Arctic Cat 2018 ZR 200 Service Manual Download

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Summary of Contents for 2018 ZR 200

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Page 2: ... 33 Troubleshooting Fuel System 34 Electrical System 35 Transistorized Ignition System 35 Testing Ignition Switches 35 Testing Electrical Resistances 36 Testing RPS Switch 37 Testing Idle Switch 37 Testing Handlebar Warmer Elements 37 Testing Handlebar Warmer Switch 37 Testing Headlight Switch 38 Testing Key Switch 38 Drive Train Track Brake Systems 39 Drive Belt 39 Drive Clutch 39 Driven Clutch 4...

Page 3: ...snowmo bile related damage Follow the directive because it deals with the possibility of damaging part or parts of the snowmobile The symbol NOTE identifies supple mentary information worthy of particular attention At the time of publication all information photographs and illustrations were technically correct Some photo graphs and illustrations used in this manual are used for clarity purposes o...

Page 4: ...use only genuine Arctic Cat parts They are precision made to ensure high quality and correct fit Preparation for Storage Prior to storing the snowmobile it is extremely important that it be properly serviced to prevent corrosion and com ponent deterioration Arctic Cat recommends the follow ing procedure to prepare the snowmobile for storage 1 Clean the seat cushion with vinyl protectant and a damp...

Page 5: ...ski wear bars adjust or replace as neces sary 5 Examine the in line fuel filter and clean or replace if necessary 6 Fill the gas tank 7 Clean the seat cushion with the vinyl protectant 8 Check the spark plug clean gap and or replace as necessary then start the engine and ensure proper carburetor adjustments Torque Conversions ft lb N m CAUTION Avoid using a plastic cover as moisture will collect o...

Page 6: ...Driveshaft 16 MC Mount Master Cylinder 30 in lb STEERING FRONT SUSPENSION CHASSIS Ski Spindle 16 Ski Wear Bar 50 in lb Ski Ski Handle 50 in lb Steering Post Chassis 96 in lb Steering Tie Rod Steering Post 20 Tie Rod Spindle Arm 15 Steering Support Spar 96 in lb Steering Support Upper Console 96 in lb A Arm Chassis 30 A Arm Spindle 20 Shock Absorber Spindle 16 Shock Absorber Chassis 16 REAR SUSPENS...

Page 7: ...engine assembly ensure all threaded areas are clean to ensure an accurate torque value is achieved 200 ENG 18 1 Torque control required Apply Loctite Lubricate with Arctic Cat 4 Stroke Engine Oil Lubricate with Arctic Cat All Temp Grease ...

Page 8: ... Clearance 0 008 0 024 Cam Lobe Height 1 050 1 059 Crank Pin Diameter min 1 1011 1 1017 Crank Pin Connecting Rod Clearance 0 0006 0 0018 Crankshaft Rod Journal Out of Round Taper 0 004 Crankshaft Runout t i r 0 0016 Valve Guide Inside Diameter max 0 22 Valve Guide Stem Clearance max Int Exh 0 0016 0 0024 0 0024 0 0031 Valve Face Width min 0 028 Valve Face Runout max 0 0012 Valve Clearance Cold 59 ...

Page 9: ...4 3 Remove the air cleaner case from the carburetor and engine Account for the gasket 4 Remove the nut A and screw B securing the choke cable to the carburetor then remove the fuel hose C from the carburetor Remove the carburetor from the engine ZR 145 5 Remove the two cap screws and lock nuts securing the upper steering post bearings and retainers then remove the retainers and bearings ONS 025 6 ...

Page 10: ...uring the muffler to the engine Remove the nuts and springs securing the muffler Remove the muffler ZR 162 14 Pull the recoil starter rope out for enough to tie a slip knot in the starter rope below the steering sup port and allow the rope to slowly retract against the recoil starter 15 Remove the knot at the handle and remove the han dle then thread the rope through the bushing in the console 16 ...

Page 11: ... an insulator block IO068 NOTE If the cylinder head will be replaced the carburetor studs may be removed by tightening the two nuts against each other then using a wrench on the inside nut remove the stud 6 Remove the recoil starter fan housing assembly 7 Remove the spark plug wire from the spark plug and remove the spark plug then remove the cap screws securing the ignition coil to the crankcase ...

