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Arctic Cat 2015 Pantera 7000, Service Manual

The Arctic Cat 2015 Pantera 7000 Service Manual is a comprehensive guide that provides detailed instructions on maintenance, repairs, and troubleshooting for this exceptional snowmobile model. Delivered as a free download, users can easily access this valuable manual from manualshive.com to keep their machines running smoothly and efficiently.

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85

CRANKSHAFT JOURNAL BEARING

NOTE: Do not interchange the crankshaft journal

bearings. To obtain the correct crankshaft-journal-to-
crankshaft-journal-bearing clearance and prevent
engine damage, the crankshaft journal bearings must
be installed in their original positions.

1. Clean the crankshaft journal bearings, crankshaft jour-

nals, and bearing portions of the crankcase. Place the

upper crankcase upside down on a bench.

2. Install the journal bearings into the upper engine case.

NOTE: Make sure the tabs of the bearings are properly

seated to the notches in the upper engine case.

SNO-298

3. Put a piece of Plastigauge® on each crankshaft journal.

SNO-320A

NOTE: Do not put the Plastigauge® over the oil hole in

the crankshaft journal.

4. Install the crankshaft journal lower bearings into the

lower crankcase and assemble the crankcase halves.

NOTE: Do not move the crankshaft until the clearance

measurement has been completed.

5. Tighten the cap screws in the order of the embossed

numbers on the crankcase; then remove the lower

crankcase and the crankshaft journal lower bearings.

6. Measure the compressed Plastigauge® width on each

crankshaft journal. 

SNO-320A

7. If the clearance is out of specification, select replace-

ment crankshaft journal bearings.

NOTE: The numbers stamped into the crankshaft web

and the numbers stamped into the lower crankcase are
used to determine the replacement crankshaft journal
bearing sizes.

SNO-322

NOTE: “J1 - J4” refer to the bearings shown in the

crankshaft web and lower crankcase illustration. If “J1 -
J4” are the same, use the same size for all of the bear-
ings.

For example: if the crankcase “J1” and crankshaft web “J1”

numbers are “6” and “1” respectively, the bearing size for “J1”

is: J1 (crankcase) – J1 (crankshaft web) + 2 = 6 – 1 + 2 = 7.

CRANKSHAFT JOURNAL BEARING COLOR CODE

2

Black 

3

Brown

4

Green

5

Yellow

6

Pink

7

Red

8

White

Summary of Contents for 2015 Pantera 7000

Page 1: ...S E R V I C E M A N U A L www arcticcat com ZR XF M Pantera 5000 7000 9000 ...

Page 2: ... snowmobile 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...

Page 3: ...Silencer 9000 109 Turbocharger Intercooler 9000 109 Fuel Systems 114 Fuel System 114 Individual Components 114 Self Diagnostic System Codes 117 Fuel Pressure Regulator 118 Throttle Body Assembly 118 Throttle Cable 124 Fuel Filter 124 Fuel Pump 125 Troubleshooting 129 Gas Tank 129 Electrical Systems 131 Ignition System 131 Throttle Position Sensor 131 Electrical Resistance Tests 5000 9000 133 Elect...

Page 4: ...ted gasolines containing up to 10 ethanol are acceptable gasolines Do not use gasolines containing methanol RECOMMENDED OIL 5000 9000 The recommended oil to use is Synthetic 0W 40 Oil in all temperatures and conditions OILCHARTJ After the engine break in period the engine oil should be changed every 2500 3000 miles 5000 or 1500 2000 miles 9000 and before prolonged storage RECOMMENDED OIL 7000 The ...

Page 5: ...epower at engagement speed For this reason calibrating the drive system is usually needed in order to attain acceptable performance Changing drive clutch engagement speed can be done several ways Some of the methods will affect other characteristics of CVT operation so you must be careful what you change Drive clutch springs are the most common way to increase engagement speed however by simply ch...

Page 6: ...o it Many possible variables and adjustments to the rear sus pension exist depending on snow conditions riding style and type of terrain These adjustments can be made to indi vidualize the snowmobile to the riding style of the operator As snow cover and riding conditions change several dif ferent adjustments can be made to change the ride and han dling characteristics for operator preference Locat...

Page 7: ...lutch 7 Apply light oil to the upper steering post bushings and to the shafts of the shock absorbers then lubri cate the rear suspension with an all temperature grease 8 Tighten all nuts bolts and cap screws making sure all calibrated nuts bolts and cap screws are tight ened to specifications Make sure all rivets holding the components together are tight Replace all loose rivets 9 Clean and polish...

Page 8: ...r or poor performance is experienced the drive clutch driven clutch alignment must be checked TRACK TENSION AND ALIGNMENT A certain amount of stretch occurs on all tracks during the first 500 miles The track must be inspected adjusted after the first 50 to 100 miles to the specifications given in the Track Specifications sub section of this section and periodically thereafter If these adjustments ...

Page 9: ...ing Clearance 0 0013 0 0020 Valve Guide Inside Diameter Intake 0 1762 0 1768 Valve Guide Inside Diameter Exhaust 0 1772 0 1776 Valve Guide Stem Clearance Intake 0 0004 0 0015 Valve Guide Stem Clearance Exhaust 0 0010 0 0020 Valve Face Width Intake 0 0315 0 0472 Valve Face Width Exhaust 0 0197 0 0354 ITEM Component Test Value Test Connections 5000 9000 Normally Closed Ignition Magneto Coil 3 tests ...

Page 10: ...T 37T 84 ZR 7000 0 5000 Black Gold 57g Black Blue 42 36 0627 070 38 4000 85 8600 21T 49T 90 XF 7000 0 5000 Black Gold 60g Black Blue 42 36 0627 070 38 4000 85 8600 21T 49T 90 Pantera 7000 0 5000 Black White 58 5 g Black Blue 42 36 0627 070 30 3200 85 8600 21T 49T 90 XF 7000 High Country 0 5000 Black Gold 53g Black Blue 36 0627 070 38 4000 85 8600 21T 49T 90 M 7000 0 5000 Black Gold 53g Black Blue ...

Page 11: ...6 119 122 125 128 131 134 23 36 0 639 84 96 99 102 105 108 112 115 118 121 124 127 130 133 136 139 24 35 0 686 84 103 106 110 113 116 120 123 126 130 133 136 140 143 146 150 8 Tooth 3 0 pitch 21 49 0 429 90 68 70 72 74 76 79 81 83 85 87 89 92 94 96 98 20 46 0 435 88 69 71 73 75 77 80 82 84 86 88 91 93 95 97 100 23 51 0 451 92 71 73 76 78 80 83 85 87 89 92 94 96 99 101 103 22 48 0 458 90 72 75 77 7...

Page 12: ...480 92 85 88 91 93 96 99 102 104 107 110 113 115 118 121 124 21 41 0 512 86 91 94 97 100 103 106 108 111 114 117 120 123 126 129 132 21 38 0 553 84 98 101 104 108 111 114 117 120 123 127 130 133 136 139 142 20 35 0 571 82 101 105 108 111 114 118 121 124 128 131 134 137 141 144 147 23 40 0 575 86 102 105 109 112 115 118 122 125 128 132 135 138 142 145 148 22 37 0 595 84 106 109 112 116 119 123 126 ...

Page 13: ...1 75 2 2 2 25 XF Sno Pro 141 1 50 1 75 2 2 2 25 SKI SHOCK Active Total Model Wire Diameter Free Length Rate Coils Tab ZR LXR M STD XF LXR Pantera 0 331 13 00 120 lb in 9 6 NO FRONT ARM Model Wire Diameter Free Length Rate Coils Tab ZR LXR XF LXR 0 312 8 25 90 250 lb in 9 8 NO Pantera 0 312 7 75 110 lb in 7 NO REAR ARM Model Wire Diameter Free Length Rate Coils Tab M STD XF 137 0 375 13 00 175 lb i...

Page 14: ...FRONT SUSPENSION CHASSIS Item Secured to Torque ft lb Ski Spindle 35 Ski Wearbar 8 Ski Ski Handle 54 in lb Handlebar Adjuster Block Standard Post 15 Handlebar Adjuster Sno Pro Post 15 Steering Support Mounting Block 8 Steering Tie Rod Link Steering Post 35 Steering Tie Rod Link Steering Arm 20 Steering Post Cap Riser Block 15 Steering Post Chassis 55 Steering Tie Rod Steering Arm 20 Tie Rod Spindl...

Page 15: ... the panel all the way out and unhinge the panel from the lower console 2 Remove all six torx head screws securing the hood 0746 792 0747 529 0746 791 3 Locate the hood harness connector located under the center vent between the intake vents and unplug the connector then move the hood slightly forward and remove the hood NOTE On the 9000 first unhook the rubber straps securing the air filter housi...

Page 16: ...rx head screws securing the hood 0746 792 3 Locate the hood harness connector located under the center vent between the intake vents and unplug the connector then move the hood slightly forward and remove the hood NOTE On the 9000 first unhook the rubber straps securing the air filter housing to the intake plenum of the hood then move the hood slightly forward and remove the hood 4 Remove the five...

