Arctic Cat 120 Sno Pro 2010 Service Manual Download

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3-31

SC084

INSTALLING

1. Place the air silencer into position making sure the

boot is properly seated to the throttle bodies and

air silencer.

2. Install the belly pan center screen; then secure the

air silencer and screen to the front bumper with the

hold-down tab and three torx-head screws.

3. Install the air intake connector and secure the con-

nector to the air silencer with new cable tie.

Air Silencer

(Liquid-Cooled F-Series

2-Stroke)



NOTE: A number of servicing procedures require

that the air silencer be removed and installed. Pay
close attention to the



NOTE: preceding a partic-

ular servicing procedure that will direct the techni-
cian to this section and sub-section for removing/
installing the air silencer.

REMOVING

1. Remove the hood and the left-side and right-side

access panels; then remove the torx-head screws

securing the console.

0743-777

2. Lift the rear of the console and disconnect the con-

sole/main harness plug-in; then remove the con-

sole.

3. Remove the springs securing the expansion cham-

ber; then remove the expansion chamber from the

engine compartment. Account for the two exhaust

gaskets.

4. With the seat adjusted to its lowest position,

remove the self-tapping screw from the right-side

seat adjustment track; then remove the seat.

ZJ100A

5. Remove the torx-head screws securing the handle-

bar close-off panel; then remove the panel.

6. Remove the lock nuts and torx-head cap screws

(A) securing the right-side front and rear spar pan-

els; then remove the torx-head screws (D) securing

the left-side rear spar panel to the gas tank and

support tube.

742-207A



NOTE: The right-side rear spar panel will remain

secured to the chassis.

7. Remove the cap screw located directly above the

ECU securing the air-silencer duct to the front

upper panel; then disconnect the air temperature

sensor and remove the duct.



NOTE: To aid in accessing the cap screw, the

ECU may be removed.

8. Remove the body screws and flange nuts (C) from

each side securing the front bumper assembly to

the chassis; then remove the two remaining self-

tapping screws (B) from each side securing the

front bumper assembly. Remove the assembly.



NOTE: At this point, remove the air silencer and

account for the rubber exhaust bumper.

Next

Back

Section

Table of Contents

Manual

Table of Contents

Summary of Contents for 120 Sno Pro 2010

Page 1: ...ile decals display the words Warning Caution and Note to emphasize impor tant 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 pos...

Page 2: ...e Service Manual Service Manual TABLE OF CONTENTS Foreword Section 1 General Information Specifications 2 Engine 3 Engine Related Items 4 Fuel Systems 5 Electrical Systems 6 Drive Train Track Brake Systems 7 Rear Suspension 8 Steering and Body ...

Page 3: ...cifications 2 Stroke 1 14 Oil Consumption Specifications 2 Stroke 1 15 EFI Specifications 1 15 Throttle Valve Angle Specifications 1 15 Fuel Pump Specifications 570 cc 1 15 Carburetor Specifications 570 cc 1 15 Electrical Specifications 1 16 Drive System Specifications 1 21 Drive Clutch Driven Pulley Related Specifications 1 21 Drive Belt Dimensions 1 21 Drive System Components 1 21 Gear Case Perf...

Page 4: ... is 87 octane regular unleaded In many areas oxygenates either ethanol or MTBE are added to the gasoline Oxygenated gasolines containing up to 10 ethanol or up to 15 MTBE are acceptable gasolines Do not use gasolines containing methanol NOTE For optimum performance do not exceed the recommended 87 octane gasoline Using a higher octane gasoline will not increase overall performance RECOMMENDED GASO...

Page 5: ...on in the Section 6 of this manual Genuine Parts When replacement of parts is necessary use only gen uine Arctic Cat parts They are precision made to ensure high quality and correct fit High Altitude Operation Operating a snowmobile at varying altitudes requires changes in performance components These changes affect drive train components and carburetion compo nents NOTE The 1100 cc turbo does not...

Page 6: ...mosphere between high altitude and sea level All of these characteristics will become more evident the higher the altitude It will be necessary to make changes to the fuel sys tems carbureted models and drive systems that sup port engine operation as altitude changes TURBOCHARGING Turbocharging is one method of compensating for loss of air density that works extremely well when applied to four cyc...

Page 7: ...rings with different spring rates are avail able 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 bind ing Equal adjustments should be maintained on both sides of the snowmobile On the Sno Pro models with air shocks they are individually adjustable for th...

Page 8: ... part of the engine 3 On the 4 stroke models change the engine oil 4 On the 2 stroke models place the rear of the snowmobile up on a shielded safety stand 5 On the 500 600 800 1000 cc start the engine and allow to idle With the engine idling pry the intake boot forward then spray an Engine Storage Pre server into the intakes until the engine exhaust starts to smoke heavily or until the engine star...

Page 9: ...tem Check exhaust system and air silencer for obstructions On the turbo models inspect the air filter and replace as necessary 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 Remove and inspect the drive belt for cracks and tears Check belt specifications Replace if dam aged ...

Page 10: ...e 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 pre mature drive belt wear After the break in period drive belt deflection should be checked according to the instructions given in Sec tion 6 of this manual DRIVE BELT BREAK IN Drive belts require a break in period of ap...

Page 11: ... 1000 1100 cc Adjust track tension and alignment Check throttle cable tension Check oil injection pump adjustment 2 stroke Check engine idle Check coolant level Check gear case lubricant level Check engine oil 4 stroke 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 ...

Page 12: ...eight 0 315 0 236 0 433 0 512 0 512 ITEM 1100 cc Engine Model Number Non Turbo Turbo AA11L5 AB11L5 Displacement 1056 cc No of Cylinders 2 Bore x Stroke 98 x 70 Cooling System Liquid Spark Plug NGK MR8AI 9 Spark Plug Gap 0 031 0 035 Piston Skirt Cylinder Clearance Non Turbo Turbo 0 0011 0 0016 0 0006 0 0010 Piston Pin Diameter Non Turbo Turbo 0 8658 0 8661 0 9447 0 9449 Piston Pin Bore Diameter Non...

Page 13: ...haft is still supported on the outer bearings using V blocks 728 144A NOTE Measure in from the shaft end the speci fied amount when checking runout at points D and F When checking runout in the center place indi cator on center of bearing as shown at point E Maximum runout at any of the three measuring points is 0 002 ENGINE TYPE SQUISH GAP 500 cc 0 059 570 cc 0 066 600 cc 0 059 800 cc 0 059 1000 ...

Page 14: ...erification use a dial indicator and scribe a mark on the flywheel for 13 BTDC 0744 905 570 cc BTDC 20 2000 RPM 0 099 0742 217 600 cc BTDC 15 2000 RPM 0 059 For timing verification use a dial indicator and scribe a mark on the flywheel for 15 BTDC 740 130A 800 cc F Series BTDC 16 2000 RPM 0 0675 0744 782 Next Back Section Table of Contents Manual Table of Contents ...

Page 15: ...1 13 1 800 cc CFR Crossfire M Series BTDC 15 5 2000 RPM 0 0634 0744 783 1000 cc BTDC 14 1800 RPM 0 057 0744 034 Next Back Section Table of Contents Manual Table of Contents ...

Page 16: ...ring once each time the engine is started The 800 cc system is checked at 4800 RPM and the 1000 cc system is checked at 6100 RPM Crossfire F Series or at 6270 RPM M Series 741 635A 739 715A 742 209A 0735 516 APV Position RPM ENGINE VALVE POSITION CYCLE RPM 600 cc Full Open 73 7400 Low High Alt 800 cc Mid Open Full Open 60 6500 Low High Alt 78 8100 Low High Alt 1000 cc Mid Open Full Open 6300 Low H...

Page 17: ...t Model TPS TOOL DC VOLTS ANALYZER TOOL DC VOLTS 500 cc Full Closed 0 412 0 414 N A Idle 0 710 0 818 0 710 0 818 Full Open 3 472 4 048 3 470 4 046 600 cc Full Closed 0 412 0 414 N A Idle 0 646 0 754 0 646 0 754 Full Open 3 472 4 485 3 470 4 485 DIAGNOSTIC TOOL 800 cc Full Closed 0 412 0 414 N A Idle 0 646 0 754 3 99 6 66 Full Open 3 472 4 485 74 97 89 37 1000 cc Full Closed 0 392 0 394 N A Idle 0 ...

Page 18: ...ensor 148 222 ohms green white brown Lighting Coil 0 12 0 18 ohm yellow yellow Spark Plug Cap 4000 6000 ohms cap end cap end Description Test Value Test Connections Voltage Regulator Rectifier 11 14 AC volts yellow brown Low Oil Light Sending Unit Less than 1 ohm float end down terminal terminal Ignition Switch Less than 1 ohm key in OFF posi tion terminal terminal Description Peak Voltage Test Te...

Page 19: ...n green Injection Coil 15 2 22 8 ohms blue white blue white Fuel Pump Coil 1 52 2 28 ohms orange orange Spark Plug Cap 4000 6000 ohms cap end cap end Description Test Value Test Connections Chassis Control Unit 10 15 DC Volts red blue low power red black high power black low power black high power Low Oil Light Sending Unit Less than 1 ohm float end down terminal terminal Ignition Switch Less than...

Page 20: ...Fuel Pump Coil 1 52 2 28 ohms orange orange Spark Plug Cap 4000 6000 ohms cap end cap end Description Test Value Test Connections Chassis Control Unit 10 15 DC Volts red blue low power red black high power black low power black high power Low Oil Light Sending Unit Less than 1 ohm float end down terminal terminal Servomotor 12 DC Volts red black counterclockwise black red clockwise black red count...

Page 21: ...4000 6000 ohms cap end cap end Description Test Value Test Connections Voltage Regulator Rectifier F Series 10 15 DC Volts red violet black Voltage Regulator Rectifier Crossfire M Series 10 15 DC Volts 11 14 AC Volts red blue yellow black black Low Oil Light Sending Unit Less than 1 ohm float end down terminal terminal Servomotor 12 DC Volts red black counter clockwise black red clockwise black re...

Page 22: ...hms red green brown green Crankshaft Position Sensor 173 211 ohms green blue Coolant Temperature Sensor 2 3k 2 6k ohms yellow black ground Injection Coil Starter Relay 3 6 ohms black yellow black Spark Plug Cap 4000 6000 ohms cap end cap end Description Test Value Test Connections Voltage Regulator Rectifier 12 14 5 DC Volts terminal terminal Magneto Coil no load three tests 36 44 AC Volts yellow ...

Page 23: ... 060 34 3600 72 7400 54 34T 66T 66 54 F5 0 5000 Red 58 0g White 42 36 0627 067 33 3500 78 8000 66 34T 54T 54 66 F 570 0 5000 Gold 73 0g Orange 44 40 0627 067 31 3300 67 6900 63 34T 57T 57 63 F6 Sno Pro 0 5000 Yellow White 70 0g Orange 46 40 0627 046 37 3900 78 8000 60 34T 60T 60 60 F8 0 5000 Orange Black 71 5g Orange 44 40 0627 046 42 4600 81 8300 56 34T 64T 64 56 F8 Sno Pro 0 5000 Orange Black 71...

Page 24: ... 94 97 100 103 106 109 112 115 118 121 124 127 130 133 62 58 88 91 94 97 100 103 106 108 111 114 117 120 123 125 128 61 59 85 88 91 94 97 99 102 105 108 110 113 116 119 121 124 60 60 83 85 88 91 93 96 99 101 104 107 109 112 115 117 120 59 61 80 83 85 88 90 93 95 98 101 103 106 108 111 114 116 58 62 77 80 82 85 87 90 92 95 97 100 102 105 107 110 112 57 63 75 77 80 82 84 87 89 92 94 97 99 101 104 10...

Page 25: ... 1 75 2 2 2 25 F Series Z1 Turbo LXR Sno Pro 128 1 25 1 75 2 2 2 25 M Series 153 162 2 25 2 2 5 2 2 5 T570 TZ1 LXR 144 1 1 75 2 2 2 25 TZ1 Turbo Z1 Turbo EXT 144 1 25 1 75 2 2 2 25 Model Diameter F Series T Series Z1 13 5 mm Crossfire CFR 7 16 Model Free Length Rate LB Inch of Coils Tab F5 T570 F570 11 25 90 6 2 8 2 NO M6 M8 STD 12 00 120 12 75 YES F 570 9 36 90 8 5 NO Bearcat 570 XT Z1 XT 9 50 14...

Page 26: ... 12 00 17 55 5 55 6 68 Model Collapsed Length Extended Length Stroke Piston Depth Bearcat XT 8 42 12 49 4 07 N A F5 F 570 Z1 8 48 12 53 4 05 N A Bearcat 570 T Series 8 09 11 78 3 69 N A CFR F6 F8 Sno Pro Z1 Turbo LXR EXT 8 17 11 76 3 59 0 58 Crossfire 600 800 8 54 12 51 3 97 0 62 M Series HCR 8 11 11 25 3 14 0 58 Model Collapsed Length Extended Length Stroke Piston Depth Bearcat 570 T Series 10 90...

Page 27: ...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...

Page 28: ...1 26 570 cc 570 ENG10 Next Back Section Table of Contents Manual Table of Contents ...

Page 29: ...1 27 1 570ENG09 Next Back Section Table of Contents Manual Table of Contents ...

Page 30: ...1 28 500 cc 500CC1A09 Next Back Section Table of Contents Manual Table of Contents ...

Page 31: ...1 29 1 500CC2A_10 Next Back Section Table of Contents Manual Table of Contents ...

Page 32: ...1 30 600 cc 600CC1B_09 Next Back Section Table of Contents Manual Table of Contents ...

Page 33: ...1 31 1 600CC2A_10 Next Back Section Table of Contents Manual Table of Contents ...

Page 34: ...1 32 800 cc 800_10_1 Next Back Section Table of Contents Manual Table of Contents ...

Page 35: ...1 33 1 800_10_2 Next Back Section Table of Contents Manual Table of Contents ...

Page 36: ...1 34 1000 cc 1000_10_2 Next Back Section Table of Contents Manual Table of Contents ...

Page 37: ...1 35 1 1000_10_1 Next Back Section Table of Contents Manual Table of Contents ...

Page 38: ...1 36 1100 cc 1100ccJAG10 Next Back Section Table of Contents Manual Table of Contents ...

Page 39: ...1 37 1 1100ccZ1RV10 Next Back Section Table of Contents Manual Table of Contents ...

Page 40: ... Engine Torque Patterns 1100 cc Engine Case Oil Separator Plates 741 582A 741 737A Oil Pan Plate Oil Pan 741 738A 741 584A Cylinder Head 741 617A Next Back Section Table of Contents Manual Table of Contents ...

Page 41: ...1 39 1 Camshaft Cover Engine Cover 741 624A 741 580A Magneto Cover Exhaust Manifold 741 583A 744 003B Next Back Section Table of Contents Manual Table of Contents ...

Page 42: ...ssis 96 in lb Suspension Mounting Bracket Upper Chassis 20 Shock Mount Frame SuspensionMounting Bracket 96 in lb Shock Mount Frame Front Upper Frame 96 in lb Steering Post SuspensionMounting Bracket 35 Steering Post Bearing Bracket Steering Support 96 in lb Steering Tie Rod Steering Post 35 Steering Tie Rod Steering Arm 30 Steering Arm SuspensionMounting Bracket 20 Drag Link Steering Arm 12 Tie Ro...

Page 43: ...ame 40 Wear Strip Rail 50 in lb End Cap Rail 80 in lb Mounting Block Rail 20 Idler Wheel Mounting Block 20 Idler Arm Pivot Idler Arm 20 Rear Arm Rail 40 Rear Arm Idler Arm 40 Front Arm Rail 40 Idler Wheel Front Arm Rail 40 Idler Wheel Pivot Assembly Rail 40 Rear Arm Shock Pivot Axle Rail 40 Front Arm Shock Bracket Axle Rail 40 Rear Arm Limiter Rail 40 Front Rail Support Rail 20 Limiter Strap Rail ...

Page 44: ...e Rail 20 Front Arm Shock Axle Rail 40 Front Arm Rail 40 Rear Shock Pivot Front Arm 20 Limiter Strap Rail Support 120 in lb Rear Arm Limiter Rail 50 Rail Support Rail 20 Skid Frame Tunnel 40 Front Arm Slide Axle Tunnel 40 Bearcat 570 T Series Z1 EXT Item Secured to Torque ft lb Wear Strip Rail 50 in lb End Cap Rail 80 in lb Mounting Block Rail 20 Idler Wheel Mounting Block 20 Rear Arm Rail 40 Rear...

Page 45: ...ng CFR 800 1000 Crossfire 800 M Series 800 1000 2 34 Engine Removing Installing F Series 500 600 800 2 42 Engine Servicing 500 600 cc 2 56 Engine Servicing 800 1000 cc 2 79 Engine Bearcat Z1 XT TZ1 Z1 2 106 Troubleshooting Engine 2 Stroke Carbureted 2 142 Troubleshooting Engine 2 Stroke EFI 2 144 Troubleshooting Engine 4 Stroke 2 148 Manual Table of Contents ...

Page 46: ...ents 2 14 Assembling 2 16 Installing 2 22 Removing Engine 1 Remove the hood and the left side and right side access panels then remove the torx head screws securing the console 0743 777 2 Lift the rear of the console and disconnect the con sole main harness plug in then remove the con sole and disconnect the battery 3 Remove the springs securing the expansion cham ber to the exhaust manifold and r...

Page 47: ...f applicable account for the two sleeves NOTE It is advisable to apply a film of grease to the end of the puller to aid in removal of the drive clutch 9 Remove the cap screw from the driven pulley and slide the driven pulley off the gear case input shaft Account for alignment washers if applicable FZ021 NOTE If the driven pulley is tight on the input shaft remove the driven pulley using the Driven...

Page 48: ... Loosen the carburetor flange clamps and remove the carburetors from the intake flanges then remove the clamp and disconnect the impulse line from the crankcase FZ006 18 Disconnect the oil injection cable from the oil pump and account for the E clip and washer then disconnect the oil supply hoses from the pump and plug the hoses to prevent leakage 19 Remove the cap screw and lock nut securing the ...

Page 49: ...flange assembly Account for the gaskets insulators and the heat deflector 2 Remove the five cap screws securing the front exhaust side shroud to the cylinder head Account for the special washers MD0276 NOTE Keep the special mounting hardware with the shrouds for assembling purposes Cap screws securing the front and rear shrouds use special washers MD0065 3 Remove the spark plug grommets MD0060 4 U...

Page 50: ...heel it must be replaced as an assembly 7 Remove the six cap screws securing the rear intake side shroud then remove the shroud Account for the special washers MD0277 MD0067 8 Remove the rubber insulator grommet from the crankcase then remove two Phillips head cap screws securing the ignition timing sensor MD0075 MD0074 CAUTION To prevent damage to the crankshaft install a protec tive insert into ...

Page 51: ...l retainer plate on the PTO side then remove the plate MD0081 12 Remove the spark plugs MD0083 13 Remove the eight cap screws two nuts and two washers securing the cylinder head to the cylin ders then remove the cylinder head Discard the cylinder head gasket MD0289 14 Remove the four 6 mm nuts and eight 10 mm nuts securing the cylinders to the crankcase NOTE Using a felt tip marker mark the cylind...

Page 52: ...e piston pin cir clip and remove the piston pin using Piston Pin Puller taking care not to drop the piston pin bear ing washers into the crankcase MD0094 NOTE The open sides of the piston pin bearing washers face inward MD0251 CAUTION When removing a cylinder make sure to support the piston so it will not be damaged Next Back Section Table of Contents Manual Table of Contents ...

Page 53: ...726 306A MD0271 17 Remove the two Allen head cap screws securing the oil injection pump then remove the pump Account for an O ring MD0090 MD0092A 18 Remove the oil injection pump driveshaft retainer Account for an O ring MD0100A 19 Remove the oil injection pump driveshaft Account for a thrust washer MD0101 Next Back Section Table of Contents Manual Table of Contents ...

Page 54: ...move any carbon buildup from the combustion chambers being careful not to nick scrape or damage the combustion chambers or the sealing surfaces 2 Inspect the spark plug holes for any damaged threads 3 Inspect the cylinder head for flatness using a straightedge and a feeler gauge Acceptable war page must not exceed 0 002 in NOTE If the warpage exceeds specification resurface the cylinder head using...

Page 55: ... tool clean carbon from the ring grooves Be sure to position the ring with its tapered side up 3 Inspect each piston for cracks in the piston pin and skirt areas 4 Inspect each piston for seizure marks or scuffing Repair with 400 grit wet or dry sandpaper and water or honing oil AN135 NOTE If scuffing or seizure marks are too deep to correct with the sandpaper it will be necessary to replace the p...

Page 56: ...ts by continuing to move each side in a figure eight motion Warped compo nents must be replaced NOTE In order to inspect insulator plate true ness it will be necessary to remove the studs A932 CRANKSHAFT NOTE If any servicing of the connecting rods center bearings or oil injection pump drive gear is necessary Arctic Cat recommends that the crank shaft be taken to a qualified machine shop for that ...

Page 57: ...INSTALLING OUTER CRANKSHAFT BEARINGS NOTE Steps 1 3 are for installing the MAG side bearing 1 Wrap a thick towel around the crankshaft then secure the crankshaft vertically in a vise 2 Heat the bearing either by placing the entire bear ing in a pan of oil on a hot plate or by squirting oil into the bearing and using a propane torch to heat the inner race of the bearing until a slight smoke is note...

Page 58: ...er bore towards the MAG side and PTO side of the cylinder 3 Pull the recoil rope and crank the engine over sev eral times while the solder is being held firmly in place 4 Remove both pieces of solder from the cylinder Using the micrometer measure the very end of the squeezed solder piece Record the reading NOTE If the solder hasn t been squeezed by the piston a larger piece of solder must be used ...

Page 59: ...asure each piston ring end gap Acceptable ring end gap must be within 0 0120 0 0196 in MD2501 PISTON PIN AND PISTON PIN BORE 1 Measure the piston pin diameter at each end and in the center Acceptable piston pin measurement must be within 0 7085 0 7087 in If any measure ment varies by more than 0 001 in the piston pin and bearing must be replaced as a set IO012 2 Insert a snap gauge into each pisto...

Page 60: ...ed holes of the crankcase and cylinders to properly tighten NOTE When the use of a lubricant is indicated use Arctic Cat 50 1 Injection Oil 1 Place the upper crankcase half with its bottom side up on two blocks of wood 2 Lightly grease the inner lips of the crankshaft seals then slide them onto the crankshaft 3 Apply oil to the crankshaft bearings then install the crankshaft into the upper crankca...

Page 61: ...hen remove the reed valve and stopper MD0088 NOTE Apply blue Loctite 243 on the machine screws when assembling then tighten the machine screws to 48 in lb NOTE Make sure the angled corner on the reed valve align with the angled corner on the reed valve stopper MD0213 NOTE If installing the reed valve cage use blue Loctite 243 on the cap screws and tighten to 96 in lb 7 Install the piston rings on ...

Page 62: ...base gasket into position on the crankcase making sure the gasket is properly ori ented so the dowel pins will fit through the holes easily 12 Rotate each piston ring until the ring ends are properly positioned with the pins in the ring grooves then apply oil to the piston assemblies and cylinder bores Using a ring compressor or the fingers compress the rings and slide the cylinder over the piston...

Page 63: ...stall the eight cap screws and two flange nuts Tighten the cap screw in three steps to 19 ft lb using the pattern shown then tighten the flange nuts to 21 ft lb MS384 MS384 0738 291 15 Install the spark plugs then tighten to 19 ft lb Pressure test the engine see Section 3 MS385 16 Position the seal retainer plate on the PTO side then install the four cap screws Tighten the cap screws to 96 in lb N...

Page 64: ...h the hole in the crankcase then install the stator Lightly coat the three Allen head cap screws with blue Loctite 243 then tighten to 48 in lb MD0076 MD0274 19 Place the ignition timing sensor wiring through the hole in the crankcase then position the ignition timing sensor and install two Phillips head cap screws coated with blue Loctite 243 Tighten the cap screws to 48 in lb MD0074 MD0073 Next ...

Page 65: ...heel cap screw to 50 ft lb MD0264 MD0278 23 Using Flywheel Spanner Wrench to hold the starter cup tighten the three cap screws from step 21 to 28 ft lb TZ067A 24 Using the six cap screws and the special washers install the rear intake side shroud Tighten the cap screws coated with red Loctite 271 to 96 in lb MD0277 25 Using the five 6 mm cap screws and the special washers install the front exhaust...

Page 66: ...ive shaft Tighten the Allen head cap screws coated with blue Loctite 243 to 48 in lb MD0294 NOTE For assembling purposes always use new O rings lubricated with oil on the oil injection pump and retainer MD0090 29 Install the first set of intake gaskets coated with High Temp Sealant heat deflector remaining gaskets insulators and flanges Secure with nuts and washers and tighten the nuts threads coa...

Page 67: ...ve 6 Remove the oil bleed plug from the oil injection pump When oil flows from pump free of air bub bles and the hose is full of oil install the oil bleed plug and tighten NOTE Place a cloth beneath the oil injection pump to contain any oil spilled during the bleeding process 7 With the throttle cable and fuel lines properly routed install the flange clamps to the intake flanges then install the c...

