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Arctic Cat Sno Pro 120 2011, Service Manual

The Arctic Cat Sno Pro 120 2011 is a high-performance snowmobile perfect for riders of all ages. Ensure your sled is running at peak performance by downloading the free Service Manual from manualshive.com. This comprehensive manual provides all the information you need to keep your sled in top condition.

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6-23

6

742-196D

15. Install the shift actuator and secure with the three

torx-head cap screws. Tighten to 41 in.-lb. Install the

gear indicator switch; then tighten securely.

ZJ186A

16. Pour 12 fl oz of Arctic Cat Synthetic ACT Drive

Fluid into the drain/fill hole; then install the plug.

Tighten to 12 ft-lb.

DISASSEMBLING GEAR CASE 
(w/o Reverse)

1. Remove the 13 torx-head cap screws securing the

gear case cover to the gear case assembly and  insert

two flat-blade screwdrivers into the notches on the

gear case; then working back and forth, pry the cover

up and off the gear case.

744-133A

744-134A

2. Drain the gear case fluid into a suitable container.

3. With a cap screw threaded into the input shaft and

using a soft hammer, drive the input shaft out of the

gear case cover.

MS329

4. Using a suitable bearing press and fixture, press the

input shaft bearing and seal out of the gear case

cover. Account for a bearing and a seal.

MS330

5. Remove the transfer gear assembly from the gear

case.

CAUTION

Do not add more or less than the recommended
amount of drive fluid to the gear case or damage to
the gear case will occur.

Manual

Table of Contents

Summary of Contents for Sno Pro 120 2011

Page 1: ...ile decals display the words Warning Caution and Note to emphasize impor tant information The symbol WARNING identifies personal safety related information Be sure to follow the directive because it d...

Page 2: ...rack Brake Systems 7 Rear Suspension 8 Steering and Body Note To navigate through this manual use the PAGE UP PAGE DOWN buttons on the keyboard click on the Table of Contents bookmarks on the left sid...

Page 3: ...ns 2 Stroke 1 10 Arctic Power Valve APV System Specifications 2 Stroke 1 10 Oil Consumption Specifications 2 Stroke 1 11 EFI Specifications 1 11 Throttle Valve Angle Specifications 1 11 Fuel Pump Spec...

Page 4: ...taining up to 10 ethanol or up to 15 MTBE are acceptable gasolines Do not use gaso lines containing methanol NOTE On the 500 600 1000 cc models for optimum performance do not exceed the recommended 87...

Page 5: ...quire calibra tion changes for varying altitudes High altitude information decal s are located beneath the hood of the snowmobile on the Crossfire M Series and on the belt guard on the remaining model...

Page 6: ...ture increases The turbocharger output must be regulated to maintain the optimum manifold pressure throughout the designed operat ing range This is accomplished by regulating the volume of exhaust gas...

Page 7: ...ugh its range of motion causing the track to sag in the middle and rub on the top part of the rear suspension arm TRACK Carefully matching the riding requirements to the type of track will ensure the...

Page 8: ...d driven pulley 12 Apply light oil to the shafts of the shock absorbers then lubricate all grease fittings front and rear sus pension spindles and upper steering shafts on the Crossfire M Series or st...

Page 9: ...harge the battery then connect the battery cables making sure to connect the positive cable first Test the electric start system 14 Inspect the entire brake system all controls head light taillight br...

Page 10: ...and adjusted during the After Break In Checkup A checklist to assist you with this service follows After Break In Checkup Checklist Below is a recommended list of items to check after the break in per...

Page 11: ...Number Non Turbo Turbo AA11L5 AB11L5 Displacement 1056 cc No of Cylinders 2 Bore x Stroke 98 x 70 Cooling System Liquid Spark Plug NGK MR8AI 9 Spark Plug Gap 0 031 0 035 Piston Skirt Cylinder Clearanc...

Page 12: ...l activate once at APV cycle RPM If the servo cycles three times cable length adjustment or valve inspection is required NOTE The 800 cc and 1000 cc have a three stage exhaust valve system The stages...

Page 13: ...uel Pressure 1100 cc Non Turbo 43 5 psi Fuel Pressure 1100 cc Turbo 36 0 psi Idle 55 0 psi Full Boost Model TPS TOOL DC VOLTS ANALYZER TOOL DC VOLTS 500 cc Full Closed 0 412 0 414 N A Idle 0 710 0 818...

Page 14: ...RPM 0 040 For timing verification use a dial indicator and scribe a mark on the flywheel for 13 BTDC 0744 905 570 cc BTDC 20 2000 RPM 0 099 0742 217 600 cc BTDC 15 2000 RPM 0 059 For timing verificati...

Page 15: ...1 13 1 1000 cc BTDC 14 1800 RPM 0 057 0744 034 Manual Table of Contents...

Page 16: ...on Timing Sensor 148 222 ohms green white brown green Lighting Coil 0 12 0 18 ohm yellow yellow Spark Plug Cap 4000 6000 ohms cap end cap end Description Test Value Test Connections Voltage Regulator...

Page 17: ...s blue white blue white Fuel Pump Coil 1 52 2 28 ohms orange orange Spark Plug Cap 4000 6000 ohms cap end cap end Description Test Value Test Connections Chassis Control Unit 10 15 DC Volts red blue l...

Page 18: ...Spark Plug Cap 4000 6000 ohms cap end cap end Description Test Value Test Connections Voltage Regulator Rectifier F Series 10 15 DC Volts red blue brown Voltage Regulator Rectifier CFR Crossfire M Ser...

Page 19: ...Coil 2 1 4 ohms red green brown green Crankshaft Position Sensor 173 211 ohms blue white green white Coolant Temperature Sensor 2 3k 2 6k ohms yellow black ground Injection Coil Starter Relay 3 6 ohms...

Page 20: ...0g Orange 44 40 0627 060 42 4600 81 8300 56 34T 64T 64 56 CFR 1000 0 3000 Purple 85 0g Orange 46 40 0627 060 42 4600 81 8300 54 34T 66T 66 54 F5 0 5000 Black Red 58 0g White 42 36 0627 067 33 3500 78...

Page 21: ...1 134 137 63 57 91 94 97 100 103 106 109 112 115 118 121 124 127 130 133 62 58 88 91 94 97 100 103 106 108 111 114 117 120 123 125 128 61 59 85 88 91 94 97 99 102 105 108 110 113 116 119 121 124 60 60...

Page 22: ...ies Sno Pro Z1 Turbo Sno Pro Z1 EXT 8 25 100 250 Model Wire Diameter A Angle B of Coils Coil Width C Length D Length E F570 F5 Z1 405 85 6 75 3 65 18 50 5 50 Bearcat 570 T Series 405 70 6 75 4 00 18 5...

Page 23: ...e Rails 5 63 0 787 T Series Idler Arm 7 12 1 181 F Series Idler Arm 5 63 1 181 Crossfire M Series Idler Arm 6 38 1 000 All Inside Rear Axle 7 12 0 787 F Series T Series Z1 Outside Front 5 63 0 787 F S...

Page 24: ...1 22 570 cc 570 ENG10 Torque Specification Tolerances Torque ft lb Tolerance 0 15 20 16 39 15 40 10 Manual Table of Contents...

Page 25: ...1 23 1 570ENG09 Manual Table of Contents...

Page 26: ...1 24 500 cc 500CC1A09 Torque Specification Tolerances Torque ft lb Tolerance 0 15 20 16 39 15 40 10 Manual Table of Contents...

Page 27: ...1 25 1 500CC2A_10 Manual Table of Contents...

Page 28: ...1 26 600 cc 600CC1B_09 Torque Specification Tolerances Torque ft lb Tolerance 0 15 20 16 39 15 40 10 Manual Table of Contents...

Page 29: ...1 27 1 600CC2A_11 Manual Table of Contents...

Page 30: ...1 28 800 cc 800_10_1 Torque Specification Tolerances Torque ft lb Tolerance 0 15 20 16 39 15 40 10 Manual Table of Contents...

Page 31: ...1 29 1 800_11_2 Manual Table of Contents...

Page 32: ...1 30 1000 cc 1000_10_2 Torque Specification Tolerances Torque ft lb Tolerance 0 15 20 16 39 15 40 10 Manual Table of Contents...

Page 33: ...1 31 1 1000_10_1 Manual Table of Contents...

Page 34: ...1 32 1100 cc 1100ccJAG11 Torque Specification Tolerances Torque ft lb Tolerance 0 15 20 16 39 15 40 10 Manual Table of Contents...

Page 35: ...1 33 1 1100ccZ1RV10 Manual Table of Contents...

Page 36: ...1 34 Engine Torque Patterns 1100 cc 1100TorquePattern Manual Table of Contents...

Page 37: ...Gas Tank Steering Support 96 in lb A Arm Upper Chassis 30 A Arm Lower Chassis 30 A Arm Upper Spindle 30 A Arm Lower Crossfire Spindle 40 A Arm Lower M Series Spindle 30 Shock Absorber Spindle 20 Sway...

Page 38: ...Support Rail 20 Inner Idler Wheel Rail 40 Skid Frame Tunnel 40 M Series Item Secured to Torque ft lb Wear Strip Rail 50 in lb End Cap Rail 80 in lb Mounting Block Rail 20 Inner Idler Wheel Mounting Bl...

Page 39: ...FR M Series 800 1000 Crossfire 800 2 15 Engine Removing Installing F Series 500 600 800 2 23 Engine Servicing 570 cc 2 37 Engine Servicing 500 600 cc 2 54 Engine Servicing 800 1000 cc 2 76 Engine Bear...

Page 40: ...ock nut and washer securing the resonator to the front upper frame and remove the resonator 4 On the XT remove the cap screws and lock nuts securing the oil reservoir to the headlight support bracket...

Page 41: ...gine forward enough to remove the cap screws C securing the rear MAG side engine mounting bracket to the engine then remove the bracket 15 Remove the lock nuts and cap screws D securing the snubber br...

Page 42: ...te the engine allowing enough room to lift it up and out of the front of the chassis FZ013 21 Remove the two cap screws securing the rear PTO side crankcase snubber bracket FZ022A 22 Remove the four c...

Page 43: ...ontain any oil spilled during the bleeding process 7 With the throttle cable and fuel lines properly routed install the flange clamps to the intake flanges then install the carburetors and secure with...

Page 44: ...he reservoir Secure with the cap screws and lock nuts NOTE On the Bearcat 570 make sure the ground wire is on the rear upper stud After the shield is installed secure with the wire with the lock nut 1...

Page 45: ...the engine and warm up to operating temperature Verify that all compo nents are functioning properly and that coolant is cir culating through the cooling system properly 28 Verify the tightening torqu...

Page 46: ...the chassis Proceed to Ser vicing Top Side Components 1 Remove the belt guard and disconnect the exhaust temperature sensor then remove the cable ties secur ing the sensor harness to the chassis NOTE...

Page 47: ...to allow room to disconnect the oil injection cable control rod from the oil injection pump CM028A 12 Loosen the clamps securing the coolant hoses con nected to the cylinders beneath the exhaust port...

Page 48: ...note the routing of the harnesses and the location of cable ties 21 Remove the lower coolant hose then move the engine toward the left and up to allow enough room to remove the remaining coolant hose...

Page 49: ...rame from step 5 to 20 ft lb NOTE Install the cap screw and lock nut D secur ing the engine mounting bracket to the front lower mounting bracket Tighten to 20 ft lb 7 Tighten the MAG side engine cap s...

Page 50: ...15 ft lb CM035 15 Install the side plate brace onto the chassis and secure the front of the brace with the four cap screws coated with blue Loctite 243 Tighten securely CM210A NOTE Install the two fro...

Page 51: ...Secure the belt guard see Section 6 26 With the air silencer properly positioned on the throt tle body assembly secure the silencer with the torx head cap screw CM026A 27 Place the hood into position...

Page 52: ...functioning properly and that coolant is circulating through the cooling system properly 33 Allow the engine to cool then check the coolant level and add coolant as necessary Verify the tight ening to...

Page 53: ...ed from the chassis Proceed to Ser vicing Top Side Components 1 Remove the belt guard and disconnect the exhaust temperature sensor then remove the cable ties secur ing the sensor harness to the chass...

Page 54: ...silencer CM026A 12 Pull the air silencer boot forward enough to gain access to the throttle body assembly CM027 13 Loosen the flange clamps securing the throttle body assembly to the flange then move...

Page 55: ...er from the engine Secure it out of the way in the engine compartment CM137 18 Remove the wiring harness wrap then disconnect the ignition main harness connectors and the temper ature sensor connector...

Page 56: ...unt for nuts and gas kets 27 Remove the clamp securing the coolant supply hose from the cylinder head to the water pump Then remove the hose from the engine CM181 Installing 1 Install the MAG side eng...

Page 57: ...to 20 ft lb and the front lower mounting bracket cap screw and lock nut B from step 3 to 30 ft lb 9 Before connecting the wiring harness plug ins clean the connectors and apply Dielectric Grease then...

Page 58: ...m to the throttle body pulley then verify oil injection pump synchroniza tion see Section 4 CM129B 16 Connect the two coolant hoses to the throttle body assembly then secure with the clamps CM131A 17...