Page 17: ...s for cracks or deterioration 2 Inspect the steering post and steering post retaining plate for cracks bends or wear 3 Inspect the adjuster caps and mounting block for cracks or wear INSTALLING Standard 1 Install steering post into position and secure to the steering stop bracket with a new M10 nut Be sure to align the steering post ball joint alignment tab with the steering stop bracket Tighten t...

Page 18: ... to align the steering post ball joint alignment tab with the steering stop bracket Tighten to 43 ft lb SNO 2218 2 Secure the tie rod assembly to the steering post using a new M10 nut Be sure to align the tie rod ball joint alignment tab with the steering post Tighten to 35 ft lb SNO 2219 3 Secure the right side steering boot to the chassis using the existing push rivets XM134A 4 Secure the top of...

Page 19: ... the rubber damper and washers INSPECTING 1 Inspect the ski for cracks or deterioration 2 Inspect the ski for abnormal bends or cracks 3 Inspect the wear bar for wear 4 Inspect all hardware and the spindle bushings for wear and damage 5 Inspect the rubber damper for damage or wear INSTALLING 1 Slide a washer onto the cap screw used to secure the ski then apply all temperature grease to the shaft p...

Page 20: ...s securing the spindle to the upper and lower A arms then using a rubber mallet remove the arms from the spindle 5 Remove the spindle INSPECTING 1 Inspect the spindle for excessive wear cracks bends or imperfections 2 Inspect the A arm bushings and axle area for wear 3 Inspect the ski spindle axle and bearings for wear damage or loose fit Replace the bearings as a set NOTE Replacing the ski bolt b...

Page 21: ...351 NOTE At this point if the technician s objective is to remove the steering arm the reinforcement bracket will need to be removed by drilling out the appropri ate rivets 6 Remove all torx head screws securing the front skid plate to the chassis then remove the cap screw and nut securing the steering arm to the chassis Account for two washers and two bushings SNO 225A INSPECTING 1 Inspect the ba...

Page 22: ...erformed on a flat level surface Ski toe out must fall within the range of 1 16 1 4 in 1 Raise the front end of snowmobile just high enough to keep the skis from contacting the floor 2 Turn the handlebar to the straight ahead position Visually inspect the handlebar for being centered and in the straight ahead position 3 With the handlebar in the straight ahead position secure the handlebar to prev...

Page 23: ...nt of the spindle and 7 8 in behind the spindle 2 The measurement from in front of the spindle to the outer edge of the wear bar bolts without using the straightedge must not exceed the rear measurement by more than 1 16 1 4 in toe out 0734 408 A Arms REMOVING NOTE On the 9000 the front bumper must be removed 1 Elevate the front of the snowmobile and secure using a suitable support stand 2 Remove ...

Page 24: ...ews and new nyloc nuts Tighten to 23 ft lb 2 Slide the lower arm into the boot then place the arm into position on the chassis Secure with the cap screws and new nyloc nuts and tighten to 55 ft lb front and 45 ft lb rear SNO 226A 3 Secure the sway bar link to the lower arm with the cap screw and new nyloc nut Tighten to 23 ft lb XM135 4 Secure the A arms to the spindle 5 Install the ski shock abso...

Page 25: ...ts Tighten the lock nuts to 32 ft lb Sway Bar REMOVING 1 Remove the nyloc nuts and cap screws securing the sway bar link to the lower A arm and the sway bar XM135 2 Remove the torx head screws securing the sway bar mounting brackets then pull the sway bar out of the snowmobile INSPECTING 1 Inspect the sway bar for any signs of twisting fatigue or wear 2 Inspect the sway bar arms for cracks or dama...

Page 26: ...he seat foam remove the seat wire from the two elastic loops then remove the cover from the seat base and seat foam INSTALLING 1 Position the cover over the seat foam and seat base then pull the two elastic loops through the slots in the seat foam and secure with the seat wire Check to make sure it is positioned straight 2 Fold the rear edge of the cushion down and around the plastic base Using a ...

Page 27: ...nt of the existing bumper to the chas sis 5 Remove the two rivets securing the snowflap to the bumper Remove the bumper INSTALLING BUMPER 1 Align the holes in the bumper with the existing holes in the tunnel then using new rivets secure rear bum per to the tunnel then secure the snowflap to the rear bumper using new rivets 2 Secure the front of the bumper to the chassis using the existing machine ...

Page 28: ...eadlight assembly screws YM 029A 7 Remove the headlight assembly INSTALLING 1 With the headlight assembly in position install the front headlight assembly screws Engage the side headlight screws in the slots and tighten until snug 2 Engage the side console tabs on the headlight assem bly then place the front of the console over the head light assembly and press down until it snaps in place 3 Insta...

Page 29: ...ming 1 Position the snowmobile on a level floor so the head light is approximately 25 ft from an aiming surface wall or similar surface NOTE There should be an average operating load on the snowmobile when adjusting headlight aim 2 Measure the distance from the floor to midpoint of the headlight 3 Using the measurement obtained in step 2 make a horizontal mark on the aiming surface 4 Make a vertic...

Page 30: ...ess panels 0746 792A 0746 791A 0746 800 NOTE At this point if the technician s objective is to service Top Side Components the engine does not have to be removed from the chassis Proceed to Ser vicing Top Side Components 1 Remove the seat then disconnect the battery cables negative cable first and solenoid harness NOTE On the LXR LTD models disconnect the seat heater harness connector 2 Remove the...

Page 31: ...re to apply a small amount of penetrating oil to the threads of the cap screws 9 On the 5000 remove the flange nuts securing the MAG and PTO side exhaust pipes to the engine and remove the exhaust and resonator pipes from the chassis NOTE On the 9000 remove the three cap screws and lock nuts securing the exhaust resonator to the exhaust pipe then remove the resonator PC050A 10 With a funnel in pos...

Page 32: ... purposes PC052A PC053A 14 Loosen the clamp securing the intercooler hose to the throttle body then loosen the clamps securing the air intake and intercooler hose to the turbocharger PC054A PC055A PC059A 15 Remove the lock nuts and screws A securing the rear intercooler brackets to the chassis and remove the brackets from the intercooler then carefully pry the intercooler out from the front bracke...

Page 33: ... the cable ties securing the wire harness and vent hose must be removed PC029A 18 Remove the cap screws and nuts securing the front spars to the steering support then remove the torx head screws securing the steering post bracket to the steering support Remove the steering support PC030 19 Remove the cap screws F or G securing the shock mounting bracket support to the shock mounting brackets then ...

Page 34: ...emove the throttle body coolant hoses ZJ018 PC211A 23 Disconnect the harness connectors from the coolant temperature sensor A oil pressure switch B and air pressure sensor C PC028A 24 Loosen the clamps and remove the drain and vent hoses and the throttle body coolant hose from the coolant oil separator tank then remove the tank from the bracket on the engine PC032 NOTE Steps 25 27 are for the 5000...

Page 35: ...re sensor boost sensor and cam position sensor 743 999A 29 From the opposite side of the throttle body discon nect the idle speed control and the throttle cable then remove the spark plug caps from the spark plugs 0743 992 30 Loosen the flange clamps securing the intake mani fold to the cylinder head then remove the manifold and throttle body assembly along with the two flanges TZ090A 31 Loosen an...

Page 36: ...hassis then remove the access panel 35 Remove the two lock nuts securing the front engine mount to the chassis 36 Remove the cap screws securing the MAG side rear engine to chassis mount then remove the mount 37 Remove the screw securing the front belt guard to the skid plate then remove the cap screws lock nuts and carriage bolt securing the PTO side chassis sup port With the fuse block out of th...

Page 37: ...ockwise enough to clear the PTO side engine to chassis mount and carefully lift the engine up and out of the chassis PC040A Installing 1 Carefully lower the engine into the chassis position ing the engine so it clears the PTO side rear engine chassis mount and on the 9000 the turbocharger clears the front of the chassis then lower the engine until the studs of the lower front engine chassis mount ...

Page 38: ...using new lock nuts A and tighten to 25 ft lb then secure the access panel to the chassis with the three screws B Tighten securely 6 Install the belly pan and secure with four screws C tightened securely then secure the PTO side engine to chassis mount bearing bracket with two new patch lock screws D Tighten the both screws to 100 ft lb 7 Secure the MAG side engine to chassis mount using the two c...

Page 39: ... fitting and cap screws to the engine and tighten the cap screws to 96 in lb then install and secure the oil return hose and oil breather hose to the engine PC036A PC243 NOTE Make sure the O rings are in place before installing the oil hoses 13 Install the coolant oil separator tank to the bracket on the engine then install the hoses with clamps to the coolant oil separator tank and secure the cla...