Page 68: ...s and lock washers Tighten the nuts to 15 ft lb FZ015 17 Place the recoil starter into position and secure the starter with the cap screws threads coated with blue Loctite 243 In a crisscross pattern tighten to 60 in lb NOTE Install the engine ground wire to the proper recoil cap screw as noted during disassem bly TZ065C FZ011D 18 With the U nut clip in place install the heat shield and secure the...

Page 69: ...8 23 Install the alignment washers if applicable then install the driven pulley on the gear case input shaft Tighten the cap screw to 32 ft lb FZ021 FZ019 24 Check drive clutch driven pulley alignment see Section 6 Install the drive belt Check belt deflec tion Secure the belt guard NOTE Make sure the rubber exhaust bumper is in position on the close off cover before installing the expansion chambe...

Page 70: ... that coolant is circulating through the cooling system properly 30 Verify the tightening torque of the drive clutch 31 Secure the console to the steering support with the torx head screws and tighten the screws securely then close the left side and right side access panels and close the hood 0743 777 CAUTION Never run the engine with the hood harness discon nected or damage to the electrical syst...

Page 71: ...ing Top Side Components 1 Remove the belt guard and disconnect the exhaust temperature sensor then remove the cable ties securing the sensor harness to the chassis NOTE For assembling purposes note the loca tion of the cable ties securing the harness to the chassis 2 Remove all springs hairpin clip and tab washer securing the expansion chamber and resonator then remove these components from the en...

Page 72: ...id Cooling System Section 3 11 Loosen the flange clamps securing the throttle body assembly to the flange then move the throt tle body assembly forward to allow room to dis connect the oil injection cable control rod from the oil injection pump CM028A 12 Loosen the clamps securing the coolant hoses con nected to the cylinders beneath the exhaust ports and the PTO side throttle body then remove the...

Page 73: ...42 238A 18 Loosen the cap screw lock nut C securing the MAG side engine mounting bracket to the front end 19 Remove the cap screw and lock nut D securing the engine bracket to the front lower mounting bracket 20 Disconnect all engine harness connectors NOTE For installing purposes note the routing of the harnesses and the location of cable ties 21 Remove the lower coolant hose then move the engine...

Page 74: ...nd secure with the hose clamp MS382D 3 Connect all electrical wiring making sure all wir ing and coolant hoses are routed properly as noted in removing then place the engine into the mounting position NOTE Secure the wiring harnesses with cable ties as noted in removing 4 Install the cap screw and nut C securing the MAG side engine mounting bracket to the side plate DO NOT TIGHTEN AT THIS TIME 742...

Page 75: ...e the hose to the fuel rail Tighten the clamp securely then using a cable tie secure the hose to the MAG side engine mounting bracket 12 Install the two coolant hoses to the MAG side and PTO side of the crankcase below the exhaust ports and the overflow hose then tighten the coolant hose clamps and the throttle body flange clamps FS271A 13 Apply a thin coat of high temperature silicone sealant to ...

Page 76: ...e sure to wipe both the crankshaft taper and clutch mounting taper clean using a clean towel 22 Apply a few drops of oil to the threads of the drive clutch cap screw then place the drive clutch into position on the crankshaft Secure with the cap screw and lock washer Tighten to 51 ft lb NOTE Apply a coat of Anti Seize Thread Com pound to the end of the input shaft 23 Install the alignment washers ...

Page 77: ...he long hook portion of the spring must be attached to the exhaust manifold or premature spring failure will result 31 Connect the exhaust temperature sensor plug in then secure the sensor harness to the chassis as noted during engine removal 32 Start the engine and warm up to operating temper ature then verify that all components are function ing properly and that coolant is circulating through t...

Page 78: ...Proceed to Servicing Top Side Components 1 Remove the belt guard and disconnect the exhaust temperature sensor then remove the cable ties securing the sensor harness to the chassis NOTE For assembling purposes note the loca tion of the cable ties securing the harness to the chassis 2 Remove all springs and the hairpin clip securing the expansion chamber and resonator then remove these components f...

Page 79: ...on harness from the ECU then remove the torx head screw securing the air silencer to the front end Remove the silencer CM026A 12 Pull the air silencer boot forward enough to gain access to the throttle body assembly CM027 13 Loosen the flange clamps securing the throttle body assembly to the flange then move the throt tle body assembly forward to allow room to dis connect the oil injection control...

Page 80: ...e way disconnect the oil hose from the oil injection pump then plug the oil hose CM029A 17 Remove the recoil starter from the engine Secure it out of the way in the engine compartment CM137 18 Remove the wiring harness wrap then disconnect the ignition main harness connectors and the tem perature sensor connector Secure the harness out of the way CM134 19 Disconnect the lower coolant hose from the...

Page 81: ...side engine mounting bracket then remove the cap screws A and B from step 21 25 Lift the engine out of the engine compartment 26 Remove the exhaust manifold and engine mount ing brackets from the engine Account for nuts and gaskets 27 Remove the clamp securing the coolant supply hose from the cylinder head to the water pump Then remove the hose from the engine CM181 Installing 1 Install the MAG si...

Page 82: ...et to engine cap screws D coated with blue Loctite 243 to 24 ft lb then tighten the lock nuts C securing the mounting bracket to the chassis from step 6 to 20 ft lb 8 Tighten the MAG side engine mounting bracket to chassis cap screw and lock nut A from step 3 to 20 ft lb and the front lower mounting bracket cap screw and lock nut B from step 3 to 30 ft lb 9 Connect all electrical wiring harness pl...

Page 83: ...nge clamps then connect the gasline hose to the throttle body assembly and tighten the clamp securely FC051 15 Install the oil pump linkage arm to the throttle body pulley then verify oil injection pump syn chronization see Section 4 CM129B 16 Connect the two coolant hoses to the throttle body assembly then secure with the clamps CM131A 17 With the air silencer boot properly positioned on the thro...

Page 84: ...omotor Secure the cable housings with the cable holder CM127 20 Rotate the servomotor clockwise to remove any slack from the cables then install the servomotor retaining clip TZ069A 21 Check APV cable adjustment See Arctic Power Valve APV System in Section 3 NOTE Before installing the drive clutch be sure to wipe both the crankshaft taper and clutch mounting taper clean using a clean towel 22 Plac...

Page 85: ...ws then tighten the two cap screws to the oil tank to 26 in lb Tighten the remaining cap screw to 20 ft lb 30 Start the engine and warm up to operating temper ature then verify that all components are function ing properly and that coolant is circulating through the cooling system properly 31 Allow the engine to cool then check the coolant level and add coolant as necessary Verify the tightening t...

Page 86: ...r of the console and disconnect the con sole main harness plug in then remove the con sole 3 Remove the hairpin clip and all springs securing the expansion chamber and resonator then remove these components from the engine compartment Account for the two exhaust gaskets NOTE On the LXR disconnect the negative cable from the battery 4 On the standard models push down on both seat retainer brackets ...

Page 87: ...the puller If the drive clutch will not release sharply strike the head of the puller Repeat this step until the clutch releases Remove the drive clutch and the drive belt 11 Remove the cap screw from the driven pulley and slide the driven pulley off the gear case input shaft Account for alignment washers FS192 NOTE If the driven pulley is tight on the driven shaft pull the driven pulley off using...

Page 88: ...on cable control rod from the oil injection pump FS178A NOTE Remove the clamps from the intake flanges to avoid damage during engine removing 19 On the 500 600 cc loosen the clamps securing the coolant hoses connected to the cylinders beneath the exhaust port and the throttle body assembly then remove the vent tube from the top of the cyl inder head CM030A 20 On the 800 cc loosen the clamps securi...

Page 89: ... flex drive shaft from the motor FS177A 23 Remove the spark plug wires from the plugs then disconnect the two wire plug in for the coolant temperature sensor located below the ignition coil FS193A FS211A NOTE On the 800 cc at the coolant filler neck bracket disconnect the knock sensor wiring con nector and slide the wiring out of the cable tie 500 600 cc 800 cc 500 600 cc 800 cc 500 600 cc 800 cc ...

Page 90: ...to disconnecting the hose place an absorbent towel beneath the hose to collect any coolant from the exchanger 26 Remove the four cap screws securing the upper bearing bracket to the upper support plate account for the two bracket plates then secure the steering post to the headlight support bracket FS182A FS183A 27 Remove the exhaust manifold from the engine Account for the flange nuts and gaskets...

Page 91: ...ward enough to remove the engine 33 Tip the engine forward and support the engine in a position to gain access to the clamp securing the coolant hose to the thermostat housing then loosen the clamp and remove the hose FS184A 34 Carefully remove the engine out the MAG side of the chassis FS186 35 Remove the clamps securing the coolant supply hoses to the engine then remove the hoses FS187A FS216A 3...

Page 92: ...0 600 cc install the front lower engine plate to the engine with four cap screws G coated with blue Loctite 243 Tighten to 50 ft lb 4 Place the engine into the engine compartment from the MAG side then tip the engine forward and support the engine in this position Connect the coolant hose to the thermostat housing FS194A 500 600 cc 800 cc CAUTION Direct the hose clamp screw to the back side of the...

Page 93: ... and secure with four cap screws D coated with blue Loctite 243 Tighten to 50 ft lb 8 Position the torque bumper against the gear case then install the PTO side engine mounting bracket NOTE Prior to installing the bracket assure that the U nut clip is centered in position FS195A 9 Using the illustration following step 2 install the cap screw and lock nut A and the lower cap screw B securing the PT...

Page 94: ...NOTE For installing purposes it may be neces sary to loosen the lock nut securing the bracket to the starter motor C Place the positive and negative cables on the starter motor then secure with the lock nuts Tighten securely FS205A 14 Place the recoil starter into position and secure the starter with the cap screws In a crisscross pattern tighten to 96 in lb FS180 FS210 15 Connect the oil supply h...

Page 95: ...open position If the marks are not aligned adjust synchronization by loosen ing the jam nuts on the adjuster Rotate the jam nuts adjuster nut until properly aligned Tighten jam nuts 0742 853 NOTE On the 500 cc when the cable adjusting nut is adjusted correctly the throttle lever will move approximately 1 8 in before the oil injection pump control arm begins to move 0742 854 0744 528 17 On the 500 ...

Page 96: ...nnect the coolant overflow hose to the cylinder head then connect the spark plug wires to the spark plugs NOTE On the 800 cc connect the knock sensor wiring to the wiring harness then secure the con nector to the coolant filler neck bracket with the push mount cable tie FS212A NOTE At this point secure the coolant hose gasline hose and on the LXR the battery cables together FS214A NOTE Steps 23 25...

Page 97: ...e Section 6 29 Secure the bearing bracket steering post assembly to the upper support plate with the bracket plates and cap screws coated with blue Loctite 243 Tighten the cap screws to 96 in lb FS182A NOTE When installing the bracket plates the wider end of the plate must be directed up FS200A 30 Install the air silencer onto the throttle bodies mak ing sure the dual intake boot is properly posit...

Page 98: ...Tighten securely NOTE If the ECU was removed to gain access to the air intake duct cap screw install the ECU using the two lock nuts Tighten the lock nuts securely then connect the harness plug ins to the ECU FS202A 35 Using the illustration following step 31 secure the left side rear spar panel to the gas tank and support tube with the three torx head screws D Tighten the screws securely 36 On th...

Page 99: ...and that coolant is circulating through the cooling system properly 44 Allow the engine to cool then check the coolant level and add coolant as necessary 45 Verify the tightening torque of the drive clutch 46 Secure the console to the steering support with the torx head screws from step 41 and tighten the screws securely then close the left side and right side access panels and close the hood 0743...

Page 100: ...t Service Parts Department Disassembling 1 Using the Flywheel Spanner Wrench to secure the flywheel remove the flywheel cap screw and flat washer then remove the three starter pulley cap screws and remove the pulley FC014 FC015 2 Install Flywheel Puller Insert onto the end of the crankshaft FC016 3 Using Flywheel Puller or suitable substitute remove the flywheel from the crankshaft by tight ening ...

Page 101: ... wire then remove the cap screw FC018 6 On the 600 cc remove the Allen head cap screws securing the magneto case to the crankcase Account for four alignment pins NOTE Note the different sized cap screws for assembling purposes FC019 RS020A 7 Remove the stator plate from the engine FC021 FC065 NOTE The stator plate screws had Loctite applied to the threads during assembly Using an impact driver app...

Page 102: ...o allow residual coolant to drain from the cylinder crank case water jacket 12 On the 500 cc remove the eight nuts securing the cylinders to the crankcase then using a rubber ham mer gently tap the cylinders and remove from the crankcase by lifting them straight up off their studs Account for gasket s and any alignment pins 13 On the 600 cc remove the four nuts and four bolts securing the cylinder...

Page 103: ...the intake flanges and reed valve assem blies FC030 18 Remove the three cap screws securing the thermo stat cap then remove the cap gasket and thermo stat FC032 19 Remove the six screws securing the water pump cover to the crankcase and remove the cover Account for the O ring gasket and the alignment pins 20 Remove the cap screw securing the water pump impeller then slide the impeller free of the ...

Page 104: ... crankshaft Account for the C ring Remove the bearing retaining pins and account for the crank case dowel pins NOTE The end bearings are not pressed onto the crankshaft After removing the seals use care not to allow the bearings to slide off the crank shaft 27 Remove the oil injection pump water pump drive shaft from the lower crankcase half Account for the thrust washer on the outer end of the sh...

Page 105: ...ve the left side and right side access panels NOTE Some photographs used in this sub sec tion are used for clarity purposes only and are not designed to depict actual conditions REMOVING TOP SIDE COMPONENTS To access top side components use the following pro cedure 1 Remove the cap screws securing the left side steering support and the side plate brace to the chassis then remove the brace CM211A C...

Page 106: ...utside diameter hose FC058 B In turn on each fitting of the crankcase run the vacuum pump to purge the cylinder crankcase water jacket of the residual coolant NOTE Removing all residual coolant from the cylinder crankcase is critical 9 Remove the cap screws and nuts securing the cyl inders to the crankcase then using a rubber ham mer gently tap the cylinders and remove from the crankcase by liftin...

Page 107: ... each ring faces the dome of the piston 726 306A 2 Apply oil to the connecting rod small end bear ings then install the small end bearings Install a washer on each side of the connecting rod NOTE The shoulder side of the washer must seat to the needle bearing CM172A NOTE Prior to installing the pistons make sure to install the MAG side piston pin circlips first 3 Place each piston over the connect...

Page 108: ... cap screws to 44 ft lb in three steps using the pattern shown 0738 220 7 Place the cylinder head into position on the cylin ders making sure the O rings are properly posi tioned then in two steps tighten the 8 mm cap screws to 25 ft lb using the pattern shown Install the spark plugs and tighten to 19 ft lb NOTE Applying a light coat of grease to the O rings will help keep them in position in the ...

Page 109: ...al tool remove any carbon buildup from the combustion chambers being careful not to nick scrape or damage the combustion chambers or the sealing surfaces 2 Inspect the spark plug holes for any damaged threads 3 Inspect the cylinder head for flatness using a straightedge and a feeler gauge Acceptable war page must not exceed 0 002 in NOTE If the warpage exceeds specification resurface the cylinder ...

Page 110: ...g as a tool clean car bon from the ring grooves Be sure to position the ring with its tapered side up 3 Inspect each piston for cracks in the piston pin and skirt areas 4 Inspect each piston for seizure marks or scuffing Repair with 400 grit wet or dry sandpaper and water or honing oil AN135 NOTE If scuffing or seizure marks are too deep to correct with the sandpaper it will be necessary to replac...

Page 111: ... pump drive gear is necessary Arctic Cat recommends that the crank shaft be taken to a qualified machine shop for that service 1 Wash the crankshaft with bearings in parts clean ing solvent 2 Inspect the bearings for wear scoring scuffing damage or discoloration Rotate the bearings Bearings must rotate freely and must not bind or feel rough If any abnormal condition is noted replace the bearing FC...

Page 112: ...Place the reed stop per assembly into position and secure with the screws tightened to 48 in lb CM164A Measuring Critical Components NOTE Critical engine specifications charts can be found in Section 1 of this manual CYLINDER HEAD VOLUME Squish Gap Method To check the squish gap a micrometer and two heavy pieces of solder will be needed 1 Remove the spark plugs from the engine 2 Simultaneously ins...

Page 113: ...ANCE 1 Measure each cylinder front to back about 1 in from the bottom of each cylinder 2 Measure the corresponding piston skirt diameter at a point 1 cm above the piston skirt at a right angle to the piston pin bore Subtract this measurement from the measurement in step 1 The difference clearance must be within 0 0030 0 0041 in AC091 PISTON RING END GAP 1 Place each piston ring in the wear portion...

Page 114: ...e crankshaft location point A PTO end from the crankshaft end Zero the indicator and rotate the crankshaft slowly Note the amount of crank shaft runout total indicator reading NOTE For runout location point specifications see Crankshaft Runout Repair Specifications in Section 1 of this manual 3 Position the indicator contact point against the crankshaft location point B MAG end from the crankshaft...

Page 115: ...ing securing the inner seal in the crankcase MS415 4 Using the seal driver carefully install the outer water pump seal Gently tap the seal down into position until it seats itself against its flange MS988 CM044 5 Position the upper crankcase half upside down on two wooden blocks then install the C ring the four bearing retaining pins and the two crankcase dowel pins 6 Place the PTO side crankshaft...

Page 116: ... sensor threads coated with white Loctite 575 and tighten to 18 ft lb FC071 NOTE Use only Arctic Cat High Temp Sealant to seal the crankcase halves 10 Assemble the crankcase halves making sure that the crankshaft gear and oil injection pump driveshaft gears mesh Rotate the crankshaft one full turn to align the crankshaft gear and pump driveshaft 11 Install the crankcase cap screws securing the cra...

Page 117: ...a new O ring in place install the oil injection pump making sure the pump shaft slot and pump driven gear shaft align Secure with two screws coated with blue Loctite 243 Tighten the two screws to 96 in lb 17 Position the ceramic rubber seal retainer and seal into the back side of the water pump impeller with the ceramic face of the seal directed out CM168 18 Using a suitable tool press the seal in...

Page 118: ...r hole in the crankcase If sealant gets into the hole carefully remove before proceeding FC072B FC072A NOTE Sealant is only required on the crankcase seam 21 Position the O ring into the water pump cover then install the cover Secure with six screws then using the pattern shown tighten to 96 in lb NOTE Lubricating the O ring with a light coat of grease will help keep the O ring in place FC134 CAUT...

Page 119: ...the letter on the top inclined surface of each ring faces the dome of the piston 726 306A 26 Apply oil to the connecting rod small end bear ings then install the small end bearings Install a washer on each side of the connecting rod TZ068 NOTE The shoulder side of the washer must seat to the needle bearing FC075 27 Place each piston over the connecting rod so the indicator dot on each piston will ...

Page 120: ...linders should slide on easily DO NOT force the cylinders on FC076 31 On the 500 cc secure each cylinder by installing the eight nuts DO NOT TIGHTEN AT THIS TIME 32 On the 600 cc secure each cylinder by installing the four nuts and four cap screws DO NOT TIGHTEN AT THIS TIME 33 Install the oil injection hoses and secure with the clamps then place the lower check valve assem bly into position and s...

Page 121: ...9 ft lb 500 cc or 25 ft lb 600 cc using the appropriate pattern shown Tighten the spark plugs to 19 ft lb 0738 204 NOTE On the 500 cc after tightening the 8 mm cap screws tighten the two remaining 6 mm cap screws to 96 in lb 0738 205 NOTE Lubricating the O ring with a light coat of grease will help keep them seated in the grooves of the cylinder NOTE At this point pressure test the engine see Sect...

Page 122: ...all the key in the crankshaft 43 Thread two puller bolts into the flywheel then slide the flywheel onto the crankshaft making sure the keyways match Remove the puller bolts NOTE Before installing the flywheel be sure to wipe the crankshaft and flywheel tapers clean using a clean towel 44 Apply red Loctite 271 to the threads of the fly wheel cap screw then finger tighten with a large flat washer DO...

Page 123: ...ice procedures in this engine section NOTE Special tools are available from the Arctic Cat Service Parts Department Disassembling NOTE When disassembling top side compo nents mark MAG side and PTO side components for assembling purposes 1 Using the Flywheel Spanner Wrench to secure the flywheel remove the flywheel cap screw and washer then remove the three starter pulley cap screws and remove the ...

Page 124: ... ground wire to the crankcase CM142A 5 Remove the Allen head cap screw A securing the stator lead wire plate to the crankcase then remove the Allen head cap screws B securing the timing sensors remove the sensors and account for the harness grommets CM141C NOTE For assembling purposes note the timing sensor with the white dot white connector is located in the upper mounting location of the crankca...

Page 125: ...park plugs NOTE On the 800 cc at this point remove the knock sensor and lock plate from the cylinder head by bending the lock plate tabs down and unthreading the sensor 10 Remove the cap screws with O rings securing the cylinder head then separate from the cylinders Account for the O rings NOTE When removing the cylinders place the engine on its intake flanges on a drain tray to allow residual coo...

Page 126: ... bearing together as a set CM151 NOTE Place a suitable length of rubber hose around the connecting rods to prevent the con necting rods from damaging the crankcase 15 Disconnect the intake flange oil lines from the oil pump then remove the cap screws securing the intake flanges Remove the intake flanges and reed valve assemblies IO014 16 Remove the lower union cap screw securing the lower check va...

Page 127: ...ing gasket and the alignment pins CM156A 19 Remove the cap screw securing the water pump impeller then slide the impeller free of the shaft Account for the cap screw washer and gasket IO018A 20 Prior to turning the engine upside down on the 800 cc remove the two crankcase cap screws A from the water pump side of the engine then remove the two cap screws B from the magneto housing On the 1000 cc re...

Page 128: ...retaining pins B and account for the crankcase dowel pins C IO023A CM165C NOTE The end bearings are not pressed onto the crankshaft After removing the seals use care not to allow the bearings to slide off the crank shaft 26 Remove the oil injection pump water pump drive shaft from the lower crankcase half Account for the thrust washer on the outer end of the shaft CM159A NOTE When replacing the in...

Page 129: ...en remove the cables and pins securing the hood to the front end remove the hood and remove the left side and right side access panels NOTE Some photographs used in this sub sec tion are used for clarity purposes only and are not designed to depict actual conditions REMOVING TOP SIDE COMPONENTS To access top side components use the following pro cedure 1 Disconnect the exhaust temperature sensor t...

Page 130: ...gain access to the hose clamp securing the coolant hose to the cylinder head then loosen the clamp Remove the coolant hose and breather hose con nected to the cylinder head CM191A NOTE On the 1000 cc remove the coolant bypass hoses from the cylinders 8 Remove the cap screws and nuts securing the cyl inders to the crankcase then using a soft hammer gently tap the cylinders and remove from the crank...

Page 131: ... around the connecting rods to prevent the con necting rods from damaging the crankcase NOTE For servicing procedures see Cleaning and Inspecting Engine and Measuring Critical Components in this sub section INSTALLING TOP SIDE COMPONENTS 1 Place the cylinder base gasket and alignment pins into position on the crankcase 2 Install the piston rings on each piston so the letter on the top inclined sur...

Page 132: ...square the piston in respect to the crankcase then using a ring compressor or the fingers compress the rings and slide the cylinder over the piston Remove the piston holder and seat the cylinder firmly onto the crankcase CM192 8 Secure each cylinder by installing the four nuts and four cap screws DO NOT TIGHTEN AT THIS TIME NOTE Never reuse cylinder cap screws Always replace with new cap screws NO...

Page 133: ...13 Install the coolant hose and secure the hose onto the cylinder head then install the coolant bypass hose onto the head NOTE On the 1000 cc install the coolant bypass hoses onto the cylinders NOTE After the coolant hose has been secured to the cylinder head secure the cylinder head up and out of the way of the cylinder to allow the cyl inder O rings to be installed CM191 14 Lubricate the O rings...

Page 134: ... spark plugs to 19 ft lb then install the spark plug wires NOTE On the 800 cc connect the knock sensor plug in NOTE If the knock sensor was removed or replaced it must be tightened to 17 ft lb and secured with a new lock plate 18 Install the APV gaskets into position as noted dur ing disassembly then with the raised edge A of the bottom of the valve aligned with the channel B of the cylinder insta...

Page 135: ...ce the head surface of each cylinder on the sur face plate covered with 400 grit wet or dry sand paper Using light pressure move each cylinder in a figure eight motion Inspect the surface for any indication of high spots A high spot can be noted by a bright metallic finish Correct any high spots before assembly by continuing to move the cylin der in a figure eight motion until a uniform bright met...

Page 136: ...ch pre load will be exerted on the crankshaft bearings when assembled CM160 CRANKSHAFT NOTE If any servicing of the connecting rods center bearings or oil injection pump drive gear is necessary Arctic Cat recommends that the crank shaft be taken to a qualified machine shop for that service 1 Wash the crankshaft with bearings in parts clean ing solvent 2 Inspect the bearings for wear scoring scuffi...

Page 137: ...asurement must not exceed specifications If measurement is not within specifications either bend or replace the reed stopper CM163 4 Inspect the reed to seat clearance Using a feeler gauge measure the clearance Clearance must be less than 0 008 in If clearance is not within speci fications replace the reed valve 5 To assemble place the reed valves on the cage with its clipped corner positioned to ...