Page 12: ...et and the location of the two dowel pins IO073 13 Remove the nut securing the flywheel to the crank shaft and starter pulley IO069B 14 Using a flywheel puller remove the flywheel IO074 15 Remove the cap screws securing the stator to the crankcase then route the stator harness out through the slot in the crankcase and remove the stator IO075A 16 Remove the cap screws securing the crankcase side co...

Page 13: ...ing rod and end cap for reference during installation then remove the cap screws and connecting rod end cap IO081A 21 Carefully work the connecting rod piston up and out of the cylinder then remove the crankshaft NOTE For assembling purposes note the arrow mark on the dome of the piston is directed to the push rod opening of the cylinder 22 Remove the hairpin clip from the governor control shaft t...

Page 14: ...d is damaged it must be replaced Measuring Cylinder Head Distortion 1 Using a non metallic carbon removal tool remove any carbon buildup from the combustion chamber being careful not to nick scrape or damage the com bustion chamber or the sealing surfaces 2 Inspect the spark plug hole for any damaged threads Repair damaged threads using a heli coil insert 3 Inspect the cylinder head for flatness u...

Page 15: ...weight oil then apply a small amount of valve lapping compound to the entire seating face of each valve 4 Attach the suction cup of a valve lapping tool to the head of the valve 5 Rotate the valve until the valve and seat are evenly polished 6 Clean all compound residue from the valve and seat Valve Springs 1 When the valve springs are weak the valve and valve seat fail to form a good seal thus al...

Page 16: ...NOTE Note the location of each ring for proper installation When installing new rings install as a complete set only Cleaning Inspecting Piston Rings NOTE Make a ring groove cleaning tool by taking an old piston ring and snapping it into two pieces then grind the end of the old ring to a 45 angle and to a sharp edge Using a ring groove cleaning tool clean carbon from the ring grooves Be sure to po...

Page 17: ...he lower thin oil ring 3 Position the thin oil ring gaps 90 from the gap of the oil ring expander and 180 from each other 4 Install the middle and top compression ring with the I D mark directed toward the dome of the piston NOTE The top compression ring can be identified by the chrome silver face of the ring Measuring Piston Pin Diameter 1 Measure the piston pin diameter at each end and in the ce...

Page 18: ...tallic finish is attained Honing Cylinder 1 Wash the cylinder in parts cleaning solvent 2 Inspect the cylinder for pitting scoring scuffing and corrosion If marks are found repair the surface using the Ball Hone NOTE To produce the proper 45 crosshatch pat tern maintain a low drill RPM If honing oil is not available use a lightweight petroleum based oil Thoroughly clean the cylinder after honing u...

Page 19: ...t must be within 1 1023 1 1029 GEN 0038 3 Measure the crank pin connecting rod clearance Measurement must be within 0 0002 0 0008 GEN 0039 CRANKSHAFT BEARINGS 0744 992 Removing 1 Using a flat blade screwdriver carefully work the oil seal from side to side out of the crankcase and cover 2 Using a suitable press and with the crankcase or crankcase cover secured into position carefully heat the case ...

Page 20: ...eaded holes of the crankcase and cylinder and head to properly tighten NOTE When the use of a lubrication is indicated use clean engine oil 1 Lubricate the piston pin connecting rod and piston pin bore with engine oil then install the piston to the connecting rod and secure the piston pin with the cir clips directed either up or down IO091A NOTE Coat the cylinder wall connecting rod bear ing surfa...

Page 21: ...mshaft lobes and running surfaces on each end of the shaft then with the crankshaft piston rotated to TDC and the timing marks of the crankshaft gear in line with the camshaft gear install the camshaft IO078A 7 Install the washer onto the governor control shaft and slide the shaft up into position from inside the crank case far enough to install the hairpin clip IO101 NOTE When installing the gove...

Page 22: ...ntil the piston is at the top of the compression stroke IO107 13 Set the valve clearance to the recommended setting with a feeler gauge and while holding the adjust ment nut tighten the rocker arm lock nuts to 88 in lb Verify valve clearance is 0 004 14 Install the air shroud to the cylinder head and secure the shroud with cap screw Tighten to 96 in lb IO098A 15 Place the air breather body assembl...