Page 40: ...E Steps 18 22 are for the 9000 only 18 Install the flanges to the manifold adapter assembly and secure with the clamps then install the manifold and throttle body assembly and secure with the two upper clamps NOTE Remove any tape sealing the intakes 19 Install and secure the throttle body coolant hoses to the coolant tank and cylinder head PC211A 20 With the spark plug wires routed properly instal...

Page 41: ...oolant temperature sensor B and install the air pressure sensor C to the bracket of the side support PC028A NOTE On the 9000 install the harness connectors and vacuum hoses to the air bypass control valve A and the waste gate control valve B to the bracket of the PTO side chassis support PC051A SNO 231C 24 With the battery cables and solenoid harness prop erly positioned in the channel of the gas ...

Page 42: ... to the chain case E MAG side steering support to the steering bracket 1 cap screw and lock nut Tighten to 23 ft lb F Shock mounting bracket support to shock mount ing brackets 5000 2 cap screws inserts and 2 lock nuts Tighten to 20 ft lb NOTE On the 9000 secure the front heat shield to the chassis with the screws PC058A NOTE On the 5000 install the MAP sensor to the bracket on the MAG side steeri...

Page 43: ...ntrol valve hose to the turbo charger and install the clamp as noted during remov ing then install the side cover and secure with the screws PC053A PC052A 32 Install the exhaust resonator to the chassis support and secure with the spring then secure the resonator to the exhaust pipe and tighten the cap screws and flange nuts to 12 ft lb NOTE Steps 33 34 are for the 5000 only 33 Position the exhaus...

Page 44: ...rn screws then install the upper console over the gas tank and install and tighten the retaining nut to the neck of the gas tank 0746 324 40 Connect the wires to the reverse alarm then install the two screws securing the console to the steering bracket NOTE On the LXR LTD models connect the har ness connector to the seat heater switch before securing the upper console 41 Connect the battery cables...

Page 45: ... Exten sion to the hood and connect the main harness con nector to the extension 51 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 coolant to the reservoir if necessary NOTE If the coolant level in t...

Page 46: ... gas tank 4 Remove the cap screw from the driven clutch and slide the driven clutch along with the drive belt off the driven shaft Account for alignment washers and sheave adjuster 5 Remove the cap screw and washer securing the drive clutch to the crankshaft 6 Using Drive Clutch Puller tighten the puller Remove the drive clutch NOTE If the drive clutch will not release sharply strike the head of t...

Page 47: ...cooling fan and remove the radiator assembly YM 035A 16 Remove the fuse block from the coolant tank and move it out of the way then remove the screws securing the right and left side facia to the chassis 17 Loosen all three hose clamps securing the intake boots to the throttle body then disconnect the air temperature sensor and remove the two screws securing the front of the air intake to the chas...

Page 48: ...the engine then disconnect the oil pressure switch oil pressure sensor and the crankshaft posi tion sensor YM 066A 26 With all hoses and wires disconnected from the engine move the engine forward and out the right side of the chassis Installing NOTE Before installing the engine be sure the starter motor and cables are installed and secured to the engine YM 041 NOTE If the thermostat to heat exchan...

Page 49: ...O 364A 6 Connect the PTO side coolant hose to the heat exchanger using the existing clamps then connect the oil pressure switch oil pressure sensor and the crankshaft sensor to the main harness Tighten cool ant hose clamps to 30 in lb NOTE All wires must be installed on the inside of the PTO side coolant hose YM 066A NOTE Route the positive and negative battery cables up and over the rear engine m...

Page 50: ...e existing cap screws and nuts then position the steering support over the side supports and both spars Secure using existing cap screws and nuts Tighten all cap screws to 25 ft lb 0747 939 12 Install steering post into position and secure to the steering stop bracket with a new M10 nut Be sure to align the steering post ball joint alignment tab with the steering stop bracket Tighten to 43 ft lb S...

Page 51: ...re using existing clamps 20 Connect the radiator fan to the main harness then secure the top of the radiator to the air intake using the hold down bracket and both screws Tighten securely YM 035A 21 Position the exhaust gasket between the engine and the exhaust manifold then secure the manifold to the engine using the existing screws Tighten to 16 ft lb YM 034 22 Secure the heat shield over the ma...

Page 52: ...pper and lower console making sure to connect the reverse alarm 26 Install the drive clutch drive belt and the driven clutch 27 Install the seat and secure using the screw NOTE On the LXR models connect the seat heater harness connector 28 Install the hood and both access panels 0747 529 ...

Page 53: ...plug allowing the remain ing coolant to drain from the engine ZJ028A 2 Remove the remaining coolant hoses then remove the clamps and hoses connecting the oil reservoir to the engine NOTE For assembling purposes note the location of the oil and coolant hoses 3 Remove the six flange nuts securing the exhaust pipes to the cylinder head then remove the pipes and discard the gaskets 746 517A NOTE Steps...

Page 54: ...er motor to the engine Remove the starter motor ZJ028C 8 On the 5000 remove the cap screws securing the two intake flanges to the cylinder head then remove the flanges ZJ029A 9 On the 9000 remove the four cap screws securing the manifold adapter assembly then remove the manifold TZ087A 10 Remove the three cap screws securing the thermostat cap to the engine then remove the cap and thermo stat ZJ03...

Page 55: ... 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 securing the flywheel to the crankshaft then using Flywheel Puller remove the flywheel ZJ034 14 Remove the flywheel key from the crankshaft then remove the starter gear ZJ036A 15 On the 5000 remo...

Page 56: ... in this sub section 18 Loosen but do not remove the tension adjuster bolt and washer A from the chain tensioner assembly Remove the two cap screws B securing the assem bly to the engine Remove the assembly ZJ038A 19 Remove the cap screws securing the camshaft covers to the cylinder head then remove the covers Remove both camshafts Account for the dowel pins 741 624A 20 Using a magnet or needle no...

Page 57: ...te the location of the different length cap screws for assem bling purposes 24 Tip the engine upside down then remove the 28 cap screws securing the upper and lower crankcase halves Using a soft hammer gently tap around the bottom half until it separates NOTE Note the location of the different length cap screws for assembling purposes 25 After separating the crankcase halves account for two O ring...

Page 58: ...sembly purposes ZJ046A 30 Reinstall the connecting rod caps with cap screws into the rods then using a soft hammer gently tap the piston assembly out the top side of the cylinder ZJ044 31 Remove the oil separator plates for the lower crank case half and account for the eight Allen head cap screws ZJ047A 32 Remove the Allen head cap screws securing the pis ton cooling jets to the upper crankcase ha...

Page 59: ...er Valve clearance must be within specifications ZJ105 NOTE When measuring valve tappet clearance on the exhaust valves rotate the engine until the decom pression pin of the valve tappet is activated then using a flat nosed punch carefully tap the decom pression arm until the decompression pin releases the tappet IO051A IO052B NOTE At this point if valve tappet clearances are within specifications...

Page 60: ...58 SNO2152 ...

Page 61: ...59 SNO2153 ...

Page 62: ...e off the intake ports of the cylinder head PISTON ASSEMBLY NOTE Whenever a piston rings or pins are out of tolerance they must be replaced Cleaning Inspecting Piston 1 Using a non metallic carbon removal tool remove any carbon buildup from the dome of the piston 2 Inspect the piston for cracks in the piston pin dome and skirt areas 3 Inspect the piston for seizure marks or scuffing NOTE If seizur...

Page 63: ...e to the piston pin bore Piston diameter must be within 3 8568 3 8574 in for the 5000 and 3 8574 3 8580 in for the 9000 If not the piston must be replaced Subtract this measurement from the mea surement in step 1 Measurement must be within 0 0011 0 0016 in for the 5000 and 0 0006 0 0010 in for the 9000 If the determined wear exceeds the limit indicated and the piston is within tolerance the cylind...

Page 64: ... piston bore is badly worn or damaged replace pin connect ing rod or piston Cleaning Inspecting Measuring Cylinder Block 1 Wash the cylinder block in parts cleaning solvent 2 Check the head gasket surface of the cylinder for dis tortion 3 Using a straightedge and feeler gauge check surface at a total of 6 locations If distortion limit exceeds 0 002 in replacement of the block will be necessary ZJ0...

Page 65: ...orresponding letters on the upper engine case are located to the upper left of the oil fil ter ZJ181B NOTE Always correspond the letters of the engine case with the case right side up and from left to right MAG to PTO Each row of letters is to be referred to the following Crankcase Stamping Crankshaft Stamping Balancer Shaft Journal Stamping Refer to the proper chart and select the correct bearing...

Page 66: ...en using a feeler gauge check that the clearance is as specified Assembling NOTE Arctic Cat recommends that new gaskets seals and O rings be installed whenever assembling the engine NOTE For assembling purposes use oil dissolv able molybdenum disulfide grease as engine assem bly grease 1 Install one piston pin circlip into one of the pistons making sure the open end is directed either up or down P...