Page 138: ...exhaust side to opposite side as the piston will rock and the reading won t be accurate Readings may vary from side to side NOTE Make sure the smaller reading is 0 059 in or less for the 800 cc or 0 058 in or less for the 1000 cc CYLINDER TRUENESS 1 Measure each cylinder in the three locations from front to back and side to side for a total of six read ings FC044 2 The trueness out of roundness is...

Page 139: ...diameter measurement must be within 1 0631 1 0634 in for the 800 cc or 1 1418 1 1422 in for the 1000 cc CRANKSHAFT RUNOUT 0742 727 1 Using the V Blocks support the crankshaft on the surface plate NOTE The V blocks should support the crank shaft on the outer bearings 2 Mount a dial indicator and base on the surface plate Position the indicator contact point against the crankshaft location point A P...

Page 140: ... a thin coat of grease to the inner seal lips of the water pump seal 2 Using the seal driver position the inner water pump shaft seal onto the seal driver and gently tap the seal down into position NOTE Grease must be applied to the lips of the inner seal before installation MS986A NOTE The seal must be installed with its spring side towards the crankshaft 3 Install the snap ring securing the inne...

Page 141: ...the crankshaft IO019A NOTE To check the bearing for proper position place the point of a sharp tool into the dimple found in the bearing race Strike the tool with the palm of the hand in either direction If the bearing moves it isn t positioned correctly and must be rotated until it drops onto the retaining pin 9 Position the two center seal rings with their end gaps 180 apart up on one and down o...

Page 142: ...l injection pump water pump driveshaft then place the Oil Seal Protector Tool at the end of the shaft FS191 16 Rotate the oil injection pump water pump drive shaft while carefully pushing it through the oil and water pump seals until the driveshaft and crank shaft gears engage then remove the oil seal pro tector tool A from the end of the shaft IO025A 17 Position the shim A on the oil injection pu...

Page 143: ...ll the coolant temperature sensor threads coated with white Loctite 575 and tighten to 18 ft lb then secure the sensor wire to the sensor with a cable tie CM172 22 Position the ceramic rubber seal into the back side of the water pump impeller with the ceramic face of the seal directed out CAUTION Be sure the oil injection pump water pump driveshaft is properly aligned with the slot of the oil inje...

Page 144: ...crankcase seam CM171B 26 Apply a thin film of low temp grease to the water pump cover O ring then position the O ring into the water pump cover With the alignment pins in place install the cover Secure with the screws using the pattern shown Tighten to 96 in lb 0742 257 27 With the bypass valve of the thermostat directed to the 12 o clock position install the thermostat and housing then in a criss...

Page 145: ...stall a washer on each side of the connecting rod TZ068 NOTE The shoulder side of the washer must seat to the needle bearing CM172A 31 Place each piston over the connecting rod so the indicator dot on each piston will point toward the intake exhaust ports then secure with an oiled pis ton pin NOTE The indicator dot is found on the piston dome CM173 32 Install the new circlips so the open end is di...

Page 146: ...lb in three steps using the appropriate pattern shown 0738 206 0738 220 NOTE Always use new cap screws when install ing the cylinders 36 Install the two cylinder O rings on the top of each cylinder making sure they are correctly positioned in the grooves FC077 NOTE Lubricating the cylinder O rings with a light coat of grease will help keep them seated in the grooves of the cylinder 37 Place new O ...

Page 147: ...e Section 3 39 With the raised edge of the valve aligned with the channel of the cylinder slide the APV assemblies into position in the cylinders then secure with cap screws Tighten to 96 in lb CM204 40 Secure the stator plate to the crankcase with the Allen head cap screws coated with blue Loctite 243 and tightened to 96 in lb 41 Route the stator harness through the opening in the crankcase then ...

Page 148: ... to wipe the crankshaft and flywheel tapers clean using a clean lint free towel 46 Apply red Loctite 271 to the threads of the fly wheel cap screw then finger tighten with a large flat washer DO NOT TIGHTEN AT THIS TIME FC080 47 Secure the starter pulley while using the spanner wrench and tighten the three cap screws from step 45 evenly to 19 ft lb FC081 48 Using the spanner wrench tighten the fly...

Page 149: ... high temperature silicone sealant to each exhaust port then install the exhaust gaskets 51 Apply a thin coat of high temperature silicone sealant to the mating surfaces of the exhaust mani fold then install the exhaust manifold and secure with the eight nuts Tighten the nuts using the pat tern shown to 17 ft lb 0742 292 Next Back Section Table of Contents Manual Table of Contents ...

Page 150: ...the console to the chassis then lift up the rear ward end of the console and disconnect the console harness plug in Remove the console 743 945A 3 Remove the two screws securing the handlebar close off panel B then remove the three screws C securing the left and right side rear spar pan els to the seat support tubes Remove the screws D securing the front spar panels to the front bum per then remove...

Page 151: ...he puller Repeat this procedure until the drive clutch releases 10 Using a 9 16 in socket and extension remove the cap screw securing the driven pulley to the input shaft ZJ250A NOTE After removing the driven pulley account for the cap screw and washers sheave adjuster alignment washers and O ring from outside the pulley then from the input shaft remove any other alignment washers These washers mu...

Page 152: ...h D hoses from the intake pipe TZ073A TZ077A NOTE On the non turbo models remove the MAP sensor from the left side upper frame 14 Remove the two cap screws and lock nuts A securing the left side upper frame to the front end Remove the one remaining cap screw and lock nut B securing the upper frame to the left side skid plate ZJ025A NOTE On the turbo models the cap screw securing the skid plate to ...

Page 153: ...ve the two coolant hoses from the throttle bodies ZJ018A 18 On the turbo models remove the coolant hoses from the throttle body then on all models discon nect and remove the coolant hoses from the ther mostat housing TZ075A 19 On the turbo models and the non turbo TZ1 remove the two cap screws and lock nuts securing the coolant separator tank assembly then discon nect the two remaining hoses from ...

Page 154: ...he two cap screws A securing the close off cover to the front end then remove the cover and on the non turbo models account for the exhaust pipe mounting tab B from the right side cap screw ZJ020A NOTE On the Bearcat Z1 XT remove the four cap screws securing the close off panel and account for the exhaust pipe mounting tab A from the left front cap screw CAUTION Anytime hoses are removed from the ...

Page 155: ...ecuring the pipe to the left side of the cylinder head TZ085B TZ099A 27 Disconnect the throttle position sensor air temper ature sensor boost sensor and cam position sen sor 743 999A 28 From the opposite side of the throttle body discon nect the idle speed control and the throttle cable 0743 992 29 Remove the spark plug wires from the spark plugs 30 Loosen the flange clamps securing the intake man...

Page 156: ...w it to lie on the tunnel ZJ022 NOTE Close off the intake ports of the cylinder head to avoid any foreign objects or components from falling into the engine 34 Remove the three cap screws securing the oil res ervoir to the chassis ZJ021A NOTE The oil reservoir will be removed with the engine 35 Remove the two lock nuts A from under the chassis skid plate then remove the through bolt B and the lock...

Page 157: ...uring the exhaust manifold to the cylinder head then remove the manifold and discard the gaskets ZJ048A 4 Remove the banjo bolts securing the oil feed pipe to the turbocharger and engine Discard the crush washers 744 771B NOTE For assembling purposes note the size of the oil port and thread taper of the banjo bolts IO028 NOTE Steps 5 and 6 are for the turbo models only 5 Remove the three lock nuts...

Page 158: ...ing the water inlet hose fitting and remove the fitting then remove the cap screws B securing the starter motor to the engine Remove the starter motor ZJ028B 8 On the non turbo models remove the cap screws securing the two intake flanges to the cylinder head then remove the flanges ZJ029A 9 On the turbo models remove the four cap screws securing the manifold adapter assembly then remove the manifo...

Page 159: ...are must be taken when removing the magneto cover not to tip the cover downward Tip ping the cover downward will allow the starter torque limiter idler gear assembly to slide out of the cover 12 Remove the four cap screws securing the oil scav enge pump to the engine then remove the pump and account for the remaining oil seal ZJ033A 13 To remove the flywheel first remove the cap screw and washer s...

Page 160: ...s on the intake camshaft face A are in the 12 o clock and 9 o clock positions and the arrows on the exhaust camshaft face B are in the 12 o clock and 3 o clock positions 741 593A 18 Remove the tension adjuster bolt and washer A from the chain tensioner assembly then remove the two cap screws B securing the assembly to the engine Remove the assembly and account for the spring and ball ZJ038A 19 Rem...

Page 161: ... 617B NOTE If removing the oil cooler for cleaning pur poses remove the union bolt securing the cooler to the engine then remove the oil cooler and account for a washer and an O ring ZJ040 22 Remove the Allen head cap screws securing the right side and left side timing chain tension guides to the engine then remove the guides and account for the timing chain and the washers located between the ten...

Page 162: ... ment marks on the crankshaft and on the crank balancer gears The rear marks are double dots A and the front marks are single dots B ZJ068A 27 Remove the front and rear crank balancers from the engine and account for the two end seals ZJ043 28 On each connecting rod remove the two connect ing rod cap screws then remove the connecting rod cap Account for the two connecting rod bear ings ZJ052B 29 W...

Page 163: ...o thrust bearings and three bearing halves ZJ053 NOTE For assembling purposes note that the oil grooves of the thrust bearings face the counter weights of the crankshaft ZJ046A 31 Remove the oil separator plates for the lower crankcase half and account for the eight Allen head cap screws ZJ047A 32 Remove the Allen head cap screws securing the piston cooling jets to the upper crankcase half then re...

Page 164: ...out of the ring groove 2 Remove each ring by working it toward the dome of the piston while rotating it out of the groove NOTE If the existing rings will not be replaced with new ones note the location of each ring for proper installation When installing new rings install as a complete set only Cleaning Inspecting Piston Rings Using a ring groove cleaning tool clean carbon from the ring grooves Be...

Page 165: ... bore must be within 0 8662 0 8664 in for the non turbo and 0 9449 0 9451 in for the turbo ATV 1069 Measuring Piston Pin Diameter Measure the piston pin diameter at each end and in the center Measurement must be within 0 8658 0 8661 in for the non turbo and 0 9447 0 9449 for the turbo If measurement is not within specifications the piston pin must be replaced ATV 1070 Installing Piston Rings 1 Ins...

Page 166: ...tal of 6 locations If distortion limit exceeds 0 002 in machining of the block will be necessary ZJ056 4 Inspect the cylinder bore for minor scoring or scuffing If marks are found repair the surface using the appropriate hone and honing oil 5 Hone the cylinder to produce a 45 crosshatch ZJ059 6 Wash the cylinder block thoroughly with hot soapy water then rinse with hot water 7 Blow dry the cylinde...

Page 167: ...in the proper thrust play 0738 540 MAIN BEARINGS Check the main bearings for signs of pitting scratches wear or damage If any of these conditions are found the bearings must be replaced NOTE Always replace the bearings as a set never replace one side only or severe engine dam age will occur CONNECTING ROD MAIN BEARING SELECTION NOTE This information is needed only if the crankshaft or the engine c...

Page 168: ...site the thrust bearing ZJ111A 4 Use the reading obtained to select the correct thrust bearing from the chart 5 Install the selected thrust bearing then using a feeler gauge check that the clearance is as speci fied Assembling Engine NOTE Arctic Cat recommends that new gaskets seals and O rings be installed whenever assem bling the engine Top Row Front Balancer Shaft Center Row Crankshaft Bottom R...

Page 169: ...the piston assemblies into the cylinder ZJ071A NOTE Prior to installing the pistons make sure the oil ring end gaps are on directly opposite sides of the piston and the compression ring end gaps are 90 from one another 4 Using Ring Compressor and a soft hammer ham mer handle carefully drive each piston into the cylinder until the top of the piston is flush with the engine case ZJ072 5 Rotate the e...

Page 170: ...e crankshaft counterweights install the first bearing and roll it into place Push the crankshaft towards the installed bearing and install the remaining bearing ZJ074A 10 Install the bearing halves to the connecting rods and caps then lubricate the bearing surfaces and connecting rod journals of the crankshaft 11 Seat the connecting rods to the crankshaft then install the rod caps and cap screws a...

Page 171: ...s A on the face of the crankshaft and balancer gears directly in line with each other at the sealing surface of the engine case NOTE The front counterbalancer has the oil pump drive gear 741 596A 16 With the crankshaft at bottom dead center install the front counterbalancer with the single dot B on the face of the crankshaft and balancer gears directly in line with each other at the sealing sur fa...

Page 172: ...se this sequence A Cap screws 1 6 10 mm to 13 ft lb B Cap screws 7 24 8 mm to 120 in lb C Cap screws 25 28 6 mm to 96 in lb 24 For final tightening of the engine case cap screws use this sequence A Cap screws 1 6 to 33 ft lb B Cap screws 7 24 to 19 ft lb NOTE Cap screws 25 28 have only the one torque value NOTE After the tightening sequence rotate the crankshaft one revolution to verify free movem...

Page 173: ...ft is directed upward and aligned with the cylinder ZJ081A 30 Install the alignment pins into the top of the engine then install the new head gasket ZJ102A 31 With the head gasket and dowel pins in place install the cylinder head by carefully tilting the head to the front side of the engine allowing the cam chain guide to slide into the passage in the cylinder head then work the head back and fort...

Page 174: ... side of the ten sion adjuster ZJ084 35 With the timing marks A on the face of the cam shaft gear properly aligned place the camshaft into position on the cylinder head 741 801A 36 With the cam chain properly seated to the gears of the crankshaft and exhaust camshaft install the intake camshaft noting that the timing marks B are properly aligned NOTE With the camshafts and cam chain in place there...

Page 175: ...starter gear on the crankshaft then install the flywheel key ZJ036A 42 Install the flywheel with the cap screw and washer Using the flywheel holder wrench from Flywheel Puller tighten the cap screw to 88 ft lb ZJ087 43 Install the oil scavenge pump alignment pins in the engine case then with the inner and outer seals A in place on the pump install the pump and secure with the four cap screws B Tig...

Page 176: ...sor to 15 ft lb and B oil pressure sensor to 10 ft lb ZJ090A 46 Install the coolant hose inlet fitting and secure with the two cap screws Tighten to 84 in lb ZJ031B 47 Install a new thermostat then install the cover and secure with the two cap screws Tighten to 84 in lb NOTE Make sure to install the thermostat with the bypass check valve directed in the up position ZJ091A ZJ092 48 On the non turbo...

Page 177: ...hten to 18 ft lb 741 586A NOTE At this point assembly of the non turbo engine is complete The remaining steps are for the turbo models only NOTE If removed install the mounting bracket to the turbocharger then with the backing plate properly positioned as noted during disassem bling secure the bracket to the turbo with the lock nuts and tighten only until snug TZ063A 52 Install the lower heat shie...

Page 178: ...onsist of the four threaded holes on the front and rear corners of the cylinder head or on the exhaust manifold 741 658A 743 993A NOTE Install the engine with the PTO side directed upward at an angle to allow proper clear ance for the oil reservoir to be positioned into the chassis 1 Using an appropriate engine hoist carefully lower the engine into the engine compartment until the rear mount studs...

Page 179: ...to the outlet D with the clamps Tighten securely ZJ090B NOTE Steps 7 10 are for the non turbo models only 7 Install the throttle bodies and secure with clamps then install the throttle cable to the throttle bodies ZJ103A 8 Install the left side upper frame to the chassis by installing the two cap screws and lock nuts A securing the frame to the front end then installing the remaining cap screw and...

Page 180: ...e then secure the pipe to the cylinder head and cylinder head cover with the three cap screws Tighten the two cap screws to the cover to 18 ft lb and the remaining cap screw to the head to 37 ft lb then tighten the intake hose clamps securely TZ085B TZ099A NOTE Place the upper frame into position and install the clip securing the wire harness to the steering support gusset TZ098A 13 Install the lo...

Page 181: ...s noted during remov ing Secure with clamps TZ081A NOTE At this time make sure the coolant hoses from the coolant tank to the throttle body assem blies and throttle bodies to the left side cylinder head are secured and properly routed On the turbo models make sure the throttle body coolant return hose is secured ZJ018B TZ075A 17 Connect the harness plug ins to the ignition coils A and camshaft sen...

Page 182: ...tor into position in the chassis and install the two springs securing the resonator to the chassis then install the exhaust pipe and secure to the manifold and resonator with six springs NOTE On the non turbo models secure the res onator to the upper frame with the tab washer and hairpin clip 24 Connect the harness plug in for the oxygen sensor NOTE Steps 25 28 are for the turbo models only 25 Ins...

Page 183: ...nes of the input shaft 31 Install the driven pulley on the gear case input shaft making sure the alignment washers if appli cable are in place FZ021 32 Secure the driven pulley with components and hardware as noted in removing Tighten to 32 ft lb FZ019 33 Check drive clutch driven pulley alignment 34 Install the drive belt so the part number can be read then install the belt guard CAUTION When ins...

Page 184: ...mmediately and repeat step B then place the ignition switch to the ON position and repeat step D E Shut the engine off and pour the remaining amount 0 9 1 or 1 U S qt of recommended oil into the oil reservoir then proceed to check engine oil level F Start the engine and allow it to warm up for 5 10 minutes G Shut the engine off then remove the oil level stick from the oil reservoir Wipe the stick ...

Page 185: ...five torx head cap screws for each side 743 945A 42 Install the handlebar close off panel then secure the panel with the two torx head cap screws Posi tion the console assembly on the headlight support bracket then connect the main hood harness Secure the console with the two torx head cap screws 43 Install the hood then install the side access panels and secure with existing mounting hardware CAU...

Page 186: ...rottle cable replace throttle switch 5 Adjust replace carburetor safety switches 6 Clean gap replace spark plugs 7 Replace spark plug caps 8 Service replace high tension wires coil 9 Replace CDI unit 10 Replace coil 11 Replace coil 12 Replace flywheel 13 Replace key Problem Engine Does Not Start No Fuel at Cylinders Condition Remedy 1 Gas tank empty 2 Shut off valve closed 3 Fuel hose broken pinch...

Page 187: ... 4 High tension wires coil shorting 5 Carburetor to cylinder air leak 6 Carburetors adjusted incorrectly dirty damaged loose 7 Gas air mixture incorrect too lean 8 Oil injection pump malfunctioning adjusted incor rectly 1 Adjust throttle cable free play service spring 2 Clean gap replace spark plugs 3 Install lower heat range spark plugs 4 Service replace high tension wires coil 5 Repair replace g...

Page 188: ...und 2 Main wiring harness four prong connector discon nected 1 Replace CDI unit 2 Connect four prong connector Problem Engine Does Not Start No Spark at Spark Plugs Condition Remedy 1 Ground connections dirty loose 2 Throttle ignition monitor switch malfunctioning ignition switch not on 3 Wiring harness shorting disconnected 4 Emergency stop switch in DOWN position malfunctioning 5 Throttle igniti...

Page 189: ...ean tank and entire fuel system Problem Engine Does Not Idle Condition Remedy 1 ECU CCU LED trouble code 2 Throttle position sensor idle adjustment incorrect 3 Injector s faulty 4 Fuel pressure regulator faulty 5 Air silencer obstructed 1 Service replace problem component 2 Adjust idle RPM to specifications 3 Replace injector s 4 Replace regulator hose 5 Clean air intake silencer Problem Engine Lo...

Page 190: ...5 Remove obstruction Problem Engine Stops Suddenly Condition Remedy 1 Gas tank empty 2 Spark absent 3 ECU CCU LED trouble code 4 Fuel filter s obstructed 5 Fuel pressure low 6 Fuel pump faulty 7 Fuel pump relay faulty 8 Gas tank vent hose obstructed 9 ECU CCU faulty 10 Fuel hose obstructed broken pinched 11 Ignition coil faulty 12 Engine seized 13 Throttle ignition monitor switch throttle cable te...

Page 191: ...ctioning adjusted incor rectly 10 Primary compression low absent 11 Gasoline octane too low 12 Water pump thermostat damaged faulty 1 Install lower heat range spark plugs 2 Add coolant 3 Remove obstruction 4 Replace seal intake flange s 5 Troubleshoot adjust drive system 6 Clean replace rings pistons 7 Remove obstruction 8 Remove obstruction 9 Replace bleed adjust oil injection pump 10 Repair repl...

Page 192: ...ose broken pinched 5 Gas tank vent hose obstructed 6 Pick up valve s obstructed damaged 7 Compression absent 8 ECU faulty 1 Fill tank 2 Replace gasoline 3 Service replace fuel pump connections wires 4 Replace service hose 5 Remove obstruction replace vent hose 6 Remove obstruction replace pick up valve s 7 Repair replace damaged worn engine compo nents 8 Replace ECU Problem Engine Does Not Start F...

Page 193: ...gine compo nents 7 Replace water pump thermostat Problem Engine Backfires Condition Remedy 1 Check Engine light illuminated 2 Spark plugs fouled damaged 1 Check codes replace problem component 2 Clean replace spark plugs Problem Engine Stops Suddenly Condition Remedy 1 Gas tank empty 2 Spark absent 3 Check Engine light illuminated 4 Fuel filter s obstructed 5 Fuel pressure low 6 Fuel pump faulty 7...

Page 194: ... Oil Flow Chart 1100 cc 3 21 Liquid Cooling System 500 600 800 1000 cc 3 21 Liquid Cooling System 1100 cc 3 22 Cooling System Schematics 3 25 Recoil Starter 500 600 cc 3 27 Recoil Starter 570 800 1000 cc 3 28 Air Silencer 570 cc 3 30 Air Intake Assembly Crossfire M Series 3 30 Air Silencer Crossfire M Series 3 30 Air Silencer Liquid Cooled F Series 2 Stroke 3 31 Air Silencer 1100 cc Non Turbo 3 33...

Page 195: ...ap screws securing the water pump cover then remove the cover and account for the O ring seal FC118 2 Remove either lower union cap screw securing the lower check valve assembly Remove the two cap screws securing the oil injection pump and pull the oil pump from the engine Leave the pump hose and cable attached 3 Remove the cap screw securing the impeller Account for the rubber washer behind the c...

Page 196: ...f snap ring pliers remove the snap ring securing the inner seal in the crankcase FC124 8 Using the hooked end of the long seal driver pull the inner seal free of the crankcase ASSEMBLING 1 Wipe the seal area clean using a clean rag FC125 2 Position the inner seal onto the seal driver spring side towards the crankshaft Gently tap into posi tion FC126A 3 Using a small screwdriver apply a light coat ...

Page 197: ...him on the oil pump end of the shaft then with the O ring installed on the retainer install the oil injection pump retainer FC130A NOTE For assembling purposes always use new O rings lubricated with oil on the oil injection pump and retainer 8 With the O ring in place on the oil injection pump align the pump with the shaft then install the pump Secure with two cap screws coated with blue Loc tite ...

Page 198: ...into the crankcase if removed FC133A NOTE Do not allow sealant into the breather hole in the crankcase If sealant gets into the hole care fully remove before proceeding FC072B 12 Position the O ring into the water pump cover then install the cover Install the cap screws then using the pattern shown tighten to 96 in lb FC134 0742 304 Water Pump 800 1000 cc DISASSEMBLING NOTE The engine must be remo...

Page 199: ... for the O ring seal and two dowel pins FS223A 3 Remove the cap screw A securing the lower check valve to the oil pump and account for the two gaskets then remove the two cap screws B securing the oil pump to the engine Remove the pump FS220A NOTE Leave the two upper check valves secured to the pump FS221A 4 Remove the cap screw securing the impeller Account for the rubber washer and gasket behind...

Page 200: ... flange FS226 7 Using the long seal driver drive the water pump mechanical seal from the crankcase FS227 8 Using a pair of snap ring pliers remove the snap ring securing the oil seal in the crankcase FS228 9 Using the hooked end of the long seal driver pull the inner seal free of the crankcase FS229 ASSEMBLING 1 Thoroughly clean the seal surfaces of the crank case 2 Position the oil seal onto the ...

Page 201: ... shaft Twist the shaft while pushing it through the oil and water pump seals until the shaft gear engages with the drive gear of the crankshaft then remove the tool FS233A IO025B 7 Position the shim on the oil pump end of the shaft then with the O ring installed on the retainer install the oil injection pump retainer IO026A 8 With the O ring in place on the oil injection pump align the pump with t...

Page 202: ... 48 in lb FS225 10 Apply sealant to the crankcase seam then install the alignment pins into the crankcase if removed FC133A 11 Position the O ring into the water pump cover then install the cover Install the cap screws then using the pattern shown tighten to 96 in lb 0742 257 Water Pump 1100 cc REMOVING 1 Drain the engine coolant see the appropriate Liq uid Cooling System in this section 2 With th...

Page 203: ...ng to aid in remov ing the bearing 5 Clean the inner and outer housings with parts cleaning solvent then dry with compressed air ASSEMBLING 0742 104 NOTE For this procedure use Water Pump Bear ing and Seal Tool Kit 1 Using the appropriate sized installation tool install the bearing F into the inner housing 2 Using the appropriate sized installation tool install the oil seal E with the spring side ...

Page 204: ...l the APV cover plates C Connect the tester pump to an impulse fitting on the crankcase then plug any remaining impulse fittings and pressurize the crankcase to 8 psi and close the valve AN128D D Monitor the pressure gauge The pressure must not drop at a rate of more than 1 psi per minute E If the pressure drops faster than specified inspect for an air leak with soapy water or by completely submer...