Page 59: ...drive clutch into position on the crankshaft and secure with the cap screw and lock washer Tighten to 55 ft lb 1000 cc or 51 ft lb 800 cc NOTE To aid in proper tightening of the drive clutch cap scre...

Page 60: ...he heat shield and secure it to the chassis and oil tank with the three cap screws then tighten the two cap screws to the oil tank to 26 in lb Tighten the remaining cap screw to 20 ft lb 30 Start the...

Page 61: ...pin clip and all springs securing the expansion chamber and resonator then remove these components from the engine compartment Account for the two exhaust gaskets NOTE On the LXR disconnect the negati...

Page 62: ...ide the driven pulley off the gear case input shaft Account for alignment washers FS192 NOTE If the driven pulley is tight on the driven shaft pull the driven pulley off using the Driven Pul ley Pulle...

Page 63: ...osen the clamps securing the coolant hoses connected to the cylinders beneath the exhaust port and the throttle body assembly then remove the vent tube from the top of the cylinder head CM030A 20 On t...

Page 64: ...the 800 cc at the coolant filler neck bracket disconnect the knock sensor wiring connec tor and slide the wiring out of the cable tie FS212A 24 Remove the harness wrap and disconnect all igni tion ma...

Page 65: ...n remove the bracket Account for the torque bumper 30 On the 500 600 cc remove the two cap screws D securing the front engine plate to the chassis then remove the cap screw E securing the MAG side eng...

Page 66: ...e mounting bracket to the engine 37 Remove the four cap screws G securing the front engine plate to the engine NOTE On the 500 600 cc LXR remove the pinion bracket assembly from the engine FS190A Inst...

Page 67: ...e engine with four cap screws G coated with blue Loctite 243 Tighten to 50 ft lb 4 Place the engine into the engine compartment from the MAG side then tip the engine forward and sup port the engine in...

Page 68: ...lip is centered in position FS195A 9 Using the illustration following step 2 install the cap screw and lock nut A and the lower cap screw B securing the PTO side bracket to the chassis then install th...

Page 69: ...position and secure the starter with the cap screws In a crisscross pattern tighten to 96 in lb FS180 FS210 15 Connect the oil supply hose A to the oil injection pump then remove the oil bleed plug B...

Page 70: ...he cable adjusting nut is adjusted correctly the throttle lever will move approximately 1 8 in before the oil injection pump control arm begins to move 0742 854 0744 528 17 On the 500 600 cc install t...

Page 71: ...hen connect the spark plug wires to the spark plugs NOTE On the 800 cc connect the knock sensor wir ing to the wiring harness then secure the connector to the coolant filler neck bracket with the push...

Page 72: ...ws to 96 in lb FS182A NOTE When installing the bracket plates the wider end of the plate must be directed up FS200A 30 Install the air silencer onto the throttle bodies making sure the dual intake boo...

Page 73: ...ion on the chassis FS203A NOTE On the LXR secure the negative battery cable to the battery 39 Install the exhaust resonator and secure to the upper frame with the tab washer and the hairpin clip 40 Pl...

Page 74: ...rews securely then close the left side and right side access panels and close the hood 0743 777 CAUTION If the engine had a major overhaul or if any major com ponent was replaced proper engine break i...

Page 75: ...t Service Parts Department Disassembling Engine 1 Remove the nuts lock washers and washers secur ing the intake flange assembly Account for the gas kets insulators and the heat deflector 2 Remove the...

Page 76: ...hers MD0277 MD0067 8 Remove the rubber insulator grommet from the crankcase then remove two Phillips head cap screws securing the ignition timing sensor MD0075 MD0073 9 Remove the three Allen head cap...

Page 77: ...e spark plugs MD0083 13 Remove the eight cap screws two nuts and two washers securing the cylinder head to the cylinders then remove the cylinder head Discard the cylinder head gasket MD0289 14 Remove...

Page 78: ...ston pin using Piston Pin Puller MD0094 NOTE The shoulder sides of the piston pin bearing washers must seat to the bearing MD0251 MD0208 NOTE Always replace with new piston rings and as a complete set...

Page 79: ...rews securing the crankcase halves Note the location of the differ ent sized cap screws 21 Separate the crankcase halves by installing two of the cap screws in opposite corners leaving the heads appro...

Page 80: ...aning solvent 3 Inspect the cylinders for pitting scoring scuffing and corrosion If marks are found repair the surface with a Ball Hone and honing oil NOTE To produce the proper 45 crosshatch pat tern...

Page 81: ...by placing each crankcase half on the surface plate covered with 400 grit wet or dry sand paper Using light pressure move each half in a fig ure eight motion Inspect the sealing surfaces for any indi...

Page 82: ...pump drive gear for any signs of worn or chipped teeth If either condition exists replace the gear NOTE Lubricate bearings thoroughly prior to assembly REMOVING OUTER CRANKSHAFT BEARINGS NOTE Steps 1...

Page 83: ...er of the cage Place the reed stopper assembly into position and secure with the three machine screws coated with blue Loctite 243 Tighten the machine screws to 48 in lb MD0213 6 When installing the r...

Page 84: ...om the bottom of each cylinder 2 Measure the corresponding piston skirt diameter at a point 1 cm above the piston skirt at a right angle to the piston pin bore Subtract this measurement from the measu...

Page 85: ...he indicator contact point against the crank shaft location point B MAG end from the crank shaft end Zero the indicator and rotate the crankshaft slowly Note the amount of crankshaft runout total indi...

Page 86: ...wel pins 5 Evenly apply a thin coat of Three Bond Sealant to the entire bottom half crankcase sealing surface NOTE Use only Three Bond Sealant to seal the crankcase halves MD0203 6 Install crankcase l...

Page 87: ...re the gasket is properly oriented so the dowel pins will fit through the holes easily 12 Rotate each piston ring until the ring ends are prop erly positioned with the pins in the ring grooves then ap...

Page 88: ...e steps to 19 ft lb using the pattern shown then tighten the flange nuts to 21 ft lb MS384 MS384 0738 291 15 Install the spark plugs then tighten to 19 ft lb Pres sure test the engine see Section 3 MS...

Page 89: ...r wiring through the hole in the crankcase then position the ignition tim ing sensor and install two Phillips head cap screws coated with blue Loctite 243 Tighten the cap screws to 48 in lb MD0074 MD0...

Page 90: ...he special washers install the front exhaust side cooling shroud and tighten to 96 in lb Install the rubber spark plug grommets then tighten the cap screws securely MD0269 MD0268 26 Lubricate the oil...

Page 91: ...with blue Loctite 243 to 48 in lb MD0294 NOTE For assembling purposes always use new O rings lubricated with oil on the oil injection pump and retainer MD0090 29 Install the first set of intake gasket...

Page 92: ...he engine Account for flange nuts and gaskets then remove the clamp securing the coolant supply hose from the cyl inder head to the water pump Remove the hose from the engine 2 Using the Flywheel Span...

Page 93: ...g the stator lead wire then remove the cap screw FC018 6 On the 600 cc remove the Allen head cap screws securing the magneto case to the crankcase Account for four alignment pins NOTE Note the differe...

Page 94: ...a drain tray to allow residual coolant to drain from the cylinder crankcase water jacket 12 On the 500 cc remove the eight nuts securing the cylinders to the crankcase then using a rubber ham mer gen...

Page 95: ...ecuring the thermostat cap then remove the cap gasket and thermostat FC032 19 Remove the six screws securing the water pump cover to the crankcase and remove the cover Account for the O ring gasket an...

Page 96: ...r removing the seals use care not to allow the bearings to slide off the crankshaft 27 Remove the oil injection pump water pump drive shaft from the lower crankcase half Account for the thrust washer...

Page 97: ...ents use the following proce dure 1 Remove the cap screws securing the left side steer ing support and the side plate brace to the chassis then remove the brace CM211A CM212A 2 Remove the three cap sc...

Page 98: ...their studs Account for gasket s and any alignment pins CM217 NOTE If servicing the MAG side only the PTO side cylinder must be removed NOTE After the cylinders have been removed cover the crankcase...

Page 99: ...the remaining circlips NOTE The indicator dot A is found on the piston dome CM194A CM195B 4 Rotate each piston ring until the ring ends are prop erly positioned on either side of the ring keeper then...

Page 100: ...ables to the ser vomotor CM219 CM220 9 Connect the two coolant hoses on the cylinders beneath the exhaust ports then install the coolant hose and breather hose onto the cylinder head CM214A 10 Apply a...

Page 101: ...petroleum based oil Thoroughly clean the cylinders after honing using detergent soap and hot water and dry with com pressed air then immediately apply oil to the cylinder bores If a bore is severely...

Page 102: ...any indication of high spots A high spot can be noted by a bright metallic finish Correct any high spots by continuing to move the half in a figure eight motion until a uniform bright metallic finish...

Page 103: ...VE ASSEMBLY 1 Inspect the reed valves stoppers and valve blocks for cracks or any deterioration CM162 2 Wash the reed valves stopper and cage assembly in parts cleaning solvent and blow dry 3 Inspect...

Page 104: ...times Remove both pieces of solder from the cylin der and measure the opposite squeezed ends with a micrometer Record reading NOTE Measure from PTO to MAG side of the piston to accurately measure the...

Page 105: ...d bore then remove the gauge and measure it with a micrometer AN061 2 The diameter measurement must be within 1 0631 1 0634 in CRANKSHAFT RUNOUT 0742 727 1 Using the V Blocks support the crankshaft on...

Page 106: ...position the inner water pump shaft seal onto the seal driver and gently tap the seal down into position NOTE Grease must be applied to the lips of the inner seal before installation MS986A NOTE The...

Page 107: ...ottom half of the crankcase sealing surface CM036A NOTE At this point if the coolant temperature sen sor was removed install the sensor threads coated with white Loctite 575 and tighten to 18 ft lb FC...

Page 108: ...alling 16 With a new O ring in place install the oil injection pump making sure the pump shaft slot and pump driven gear shaft align Secure with two screws coated with blue Loctite 243 Tighten the two...

Page 109: ...t into the breather hole in the crankcase If sealant gets into the hole carefully remove before proceeding FC072B FC072A NOTE Sealant is only required on the crankcase seam 21 Position the O ring into...

Page 110: ...each piston so the letter on the top inclined surface of each ring faces the dome of the piston 726 306A 26 Apply oil to the connecting rod small end bearings then install the small end bearings Inst...

Page 111: ...rankcase NOTE The cylinders should slide on easily DO NOT force the cylinders on FC076 31 On the 500 cc secure each cylinder by installing the eight nuts DO NOT TIGHTEN AT THIS TIME 32 On the 600 cc s...

Page 112: ...ate pattern shown Tighten the spark plugs to 19 ft lb 0738 204 NOTE On the 500 cc after tightening the 8 mm cap screws tighten the two remaining 6 mm cap screws to 96 in lb 0738 205 NOTE Lubricating t...

Page 113: ...heel then slide the flywheel onto the crankshaft making sure the keyways match Remove the puller bolts NOTE Before installing the flywheel be sure to wipe the crankshaft and flywheel tapers clean usin...

Page 114: ...performing service procedures in this engine section NOTE Special tools are available from the Arctic Cat Service Parts Department Disassembling NOTE When disassembling top side components mark MAG s...

Page 115: ...CM142A 5 Remove the Allen head cap screw A securing the stator lead wire plate to the crankcase then remove the Allen head cap screws B securing the timing sensors remove the sensors and account for t...

Page 116: ...d by bend ing the lock plate tabs down and unthreading the sen sor 10 Remove the cap screws with O rings securing the cylinder head then separate from the cylinders Account for the O rings NOTE When r...

Page 117: ...prevent the connect ing rods from damaging the crankcase 15 Disconnect the intake flange oil lines from the oil pump then remove the cap screws securing the intake flanges Remove the intake flanges a...

Page 118: ...the water pump side of the engine then remove the two cap screws B from the magneto housing On the 1000 cc remove the one crankcase cap screw C located above the thermostat housing 742 198B 742 197B 2...

Page 119: ...When replacing the inner water pump seals use the recommended Water Pump Bearing and Seal Tool Kit only 27 Place the crankcase on the bench with the water pump side down Using the long seal driver dri...

Page 120: ...op side components use the following proce dure 1 Disconnect the exhaust temperature sensor then cut the cable tie securing the sensor harness to the APV cable 2 Remove the expansion chamber and reson...

Page 121: ...ing a soft hammer gen tly tap the cylinders and remove from the crankcase by lifting them straight up off their studs Account for gasket s and alignment pins CM192 NOTE If servicing the MAG side only...

Page 122: ...pins into position on the crankcase 2 Install the piston rings on each piston so the letter on the top inclined surface of each ring faces the dome of the piston 726 306A 3 Apply oil to the connecting...

Page 123: ...ecure each cylinder by installing the four nuts and four cap screws DO NOT TIGHTEN AT THIS TIME NOTE Never reuse cylinder cap screws Always replace with new cap screws NOTE The cylinders will be tight...

Page 124: ...der O rings to be installed CM191 14 Lubricate the O rings with a light coat of grease then install the two cylinder O rings on the top of each cylinder making sure they are correctly posi tioned in t...

Page 125: ...6 in lb CM147A 19 Install the side plate brace then secure with the cap screws coated with blue Loctite 243 NOTE Install the two front lower cap screws first to properly align the remaining cap screws...