Page 67: ...r ZJ073A 6 With new O ring install the piston cooling jets with Allen head cap screws then tighten to 84 in lb ZJ054A NOTE Prior to installing the jets make sure the ori fices are clear of any debris or contaminants ZJ055A 7 With the proper bearings selected install the half bearings into the upper engine case then lubricate the bearing faces liberally with engine assembling grease taking care not...

Page 68: ...il snug 12 Alternately tighten each of the connecting rod cap screws evenly to 25 ft lb then in turn tighten each cap screw an additional 90 turn to obtain the final recommended torque value ZJ075 NOTE Rotate the crankshaft one revolution to ver ify free movement 13 With the O ring lubricated with engine oil install the oil relief valve ZJ076A NOTE Prior to installing the oil relief valve make sur...

Page 69: ...r and lower engine cases 21 Install the lower crankcase half to the upper engine case then verify the cases are properly seated together 22 Install the 10 mm 8 mm and 6 mm cap screws into the proper locations in the crankcase then with the torque pattern shown as numbered on the case tighten the cap screws only until snug 741 582A 23 For initial tightening of the engine case cap screws use this se...

Page 70: ... 28 Install the cam chain tensioner then install the wash ers between the engine case and guide tensioner and secure with two Allen head cap screws coated with blue Loctite 243 Tighten to 84 in lb ZJ080 29 Position the pistons at the top dead center position by rotating the crankshaft until the keyway on the crankshaft is directed upward and aligned with the cylinder ZJ081A 30 Install the alignmen...

Page 71: ...mshaft NOTE The exhaust camshaft must be installed first When installing the cam chain to the gear of the exhaust camshaft position the chain so no slack between the crankshaft gear and exhaust camshaft exists when the camshaft is installed All slack in cam chain must be on the side of the tension adjuster ZJ084 35 With the timing marks A on the face of the cam shaft gear properly aligned place th...

Page 72: ... then install the engine cover and secure with four cap screws and plastic washers Using the pattern shown tighten the cap screws to 120 in lb 741 580A NOTE At this point install the spark plugs 42 Place the starter gear on the crankshaft then install the flywheel key ZJ036A 43 Install the flywheel with the cap screw and washer Using the flywheel holder wrench from Flywheel Puller tighten the cap ...

Page 73: ...ture and oil pressure sensors were removed install the sensors and tighten in the following sequence A coolant tem perature sensor to 15 ft lb and B oil pressure sensor to 10 ft lb ZJ090A 47 Install the coolant hose inlet fitting and secure with the two cap screws Tighten to 84 in lb ZJ031B 48 Install a new thermostat then install the cover and secure with the two cap screws Tighten to 84 in lb NO...

Page 74: ...embly of the 5000 engine is complete Steps 53 59 are for the 9000 only 53 If removed install the mounting bracket to the turbo charger then with the backing plate properly posi tioned as noted during disassembling secure the bracket to the 9000 with the lock nuts and finger tighten only TZ063A 54 Install the lower heat shield onto the turbocharger and exhaust manifold with the cap screws Tighten t...

Page 75: ... secure the hoses with the hose clamps 743 991A 59 With the turbocharger secured install the oil feed pipe with the banjo bolts and two new crush washers on each side of the union Tighten to 11 ft lb 744 771B NOTE Make sure when installing the oil feed pipe that the correct banjo bolt is securing the pipe to the engine and turbocharger as noted in disassembling ...

Page 76: ...74 Assembly Schematic 5000 9000 1100ccJAG12 Torque Specification Tolerances Torque ft lb Tolerance 0 15 20 16 39 15 40 10 ...

Page 77: ...75 1100ccZ1RV10 ...

Page 78: ...76 Engine Torque Patterns 5000 9000 1100TorquePattern12 ...

Page 79: ...Service Parts Department Disassembling 1 With the engine secured to a suitable engine stand remove the ignition coils from the cylinder head cover then remove the spark plugs YM 002 2 Remove the six Allen head screws securing the cyl inder head cover to the cylinder head then remove the cover Account for the gasket YM 010 3 Remove both plastic plugs from the MAG cover YM 003A NOTE The engine cylin...

Page 80: ...the crankcase taking note the location of the black screw YM 004 7 Thread the MAG Cover Removal Cap Screw p n 2623 100 into the timing mark hole then carefully pull the MAG cover from the crankcase Account for two dowel pins and a gasket YM 080 YM 081 8 Remove the starter gear and shaft YM 007 9 Remove the cap screw securing the flywheel to the crankshaft Account for the washer and the shaft insid...

Page 81: ...ly YM 011A 14 Remove the two Allen head screws securing the chain tensioner to the cylinder assembly Remove the tensioner and gasket YM 012 YM 013 15 Remove the cap screws securing the camshaft covers to the cylinder head then remove the covers Remove both camshafts Account for twelve dowel pins YM 014 NOTE Keep each camshaft cover with the appropri ate camshaft for installation purposes The I mar...

Page 82: ... cap screws securing the oil pan to the crankcase Using a soft hammer gently tap around the oil pan until it separates Account for the oil pan gasket and two dowel pins YM 018 NOTE Note the location of the different length cap screws for assembling purposes 20 Remove the cap screw securing the oil pump driven gear to the oil pump then remove the oil pump chain and timing chain from the crankshaft ...

Page 83: ...r poses 24 Remove the crankshaft and piston assembly from the crankcase 25 Straighten the locking tabs securing the cap screws securing the balancer shaft then remove both cap screws and both balancer weights NOTE To remove the cap screws C place a small piece of wood B between the balancer weight C and the crankcase SNO 384A SNO 383A 26 Remove the snap ring securing the water pump drive gear then...

Page 84: ...each valve lifter and valve pad so that they can be reinstalled in their original place 4 To select the correct replacement shim for an out of specification clearance note the three digit number on the surface of the existing shim then refer to the appropriate Tappet Shim Selection Table Exhaust or Intake in this sub section and use this procedure A Find the Measured Tappet Clearance from step 3 i...

Page 85: ...83 SNO2152 ...

Page 86: ...84 SNO2153 ...

Page 87: ...e the crankcase halves NOTE Do not move the crankshaft until the clearance measurement has been completed 5 Tighten the cap screws in the order of the embossed numbers on the crankcase then remove the lower crankcase and the crankshaft journal lower bearings 6 Measure the compressed Plastigauge width on each crankshaft journal SNO 320A 7 If the clearance is out of specification select replace ment...

Page 88: ...rings install as a complete set only Measuring Piston Ring End Gap Installed 1 Place each piston ring in the wear portion of the cyl inder Use the piston to position each ring squarely in the cylinder NOTE Remove any carbon then clean the top of the cylinder bore before inserting the piston rings 2 Using a feeler gauge measure each piston ring end gap Acceptable ring end gap must be within the fol...

Page 89: ...n must be replaced SNO 292 Installing Piston Rings 1 Install the piston rings according to the illustration below Stagger the end gaps of the upper and lower thin oil rings until they are on directly opposite sides of the piston SNO 293A NOTE Be sure to install the piston rings so that the manufacturer marks A face up 2 Rotate the rings until the ring end gaps are 120 from one another SNO 294A CRA...

Page 90: ...ulfide grease as engine assem bly grease 1 Install the balancer driven gear A then install the balancer shaft B making sure to face the punch mark C on the balancer driven gear inward Align the projection D on the balancer shaft with the slot E in the balancer driven shaft SNO 385A 2 Install the water pump drive gear A by aligning the punch mark B on the water pump gear with the shorter spline C o...

Page 91: ...ected towards the exhaust side of the engine install the piston assem blies into the cylinder using Ring Compressor and a soft hammer SNO 297 9 Rotate the engine to the upside down position for installing the crankshaft 10 With the proper bearings selected install the half bearings into the upper engine case then lubricate the bearing faces liberally with engine assembling grease taking care not t...

Page 92: ... light film of seal ant onto the sealing surfaces of the upper and lower engine cases SNO 301 NOTE Do not allow any sealant to come into con tact with the oil galley or crankshaft journal bearings Do not apply sealant to within 0 08 0 12 in of the crankshaft journal bearings 15 Install the lower crankcase half to the upper engine case then verify the cases are properly seated together 16 Install t...

Page 93: ...0A NOTE At this time install the timing chain around the crankshaft as it must go on before the oil pump chain 21 Position the oil pump chain around the crankshaft then install the oil pump driven gear and secure using the existing cap screw Tighten to 11ft lb YM 019 NOTE Install the oil pump driven gear with the stamped mark 4XV facing towards the oil pump assembly SNO 305 22 With a new gasket an...

Page 94: ...lb SNO 280 28 Tighten the cylinder head bolts further to reach the specified angle 175 185 in the proper tightening sequence as shown Do not use a torque wrench for this step SNO 308 29 Tighten the Allen head screws 1 and 2 to 104 in lb 30 Position the intake and exhaust camshaft assemblies into the head 31 Turn the crankshaft clockwise When piston 3 is at TDC on the compression stroke align the I...