Page 205: ...om the spark plugs 2 Remove the four cap screws securing the engine cover to the cylinder head then remove the cover and account for the two locating pins from the intake side of the cylinder head ZJ104A 3 Using Drive Clutch Spanner Wrench rotate the engine two full revolutions NOTE Rotating the engine two full revolutions will ensure that any oil trapped in the tappet shim is purged to maintain a...

Page 206: ...mpartment 7 Remove the cable ties noting their locations for assembling purposes securing the wiring harness to the throttle body fuel rail then loosen the intake flange clamps securing the throttle bodies Remove the throttle bodies and place them on the tunnel NOTE After removing the throttle bodies close off the intake ports of the cylinder head to avoid any foreign objects or components from fa...

Page 207: ...ble Exhaust or Intake and use this procedure A Find the Measured Tappet Clearance from step 5 in the left side vertical column of the table B Find the Present Shim Size three digit num ber at the top side horizontal column of the table C Match the clearance in the vertical column with the present shim size to obtain the recom mended replacement shim Next Back Section Table of Contents Manual Table...

Page 208: ...3 15 3 SNO2152 Next Back Section Table of Contents Manual Table of Contents ...

Page 209: ...3 16 SNO2153 Next Back Section Table of Contents Manual Table of Contents ...

Page 210: ...the ten sion adjuster ZJ084 13 With the timing marks A on the face of the exhaust camshaft gear properly aligned place the camshaft into position on the cylinder head 0741 801 14 With the cam chain properly seated to the gears of the crankshaft and exhaust camshaft install the intake camshaft noting that the timing marks B are properly aligned NOTE With the camshafts and cam chain in place there s...

Page 211: ...valves rotate the engine until the decompression pin of the valve tappet is acti vated then using a screwdriver carefully tap the decompression arm until the decompression pin releases the tappet IO051A IO052B 20 After rechecking for proper valve tappet clear ance install the timing inspection plug to the mag neto case and tighten to 22 ft lb NOTE At this time remove the items used to close off th...

Page 212: ...e turbo models install the spark plug wires ZJ094C NOTE On the non turbo models before installing the air silencer make sure the gasline hose is routed over the air silencer NOTE On the non turbo models to finalize this procedure install the air silencer Proceed to Air Silencer 1100 cc Non Turbo sub section and fol low steps 3 12 of INSTALLING Changing Oil Filter 1100 cc NOTE Recycle or properly d...

Page 213: ...p 12 start the engine The warning light should go out within five seconds If it does proceed to step 14 NOTE If the warning light does not go out shut the engine off immediately and repeat step 11 then place the ignition switch to the ON position and repeat step 13 14 Shut the engine off and pour the remaining amount 0 9 l or 1 U S qt of recommended oil into the oil reservoir then proceed to check...

Page 214: ...ool ant hose to the water pump Do not remove the hose from the water pump at this time CM201A NOTE The hose clamp to loosen is from the ver tical fitting Do not remove the hose from the 90 fitting 4 Tip the snowmobile upright then place a suitable drain pan beneath the engine Remove the coolant hose from the water pump and allow the coolant to drain 5 After the coolant has completely drained insta...

Page 215: ...uired mix coolant for a temperature of 36 C 34 F Follow mixing recom mendations of the manufacturer of the coolant NOTE At this point secure the console with the torx head screws INSPECTING COOLANT HOSES AND CLAMPS All coolant hoses and connections should be checked annually for deterioration cracks and wear All coolant hoses and clamps should be replaced every four years INSPECTING THERMOSTAT 1 I...

Page 216: ...t the engine and allow it to run for five min utes 7 With the engine cool loosen the bleed screw and allow the coolant level in the filler neck to drop then with the bleed screw loose add coolant into the filler neck until no air is visible or heard at the bleed screw Tighten the bleed screw and add cool ant to the reservoir if necessary NOTE If the coolant level in the filler neck sud denly drops...

Page 217: ...MPS All coolant hoses and connections should be checked annually for deterioration cracks and wear All coolant hoses and clamps should be replaced every four years INSPECTING THERMOSTAT 1 Inspect the thermostat for corrosion wear or spring damage 2 Using the following procedure inspect the ther mostat for proper operation A Suspend the thermostat in a container filled with water B Heat the water a...

Page 218: ...ling systems in the Arctic Cat snowmo biles Some components may vary from model to model therefore the technician should use discretion and sound judgment when servicing a particular cooling system 0744 065 0744 064 1100 cc Non Turbo 1100 cc Turbo Next Back Section Table of Contents Manual Table of Contents ...

Page 219: ...3 26 0742 314 738 067A F Series 2 Stroke CFR Crossfire M Series Next Back Section Table of Contents Manual Table of Contents ...

Page 220: ...m the roller untie the slip knot and remove the rope CLEANING AND INSPECTING NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is necessary 1 Clean all recoil starter components 2 Inspect all springs washers and pawl for wear or damage 3 Inspect the roller and case for cracks or damage 4 Inspect the center hub for wear cracks or damage 5 Inspect the rope for breaks...

Page 221: ...case then secure the starter with cap screws Tighten to 96 in lb NOTE Before tightening the cap screws slowly pull the recoil rope until the pawl engages then tighten the cap screws centering the recoil against the magneto case 2 Thread the rope through the bushing in the con sole then install the handle and secure with a knot Seat the cap 3 Release the slip knot in the rope Recoil Starter 570 800...

Page 222: ...stalled NOTE The main spring must seat evenly in the recoil case 3 Insert the rope through the hole in the roller and tie a knot in the end then wrap the rope counterclock wise around the roller leaving approximately 20 in of rope free of the roller 4 Apply low temperature grease to the main spring and hub 5 Align the hook in the end of the main spring with the notch in the roller 6 Carefully slid...

Page 223: ... to the hood screen right side FC248 2 With the hood closed loosen the headlight adjust ment knobs 3 Carefully push the headlight lenses rearward far enough to remove the torx head screws securing the air silencer plenum to the hood 4 Open the hood then remove the O rings securing the air silencer plenums to the hood and remove the air silencer plenums INSTALLING 1 Press the air silencer plenums i...

Page 224: ... expansion chamber from the engine compartment Account for the two exhaust gaskets 4 With the seat adjusted to its lowest position remove the self tapping screw from the right side seat adjustment track then remove the seat ZJ100A 5 Remove the torx head screws securing the handle bar close off panel then remove the panel 6 Remove the lock nuts and torx head cap screws A securing the right side fro...

Page 225: ...nstall the duct into the silencer NOTE To aid in installing the duct it can be help ful to apply a thin film of WD 40 to the air silencer seal and to work the duct back and forth until the sleeve of the duct is properly seated into the silencer 5 Secure the intake duct to the upper frame with the cap screw Tighten securely NOTE If the ECU was removed to gain access to the duct cap screw install th...

Page 226: ...f the seat support assembly Remove the seat ZJ100A 2 Remove the two torx head cap screws A secur ing the console to the chassis then lift up the rear ward end of the console and disconnect the console harness plug in Remove the console 741 744A 3 Remove the torx head cap screws securing the upper front rear panels C and the handlebar close off panel B along with the body screws securing the knee p...

Page 227: ...ke boot to the throttle bodies ZJ013A 11 Remove the breather hose from the air silencer ZJ096B 12 Move the air silencer far enough to the right to bypass the air silencer mounting bracket then slide the air silencer rearward and disconnect the air temperature sensor Remove the air silencer from the chassis ZJ015A 13 Inspect the throttle valve thoroughly for carbon residue buildup If signs of carbo...

Page 228: ...directed properly as noted during removing install the air silencer and secure to the chassis with the two torx head cap screws Secure the flange clamps to the throttle body NOTE To aid in installing the air silencer apply a coat of alcohol on the insides of the intake boot openings NOTE Install the air silencer at an angle posi tioning it to the PTO side throttle body first and tightening its cla...

Page 229: ...all the handlebar close off panel and secure it with two torx head cap screws 10 Place the console into position on the headlight support bracket then connect the console harness connector ZJ098A 11 Secure the console to the chassis with the two torx head cap screws 12 Install the seat to the lowest position then install the machine screw threads coated with blue Loc tite 243 into the seat support...

Page 230: ...Damage to the filter may occur CAUTION A torn air filter can cause damage to the turbocharger engine Contaminants may get inside the turbo charger engine if the filter is torn Carefully examine the filter for holes or tears Replace the filter with a new one if torn CAUTION Do not run the engine without the air filter installed Severe damage to the turbocharger engine will occur WARNING The rotatin...

Page 231: ... return hose then using a suitable clamping device clamp off the two hoses Loosen the hose clamps and disconnect the hoses from the turbo 743 991A 12 Remove the three lock nuts and washers A secur ing the bracket of the turbocharger to the engine then loosen the lock nuts B securing the mount ing bracket to the turbocharger NOTE If the oil hose has to be removed from the engine note the banjo bolt...

Page 232: ...te for installing purposes TZ063A 15 Remove the lock nuts securing the turbo outlet then remove the turbo outlet from the turbocharger and account for the gasket TZ091A 16 Remove the four lock nuts securing the turbo to the exhaust manifold Account for the gasket and flat washers TZ092A INSPECTING 1 With the turbocharger outlet removed inspect the turbine exhaust blades for any signs of wear or da...

Page 233: ...exhaust manifold and secure with the flat washers and lock nuts Tighten only until snug 4 Install the lower heat shield onto the turbocharger and exhaust manifold with the four cap screws Tighten to 56 in lb 5 With the gaskets in place install the exhaust mani fold and turbocharger assembly to the engine then using the pattern shown tighten the exhaust mani fold to 19 ft lb 0744 003 6 Install the ...

Page 234: ...st springs 12 Install the upper heat shield and secure to the exhaust manifold and turbocharger with the four cap screws Tighten to 56 in lb TZ061 13 Connect the coolant return hose to the turbo and secure with the hose clamp TZ060A 14 Connect the air bypass hose and the air bypass control valve hose to the intake pipe and secure with the clamps 743 983A 15 Install the hose from the waste gate con...

Page 235: ...how high or low the exhaust port is in relation to the cylinder Engines designed for racing have a high port exhaust system and will produce more horse power at higher RPM but only with the loss of low end power and overall fuel economy Low port engines will produce maximum horsepower in the low RPM ranges and provide good mid range fuel economy but they sacrifice top end performance The APV syste...

Page 236: ...h port position The RPM that the valves open is different with each model If the servomotor cycles the exhaust valves as explained above the exhaust valve circuit is operating satisfactorily If the servomotor makes no attempt to open the valves or if the servo attempts to cycle the valves three times then stops working a problem exists and it must be corrected Servomotor Cycles Three Times In this...

Page 237: ...M123A NOTE For installing purposes note the side that the servomotor cables are installed on 3 Slide each cable drum out of the slot of the servo motor actuator CM124A NOTE Before proceeding with the cable adjust ment ensure that the exhaust valves are free to move 4 While holding the cable housing firmly pull the cable as far out as it will go then release Repeat three to four times The cable exh...

Page 238: ...n the pulley was removed from the servo make certain to align the space between the two cable slots with the mark on the shaft of the servo Tighten the nut to 35 in lb MS401A FZ087A REMOVING DISASSEMBLING NOTE To avoid a parts mix up only remove one valve assembly at a time from the engine 1 Remove the exhaust valve assembly from the engine FC115 CM147 2 Remove the retaining screw securing the exh...

Page 239: ...ng stays in place at the end of the cable 2 With the cover gasket properly positioned place the valve stopper on the cable end and slide it down until the cable end is inside the stopper FC113 3 With the valve plate gasket properly positioned slide the exhaust valve through the valve plate and insert it into the valve stopper Secure with the retaining screw Tighten to 48 in lb FC112 NOTE Note that...

Page 240: ...ies will create a low voltage condition and activate the fail safe mode The fail safe mode is an ECU operated engine RPM limiter When activated the fail safe mode will be seen as an immediate loss of engine horsepower CAUTION On the 600 cc the long side of the exhaust valve must be facing toward the cylinder head or severe engine damage may occur 600 cc Problem Engine loses power no top end Condit...

Page 241: ...erature engine condition and adjusts the ignition timing accordingly This system is not adjustable and is maintenance free If a system fault is suspected use an ohmmeter to check continuity of the exhaust pipe temperature sen sor located in the expansion chamber A reading of either 0 ohm or infinity indicates a failed sensor 0737 314 NOTE A disabled ECT system WILL NOT cause engine damage however ...

Page 242: ...4 4 1 SECTION 4 FUEL SYSTEMS TABLE OF CONTENTS Fuel Systems 4 2 Fuel System Carbureted 4 2 Fuel System EFI 4 15 Fuel System Related Items 4 32 Manual Table of Contents ...

Page 243: ... If any cracks are evident in the hoses replace them making sure none are against any hot or moving parts Hoses must fit tightly If hoses do not fit tightly cut 6 mm 1 4 in from the end and install 4 Check the impulse hose for cracks or any possible air leaks The hose must fit tightly at both ends If loose or cracked replace the hose 5 Check each carburetor vent hose for kinks or obstructions remo...

Page 244: ...om the carburetor TZ103A TZ104A 4 Loosen the carburetor flange clamp then remove the carburetor TZ102A NOTE Slide the carburetor into the air silencer boot until free of the flange then remove carbure tor 5 Remove the clamp and disconnect the fuel hose from the carburetor inlet fitting then loosen the lock plate screw and remove the lock plate from the missing body top CAUTION When installing the ...

Page 245: ...ng B344 3 Remove the float arm pin then remove the float arm KEY 1 Mixing Body Assy 2 Starter Plunger Cap 3 Starter Plunger Spring 4 Starter Plunger 5 Spring 6 Idle Speed Screw 7 Spring 8 Pilot Air Screw 9 Pilot Jet 10 Baffle Ring 11 Main Jet 12 Mixing Body Top 13 Piston Valve Spring 14 Plate 15 Magnet Block 16 Screw w Washer 17 E Clip 18 Washer 19 Jet Needle 20 Piston Valve 21 Needle Jet 22 Self ...

Page 246: ...move the pilot jet CM052 7 While counting the rotations for installing purposes rotate the pilot air screw clockwise until lightly seated then remove the pilot air screw and spring CM053A 8 Remove the idle speed screw and spring CM053B 9 Remove the Phillips head screw securing the throttle cable retainer to the piston valve then remove the retainer Account for the jet needle with E clip and washer...

Page 247: ...able damage 6 When applicable inspect the tips of the idle speed screw jet needle pilot air screw needle valve and fuel mixture screw for wear damage or distortion NOTE When inspecting the inlet needle inspect the side guides and tip for wear If the guides show any sign of wear replace the inlet needle 7 Inspect the pilot jet and main jet for obstructions or damage 8 Inspect the starter plunger an...

Page 248: ... ring and main jet into position and secure AH084 5 In order place a washer and inlet seat into position and secure Install the inlet needle valve CM051 6 Place the float arm into position and secure with the pin CM050A 7 Check the float arm height Using a calipers mea sure the distance from the gasket surface to the top of the float arm with the carburetor inverted If measurement is not within 22...

Page 249: ...retainer into the piston valve and secure with the Phillips head screw Guide the cable end down into the cable retainer slot and slide the cable end to the center of the piston valve Release the spring and retainer plate to lock the cable in position AH075 NOTE The round part of the cable end must come through the hole in the plate piston valve If it doesn t the cable isn t assembled to the piston...

Page 250: ...ect the console main harness plug in 9 With the belt guard secured start the engine and warm up to operating temperature then adjust the carburetors if necessary until proper calibration is attained 10 Secure the console to the steering support with the torx head screws and tighten the screws securely then close the left side access panel and close the hood ADJUSTING Choke Cables 1 Be sure the ign...

Page 251: ...trol is equipped with a 3 prong emergency stop switch connector There must be free play between the lever and the con trol housing 0741 518A NOTE If cable free play gap is not correct rotate each swivel adapter an equal amount until recom mended free play is achieved Each piston valve must be resting against the tip of its idle speed screw NOTE If throttle cable free play is incorrect the carburet...

Page 252: ...carburetor idle speed screw clockwise until the tachometer reads slightly above 1500 RPM then rotate the idle speed screw counterclockwise to achieve exact 1500 RPM reading The piston valves should now be synchro nized and the engine should idle without holding any throttle pressure NOTE If the engine has no ignition spark with the throttle in the idle position but has proper spark with the thrott...

Page 253: ...e into each mixing body top 8 Install each piston valve and mixing body top on the carburetors Tighten securely then secure the tops to the carburetors with the plates 9 Adjust the carburetors see appropriate ADJUST ING sub section 10 Synchronize the oil injection pump see Related Items in this section Choke Cable 570 cc REMOVING 736 596A 1 Bend down the lock tabs locking each brass choke cable ho...

Page 254: ...rectly incorrect 3 Pilot air passage obstructed damaged 4 Pilot jet loose 5 Float inlet needle obstructed damaged adjusted incorrectly 6 Main jet loose too large 7 Primary air passage obstructed 1 Adjust pilot air screw 2 Replace needle jet replace adjust jet needle E clip 3 Remove obstruction replace pilot air screw carburetor 4 Tighten pilot jet 5 Remove obstruction replace inlet needle float ad...

Page 255: ...emove obstruction replace inlet needle float adjust float tab 3 Remove obstruction Problem General Fuel System Engine Cuts Out at High RPM Condition Remedy 1 Fuel delivery inadequate 2 In line fuel filter obstructed damaged 3 Gasoline contaminated 4 Gas tank vent hose obstructed 1 Repair replace fuel pump impulse hose 2 Remove obstruction replace in line fuel filter 3 Replace gasoline de ice clean...

Page 256: ...or coil located on the stator provides the injectors with DC voltage for operation through the ECU 4 A lighting coil located on the stator plate provides output to the CCU regulator rectifier to operate accessories and the lighting system 5 An electrical control unit ECU calculates input from sensors air temperature sensor coolant tem perature sensor throttle position sensor ignition timing sensor...

Page 257: ...arge coils operating the ECU the injector coil which operates the injectors the fuel pump coil which operates the fuel pump and the lighting coil chassis control unit operating all accesso ries and the lighting system NOTE On the 500 cc the ECU is coded with a let ter A B C On the 600 800 1000 cc the ECU is coded with symbols When replacement of the ECU is necessary the ECU must be replaced with a...

Page 258: ...e code letter IO031A On the 600 800 1000 cc the injectors are coded with symbols and are color coded yellow and green When replacement of a fuel injector is neces sary the injector must be replaced with an injector of the same code symbol and color FS025 FUEL PRESSURE REGULATOR The fuel pressure regulator is located in the fuel pump The fuel pressure regulator maintains the fuel pressure at a cons...

Page 259: ... adjustments to the necessary cylinder via the ECU lim iting damage to internal engine components Detona tion can be caused by many variables including poor fuel quality lean operating conditions or modified engine components systems KNOCK SENSOR 1100 cc Turbo This sensor detects the presence of knock and uses it to maximize the boost level without harming the engine Self Diagnostic EFI System Cod...

Page 260: ...ance replace the stator NOTE If the resistance test is good a peak read ing voltage test should also be made Refer to Peak Voltage Tests in Section 5 Lighting Coil Resistance Test The lighting coil located on the stator provides AC power to the lighting system and accessories through the chassis control unit 500 600 cc or regulator recti fier 800 1000 cc To test the lighting coil resistance follow...

Page 261: ...l connectors are clean and tight Apply dielectric grease to all connectors Testing Individual Components NOTE For the following tests use the Fluke Model 77 Multimeter or a multimeter of the same quality THROTTLE POSITION SENSOR If the sensor should malfunction see appropriate Throttle Position Sensor in Section 5 FUEL INJECTORS Testing Resistance 1 Disconnect the fuel injector wiring harness 2 Se...

Page 262: ...t be replaced FUEL PRESSURE REGULATOR 1 Using the Fuel Pressure Test Kit connect the tes ter to the regulator fuel inlet AO053 NOTE A short piece of 3 8 in I D hose will be needed to make the above connections 2 Pressurize the regulator to 2 0 2 2 kg cm 28 31 3 psi Turn the pressure tester shut off valve to the OFF position Observe the gauge for several min utes and note any loss of pressure If pr...

Page 263: ... secure with push pins 2 Connect the wiring harness to the air temperature sensor Secure the sensor leads with cable ties so they do not rub on any other components Throttle Body Assembly REMOVING 500 600 800 1000 cc NOTE The expansion chamber and air silencer must be removed for this procedure see Section 3 1 Disconnect the wiring harness from each injector and from the throttle position sensor c...

Page 264: ...MAP sensor hoses from the throttle body ZJ018A ZJ289A 2 Loosen the throttle cable jam nut then remove the throttle cable from the bracket and the throttle valve cam ZJ103A 3 Remove the cable ties securing the fuel injector wiring harness to the fuel rail then disconnect the harness from the fuel injectors NOTE For installing purposes note the location of all cable ties ZJ094D 4 Loosen the clamps s...

Page 265: ...sensor from the throttle body assembly ZJ132A ASSEMBLING INSTALLING 1100 cc Non Turbo 1 Place the throttle sensor in position on the throttle body assembly then secure with the screw ZJ132A 2 With the color marks properly aligned as noted during disassembling install the ISC valve and secure it to the throttle body assembly with the two different size screws ZJ131A 3 Install the fuel injectors ont...

Page 266: ...opriate Throttle Position Sensor in Section 5 ZJ255 6 Install the throttle cable to the bracket on the throt tle body assembly and to the throttle valve cam then secure the cable with the jam nut NOTE Assure proper free play exists in the throt tle cable when securing the jam nut ZJ103A NOTE To finalize this procedure install the air silencer Proceed to Section 3 Air Silencer 1100 cc Non Turbo sub...

Page 267: ...hem from the throttle body TZ075B NOTE If the snowmobile is in warranty breaking the seal on the idle screw jam nut or the Phillips head screws on the TPS will void warranty 6 Loosen the clamps securing the hose to the intake pipe and throttle body TZ085A 7 Remove the four cap screws securing the throttle body to the intake manifold and account for the throttle cable support bracket TZ109A 8 Remov...

Page 268: ... the fuel pressure regulator to the fuel rail and remove the regulator ASSEMBLING INSTALLING 1100 cc Turbo 1 If removed during disassembling with a new O ring in place install the fuel pressure regulator and secure it to the fuel rail Tighten to 96 in lb 2 Install the injectors into the fuel rail then install the four harness connectors to the injectors and connect the injector harness to the main...

Page 269: ...g the intake pipe to the throttle body and secure with the hose clamps 7 Install the coolant hoses B to the throttle body and secure with the clamps then install the har ness connector to the throttle position sensor A TZ075B 8 Install the harness connector to the idle speed con trol B then install the throttle cable to the throt tle body pulley and secure the cable with the jam nuts TZ108A NOTE A...

Page 270: ...loosen the oil injection cable jam nuts 5 On the other models remove the handlebar pad and the console if applicable 6 Remove the cable ties securing the throttle cable 7 Remove the throttle cable ends from the throttle lever and from the throttle control housing NOTE Some EFI models are equipped with a control rod activated oil pump If it must be removed the rod simply snaps off and on at the con...

Page 271: ... injection pump CAUTION Compress the throttle control lever to ensure free movement If the throttle cable sticks or binds correct the problem before starting the engine Next Back Section Table of Contents Manual Table of Contents ...

Page 272: ...4 729 425000 30 C 86 F 1 139 7550 Temperature Volts Ohms Temperature Volts Ohms 110 C 230 F 0 115 129 28 C 82 F 1 377 1800 108 C 226 F 0 129 137 26 C 79 F 1 459 1950 106 C 223 F 0 143 145 24 C 75 F 1 541 2100 104 C 219 F 0 157 153 22 C 72 F 1 623 2250 102 C 216 F 0 171 161 20 C 68 F 1 705 2400 100 C 212 F 0 185 169 18 C 64 F 1 806 2670 98 C 208 F 0 192 180 16 C 61 F 1 907 2940 96 C 205 F 0 199 191...

Page 273: ...e remaining union bolts securing the check valves to the pump Account for the washer gaskets 9 Remove the check valves Account for two gaskets INSTALLING 1 In turn on each front union bolt install a washer gasket check valve and washer gasket then install on the oil injection pump 2 Place the gasket and oil injection pump near the engine then install the lower union bolt through a gasket check val...

Page 274: ... boss 4 If the marks are not aligned adjust synchroniza tion by loosening the jam nut s on the adjuster Rotate the jam nuts adjuster nut until proper align ment is attained Tighten jam nut s 5 Return the control arm throttle cable to the CLOSED position NOTE On models with a cable operated oil pump connect the throttle cable to the throttle lever then adjust the cable linkage adjusting nut so the ...

Page 275: ...chassis movement 7 With the control arm secured in the FULL CLOSED Idle position start the engine and run the engine at recommended RPM for 3 minutes Compare the amount of oil used against the speci fications on the chart in Section 1 NOTE Before starting the engine make sure that no air is present in the testing equipment 8 With the control arm secured in the FULL OPEN position line to line run t...

Page 276: ...emove the hose clamps and discard then slowly remove the fuel hoses from the fuel filter Dispose of the excess fuel from the filter properly 3 Inspect the fuel lines thoroughly for any signs of cracking cuts or wear points INSTALLING 1 Place the new hose clamps on the fuel hoses then with the fuel pump inlet and outlet noted connect the fuel hoses to the fuel pump Secure with the hose clamps 2 Sec...

