Arctic Cat 2018 ZR 200, Service Manual

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2018 ZR 200 Service Manual
Table of Contents
General Information/Foreword.......................................... 2
Snowmobile Identification ............................................. 2
Recommended Gasoline and Oil.................................. 3
Break-In Procedure ...................................................... 3
Genuine Parts............................................................... 3
Preparation for Storage ................................................ 3
Preparation After Storage ............................................. 4
Torque Conversions (ft-lb/N-m)..................................... 4
Torque Specifications.................................................... 5
Engine Torque Diagram ................................................ 6
Engine Specifications ................................................... 7
Carburetor Specifications ............................................. 7
Track Specifications ...................................................... 7
Front/Rear Shock Spring .............................................. 7
Rear Suspension Spring............................................... 7
Front Shock Absorber ................................................... 7
Rear Shock Absorber ................................................... 7
Engine ................................................................................. 8
Removing...................................................................... 8
Disassembling .............................................................. 9
Servicing Components ............................................... 13
Assembling ................................................................. 19
Installing ..................................................................... 23
Changing Oil ............................................................... 26
Recoil Starter.............................................................. 26
Troubleshooting Engine .............................................. 28
Fuel System...................................................................... 29
In-Line Fuel Filter........................................................ 29
Carburetor................................................................... 29
Throttle Cable ............................................................. 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...............................................................41
Drive Clutch/Driven Clutch ..........................................42
Dropcase .....................................................................42
Track ............................................................................44
Brake System ..............................................................46
Troubleshooting Track..................................................49
Rear Suspension ..............................................................50
Removing Skid Frame .................................................50
End Cap ......................................................................50
Wear Strip ...................................................................51
Rear Suspension Arm/Rear Springs ...........................51
Rear Idler Wheels and Axle.........................................52
Slide Rail .....................................................................53
Installing Skid Frame ...................................................54
Steering and Body............................................................55
Steering Post...............................................................55
Ski ...............................................................................57
Ski Wear Bar ...............................................................57
Tie Rods ......................................................................57
Spindle ........................................................................58
Ski Alignment ..............................................................59
Front Suspension A-Arms ...........................................60
Belly Pan .....................................................................61
Seat Assembly ............................................................62
Gas Tank/Fuel Pump Assembly ..................................63
Headlight Assembly.....................................................64
Wiring Diagram .................................................................65