Page 23: ...net of the flywheel is under the legs of the ignition coil then insert a flat 0 020 feeler gauge between the lower leg of the coil and the flywheel IO099 21 Loosen the ignition coil mounting cap screws from step 16 enough to allow the coil to draw against the feeler gauge Tighten the cap screw enough to hold the position of the coil then repeat the procedure for the other cap screw when an air gap...

Page 24: ...four cap screws threads coated with blue Loctite 243 and washers Tighten to 18 ft lb ONS 032 NOTE The cap screws must be positioned to the arrow side of the holes in the crankcase ONS 033 ONS 034 2 Place the engine assembly into position in the engine compartment 3 Loosely secure the engine to the chassis using new lock nuts Do not tighten at this time ONS 031 4 Loosely secure the torque bumper as...

Page 25: ...rt and the handle then tie a knot at the end of the rope and pull the handle up and onto the knot 11 Untie the slip knot at the starter case and allow it to slowly rewind into the case 12 Position the tie rods on the steering post then secure using the existing cap screws washers and lock nuts threads coated with blue Loctite 243 Tighten to 20 ft lb 13 Position the bearings on each side of the ste...

Page 26: ...43 20 Install the exhaust gasket onto the studs of the engine then install the muffler assembly over the studs Secure using a new lock washer existing nuts and springs Tighten the nuts to 60 in lb then using a medium sized needle nose pliers bend the best fit ting tabs tight against the nuts NOTE The long tab on the lock washer should be installed toward the front of the snowmobile and bent all th...

Page 27: ...oved to access the recoil starter see Engine section REMOVING DISASSEMBLING 1 Remove the cap screws securing the recoil starter to the engine cover 2 Pull the rope out of the housing noting the direction in which the rope is wound for assembling and align with the notch in the roller then release the spring pressure on the reel 3 Remove the knot from the end of the rope then remove the shoulder sc...

Page 28: ...he shoulder screw Tighten to 57 in lb 3 Route the recoil rope through the rope guide of the recoil housing and through the recoil handle then tie a knot in the rope 4 Wind the rope counterclockwise 3 4 turns around the reel then secure the recoil starter to the engine cover Tighten to 96 in lb WARNING Exercise extreme caution when installing as the spiral spring may disengage and cause severe inju...

Page 29: ...1 Throttle stop screw turned out too far 2 Idle fuel adjuster screw out of adjustment 3 Air silencer obstructed 4 Drive clutch dirty 1 Adjust throttle stop screw 2 Adjust idle fuel adjuster screw 3 Clean air silencer 4 Clean drive clutch Problem Engine Loses Power Condition Remedy 1 Spark plug fouled 2 External coil faulty 3 Gas tank vent hose obstructed 4 Compression low 5 Muffler restricted 1 Re...

Page 30: ...emove the clamping pliers Carburetor REMOVING 1 Remove the screws securing the air cleaner cover to the air cleaner case and account for the filter and retaining plate ZR 143 2 Remove the flanged nuts securing the air cleaner assembly to the carburetor and engine Account for the plate ZR 144 3 Remove the air cleaner case from the carburetor and engine Account for the gasket 4 Remove the nut A and ...

Page 31: ... the casting 2 Inspect the float for perforations or damage 3 Inspect the gaskets for distortion tears or noticeable damage 4 When applicable inspect the idle fuel adjuster screw needle jet assembly and pilot jet for wear damage or distortion 5 Inspect the nozzle and main jet for obstructions or damage 6 Inspect the carburetor insulator for damage cracks and tightness 7 Place the carburetor insula...

Page 32: ...the float pin D 3 Secure the float chamber w rubber gasket to the car buretor with the cap screw C 4 Install the pilot jet B 5 Install the idle fuel adjuster screw A and rotate the screw clockwise until lightly seated then rotate the screw counterclockwise the proper number of rota tions as noted during disassembling Install the plas tic cap INSTALLING 1 Install the gasket then with the governor r...

Page 33: ...tle valve which in turn determines the proper idle speed Rotate the screw clockwise to increase engine idle speed and counterclockwise to decrease engine idle speed Throttle Cable The correct throttle cable adjustment is when with the engine OFF the carburetor throttle is completely open against its limit while the throttle lever lightly contacts the handlebar grip The throttle arm on the carburet...