Page 277: ...d the fuel outlet of the fuel pump 2 Carefully install the smart valves and fuel pump into the gas tank then while holding the pump in place install a new sealing washer D washer and mounting nut B Tighten to 24 ft lb 3 With a new O ring E in the outlet fitting A secure the fitting to the fuel pump and tighten to 70 in lb 4 Connect the gasline hose to the outlet of the fuel pump and tighten secure...

Page 278: ...lse fitting TESTING PRESSURE 1 Connect a pressure gauge between fuel pump and carburetor using a piece of fuel hose and a T fit ting 2 Place snowmobile on a safety stand and start the engine At the following engine speeds the speci fied pressures must be indicated 3 Remove gauge and hose and connect fuel hose to carburetor TESTING VACUUM NOTE Make sure adequate fuel is in the carbure tor for this ...

Page 279: ...ender 4 Stroke 5 19 Testing Electric Fuel Pump 2 Stroke 5 19 Testing Electric Fuel Pump 4 Stroke 5 20 Testing Ignition Key Switch 4 Stroke 5 20 Testing Ignition Components 4 Stroke 5 20 Emergency Stop Switch 5 21 Solenoid Electric Start Models 5 21 Fuse 5 22 Ignition Switch Electric Start Function 5 22 Starter Motor 2 Stroke 5 23 Starter Motor 4 Stroke 5 29 Magneto 4 Stroke 5 32 Troubleshooting El...

Page 280: ...e in the ON position 2 Crank the engine over and check for spark If no spark is present check to make sure the throttle cable is properly tensioned Compress the throttle control and while holding the throttle control in this position crank the engine over and check for spark If spark is now present adjust the throttle cable tension NOTE There must be 0 030 0 060 in free play between the throttle l...

Page 281: ...e black white wire of the emergency stop switch 3 With the throttle lever in the idle position and the emergency stop knob in the up RUN position the meter must read no resistance open If the meter reads resistance closed replace the switch 4 With the throttle lever in the idle position and the emergency stop knob in the down STOP posi tion the meter must read resistance closed If the meter reads ...

Page 282: ...h the emergency stop knob located on top of the throttle control in the ON pulled up position and the throttle lever compressed the meter must read resistance closed 4 If the meter reads no resistance open and the lever control housing free play is correct replace the throttle switch 5 If the meter reads resistance closed but the engine will not start with the ohmmeter leads still connected altern...

Page 283: ...r reading changes from open to closed Repeat this step for the other carburetor safety switch NOTE The correct throttle lever housing gap should be in a range of 0 375 0 500 in the moment the meter reading changes from open to closed A switch that changes from open to closed before the other one is the switch that must be raised to attain safety switch synchronization 742 349A 4 If an adjustment i...

Page 284: ... plugged into the analyzer for testing voltage Always verify bat tery voltage is at least 4 9 DC volts before testing TPS CHECKING TPS NOTE If the snowmobile is in warranty breaking the seal on the idle screw jam nut or the Phillips head screws on the TPS will void warranty If the TPS is tested out of specification the throttle body must be replaced If the snowmobile is out of war ranty proceed to...

Page 285: ...SED POSITION set ting If the FULL CLOSED POSITION setting is cor rect replace the sensor REPLACING TPS NOTE Replacing the TPS is for out of warranty snowmobiles only NOTE It is important that the throttle shaft is in the completely closed position for this procedure Removing 1 Disconnect the throttle cable from the throttle shaft 2 Rotate the idle screw counterclockwise until it no longer contacts...

Page 286: ... all the way to the full open throttle position If the voltage seems to be erratic or doesn t meet the prescribed specification repeat this procedure several times to confirm results NOTE If at any point throughout the throttle range the meter reads no voltage open hold the throttle lever in that position If the voltage does not return the throttle body must be replaced 5 If the full open throttle...

Page 287: ...the throttle body ZJ254A TZ119A 3 Install the screw s flat washer s and lock washer s securing the sensor to the throttle body Do not tighten at this time 4 Adjust the TPS see Adjusting TPS in this sub section 5 Disconnect the adjustment tool harness from the TPS Connect the snowmobile TPS harness to the newly installed or adjusted TPS NOTE Before installing the TPS harness connec tor apply dielec...

Page 288: ...g from the ignition coil 2 Set the selector in the OHMS position 3 Connect the red meter lead to the orange black lead then connect the black meter lead to the orange red lead 4 Ignition coil primary resistance must be between 0 24 0 36 ohm IGNITION COIL Secondary 1 Remove the spark plug caps from the high tension wires 2 Set the selector in the OHMS position 3 Connect the red meter lead to one hi...

Page 289: ... 4 Lighting coil resistance must be 0 15 ohm 20 IGNITION COIL Primary 1 Disconnect the double wire plug from the CDI unit to the ignition coil 2 Set the selector in the OHMS position 3 Connect the red meter lead to the orange wire in the plug then connect the black meter lead to the black wire in the plug 4 Ignition coil primary resistance must be between 0 26 0 35 ohm IGNITION COIL Secondary 1 Re...

Page 290: ...gneto 2 Meter reading must be 19 ohms 20 LIGHTING COIL 1 Disconnect the main harness from the magneto 2 Set the selector in the OHMS position 3 Connect the two meter leads to each of the yellow leads in the connector from the engine 4 Lighting coil resistance must be 0 11 ohm 20 IGNITION TIMING SENSOR 1 Disconnect timing sensors 1 and 2 green white and brown green from the main harness 2 Set the s...

Page 291: ...ow wire in the connector then connect the black maxiclip and meter lead to the black wire in the connector 4 Start the engine and allow it to idle Meter reading must be within 12 15 DC volts Voltage Regulator Test F8 NOTE The following test should be made using MaxiClips and the Fluke Model 77 Multimeter set to the DC Volt scale This test should be made at the three pin connector of the regulator ...

Page 292: ...ds If the icon stays illu minated while the engine is running the CCU ECU is receiving input that is outside of its established param eters FZ001D FZ003B NOTE If the icon illuminates while the engine is running the CCU is receiving input that is outside of its established parameters Accessing CCU Codes 1 Connect the appropriate harness from CCU Diag nostic Test Kit to the diagnostic port 2 Start t...

Page 293: ...o red black The servomotor should rotate in the oppo site direction 5 Install the servomotor NOTE If the servo operates correctly in the above test but fails to operate when connected to the ECU CCU regulator rectifier at the designated RPM proceed to Potentiometer test POTENTIOMETER NOTE The following test should be made using MaxiClips and the Fluke Model 77 Multimeter set to the ohms scale 1 Re...

Page 294: ...d brown green wires in the connector from the sensor 2 Pull the recoil starter rope briskly Meter reading must be within specification PRIMARY COIL 1 Connect the red meter lead to the orange black wire then connect the black meter lead to the orange red wire 2 Pull the recoil starter rope briskly Meter reading must be within specification LIGHTING COIL 1 Connect the red meter lead to one yellow wi...

Page 295: ...or from the sensor 2 Pull the recoil starter rope briskly Meter reading must be within specification Peak Voltage Output Tests 800 1000 cc NOTE The following tests should be made using the Fluke Model 77 Multimeter set to the DC Volt scale with Peak Voltage Reading Adapter For engine running test use MaxiClips NOTE Peak Voltage Tests unless otherwise indi cated were made with connectors unplugged ...

Page 296: ...of a 1 2 in hole in a plastic float The switch located in the stem of the sending unit is positioned through the hole in the float When the float drops to the lower part of the stem the magnet closes the elec trical contacts located in the stem allowing the cur rent to pass on to the warning light If the sensor should fail it must be replaced To test the sensor use the following procedure 1 Remove...

Page 297: ...torx head cap screws securing the console to the steering support then move the con sole out of the way 2 With the meter selector set to the DC Volt position connect the red meter lead to the gray wire of the connector plug in at the gauge then connect the black meter lead to a chassis ground 3 With the rear of the snowmobile on a shielded safety stand run the engine at 2000 RPM 4 Meter reading mu...

Page 298: ...o each of the ignition key switch terminals 2 With the switch in the OFF position the meter must read less than 1 ohm of resistance 3 With the switch in the ON position the meter must read OL infinite resistance Testing Ignition Components 4 Stroke NOTE The battery must be at full charge for these tests VOLTAGE REGULATOR RECTIFIER DC Voltage Output 1 Set the meter selector to the DC Voltage positi...

Page 299: ...he red green wire then connect the black tester lead to the brown green wire 3 Crank the engine over using the electric starter 4 The meter reading must be at least 5 0 DC volts for both coils Emergency Stop Switch RESISTANCE 1 Remove the four torx head cap screws securing the front rear throttle control housing assembly to the handlebar 2 Set the selector to the OHMS position 3 Connect one tester...

Page 300: ... ignition switch then remove the switch from the console 2 Using the ohmmeter test the connections indi cated in the following chart If the meter reads more than one ohm of resistance the switch must be replaced 0742 118 NOTE If the ignition switch tests good verify battery voltage to the harness side of the switch plug in If there is no voltage troubleshoot the bat tery switch fuse or starter rel...

Page 301: ...cket to the starter motor and remove the bracket REMOVING 800 cc LXR NOTE To remove the starter motor the air silencer must be removed Proceed to the appro priate Air Silencer sub section in Section 3 1 Disconnect the battery 2 Remove the expansion chamber and the resonator 3 Remove the lock nuts and washers securing the cables to the starter motor then remove the cables from the starter motor 4 L...

Page 302: ...t then dry with compressed air AI029 2 Inspect all threaded areas for damaged or stripped threads 3 Inspect the brush holder assembly and brushes for damage or wear Using a calipers measure the length of the brushes If brush measurement is less than 0 30 in replace brushes as a set along with new brush springs AI030 4 Inspect brush leads for cracks wear or fraying If any of these conditions exist ...

Page 303: ...ing any buildup from the com mutator use compressed air to clean 9 Inspect the armature for shorting Use the multit ester and the following procedure A Set the selector on the OHMS position then touch the leads and zero the meter B Touch the black tester lead to the armature shaft C Using the red tester lead probe the commutator end of the armature The meter indicator should not move If the indica...

Page 304: ... washers on the stud Apply a small amount of red Loctite 271 to the stud threads and secure with the nut Tighten to 60 in lb AI039 3 Place the brush holder into position in the commu tator cap NOTE Position the longest positive brush lead beneath the ground wire on right side 4 Place a cap screw through the left ground brush lead eyelet and position the eyelet flat against the brush holder Secure ...

Page 305: ...ose the snap ring 3 Using a side cutter diagonal cutter or suitable pli ers remove and discard the snap ring 4 Remove the snap ring retainer note end for end orientation pinion spring spring retainer and pinion gear Retain all components CLEANING AND INSPECTING PINION NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is necessary 1 Using parts cleaning solvent wash...

Page 306: ...ng failure will result 3 Connect the battery INSTALLING 500 600 cc LXR 1 Install the mounting bracket to the starter motor then secure with existing hardware Tighten securely 2 Place the flex drive shaft into position on the pinion driveshaft so the set screws are aligned with the flat side of the pinion driveshaft then tighten the set screws coated with blue Loctite 243 securely 3 Place the mount...

Page 307: ...starter motor in a suitable clamping device then remove the two long cap screws from the starter motor ZJ140A 2 For assembling purposes make alignment marks on the bearing housing magnet housing and brush assembly ZJ152A 3 Remove the bearing housing A and the magnet hous ing B with armature from the brush assembly C ZJ141A 4 With the armature removed from the magnet hous ing remove snap ring D fro...

Page 308: ...tor should not change If the indicator shows resistance the armature is shorted and must be replaced 11 Inspect the armature for shorting using a growler and the following procedure A Place the armature in the growler B While holding a metal strip on the armature rotate the armature an entire revolution If the metal strip vibrates at any point on the arma ture the armature is shorted and must be r...

Page 309: ...t NOTE If alignment marks were not made during disassembling align properly by matching notch on the magnet housing to notch on the brush assembly ZJ153A 4 With a suitable driving tool install new seal into the bearing housing then install the bearing housing NOTE Prior to installing the bearing housing position the locking plate with the tabs A of the locking plate aligned with the cap screw ears...

Page 310: ...securing the oil tank to the chassis then remove the clamps securing the oil return and oil supply hoses from the mag neto cover Disconnect the hoses along with the breather hose located at the top of the tank and remove the oil tank ZJ146A 3 To gain access to the magneto cover remove the remaining coolant hoses from the water pump oil cooler and separator tank 4 Remove the eighteen cap screws sec...

Page 311: ...ins in the engine for the magneto cover then with a new gasket install the cover and with the pattern shown tighten the 18 cap screws to 84 in lb 741 583A NOTE Assure that the oil pump seal is in place prior to installing the magneto cover ZJ151A 4 Install the coolant hoses to the water pump oil cooler and separator tank then secure the hoses with the clamps 5 Place the oil tank into position in t...

Page 312: ...brakelight switch connect one tester lead to the brown terminal then connect the other lead to the black terminal 3 With the brake lever compressed the meter must read 1 ohm or less resistance With the brake lever released the meter must read OL open If the meter does not read as specified the brakelight switch is defective and must be replaced 4 To remove the switch remove the snap ring then remo...

Page 313: ...mperature of 20 C 68 F NOTE To access the element connectors the handlebar control assembly for the side being tested must be removed 1 Remove the handlebar pad if applicable then disconnect the handlebar warmer three wire con nector 2 In the element connector connect one ohmmeter lead to the green white lead then connect the other ohmmeter lead to the green lead 3 The meter must read between 6 3 ...

Page 314: ...the han dlebar pad Testing Passenger Handwarmer Switch 1 Disconnect the lead wires from the switch 2 With the switch in the LO position connect one ohmmeter lead to the green white wire at the con nector then connect the other ohmmeter lead to the brown wire at the connector The meter must read less than 1 ohm of resistance 3 With the switch in the MED position connect one ohmmeter lead to the gre...

Page 315: ... meter lead to the red blue main har ness connector then connect the other meter lead to the black main harness connector 3 Start the engine The meter must read 12 15 volts NOTE If this voltage test does not read within specification troubleshoot the main harness F 2 fuse K 2 relay or the F 7 main fuse Testing Speedometer Sensor NOTE The following test should be made using MaxiClips and the Fluke ...

Page 316: ... resistance With the reverse button released the meter must read OL open NOTE If the meter does not read as specified in either test the switch is defective and must be replaced Testing Shift Actuator 500 600 1100 cc NOTE The actuator is located on the gear case above the left side footrest 1 Disconnect the actuator two wire connector then connect Actuator Test Harness onto the harness side of the...

Page 317: ...5 40 Troubleshooting Servomotor SERVO1A Next Back Section Table of Contents Manual Table of Contents ...

Page 318: ...5 5 41 SERVO2 Next Back Section Table of Contents Manual Table of Contents ...

Page 319: ...p 21 NOTE All Magneto Diagrams on p 1 Snowmobile Model Main Harness Hood Console Harness Handlebar Harness Bearcat 570 Bearcat 570 XT F 570 T570 p 2 p 14 p 19 Crossfire 600 M6 p 4 p 13 p 17 CFR Crossfire Crossfire Sno Pro M Series M Series Sno Pro 800 1000 cc p 8 p 13 p 17 F5 LXR p 3 p 15 p 18 F6 Sno Pro p 5 p 16 p 18 F8 LXR p 6 p 15 p 18 F8 Sno Pro p 7 p 16 p 18 Bearcat Z1 XT TZ1 Z1 Z1 LXR p 9 p ...

Page 320: ...Magneto 0744 205 1 Section Table of Contents Wiring Diagram Table of Contents Manual Table of Contents ...

Page 321: ...Main Harness p n 1686 527 F 570 p n 1686 528 T570 p n 1686 534 Bearcat 570 XT p n 1686 535 Bearcat 570 0744 182 2 Section Table of Contents Wiring Diagram Table of Contents Manual Table of Contents ...

Page 322: ...Main Harness p n 1686 553 F5 LXR 0744 188 3 Section Table of Contents Wiring Diagram Table of Contents Manual Table of Contents ...

Page 323: ...Main Harness p n 1686 554 Crossfire 600 M6 0744 181 4 Section Table of Contents Wiring Diagram Table of Contents Manual Table of Contents ...

Page 324: ...Main Harness p n 1686 551 F6 Sno Pro 0744 187 5 Section Table of Contents Wiring Diagram Table of Contents Manual Table of Contents ...

Page 325: ...Main Harness p n 1686 539 F8 LXR 0744 185 6 Section Table of Contents Wiring Diagram Table of Contents Manual Table of Contents ...

Page 326: ...Main Harness p n 1686 538 F8 Sno Pro 0744 186 7 Section Table of Contents Wiring Diagram Table of Contents Manual Table of Contents ...

Page 327: ...Main Harness p n 1686 533 CFR Crossfire M Series 800 1000 cc 0744 178 8 Section Table of Contents Wiring Diagram Table of Contents Manual Table of Contents ...

Page 328: ...Main Harness p n 1686 522 Bearcat Z1 XT p n 1686 581 TZ1 TZ1 LXR p n 1686 575 Z1 p n 1686 518 Z1 LXR 0744 192 9 Section Table of Contents Wiring Diagram Table of Contents Manual Table of Contents ...

Page 329: ...arness p n 1686 516 TZ1 Turbo LXR Z1 Turbo Sno Pro p n 1686 520 Z1 Turbo LXR p n 1686 519 Z1 Turbo Z1 Turbo EXT 0744 203 10 Section Table of Contents Wiring Diagram Table of Contents Manual Table of Contents ...

Page 330: ...sole Harness p n 1686 547 Bearcat Z1 XT Z1 Z1 Turbo EXT Z1 Turbo Sno Pro p n 1686 549 TZ1 Z1 LXR Z1 Turbo LXR 0744 194 11 Section Table of Contents Wiring Diagram Table of Contents Manual Table of Contents ...

Page 331: ...Console Harness p n 1686 548 TZ1 LXR TZ1 Turbo LXR 0744 193 12 Section Table of Contents Wiring Diagram Table of Contents Manual Table of Contents ...

Page 332: ...Hood Harness p n 1686 565 CFR Crossfire M Series 0744 179 13 Section Table of Contents Wiring Diagram Table of Contents Manual Table of Contents ...

Page 333: ...Console Harness p n 1686 576 Bearcat 570 p n 1686 567 Bearcat 570 XT F 570 T570 0744 184 14 Section Table of Contents Wiring Diagram Table of Contents Manual Table of Contents ...

Page 334: ...Console Harness p n 1686 573 F5 LXR F8 LXR 0744 190 15 Section Table of Contents Wiring Diagram Table of Contents Manual Table of Contents ...

Page 335: ...Console Harness p n 1686 572 F6 Sno Pro F8 Sno Pro 0744 191 16 Section Table of Contents Wiring Diagram Table of Contents Manual Table of Contents ...

Page 336: ...Handlebar Harness p n 1686 566 Crossfire M Series p n 1686 575 CFR 0744 180 17 Section Table of Contents Wiring Diagram Table of Contents Manual Table of Contents ...

Page 337: ...Handlebar Harness p n 1686 574 F Series 0744 189 18 Section Table of Contents Wiring Diagram Table of Contents Manual Table of Contents ...

Page 338: ...Handlebar Harness p n 1686 537 Bearcat 570 570 XT F 570 T570 0744 183 19 Section Table of Contents Wiring Diagram Table of Contents Manual Table of Contents ...

Page 339: ...ss p n 1686 568 TZ1 TZ1 LXR TZ1 Turbo LXR Z1 Z1 LXR Z1 Turbo LXR Z1 Turbo EXT Z1 Turbo Sno Pro p n 1686 577 Bearcat Z1 XT 0744 195 20 Section Table of Contents Wiring Diagram Table of Contents Manual Table of Contents ...

Page 340: ...Passenger Seat Harness p n 1686 570 TZ1 Models 21 0744 197 Section Table of Contents Wiring Diagram Table of Contents Manual Table of Contents ...

Page 341: ...Clutch Driven Pulley 6 10 Drive Train Brake Disc 6 12 Drive Sprockets 6 30 Track Tension 6 33 Track Alignment 6 33 Brake System Hydraulic 6 34 Brake Lever Master Cylinder Assembly 6 43 Troubleshooting Track 6 44 Troubleshooting Hydraulic Brake System 6 45 Troubleshooting Drive Clutch Driven Pulley 6 46 Troubleshooting Drive Belt 6 47 Manual Table of Contents ...

Page 342: ...ffect as one that is too long Drive belt construction has an influence on the way the drive clutch and driven pulley will shift and on the amount of power that will be transmitted through the system ONLY ARCTIC CAT DRIVE BELTS SHOULD BE USED Different brands of belts may not have the same construction causing either more friction or more slippage when the belt is wedged between the sheaves and thu...

Page 343: ...the crankshaft ZJ292 NOTE Before installing the clutch puller apply oil to the threads of the puller and a small amount of grease to the tip of the puller 2 Using the Drive Clutch Puller and a breaker bar and the Drive Clutch Spanner Wrench tighten the puller If the drive clutch will not release sharply strike the head of the puller Repeat this step until the clutch releases ZJ293 3 Remove the dri...

Page 344: ... for proper compression rate qualities see Drive System Components in Sec tion 1 of this manual 6 Inspect rollers for damage or wear Assembling 1 With the head of each cam arm pin positioned towards the direction of the drive clutch rotation install the cam arms NOTE The drive clutch rotates counterclock wise 2 With the cam arm pin properly positioned apply green Loctite 620 to the set screw holes...

Page 345: ...ue specification Driven Pulley REMOVING 1 Remove the drive belt NOTE For removing drive belt see Drive Belt in this section 2 Using a 9 16 in socket and extension remove the cap screw securing the driven pulley to the input shaft 3 Slide the driven pulley off the shaft NOTE Account for and remove any alignment washers These washers must be used during installing DISASSEMBLING 1 Prior to disassembl...

Page 346: ...ke each screw with a hammer 4 Release the compression of the spring by remov ing the wing nut then remove the movable sheave Account for the torque bracket retainer FS093 FS094 5 Remove the stationary sheave then remove the plastic washer spring seat and the spacer CM062 6 Remove the spring and remaining spring seats CM063 CM064 Next Back Section Table of Contents Manual Table of Contents ...

Page 347: ...er of the shaft and the inside diame ter of the bearing Compare the readings Clear ance between the shaft and the respective bearing must not exceed 0 020 in If the clearance exceeds the specification the driven pulley must be replaced NOTE The movable sheave bearing is a non ser viceable component CM101 FS122 FS123 REPLACING TORQUE BRACKET BEARING COVER BEARING 1 Remove the snap ring 2 Using a su...

Page 348: ...nough to install the spring pin CM066 CM067A 4 Tap the spring pin back into place CM068A ASSEMBLING 1 Place the torque bracket onto the Driven Pulley Compressor Tool then install the spring seats onto the torque bracket and place the spring into posi tion CM064 CAUTION Care must be taken not to damage the driven pulley shaft Next Back Section Table of Contents Manual Table of Contents ...

Page 349: ... sheave onto the sta tionary sheave FS093 5 With the pulley in place on the compressor install the compressor flange spacer and wing nut then compress the driven pulley spring CM069 6 Install the torx head cap screws securing the mov able sheave Tighten in a crisscross pattern to 72 in lb CM061 7 Remove the pulley from the compressor INSTALLING 1 Set the brake lever lock 2 Install the alignment wa...

Page 350: ... shaft Remove the cap screw and washers securing the driven pulley NOTE If the driven pulley is tight on the shaft pull the driven pulley off using the Driven Pulley Puller 2 To move the driven pulley inward on the shaft remove alignment washer s from the gear case side of the pulley 3 To move the driven pulley outward on the shaft install additional alignment washer s on the gear case side of the...

Page 351: ...ighten all engine mounting hardware in the sequence used in step 1 4 With all mounting hardware tightened install the drive clutch and the driven pulley then repeat steps 2 3 of Checking Parallelism sub section DRIVE BELT DEFLECTION Drive belt length condition and deflection are all important for peak performance To check and adjust drive belt deflection use the following procedure 1 Turn the engi...

Page 352: ... for this procedure 1 Remove the access panels from both sides of the snowmobile 2 Engage the brake lever lock then remove the cap screw securing the driven pulley to the input shaft Remove the pulley from the shaft ZJ182A NOTE After removing the driven pulley account for any alignment washers if applicable These washers must be used during installing 3 On the F Series T Series Z1 remove the torx ...

Page 353: ...gainst the driveshaft cap screw until the gear case is free from the studs of the mounting plate 8 Remove the cap screw from the inner driveshaft from step 5 then remove the gear case NOTE If the gear case is difficult to remove it may be necessary to loosen the track tension NOTE On the 2 stroke models account for the torque bumper 9 Remove the hairpin clip and springs securing the resonator then...

Page 354: ...brake caliper unless being serviced NOTE At this point if necessary remove the track INSTALLING TRACK DRIVESHAFT GEAR CASE NOTE At this point if the track was removed install the track NOTE Steps 1 8 are for installing the track drive shaft If only installing the gear case proceed to step 9 NOTE Prior to installing the driveshaft apply a coat of Anti Seize Thread Compound to the inter nal splines ...