Page 95: ...oner clip while pushing the rod into the housing or the rod may be ejected SNO 312A 35 With the tensioner rod compressed flip the hook A over the rod B to secure it down SNO 313A 36 Install the chain tensioner assembly and secure using the existing allen head screws Tighten to 104 in lb NOTE Be sure to install the timing chain tensioner gasket so its section with the L mark is protruding from the ...

Page 96: ...rfaces of the cylinder head cover gasket Tighten the cylin der head cover screws in a crisscross pattern to 7 2 ft lb SNO 317 39 Install the spark plugs Tighten to 8 7 ft lb 40 Install the ignition coils over the spark plugs making sure they are fully seated ...

Page 97: ...95 Assembly Schematic 7000 1049cc_14_2 Torque Specification Tolerances Torque ft lb Tolerance 0 15 20 16 39 15 40 10 ...

Page 98: ...96 1049cc_14_1 ...

Page 99: ... replace vent hose 6 Remove obstruction replace pick up valve s 7 Repair replace damaged worn engine components 8 Replace ECM Problem Engine Does Not Start Fuel Does Not Ignite Condition Remedy 1 ECM Check Engine light failed 2 Spark absent 3 Compression low 4 Engine flooded 5 Gasoline contaminated 1 Check codes repair as necessary 2 Check for spark see No Spark at Spark Plugs sub sec tion 3 Servi...

Page 100: ...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 Fuel pump relay faulty 8 Gas tank vent hose obstructed 9 ECM faulty 10 Fuel hose obstructed broken pinched 11 Ignition coil faulty 12 Engine seized 13 Throttle ignition monitor switch throttle cable ten sion faulty adjusted inco...

Page 101: ...0 9000 0742 104 1 Secure the water pump in a suitable support device then remove the two Phillips head screws A secur ing the inner outer pump housings 2 Separate the inner outer pump housings then remove the E clip B from the impeller shaft remove the shaft from the inner housing and remove the ceramic seal C from the shaft 3 With the inner housing secured in a suitable clamp ing device and using...

Page 102: ...he screws with an impact driver INSTALLING 5000 9000 1 With a new O ring A in place on the inner housing and the water pump shaft B properly aligned with the oil feed pump shaft install the water pump ZJ123A 2 With the water pump properly positioned secure the pump with two cap screws and tighten to 84 in lb 3 Install the water inlet hose and secure with the clamp then install the separator tank b...

Page 103: ...der A and the rubber damper B from the impeller using a small flat head screwdriver making sure not to damage the impeller shaft SNO 375A INSTALLING 7000 1 Apply tap water or coolant to the outer surface of the new oil seal then install the oil seal A into the water pump housing using a socket of the same diameter SNO 376A 2 Install the bearing using a socket of the same diame ter then apply seala...

Page 104: ...tion crank the engine over to get the psi reading Compression should be 213 3 psi NOTE Verify both cylinder compression readings are within 10 of each other Changing Oil Filter 5000 9000 NOTE For this procedure disconnect the hood har ness and the air intake connector from the air silencer then remove the cables and pins securing the hood to the front end remove the hood and remove the access pane...

Page 105: ...lluminate place the ignition switch in the OFF position and repeat step 11 then place the ignition switch in the ON posi tion and repeat step 12 13 If the warning icon illuminates from step 12 start the engine The warning icon should go out within five seconds If it does let the engine run for 5 10 minutes then proceed to step 14 NOTE If the warning icon does not go out shut the engine off immedia...

Page 106: ...NOTE If the warning icon 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 12 If the warning icon does not go out take the snowmobile to an authorized Arctic Cat Snowmobile dealer for service If not under warranty this service is at the discretion and expense of the snowmobile owner 13 Once the engine has reached op...

Page 107: ...de access panels and hood NOTE Place the hood along side the snowmobile then using Hood Harness Extension connect the hood to the main harness 2 Loosen the bleed screw and add coolant into the filler neck until coolant is visible at the bleed screw then tighten the bleed screw and add coolant to the coolant reservoir Full Cold line 744 032A 3 Start the engine and allow it to run for five minutes 4...

Page 108: ...YSTEM NOTE Place the hood along side the snowmobile then using Hood Harness Extension connect the hood to the main harness 1 With all hoses and hose clamps installed add coolant into the filler neck until coolant is visible at the bot tom of the neck then add coolant to the coolant res ervoir Full Cold line 0747 547 0747 766 2 Start the engine and allow it to run until the radiator fan turns on th...

Page 109: ...erifying it has returned to the fully closed position Cooling System Schematics The following schematics are representative of the differ ent styles of cooling systems in the Arctic Cat snowmo biles 0746 354 CAUTION Never heat the thermostat to the fully open position or damage to the thermostat may occur 5000 ...

Page 110: ...108 0746 522 0747 953 9000 7000 ...

Page 111: ... front of the air intake to the chassis using the two screws and the routing clamp Tighten securely 5 Install the hood connect the hood harness and install both access panels Air Silencer 9000 REMOVING INSPECTING 1 Remove the air cleaner cover then remove the air filter 2 Inspect the filter for tears or dirt and replace if neces sary Clean any debris from inside the air intake ple num INSTALLING P...

Page 112: ...o cap screws and nuts securing shock mount support bracket Remove the rear heat shield front spar and shock mount SNO 232A NOTE To aid in the removal of the assembly from step 6 drill out the rivet A securing the rear heat shield to the left spar tube 8 Remove the banjo bolts with four crush washers securing the oil feed pipe to the turbocharger and to the engine Discard the washers CAUTION Do not...

Page 113: ...move the cap screws securing the lower heat shield to the exhaust manifold and turbocharger then remove the mounting bracket 13 Remove the lock nuts securing the turbocharger out let then remove the turbocharger outlet from the tur bocharger and account for the gasket 14 Remove the four lock nuts securing the turbocharger to the exhaust manifold Account for the gasket and flat washers INSPECTING 1...

Page 114: ...he three lock nuts securing the turbocharger mounting bracket to the engine Tighten the nuts to 30 ft lb and bend each tab to secure the nut PC234A 7 Tighten the two lock nuts from step 2 to 30 ft lb 8 Using a crisscross pattern tighten the lock nuts from step 3 securing the turbocharger to the exhaust manifold to 30 ft lb 9 Connect the coolant feed hose and oil return hose to the 9000 release the...

Page 115: ...er air bypass valve and the air duct as an assembly into the four mounting brackets 16 Secure the outlet hose air duct and intercooler using the existing clamps A then install the air filter B and all hoses connected to the intercooler SNO 231A 17 Connect the oxygen sensor then install the cap screws nuts new gasket and spring securing the resonator to the chassis PC227 NOTE Check the coolant leve...

Page 116: ... at a constant psi the ECM evaluates the information it receives from the electrical sensors and opens the injectors for precise periods of time pulse widths to meet engine demands NOTE The entire EFI system depends on all coils functioning properly on the stator Individual Components ECM The ECM is the brain of the EFI system It uses sensor inputs to determine the correct fuel air ratio for the e...

Page 117: ...securely 2 Connect the wiring harness to the air temperature sensor Secure the sensor wires with cable ties so they do not rub on any other components COOLANT TEMPERATURE SENSOR This sensor detects coolant temperature The ECM measures the current flow through the sensor to ground From this mea surement the ECM can determine the engine coolant temper ature and calculate the correct fuel air mixture...

Page 118: ...h injector 2 Install the injectors into the throttle body assembly 3 Place the fuel rail into position on top of the injectors and secure with existing spacers washers and cap screws SNO 369 4 Connect the fuel delivery hose to the fuel rail and secure with the orange clamp 5 Connect the wiring harness to the injectors Cable tie as needed FUEL PRESSURE REGULATOR The fuel pressure regulator maintain...

Page 119: ...ower opening thereby allowing more exhaust gas to pass by the turbine increasing the boost level KNOCK SENSOR This sensor controls engine knock or detonation The knock sensor assesses structure borne noise vibrations caused by rapid pressure rises detonation in either cyl inder and performs calibration adjustments to the neces sary cylinder via the ECM limiting damage to internal engine components...

Page 120: ...re circuit low P0108 Manifold absolute pressure circuit high P0112 Intake air temp sensor circuit low P0113 Intake air temp sensor circuit high P0115 Engine coolant temp sensor 1 circuit P0117 Engine coolant temp sensor 1 circuit low P0118 Engine coolant temp sensor 1 circuit high P0120 Throttle position sensor circuit P0122 Throttle position sensor circuit low P0123 Throttle position sensor circu...

Page 121: ... assembling purposes note from which side the fuel injectors were removed ASSEMBLING INSTALLING 5000 1 Install the fuel injectors onto the throttle body assem bly then secure the fuel rail and injectors to the throttle body assembly with the two screws and the retaining clips ZJ291A ZJ290 2 Install the throttle body assembly to the intake boots and tighten the clamps then install the coolant hoses...