Page 34: ... 2 Seat the drum into its lever recess then secure the lever with a pin and push nut 3 Place the throttle cable into the throttle cable bracket and secure with jam nuts 4 Slide the end of the throttle cable into the throttle cable lever 5 Secure the throttle cable to the steering post with a cable tie then install the handlebar pad 6 Open and close the throttle lever to make sure of no binding or ...

Page 35: ...dle jet float Problem Carburetor Too Lean 0 1 4 Opening Condition Remedy 1 Choke valve hanging open 2 Pilot jet outlet obstructed 3 Float needle jet obstructed damaged adjusted incor rectly 1 Adjust service choke cable valve assembly 2 Remove obstruction 3 Remove obstruction replace needle jet float Problem Carburetor Too Lean 1 4 3 4 Opening Condition Remedy 1 Pilot jet outlet main jet obstructed...

Page 36: ...f working voltage of the transistor TR2 when the ignition timing approaches the rated RPM and thus the transistor TR2 is turned on As a result the base current of TR1 flowing through the resistor R is by passed and the transistor TR1 is turned off from the conductive state The current flowing through the primary winding 2 is thus interrupted and rapid change occurs in the magnetic flux across the ...

Page 37: ...Resistances NOTE The following test procedure starts by test ing the resistance for the spark plug cap and working back to the stator under the flywheel Replace any component that does not have a test value within spec ifications SPARK PLUG CAP 1 Remove the spark plug cap from the high tension lead by rotating it counterclockwise 2 Set the selector in the OHMS position 3 Connect one tester lead to...

Page 38: ...sistance with pressure on the throttle the throttle cable will need to be adjusted Refer to the throttle cable section in the service manual If the meter still reads less than 1000 ohms replace the front throttle control assembly 4 Move the throttle lever to the wide open position The meter must read less than 1 ohm If the meter reads OL infinite resistance replace the front throt tle control asse...

Page 39: ...sistance ONS 042 3 With the headlight toggle in the LOW BEAM posi tion connect one ohmmeter lead to pin and the other ohmmeter lead to pin The meter must read 1 ohm or less resistance ONS 043 4 Connect the white wire to the bottom terminal LOW BEAM the yellow wire to the middle terminal and the blue wire to the top terminal HIGH BEAM on the switch Close and latch the hood Testing Key Switch 1 Open...

Page 40: ... between the clutches rotate the driven clutch to help the driven clutch open ZR 126 4 Remove the drive belt by pulling it up and over the sheave INSTALLING 1 Place the belt so the part number can be read between the sheaves of the driven clutch then rotate the driven clutch to help the driven clutch open ZR 127 2 With the sheaves apart roll the belt over the drive clutch 3 Release the brake lever...

Page 41: ... damage or wear Assembling 1 Starting at the top of the movable sheave install the rollers with the painted side to the right and continue around the sheave adding all six rollers in the same orientation ONS 036 NOTE Available roller weight kits from Arctic Cat are p n 0646 987 18g Blue p n 0646 988 14g Red and p n 0646 989 10g Black 2 Install the four sliders into the cover then install the cover...

Page 42: ...riven cam and movable sheave bearings for wear If wear is present replace the bracket or sheave REPLACING ROLLERS 1 With the driven cam removed remove the roller screws securing the rollers in the movable sheave ZR 122 2 Place a new roller into position and secure with the existing roller screws Tighten to 8 ft lb ASSEMBLING NOTE The driven spring rate will increase 1 to 3 and A to C Increasing dr...

Page 43: ...washer securing the driven clutch to the driven shaft then remove the driven clutch 2 To move the stationary sheave inward on the shaft remove alignment washers located on driven shaft 3 To move the driven clutch outward on the shaft add alignment washers to the driven shaft NOTE Available shim washers from Arctic Cat are p n 0648 835 0 039 in and p n 0648 836 0 020 in 4 Arrange washers to obtain ...

