield in position, secure the windshield to the frame using the four screws. Tighten securely.

7. Connect the console harness; then install the hood assembly and secure with the screws.

Headlight Bulb

NOTE: The bulb portion of the headlight is fragile.

HANDLE WITH CARE. When replacing the headlight bulb, the bulb assembly must first be removed from the housing. Do not touch the glass portion of the bulb. If the glass is touched, it must be cleaned with a dry cloth before installing.

1. Disconnect the headlight harness connector from the bulb; then remove the rubber grommet from the headlight housing.

2. Rotate the bulb retainer counterclockwise until it unlocks from the housing; then remove the bulb.

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.

0746-096

3. Install the bulb and retainer; then rotate the retainer clockwise until it properly locks in place.

4. Install the rubber grommet; then connect the headlight harness connector to the bulb.

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.

0746-807

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.

0747-529

2. Park the snowmobile on a level surface; then remove the torx-head screws and the rear access plate from beneath the snowmobile.

3. Place a drain pan beneath the engine oil drain screw; then remove the screw and allow the oil to drain completely. Install the drain screw. Tighten the screw with a new gasket to 10 ft-lb.

Engine Removing/Installing

— 3000

This engine sub-section has been organized to show a progression for the removing/installing of the Arctic Cat 3000 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 disconnect the hood harness and remove the torx screws securing the hood. Remove the hood.

XM318A

4. Remove both seats; then disconnect the battery cables (negative cable first). Remove the battery.

5. Remove the retaining nut from the neck of the gas tank and the two screws securing the upper console. Disconnect the wires from the reverse alarm, heated shield outlet, heated seat, and the accessory outlet; then loosen the 1/4 turn screws securing the lower console to the skid plate and remove both upper and lower consoles.

6. Remove the gas line vent hose from the check valve; then disconnect the gasline hose connector hose from the outlet of the fuel pump by pressing inward on the white connector, pressing in the black release, and finally pulling back on the hose.

7. Remove the cable ties securing the fuel pump wires and the fuel level sender wires.

XM402

8. Remove the four cap screws securing the gas tank assembly. Remove the gas tank.

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

10. Remove the cap screw and washer securing the drive clutch to the crankshaft.

11. Using the appropriate drive clutch puller, tighten the puller. Remove the drive clutch.

NOTE: If the drive clutch will not release, sharply

strike the head of the puller. Repeat this step until the clutch releases.

14. Loosen the two hose clamps securing the air silencer to the throttle body and the intake tube; then disconnect the ignition coils from the main harness. Remove the spark plug caps from the engine; then remove the three screws securing the air silencer to the tunnel. Remove the silencer.

XM427

15. Disconnect all connectors from the throttle body assembly; then remove the screw and clamp securing the harness to the throttle body.

12. Remove the five springs securing the resonator to the exhaust manifold; then disconnect the oxygen sensor. Remove the resonator.

XM401A

13. Remove the four nuts securing the exhaust manifold to the engine. Account for two exhaust gaskets.

XM426

16. Loosen the nut securing the cable. Remove the cable and the throttle body assembly.

XM406

17. Disconnect the main harness from both injectors; then remove the four cap screws securing the intake manifold to the engine. Remove the manifold.

XM403

+ 168 hidden pages

Arctic Cat ZR/XF/M Pantera/Notseman 3000, ZR/XF/M Pantera/Notseman 7000, ZR/XF/M Pantera/Notseman 9000 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Snowmobile Identification

Recommended Gasoline

RECOMMENDED OIL (3000)

RECOMMENDED OIL (7000/9000)

Engine Break-In

Drive Belt Break-In

3000

7000/9000

Genuine Parts

Varying Altitude Operation

CLUTCHING

ENGINE

SUSPENSION

TRACK

Preparation for Storage

Preparation After Storage

Engine Specifications

3000

7000

9000

Electrical Specifications

Drive System Components

Track Specifications

Suspension Specifications

SPRINGS

IFP SHOCK ABSORBERS

Torque Conversions

Torque Specifications

Steering and Body

SPECIAL TOOLS

Steering Post

REMOVING

INSTALLING

Ski (ZR/XF/Pantera)

REMOVING

INSPECTING

INSTALLING

INSPECTING

INSTALLING

Ski (Norseman)

REMOVING

Ski (XF HC/M)

Ski Wear Bar

REMOVING

INSPECTING

INSTALLING

REMOVING

INSTALLING

REMOVING

INSPECTING

INSTALLING

Spindle (XF HC/M)

INSTALLING

REMOVING

INSPECTING

Steering Tie Rod

REMOVING

INSPECTING

INSTALLING

Ski Alignment

CHECKING

ADJUSTING

REMOVING

VERIFYING

A-Arms (XF HC/M)

INSPECTING

INSTALLING

REMOVING

INSPECTING

INSTALLING

Ski Shock Absorber

REMOVING

CLEANING AND INSPECTING

INSTALLING

Sway Bar

REMOVING