Page 126: ...s 4 Inspect each piston for seizure marks or scuffing Repair with 400 grit wet or dry sandpaper and water or honing oil AN135 NOTE If scuffing or seizure marks are too deep to correct with the sandpap...

Page 127: ...pin must also be replaced FC040 4 Inspect the oil injection pump drive gear for any signs of worn or chipped teeth If either condition exists replace the gear NOTE Lubricate bearings thoroughly prior...

Page 128: ...ces of solder down through the spark plug hole and push them up against the inner cylinder bore towards the MAG side and PTO side of the cylinder 3 Pull the recoil rope and crank the engine over sever...

Page 129: ...port of its respective cylinder Use the piston to position each ring squarely in each cylinder 2 Using a feeler gauge measure each piston ring end gap Acceptable ring end gap must be within 0 0120 0...

Page 130: ...and rotate the crankshaft slowly Note the amount of crankshaft runout total indicator reading FC046 4 Position the indicator contact point against the crank shaft at location point C center Zero the i...

Page 131: ...O023A CM165C 6 Place the crankshaft end bearings into position mak ing sure the bearing retaining pin hole is positioned inward NOTE The bearing retaining pin hole is the hole that does not go entirel...

Page 132: ...cap screws 1 10 in two steps from 13 ft lb to 31 ft lb using the appropriate pattern shown 742 198A 742 197A 13 On the 800 cc tighten cap screw 11 to 96 in lb then turn the engine right side up and t...

Page 133: ...7A NOTE For assembling purposes always use a new O ring lubricated with oil on the oil injection pump 19 Place the lower union assembly with new gaskets into position and secure with the gaskets and u...

Page 134: ...with a cap screw and washer Be sure the rubber side of the washer is lubricated with a light coat of grease and directed toward the impeller Apply blue Loctite 243 to the threads of the cap screw and...

Page 135: ...the cap screws to 96 in lb CM157A CM155A 28 Install the dowel pins into the crankcase then place the cylinder base gasket into position on the crank case 29 Install the piston rings on each piston so...

Page 136: ...the crankcase then using a ring compressor or the fingers compress the rings and slide the cylinder over the piston Remove the piston holder and seat the cylinder firmly onto the crankcase NOTE The c...

Page 137: ...en the cap screws in two steps to 25 ft lb using the appropriate pattern shown 0742 200 0742 199 NOTE At this point on the 800 cc install the spark plugs and on both models tighten the spark plugs to...

Page 138: ...de the flywheel onto the crankshaft making sure the keyways match CM180 NOTE Before installing the flywheel be sure to wipe the crankshaft and flywheel tapers clean using a clean lint free towel 46 Ap...

Page 139: ...ly a thin coat of high temperature silicone seal ant to each exhaust port then install the exhaust gas kets 51 Apply a thin coat of high temperature silicone seal ant to the mating surfaces of the exh...

Page 140: ...orx head cap screws A securing the console to the chassis then lift up the rearward end of the console and disconnect the console har ness plug in Remove the console 743 945A 3 Remove the two screws s...

Page 141: ...the head of the puller Repeat this procedure until the drive clutch releases 10 Using a 9 16 in socket and extension remove the cap screw securing the driven pulley to the input shaft ZJ250A NOTE Afte...

Page 142: ...two cap screws and lock nuts A secur ing the left side upper frame to the front end Remove the one remaining cap screw and lock nut B securing the upper frame to the left side skid plate ZJ025A NOTE...

Page 143: ...ostat housing TZ075A 19 On the turbo models and the non turbo TZ1 remove the two cap screws and lock nuts securing the cool ant separator tank assembly then disconnect the two remaining hoses from the...

Page 144: ...he right side cap screw ZJ020A NOTE On the Bearcat Z1 XT remove the four cap screws securing the close off panel and account for the exhaust pipe mounting tab A from the left front cap screw TZ078A 24...

Page 145: ...res from the spark plugs 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 Remove...

Page 146: ...6 Using an appropriate engine hoist lift the engine from the proper lift points with oil reservoir from the chassis 741 658A 743 993A NOTE Lift the engine at an angle with the PTO side upward to allow...

Page 147: ...bo models only 5 Remove the three lock nuts and washers A securing the bracket of the turbocharger to the engine then loosen the lock nuts B securing the bracket to the turbocharger 743 780C 6 Remove...

Page 148: ...gine then remove the cap and thermo stat and account for the harness bracket from the lower cap screw ZJ030A NOTE Note the position of the thermostat bypass check valve for assembling purposes ZJ091A...

Page 149: ...e 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 ZJ03...

Page 150: ...9 Remove the cap screws securing the camshaft covers to the cylinder head then with the covers removed remove the timing chain from the camshaft sprock ets Remove the camshafts from the cylinder head...

Page 151: ...urposes 741 584B 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...

Page 152: ...44 NOTE Because the connecting rods and connect ing rod caps are unique note the I D marks and keep all associated parts together for assembling pur poses NOTE For assembling purposes note that the do...

Page 153: ...s worn excessively cracked or damaged in any way replacement is nec essary PISTON ASSEMBLY NOTE Oversized pistons are available allowing the cylinder to be bored oversized NOTE Whenever a piston rings...

Page 154: ...piston 0738 532 Measuring Piston Skirt Cylinder Clearance 1 Measure the cylinder front to back in six places using a cylinder bore gauge Record the largest number 2 Measure the diameter of the corresp...

Page 155: ...are no less than 90 from one another MEASURING CONNECTING ROD SMALL END BORE INSIDE DIAMETER 1 Using a small bore gauge measure the connecting rod small end bore inside diameter 2 Measurement must be...

Page 156: ...EASURING CRANKSHAFT MAIN ROD JOURNALS Bearing Surfaces 1 Using a micrometer measure each main and con necting rod bearing journal from along its length and 180 from the first measurement Measurement m...

Page 157: ...ll making sure the oil relief A is directed toward the crankshaft ZJ074A NOTE Always install the correct thrust bearing from above on mag side then use proper bearing from the following chart on the P...

Page 158: ...e other piston connecting rod assembly 3 With the piston rings installed lubricate each piston and cylinder with engine oil then with the dots on the top of the pistons directed towards the exhaust si...

Page 159: ...then with the grooved side of the bearings A facing out ward towards the crankshaft counterweights install the first bearing and roll it into place Push the crank shaft towards the installed bearing...

Page 160: ...oil pump drive gear 741 596A 16 With the crankshaft at bottom dead center install the front counterbalancer with the single dot B on the face of the crankshaft and balancer gears directly in line with...

Page 161: ...With a new O ring install the oil cooler washer and the union bolt then tighten to 52 ft lb ZJ077 26 With a new gasket install the oil pan and install the different length cap screws as noted in disa...

Page 162: ...sequence A Cap screws 1 6 initially to 18 ft lb B Flange nuts 7 8 to 18 ft lb C Flange nuts 9 10 to 10 ft lb D Flange nuts 11 12 to 18 ft lb E Cap screws 13 14 to 96 in lb F Cap screws 1 6 in two step...

Page 163: ...y timed install the camshaft covers along with cam chain ten sioner guide number two then using the pattern shown tighten the twelve cap screws to 84 in lb 741 624A 38 Install the cam chain tensioner...

Page 164: ...ecure with the four cap screws B Tighten to 84 in lb 0742 125 44 With the two pins installed in the engine case first install the starter torque limiter A and spacer B then install the inner spacer C...

Page 165: ...re to install the thermostat with the bypass check valve directed in the up position ZJ091A ZJ092 48 On the non turbo models install the two intake flanges then secure with the four cap screws Tighten...

Page 166: ...he lock nuts and tighten only until snug TZ063A 52 Install the lower heat shield onto the turbocharger and exhaust manifold with the cap screws Tighten to 60 in lb 53 With the gaskets in place install...

Page 167: ...and mount are in proper alignment then lower the engine completely into the chassis 3 Secure the engine to the chassis with lock nut C and long through bolt B on the front engine mount then install th...

Page 168: ...curely ZJ024A NOTE Prior to securing the left side upper frame to the steering support make sure the ECU harness is directed below the upper frame 10 Install the ECU to the left side upper frame and s...

Page 169: ...ame gas hose clip and air silencer to the steering support then install the remaining cap screw B securing the air silencer to the upper frame 743 995A 15 Install the four remaining cap screws securin...

Page 170: ...ont end with the two cap screws A noting the mounting tab non turbo only B is installed with the right side cap screw Tighten cap screws securely ZJ020A NOTE On the Bearcat Z1 XT install the close off...

Page 171: ...g the drive clutch be sure to wipe both the crankshaft taper and clutch mounting taper clean using a clean towel 30 Place the drive clutch into position on the crankshaft and secure with the cap screw...

Page 172: ...p beneath the coolant tank to purge air from the oil hose ZJ004A NOTE When air can no longer be heard purging from oil pump bleed tighten the bleed bolt to 7 5 ft lb C Without starting the engine plac...

Page 173: ...nt leaks in the engine compartment then shut the engine off and allow it to cool 40 Repeat steps 38 39 at least two more two times more if necessary until no air is in the cooling sys tem 41 Install t...

Page 174: ...cracked broken pinched discon nected 8 Carburetors adjusted incorrectly dirty damaged 9 Primary compression crankcase absent 1 Fill tank 2 Open shut off valve 3 Replace service hose 4 Remove obstructi...

Page 175: ...ructed broken pinched 3 Head gasket s burned out 4 Cylinder head loosening 5 Spark plugs loose 6 Impulse hose cracked 7 High tension wires coil faulty 1 Remove obstruction replace in line fuel filter...

Page 176: ...pump faulty 6 Fuel hose broken pinched 7 Gas tank vent hose obstructed 8 Pick up valve s obstructed damaged 9 Primary compression absent 10 ECU CCU faulty 1 Fill tank 2 Replace dropping resistor 3 Re...

Page 177: ...ce replace high tension leads coil 5 Replace ECU CCU 6 Repair fuel regulator injector s 7 Replace bleed adjust oil injection pump Problem Engine Four Cycles Floods Excessively Condition Remedy 1 ECU L...

Page 178: ...oning 5 Spark plugs fouled damaged 6 Idle speed control ISC valve not functioning 7 ECU faulty 8 Ignition timing sensor faulty 1 Check all ground connections clean and tight 2 Repair replace connect w...

Page 179: ...ompression low absent 7 Water pump thermostat damaged faulty 1 Add coolant 2 Remove obstruction 3 Troubleshoot adjust drive system 4 Clean replace rings pistons 5 Remove obstruction 6 Repair replace d...

Page 180: ...Flow Chart 1100 cc 3 21 Liquid Cooling System 500 600 800 1000 cc 3 21 Liquid Cooling System 1100 cc 3 22 Cooling System Schematics 3 25 Recoil Starter 500 600 cc 3 27 Recoil Starter 570 800 1000 cc 3...

Page 181: ...1 Remove the cap screws securing the water pump cover then remove the cover and account for the O ring seal FC118 2 Remove either lower union cap screw securing the lower check valve assembly Remove...

Page 182: ...7 Using a pair of snap ring pliers remove the snap ring securing the inner seal in the crankcase FC124 8 Using the hooked end of the long seal driver pull the inner seal free of the crankcase ASSEMBL...

Page 183: ...7 Position the shim on the oil pump end of the shaft then with the O ring installed on the retainer install the oil injection pump retainer FC130A NOTE For assembling purposes always use new O rings...

Page 184: ...e alignment pins into the crankcase if removed FC133A NOTE Do not allow sealant into the breather hole in the crankcase If sealant gets into the hole carefully remove before proceeding FC072B 12 Posit...

Page 185: ...cover and account for the O ring seal and two dowel pins FS223A 3 Remove the cap screw A securing the lower check valve to the oil pump and account for the two gas kets then remove the two cap screws...

Page 186: ...etainer and shaft flange FS226 7 Using the long seal driver drive the water pump mechanical seal from the crankcase FS227 8 Using a pair of snap ring pliers remove the snap ring securing the oil seal...

Page 187: ...at the end of the shaft Twist the shaft while pushing it through the oil and water pump seals until the shaft gear engages with the drive gear of the crankshaft then remove the tool FS233A IO025B 7 Po...

Page 188: ...ew and tighten to 48 in lb FS225 10 Apply sealant to the crankcase seam then install the alignment pins into the crankcase if removed FC133A 11 Position the O ring into the water pump cover then insta...

Page 189: ...ith parts clean ing solvent then dry with compressed air ASSEMBLING 0742 104 NOTE For this procedure use Water Pump Bearing and Seal Tool Kit 1 Using the appropriate sized installation tool install th...

Page 190: ...must not drop at a rate of more than 1 psi per minute E If the pressure drops faster than specified inspect for an air leak with soapy water or by completely submerging the pressurized engine in clean...

Page 191: ...tappet shim is purged to maintain an accurate clearance reading 4 Rotate the engine until the camshaft lobe of the valve being measured is directly away from the tappet 5 Using an appropriate thickne...

Page 192: ...the throttle body fuel rail then loosen the intake flange clamps securing the throttle bodies Remove the throttle bodies and place them on the tunnel NOTE After removing the throttle bodies close off...