Page 44: ...ase and not the lower pulley then apply heat to the case around the lower pulley 5 Using a suitable press or an adequate press tool press the lower pulley from the bearing ASSEMBLING NOTE The bearings within the dropcase and the dropcase cover are not serviceable If a bearing is damaged the cover or case assemblies will have to be replaced 1 With the bearing clean and free of debris press the lowe...

Page 45: ...ignment are interrelated therefore always check both even if only one adjustment seems necessary Track tension is directly related to the overall perfor mance of the snowmobile If the track is too loose it may slap against the tunnel causing wear or it may ratchet on the track drive sprockets Arctic Cat recommends that the track tension be checked once a month and adjusted accordingly Checking Tra...

Page 46: ...ack tension is adjusted Checking Track Alignment 1 Position the tips of the skis against a wall then using a shielded safety stand raise the rear of the snowmo bile off the floor making sure the track is free to rotate 2 Start the engine and accelerate slightly Use only enough throttle to turn the track several revolutions SHUT ENGINE OFF NOTE Allow the track to coast to a stop DO NOT apply the br...

Page 47: ...e brake lever assembly to the handlebar Remove the assembly ONS 024 2 Remove the screws rivets and washers securing the brake disc guard and the right side footrest to the chassis then remove them as an assembly ZR 157 3 Remove the two screws securing the brake caliper assembly ZR 158 4 Remove the cap screw and washer securing the brake disk assembly to the driveshaft then remove the brake disc ZR...

Page 48: ...cure at this time leaving them loose enough to allow the caliper to move 4 Squeeze the brake lever This will center the caliper on the disc Tighten the cap screws threads coated with blue Loctite 243 to 80 in lb Release the brake lever and verify that the caliper is centered over the disc If the caliper is not centered adjust the mount ing location as needed ZR 158 5 Secure the footrest and brake ...

Page 49: ...o the syringes then fill the syringe that will be installed into the master cylinder 1 4 full of DOT 4 or 5 brake fluid Fill the other syringe 3 4 full ZR 102 NOTE Purge all air from the syringes and fittings before proceeding 6 With the caliper below the master cylinder remove the bleed port screw from the master cylinder and attach the syringe ZR 096 7 Remove the bleed port screw from the calipe...

Page 50: ...pin Spread to secure ZR 100 14 Position the brake caliper in its location on the disc and loosely secure at this time leaving them loose enough to allow the caliper to move 15 Squeeze the brake lever This will center the caliper on the disc Tighten the cap screws to 80 in lb Release the brake lever and verify that the caliper is centered over the disc If the caliper is not centered adjust the moun...

Page 51: ...n the driver decelerates com ing into a corner the center of gravity is transferred for ward putting the required pressure onto the skis and reducing the pressure on the rear suspension position C This is essentially what weight transfer is all about the shift of weight to the rear of the machine for positive traction and good acceleration or to the front of the machine for positive handling and c...

Page 52: ...he slide rail 3 Using a straightedge inspect the slide rail for any unusual bends Place the straightedge along the bot tom surface of the slide rail If the rail is found to be bent it must be replaced 4 Place the straightedge along the side of the slide rail If rail is found to be bent it must be replaced INSTALLING NOTE Use a file to remove any sharp edges on the lower portion of the rail 1 Align...

Page 53: ... removed remove the cap screws and flat washers securing the outer idler wheels Remove the idler wheels from the axle and account for the adjuster bushings 2 Slide the axle out of the rear axle housing and the rear spacer CLEANING AND INSPECTING 1 Clean the bearings with a clean cloth 2 Inspect all idler wheel bearings Rotate each bearing by hand and if any roughness or binding is noted replace th...

Page 54: ...securing the cross brace axle to the slide rail SNO 974 3 Remove the cap screw securing the rear suspension arm to the support bracket 4 Remove the cap screws and lock nuts securing the rear suspension arm support bracket SNO 975 5 Remove the cap screw and washer securing the rear idler wheel to the axle Slide the wheel off the axle and account for the adjuster bushing 6 Remove the two cap screws ...

Page 55: ...ap screw Tighten to 20 ft lb 5 Secure the cross brace axle to the slide rail with the cap screw threads coated with blue Loctite 243 Tighten to 20 ft lb SNO 974 6 Place the shock pad into position and secure with a solid rivet and push nut SNO 995 7 Place the end cap onto the rail and secure with the cap screw washers and lock nut Tighten to 80 in lb Installing Skid Frame 1 Pull the track away fro...