Page 122: ...t bracket TZ109A 5 Remove the four screws securing the ISC valve to the throttle body TZ110A NOTE Remove the throttle body ISC valve before using any type of cleaner to clean the throttle body 6 Using a throttle body cleaner spray throttle valve once and clean the venturi of carbon buildup A fine nylon brush may be needed to clean carbon deposits AO252 7 Carefully blow dry the throttle body and be...

Page 123: ... 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 harness connector TZ116A 3 Install new injector gaskets into the intake flange and install the fuel rail injectors Secure with the two cap screws and tighten to 18 ft lb then install and secure the hose to the fuel pressure regulator TZ117 TZ11...

Page 124: ...l the hood and side panels Connect the hood harness REMOVING DISASSEMBLING 7000 NOTE To remove the throttle body assembly it is necessary to remove the access panels hood air intake assembly and the two front spars 1 Remove the coolant hoses and MAP sensor hoses from the throttle body YM 043A 2 Disconnect the throttle body harness from the main harness then loosen the three screws securing the thr...

Page 125: ...ighten securely YM 047A YM 048A 2 Connect all connections of the throttle body harness to the throttle body sensors Secure the harness to the fuel rail using cable ties YM 045A 3 Install the throttle cable to the bracket on the throttle body assembly and to the throttle valve cam then secure the cable with the jam nut 4 Install the throttle body assembly to the intake boots and tighten the clamps ...

Page 126: ...to the handlebar and steer ing post with cable ties 6 Adjust the throttle cable tension by turning the jam nuts in the appropriate direction until 0 030 0 060 in free play exists in the throttle lever and the butterfly completely opens and closes Tighten the jam nuts securely 741 518A 7 Synchronize the oil injection pump see Oil Injec tion Pump in this section Fuel Filter NOTE The fuel filter shou...

Page 127: ...el rail side hose clamp is tight by crimping the clamps until the two clamp areas touch XM282 NOTE On the 9000 insert the filter making sure the lip sits between the tab and clamp SNO 1021 4 Install the gas tank 9000 seat and hood then start the engine and inspect the gasline hoses and filter for any signs of leaks 5 Secure the fuel filter to the fuel filter bracket then install both consoles and ...

Page 128: ... from the outlet of the fuel pump by pressing inward on the white connec tor pressing in the black release and finally pulling back on the hose 3 Remove and retain the six torx head screws securing the fuel pump in the fuel tank then remove the snap ring 4 Carefully remove the fuel pump and fuel pickup assembly from the gas tank noting the orientation of the fuel pump outlet for assembling purpose...

Page 129: ... the fuel hose SNO 706 5 Install the snap ring over the fuel pump and secure the fuel pump to the gas tank assembly using the existing torx head screws Tighten to 40 in lb 6 Connect the fuel pump harness connector to the main harness and secure to the snap ring with a cable tie then secure the gasline hose to the fuel pump making sure it locks into place 7 Install the upper and lower consoles usin...

Page 130: ...ump opening in the gas tank then install the fuel pump and orientate it so the fuel hose connection faces the front right of the snowmobile YM 051 2 Install the retaining ring over the fuel pump and secure the fuel pump to the gas tank assembly using the existing torx head screws Tighten to 40 in lb 3 Connect the fuel pump harness connector to the main harness and secure to the retaining ring with...

Page 131: ...od and seat PANTERA REMOVING 1 Remove both access panels and hood 2 Remove the passenger seat operator seat lower con sole and the storage box lid NOTE On models with the rear gas tank installed proceed to step 3 For other models proceed to step 7 3 Remove the two machine screws securing the upper console then disconnect the reverse alarm heated seat switch and the heated shield from the main har ...

Page 132: ... connectors then use the two machine screws to secure the upper console NOTE Steps 4 7 are for Pantera LTD models with the rear gas tank 4 Route the gasline hose assembly through the center rear hole in the front fuel tank if removed and toward the elbow fitting in the rear fuel tank 5 Install new hose clamp over the gasline hose then press the gasline hose fully onto the fitting Use Fuel Hose Cla...

Page 133: ...le lever in the idle position the meter must read less than 1 ohm If the meter reads OL infinite resistance replace the control assembly 3 Move the throttle lever to the wide open position The meter must read OL infinite resistance If the meter reads less than 1000 ohms replace the control assembly Throttle Position Sensor VERIFYING TPS ADJUSTMENT TOOL Before using the TPS adjustment tool verify i...

Page 134: ...ent 3 Using Throttle Position Sensor TPS Adjustment Tool Kit connect its wiring harness to the TPS Con nect the red and black digital voltmeter leads to the white and black jacks of the TPS adjustment tool 4 While observing the digital voltmeter slowly rotate the sensor until idle voltage specification is observed on the LCD of the multimeter While holding the sensor in this position tighten the s...

Page 135: ...the CATT II Tool Instructions will be included with the tool NOTE Before installing the TPS harness connector apply dielectric grease to the connector pins Electrical Resistance Tests 5000 9000 NOTE Replace any component that does not have a test value within specifications If the component tests satisfactorily but is suspected to be faulty con nect the red meter lead to a component lead and the b...

Page 136: ... 0 15 0 23 ohm Crankshaft Position Sensor 1 Disconnect the sensor 2 Connect the red meter lead to the gray wire then connect the black meter lead to the black wire 3 Resistance must be 336 504 ohms Ignition Coil 1 Disconnect an ignition coil connector 2 Connect the red meter lead to the orange wire then connect the black meter lead to the other wire 3 Resistance must be 1 19 1 61 ohms Injection Co...

Page 137: ...istance NOTE If the meter does not show as specified trou bleshoot or replace the switch component the con nector or the switch wiring harness Starter Relay Solenoid TESTING NOTE The electric start solenoid may be tested using either one of the following methods Method 1 1 Disconnect the solenoid connector from the main wiring harness 2 Place the ohmmeter leads across the solenoid coil terminals T...

Page 138: ...ollowing procedure 1 With the ignition switch plugged in place the emer gency stop switch to the OFF position 2 Connect the red tester lead to the black yellow wire then connect the black tester lead to a suitable ground 3 Rotate the key to the START position and verify bat tery voltage NOTE If no battery voltage is present troubleshoot the harness and or the starter relay solenoid Starter Motor R...

Page 139: ...EANING AND INSPECTING 1 Thoroughly clean all components except the arma ture and brushes in parts cleaning solvent then dry with compressed air 2 Inspect all threaded areas for damaged or stripped threads 3 Inspect the brush holder assembly and brushes for damage or wear Using a caliper measure the length of the brushes If brush measurement is less than 0 40 in replace with new brushes and brush s...

Page 140: ... an entire revolution If the metal strip vibrates at any point on the armature the armature is shorted and must be replaced 0725 653 12 Inspect the ground brushes to make sure they are properly grounded Use a multimeter and the follow ing procedure A Set the selector to the OHMS position B Touch the black tester lead to a ground brush C Touch the red tester lead to the brush holder assembly NOTE I...

Page 141: ...the two long cap screws securing the starter motor together then tighten the cap screws to 108 in lb ZJ140A INSTALLING 7000 1 Install the starter motor into the engine then with the negative battery cable positioned to the top mounting hole install the two cap screws threads coated with blue Loctite 243 and tighten to 19 ft lb 2 Install the positive cable to the starter motor and tighten securely ...

Page 142: ... 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 securing the mag neto cover to the engine then remove the cover and account for the dowel pins the oil pump seal and the gasket ZJ147 5 Remove the cap screws securing the harness clamp and timing sensor to the magneto cover ZJ148A 6 Remove the three cap...

Page 143: ...resonator and secure using existing hard ware NOTE At this point fill and bleed the oil and cool ing systems REMOVING 7000 NOTE Prior to removing the magneto the engine oil and cooling system must be drained 1 Disconnect the connector for the oxygen sensor then remove the cap screws nuts and springs securing the resonator 2 Remove the cap screws and nuts securing the MAG side chassis support then ...

Page 144: ...n threads coated with blue Loctite 243 to 7 2 ft lb YM 057A NOTE Be sure to apply a small amount of sealant to the grommet before pressing it into the cover SNO 380 2 Install the two alignment pins in the engine for the magneto cover then with a new gasket install the cover and with a crisscross pattern tighten the screws to 8 7 ft lb YM 056 NOTE The black screw A indicated by the black arrow B mu...

Page 145: ...ING 1 Press the switch into the brake lever assembly mak ing sure it is fully seated 2 Position the O ring into the reservoir then secure the reservoir to the piston assembly using the existing screws Tighten securely 3 Connect the switch harness to the main wiring har ness Position the wires so they will not be either pinched or come in contact with any moving compo nents Start the engine and che...

Page 146: ... lead to the green lead 3 The meter must read between 1 5 and 6 9 ohms 4 In the element connector connect the ohmmeter between the green black lead and the yellow lead 5 The meter must read between 5 5 and 23 0 ohms NOTE If either test is not within specification replace the thumb warmer element 6 Connect the leads then install and secure the handle bar pad if applicable Testing Handlebar Warmer T...