Page 193: ...m Selection Table Exhaust or Intake and use this procedure A Find the Measured Tappet Clearance from step 5 in the left side vertical column of the table B Find the Present Shim Size three digit numbe...

Page 194: ...3 15 3 SNO2152 Manual Table of Contents...

Page 195: ...3 16 SNO2153 Manual Table of Contents...

Page 196: ...on the side of the tension adjuster ZJ084 13 With the timing marks A on the face of the exhaust camshaft gear properly aligned place the camshaft into position on the cylinder head 0741 801 14 With t...

Page 197: ...ce on the exhaust valves rotate the engine until the decom pression pin of the valve tappet is activated then using a screwdriver carefully tap the decompression arm until the decompression pin releas...

Page 198: ...rk plug wires ZJ094C NOTE On the non turbo models before installing the air silencer make sure the gasline hose is routed over the air silencer NOTE On the non turbo models to finalize this pro cedure...

Page 199: ...light should go out within five seconds If it does proceed to step 14 NOTE If the warning light does not go out shut the engine off immediately and repeat step 11 then place the ignition switch to the...

Page 200: ...he hose clamp to loosen is from the vertical fitting Do not remove the hose from the 90 fitting 4 Tip the snowmobile upright then place a suitable drain pan beneath the engine Remove the coolant hose...

Page 201: ...should be checked annually for deterioration cracks and wear All coolant hoses and clamps should be replaced every four years INSPECTING THERMOSTAT 1 Inspect the thermostat for corrosion wear or sprin...

Page 202: ...OTE If the coolant level in the filler neck suddenly drops when the bleed screw is loosened an air lock occurred in the cylinder head Add coolant to the filler neck until full before starting the engi...

Page 203: ...ect the thermostat for corrosion wear or spring damage 2 Using the following procedure inspect the thermo stat for proper operation A Suspend the thermostat in a container filled with water B Heat the...

Page 204: ...ent styles of cooling systems in the Arctic Cat snowmo biles Some components may vary from model to model therefore the technician should use discretion and sound judgment when servicing a particular...

Page 205: ...3 26 0742 314 738 067A F Series 2 Stroke CFR Crossfire M Series Manual Table of Contents...

Page 206: ...D INSPECTING NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is nec essary 1 Clean all recoil starter components 2 Inspect all springs washers and pawl for wear or d...

Page 207: ...onsole and allow the rope to slowly retract against the starter case 2 Remove the knot at the handle remove the handle and account for the handle cap then thread the rope through the bushing in the co...

Page 208: ...9 Apply a low temperature grease to the friction plate Place the pawl activator into position on the friction plate making sure the arms of the activator are prop erly positioned to the pawl 10 Place...

Page 209: ...the air silencer in position there fore the engine must never be run with the air silencer removed REMOVING 1 Remove the cable tie securing the air intake connec tor to the lower air silencer and rem...

Page 210: ...rature sensor and remove the duct NOTE To aid in accessing the cap screw the ECU may be removed 8 Remove the body screws and flange nuts C from each side securing the front bumper assembly to the chas...

Page 211: ...seat then install the machine screw threads coated with blue Loctite 243 to the right side of the seat support 8 Place the rubber exhaust bumper into position on the air silencer FS203A 9 Place gasket...

Page 212: ...panel to the front bumper 5 Remove the four cap screws securing the upper bear ing bracket to the upper support plate ZJ097A 6 Remove the four cap screws securing the support plate to the steering sup...

Page 213: ...ly for carbon resi due buildup If signs of carbon buildup exist the throttle body should be cleaned see Fuel System EFI Throttle Body Assembly in Section 4 ZJ125 14 Remove the air temperature sensor f...

Page 214: ...g its clamp then working it back and forth and with an angle tool slide the mag side air silencer boot onto the throttle body and tighten its clamp Once in place and secured carefully inspect that the...

Page 215: ...ry 2 Clean any debris from inside the air intake plenum INSTALLING 1 Place the air filter into position into the plenum 2 Secure the air cleaner cover onto the plenum Turbocharger Intercooler 1100 cc...

Page 216: ...ve the clamp securing the coolant return hose to the return line of the turbo charger Remove the hose TZ060A 8 Remove the four cap screws securing the upper heat shield to the turbo outlet and exhaust...

Page 217: ...securing the mounting bracket to the turbocharger NOTE If the oil hose has to be removed from the engine note the banjo bolt securing the hose to the turbo has the smaller feed holes 743 780C 13 Remo...

Page 218: ...he turbocharger secured in a suitable vise and the gasket in place secure the turbo outlet to the tur bocharger with the washers and lock nuts Tighten the lock nuts to 30 ft lb TZ091A 2 Install the mo...

Page 219: ...ern tighten the lock nuts from step 3 securing the turbo to the exhaust mani fold to 30 ft lb TZ092A 9 Connect the coolant feed hose and oil return hose to the turbo release the clamps and secure the...

Page 220: ...into the grommets of the mounting bracket then connect the intercooler hoses to the turbo and to the intake plenum Tighten all hose clamps securely 18 Start the engine and allow the engine to idle for...

Page 221: ...within the ECU has been programmed to raise and lower the power valves at a specific engine rpm When this rpm is reached DC current is routed to the servomotor by the ECU Servomotor The servomotor con...

Page 222: ...is too low D Servomotor failure E Blown fuse F Voltage Regulator Rectifier 800 1000 cc NOTE For testing individual APV system compo nents see Section 5 MAINTENANCE The APV system requires only period...

Page 223: ...1 NOTE The measurements must be within the speci fications from the chart If the measurements are within specifications no adjustment is necessary proceed to step 8 If they are not within specifica ti...

Page 224: ...t and a soft abrasive such as a Scotch Brite pad 2 Inspect all parts for nicks burrs or other signs of unusual wear Replacing Oil Seal 1 Carefully pry the seal up from beneath taking care not to damag...

Page 225: ...valve plate and insert it into the valve stopper Secure with the retaining screw Tighten to 48 in lb FC112 NOTE Note that the exhaust valve gaskets are directional and must be installed correctly 4 Sl...

Page 226: ...cally adjusts the ignition timing to provide maximum performance through a variety of operating conditions The ECU receives input on engine RPM demand and exhaust temperature engine condition and adju...

Page 227: ...4 4 1 SECTION 4 FUEL SYSTEMS TABLE OF CONTENTS Fuel Systems 4 2 Fuel System Carbureted 4 2 Fuel System EFI 4 14 Fuel System Related Items 4 30 Manual Table of Contents...

Page 228: ...g parts Hoses must fit tightly If hoses do not fit tightly cut 6 mm 1 4 in from the end and install 4 Check the impulse hose for cracks or any possible air leaks The hose must fit tightly at both ends...

Page 229: ...carburetor TZ103A TZ104A 4 Loosen the carburetor flange clamp then remove the carburetor TZ102A NOTE Slide the carburetor into the air silencer boot until free of the flange then remove carburetor 5...

Page 230: ...nd the seat Account for a washer from the seat KEY 1 Mixing Body Assy 2 Starter Plunger Cap 3 Starter Plunger Spring 4 Starter Plunger 5 Spring 6 Idle Speed Screw 7 Spring 8 Pilot Air Screw 9 Pilot Je...

Page 231: ...le counting the rotations for installing purposes rotate the pilot air screw clockwise until lightly seated then remove the pilot air screw and spring CM053A 8 Remove the idle speed screw and spring C...

Page 232: ...tortion NOTE When inspecting the inlet needle inspect the side guides and tip for wear If the guides show any sign of wear replace the inlet needle 7 Inspect the pilot jet and main jet for obstruction...

Page 233: ...he float arm height Using a calipers mea sure the distance from the gasket surface to the top of the float arm with the carburetor inverted If mea surement is not within 22 24 mm adjust by bending the...

Page 234: ...alve into position making sure the full length groove in the piston valve is aligned with the pin in the mixing chamber bore then thread the mixing body top onto the carburetor and tighten securely CM...

Page 235: ...ttained Securely tighten the adjuster jam nut 0732 848 5 Repeat steps 3 and 4 on each carburetor NOTE If a carburetor choke cable is adjusted too tight the engine will only operate on 1 cylinder at id...

Page 236: ...e play in the throttle lever 6 After synchronization has been attained install the air silencer boots over the intake bores of the carbu retors Pilot Air Screws 1 While counting the rotations carefull...

Page 237: ...t cable on the oil injection pump secure with the jam nuts 3 Install the oil injection cable on the control arm secure with a washer and E ring NOTE Install the PTO side carburetor if removed 4 Instal...

Page 238: ...ll not seat 2 Pilot air screw too far in 3 Pilot air passage obstructed damaged 4 Float inlet needle obstructed damaged adjusted incorrectly 5 Pilot jet loose 1 Adjust service replace choke cable plun...

Page 239: ...Adjust E clip Problem Carburetor Too Lean 3 4 WOT Opening Condition Remedy 1 Main jet obstructed too small 2 Float inlet needle obstructed damaged adjusted incorrectly 3 Needle jet jet needle obstruc...

Page 240: ...the stator plate provides output to the CCU regulator rectifier to operate accessories and the lighting system 5 An electrical control unit ECU calculates input from sensors air temperature sensor coo...

Page 241: ...l air mix ture ratio This sensor is very sensitive to temperature change Resistance will drop as the temperature rises COOLANT TEMPERATURE SENSOR This sensor is very sensitive to temperature change Th...

Page 242: ...TDC twice per cycle once on the exhaust stroke and once on the compression stroke MANIFOLD ABSOLUTE PRESSURE MAP SENSOR 1100 cc This sensor measures pressure in the intake manifold when the engine is...

Page 243: ...L COMPONENTS NOTE With the Arctic Cat EFI System the ECU must receive the proper current output from four coils two charge coils an injector coil and a fuel pump coil to function as designed If a prob...

Page 244: ...the analyzer test harness to the ECU diag nostic connector 2 Connect the analyzer test harness red and black leads to a 12 volt battery 3 Turn the analyzer switch ON 4 Press the analyzer MENU SELECT...

Page 245: ...ll the upper and lower O rings onto each injector 2 Install the injectors into the throttle body assembly 3 Place the injector hold down plate into position on top of the injectors and secure with two...

Page 246: ...OHMS position and test the resistance between the two leads from the sensor 3 Compare the resistance reading to the Voltage Resis tance Chart Coolant Temperature in this sub sec tion If resistance is...

Page 247: ...he flanges and boots are positioned properly Secure with flange clamps 3 Where applicable connect the oil pump control rod NOTE The coolant hoses must be connected first then the throttle body assembl...

Page 248: ...oots then remove the throttle body assembly 5 Remove the retaining clips securing the fuel rail to the injectors then remove the two screws securing the fuel rail to the throttle body assembly Remove...

Page 249: ...crews ZJ131A 3 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 ZJ29...

Page 250: ...torx head cap screws A securing the console to the chassis then lift up the rearward end of the console and disconnect the console har ness plug in Remove the console 743 945A 2 Remove the two screws...

Page 251: ...SC valve before using any type of cleaner to clean the throttle body 9 Using a throttle body cleaner spray throttle valve once and clean the venturi of carbon buildup A fine nylon brush may be needed...

Page 252: ...g in place install the fuel pressure regulator and secure it to the fuel rail Tighten to 96 in lb 2 Install the injectors into the fuel rail then install the four harness connectors to the injectors a...

Page 253: ...ure the panels with the cap screws 743 945A 10 Install the handlebar close off panel then secure the panel with the two screws Position the console assembly on the headlight support bracket then con n...

Page 254: ...the throttle cable end on the throttle lever 3 Route the throttle cable from the throttle switch assembly to the throttle body assembly and oil injec tion pump avoid any sharp bends or moving compo ne...

Page 255: ...2 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...

Page 256: ...9 Remove the check valves Account for two gaskets INSTALLING 1 In turn on each front union bolt install a washer gas ket check valve and washer gasket then install on the oil injection pump 2 Place th...

Page 257: ...the control arm throttle cable to the CLOSED position NOTE On models with a cable operated oil pump connect the throttle cable to the throttle lever then adjust the cable linkage adjusting nut so the...

Page 258: ...ing the rod pre vents misalignment of the control arm due to engine chassis movement 7 With the control arm secured in the FULL CLOSED Idle position start the engine and run the engine at recommended...

Page 259: ...amps on the fuel hoses then with the fuel pump inlet and outlet noted connect the fuel hoses to the fuel pump Secure with the hose clamps 2 Secure the fuel filter to the fuel filter bracket then start...

Page 260: ...he retaining plate then remove the fuel pump and account for the seal B NOTE Before removing the fuel pump note the orien tation of the fuel pump outlet for assembling purposes 3 Remove and discard th...

Page 261: ...00 RPM for a period of 30 seconds Note maximum reading of gauge Reading must be within the range listed 3 Stop engine Connect fuel hose Turn the shut off valve to the OPEN position Gas Tank Seat Assem...

Page 262: ...7 Testing Electric Fuel Pump 2 Stroke 5 17 Testing Electric Fuel Pump 4 Stroke 5 17 Testing Ignition Components 4 Stroke 5 18 Emergency Stop Switch 5 19 Solenoid 2 Stroke 5 19 Starter Relay 1100 cc 5...