Page 355: ...t to the output shaft with the cap screw coated with blue Loctite 243 and washer Tighten to 70 ft lb 742 020A NOTE If the gear case is not installed do not secure the driveshaft to the output shaft at this time Proceed to step 7 7 Place the resonator into position and secure with the springs and hairpin clip 8 Install the skid frame see Section 7 NOTE At this point if the gear case is installed pr...

Page 356: ...n installing the torque bumper 12 On the 1100 cc install the torx head cap screw A from the back side of the chassis then install the snubber bracket ZJ308A 13 On the 500 600 1100 cc F Series connect shift actuator harness A and gear indicator switch har ness B ZJ183A 14 Install the toe shield and toe hook bracket then install the torx head cap screws Tighten securely 0742 089 15 On the 600 cc Cro...

Page 357: ...sec tion 21 Install and secure the side panels DISASSEMBLING GEAR CASE w Reverse 1 On electronic reverse models remove the three torx head cap screws securing the shift actuator to the gear case and remove the actuator then remove the gear indicator switch ZJ186A 2 Remove the torx head cap screws securing the gear case cover to the gear case assembly then insert two flat blade screwdrivers into th...

Page 358: ...he input shaft bearing out of the gear case cover Account for a bearing and a seal ZJ191 MS331 8 Secure the gear case in a suitable clamping device then using the procedure from step 5 remove the outer bearing from the transfer gear ZJ192 9 Place the gear case on its side then using a soft hammer tap the output shaft until the slider and output gear assembly come free of the gear case CAUTION If t...

Page 359: ...her and thrust bearing ZJ196 NOTE For assembling purposes note that the thrust bearing is positioned between the thrust washer and the gear assembly ZJ197 13 Remove the retaining ring and thrust washer securing the slider housing assembly to the output shaft assembly ZJ200 14 Using a suitable puller remove the bearing from the output shaft 15 Using a suitable seal removing tool remove the output i...

Page 360: ...tion Rotate the bearings Bearings must rotate freely and must not bind or feel rough If any abnormal condition is noted replace the bearing NOTE The output shaft bearing is a non service able component If any damage or binding is noted the output shaft assembly must be replaced 8 Apply a light film of Arctic Cat Synthetic ACT Drive Fluid to the unsealed bearings prior to assembling ASSEMBLING GEAR...

Page 361: ...washer Using a suitable press install the inner bearing onto the transfer gear shaft ZJ208 6 Install the output gear assembly into the slider assembly until the inner bearing is properly seated ZJ194 7 With the alignment notches of the slider and gear case properly positioned install the slider output gear assembly into the gear case ZJ201 8 Using a suitable bearing press install the outer bearing...

Page 362: ...rk shaft then install a new oil seal NOTE Apply a film of grease to the oil seal prior to installing 12 With the alignment marks properly positioned install the shift fork arm to the shaft Secure the arm with the remaining retaining ring ZJ301A 13 Install the slider blocks to the shift fork assembly then install the fork assembly into the slider and gear case ZJ205 NOTE Make sure to install the sl...

Page 363: ...into the drain fill hole then install the plug Tighten to 12 ft lb DISASSEMBLING GEAR CASE w o Reverse 1 Remove the torx head cap screws securing the gear case cover to the gear case assembly MS327A 2 Insert two flat blade screwdrivers into the notches on the gear case then working back and forth pry the cover up and off the gear case CAUTION Care must be taken not to allow silicone sealant into t...

Page 364: ...r case cover Account for a bearing and a seal MS330 MS331 6 Remove the transfer gear assembly from the gear case MS512 7 Secure the transfer gear in a suitable clamping device then using two flat blade screwdrivers from opposite sides of the cover bearing evenly pry the input shaft bearing up and off the shaft 8 Using a suitable bearing press and fixture remove the main bearing from the transfer g...

Page 365: ...gear case on its side then using a soft hammer tap the output shaft until the output gear assembly is free of the gear case MS520 12 Noting the position of the gap remove the retain ing ring using a flat blade screwdriver MS518A 13 With a suitable bearing press and fixture remove the bearing from the ring gear MS519 CAUTION Always use a proper insert or thread a cap screw into the end of the outpu...

Page 366: ... the bearings Bearings must rotate freely and must not bind or feel rough If any abnormal condition is noted replace the bearing 6 Inspect the planetary and ring gears for wear cracks or chipped teeth 7 Apply a light film of Arctic Cat ACT Drive Fluid to the unsealed bearings prior to assembling ASSEMBLING GEAR CASE w o Reverse 1 Using an appropriate seal installation tool install the oil seal int...

Page 367: ...he retaining ring is properly positioned as noted during disassem bling MS518A 6 Using a suitable bearing press install the outer bearing A to the transfer gear assembly then install the spacer B and press the inner bearing C to the assembly MS515A 7 Install the transfer gear assembly into the plane tary gear assembly making sure the transfer gear inner bearing is fully seated into the gear case M...

Page 368: ...349 11 Apply a film of High Temp Silicone Sealant to the sealing surfaces of the gear case MS350A 12 With the dowel pins in place install the cover to the gear case and secure with cap screws then using a crisscross pattern tighten to 12 5 ft lb 744 133C CAUTION Care must be taken not to allow silicone sealant into the cap screw holes and dowel pin holes or damage to the gear case may occur when t...

Page 369: ...mobile is on a level surface to ensure the lubricant drains prop erly and completely 6 Secure the snowmobile in this position until the lubricant is completely drained 7 When the lubricant has completely drained form the gear case tip the snowmobile back to the upright position remove the drain adapter and install and securely tighten the drain plug then remove the check fill plug 8 Pour the recom...

Page 370: ... ACT Gear Case Fluid into the check fill hole then install the plug Tighten to 12 ft lb 21 Install the driven pulley then install the drive belt see Drive Belt sub section and the belt guard 22 Install and close the access panels Drive Sprockets REMOVING NOTE The drive sprockets must be removed from the gear case end of the driveshaft ZJ216A 1 For installing purposes scribe a line on the drive sha...

Page 371: ...to the driveshaft lightly chamfer the inside edge of the sprocket to avoid binding MS362 1 Properly align the scribed line on the driveshaft from removing with the timing arrow on the drive sprocket then slide the sprocket onto the driveshaft as far as it will go MS360A 2 Using a suitable press and fixture press the drive shaft into the sprocket until it aligns with the line scribed in removing MS...

Page 372: ...eshaft align the sprocket alignment marks or the sprockets won t be timed correctly 740 043A 4 Using a calipers measure distances between the sprockets and from the sprockets to each end of the driveshaft for proper location see appropriate illustration MS364 744 059B 742 367A 744 061A Next Back Section Table of Contents Manual Table of Contents ...

Page 373: ...track tension must be loosened it may be necessary to loosen the rear axle assem bly slightly NOTE Vigorously push the underside of the track up and down Track must not hit the top of the tunnel or slap the skid frame 4 After correct track tension is obtained check track alignment see Track Alignment in this section NOTE Track tension and track alignment are interrelated always check both even if ...

Page 374: ...OTE Do not pump the brake lever as it will pro duce an inaccurate reading 2 Measure the distance between the brake lever and the handlebar The distance must be greater than 1 in 741 328C 3 If the distance is less than specified check the brake fluid level see Checking and Adding Brake Fluid in this sub section inspect for leakage and check the brake pads see Checking and Replacing Brake Pads in th...

Page 375: ...he reservoir cover and fill the reservoir with approved brake fluid 2 Slide a piece of flexible tubing over the ball of the bleeder valve and direct the other end into a con tainer 739 269B 3 Slowly compress the brake lever and hold Open the bleeder valve to release the fluid and air When the fluid stops flowing close the bleeder valve then release the brake lever 4 Repeat step 3 until the brake f...

Page 376: ...shing out the other piston from the caliper ZJ224 5 Using a flat blade tool slowly and carefully push the piston into the caliper 6 Position the new brake pads into the caliper 7 Repeat steps 4 6 for the other pad then secure the pads with the pin and hairpin clip ZJ223 8 Remove the reservoir cover and remove the remaining fluid then fill the reservoir with fresh fluid 9 Pump the brake lever to en...

Page 377: ... outside housing Account for the O ring ZJ219A NOTE To aid in removing the inner caliper hous ing completely loosen track tension 9 Remove the four lock nuts A and the Phillips head cap screw with lock nut B securing the cali per housing assembly to the chassis then remove the inside caliper housing along with the brake disc from the driveshaft Account for the caliper spacer and the disc spacer 74...

Page 378: ...he small O ring installed between the inner and outer housings 13 Position a piece of wood between the pistons Using low pressure compressed air blow into the caliper brake hose fitting to remove the brake pistons ZJ228A NOTE Remove the two remaining torx head cap screws securing the caliper halves Account for the small O ring MS320A 14 Remove the pistons and O rings then discard the O rings ZJ229...

Page 379: ...ers for gouges cracks pitting scuffing or corrosion If any of these conditions exist replace the caliper 4 Clean the caliper inner wall surface using a soft lint free cloth and clean brake fluid ZJ225A MS320A 5 Inspect the condition of the brake pads Replace if damaged or worn The brake pad thickness must be greater than 0 20 in If the brake pad thickness is less than specified replacement of both...

Page 380: ...alling the piston make sure the piston O ring is properly seated in the groove of the caliper housing 3 Place the small O ring into position then assemble the two caliper halves Secure with the two torx head cap screws Tighten only until snug ZJ231A NOTE Always use a new O ring and make sure the O ring is properly seated in the outer brake housing MS320A 4 Using a suitable press install a new inne...

Page 381: ... bearing spacer and outer bearing to maintain proper align ment of the spacer for driveshaft installation ZJ242 ZJ243 7 Apply Anti Seize Thread Compound to the splines of the brake disc then with the brake caliper spacer properly installed slide the caliper onto the driveshaft far enough to install the spacer and brake disc CAUTION When installing a bearing always press on the outer race of the be...

Page 382: ...ng and place the housing into position then secure with the two Allen head cap screws Tighten to 17 ft lb NOTE Always use a new O ring and make sure the O ring is properly seated in the outer brake housing MS320A ZJ219A 11 Install the brake pads then secure the brake pads with the retaining pin and hairpin clip 12 Bleed the brake system see Bleeding Brake Sys tem in this sub section 13 Engage the ...

Page 383: ...r Discard the two crush washers 3 Remove the snap ring C and pin D securing the brake lever to the master cylinder 4 Using a small screwdriver compress the tabs of the brakelight switch E to release it from the master cylinder 5 Remove the two torx head screws F and clamp securing the brake reservoir to the handlebar then place a towel over the reservoir and remove the assembly from the handlebar ...

Page 384: ...oblem Track Edge Frayed Drive Lugs Worn Condition Remedy 1 Track alignment adjusted incorrectly 1 Align replace track Problem Track Worn Adjacent to Outer Drive Lugs Condition Remedy 1 Track tension adjusted incorrectly 1 Adjust track tension 2 Rear idler wheels dirty damaged 2 Clean replace idler wheels Problem Track Ratchets Slaps Tunnel Condition Remedy 1 Track tension adjusted incorrectly too ...

Page 385: ...fluid overheated contaminated 2 Master cylinder damaged faulty 3 Caliper brake hose leaking 4 Air ducts obstructed missing 5 Brake lever linkage damaged 1 Replace fluid 2 Replace master cylinder 3 Replace caliper O ring repair piston replace piston O ring brake hose 4 Remove obstruction replace air ducts 5 Repair replace lever mounting bolt Problem Brakes Drag Condition Remedy 1 Master cylinder da...

Page 386: ...driven pulley 3 Service driven pulley 4 Clean replace bearing movable sheave Problem Excessive Belt Drag Impaired Drive Clutch Disengagement Condition Remedy 1 Drive clutch components dirty damaged 2 Drive belt does not meet measurement specifications 1 Clean replace drive clutch components 2 Replace drive belt Problem Engine RPM Suddenly Increases Drive Clutch Vibrates Condition Remedy 1 Cam arm ...

Page 387: ...ace drive belt 2 Replace drive clutch spring 3 Clean replace drive clutch 4 Adjust offset parallelism center to center distance Problem Drive Belt Lugs Torn Off Frayed Worn in One Spot Condition Remedy 1 Drive belt does not meet measurement specifications 2 Offset parallelism center to center distance adjusted incorrectly 3 Drive clutch engagement idle RPM too high 4 Drive clutch components dirty ...

Page 388: ...Frame Mounting Locations 7 6 Servicing Rear Suspension Bearcat XT 7 10 CFR Crossfire 7 34 M Series 7 61 F Series Z1 7 77 Bearcat 570 T Series Z1 EXT 7 96 Servicing ACT Shock 7 117 Rebuilding Recharging Fox Air Shocks 7 120 Servicing Fox Zero Pro Shock Absorbers 7 125 Shaft Eyelet 7 129 Pressurizing Rebuildable Shocks 7 130 Manual Table of Contents ...

Page 389: ...en the rear axle center and the ski saddle center Also assume that the ski saddle center is the same height off the ground as the rear axle center This produces the standard position arrangement 0728 180 Under acceleration when the center of gravity is trans ferred to the rear of the machine the rear suspension collapses slightly This brings the rear arm point down ward and with the front arm stat...

Page 390: ...inations of springs and shocks If changes are necessary several spring and shock sizes are available While making these changes keep the following points in mind Heavier Or Stiffer Springs 1 These will require shocks with more rebound con trol or the front end will become like a pogo stick 2 With stiffer springs the front end will become more aggressive in the corners as more weight will be transf...

Page 391: ... lb 727 720A NOTE When making any changes to the front or rear suspension the change should be made at both ends to keep the suspension balanced For example installing stiffer springs in front may require installing the next step stiffer spring in back to keep everything in balance ADJUSTING REAR ARM COUPLER Groove Style NOTE The couplers are installed in the 2 groove position at production The re...

Page 392: ...the shocks and spring which assist the rear springs The result is a smoother ride for the operator If additional coupler action is desired the coupler blocks can be set to the number 2 or 3 position Each of the coupler blocks has three positions numbered on the inside surface of the block When changing the block position change both to the same number To make the coupler adjustment follow the proc...

Page 393: ... disassembling and assembling the suspension all stock mounting locations be used as shown in the following illustrations 0744 840 0744 839 CAUTION All stock mounting locations must be used If any alterations to the skid frame are made shock absorber and suspension damage may occur T Series Models F Series Models Next Back Section Table of Contents Manual Table of Contents ...

Page 394: ...7 7 7 0744 126 0744 837 Bearcat 570 Crossfire Standard Next Back Section Table of Contents Manual Table of Contents ...

Page 395: ...7 8 0744 128 0744 835 CFR M Series Next Back Section Table of Contents Manual Table of Contents ...

Page 396: ...7 9 7 0744 841 0744 842 Bearcat XT Z1 Turbo EXT Next Back Section Table of Contents Manual Table of Contents ...

Page 397: ... to the tunnel NOTE The support stand should hold the snow mobile level but not raised off the floor 4 Remove the front cap screws securing the skid frame to the tunnel Account for a flat washer and a lock washer 5 Remove the support stand then tip the snow mobile onto one side using a suitable handlebar support stand Remove the skid frame NOTE At this point if servicing the articulating skid fram...

Page 398: ... sharp edges on the lower portion of the rail 1 Align the wear strip with the openings windows in the track and from the back start the wear strip onto the rail then using a block of wood and a hammer drive the wear strip forward into posi tion 739 884A 2 Secure with a machine screw and lock nut Tighten to 50 in lb End Caps NOTE The skid frame does not have to be removed for this procedure REMOVIN...

Page 399: ...f being replaced 1 Using a 3 16 in drill bit drill out the rivets secur ing each front and rear shock pad to the slide rail Account for the retaining brackets AG476D 2 Remove the shock pads INSPECTING NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is necessary 1 Inspect the pad and retaining brackets for damage or wear 2 Inspect the rivet holes in the slide rail...

Page 400: ...n any way replacement is necessary 1 Clean the bearing with a clean cloth 2 Inspect each idler wheel and each plastic hub for cracks or damage 3 Rotate the idler wheel bearing by hand and inspect for binding or roughness 4 If a bearing must be replaced on idler wheels with a removable bearing use this procedure A Remove the wheel insert if applicable and the snap ring B Using a hydraulic press pre...

Page 401: ...w into the top mounting block hole prior to tightening MS009A 2 Place the two shim washers if applicable idler wheel and axle against the mounting block mak ing sure a flat washer is on the outside of the idler wheel MS004 NOTE On idler wheels with inserts install spac ers MS005 3 Secure the idler wheel assembly with a cap screw and a lock nut Tighten cap screws to 20 ft lb Next Back Section Table...

Page 402: ...of the upper bushing is oriented outwards SC014B 3 Loosen the cap screws securing the pivot arm to the idler arm then remove the pivot arm assembly Account for two pivot arm spacers SC014A NOTE Unless the pivot arm is being replaced the cap screws and lock nuts do not need to be removed to remove the pivot arm MS064 4 Using the appropriate Idler Wheel Puller Kit remove the wheel WARNING Care must ...

Page 403: ...ding or roughness 4 If a bearing must be replaced see Idler Wheels Mounting Blocks Cleaning and Inspecting in this sub section 5 Inspect the spring spring slide sleeve washers slide block insert and shaft area for wear 6 Inspect the adjusting cams and arms for cracks INSTALLING 1 Slide the sleeve and spring onto the idler arm MS069 2 Place the slide spacer and slide block with spring in slide bloc...

Page 404: ...lared side of the bushing out Secure the pivot arm to the idler arm with cap screws and lock nuts Tighten to 20 ft lb SC014A NOTE When tightening the pivot arm lock nuts tighten the lower lock nut first or binding may occur 7 Install the skid frame see Installing Skid Frame in this sub section NOTE Install the rear arm springs onto the adjuster blocks after the skid frame has been installed Idler ...

Page 405: ...nd bushings SC019A AG553D NOTE Mark the hole that the upper shock links are mounted in for assembly purposes MS076 3 Remove the cap screw and lock nut securing the upper shock links to the idler arm Account for a lock nut spacer and axle links SC020A MS031 4 Remove the cap screw washer and lock nut secur ing the rear arm to the slide rail Account for the serrated axles and axle tube SC021A Next Ba...

Page 406: ... and Inspecting in this sub section ASSEMBLING 1 Install the rear arm onto the idler arm with an alu minum axle bushing assemblies and two cap screws coated with blue Loctite 243 Tighten only until snug SC022A 2 Place the rear arm assembly into position Secure with a cap screw washer and lock nut Tighten to 40 ft lb SC021A 3 Place a support beneath the rear arm then tighten the cap screws from ste...

Page 407: ... arm springs onto the adjuster blocks after the skid frame has been installed Front Arm Front Shock Absorber Front Inner Idler Wheels NOTE The skid frame must be removed for this procedure see Removing Skid Frame in this sub section and the rear springs must be removed from the adjusting cams REMOVING 1 Remove the lower cap screws and lock nuts secur ing the limiter straps to the rail support Acco...

Page 408: ...086A INSPECTING NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is necessary 1 Inspect all front arm weldments for cracks or unusual bends 2 Closely inspect all tubing for cracks or unusual bends 3 Inspect the idler wheel bearings bushings and front arm spacers for wear or damage 4 Inspect the shock absorber for any signs of oil leakage especially at the point wh...

Page 409: ... idler wheel shock bracket assembly into position on the skid frame making sure the axle is aligned with the hole in the slide rail Secure with the cap screw and a new lock nut Tighten only until snug SC026A 4 Position the front arm into the slide rail Secure with cap screws and lock nuts Tighten to 40 ft lb SC029 NOTE At this point tighten the lock nut from step 3 to 40 ft lb SC030 5 Secure the u...

Page 410: ... the skid frame it may be necessary to loosen all axle cap screws lock nuts to make removing eas ier 1 Remove the cap screw and lock nut securing the shock absorber to the eyelet of the idler arm and remove the shock absorber Account for a sleeve cap screw lock nut and bushings MS089A MS091 NOTE For ease of servicing the rear arm compo nents engage the overload springs 2 Mark the hole that the sho...

Page 411: ...ear or outer rubber separation from plastic wheel 5 Rotate the idler wheel bearings by hand and inspect for any signs of binding or roughness 6 If the idler wheel has a removable bearing and the bearing must be replaced see Idler Wheels Mounting Blocks Cleaning and Inspecting in this sub section 7 Inspect the shock absorber for any signs of oil leakage especially at the point where the shock shaft...

Page 412: ...as a non removable bearing install the flared spacers with the flared side of the spacer directed towards the pivot bracket 4 Lower the idler wheel pivot assembly down between the rails Align the axle with the mount ing hole as noted during disassembling Secure with the cap screw and a new lock nut Tighten to 40 ft lb SC033 SC034A 5 Position the shock links in the appropriate holes of the idler ar...

Page 413: ... from the slide rail Account for a cap screw lock nut and two flat washers MS016A 2 Remove the machine screw and lock nut securing the wear strip to the front of the slide rail 3 Using a suitable driving tool drive the wear strip off the rail AG510D NOTE If binding of the wear strip occurs use a pipe wrench start from either end and hook the edge of the wear strip with the pipe wrench jaw and twis...

Page 414: ... slide rails SC039A NOTE If removing the cap screw is necessary to replace the slide rail install the cap screw from the opposite side into the assembly to secure the components and aid in replacing the slide rail 9 Remove the cap screw and flat washer securing the spring slide and overload spring to the rail Account for a spacer the slide block overload spring retainer clips bushing one small was...

Page 415: ...bit drill out the rivets and remove the shock pads Note the shock pad location for instal lation Account for the retaining brackets MS116A INSPECTING NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is necessary 1 Inspect the slide rail for cracks A elongated holes B or unusual bends MS220A 2 Inspect the wear strip for wear The wear strip must be 0 42 in thick or ...

Page 416: ... secure with cap screw coated with blue Loctite 243 and tighten to 40 ft lb SC042A 4 Secure the two front rail supports with cap screws coated with blue Loctite 243 Tighten to 20 ft lb SC047A 5 Secure the limiter straps to the front rail support with cap screws washers and lock nuts and tighten to 120 in lb 6 Place the overload spring with retaining clips and bushing to the proper hole in the slid...

Page 417: ...ew flat washers idler wheel and a lock nut Tighten to 20 ft lb MS122 11 Secure the end cap onto the slide rail using a cap screw flat washers and a lock nut Tighten to 80 in lb MS206A NOTE Apply a light coat of grease to the slide rail surface to aid in installing a new wear strip Use a file to remove any sharp edges on the lower portion of the rail MS288 12 From the back start the wear strip onto...

Page 418: ...owing procedure refer to illus tration 744 166A on the following page 1 Remove the rear idler wheel cap screw A washer and lock nut from the cap screw side of the skid frame 2 Remove the two cap screws B and lock nuts securing the articulating skid frame to the slide rail 3 With the adjuster rod axle C in place in the adjuster rods D remove the lock nuts E from the adjuster springs F then remove t...

Page 419: ...en in order on the rear axle I install the center idler wheel the remaining spacer J and washer K Continue to slide the rear axle through the other side of the swing arm 3 Slide an adjuster bushing H on each end of the rear axle making sure the bushings are properly positioned to the adjuster bolts then secure each rear axle idler wheel with a cap screw G Tighten only until snug 4 Install the adju...

Page 420: ...assembly with the appropriate hole in the tunnel Secure the rear arm assembly with a cap screw DO NOT TIGHTEN AT THIS TIME NOTE Do not install the short legs of the rear springs onto the adjusting cams at this time 6 At this time tighten all four skid frame mounting cap screws to 40 ft lb 7 Using the Rear Suspension Spring Tool install the short legs of the rear springs onto the adjusting cams mak...

Page 421: ... remove the rear cap screws securing the skid frame to the tunnel NOTE The support stand should hold the snow mobile level but not raised off the floor 4 Remove the front arm cap screws securing the skid frame to the tunnel Account for a flat washer and axle 5 Remove the support stand then tip the snow mobile onto one side using a suitable handlebar support stand Remove the skid frame Wear Strips ...

Page 422: ... the rail 1 Align the wear strip with the openings windows in the track and from the back start the wear strip onto the rail then using a block of wood and a hammer drive the wear strip forward into posi tion 739 884A 2 Secure with a machine screw and lock nut Tighten to 50 in lb End Caps NOTE The skid frame does not have to be removed for this procedure REMOVING 1 Remove the lock nut washers and ...

Page 423: ...n excessively cracked or damaged in any way replacement is necessary 1 Inspect the pads for damage or wear 2 Inspect the rivet holes in the slide rail for damage or elongation INSTALLING 1 Place the rear pads into position on the slide rail 2 Secure the rear pads with new push nuts 3 Place the front pads and retaining brackets into position on the slide rail 4 Secure the front pads with rivets Idl...

Page 424: ...ected away from the bearing MS007A E Install the insert if applicable MS008 INSTALLING 1 Secure the mounting block on the slide rail with a cap screw and lock nut Tighten to 20 ft lb NOTE For proper alignment install an idler wheel cap screw into the top mounting block hole prior to tightening MS009A 2 Place the idler wheel to the mounting block then secure the idler wheel assembly with a cap scre...