Page 147: ... main harness wire then connect the other ohmmeter lead to the green red main harness wire The meter must read the following 5 NOTE If resistance is not within specification trou bleshoot the switch connector located below the steering support If the switch connector tests good replace the switch PASSENGER HEATER SWITCH Resistance 1 Disconnect the main harness element connector 2 Connect one ohmme...

Page 148: ...he switch the control assembly must be disassembled 1 Disconnect the two wire connector from the handle bar control 2 Connect one ohmmeter lead to one pin then connect the other ohmmeter lead to the other pin PC253B 3 With the reverse button pressed in the meter must read less than 1 ohm of resistance With the reverse button released the meter must read OL infinite resistance NOTE If the meter doe...

Page 149: ... C 90 F 1 072 7035 40 C 40 F 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 ...

Page 150: ... into the adjuster Install the sheave adjuster and cap screw onto the driven clutch then tighten the cap screw until the movable sheave opens far enough to allow the belt to be removed 4 Remove the drive belt from the driven clutch first then from the drive clutch NOTE Each time the driven clutch cap screw is removed the hole in the driven shaft should be cleaned free of any Loctite residue INSTAL...

Page 151: ...he position of the alignment notches in the cap screws for assembly purposes Account for both O rings 0739 038 Cleaning and Inspecting 1 Using parts cleaning solvent wash grease dirt and foreign matter off all components dry with com pressed air 2 Remove any drive belt dust accumulation from the stationary sheave movable sheave and bushings using parts cleaning solvent only 3 Inspect stationary sh...

Page 152: ...on Driven Clutch REMOVING 1 Remove the drive belt 2 Slide the driven clutch off the shaft NOTE Account for any alignment washers These washers must be in place during installation DISASSEMBLING 1 Place the driven clutch on the Driven Clutch Com pressor Tool then install the compressor flange and compress the driven clutch spring 2 Mark the moveable sheave stationary sheave and the torque bracket f...

Page 153: ...ap ring 2 Using a suitable driving tool drive the bearing out 3 Install the new bearing then secure with a new snap ring REPLACING ROLLERS 1 Bend the locking tabs down away from the shoulder bolt then remove the bolt XM143 2 Place a new roller into position and secure with the shoulder bolt with a drop of red Loctite 271 Tighten securely and bend the lock tabs to contact the bolt head NOTE If the ...

Page 154: ... Tighten to 20 ft lb threads coated with blue Loctite 243 3 Check drive clutch driven clutch alignment then install the drive belt Drive Clutch Driven Clutch If premature drive belt wear is experienced or if drive belt turns over check parallelism offset Also parallelism offset must be checked whenever either drive clutch or driven clutch is serviced To check offset use appropriate Clutch Alignmen...

Page 155: ...on the drive belt just enough to remove all slack Note the amount of deflection on the ruler at the bottom of the straight edge The deflection should be at 1 1 4 in 0743 319 NOTE Push down on the belt with the ruler only until the bottom of the belt flexes upward then read the amount of deflection 3 To correct drive belt deflection remove the sheave adjuster from the clutch remove or add shim wash...

Page 156: ...ompletely removed This will help keep debris oil out of the screw holes 7 Swing the chain case out of the way Account for a thrust washer on the reverse shaft SNO 964A 8 Remove the reverse gear reverse fork reverse shift rack and the reverse shift shafts as an assembly 9 Remove the snap ring from the driveshaft then remove the reverse chain and sprockets Account for a thrust washer behind the uppe...

Page 157: ...g then from the left side carefully remove the driven shaft assembly keeping the bearing 90 to the shaft 17 Remove the skid frame assembly 18 Remove the brake cover and the left side footrest NOTE DO NOT split the brake caliper unless neces sary service work is required 19 Remove the cap screws securing the inner caliper to the tunnel then remove the inner caliper YM 077A 20 Pull the driveshaft ou...

Page 158: ...liper assembly and secure with three cap screws and the snap ring Tighten the cap screws securely YM 077A NOTE If the brake caliper was split proceed to step 4 If not proceed to step 6 4 Install the brake disc and secure with the snap ring 5 Making sure the seal is correctly installed in the outer brake caliper install on the inner caliper and secure with two cap screws Tighten to 25 ft lb PC173A ...

Page 159: ...lock making sure to have the tensioner on the fifth notch PC085A NOTE On 7000 models turn the chain tension adjustment bolt clockwise until it is finger tight then loosen it 1 1 2 turns While holding the bolt with a wrench tighten the jam nut to 18 ft lb YM 053 16 Secure the top sprocket using the existing thrust washer and black snap ring making sure it is fully seated into the groove YM 097 17 B...

Page 160: ...and gently rotate coun ter clockwise to make sure the shift fork is in the for ward position When the shift fork is in the forward position make sure the notch in the extension is directed downward YM 101 24 Install spring into the bottom of shift actuator detent block and install into the chain case cover The notch in the extension should be lined up with the notch in the block YM 102 NOTE To ver...

Page 161: ...on the inside of the sprockets on the drive sprockets for proper sprocket timing YM 071A 3 Using a suitable press positioned against the tension collar of the drive sprocket located on the gear case and of the driveshaft press the drive sprockets off the driveshaft YM 069A CLEANING AND INSPECTING 1 Thoroughly wash all metallic components in parts cleaning solvent Dry using compressed air 2 Wash al...

Page 162: ... timing arrow lines from removing are aligned then using the press fixture press the sprocket to the remaining alignment line NOTE When pressing new sprockets on the drive shaft align the sprocket alignment marks or the sprockets won t be timed correctly YM 072A 4 Using a calipers measure distances between the sprockets and from the sprockets to each end of the driveshaft for proper location see a...

Page 163: ...lack in the track 4 Check track alignment see Track Alignment sub section in this section 5 After proper track tension is obtained tighten the idler wheel axle cap screws to 34 ft lb NOTE Since track tension and track alignment are interrelated always check both even if only one adjustment seems necessary Track Alignment NOTE Proper track alignment is when the rear idler wheels are equidistant fro...

Page 164: ... see Track Ten sion sub section in this section 7 After proper track tension and alignment are obtained tighten the idler wheel axle cap screw to 34 ft lb then tighten the adjusting bolt to 84 in lb NOTE Field test the track under actual conditions and after the field test check track alignment and track tension adjust as necessary Brake System Hydraulic CHECKING BRAKE LEVER TRAVEL 1 Compress the ...

Page 165: ...e lever repeatedly until all brake fluid is expelled Close the bleeder valve 3 Add new approved brake fluid to the reservoir then compress the brake lever and hold Open the bleeder valve Repeat the compression until brake fluid flows free of air bubbles and appears clean NOTE It may be necessary to refill the reservoir a number of times to eliminate all air bubbles in the system 4 When the brake f...

Page 166: ... the cover Remove the tube from the bleeder valve CHECKING AND REPLACING BRAKE PADS 1 Remove the brake shield then remove the retaining pin securing the brake pads PC195 2 Remove one brake pad and measure the thickness PC196 PC199 NOTE Brake pad thickness must be greater than 0 20 in If brake pad thickness is less than specified replacement of both pads is necessary Always replace with new pads an...

Page 167: ... the bleeder valve and compress the brake lever several times to drain the reservoir of fluid 5 Remove the brake hose from the caliper Use an absorbent towel to collect any remaining brake fluid 6 Remove the retaining pin securing the brake pads then remove both pads PC195 NOTE If servicing the brake disc only remove the cap screws securing the caliper housings together then remove the outside hou...

Page 168: ...hey must be secured together with the seal installed between the inner and outer housings 9 Position a piece of wood between the pistons Using low pressure compressed air blow into the caliper brake hose fitting to loosen the brake pistons PC221A 10 Remove the two screws securing the caliper halves Discard the seal PC219A PC173 11 Remove the pistons A and O rings B then dis card the O rings PC220A...

Page 169: ...In each caliper half apply approved brake fluid to the brake piston then while twisting install the pis ton with the dished side facing out PC201 NOTE To aid in installing the piston make sure the piston O ring is properly seated in the groove of the caliper housing 3 Using a suitable press install a new inner bearing into the caliper housing until it is properly seated ZJ239A 4 Install the snap r...

Page 170: ...o 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 INSPECTING 1 Inspect the snap ring and pin securing the brake lever for wear or damage then inspect the brake lever for cracks or damage 2 Inspect the master cylinder reservoir and cover for cracks and leakage NOTE The master cylinder is a no...

Page 171: ...pair piston replace piston O ring Problem Lever Spongy Bottoms Out Condition Remedy 1 Brake system air bubbles present 2 Master cylinder damaged faulty 1 Bleed brake system 2 Replace master cylinder Problem Oscillation Feedback in Lever Condition Remedy 1 Brake pad residue present on brake disc 2 Caliper loose 1 Replace pads clean disc 2 Tighten mounting bolts Problem Loss of Brake Condition Remed...