Page 263: ...emer gency stop switch are in the ON position 2 Crank the engine over and check for spark If no spark is present check to make sure the throttle cable is properly tensioned Compress the throttle contr...

Page 264: ...must read OL infinite resistance Throttle Control Switch 1 Disconnect the handlebar harness connector then connect one ohmmeter lead to the green yellow pin 2 wire and the other lead to the red violet...

Page 265: ...meter reads resistance closed but the engine will not start with the ohmmeter leads still connected alternately release and compress the throttle lever then move the emergency stop knob down and up 6...

Page 266: ...ttle lever pin so that depression of the throttle lever does not move the lever pin in its control slot 0728 916 7 Slowly depress the throttle lever to increase engine RPM NOTE Engine RPM must be allo...

Page 267: ...talling the TPS harness connector apply dielectric grease to the connector pins ADJUSTING TPS NOTE Adjusting the TPS is for out of warranty snowmobiles only NOTE It is important that the throttle shaf...

Page 268: ...Air Silencer 1100 cc Non Turbo sub section in Section 3 and follow steps 1 12 of REMOVING NOTE On the turbo models remove the console and left rear spar panel VERIFYING TPS ADJUSTMENT TOOL Before usin...

Page 269: ...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 screw s securin...

Page 270: ...ohms FUEL PUMP COIL 1 Test between the two orange wires in the four prong connector from the stator 2 Meter reading must be 1 52 2 28 ohms INJECTION COIL 1 Test between the two blue white leads in the...

Page 271: ...d to the green white wire then connect the black tester lead to the brown green wire 4 Sensor resistance must 148 222 ohms LIGHTING COIL 1 Disconnect the main harness from the lighting coil four wire...

Page 272: ...t be 0 08 0 12 ohm IGNITION TIMING SENSOR 1 Disconnect timing sensors 1 and 2 green white and brown green from the main harness 2 Set the selector in the OHMS position then connect the meter leads to...

Page 273: ...g circuits Both outputs have a circuit breaker self resetting devices protecting components from over current and short circuit situations If a system stops working a short has likely occurred and the...

Page 274: ...and by pulling the recoil starter rope briskly LOW POWER 1 Connect the red maxiclip and meter lead to the red blue lead of the connector then connect the black maxiclip and meter lead to the black lea...

Page 275: ...5000 ohms 4 Continue the pulley rotation and there will be a small area in the rotation where the ohm reading will disappear then it will return again 5 Continue the pulley rotation and the ohms shou...

Page 276: ...to the ground wire 2 Pull the recoil starter rope briskly Meter reading must be 6 5 7 0V CHARGE COIL 1 1 Connect the red meter lead to the brown white wire then connect the black meter lead to the gre...

Page 277: ...in the float When the float drops to the lower part of the stem the magnet closes the electrical contacts located in the stem allowing the current to pass on to the warning light If the sensor should...

Page 278: ...t the gauge then connect the black meter lead to a chassis ground 3 With the rear of the snowmobile on a shielded safety stand run the engine at 2000 RPM 4 Meter reading must be within 10 15V DC at th...

Page 279: ...ailed check all connections etc and test again If no voltage is present replace the stator assembly Resistance 1 Set the meter selector to the OHMS position 2 Test between the three yellow wires for a...

Page 280: ...nternal contacts make connection 3 Disconnect the battery from the solenoid 4 A loud audible click should be heard as the sole noid internal contacts release NOTE An in line ammeter would measure betw...

Page 281: ...the expansion chamber 3 Remove the positive lead from the starter motor then remove the two cap screws securing the MAG side starter motor bracket to the engine Remove the bracket and starter motor an...

Page 282: ...on must snap out against the stopper If the motor does not spin remove the red cable imme diately Check the battery condition and all connec tions If everything checks out satisfactorily and the start...

Page 283: ...move the starter motor the air silencer must be removed Proceed to appropriate Air Silencer sub section in Section 3 2 Remove cap screw A securing the positive cable to the starter motor then remove t...

Page 284: ...measure the undercut Maximum undercut groove must be 0 008 in SNO2171 10 Inspect the commutator for shorting using a multim eter and the following procedure A Set the selector to the OHMS position B...

Page 285: ...g the alignment marks made in disassembling install the magnet housing then with the magnet housing properly seated to the brush assembly install the snap ring shim and locking plate to the armature s...

Page 286: ...hree cap screws securing the oil tank to the chassis then remove the clamps securing the oil return and oil supply hoses from the magneto cover Disconnect the hoses along with the breather hose locate...

Page 287: ...he magneto cover then with a new gasket install the cover and with the pattern shown tighten the 18 cap screws to 84 in lb 741 583A NOTE Assure the oil pump seal is in place prior to installing the ma...

Page 288: ...rminal then connect the other lead to the black terminal 3 With the brake lever compressed the meter must read 1 ohm or less resistance With the brake lever released the meter must read OL open If the...

Page 289: ...ve the handlebar pad if applicable then dis connect the handlebar warmer three wire connector 2 In the element connector connect one ohmmeter lead to the green white lead then connect the other ohmmet...

Page 290: ...in the MED position connect one ohmmeter lead to the green red wire at the connec tor then connect the other ohmmeter lead to the brown wire at the connector The meter must read less than 1 ohm of res...

Page 291: ...t to the DC Volt scale NOTE Prior to testing the sensor inspect the three wire connector on the sensor harness for contamina tion broken pins and or corrosion With the engine running note that a power...

Page 292: ...ator 500 600 1100 cc NOTE The actuator is located on the gear case above the left side footrest 1 Disconnect the actuator two wire connector then connect Actuator Test Harness onto the harness side of...

Page 293: ...5 32 Troubleshooting Servomotor SERVO1Arv Manual Table of Contents...

Page 294: ...5 5 33 SERVO2rv Manual Table of Contents...

Page 295: ...Harness Hood Console Harness Handlebar Harness Bearcat 570 LTD Bearcat 570 XT F570 T570 p 2 p 15 p 20 Crossfire 6 M6 p 4 p 14 p 18 CFR Crossfire Sno Pro LTD M Series Sno Pro 800 1000 cc p 8 p 14 p 18...

Page 296: ...Magneto 0744 205 1 Table of Contents Manual Diagram Table of Contents...

Page 297: ...Main Harness p n 1686 600 F570 p n 1686 612 Bearcat 570 XT p n 1686 601 Bearcat 570 LTD T570 0745 594 2 Table of Contents Manual Diagram Table of Contents...

Page 298: ...Main Harness p n 1686 603 F5 LXR 0745 595 3 Table of Contents Manual Diagram Table of Contents...

Page 299: ...Main Harness p n 1686 598 Crossfire 6 M6 0745 596 4 Table of Contents Manual Diagram Table of Contents...

Page 300: ...Main Harness p n 1686 604 F6 Sno Pro 0745 597 5 Table of Contents Manual Diagram Table of Contents...

Page 301: ...Main Harness p n 1686 606 F8 EXT F8 LXR 0745 603 6 Table of Contents Manual Diagram Table of Contents...

Page 302: ...Main Harness p n 1686 605 F8 Sno Pro LTD 0745 604 7 Table of Contents Manual Diagram Table of Contents...

Page 303: ...Main Harness p n 1686 597 CFR 800 CFR 1000 Crossfire 800 Sno Pro LTD M8 HCR Sno Pro LTD M1000 Sno Pro 0745 598 8 Table of Contents Manual Diagram Table of Contents...

Page 304: ...Main Harness p n 1686 613 Bearcat Z1 XT p n 1686 615 Bearcat Z1 XT LTD 0745 607 9 Table of Contents Manual Diagram Table of Contents...

Page 305: ...Main Harness p n 1686 611 TZ1 Turbo LXR LTD p n 1686 609 Z1 Turbo EXT LXR p n 1686 599 Z1 Turbo Sno Pro 0745 600 10 Table of Contents Manual Diagram Table of Contents...

Page 306: ...Main Harness p n 1686 610 TZ1 LXR LTD p n 1686 608 Z1 LXR p n 1686 607 Z1 Sno Pro 0745 599 11 Table of Contents Manual Diagram Table of Contents...

Page 307: ...Console Harness p n 1686 547 Bearcat Z1 XT Z1 Sno Pro Z1 Turbo Sno Pro p n 1686 549 Bearcat Z1 XT LTD TZ1 Z1 LXR Z1 Turbo EXT LXR 0744 194 12 Table of Contents Manual Diagram Table of Contents...

Page 308: ...Console Harness p n 1686 631 TZ1 LXR LTD TZ1 Turbo LXR LTD 0745 601 13 Table of Contents Manual Diagram Table of Contents...

Page 309: ...Hood Harness p n 1686 614 CFR Crossfire M Series 0744 179 14 Table of Contents Manual Diagram Table of Contents...

Page 310: ...Console Harness p n 1686 567 Bearcat 570 LTD Bearcat 570 XT F570 T570 0745 602 15 Table of Contents Manual Diagram Table of Contents...

Page 311: ...Console Harness p n 1686 573 F5 LXR F8 EXT F8 LXR 0744 190 16 Table of Contents Manual Diagram Table of Contents...

Page 312: ...Console Harness p n 1686 572 F6 Sno Pro F8 Sno Pro LTD 0744 191 17 Table of Contents Manual Diagram Table of Contents...

Page 313: ...Handlebar Harness p n 1686 566 Crossfire M Series p n 1686 575 CFR 0744 180 18 Table of Contents Manual Diagram Table of Contents...

Page 314: ...Handlebar Harness p n 1686 574 F5 LXR F6 Sno Pro F8 EXT F8 LXR F8 Sno Pro LTD 0744 189 19 Table of Contents Manual Diagram Table of Contents...

Page 315: ...Handlebar Harness p n 1686 537 Bearcat 570 LTD 570 XT F570 T570 0744 183 20 Table of Contents Manual Diagram Table of Contents...

Page 316: ...Handlebar Harness p n 1686 568 TZ1 TZ1 LXR LTD TZ1 Turbo LXR LTD Z1 LXR Sno Pro Z1 Turbo EXT LXR Sno Pro p n 1686 577 Bearcat Z1 XT LTD 0744 195 21 Table of Contents Manual Diagram Table of Contents...

Page 317: ...Passenger Seat Harness p n 1686 570 TZ1 Models 22 0744 197 Table of Contents Manual Diagram Table of Contents...

Page 318: ...Ignition Main Harness p n 1686 628 Sno Pro 500 23 0745 605 Table of Contents Manual Diagram Table of Contents...

Page 319: ...Hood Harness p n 1686 587 Sno Pro 500 24 0744 201 Table of Contents Manual Diagram Table of Contents...

Page 320: ...Ignition Main Harness p n 1686 629 Sno Pro 600 25 0745 606 Table of Contents Manual Diagram Table of Contents...

Page 321: ...Hood Harness p n 1686 596 Sno Pro 600 C C p n 1686 595 Sno Pro 600 Sno Cross 26 0744 202 Table of Contents Manual Diagram Table of Contents...

Page 322: ...Handlebar Harness p n 1686 590 Sno Pro 500 27 0744 200 Table of Contents Manual Diagram Table of Contents...

Page 323: ...Main Harness p n 1686 578 Sno Pro 120 28 0744 204 Table of Contents Manual Diagram Table of Contents...

Page 324: ...lutch Driven Pulley 6 9 Drive Train Brake Disc 6 12 Drive Sprockets 6 29 Track Tension 6 31 Track Alignment 6 32 Brake System Hydraulic 6 32 Brake Lever Master Cylinder Assembly 6 41 Troubleshooting H...

Page 325: ...drive clutch and driven pulley will shift and on the amount of power that will be transmitted through the sys tem ONLY ARCTIC CAT DRIVE BELTS SHOULD BE USED Different brands of belts may not have the...

Page 326: ...pply oil to the threads of the puller and a small amount of grease to the tip of the puller 2 Using the Drive Clutch Puller and a breaker bar and the Drive Clutch Spanner Wrench tighten the puller If...

Page 327: ...tem Components in Section 1 of this manual 6 Inspect rollers for damage or wear Assembling 1 With the head of each cam arm pin positioned towards the direction of the drive clutch rotation install the...

Page 328: ...Remove the drive belt NOTE For removing drive belt see Drive Belt in this section 2 Using a 9 16 in socket and extension remove the cap screw securing the driven pulley to the input shaft 3 Slide the...

Page 329: ...sh grease drive belt dust and foreign matter off all components 2 Inspect the rollers for damage cracks or wear 3 Inspect the sheaves for any gouges cracks or other damage Also inspect threaded areas...

Page 330: ...Using a suitable driving tool drive the bearing out 3 Install the new bearing then secure with the snap ring REPLACING ROLLERS 1 Drive the spring pins through the stationary sheave until the cam roll...

Page 331: ...esult if the plastic washer is not installed 2 Noting the alignment marks made during disassem bling and with the spring seat and spacer on the sta tionary sheave shaft place the stationary sheave ont...

Page 332: ...pulley is serviced To check offset use appropriate Clutch Alignment Bar To check parallel ism use Parallelism Bar CHECKING OFFSET 1 Open the left side access panel then remove the belt guard 2 Install...

Page 333: ...f the drive clutch sheave Mea surement Y must be 0 060 in 0 020 in more than measurement X but Y must not exceed measure ment X by more than 0 100 in 0744 609 3 If parallelism is not within specificat...