Page 425: ...142 MS064 NOTE Account for a flanged axle flared bush ing idler spacer collars and lock nuts 3 Remove the idler wheel NOTE Use Idler Wheel Puller Kit to remove the wheel MS143 4 On the CFR Crossfire remove the snap ring secur ing the rear arm idler wheels to the inner carriage axle and account for the wave washers then remove the axle from the idler arm 5 Remove the cap screw flat washer and lock ...

Page 426: ...aning and Inspecting in this sub section 5 Inspect the spring spring slide sleeve washers slide block insert and shaft area for wear 6 Inspect the adjusting cams and arms for cracks INSTALLING NOTE Steps 1 and 2 are for the CFR and Cross fire standard 1 Slide the sleeve and spring onto the idler arm MS145 2 Place the spring slide and slide block with spring in slide block into position on the slid...

Page 427: ...pivot arm to the idler arm with cap screws and lock nuts Tighten to 20 ft lb FZ048A NOTE When tightening the pivot arm lock nuts tighten the lower lock nut first or binding may occur FZ048B NOTE On the standard and Crossfire Sno Pro install the wave washer and idler wheel along with the snap ring onto the axle then using a suitable driving tool carefully drive the snap ring into the idler wheel un...

Page 428: ... using a suitable driving tool carefully drive the snap ring into the idler wheel until properly seated in the groove of the axle CM239 10 Grease the idler arm and rear arm grease fittings with a low temperature grease Rear Axle and Idler Wheels NOTE The skid frame must be removed for this procedure see Removing Skid Frame in this sub section DISASSEMBLING 1 Remove the cap screw and large flat was...

Page 429: ... place a bush ing E inner idler wheel D rear idler wheel spacer C inner idler wheel D and bushing E on the axle Slide the axle through the opposite slide rail axle slot 2 Place the adjuster bushings A on the axle on the outside of each axle slot then install the outer idler wheels on the axle and secure with two cap screws coated with blue Loctite 243 and large flat washers Tighten cap screws only...

Page 430: ...w and lock nut securing the upper shock eyelet to the idler arm Account for a spacer cap screw and lock nut FZ040A NOTE Mark the hole that the upper shock links are mounted in for assembly purposes MS155 3 On the standard and CFR remove the cap screw and lock nut securing the upper shock links to the idler arm Account for a cap screw lock nut spacer and axle links MS156A Next Back Section Table of...

Page 431: ... rail Account for the serrated axles and axle tube FZ042A NOTE On the Sno Pro remove the cap screws and lock nuts securing the rear arm shock absorber and shock link to the pivot arm CM233A NOTE To remove the rear arm it may be neces sary to loosen the rear arm limiter FZ042C MS028 5 Remove the cap screw and lock nut securing the rear arm to the idler arm Account for the alumi num axle and bushing...

Page 432: ...p screw and lock nut Tighten to 40 ft lb FZ043 NOTE If the rear arm limiter was loosened treat the threads of the cap screw with blue Loctite 243 and tighten to 40 ft lb FZ042C 2 Install the rear arm onto the idler arm with an alu minum axle bushing assemblies and two cap screws coated with blue Loctite 243 Tighten only until snug FZ044 3 Position the shock links in the appropriate holes of the id...

Page 433: ...ge axle to the idler arm then install a wave washer and idler wheel Secure with the snap ring CM232 739 992A NOTE Install the rear arm springs onto the adjuster blocks after the skid frame has been installed 5 On the standard and CFR install the rear upper idler wheels rear springs and pivot arm see Rear Upper Idler Wheels Rear Springs in this sub sec tion NOTE Steps 6 and 7 are for the Sno Pro on...

Page 434: ... lower cap screws and lock nuts secur ing the limiter straps to the rail support Account for flat washers MS161A NOTE On the Sno Pro remove the cap screws and lock nuts securing rear arm shock absorber and shock link to the front arm pivot and account for the sleeves CM233A 2 Remove the cap screw and lock nut securing the upper front shock absorber eyelet to the front arm Pull the shock eyelet fre...

Page 435: ...ck nut from the front shock axle then from one side tap the assembly rearward far enough for the axle assem bly to clear the slide rails Account for an axle two spacers and two shim washers NOTE Loosen the front rail support cap screws enough to gain clearance to remove the front shock axle FZ094A FZ052 MS167 7 On the CFR remove the lock nut and cap screw securing the rear shock pivot inner idler ...

Page 436: ...any cracks signs of separation or for unthreading 6 Inspect the shock absorber for damage INSTALLING 1 On the CFR install the front arm mounting brack ets to the slide rails Secure with cap screws and lock nuts tightened to 20 ft lb MS170 2 Move the rear shock pivot inner idler wheel assem bly to the appropriate mounting location Secure with cap screws and lock nuts tightened to 40 ft lb FZ094B MS...

Page 437: ...k nut Tighten securely MS174 NOTE Do not over tighten the shock absorber cap screw as the shock eyelet must be free to pivot NOTE On the Sno Pro secure the rear arm shock absorber and shock link to the pivot arm bracket with cap screws and lock nuts Tighten securely CM233A 7 Secure the limiter straps with cap screws washers and lock nuts Tighten to 120 in lb MS161A 8 Secure the front inner idler w...

Page 438: ...a sleeve cap screw lock nut and bushings MS175A AG665D 2 Remove the cap screw and lock nut securing the shock rod links to the idler arm Account for a spacer and two axle links MS176A NOTE Mark the hole that the upper shock links are mounted in for assembling purposes MS025 3 Remove the cap screw and lock nut securing the idler wheel pivot assembly to the slide rails then from one side tap the ass...

Page 439: ...any signs of oil leakage especially at the point where the shock shaft enters the shock body 8 Inspect the rubber shock bushings located in the shock absorber eyelets for cracks or deterioration 9 Inspect the shock absorber eyelet welds at each end for any cracks or signs of separation 10 Inspect the welds securing the eyelets of the shock links and pivot bracket for cracks or signs of sepa ration...

Page 440: ...of the idler arm brackets as noted in disassembling Place a spacer between the center of the brackets then insert the link axles into the upper shock link eyelets Secure with a cap screw washer and lock nut Tighten securely MS176A 6 Secure the shock absorber to the idler arm with bushings sleeve lock nut and a cap screw Tighten securely MS175A NOTE Do not over tighten the shock absorber cap screw ...

Page 441: ...trip rearward off the slide rail NOTE If binding of the wear strip occurs it may be necessary to use a pipe wrench start from either end and hook the edge of the wear strip with the pipe wrench jaw and twist the wear strip off the slide rail Move the pipe wrench 3 in and again twist the wear strip off the rail Repeat this procedure until the wear strip is free of the rail 3 Remove the cap screws a...

Page 442: ...e front inner idler wheel assembly to the slide rails SC055B NOTE On the CFR note the mounting position of the front arm mounting bracket then remove the cap screws securing the front arm mounting bracket Account for lock nuts MS188A 8 On the standard and Sno Pro remove the cap screw securing the front arm to the slide rail FZ061A 9 Remove the cap screw from the rear arm limiter A then remove the ...

Page 443: ...Whenever a part is worn excessively cracked or damaged in any way replacement is necessary 1 Inspect the slide rail for cracks A elongated holes B or unusual bends MS220A 2 Inspect the wear strip for wear The wear strip must be 0 42 in thick or thicker If the wear strip measurement is less than specified replacement of both wear strips is necessary 0743 189 INSTALLING 1 Install the shock pads and ...

Page 444: ...y until snug FZ075 ZJ269A 5 On the standard and Sno Pro secure the front arm to the slide rail Tighten only until snug NOTE On the CFR secure the front arm mount ing bracket with the cap screws and lock nuts Tighten to 20 ft lb MS197 6 Install the cap screw if removed and lock nut securing the front inner idler wheel assembly to the slide rails Tighten only until snug MS198A 7 Install the front ar...

Page 445: ...4 11 Secure the idler wheel mounting blocks with the cap screws and lock nuts Tighten to 20 ft lb NOTE To obtain proper alignment for the idler wheel cap screw place the cap screw in the top hole through the rail and mounting block prior to tightening FZ073A 12 Secure the idler wheels to the mounting blocks with existing hardware Tighten to 20 ft lb SC056C 13 Install the front arm limiter straps t...

Page 446: ...way from the tunnel and spread open then place the skid frame into the track 3 Position the front of the skid frame into the tunnel and align the front arm and axle with the appropri ate mounting hole in the tunnel Insert the cap screw then install the washer and lock nut through the tunnel mounting hole and through the front arm DO NOT TIGHTEN AT THIS TIME Repeat this procedure on the other side ...

Page 447: ...his time 6 At this time tighten the two rear arm assembly cap screws to 40 ft lb then tighten the front arm cap screws and lock nuts to 40 ft lb 7 Using the Rear Suspension Spring Tool install the short legs of the rear springs onto the adjusting cams making sure the cams are in the same adjust ment positions 8 Check track tension deflection and alignment adjust if necessary see Track Tension and ...

Page 448: ... frame to the tunnel Account for lock washers and flat washers NOTE The support stand should hold the snow mobile level but not raised off the floor 4 Remove the front lock nuts and cap screws secur ing the skid frame to the tunnel Account for a flat washer and axles 5 Remove the support stand then tip the snow mobile onto one side using a suitable handlebar support stand Remove the skid frame Wea...

Page 449: ...the rail 1 Align the wear strip with the openings windows in the track and from the back start the wear strip onto the rail then using a block of wood and a ham mer drive the wear strip forward into position 739 884A 2 Secure with a machine screw and lock nut Tighten to 50 in lb End Caps NOTE The skid frame does not have to be removed for this procedure REMOVING 1 Remove the lock nut washers and c...

Page 450: ...n any way replacement is necessary 1 Inspect the pads for damage or wear 2 Inspect the cap screw holes in the slide rail for damage or elongation INSTALLING 1 Place the front pads into position on the slide rail 2 Secure the front pads with new push nuts 3 Place the rear pads into position on the slide rail 4 Secure the rear pads with the torx head screws and lock nuts Idler Wheels Mounting Blocks...

Page 451: ...s directed away from the bearing MS007A INSTALLING 1 Secure the mounting block on the slide rail with a cap screw and lock nut Tighten to 20 ft lb NOTE For proper alignment install an idler wheel cap screw into the top mounting block hole prior to tightening CM228A 2 Place the idler wheel to the mounting block then secure the idler wheel assembly with a cap screw flat washer and a lock nut Tighten...

Page 452: ...ach axle slot then install the outer idler wheels on the axle and secure with two cap screws coated with blue Loctite 243 and large flat washers Tighten cap screws only until snug CM225 CM224A NOTE Make sure the hole in the bushing is directed to the adjusted bolt CM261A NOTE Tighten the rear idler wheel axle only until snug until the skid frame has been installed and track tension has been adjust...

Page 453: ...link to the pivot arm CM232 NOTE With the rear arm shock and shock link removed account for the four sleeves 4 Remove the cap screw and lock nut securing the rear arm to the idler arm Account for the alumi num axle and flared bushings CM235C NOTE To loosen and remove the remaining cap screw from the rear arm idler arm it may be neces sary to reinstall the cap screw 5 Remove the cap screw and lock ...

Page 454: ...MBLING 1 Place the rear arm assembly into position between the slide rails Secure with a cap screw and lock nut Tighten to 40 ft lb CM236 2 Install the idler arm onto the rear arm with an alu minum axle bushing assemblies and two cap screws Tighten to 34 ft lb CM237 NOTE If the rear arm limiter and rail support were loosened after step 4 of disassembling tighten to 20 ft lb CM235B 3 With the sleev...

Page 455: ... wheel along with the snap ring onto the axle then using a suitable driving tool carefully drive the snap ring into the idler wheel until properly seated in the groove of the axle CM239 8 Grease the idler arm and rear arm grease fittings with a low temperature grease Front Arm Assembly NOTE The skid frame must be removed for this procedure see Removing Skid Frame in this sub section and the rear s...

Page 456: ...p screw washer and lock nut from the front shock axle then from one side tap the assembly rearward far enough for the axle assem bly to clear the slide rails Account for an axle two spacers two shim washers and rubber bushing NOTE It may be necessary to loosen the front rail support cap screws enough to gain clearance to remove the front shock axle CM244 CM245 INSPECTING NOTE Whenever a part is wo...

Page 457: ... washer and a new lock nut Tighten to 40 ft lb NOTE If the front rail support cap screws were loosened after step 6 of removing tighten to 20 ft lb 3 Secure the front outer idler wheel to the idler wheel mounting block with cap screws flat wash ers and lock nuts Tighten to 20 ft lb CM243A 4 Position the front arm with aluminum axle to the mounting location in the slide rail Secure with cap screws ...

Page 458: ...il Account for a cap screw lock nut and two flat washers CM222A 2 Remove the machine screw and lock nut securing the wear strip to the front of the slide rail CM222B NOTE If binding of the wear strip occurs it may be necessary to use a pipe wrench start from either end and hook the edge of the wear strip with the pipe wrench jaw and twist the wear strip off the slide rail Move the pipe wrench 3 in...

Page 459: ...he idler wheel then remove the adjuster bushing CM253 NOTE The adjusting bolt may have to be loos ened to remove the adjuster bushing 7 Remove the cap screws and lock nuts securing the track adjuster bracket CM254A 8 Remove the cap screws washers and lock nut from the rear arm CM255A NOTE If removing the rear arm cap screw is nec essary install the cap screw from the opposite side slide rail not b...

Page 460: ... remove the torx head screws and lock nuts securing the shock pads to the rails MS117A INSPECTING NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is necessary 1 Inspect the slide rail for cracks A elongated holes B or unusual bends MS220A 2 Inspect the wear strip for wear The wear strip must be 0 42 in thick or thicker If the wear strip measurement is less than s...

Page 461: ...upports and rear arm limiter B to the slide rail then tighten the rail supports and rear arm limiter to 20 ft lb CM250B CM249B NOTE Make sure the spacers are installed to the front rail support before installing NOTE At this time tighten the cap screws and lock nuts from steps 2 and 3 to 40 ft lb CM258 CM259 5 Secure the front arm to the slide rail with the cap screw and lock nut Tighten to 40 ft ...

Page 462: ...top mounting block hole prior to tightening CM262A 9 Place the idler wheels onto the mounting blocks then install the cap screw and lock nut securing the idler wheels to the mounting blocks Tighten to 20 ft lb 10 Install the front arm limiter straps to the front rail support Tighten to 120 in lb CM240B 11 Secure the end cap onto the slide rail using a cap screw flat washers and a lock nut Tighten ...

Page 463: ...om of the tunnel 4 Elevate the rear of the skid frame and the track into position in the tunnel 5 Align the rear arm assembly with the appropriate hole in the tunnel Secure the rear arm assembly with a cap screw coated with red Loctite 271 lock washer and flat washer DO NOT TIGHTEN AT THIS TIME NOTE Do not install the short legs of the rear springs onto the adjusting cams at this time 6 At this ti...

Page 464: ...g remove the rear arm assembly cap screws securing the skid frame to the tunnel NOTE The support stand should hold the snow mobile level but not raised off the floor 4 Remove the support stand then using a suitable handlebar support stand tip the snowmobile onto one side 5 Slide the skid frame rearward far enough to drop the front arm out of the slider axle then remove the skid frame Wear Strips R...

Page 465: ... of the rail 1 Align the wear strip with the openings windows in the track and from the back start the wear strip onto the rail then using a block of wood and a ham mer drive the wear strip forward into position 739 884A 2 Secure with a machine screw and lock nut Tighten to 50 in lb End Caps NOTE The skid frame does not have to be removed for this procedure REMOVING 1 Remove the lock nut and cap s...

Page 466: ...de rail for damage or elongation INSTALLING 1 Place the pads and retaining brackets into position on the slide rail 2 Secure the pads with rivets Idler Wheels Mounting Blocks REMOVING NOTE The skid frame does not have to be removed for this procedure 1 Remove the cap screw and lock nut securing the idler wheel to the idler wheel mounting block then remove the cap screw and lock nut securing the mo...

Page 467: ...heel cap screw into the top mounting block hole prior to tightening FZ031A 2 Place the idler wheel to the mounting block then secure the idler wheel assembly with a cap screw flat washer and a lock nut Tighten to 20 ft lb FZ032 Rear Arm Assembly NOTE The skid frame must be removed for this procedure see Removing Skid Frame in this sub section REMOVING 1 Using the Rear Suspension Spring Tool remove...

Page 468: ...FZ035A FZ036 4 Remove the idler wheel NOTE Use the appropriate Idler Wheel Puller Kit to remove the wheel FZ037 5 Remove the cap screw flat washer and lock nut securing the spring slide to the slide rail Account for the spring slide and all mounting hardware FZ038A MS014 6 Remove the spring and sleeve from the idler arm FZ039 Next Back Section Table of Contents Manual Table of Contents ...

Page 469: ...TE Whenever a part is worn excessively cracked or damaged in any way replacement is necessary 1 Clean the bearings with a clean cloth 2 Inspect each idler wheel for cracks or damage 3 Inspect the bushings located in the arm pivot area for wear or damage 4 Inspect all welds and the tubing of the rear arm idler arm for cracks or unusual bends 5 Inspect the two adjusting cams for damage 6 Rotate the ...

Page 470: ...ighten securely FZ040C NOTE Do not over tighten the shock absorber cap screw as the shock eyelet must be free to pivot NOTE Install the rear arm springs onto the adjuster blocks after the skid frame has been installed 5 Slide the sleeve and spring onto the idler arm MS145 6 Place the spring slide and slide block with spring in slide block into position on the slide rail Secure with a cap screw and...

Page 471: ...rks on the idler arm to the centerline of the pivot arm assembly Secure the pivot arm to the idler arm with cap screws and lock nuts Tighten to 20 ft lb FZ048A NOTE When tightening the pivot arm lock nuts tighten the lower lock nut first or binding may occur Make sure the flared side of the bushing is directed outward FZ048B 11 Grease the idler arm and rear arm grease fittings with a low temperatu...

Page 472: ... the axle through the slide rail axle slot then place a bush ing A inner idler wheel B rear idler wheel spacer C inner idler wheel D and bushing E on the axle Slide the axle through the opposite slide rail axle slot 2 Place the plastic adjuster bushings on the axle on the outside of each axle slot then install the outer idler wheels on the axle and secure with two cap screws coated with blue Locti...

Page 473: ...t and cap screw securing the rear shock pivot to the front arm FZ049A 4 Remove the cap screw and lock nut securing the front arm to the front arm mounting bracket FZ050A 5 Remove the front arm and account for the front arm axle 6 Remove the cap screw securing the front outer idler wheel to the idler wheel mounting block Account for lock nut cap screw and flat washer FZ029A 7 Remove the cap screw a...

Page 474: ...ck body 5 Inspect the shock absorber eyelet welds at each end for any cracks signs of separation or for unthreading INSTALLING 1 With the rubber bushing in place install the axle into the lower shock eyelet bushing assembly then install the two shim washers and two spacers CM246A 2 Place the front arm shock axle assembly into posi tion on the skid frame making sure the spacers and washers are prop...

Page 475: ... arm with cap screws washers and lock nuts Tighten to 120 in lb ZJ270 Slide Rails NOTE The skid frame must be removed for this procedure see Removing Skid Frame in this sub section REMOVING NOTE When replacing one or both slide rails is necessary remove one slide rail at a time The remaining slide rail will then hold the crossbraces axles and brackets in their correct assembly order Always mark th...

Page 476: ... the wear strip off the rail Repeat this procedure until the wear strip is free of the rail 3 Remove the front arm limiter straps from the front arm of the skid frame ZJ270 4 Remove the cap screws securing the two front rail supports to the slide rail FZ080A 5 Remove the cap screws and lock nuts securing the front outer idler wheel and the idler wheel mount ing block FZ081A FZ057A 6 Remove the loc...

Page 477: ...ove the cap screws and lock nuts securing the inner idler wheel and mounting block NOTE On the Sno Pro models remove the cap screws and lock nuts securing the second inner idler wheel and mounting block FZ060A 9 Remove the cap screw securing the front arm to the slide rail FZ061A 10 Remove the cap screw from the rear arm limiter FZ062A 11 Remove the cap screw securing the rear arm cou pler block t...

Page 478: ...hock pads must be replaced refer to Shock Pads at the beginning of this procedure INSPECTING NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is necessary 1 Inspect the slide rail for cracks A elongated holes B or unusual bends MS220A 2 Inspect the wear strip for wear The wear strip must be 0 42 in thick or thicker If the wear strip measurement is less than specif...

Page 479: ...ts securing the front shock axle A and rear arm assembly B to the slide rails Tighten only until snug FZ083B FZ084B 5 Secure the front arm to the slide rail with the cap screws and lock nuts Tighten to 40 ft lb FZ070 NOTE At this point return to steps 3 and 4 and tighten the rear arm and front arm cap screws and lock nuts to 40 ft lb 6 Install the adjuster bushing and rear idler wheel Install a ca...

Page 480: ...ail Secure with a cap screw and washer Tighten to 20 ft lb FZ074 10 Install the inner idler wheel mounting block and secure with cap screw and lock nut Tighten to 20 ft lb FZ073 NOTE To obtain proper alignment for the idler wheel cap screw place the cap screw in the top hole through the rail and mounting block prior to tightening FZ073A NOTE On the Sno Pro models install the rear inner idler wheel...

Page 481: ...washers and lock nut Tighten to 120 in lb FZ078A 14 Secure the end cap onto the slide rail using a cap screw flat washers and a lock nut Tighten to 80 in lb FZ079A NOTE Apply a light coat of grease to the slide rail surface to aid in installing a new wear strip Use a file to remove any sharp edges on the lower portion of the rail MS288 15 From the back start the wear strip onto the rail then using...

Page 482: ...ssembly with the appropriate hole in the tunnel Secure the rear arm assembly with a cap screw lock washer and flat washer AT THIS TIME TIGHTEN ONLY UNTIL SNUG 6 Tip the snowmobile onto the other side then align the pivot arm assembly with the appropriate hole in the tunnel Secure the rear arm assembly with a cap screw lock washer and flat washer AT THIS TIME TIGHTEN ONLY UNTIL SNUG NOTE Do not ins...

Page 483: ...e the rear cap screws securing the skid frame to the tunnel Account for lock washers and flat washers NOTE The support stand should hold the snow mobile level but not raised off the floor 4 Remove the support stand then using a suitable handlebar support stand tip the snowmobile onto one side 5 Slide the skid frame rearward far enough to drop the front arm out of the slider axle then remove the sk...

Page 484: ...n of the rail 1 Align the wear strip with the openings windows in the track and from the back start the wear strip onto the rail then using a block of wood and a ham mer drive the wear strip forward into position 739 884A 2 Secure with a machine screw and lock nut Tighten to 50 in lb End Caps NOTE The skid frame does not have to be removed for this procedure REMOVING 1 Remove the lock nut and cap ...

Page 485: ...shock pad to the slide rail Account for the retaining brackets AG476D 2 Remove the torx head screws and lock nuts secur ing the rear shock pads to the slide rail MS117A 3 Remove the shock pads INSPECTING NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is necessary 1 Inspect the pad and retaining brackets for damage or wear 2 Inspect the rivet holes in the slide r...

Page 486: ...spect each idler wheel for cracks or damage 3 Rotate the idler wheel bearing by hand and inspect for binding or roughness 4 If a bearing must be replaced use this procedure A Remove the bearing snap ring B Using a suitable press or suitable driving tool remove the bearing from the inside of the wheel C Press the new bearing on its outer race into the idler wheel MS006A D Install the snap ring maki...

Page 487: ...his procedure see Removing Skid Frame in this sub section REMOVING 1 Using the Rear Suspension Spring Tool remove the spring from the adjusting cam TZ002A 2 Mark the pivot arm and the idler arm for assembly purposes TZ003 3 Loosen the cap screws and lock nuts securing the pivot arm assembly to the idler arm then remove the pivot arm assembly Account for a flanged axle idler spacer and washer TZ004...

Page 488: ...load spring is being removed use a punch to drive the bushing out from the back side of the slide rail and remove the spring TZ006A TZ008 6 Remove the spring and sleeve from the idler arm TZ009 NOTE Use the same procedure for the other side 7 Remove the cap screw and lock nut securing the upper shock eyelet to the idler arm then remove the cap screw and lock nut securing the upper shock links to t...

Page 489: ...eves TZ013A TZ014 10 Remove the cap screws securing the idler arm to the rear arm Account for the aluminum axle TZ015A 11 Remove the cap screw and lock nut securing the rear arm to the slide rail Account for the bushings and axle tube TZ016A CLEANING AND INSPECTING NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is necessary 1 Clean the bearings with a clean clot...

Page 490: ...OTE The shock absorber and links must be secured to the rear shock pivot before installing to the slide rails TZ017A 4 Assemble the rear shock pivot idler wheel assem bly with the axle A axle tube B axle spacers C and shim washers if applicable TZ014A 5 Install the rear shock pivot idler wheel assembly to the mounting location in the slide rails and secure with cap screws and lock nuts Tighten to ...

Page 491: ...ith spring in slide block into position on the slide rail Secure with a cap screw and washer Tighten to 20 ft lb TZ008 NOTE Install the rear arm springs onto the adjuster blocks after the skid frame has been installed TZ021 9 With a suitable driving tool install the rear upper idler wheel on the idler arm TZ022 CAUTION When driving the idler wheel onto the idler arm use a tool to contact the insid...