Page 172: ...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 pin bent damaged 2 Cam arm damaged broken 3 Drive clutch out of balance 1 Replace pin...

Page 173: ... ski saddle cen ter Also assume that the ski saddle center is the same height off the ground as the rear axle center This pro duces 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 col lapses slightly This brings the rear arm point downward and with the front arm stationary the teeter totter effe...

Page 174: ...is being removed from the shock the sound of air loss is from the pump hose not from the shock 5 Install the air valve cap onto the shock FRONT ARM SPRING TENSION Having very light front arm spring tension is desirable When riding in 4 in or more of snow the machine will be quicker if the front spring tension is adjusted lightly If the spring tension is adjusted too stiff the track angle at the fr...

Page 175: ...ki lift under acceleration is greatly reduced which provides improved handling Sec ond when riding through rough terrain the rear suspension arm receives some needed assistance from the front arm shock and spring as the rear arm is fully collapsed and locked up by the coupler blocks The front arm then starts to collapse the shocks and spring which assist the rear springs The result is a smoother r...

Page 176: ...or disengage the spring tension blocks use a spark plug socket and a screwdriver to adjust the spring block to the desired position Make sure both spring blocks are in the same position either engaged or disengaged 744 457A ...

Page 177: ...ctic Cat recommends that when disassembling and assembling the suspension all stock mounting locations be used as shown in the following illustrations 0747 411 0747 413 CAUTION All stock mounting locations must be used If any alterations to the skid frame are made shock absorber and suspension damage may occur ZR and XF 137 Models XF 141 Models ...

Page 178: ...176 0747 413 0748 835 M Models Pantera Models ...

Page 179: ...r steering post stand tip the snowmobile onto one side 4 On the ZR and Pantera slide the skid frame rearward far enough to drop the front arm out of the slider axle then remove the skid frame 5 On the M and XF remove the two cap screws and nuts securing the front of the skid frame to the chas sis Account for two washers End Caps REMOVING 1 Remove the lock nut and cap screw securing the end cap FZ0...

Page 180: ...r wear 2 Inspect the rivet holes in the slide rail for damage or elongation INSTALLING 1 Place the pads brackets into position on the slide rail 2 Secure the pads with existing torx head screws and nuts Idler Wheels Mounting Blocks REMOVING 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 mounting blo...

Page 181: ...the cap screws securing the front arm to the rails 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 7 Remove the cap screw and lock nut securing the idler wheel mounting block to the slide rail 8 Remove the cap screws washer and lock nut from the fro...

Page 182: ...rail Secure with cap screws and lock nuts Tighten to 40 ft lb NOTE Move the rear arm assembly forward enough to allow the rear arm springs to be installed into the slide blocks 6 Secure the rear shock pivot to the front arm with cap screw and lock nut Tighten to 20 ft lb XM004A 7 Secure the upper shock eyelet and axle in the mount ing hole of the front arm Secure with a cap screw and lock nut Tigh...

Page 183: ...uring the upper front shock absorber eyelet to the front arm Pull the shock eyelet free of the bracket Account for a spacers 3 Remove the two cap screws securing the front arm to the rails Account for two washers YM 119A INSPECTING 1 Inspect all front arm weldments for cracks or unusual bends then inspect the front arm mounting brackets for cracks and for elongated holes 2 Closely inspect all tubi...

Page 184: ...g slide and all mounting hardware 6 Remove the spring and sleeve from the idler arm 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 link to the idler arm Account for the cap screws lock nuts and sleeves 8 Remove the cap screw A and lock nut securing th...

Page 185: ...Z103A 2 Install the rear arm onto the idler arm with an alumi num axle and two cap screws Tighten to 40 ft lb FZ101A 3 With the sleeves installed install the shock absorber link to the lower mounting hole of the rear shock pivot then install the shock absorber with cap screws A and B and lock nuts Tighten securely FZ102A 0742 877 4 With the sleeves installed install the shock absorber link to the ...

Page 186: ... arm assembly Secure the offset arm to the idler arm with cap screws and lock nuts Tighten to 20 ft lb FZ048A NOTE When tightening the offset arm lock nuts tighten the upper lock nut first to ensure an even clamp load Make sure the flared side of the bushing is directed outward 11 Grease the idler arm and rear arm grease fittings with an all temperature grease Rear Arm Assembly RR SNO 265 REMOVING...

Page 187: ...ecuring the rear arm to the slide rail Account for the axle tube XM090A INSTALLING 1 Slide the axle tube into the rear arm then position the rear arm with the holes in the slide rails Secure using existing cap screws threads coated with blue Loctite 243 Tighten to 20 ft lb XM090A 2 Install the aluminum axle into the idler arm then position the idler arm between the rear arm and secure using existi...

Page 188: ... washers then remove the axle from the idler arm XM001A CM232 2 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 rear shock link to the idler arms XM003A 3 Remove the cap screws and lock nuts securing the rear arm shock absorber and shock link to the offset arm XM004A NOTE With the rear arm shock and shock link r...

Page 189: ...th existing cap screws Tighten to 20 ft lb XM007A 2 Install the idler arm onto the rear arm with an alumi num axle bushing assemblies and two cap screws Tighten to 40 ft lb XM006A 3 With the sleeves installed place the shock absorber and shock link between the offset arm bracket Secure with the cap screws and lock nuts Tighten securely XM004A NOTE Do not over tighten the shock absorber cap screw a...

Page 190: ... for assembly purposes 3 Loosen the cap screws and lock nuts securing the offset arm assembly to the idler arm then remove the offset arm assembly Account for a flanged axle idler spacer and washer YM 120 4 Remove the idler wheel NOTE Use the Idler Wheel Puller Kit to remove the wheel 5 Remove the cap screw flat washer and lock nut securing the spring slide to the slide rail Account for the spring...

Page 191: ...le of the idler arm along with the cap screw and lock nut then secure the shock absorber to the idler arm with cap screws and lock nuts Tighten securely YM 121 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 cams after the skid frame has been installed 4 Slide the sleeves and springs onto the idler ...

Page 192: ...blue Loctite 243 and flat washers Tighten cap screws only until snug NOTE Tighten the rear idler wheel axle only until snug until the skid frame has been installed and track tension has been adjusted then the axle assembly must be tightened to 34 ft lb 3 Install the skid frame see Installing Skid Frame in this sub section Installing Skid Frame 1 Using a piece of cardboard on the floor to protect a...

Page 193: ... NOTE Do not install the short legs of the rear springs onto the adjusting cams at this time 8 At this time place the snowmobile to the upright position then tighten all cap screws to 40 ft lb 9 On the ZR 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 adjustment positions 10 Adjust track tension see the ...

Page 194: ...ased ZR 004 ZR 017 2 Using a 1 in wrench loosen the bearing assembly and remove the shock rod and valve assembly from the shock body ZR 003 ZR 016 3 Pour the oil from the shock body into a suitable container then hang the shock body upside down and let it drip into the container 4 Clamp the shock rod and valve assembly in bench vise then remove the nut securing the valve stack Description p n Floa...

Page 195: ...ng 7 Items to replace A Floating piston O ring B Shock shaft bearing cap if any signs of oil leaks or damage C Any part worn or damaged ASSEMBLING 1 Lubricate the O rings in the bearing end cap then install the bearing cap seal protector onto the end of the shock rod Install the bearing end cap ZR 013 2 Install the valve stack onto the shock rod then secure using the existing nut Tighten to 15 ft ...

Page 196: ...gin to thread the cap into the body As the cap threads into the body oil will escape Lift slightly on the shaft while threading until the O ring contacts the shock body Tighten the bearing cap to 50 ft lb ZR 003 8 With shock oil around the seals in the bearing cap and on the shock rod slowly compress the shock rod until the shock eyelet bottoms out Pressurize the shock with nitrogen to 200 psi and...

Page 197: ... AGNETOS ...

Page 198: ... AIN ARNESS P N 2 82 30 4 30 4 4 8 4 82 30 4 P N 30 8 30 30 30 2 30 30 22 P N 0ANTERA 4 ...

Page 199: ... AIN ARNESS P N 30 4 8 30 4 4 30 4 82 30 4 2 30 4 82 30 4 P N 2 8 30 2 30 30 22 ...

Page 200: ... AIN ARNESS P N 2 82 ...

Page 201: ... OOD ARNESS P N 0ANTERA 4 8 2 ...

Page 202: ... OOD ARNESS P N 2 82 2 ODELS 8 ODELS ODELS ...

Page 203: ... ANDLEBAR ARNESS P N 2 30 22 2 ...

Page 204: ... ANDLEBAR ARNESS P N 2 82 2 EXCEPT 30 22 8 EXCEPT 2 2 8 0ANTERA ...

Page 205: ... 0ASSENGER 3EAT ARNESS P N ...

Page 206: ...Printed in U S A Trademarks of Arctic Cat Inc Thief River Falls MN 56701 p n 2260 468 ...

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