Page 334: ...nd left side access panels and the hood DRIVE BELT DEFLECTION Drive belt length condition and deflection are all impor tant for peak performance To check and adjust drive belt deflection use the follo...

Page 335: ...or any alignment washers if applicable These washers must be used during installing 3 On the F Series T Series Z1 remove the torx head cap screws securing the toe shield and hook bracket to the chassi...

Page 336: ...l the gear case is free from the studs of the mounting plate 8 Remove the cap screw from the inner driveshaft from step 5 then remove the gear case NOTE If the gear case is difficult to remove it may...

Page 337: ...GEAR CASE NOTE At this point if the track was removed install the track NOTE Steps 1 8 are for installing the track drive shaft If only installing the gear case proceed to step 9 NOTE Prior to install...

Page 338: ...t shaft at this time Proceed to step 7 7 Place the resonator into position and secure with the springs and hairpin clip 8 Install the skid frame see Section 7 NOTE At this point if the gear case is in...

Page 339: ...indicator switch harness B ZJ183A 14 Install the toe shield and toe hook bracket then install the torx head cap screws Tighten securely 0742 089 15 On the 600 cc Crossfire M Series connect shift actu...

Page 340: ...ctuator to the gear case and remove the actuator then remove the gear indicator switch ZJ186A 2 Remove the torx head cap screws securing the gear case cover to the gear case assembly then insert two f...

Page 341: ...t shaft bearing out of the gear case cover Account for a bearing and a seal ZJ191 MS331 8 Secure the gear case in a suitable clamping device then using the procedure from step 5 remove the outer beari...

Page 342: ...ZJ197 13 Remove the retaining ring and thrust washer secur ing the slider housing assembly to the output shaft assembly ZJ200 14 Using a suitable puller remove the bearing from the output shaft 15 Usi...

Page 343: ...any damage or binding is noted the output shaft assembly must be replaced 7 Apply a light film of Arctic Cat Synthetic ACT Drive Fluid to the unsealed bearings prior to assem bling ASSEMBLING GEAR CA...

Page 344: ...s properly seated ZJ194 7 With the alignment notches of the slider and gear case properly positioned install the slider output gear assembly into the gear case ZJ201 8 Using a suitable bearing press i...

Page 345: ...e shaft Secure the arm with the remaining retaining ring ZJ301A 13 Install the slider blocks to the shift fork assembly then install the fork assembly into the slider and gear case ZJ205 NOTE Make sur...

Page 346: ...rs into the notches on the gear case then working back and forth pry the cover up and off the gear case 744 133A 744 134A 2 Drain the gear case fluid into a suitable container 3 With a cap screw threa...

Page 347: ...to the gear case MS513 9 Remove the planetary gear assembly from the gear case then remove the retaining ring securing the gear assembly from the planetary gear MS516A NOTE Note the orientation of the...

Page 348: ...or feel rough If any abnormal condition is noted replace the bearing 6 Inspect the planetary and ring gears for wear cracks or chipped teeth 7 Apply a light film of Arctic Cat ACT Drive Fluid to the u...

Page 349: ...ure the gap of the retaining ring is properly positioned as noted during disassembling MS518A 6 Using a suitable bearing press install the outer bear ing A to the transfer gear assembly then install t...

Page 350: ...re with cap screws then using a crisscross pattern tighten to 12 5 ft lb 744 133C 744 134C 12 Pour 15 fl oz of Arctic Cat Synthetic ACT Gear Case Fluid into the drain fill hole then install the plug T...

Page 351: ...ate slightly Use only enough throttle to turn the track several revolutions SHUT ENGINE OFF 13 Remove the access panels then remove the belt guard 14 Remove the drive belt see Drive Belt sub section t...

Page 352: ...NG NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is nec essary 1 Thoroughly wash all metallic components in parts cleaning solvent Dry using compressed air 2 Wash...

Page 353: ...l it aligns with the line scribed in removing MS361A 3 Slide the remaining sprocket onto the driveshaft making sure the timing arrow lines from removing are aligned then using the press fixture press...

Page 354: ...snowmobile on its side 2 Hook a spring scale around a track clip at mid span then pull the track down with the scale to the appro priate weight and measure the distance between the bottom of the wear...

Page 355: ...rotate the track several revolu tions SHUT THE ENGINE OFF NOTE Allow the track to coast to a stop Do not apply the brake because it could produce inaccurate alignment conditions 3 When the track stops...

Page 356: ...of the bleeder valve and direct the other end into a con tainer 739 269B 2 Slowly compress the brake lever and hold Open the bleeder valve to release the fluid then compress the brake lever repeatedl...

Page 357: ...oir Replace the cover NOTE The above procedure will allow room for the fluid from the caliper when the pistons are pushed into the caliper for installing new brake pads Replac ing the cover will preve...

Page 358: ...springs and hairpin clip securing the resonator to the exhaust pipe and chassis Remove the resonator 2 Remove the torx head cap screws securing the toe shield and hook bracket to the chassis then rem...

Page 359: ...ttern on the inner race of the bearing until the bearing is out of the housing Account for the spacer NOTE Never reuse bearings that have been removed Always use new bearings ZJ226 11 Remove the retai...

Page 360: ...ary 1 Inspect the brake pistons for gouges cracks pitting scuffing or corrosion If any of these conditions exist replace the piston NOTE The inner and outer caliper housings are not serviceable compon...

Page 361: ...is neces sary 0739 269 6 Inspect the brake hose for cracks and deterioration and check the condition of the threaded connectors Assembling Installing 1 Apply approved brake fluid to the new O ring the...

Page 362: ...new O ring and make sure the O ring is properly seated in the outer brake housing MS320A 4 Using a suitable press install a new inner bearing into the caliper housing until it is properly seated ZJ241...

Page 363: ...t hammer and tap the caliper from side to side until the caliper is properly seated to the tunnel 9 Install the Phillips head cap screw and lock nut B then install the four lock nuts A Tighten to 20 f...

Page 364: ...ing torx head cap screws then tighten to 17 ft lb ZJ210A 15 Connect the harness connector to the speedometer sensor plug in 16 Install the toe shield and toe hook bracket then install the torx head ca...

Page 365: ...reservoir and cover for cracks and leakage NOTE The master cylinder is a non serviceable component If any wear or damage is detected the master cylinder must be replaced 3 Inspect the brake fluid hos...

Page 366: ...n Remedy 1 Brake fluid overheated contaminated 2 Master cylinder damaged faulty 3 Caliper brake hose leaking 4 Air ducts obstructed missing 5 Brake lever linkage damaged 1 Replace fluid 2 Replace mast...

Page 367: ...rive 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 Pr...

Page 368: ...d 6 Drive belt damaged from improper break in 1 Replace drive belt 2 Adjust offset parallelism center to center distance 3 Service drive clutch reduce idle RPM 4 Clean replace drive clutch components...

Page 369: ...tions 7 5 Servicing Rear Suspension Bearcat XT 7 9 CFR 7 32 Crossfire M Series 7 54 F Series Z1 7 70 Bearcat 570 T Series EXT Models 7 89 Servicing ACT Shock 7 109 Rebuilding Recharging Fox Air Shocks...

Page 370: ...r 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 m...

Page 371: ...me like a pogo stick 2 With stiffer springs the front end will become more aggressive in the corners as more weight will be transferred to the skis when decelerating Also more weight is transferred to...

Page 372: ...2nd block position set for 150 to 200 lb 3rd block position set for over 200 lb 727 720A NOTE When making any changes to the front or rear suspension the change should be made at both ends to keep th...

Page 373: ...mmends that when disassembling and assembling the suspension all stock mounting locations be used as shown in the following illustrations 0744 840 0744 839 CAUTION All stock mounting locations must be...

Page 374: ...7 6 0744 126 0745 585 Bearcat 570 Crossfire Models Manual Table of Contents...

Page 375: ...7 7 7 0744 128 0745 584 CFR M Series Manual Table of Contents...

Page 376: ...7 8 0744 841 0744 842 Bearcat XT EXT Models Manual Table of Contents...

Page 377: ...floor 4 Remove the front cap screws securing the skid frame to the tunnel Account for a flat washer and a lock washer 5 Remove the support stand then using a suitable handlebar support stand tip the...

Page 378: ...ck of wood and a hammer drive the wear strip forward into position 739 884A 2 Secure with a machine screw and lock nut Tighten to 50 in lb End Caps NOTE The skid frame does not have to be removed for...

Page 379: ...part is worn excessively cracked or damaged in any way replacement is nec essary 1 Inspect the pad and retaining brackets for damage or wear 2 Inspect the rivet holes in the slide rail for damage or...

Page 380: ...securing the bearing the idler wheel is not serviceable A Remove the wheel insert if applicable and the snap ring B Using a hydraulic press press the bearing out the inside of the wheel C Press the ne...

Page 381: ...hten to 20 ft lb MS208 Rear Upper Idler Wheels Rear Springs NOTE The skid frame must be removed for this pro cedure see Removing Skid Frame in this sub sec tion REMOVING 1 Using the Rear Suspension Sp...

Page 382: ...k and washer SC016A MS068 6 Remove the spring and sleeve from the idler arm MS069 NOTE Use the same procedure for the other side CLEANING AND INSPECTING NOTE Whenever a part is worn excessively cracke...

Page 383: ...arm spacers onto the idler arm MS064 5 Place the flared bushings with a thin flat washer through the back side of the pivot arm assembly NOTE If the flared bushing in the pivot arm is loose it must b...

Page 384: ...er Wheels Rear Springs in this sub section MS074 2 Remove the cap screw and lock nut securing the upper shock eyelet to the idler arm Account for a spacer lock nut and bushings SC019A AG553D NOTE Mark...

Page 385: ...arm pivot area for wear or damage 5 Inspect all welds and the tubing of the upper arm for cracks or unusual bends 6 Inspect the two adjusting cams for damage 7 If an idler wheel bearing must be replac...

Page 386: ...els rear springs and offset pivot idler see Rear Upper Idler Wheels Rear Springs in this sub section 8 Install the skid frame see Installing Skid Frame in this sub section NOTE Install the rear arm sp...

Page 387: ...the bracket MS086A INSPECTING NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is nec essary 1 Inspect all front arm weldments for cracks or unusual bends 2 Closely...

Page 388: ...SC027 3 Place the idler wheel shock bracket assembly into position on the skid frame making sure the axle is aligned with the hole in the slide rail Secure with the cap screw and a new lock nut Tight...

Page 389: ...ving center components from the skid frame loosening all axle cap screws lock nuts will make removing easier 1 Remove the cap screw and lock nut securing the shock absorber to the eyelet of the idler...

Page 390: ...aration from plastic wheel 5 Rotate the idler wheel bearings by hand and inspect for any signs of binding or roughness 6 If the idler wheel has a removable bearing and the bearing must be replaced see...

Page 391: ...side of the spacer directed towards the pivot bracket 4 Lower the idler wheel pivot assembly down between the rails Align the axle with the mounting hole as noted during disassembling Secure with the...

Page 392: ...w lock nut and two flat washers MS016A 2 Remove the machine screw and lock nut securing the wear strip to the front of the slide rail 3 Using a suitable driving tool drive the wear strip off the rail...

Page 393: ...ace the slide rail install the cap screw from the opposite side into the assembly to secure the compo nents and aid in replacing the slide rail 9 Remove the cap screw and flat washer securing the spri...

Page 394: ...ted holes B or unusual bends MS220A 2 Inspect the wear strip for wear The wear strip must be 0 42 in thick or thicker If the wear strip measure ment is less than specified replacement of both wear str...

Page 395: ...spring with retaining clips and bushing to the proper hole in the slide rail MS119A 6 Place the spring into the spring slide then with the overload spring in position place the spring slide and slide...

Page 396: ...grease to the slide rail surface to aid in installing a new wear strip Use a file to remove any sharp edges on the lower portion of the rail MS288 11 From the back start the wear strip onto the rail t...

Page 397: ...ding or roughness 3 Inspect all bushings for wear or damage 4 Inspect all weldments and the tubing of the arms and spacers for cracks or unusual bends 5 Inspect the track bumper guides for wear 6 Insp...

Page 398: ...T THIS TIME Repeat this procedure on the other side 739 992A NOTE To aid in centering the front arm with the hole in the tunnel position the skid frame and track at a 45 angle to the bottom of the tun...

Page 399: ...ms at this time 7 At this time place the snowmobile to the upright position then tighten both rear arm mounting cap screws to 40 ft lb NOTE At this point tighten all remaining skid frame mounting hard...

Page 400: ...hold the snowmo bile level but not raised off the floor 4 Remove the front arm cap screws securing the skid frame to the tunnel Account for a flat washer and axle 5 Remove the support stand then usin...

Page 401: ...ock of wood and a hammer drive the wear strip forward into position 739 884A 2 Secure with a machine screw and lock nut Tighten to 50 in lb End Caps NOTE The skid frame does not have to be removed for...

Page 402: ...to position on the slide rail then secure with new push nuts 2 Place the front pads and retaining brackets into posi tion on the slide rail then secure with rivets Idler Wheels Mounting Blocks NOTE Th...

Page 403: ...lock hole prior to tightening MS009A 2 Place the idler wheel to the mounting block then secure the idler wheel assembly with a cap screw flat washer and a lock nut Tighten to 20 ft lb MS136 Rear Upper...