Page 492: ...k nut first or binding may occur Make sure the flared side of the bushing is directed outward TZ004C 13 Grease the idler arm and rear arm grease fittings with a low temperature grease Rear Axle and Slide Rail Idler Wheels DISASSEMBLING REAR AXLE NOTE The skid frame must be removed for this procedure see Removing Skid Frame in this sub section 0742 937 1 Remove the cap screw and large flat washer s...

Page 493: ... only until snug until the skid frame has been installed and track tension has been adjusted then the axle assembly must be tightened to 20 ft lb 3 Install the skid frame see Installing Skid Frame in this sub section 4 Adjust track tension and alignment see Track Alignment in Section 6 Front Arm Assembly NOTE The skid frame must be removed for this procedure see Removing Skid Frame in this sub sec...

Page 494: ...pect all front arm weldments for cracks or unusual bends then inspect the front arm mount ing brackets for cracks and for elongated holes 2 Closely inspect all tubing for cracks or unusual bends 3 Inspect the bearings bushings and front arm spac ers for wear or damage 4 Inspect the shock absorber for damage and for any signs of oil leakage especially at the point where the shock shaft enters the s...

Page 495: ...ening TZ025 4 Secure the idler wheel to the mounting block with a cap screw and a lock nut Tighten cap screw to 20 ft lb TZ026 5 Install the axle into the front arm then position the front arm to the mounting location of the slide rail Secure with cap screws and lock nuts Tighten to 40 ft lb TZ028A 6 Secure the upper shock eyelet and axle in the mounting hole of the front arm Secure with a cap scr...

Page 496: ...hen using a suitable driving tool drive the wear strip rearward off the slide rail FZ026B NOTE If binding of the wear strip occurs it may be necessary to use a pipe wrench start from either end and hook the edge of the wear strip with the pipe wrench jaw and twist the wear strip off the slide rail Move the pipe wrench 3 in and again twist the wear strip off the rail Repeat this procedure until the...

Page 497: ...te side into the assem bly to secure components and aid in replacing the slide rail TZ036 NOTE If not already done remove the short spring leg from the adjusting cam 7 Remove the cap screws and lock nuts securing the inner idler wheel and mounting block TZ037A 8 Remove the cap screw securing the front arm to the slide rail TZ038A 9 Remove the lock nut from the cap screw securing the rear arm pivot...

Page 498: ...lat washer securing the spring slide and overload spring to the rail then using a suitable driving tool remove the bushing securing the overload spring to the rail Account for a spacer the slide block overload spring retainer clips bushing one small washer and two large washers TZ040A TZ041 12 Remove the cap screw and lock nut securing the overload spring tension block to the slide rail TZ042A 13 ...

Page 499: ... Remove the torx head cap screws and lock nuts securing the track adjuster bracket TZ048A NOTE At this point the slide rail should be free of the skid frame components and can be removed TZ049 NOTE If the shock pad must be replaced refer to Shock Pads at the beginning of this procedure INSPECTING NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is necessary 1 Insp...

Page 500: ...turn to step 1 and tighten the rear arm and front arm cap screws and lock nuts to 40 ft lb then tighten the rear arm pivot idler wheel assembly to 20 ft lb 4 Install coupler block w bushing Secure with cap screw and lock nut Tighten securely TZ046A 5 Install the adjuster bushing and rear idler wheel Install a cap screw and flat washer Tighten only until snug NOTE Care must be taken that the adjust...

Page 501: ... lb TZ053A 10 Install the inner idler wheel mounting block and secure with cap screws and lock nuts Tighten to 20 ft lb TZ035B NOTE To obtain proper alignment for the idler wheel cap screw place the cap screw in the top hole through the rail and mounting block prior to tightening 11 Secure the outer idler wheel mounting block with the cap screw and lock nut Tighten to 20 ft lb then secure the idle...

Page 502: ...ges on the lower portion of the rail TZ056 15 From the back start the wear strip onto the rail then using a soft hammer drive the wear strip for ward into position Secure with a torx head screw and lock nut Tighten to 50 in lb TZ057 FZ026B 16 Install the skid frame see Installing Skid Frame in this sub section NOTE Install the rear arm springs onto the adjuster blocks after the skid frame has been...

Page 503: ...w TIGHTEN ONLY UNTIL SNUG 6 Tip the snowmobile onto the other side then align the rear arm assembly with the appropriate hole in the tunnel Secure the pivot arm assembly with a cap screw lock washer and flat washer TIGHTEN ONLY UNTIL SNUG NOTE Do not install the short legs of the rear springs onto the adjusting cams at this time 7 At this time place the snowmobile to the upright position then tigh...

Page 504: ...the shock rod and valve assembly from the shock body FS252 FS055 3 Pour the oil from the shock body into a suitable container 4 Remove the pressure valve assembly Account for the O ring FS253 5 Using Floating Piston Removal Tool remove the floating piston WARNING Before any service is performed on the gas shock absorber first discharge all pressure from the shock remote reservoir Remove the valve ...

Page 505: ... any signs of oil leaks or damage C Any part worn or damaged NOTE For shaft eyelet replacement see Shaft Eyelet sub section ASSEMBLING 1 Set Floating Piston Installation Location Tool to 5 80 in FS255 2 Lubricate the O ring and Teflon strap on floating piston then press the floating piston into shock until flush with the top of the body FS063 FS256 3 Install floating piston tool onto floating pist...

Page 506: ... the eyelet will allow air to escape from the valve stack piston assembly 7 While holding up on the eyelet thread the bearing assembly into the body FS259A 8 Using a 1 in wrench tighten the bearing assembly FS252 9 Pressurize the shock with nitrogen to 200 psi see Pressurizing Rebuildable Shocks sub section FS251 10 Install the valve screw with O ring into the pres sure valve assembly FS253 11 Tes...

Page 507: ... FS141 2 While holding the end cap unscrew the air chamber FS142 NOTE The air chamber should only be hand tight 3 Drain the oil from the air chamber FS143 4 Remove the air chamber from the bottom of the shock body FS144 5 Using a pick remove the air valve ball from the nitrogen bladder WARNING Always wear latex or rubber gloves when servicing a shock absorber with shock oil Next Back Section Table...

Page 508: ...e shock FS147 8 Using a 5 64 in Allen wrench remove the set screw from the bearing cap FS148 9 Using a magnet on an Allen wrench remove the bleed ball FS149 10 Using Spanner Wrench loosen the bearing cap FS150 11 Remove the shock rod piston assembly from the shock body FS151 Next Back Section Table of Contents Manual Table of Contents ...

Page 509: ...ly install the floating piston into the shock body until it is below the threads FS155 3 Using Floating Piston Installation Location Tool install the floating piston while using the inflation needle to vent the shock body NOTE Refer to the Rebuildable Shock Specifica tions sub section in Section 1 FS156 4 Using Fox Racing Shock Oil fill the shock body to the bottom of the threads then allow to sit...

Page 510: ...cap into position FS160 8 Using Spanner Wrench tighten the bearing cap FS161 NOTE When tightening the bearing cap note air and excess oil being bled from the hole in the cap FS150A 9 Install the bleed ball and set screw into the bearing cap FS162 FS163 10 Charge the shock with nitrogen to 200 psi FS164 Next Back Section Table of Contents Manual Table of Contents ...

Page 511: ...eration 14 Using compressed air blow all oil from the holes in the bearing cap FS167 15 Lubricate the seal on the air chamber with Fox Float Fluid FS168 16 Slide the air chamber onto the shock body FS169 17 Add 1 cc of Fox Float Fluid into the chamber FS170 18 Thread the air chamber into the end cap until hand tight FS171 Next Back Section Table of Contents Manual Table of Contents ...

Page 512: ... and polyurethane bush ings from the eyelets on both ends of the shock 2 Clean the entire shock assembly with soapy water Dry the shock assembly with compressed air NOTE If compressed air is not available use clean towel to dry the shock assembly 3 Clamp the body eyelet of the shock securely in vise with shaft side up 4 Remove the button head screw from the nitrogen valve in the shock body FS040 W...

Page 513: ... pointing up 12 Loosen and remove the nitrogen valve from the body FS014 13 Remove the shock body from the vise then invert the shock body and place it on a folded shop towel open end down 14 Using compressed air NEVER USE HIGH PRESSURE NITROGEN insert the air gun noz zle into the nitrogen valve port and blow the IFP out of the shock body and onto the folded shop towel FS012 15 Clean the body tube...

Page 514: ...e the O ring seal from the IFP 5 Install the new well lubricated O ring into the FIST bearing Check to make sure the O ring is properly seated and is not twisted NOTE To aid in proper seating of the O ring it may be advisable to use a soft blunt object non writing end of a pen etc to push it in 6 Install the new well lubricated O rings into the bearing housing making sure the shaft O ring is in th...

Page 515: ...side facing up toward the open end of the shock body to just below the bearing threads FS015 7 Using Floating Piston Installation Location Tool install the floating piston while using the inflation needle to vent the shock body NOTE Refer to the Shock Absorber Specifica tions sub section in Section 1 NOTE Depth is measured from the edge of the body opening to the outside edge of the IFP not the ce...

Page 516: ...he shock shaft should be fully extended from the pressure before the final pressure reading is taken Continue charging while pulling the reservoir away from the needle using a smooth straight motion Keep the reservoir as straight as possible to prevent the needle from bending As the reservoir and needle separate a popping sound should be heard FS016 22 Install the button head screw into the nitrog...

Page 517: ...ly 4 With the reservoir pressurized push down on the shock shaft until it nearly bottoms and release it The shaft should return to its extended position smoothly NOTE If a soft spot or a mushy area is felt as the shaft is pushed down this would indicate air in the shock body If there is air in the shock body dis charge the reservoir gas pressure Disassemble the shock to the point that the filling ...

Page 518: ...Front Suspension Mounting Bracket Bearcat F Series T Series Z1 8 28 Console Crossfire M Series 8 32 Console Bearcat F Series T Series Z1 8 33 Front Bumper Belly Pan Assembly Crossfire M Series 8 33 Gas Tank Seat Assembly Crossfire M Series 8 36 Gas Tank Seat Assembly Bearcat F Series T Series Z1 8 37 Seat Cushion 8 38 Taillight Brakelight Assembly 8 39 Windshield CFR Crossfire M Series 8 40 Windsh...

Page 519: ...2 From beneath the front end remove the lock nut and washer securing the steering post to the steer ing post stop FC199 3 Tip the snowmobile upright Remove the handlebar pad 4 Remove the cable ties securing the wiring and brakeline hose and throttle cable to the steering post NOTE Remove the routing clips securing the brake hose and wiring to the steering support 5 On the standard models remove fo...

Page 520: ...o be moved for ward so the mounting block and steering post can be removed CM005 13 Remove the steering post Account for all mount ing hardware INSPECTING NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is necessary 1 Inspect all welded areas for cracks or deterioration 2 Inspect the steering post and steering post retaining plate for cracks bends or wear 3 Inspe...

Page 521: ... screws and lock nuts Tighten to 120 in lb 8 On the Sno Pro and HCR models install the adjust ing block cover and position the handlebar into the mounting block then install the handlebar clamp and tighten the four cap screws to 20 ft lb 0743 467 NOTE Steps 9 13 are for the CFR 9 Install the handlebar riser block assembly to the steering post then secure the assembly with the retainers A and set s...

Page 522: ...t the main hood harness connector then remove the console 3 On the standard models remove the four cap screws lock nuts and adjuster block caps securing the handlebar riser assembly to the steering post then lay the handlebar riser assembly aside Account for the lower adjuster block 4 On the LXR Sno Pro EXT models remove the two screws from the handlebar pad then remove the self tapping screw secu...

Page 523: ... of the way 9 On the non turbo TZ1 Z1 remove the two cap screws A securing the front end close off cover to the chassis ZJ020A NOTE For installing purposes note the location of the exhaust pipe mounting tab B 10 Remove and discard the lock nut securing the steering tie rod to the steering post ZJ156A 11 Remove and discard the lock nut and washer secur ing the steering post to the chassis then care...

Page 524: ...ite 243 Tighten the cap screws to 96 in lb FS182A NOTE When installing the bracket plates the wider end of the plate must be directed up FS200A 4 On the Bearcat 570 F Series T Series place the rubber exhaust bumper into position on the air silencer FS203A 5 On the Bearcat F Series T Series place gaskets on the resonator and exhaust manifold then install the expansion chamber Secure the chamber to ...

Page 525: ...until the handlebar is properly secured 13 After the handlebar is locked in position release the cam lever and rotate it one turn clockwise then press down on the cam lever until it locks in place NOTE At this point gently lift the cam lever with out pressing in on the lock pin If the cam lever cannot be lifted the lock pin is secure 14 Secure the console to the steering support with the torx head...

Page 526: ...nowmobile off the floor 3 Remove the lock nuts and washers securing the wear bar to the ski 0743 185 4 Pry the rear of the wear bar down until the wear bar studs are clear of the ski then slide the wear bar rear ward until the front of the wear bar is free from the ski 5 Remove the wear bar INSTALLING 1 Insert the front of the wear bar into the hole at the front of the ski and swing the wear bar u...

Page 527: ...se then remove the cap screws and lock nuts E securing the steer ing arms to the drag link Remove the arms and account for the axles F inside the steering arms NOTE With the steering arms removed note the direction of the steering arms for installing purposes ZJ161A 6 If replacing using a suitable punch drive the two bearings out of the drag link ZJ162 INSPECTING NOTE Whenever a part is worn exces...

Page 528: ...the turbo models position the intercooler into the grommets of the mounting bracket then con nect the intercooler hoses to the turbo and to the intake plenum Tighten all hose clamps securely 6 On the Z1 install the exhaust pipe and secure the pipe to resonator manifold and the mounting tab with springs then connect the oxygen sensor and install the hood 7 Using a quality low temperature grease gre...

Page 529: ...spect the ball joint pivot area for wear Apply a low temperature grease to the ball joints INSTALLING 1 Place the center steering link into position on the steering arm Secure with a new lock nut and washer Tighten to 20 ft lb CM268A 2 Place the rod ends into position on the steering arm Secure with the Allen head cap screw coated with green Loctite 609 Tighten to 30 ft lb CM266A 3 Place the tie r...

Page 530: ...d air Inspect the ball joint pivot area for wear Apply a low temperature grease to the ball joint ASSEMBLING AND INSTALLING 1 Install the jam nuts onto the ball joints then thread the ball joints into the tie rod 2 Secure the steering tie rod and the left side inner tie rod to the drag link with the cap screw threads coated with green Loctite 609 and new lock nut and tighten to 35 ft lb then secur...

Page 531: ...indle with a good low temperature grease Rotate the spindle If the movement remains rough replace the spindle NOTE When greasing the spindle use enough so it can be seen coming out at both the top and bottom of the spindle 5 Inspect the spindle axle and bearings for wear damage or loose fit Replace the bearings as a set NOTE Replacing the ski bolt bushings is diffi cult The existing bushings will ...

Page 532: ...t to the spindle then remove the ball joint from the spindle NOTE Note whether the tie rod is installed on the top side or on the bottom side of the spindle arm for installing purposes 4 Remove the cap and snap ring from the top of the spindle then remove the cap screw securing the spindle arm to the spindle Remove the spindle arm and account for and note the number of thrust washers for installin...

Page 533: ...r loose fit Replace the bearings as a set 6 Inspect the tie rod ball joint in place If damage wear or unusual bends are noted loosen the jam nut then remove the ball joint from the tie rod NOTE Replacing the ski bolt bushings is diffi cult The existing bushings will be damaged during removal Be careful however not to damage the spindle when removing the bushing Press the new bushings into the spin...

Page 534: ...7 ZJ295A 7 Install the cap screw threads coated with green Loctite 609 securing the steering arm to the spin dle then tighten to 40 ft lb ZJ176A 8 Install the snap ring and spindle cap ZJ172 9 Place the steering tie rod ball joint into position on the steering arm as noted during removing and secure with a lock nut Tighten to 30 ft lb then install the tie rod cap 10 Install the ski and tighten to ...

Page 535: ...approximate equal num ber of threads exposed on each ball joint 1 Place the steering tie rod into position on the upper arm of the steering shaft Secure with the cap screw coated with green Loctite 609 washer and new lock nut Tighten the lock nut to 30 ft lb FC206 2 Place the steering tie rod into position on the steer ing post Secure with the cap screw coated with green Loctite 609 and new lock n...

Page 536: ...ch ball joint 2 Place the tie rod assembly into position then rotate the steering tie rod until the holes in the ball joints align with the holes in the steering post and the drag link 3 Secure the steering tie rod to the steering post with the new lock nut and tighten to 35 ft lb then secure the steering tie rod and left side inner tie rod to the drag link with the cap screw threads coated with g...

Page 537: ...ghtedge 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 approxi mately 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 lie...

Page 538: ...tside edge of the left side wear bar bolts to the outside edge of the right side wear bar bolts with out using the straightedge in two places approxi mately 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 measure ment by more than 1 16 1 4 in t...

Page 539: ...ront bumper then remove the center belly pan screws and air silencer SC077A 8 Remove the 15 torx head screws securing the cen ter belly pan to the frame then remove the belly pan Note the location of the different length screws for installing purposes SC081 9 Remove the two cap screws and lock nuts securing the lower arm then remove the arm Account for all mounting hardware and bearings SC082A 10 ...

Page 540: ... into position on the chas sis and secure with the cap screws and lock nuts Tighten each cap screw and lock nut to 30 ft lb M Series or to 40 ft lb Crossfire SC083A SC082A 2 On the Crossfire secure the sway bar link to the front arm with the cap screw and lock nut Tighten the lock nut to 96 in lb SC078A 3 Place the center belly pan into position then secure with the 15 torx head screws SC081 4 Pla...

Page 541: ...nto the floor Front Suspension Arms Bearcat F Series T Series Z1 REMOVING UPPER ARMS NOTE For installing purposes note the position of the axle shoulders ZJ168A 1 Elevate the front of the snowmobile with a suitable safety stand or lift 2 Remove the cap screw and lock nut securing the upper arms to the spindle Account for the spindle axle 3 Remove the cap screw and lock nut securing the front upper...

Page 542: ...t 2 On the Z1 remove the hood then remove the self tapping screws securing the front bumper assembly to the chassis and left side and right side panels ZJ166B 3 On the Z1 remove the two body screws and lock nuts securing the bottom of the bumper assembly to the chassis ZJ167A 4 Remove the cap screw and lock nut securing the shock absorber to the spindle then remove the shock from the spindle and a...

Page 543: ...A arm to the chassis then tighten to 32 ft lb NOTE When installing the rear cap screw of the A arm keep the cap screw approximately 1 2 in out from being fully installed allowing for easier installation of the lock nut 4 Install the sway bar link to the lower A arm 5 Position the spindle into the lower A arm then install the lower A arm retainer and secure the cap to the spindle with the four torx...

Page 544: ...s 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 posi tion Install both cap screws from the front Tighten the lock nuts to 20 ft lb Bearcat Crossfire M Series or 32 ft lb F Series T Series Sway Bar CFR Crossfire REMOVING 1 Remove the lock nuts and...

Page 545: ...r mounting brackets and secure the brack ets with the lock nuts and tighten to 120 in lb Front Suspension Mounting Bracket Bearcat F Series T Series Z1 NOTE On the liquid cooled F Series to remove the front suspension mounting bracket it will be necessary to remove the air silencer Proceed to Air Silencer Liquid Cooled F Series 2 Stroke sub section in Section 3 and follow REMOVING proce dure REMOV...

Page 546: ...8 29 8 0744 930 Next Back Section Table of Contents Manual Table of Contents ...

Page 547: ...ap screw and remove the left side steering suspension compo nents 13 Remove the cap screws and lock nuts H securing the two steering arms to the suspension mounting bracket 14 Remove the lock nuts and cap screws I securing the two shock absorber mounting frames to the sus pension mounting bracket then remove the four lock nuts and cap screws J securing the shock mounting frames to the front upper ...

Page 548: ...sway bar to the mounting position 9 Install the left side shock absorber with sleeve to the shock mounting frame with cap screw and lock nut G 10 With the axles F properly installed install the left side upper A arms then install the lower A arm with all cap screws and lock nuts correspond ing to E 11 Install the left side steering arm with axle to the suspension mounting bracket with cap screw an...

Page 549: ...ing bracket with the two body screws and lock nuts Tighten securely then install the hood ZJ167A NOTE On the liquid cooled F Series to finalize the installing of the front suspension mounting bracket proceed to Air Silencer Liquid Cooled F Series 2 Stroke sub section in Section 3 and fol low INSTALLING procedure Console Crossfire M Series REMOVING 1 Pull the recoil starter rope outward then tie a ...

Page 550: ...irpin clip and torx head cap screws securing the side panels then remove the panels 2 Remove the cable tie and remove the air intake connector from the air silencer 3 Remove the screws securing the hood cables to the chassis then with the hood secured remove the hairpin clips from the hood pins SC067A 4 Remove the pins securing the hood to the front bumper and remove the hood 5 Disconnect the exha...

Page 551: ... screws securing the belly pan to the chassis SC074A SC076A 12 Tip the snowmobile onto its side using a suitable support stand under the handlebar then remove the remaining torx head cap screws securing the front bumper to the chassis SC075A 13 Remove the remaining torx head cap screws secur ing the center left and right side belly pans to the chassis NOTE For assembling note the location of the d...

Page 552: ...x head cap screws NOTE Make sure to install the longer and stub nose torx head cap screws to the proper locations as noted during removing 3 Place the front bumper into position then secure with the eight torx head screws SC074A SC075A 4 With the air temperature sensor connected place the air silencer into position on the front bumper then place the belly pan screen into position 5 Secure the bell...

Page 553: ...and washers from inside the storage compartment securing the seat to the gas tank chassis 3 Remove the console see the appropriate Console in this section 4 Drain the gasoline from the gas tank 5 Remove the two lock nuts securing the steering post mounting blocks to the gas tank then remove the two lock nuts securing the gas tank to the chas sis Disconnect the fuel hose and the fuel pump two wire ...

Page 554: ...ne screw E from the right side of the seat support assembly Remove the seat NOTE On the TZ1 standard remove the two torx head cap screws securing the seat frame to the tunnel 6 Remove the four cap screws F securing the sup port tubes to support plate 7 Remove the six torx head screws G securing the seat support assembly to the tunnel then slide the support back out of the way ZJ010A 8 Disconnect t...

Page 555: ...odel to model The technician should use discretion and sound judgment REMOVING 1 Remove the gas tank seat assembly see the appro priate Gas Tank Seat Assembly in this section 2 Remove the two screws securing the taillight cover then remove the cover 3 Remove the two screws securing the front of the seat cushion to the seat base 4 Using a sharp tool pry out all staples securing the seat cover to th...

Page 556: ... with the two self tapping screws 7 Carefully route the harness beneath the Speedrack mount and through the hole in the storage compart ment panel then connect the harness connector 8 Tighten the three right side mount cap screws then lower the front seat 9 Place the rear seat into position on the mount mak ing sure the four pin holes are properly aligned with the mounting location on the mount 10...

Page 557: ... hood with the rein stallable rivets Windshield Bearcat F Series T570 TZ1 Z1 Non Turbo REMOVING 1 Remove the plastic rivet securing the front of the windshield to the windshield bracket 2 Remove the two torx head screws securing the windshield to the console then separate the wind shield from the console INSTALLING 741 637A 1 Place the windshield into position on the console 2 Secure the windshiel...

Page 558: ...ide install the 1 4 in cap screw in the front hole and the 5 16 in cap screw in the rear hole Secure with a flat washer and lock nut Tighten securely 4 If applicable connect the passenger handwarmer wiring harness 5 Place the rack into position and secure with the cap screws washers and cap Tunnel Chassis Rear Bumper Snowflap Bearcat XT REMOVING REPLACING TUNNEL To remove and or replace a tunnel o...

Page 559: ...nician should use discretion and sound judgment A Section 2 Engine B Section 6 Drive Train Track Brake Systems C Section 7 Rear Suspension D Section 8 Steering and Body REMOVING BUMPER SNOWFLAP 1 Drill out the rivets securing the snowflap to the tunnel end cap then disconnect the taillight har ness connector Remove the snowflap taillight 0743 320 2 Remove the two self tapping screws securing the t...

Page 560: ... 1 Remove the two torx head screws located to the outside of the headlight adjustment knobs then remove the single torx head cap screw from beneath the console located between the head lights 743 439A 2 Remove the cap screw and lock nut securing the front of the headlight assembly to the air silencer 3 Lift the front of the console enough to allow the headlight housing to be removed then remove th...

Page 561: ...bulb 2 Insert the bulb into the headlight housing 3 Press the air intake assembly into place on the hood and secure with the O rings then close the hood 4 Carefully push the headlight lenses rearward far enough to install the torx head screws Tighten the screws securely 5 Tighten the headlight adjustment knobs 6 Check headlight aim see Adjusting Headlight Aim in this sub section Adjusting Headligh...

Page 562: ...W BEAM 6 Observe the headlight beam aim Proper aim is when the most intense beam is centered on the ver tical mark 5 cm 2 in below the horizontal mark on the aiming surface 0741 448 7 Adjust the headlight housing mounting screws on the 3 bulb models or the console adjustment knobs on the 4 bulb models until correct aim is obtained Shut the engine off Back Section Table of Contents Manual Table of ...

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Arctic Cat 120 Sno Pro 2010, Service Manual

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