Page 56: ...able 7 Remove the screw securing the brake lever assembly to the handlebar Remove the assembly ONS 024 8 Cut the cable ties securing the cables to the steering post 9 Using a sharp knife cut the grips off the handlebar then remove the hand warmers 10 Using a solvent clean the old adhesive from the han dlebar 11 Loosen the screw securing the emergency stop switch to the handlebar then remove the st...

Page 57: ...ring post bearings into position on the steering post and secure the steering post bearing assembly to the support with the bearing retainer cap screws harness guide supports and lock nuts 4 Tighten the four cap screws and nuts securing the steering post to 96 in lb ONS 025 NOTE Check all fasteners to ensure they are tight Turn the handlebar full left and full right several times to ensure free mo...

Page 58: ...the ski 4 Install the remaining washer and lock nut then tighten the lock nut to 16 ft lb NOTE Ensure that the cotter pin slot in the cap screw is still horizontal with the ski 5 Install a new cotter pin from the back side of the ski cap screw and spread the pin Ski Wear Bar The ski wear bar is a replaceable bar attached to the underside of the ski The purpose of the wear bar is to assist in turni...

Page 59: ...nt and jam nut 2 Secure the inner tie rod to the steering post with washers and new lock nuts Tighten to 20 ft lb 3 Secure the outer tie rod to the spindle with a washer and new lock nut coated with blue Loctite 243 Tighten to 15 ft lb ZR 116 4 Lock the jam nuts against the tie rod then adjust ski alignment see Ski Alignment sub section Spindle REMOVING 1 Position the front of the snowmobile up on...

Page 60: ...e ski wear bar bolts in two places approxi mately 18 20 cm 7 8 in in front of the spindle and 18 20 cm 7 8 in behind the spindle Record the measurements taken for the left side 729 887A 5 Place the straightedge against the outside edge of the track so it lies near the inside edge of the right side ski 6 Measure the distance from the straightedge to the right ski wear bar bolts in two places 18 20 ...

Page 61: ...A arms Remove the spindle and ski as an assembly SNO 980 2 Remove the cap screws and lock nuts securing the shock to the chassis bracket and the lower A arm then remove the shock Account for the upper shock bushing SNO 979 3 Remove the rivets securing the tie rod boots to the chassis making sure not to drill into the boots then slide the boots off the tie rods SNO 981 4 Remove the rivets securing ...

Page 62: ...s and washers Tighten to 20 ft lb SNO 985 4 Secure the belly pan to the chassis using new rivets then secure the tie rod boots to the chassis using new rivets SNO 982 5 Install the shock to the shock bracket and the lower A arm using the existing upper axle cap screws and new lock nuts Tighten to 16 ft lb 6 Install the spindle and ski assembly to the A arms and secure using new lock nuts Tighten t...

Page 63: ...ly REMOVING 1 Open the hood then remove the shoulder screws securing the seat base to the chassis Remove the two screws washers and nuts securing the rear of the belly pan and the seat base to the chassis ONS 022 2 Remove the gas cap from the gas tank then carefully slide the seat base rearward 3 Disconnect the taillight harness from the main har ness 4 Remove the screws securing the seat assembly...

Page 64: ...lamps 3 Use Fuel Hose Clamp Tool to make sure the hose clamps are tight by crimping the clamps until the two clamp areas touch XM282 4 Secure the vent hose to the plastic elbow and secure using the existing clamp then secure the gas hose to the gas tank elbow using a new clamp 5 Use Fuel Hose Clamp Tool to make sure the hose clamp is tight by crimping the clamps until the two clamp areas touch 6 P...

Page 65: ...bber boot 2 Rotate the spring retainer securing the bulb in the headlight then carefully remove the bulb 3 Remove the two pins securing the outer portion of the headlight then remove the screw securing the lower portion of the headlight Remove the headlight from the hood SNO 988 INSTALLING 1 Install the headlight assembly into the hood tabs and secure using the existing pins and screw NOTE The hoo...

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Arctic Cat 2018 ZR 200, Service Manual

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