Page 404: ...arm 5 Remove the cap screw flat washer and lock nut securing the spring slide to the slide rail Account for the spring slide and all mounting hardware SC049B MS014 6 Remove the spring and sleeve from...

Page 405: ...e with a cap screw and washer Tighten to 34 ft lb MS014 3 Install the rear upper idler wheel on the idler arm AG545D MS072A 4 Install the idler spacer collar onto the idler arm MS064 5 Place the flare...

Page 406: ...d Frame in this sub sec tion DISASSEMBLING 1 Remove the cap screw and large flat washer securing the outer rear idler wheel Remove the outer idler wheel from the shaft 0742 921 2 Loosen the track adju...

Page 407: ...ace the adjuster bushings A on the axle on the outside of each axle slot then install the outer idler wheels on the axle and secure with two cap screws coated with blue Loctite 243 and large flat wash...

Page 408: ...dler arm Account for a cap screw lock nut spacer and axle links MS156A MS031 4 Remove the cap screw and lock nut securing the rear arm to the slide rail Account for the serrated axles and axle tube FZ...

Page 409: ...ler arm with an alumi num axle bushing assemblies and two cap screws coated with blue Loctite 243 Tighten only until snug FZ044 3 Position the shock links in the appropriate holes of the idler arm bra...

Page 410: ...he rear springs must be removed from the adjusting cams REMOVING 1 Remove the lower cap screws and lock nuts securing the limiter straps to the rail support Account for flat washers MS161A 2 Remove th...

Page 411: ...assembly to clear the slide rails Account for an axle two spacers and two shim washers NOTE Loosen the front rail support cap screws enough to gain clearance to remove the front shock axle FZ094A FZ0...

Page 412: ...front arm mounting brackets to the slide rails Secure with cap screws and lock nuts tightened to 20 ft lb MS170 2 Move the rear shock pivot inner idler wheel assem bly to the appropriate mounting loca...

Page 413: ...s Tighten to 20 ft lb SC056A Rear Shock Absorber and Shock Links Idler Wheel Pivot Assembly NOTE Before removing the skid frame by using the Rear Suspension Spring Tool remove the spring from the adju...

Page 414: ...mbly to the slide rails then from one side tap the assembly rearward far enough to clear the slide rails and mounting brackets Remove the assembly MS178 4 Remove the axle from the shock pivot Account...

Page 415: ...spect the axle surfaces for any signs of corrosion If corrosion is found lightly buff the surface of the axle with 400 wet or dry sandpaper then apply a light coat of grease ASSEMBLING 1 Secure the sh...

Page 416: ...then remove the machine screw and lock nut securing the wear strip to the front of the slide rail Account for a cap screw lock nut and two flat washers MS016A MS213A 2 Using a suitable driving tool d...

Page 417: ...shers if necessary and lock nut securing the front shock mount axle SC055C 6 Remove the cap screw and flat washer securing the spring slide to the rail Account for a spacer and the slide block SC049B...

Page 418: ...the wear strip for wear The wear strip must be 0 42 in thick or thicker If the wear strip measure ment is less than specified replacement of both wear strips is necessary 0743 189 INSTALLING 1 Secure...

Page 419: ...and the lock nut Tighten only until snug SC055A 7 Install the cap screws securing the three rail supports to the slide rail Tighten to 20 ft lb 8 Return to steps 4 6 and tighten cap screws and lock n...

Page 420: ...d cap onto the slide rail using a cap screw flat washers and a lock nut Tighten to 80 in lb MS206A NOTE Apply a light coat of grease to the slide rail surface to aid in installing a new wear strip Use...

Page 421: ...tunnel 4 Elevate the rear of the skid frame and the track into position in the tunnel 5 Align the rear arm assembly with the appropriate hole in the tunnel Secure the rear arm assembly with a cap scre...

Page 422: ...ut not raised off the floor 4 Remove the front lock nuts and cap screws securing the skid frame to the tunnel Account for a flat washer and axles 5 Remove the support stand then tip the snow mobile on...

Page 423: ...ear strip forward into position 739 884A 2 Secure with a machine screw and lock nut Tighten to 50 in lb End Caps NOTE The skid frame does not have to be removed for this procedure REMOVING 1 Remove th...

Page 424: ...sition on the slide rail then secure with the torx head screws and lock nuts Idler Wheels Mounting Blocks NOTE The skid frame does not have to be removed for this procedure REMOVING 1 Remove the cap s...

Page 425: ...ock then secure the idler wheel assembly with a cap screw flat washer and a lock nut Tighten to 20 ft lb CM229 Rear Axle NOTE The skid frame must be removed for this pro cedure DISASSEMBLING 1 Remove...

Page 426: ...s Tighten cap screws only until snug CM225 CM224A NOTE Make sure the hole in the bushing is directed to the adjusted bolt CM261A NOTE Tighten the rear idler wheel axle only until snug until the skid f...

Page 427: ...removed account for the four sleeves 4 Remove the cap screw and lock nut securing the rear arm to the idler arm Account for the aluminum axle and flared bushings CM235C NOTE To loosen and remove the...

Page 428: ...Tighten to 40 ft lb CM236 2 Install the idler arm onto the rear arm with an alumi num axle bushing assemblies and two cap screws Tighten to 34 ft lb CM237 NOTE If the rear arm limiter and rail suppor...

Page 429: ...ssembly NOTE The skid frame must be removed for this pro cedure see Removing Skid Frame in this sub sec tion and the rear springs must be removed from the adjusting cams REMOVING 1 Remove the cap scre...

Page 430: ...y cracked or damaged in any way replacement is nec essary 1 Inspect all front arm weldments for cracks or unusual bends then inspect the front arm mounting brackets for cracks and for elongated holes...

Page 431: ...mounting location in the slide rail Secure with cap screws Tighten to 40 ft lb CM248 5 With the serrated axle installed secure the shock absorber in the appropriate mounting hole of the front arm Secu...

Page 432: ...wrench start from either end and hook the edge of the wear strip with the pipe wrench jaw and twist the wear strip off the slide rail Move the pipe wrench 3 in and again twist the wear strip off the...

Page 433: ...the cap screws and lock nuts securing the track adjuster bracket CM254A 8 Remove the cap screws washers and lock nut from the rear arm CM255A NOTE If removing the rear arm cap screw is neces sary inst...

Page 434: ...ct the wear strip for wear The wear strip must be 0 42 in thick or thicker If the wear strip measure ment is less than specified replacement of both wear strips is necessary AG530D 0743 189 INSTALLING...

Page 435: ...ront arm to the slide rail with the cap screw and lock nut Tighten to 40 ft lb CM260 5 Secure the track adjuster bracket with the cap screws and lock nuts Tighten to 120 in lb CM254A 6 Install the adj...

Page 436: ...mounting blocks then install the cap screw and lock nut securing the idler wheels to the mounting blocks Tighten to 20 ft lb 9 Install the front arm limiter straps to the front rail support Tighten t...

Page 437: ...r of the skid frame and the track into position in the tunnel 5 Align the rear arm assembly with the appropriate hole in the tunnel Secure the rear arm assembly with a cap screw coated with red Loctit...

Page 438: ...port stand should hold the snowmo bile level but not raised off the floor 4 Remove the support stand then using a suitable han dlebar support stand tip the snowmobile onto one side 5 Slide the skid fr...

Page 439: ...a block of wood and a hammer drive the wear strip forward into position 739 884A 2 Secure with a machine screw and lock nut Tighten to 50 in lb End Caps NOTE The skid frame does not have to be removed...

Page 440: ...to position on the slide rail 2 Secure the pads with rivets Idler Wheels Mounting Blocks NOTE The skid frame does not have to be removed for this procedure REMOVING 1 Remove the cap screw and lock nut...

Page 441: ...the idler wheel to the mounting block then secure the idler wheel assembly with a cap screw flat washer and a lock nut Tighten to 20 ft lb FZ032 Rear Arm Assembly NOTE The skid frame must be removed...

Page 442: ...screw flat washer and lock nut securing the spring slide to the slide rail Account for the spring slide and all mounting hardware FZ038A MS014 6 Remove the spring and sleeve from the idler arm FZ039 N...

Page 443: ...way replacement is nec essary 1 Clean the bearings with a clean cloth 2 Inspect each idler wheel for cracks or damage 3 Inspect the bushings located in the arm pivot area for wear or damage 4 Inspect...

Page 444: ...and lock nuts Tighten securely FZ040C NOTE Do not over tighten the shock absorber cap screw as the shock eyelet must be free to pivot NOTE Install the rear arm springs onto the adjuster blocks after...

Page 445: ...n 10 Align the marks on the idler arm to the centerline of the pivot arm assembly Secure the pivot arm to the idler arm with cap screws and lock nuts Tighten to 20 ft lb FZ048A NOTE When tightening th...

Page 446: ...t hand side slide the axle through the slide rail axle slot then place a bushing A inner idler wheel B rear idler wheel spacer C inner idler wheel D and bushing E on the axle Slide the axle through th...

Page 447: ...lock nut securing the front arm to the front arm mounting bracket FZ050A 5 Remove the front arm and account for the front arm axle 6 Remove the cap screw securing the front outer idler wheel to the id...

Page 448: ...shim washers and two spacers CM246A 2 Place the front arm shock axle assembly into position on the skid frame making sure the spacers and wash ers are properly positioned Secure with the cap screw wa...

Page 449: ...emoved for this pro cedure see Removing Skid Frame in this sub sec tion REMOVING NOTE When replacing one or both slide rails is necessary remove one slide rail at a time The remaining slide rail will...

Page 450: ...t rail supports to the slide rail FZ080A 5 Remove the cap screws and lock nuts securing the front outer idler wheel and the idler wheel mounting block FZ081A FZ057A 6 Remove the lock nut and flat wash...

Page 451: ...ng the front arm to the slide rail FZ061A 10 Remove the cap screw from the rear arm limiter FZ062A 11 Remove the cap screw securing the rear arm coupler block to the slide rail Account for the block b...

Page 452: ...sively cracked or damaged in any way replacement is nec essary 1 Inspect the slide rail for cracks A elongated holes B or unusual bends MS220A 2 Inspect the wear strip for wear The wear strip must be...

Page 453: ...and tighten the rear arm and front arm cap screws and lock nuts to 40 ft lb 5 Install the adjuster bushing and rear idler wheel Install a cap screw and flat washer Tighten only until snug FZ066 NOTE C...

Page 454: ...the rail and mounting block prior to tighten ing FZ073A NOTE On the Sno Pro models install the rear inner idler wheel mounting block and idler wheel 10 Secure the outer idler wheel mounting block with...

Page 455: ...n the lower portion of the rail MS288 14 From the back start the wear strip onto the rail then using a soft hammer drive the wear strip forward into position Secure with a torx head screw and lock nut...

Page 456: ...the tunnel Secure the rear arm assembly with a cap screw lock washer and flat washer AT THIS TIME TIGHTEN ONLY UNTIL SNUG NOTE Do not install the short legs of the rear springs onto the adjusting cams...

Page 457: ...d should hold the snowmo bile level but not raised off the floor 4 Remove the support stand then using a suitable han dlebar support stand tip the snowmobile onto one side 5 Slide the skid frame rearw...

Page 458: ...he wear strip forward into position 739 884A 2 Secure with a machine screw and lock nut Tighten to 50 in lb End Caps NOTE The skid frame does not have to be removed for this procedure REMOVING 1 Remov...

Page 459: ...to posi tion on the slide rail then secure with rivets 2 Place the rear pads into position on the slide rails then secure with the torx head screws and lock nuts Tighten securely Idler Wheels Mounting...

Page 460: ...wheel to the mounting block then secure the idler wheel assembly with a cap screw flat washer and a lock nut Tighten to 20 ft lb TZ026 Rear Arm Rear Shock Pivot Assembly NOTE The skid frame must be r...

Page 461: ...to remove the wheel TZ005 5 Remove the cap screw flat washers and lock nut securing the spring slide and overload spring to the slide rail Account for the spring slide and all mount ing hardware TZ00...

Page 462: ...d lock nut securing the rear shock pivot idler wheel assembly to the slide rails then remove the assembly and account for the axle axle spacers and shim washers if applicable TZ012A 9 Remove the cap s...

Page 463: ...ear arm onto the idler arm with an alumi num axle and two cap screws Tighten to 40 ft lb TZ015A 3 With the sleeves installed install the shock absorber and links to the mounting hole of the rear shock...

Page 464: ...slide block with spring in slide block into position on the slide rail Secure with a cap screw and washer Tighten to 20 ft lb TZ008 NOTE Install the rear arm springs onto the adjuster blocks after th...

Page 465: ...ten the lower lock nut first or binding may occur Make sure the flared side of the bushing is directed outward TZ004C 13 Grease the idler arm and rear arm grease fittings with a low temperature grease...

Page 466: ...dler 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 20 ft lb 3 Install the skid frame see Installing...

Page 467: ...arm mounting brackets for cracks and for elongated holes 2 Closely inspect all tubing for cracks or unusual bends 3 Inspect the bearings bushings and front arm spacers for wear or damage 4 Inspect the...

Page 468: ...e into the front arm then position the front arm to the mounting location of the slide rail Secure with cap screws and lock nuts Tighten to 40 ft lb TZ028A 6 Secure the upper shock eyelet and axle in...

Page 469: ...inding of the wear strip occurs use a pipe wrench start from either end and hook the edge of the wear strip with the pipe wrench jaw and twist the wear strip off the slide rail Move the pipe wrench 3...

Page 470: ...from the cap screw securing the rear arm pivot idler wheel assembly to the slide rail TZ039A NOTE If removing the cap screw is necessary to replace the slide rail install the cap screw from the oppos...

Page 471: ...remove the adjuster bushing 14 Remove the cap screw securing the rear arm coupler block to the slide rail Account for the block bush ing cap screw and lock nut TZ046A 15 Remove the lock nut from the...

Page 472: ...A elongated holes B or unusual bends MS220A 2 Inspect the wear strip for wear The wear strip must be 0 42 in thick or thicker If the wear strip measure ment is less than specified replacement of both...

Page 473: ...idler wheel Install a cap screw and flat washer Tighten only until snug NOTE Care must be taken that the adjuster bushing slot with the hole is aligned properly with the adjuster bolt TZ045A NOTE Tig...

Page 474: ...e the outer idler wheel mounting block with the cap screw and lock nut Tighten to 20 ft lb then secure the idler wheel to the mounting blocks with existing hardware Tighten to 20 ft lb TZ055 NOTE To o...

Page 475: ...lling Skid Frame in this sub section NOTE Install the rear arm springs onto the adjuster blocks after the skid frame has been installed Installing Skid Frame 1 Using a suitable handlebar support stand...

Page 476: ...onto the adjusting cams at this time 7 At this time place the snowmobile to the upright position then tighten both rear arm mounting cap screws to 40 ft lb NOTE At this point tighten all remaining sk...

Page 477: ...y and remove the shock rod and valve assembly from the shock body FS252 FS055 3 Pour the oil from the shock body into a suitable con tainer 4 Remove the pressure valve assembly Account for the O ring...

Page 478: ...ing Piston Installation Location Tool to 5 80 in FS255 2 Lubricate the O ring and Teflon strap on floating pis ton then press the floating piston into shock until flush with the top of the body FS063...

Page 479: ...mbly FS252 9 Pressurize the shock with nitrogen to 200 psi see Pressurizing Rebuildable Shocks sub section FS251 10 Install the valve screw with O ring into the pres sure valve assembly FS253 11 Test...

Page 480: ...ght 3 Drain the oil from the air chamber FS143 4 Remove the air chamber from the bottom of the shock body FS144 5 Using a pick remove the air valve ball from the nitrogen bladder FS145A 6 Using an All...

Page 481: ...rod piston assembly from the shock body FS151 12 Drain the oil from the shock body into a suitable con tainer 13 Using Floating Piston Removal Tool remove the floating piston FS152 NOTE For ease in r...

Page 482: ...Shock Specifica tions sub section in Section 1 FS156 4 Using Fox Racing Shock Oil fill the shock body to the bottom of the threads then allow to sit 1 2 min utes to ensure no air is in the oil FS157 5...

Page 483: ...ball and set screw into the bearing cap FS162 FS163 10 Charge the shock with nitrogen to 200 psi FS164 11 Using a 3 16 in Allen wrench tighten the nitrogen bladder FS165 12 Install the air valve ball...

Page 484: ...O ring is properly positioned in the chamber 19 Invert the shock and secure by the end cap to assure the air chamber is tight FS172 20 Using a hand pump as an initial setting inflate the air chamber t...

Page 485: ...to center of the nitrogen valve to release the pressure FS016 6 When the shock is fully discharged pull the needle away from the reservoir in a straight smooth motion 7 Loosen but do not remove the be...

Page 486: ...he shock body and onto the folded shop towel FS012 15 Clean the body tube reservoir tube and the IFP with solvent Dry with compressed air in a well ventilated area 16 Set body assembly aside on a clea...

Page 487: ...t may be advisable to use a soft blunt object to push it in 8 Install FIST bearing into housing Check for proper orientation of the FIST bearing The stepped side of the FIST bearing should be visible...

Page 488: ...ately 0 5 in below the oil surface 10 Slowly stroke the shaft assembly up and down over about a 1 inch range two to three times being very careful not to pull the piston assembly out of the oil NOTE A...

Page 489: ...ll the button head screw into the nitrogen valve FS040 23 Clean all oil residue from the shock and reservoir with solvent and dry with compressed air in a well ventilated area 24 Install the polyureth...

Page 490: ...the shock shaft until it nearly bottoms and release it The shaft should return to its extended position smoothly NOTE If a soft spot or a mushy area is felt as the shaft is pushed down this would indi...

Page 491: ...nt Suspension Mounting Bracket Bearcat F Series T Series Z1 8 27 Console CFR Crossfire M Series 8 31 Console Bearcat F Series T Series Z1 8 32 Front Bumper Belly Pan Assembly CFR Crossfire M Series 8...

Page 492: ...ering post stop FC199 3 Tip the snowmobile upright Remove the handlebar pad 4 Remove the cable ties securing the wiring and brake line hose and throttle cable to the steering post NOTE Remove the rout...

Page 493: ...unting hardware INSPECTING NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is nec essary 1 Inspect all welded areas for cracks or deterioration 2 Inspect the steerin...

Page 494: ...far enough to hold the handlebar in position 11 Depress the lock pin lift up on the cam lever and swing the handlebar up and rotate to the desired posi tion then press down on the cam lever until the...

Page 495: ...ck 4 On the LXR Sno Pro EXT models remove the two screws from the handlebar pad then remove the self tapping screw securing the retainers A to the riser block assembly Remove the retainer 0744 927 5 O...

Page 496: ...11 Remove and discard the lock nut and washer secur ing the steering post to the chassis then carefully guide the steering post out of the chassis ZJ157A NOTE For installing purposes note the number...

Page 497: ...xhaust bumper into position on the air silencer FS203A 5 On the Bearcat F Series T Series place gaskets on the resonator and exhaust manifold then install the expansion chamber Secure the chamber to m...

Page 498: ...ever and rotate it one turn clockwise then press down on the cam lever until it locks in place NOTE At this point gently lift the cam lever without pressing in on the lock pin If the cam lever cannot...

Page 499: ...until the front of the wear bar is free from the ski 5 Remove the wear bar INSTALLING 1 Insert the front of the wear bar into the hole at the front of the ski and swing the wear bar upward 2 Insert th...

Page 500: ...he direction of the steering arms for installing purposes ZJ161A 6 If replacing using a suitable punch drive the two bearings out of the drag link ZJ162 INSPECTING NOTE Whenever a part is worn excessi...

Page 501: ...On the Z1 install the exhaust pipe and secure the pipe to resonator manifold and the mounting tab with springs then connect the oxygen sensor and install the hood 7 Using an all temperature grease gr...

Page 502: ...nut and washer Tighten to 20 ft lb CM268A 2 Place the rod ends into position on the steering arm Secure with the Allen head cap screw coated with green Loctite 609 Tighten to 30 ft lb CM266A 3 Place t...

Page 503: ...ure the steering tie rod and the left side inner tie rod to the drag link with the cap screw threads coated with green Loctite 609 and new lock nut and tighten to 35 ft lb then secure the right side i...

Page 504: ...s for wear dam age or loose fit Replace the bearings as a set NOTE Replacing the ski bolt bushings is difficult The existing bushings will be damaged during removal Be careful however not to damage th...

Page 505: ...pindle arm and account for and note the number of thrust wash ers for installing purposes ZJ172 ZJ177 NOTE The cap screw must be removed to remove the spindle from the spindle housing 5 Using a soft h...

Page 506: ...spin dle when removing the bushing Press the new bush ings into the spindle INSTALLING 1 Place the upper arm end with axle into position in the spindle Secure with cap screw and lock nut Tighten only...

Page 507: ...nt end Steering Tie Rod CFR Crossfire M Series REMOVING 1 Remove the cap screw and lock nut securing the steering tie rod to the steering post Discard the lock nut FC202 2 Remove the cap screw and loc...

Page 508: ...the way to gain access to the close off cover NOTE On the turbo models loosen the intercooler hose clamps at the intake pipe and the turbocharger then carefully work the intercooler upward until it re...

Page 509: ...l hose clamps securely 7 On the Bearcat 570 F Series T Series place the rub ber exhaust bumper into position on the air silencer FS203A 8 On the Bearcat F Series T Series place gaskets on the resonato...

Page 510: ...use the following procedure 1 Secure the steering tie rod in the centered position 2 Loosen both inner tie rod jam nuts on the same side as the ski to be aligned 3 Using a wrench on the spindle tie ro...

Page 511: ...spindle to the front suspension arms Account for all mounting hardware CM269B 6 On the Crossfire remove the cap screw and lock nut securing the sway bar link to the front suspension arm SC078A 7 Remo...

Page 512: ...the washers and bearings SC083A INSPECTING NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is nec essary 1 Inspect the arm welded areas for cracks or any signs of de...

Page 513: ...s and secure with the three torx head screws SC084 SC077A 5 Secure the arms to the spindle with existing hard ware Tighten the upper arm lock nut and cap screw to 30 ft lb and the lower arm lock nut a...

Page 514: ...e arm tubing for signs of twisting or bend ing INSTALLING UPPER ARMS 1 With the axles properly installed as noted during removing install the front and rear upper arms to the chassis then secure the a...

Page 515: ...of deterioration 2 Inspect the bearings and axles for wear or damage 3 Inspect the arm tubing for signs of twisting or bend ing INSTALLING LOWER A ARM 1 If removed install new split bearings onto the...

Page 516: ...e spring retainer from the top of the spring Inspect the shock absorber by quickly compressing and extending the shock plunger while firmly holding the shock body Resistance must be felt in both direc...

Page 517: ...he sway bar links and four sleeves INSPECTING NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is nec essary 1 Inspect the sway bar for any signs of twisting fatigue...

Page 518: ...8 28 0744 930 Manual Table of Contents...

Page 519: ...t side lower A arms 10 Remove all cap screws and lock nuts corresponding to E securing the left side lower A arm and the left side upper A arms to the suspension mounting bracket NOTE At this point re...

Page 520: ...me with cap screw and lock nut corresponding to G left side 6 At this time position the drag link and steering arms into the suspension mounting bracket then with axles in place install the right side...

Page 521: ...lenum Tighten all hose clamps securely 19 To install the front bumper assembly first secure the bumper to the left side and right side panels with the self tapping screws ZJ166B 20 Secure the bottom o...

Page 522: ...umper Belly Pan Assembly CFR Crossfire M Series REMOVING 1 Remove the hairpin clip and torx head cap screws securing the side panels then remove the panels 2 Remove the cable tie and remove the air in...

Page 523: ...crews and lock nuts securing the front left and right side belly pan to the front bumper SC073A 11 In the left and right side ski well remove the two torx head cap screws securing the front bumper to...

Page 524: ...G NOTE Steps 1 2 should be used for each side belly pan 1 Install the left or right side belly pan and secure within the ski well and below the running boards with the torx head cap screws SC076A 2 In...

Page 525: ...ure with new cable ties 11 Install the side panels and secure with the torx head cap screws and hairpin clip Gas Tank Seat Assembly CFR Crossfire M Series REMOVING 1 On the CFR Crossfire trip the seat...

Page 526: ...e the two screws D securing the knee pads to the gas tank then remove the remaining body screws securing the knee pads to the steering sup port 5 On the standard models push down on both seat retainer...

Page 527: ...side access panels 9 On the standard models place the seat into position on the chassis then push down on the rear of the seat until it locks securely in place NOTE On the LXR Sno Pro Z1 TZ1 LXR model...

Page 528: ...t away then disconnect the tail light harness connector 0743 444 3 Loosen but do not remove the three right side seat Speedrack mount cap screws 4 Carefully route the harness connector through the hol...

Page 529: ...in the socket by pushing it straight in 6 Push the socket into the housing and rotate it clock wise to lock into place 7 Connect the harness connector 8 Secure the access panel with the torx head cap...

Page 530: ...ly to the tunnel Account for the washers 3 If applicable disconnect the passenger handwarmer wiring harness 4 Remove the backrest assembly from the tunnel Account for the two spacers INSTALLING 1 Plac...

Page 531: ...nd secure the rear fenders 2 With the snowflap support in place install the snow flap and secure with the torx head cap screws wash ers and lock nuts Tunnel Chassis Rear Bumper Snowflap CFR Crossfire...

Page 532: ...ion on the tunnel then install the four machine screws and rivets securing the bumper to the tunnel Tighten the screws to 96 in lb Headlight Assembly Bearcat F Series T Series Z1 REMOVING HEADLIGHT BU...

Page 533: ...lowing pro cedure 1 With the hood closed loosen the headlight adjust ment knobs 2 Carefully push the headlight lenses rearward far enough to remove the torx head screws securing the air intake assembl...

Page 534: ...a horizontal mark on the aiming surface 4 Make a vertical mark intersecting the horizontal mark on the aiming surface directly in front of the headlight 5 Start the engine Select the headlight dimmer...

Page 535: ...Printed in U S A Trademarks of Arctic Cat Inc Thief River Falls MN 56701 p n 2258 805...

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